Atul Patil, Deputy GM, Marketing and Strategic Planning, Mitsubishi Electric India.

What are the new technologies in automation that will be game-changers for factories in 2025?

By 2025, several emerging technologies are set to revolutionise factory automation. 5G connectivity will enable ultra-reliable, low-latency communication, facilitating real-time data transfer and seamless connectivity between devices, robots, and machines, which will boost efficiency and support autonomous decision-making. AI and machine learning will drive smarter factory operations by predicting and addressing operational issues, optimising workflows, and enabling autonomous systems like robots and drones to perform complex tasks with greater precision. Collaborative robots (cobots) will evolve to work more effectively alongside human workers, improving flexibility, productivity, and safety in manufacturing environments. Autonomous mobile robots (AMRs) will enhance material handling and logistics, automating repetitive tasks and reducing human labour in low-value activities. Additive manufacturing, or 3D printing, will allow for on-demand production of customised components, cutting inventory costs and material waste while offering greater design flexibility. Finally, digital twins, virtual replicas of factory systems, will provide real-time monitoring, predictive analytics, and simulations, helping to optimise operations and minimise downtime. These advancements will collectively transform factories into smarter, more efficient, and agile production environments.

With the growth of Industrial IoT, how do you foresee trends like connected workspaces, AI/ML, robotics, and the industrial metaverse influencing factory operations?

Connected workspaces, powered by Industrial Internet of Things (IIoT) devices, will enable real-time monitoring of factory floors, allowing workers to receive instant feedback and updates that improve decision-making and enhance safety. AI and machine learning (ML) will further drive productivity by enabling predictive maintenance, optimising production schedules, and identifying patterns in operational data to reduce downtime, waste, and improve overall efficiency. Robotics, especially AI-powered systems, will take over complex tasks like quality control and assembly, boosting operational efficiency. Collaborative robots will work seamlessly alongside humans, enabling better human-robot interaction and allowing workers to focus on more strategic activities. Finally, the rise of the industrial metaverse will create immersive virtual environments for remote monitoring, simulation, and troubleshooting. This digital space will provide real-time insights into factory operations and offer interactive training programs, making factory management more dynamic and engaging. Together, these technologies will significantly enhance manufacturing productivity, flexibility, and safety.

• e-F@ctory: Mitsubishi Electric’s e-F@ctory integrates IIoT, AI, and automation to enable connected workspaces, smart manufacturing, and operational efficiency.
• MELSOFT MaiLab: This data science tool leverages AI/ML to drive predictive maintenance and process optimisation.
• MELSOFT Gemini: A 3D simulation software supporting industrial applications, helping manufacturers test and refine production strategies virtually.
• MELFA Robots: Mitsubishi Electric’s robotic solutions are IIoT-ready, enhancing automation and collaboration.

How are edge computing and real-time analytics expected to shape factory processes in the near future?

Edge computing will play a pivotal role in enhancing factory operations by reducing latency and enabling real-time decision-making on the factory floor. By processing data closer to the source of collection, it ensures faster responses, which is crucial for tasks such as robotic control, quality checks, and process optimisation. This local data processing allows factories to leverage real-time analytics to identify inefficiencies, predict potential failures, and optimise resource usage, ultimately improving production uptime and operational efficiency. Additionally, edge computing enhances data sovereignty and security by allowing sensitive information to be processed locally, reducing the need to transmit it to centralised cloud servers. This not only strengthens data security but also helps factories comply with regional data privacy regulations, safeguarding both operational and regulatory interests.

What challenges do factories face in integrating legacy systems with new automation technologies?

Integrating new automation technologies into factories can present several challenges, particularly when dealing with legacy systems. Compatibility issues arise, as older systems may not work seamlessly with newer technologies, necessitating costly upgrades or custom integration solutions to bridge the gap. Additionally, legacy systems often create data silos, making it difficult for new automation technologies to access and utilise the data effectively. Efforts to integrate these systems must focus on breaking down these silos and enabling smooth data flow across platforms. A key challenge in this transition is the skill gap, as many factories face a shortage of workers who are proficient in both legacy systems and emerging automation technologies. Training programs and cross-skilling initiatives will be crucial to address this gap and ensure a smooth adaptation. Furthermore, the high initial investment required to integrate new technologies with older systems can be a significant barrier, particularly for small and mid-sized manufacturers. A thorough cost-benefit analysis will be essential to determine the long-term value and justify the investment in modernisation and digitisation.

How are sustainability goals influencing automation strategies in manufacturing?

Sustainability is driving automation strategies in several ways:

Energy Efficiency: AI and machine learning algorithms will optimise energy consumption by adjusting factory operations based on real-time demand and usage, helping to minimise waste and reduce energy costs. Advanced automation systems are being integrated with energy management solutions, such as Mitsubishi Electric’s Power Monitoring Products, to track and optimise energy usage in real time. Smart equipment like inverters, motors, and controllers designed to reduce energy consumption are prioritised, enabling manufacturers to meet energy efficiency targets.

Waste Reduction: Automation will help minimise material waste by optimising production processes, improving quality control, and enabling more precise manufacturing. Technologies like additive manufacturing (3D printing) will also help reduce waste by using only the material required for production. Factories are investing in robotics and smart systems to facilitate recycling and repurposing of waste materials, supporting circular economy principles.

Digital Twins for Sustainable Planning:

• Simulation Software: Tools like MELSOFT Gemini 3D Simulation Software allow manufacturers to model and test sustainable production processes before implementation, minimising waste and inefficiencies.
• Scenario Analysis: Digital twins enable analysis of the environmental impact of different production strategies, guiding greener decision-making

Smart Factories and Industry 4.0

• IoT Integration: Smart sensors and IoT devices help monitor and control energy use, water consumption, and emissions, driving sustainable operations.
• e-F@ctory Initiatives: Mitsubishi Electric’s e-F@ctory solutions promote lean and green manufacturing by integrating all production layers for optimised sustainability.

Circular Economy: Automation technologies will facilitate the adoption of circular economy practices by enabling better tracking of materials, promoting recycling, and supporting remanufacturing efforts, which will reduce the need for raw materials and lower environmental impact.

Carbon Footprint: IoT and real-time analytics will allow factories to monitor their carbon emissions, optimise processes to reduce energy use, and align operations with environmental regulations, helping companies meet sustainability targets.

Sustainability goals are no longer optional but a critical part of industrial strategies. By leveraging cutting-edge automation solutions, manufacturers can achieve greater operational efficiency while meeting their environmental responsibilities.

What are some critical factors for companies to consider when planning their automation investments in 2025?

First, technology readiness is crucial; organisations should assess existing technologies and processes to identify vulnerabilities. Additionally, product volume growth projections are essential; if forecasts indicate that current operations will not meet future demand, automation may be justified to enhance capacity and efficiency. Labour availability and cost also play a significant role in the decision-making process. With rising labour costs and increasing turnover rates, companies should evaluate their time-to-hire metrics and consider automation as a solution to alleviate workforce challenges. Furthermore,Smart Manufacturing should definitely be one of the key consideration points. Companies can implement solutions that support smart factory initiatives, such as Mitsubishi Electric’s e-F@ctory which enable Integration of automation with digital technologies like AI, predictive analytics, digital twins, and 5G for enhanced decision-making and agility. Scalability and Future-Proofing needs to be ensured by choosing systems that are scalable and adaptable to future needs, including capacity for new technologies like AI, machine learning, and IoT, along with investing in platforms with modular architectures that allow for phased implementation. Incorporating Interoperability and Open Standards that ensure that automation systems can integrate seamlessly with existing infrastructure and communicate effectively across platforms with priority solutions that comply with open standards, such as OPC UA, to avoid vendor lock-in.

Health and safety concerns cannot be overlooked either; integrating robotics can reduce workplace injuries, enhancing employee satisfaction and retention. By carefully considering these factors, companies can make informed decisions about their automation strategies in 2025.

(The views expressed in interviews are personal, not necessarily of the organisations represented)

Atul Patil, Deputy General Manager, Marketing and Strategic Planning Department, Factory Automation & Industrial Division of Mitsubishi Electric India, is Bachelor of Engineering in Industrial Electronics from Bharati Vidyapeeth College of Engineering, Pune and holds a Master of Management Studies from Pune University.

His professional experience spans over 20 years in Automation Industry. He started his career as sales engineer and worked on various platforms since then. From last 16 years, he is working on national-level profile and having experience across various industries in Automation sector.

In the current role, he is heading the Marketing Department of the Factory Automation & Industrial Division, Mitsubishi Electric India Pvt Ltd.

He is responsible for Product Marketing, Channel Business and Marketing Communications activities. His key role is to ensure Top Line Growth of all Products and maintain the profitability of the organisation. The key accountabilities include developing and executing marketing strategy, ensuring geographical expansion plans, implementing growth drives through Channel Partner Network, developing a revenue model by expanding localisation of product portfolio, developing leadership pool and enhance leadership skill to drive organisation culture and attract and retain talents within the organisation. 

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