Sameer Gandhi, MD, OMRON Automation India.

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

Starting 2025, several innovative technologies are poised to further enhance transformation of factory automation. Smart manufacturing, which integrates digital technologies such as IoT, AI, and machine learning with physical production processes, will enhance efficiency and sustainability. Robotic process automation will see advancements with more sophisticated robots handling repetitive tasks, thus allowing human workers to focus on strategic roles. Automated drones will also see more depemployment in fields such as agriculture and logistics for tasks like crop monitoring and inventory management. Additionally, agentic AI will enable intelligent, autonomous agents to independently make decisions and tackle complex tasks, boosting productivity and operational efficiency.

Generative AI will play a vital role in predictive maintenance, real-time analytics, and dynamic workflow management, helping to optimise factory operations and reduce downtime. Advanced orchestration will coordinate tasks among humans, robots, and AI agents, ensuring seamless workflows and managing complex operations with enhanced efficiency. These technologies will not only increase productivity but also contribute to creating a more sustainable and efficient manufacturing environment.

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

As we look ahead into 2025 and beyond, the growth of Industrial IoT (IIoT) will significantly make progress in transforming factory operations. Key trends include connected workspaces that enable seamless connectivity between machines, devices, and workers, leading to more efficient workflows and real-time monitoring. The integration of AI and machine learning with IIoT will revolutionise data analysis and decision-making, predicting machine failures, optimising production schedules, and enhancing supply chain visibility. This will result in more autonomous and efficient factory operations, boosting productivity.

Advanced robotics, powered by IIoT, will handle complex tasks, improving precision and productivity, while collaborative robots will enhance safety and efficiency. The industrial metaverse will create digital twins, virtual replicas of physical factories, allowing real-time simulation, monitoring, and optimisation of operations. These trends will foster a more agile, responsive, and sustainable manufacturing environment, significantly influencing factory operations in India by 2025.

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

Edge computing and real-time analytics are set to significantly transform factory processes in India in the near future. By processing data closer to the source, edge computing minimises latency, enabling real-time decision-making and faster response times. This is crucial for applications requiring immediate feedback, such as quality control and predictive maintenance. It also lends more efficient data processing at the factory level, reducing the need to send large volumes of data to centralised cloud servers, which saves bandwidth and enhances data security and privacy.

Real-time analytics can predict equipment failures before they occur, allowing for proactive maintenance and reducing downtime and maintenance costs. With real-time insights, factories can optimise production schedules, manage inventory more effectively, and streamline supply chain operations, leading to increased productivity and reduced operational costs. Moreover, real-time monitoring and analytics help ensure compliance with safety regulations and standards, detecting anomalies and potential hazards early to maintain a safer working environment. These advancements will make factory operations more agile, efficient, and resilient, driving the next wave of industrial innovation.

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

Integrating legacy systems with new automation technologies presents several challenges, including compatibility issues, data silos, high costs, and operational disruptions. Factories need to break down data silos to ensure smooth data flow and invest in training to address skill gaps. The transition can be expensive and may lead to downtime, requiring careful planning and robust cybersecurity measures to avoid vulnerabilities.

Addressing these challenges requires a collaboration with a good automation solution provider which drives the transformation from a long term and strategic perspective (and not a piece-meal approach), thorough planning, and the use of middleware solutions to bridge the gap between old and new systems. Also, factories must prioritise training and development to equip the workforce with the necessary skills, while also ensuring minimal disruption to ongoing operations during the integration process.

How are sustainability goals influencing automation strategies in manufacturing?

Sustainability goals are significantly shaping automation strategies in India's manufacturing sector- not only helping in achieving sustainability goals but also in enhancing operational efficiency and reducing costs in the long run.Factories are increasingly adopting automation technologies that optimise energy use. This includes smart sensors and IoT devices that monitor and manage energy consumption in real-time, reducing waste and lowering carbon footprints. Automation is also facilitating the integration of renewable energy sources like solar and wind into manufacturing processes, managing the variability of renewable energy to ensure a stable and sustainable power supply.

Advanced automation technologies, such as AI and machine learning, are being used to minimise waste by enabling precise control over production processes, and to support circular economy initiatives by allowing efficient recycling and reuse of materials. Automated systems ensure compliance with environmental regulations by providing accurate data for sustainability reporting, thus helping manufacturers track their progress towards sustainability targets.

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

Companies planning their automation investments in India for 2025 should consider several critical factors. First, evaluating the potential return on investment (RoI) is essential, focusing on technologies that offer significant cost savings, productivity improvements, and long-term benefits. It is also crucial to ensure scalability so that the automation solutions can accommodate future growth, handle increased production volumes, and integrate with other systems as the business expands. Seamless integration with existing legacy systems helps minimise disruptions and leverage current investments. Effective data management, including easy access to data and support for real-time analytics, is crucial also for better decision-making.

Furthermore, investing in workforce training and skill development is paramount to ensure smooth adoption and operation of new technologies. Companies must also prioritise robust cybersecurity measures to protect sensitive data and maintain operational integrity. Aligning automation investments with sustainability goals can enhance operational efficiency and reduce environmental impact, incorporating energy-efficient technologies and practices. Finally, selecting the right automation technology partners with a proven track record, strong support services, and the ability to provide customised solutions is critical. By considering these factors, companies can make informed decisions that maximise the benefits of their automation investments.

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

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