If India is to realise the vision of becoming the factory of the world, it cannot be done by adopting conventional manufacturing techniques that involve loading the shop floors with cheap labour and strenuous work. Indian manufacturing would not only need to be cost-competitive globally but would also need to focus on Domestic Value Addition, thus driving up the export share of India globally.
The only way for Indian Manufacturing to realise this vision is to innovate and repurpose the conventional manufacturing system to Flexible Manufacturing System. A conventional manufacturing system comprises fixed assembly lines that have machines and tools that perform a specific task and transportation systems like conveyors that take the product to different machines. Such manufacturing lines must be shut down to set up a different product and often any breakdown in any section of the entire line can lead to inordinate delays in production. FMS on the other hand offers modularity and a self-organising production system with the help of collaborative robots and smart automation systems, that can optimise the workloads between different machines accommodating any priority orders or change in order or raw material volumes. FMS enables us to maintain the quality of the product and improve overall productivity, thereby reducing operating costs.
While the concept of Flexible Manufacturing System has existed for quite some time, their adoption has been far and few in between as they are more complex and were difficult to conceptualise and implement since they required predictive intelligence and advanced automation systems. The rise of Digital Twin and computing capability now allows processing of large volumes of data thereby enabling powerful simulations, thus reducing these complexities to a very large extent. Through simulation, the entire production shop floor can now be created virtually, and the impact and performance of each component can be measured and tested by creating different scenarios. These digital models help set up robust and efficient physical processes that can be modified on the fly, thereby eliminating the need for educated guesses and intuitions in designing the process.
The nature of FMS itself requires the use of highly advanced automation and storage systems to ensure quick access to raw materials, work in progress (intermediary goods), and finished goods. It also involves extensive utilisation of Autonomous Mobile Robots to move the materials and workstations, accommodating changes in layout as per the business requirements. Advanced automation systems, such as Shuttle & Crane-based Automated Storage and Retrieval Systems, can enhance storage volumes, throughput, and dynamic material buffering according to the production plan. Meanwhile, the Autonomous Mobile Robot (AMR) technology, powered by 3D Lidars and cameras, has undergone significant improvement over the past decade. It has evolved from primitive Automated Guided Vehicles that operated on fixed paths, like magnetic tape or rail, to becoming more intelligent, safe, easier to deploy, and capable of natural navigation. The final crucial component for developing an efficient FMS is the collaborative robot, which can perform operations such as pick and place, primary and secondary packaging, and more. Flexible Manufacturing Systems will go a long way in helping India build a resilient and adaptable manufacturing setup that will serve the global supply chains in uncertain times. Also, while developing such systems, it is important to find a balance between adoption of robots and speed of execution as humans will not be able to keep up with the same speed of work as robots and the work would need to be designed more carefully, by separating the tasks between robots and humans. This would mean that humans will assist in tasks that require complex problem-solving or subjective judgement. Although machine vision and gripping technology have advanced by leaps and bounds, human dexterity and hand-eye coordination still cannot be automated, and tasks such as complex packing, assembly, etc. will continue to be done by humans. Robots will add efficiency by automating tedious and repetitive tasks. The right balance of human-robot collaboration will be the key to designing such advanced manufacturing systems. One of the biggest myths associated with Robotics & Automation is that it will lead to job losses. However, this is indeed a myth. For instance, South Korea, which has a Robot Density (Industrial Robots per 10,000 workers) of 932, maintains an unemployment rate of around 2.6%. On the other hand, India has a Robot Density of 4 and a high unemployment rate. There is substantial evidence suggesting that the adoption of advanced manufacturing techniques involving robotics and automation actually leads to the creation of a greater number of jobs and higher wages, as observed in economies like South Korea. With a young population, India is not currently facing the issue of labour shortage, unlike some developed Western economies, which has compelled them to turn to automation. Industries manufacturing in India should not wait for labour shortage to adopt automation, but rather should adopt automation as a strategy to create a competitive advantage that will help them scale their manufacturing and business and enable them to become global behemoths. The writer is Co-Founder, Addverb
