Apart from data driven decision-making and supply chain optimisation, AI is also analysing data from sensors and machines to predict potential breakdowns and maintenance needs, enabling proactive maintenance and minimising downtime.
As per Nitin Bakshi, by leveraging IoT devices, sensors, and connected machines, one can collect machine data for analytics and predictive models. "This will enable in early fault detection, anticipating equipment failures and scheduling maintenance activities proactively," he added. He further noted that conditionbased maintenance schedules are based on actual equipment condition, optimising component lifespan, and minimising unnecessary maintenance.
Bakshi also underscored the importance of predictive maintenance tools in streamlining operations. According to him, by implementing Advance EcoStruxure and Aveva Advanced Analytics tools, Schneider Electric has enabled predictive maintenance in their manufacturing facilities, thereby reducing unplanned downtime, optimising spare costs, and ensuring efficient operations.
Talking about its benefits, Rajesh Parameswaran, Executive Director & Industrial Sector Leader - India/South Asia, IBM Consulting said, "Predictive maintenance solutions predict machine behaviour on basis of historical trends and health indicators in real time. It primarily involves deploying sensors and capturing data and using it for decision making in any meaningful way."
He further notes that "with data, maintenance managers can fix the problem without losing equipment utilisation, while saving cost on scheduled maintenance. Besides, asset performance management solutions also provide potential failure root causes saving lengthy debugging procedures."
The rise of additive manufacturing
Additive Manufacturing (3D printing) is a game changer for the manufacturing industry as it allows for flexibility of supply chains without physical constraints of location and proximity. Commenting on its benefits, Deepak Keni, Executive Vice President - Digital, Strategy and Agtech of Deepak Fertilizers & Petrochemical Ltd said, "Additive manufacturing allows for easy portability and customisation of designs as per the product and process needs and allows for easy manufacturing of one unit or millions of units without heavy investment in infrastructure and immovable assets. The assembly line and manufacturing processes can be condensed with a high degree of customisation and offers flexibility to produce parts or entire components on demand."
He further noted that retailers and service units can also become manufacturers with this technology, allowing the company to provide the best value and services to customers, while the cost of storage and inventory/spare part is drastically reduced.
According to Ranjit Patil, "With 3D printing, the manufacturers can create complex and intricate designs, reduce material usage, and eliminate the need for assembly processes."
This (additive manufacturing) technology has opened new possibilities in sectors such as, healthcare, aerospace, automotive, and consumer goods. "It allows for rapid prototyping, small-scale production, and customisation of products to meet specific customer requirements. Additionally, 3D printing has the potential to decentralise manufacturing, reduce supply chain complexities and enable localised production," he added.
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