Kapil Agarwal, Senior Vice President & Local Division Manager, Process Industries, ABB India

What is the current state of digital transformation in process industries?

The current state of digital transformation in process industries is characterised by widespread adoption of advanced technologies aimed at enhancing productivity, efficiency, and sustainability. Indian manufacturing players, among others, have embraced digital transformation, driven by the need for higher productivity, shorter product life cycles, and stringent safety and environmental standards. Key technologies such as advanced analytics, artificial intelligence, and process automation solutions are central to this transformation, enabling real-time monitoring, predictive maintenance, and optimisation of energy and resource efficiency. Companies across sectors like cement, hydrocarbons, chemicals, mining, metals, and power generation are leveraging these digital tools to reduce emissions, improve cybersecurity, and increase operational efficiency, thus achieving significant value creation and sustainability goals.

What key technologies are driving digital transformation in process industries today?

Key technologies driving digital transformation in process industries today include generative artificial intelligence (Gen AI), data analytics, machine learning (ML), and cloud and edge computing. These technologies are essential for enhancing operational efficiency, process performance, and sustainability. Advanced solutions like advanced process control (APC), energy management systems (EMS), and manufacturing execution systems (MES) are foundational, with evolving applications tailored to specific industry needs. Additionally, ABB India supports the integration of real-time data transmission and cybersecurity measures, which ensures robust and secure digital operations. Partnerships and co-creation efforts further accelerate the adoption and scaling of these transformative technologies, helping industries achieve net-zero emissions and unprecedented levels of efficiency and productivity.

What role does data analytics play in the decision-making processes within these industries?

Data analytics plays a pivotal role in the decision-making processes within process industries by providing actionable intelligence derived from vast amounts of data. It enhances decision-making through real-time monitoring and analysis of resources and assets, allowing businesses to track and manage their operations efficiently throughout the product lifecycle. By identifying patterns and trends, AI algorithms, combined with data analytics, offer insights into resource optimisation and waste reduction opportunities. This enables businesses to implement circular strategies, optimise processes, and achieve higher levels of sustainability and efficiency in the era of Industry 4.0.

What are the biggest challenges or barriers to digital transformation in process industries?

The biggest challenges to digital transformation in process industries include the substantial investments required for infrastructure development and the need for skilled personnel to implement and operate advanced technologies. Companies must navigate the complexities of training or hiring individuals with the right expertise, which can be a significant hurdle. Additionally, there are ethical and legal implications associated with the large-scale deployment of automation, particularly concerning its impact on human workforces. Addressing these challenges is essential for ensuring a smooth transition to digital operations while balancing technological advancements with workforce considerations.

How are sustainability and environmental concerns influencing digital transformation strategies?

Sustainability and environmental concerns are significantly influencing digital transformation strategies by driving the adoption of industrial software solutions that enhance transparency and optimise resource management. These solutions provide a unified system for monitoring emissions, energy use, and compliance, facilitating data-driven decision-making that minimises environmental impact. By streamlining processes and predicting equipment maintenance needs, industrial software reduces energy consumption, emissions, and waste, contributing to overall sustainability goals. As companies focus on reducing their environmental footprint, digital transformation strategies increasingly prioritise efficiency, resource optimisation, and the integration of circular economy principles to meet sustainability commitments and enhance operational performance.

One such practical application is decarbonising steel production with AI and data analytics, which ABB implemented for a steelmaker. Complex distribution networks for electricity, steam, by-product gases and imported fuels account for as much as 20% of production costs. Iron ore reduction is where most carbon emissions come from in steelmaking. The latest enterprise-grade platforms and suites of AI and ML enabled applications enable companies to deploy and monitor advanced controllers, data analytics and optimisation solutions at the edge, to and from an industrial cloud/multi-cloud, or on-premises. The steelmaking plant mentioned reported initial results of 10% less flaring of gases and 15% accuracy improvement of electricity procurement forecasts.

What advice would you give to companies just beginning their digital transformation journey?

As companies embark on digital transformation, it’s crucial to start with a clear vision that aligns with long-term goals. Engaging stakeholders, including employees, customers, and partners, is essential for buy-in and diverse insights. I believe establishing performance metrics specific to industrial automation, such as production efficiency and equipment uptime, enables companies to measure the impact of digital initiatives and make informed decisions. Measuring progress with established KPIs allows for data-driven decisions and tracking the impact of digital initiatives. Data security cannot be overlooked; robust cybersecurity measures are necessary to protect sensitive information and build trust. By adhering to these principles, companies can effectively navigate the complexities of digital transformation, optimise their processes, and maintain a competitive edge in the market.

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

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