Vijay Mathew, Director, Industrial Technologies, Frost & Sullivan.

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

In my view, the landscape of factory automation is poised for some transformative shifts in 2025, driven largely by advancements in technology that not only enhance production efficiency but fundamentally alter how we conceive of and manage factory operations. Given the trends we're observing, there are three particular technologies that I believe will be game-changers.

First, adaptive robotics stand out to me as a critical development. The ability for robots to learn and adapt in real-time to changing manufacturing tasks without human intervention could revolutionise production flexibility and efficiency. This adaptability is crucial, especially for industries where customisation and rapid product changes are becoming the norm rather than the exception.

Second, the integration of digital twins within the industrial metaverse is another trend I'm particularly excited about. This technology offers a level of simulation and forecasting that can dramatically reduce downtime and predict future maintenance needs, which not only optimises operations but also extends the lifecycle of machinery and equipment. The potential for global teams to collaborate in a virtual space and solve problems before they impact the physical world is something that could redefine the boundaries of manufacturing.

Lastly, the role of edge computing in factory settings is becoming increasingly important. Processing data on-site and in real-time minimises delays and enhances decision-making capabilities. This is particularly crucial in environments where even milliseconds of lag can lead to significant disruptions or losses. Edge computing, in my opinion, will become indispensable as factories become more data-driven and reliant on instantaneous feedback loops.

These technologies are not just about keeping up with industrial trends; they're about setting a new standard for what factories can achieve. They align closely with a future where agility, precision, and sustainability are at the forefront of industrial operations.

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 shape the future of factory processes, and I believe their impact cannot be overstated. From my perspective, these technologies are pivotal for enhancing operational efficiency and agility within manufacturing settings.

Firstly, edge computing addresses one of the fundamental challenges in factory automation—latency in data processing. By processing data directly at the source, we reduce the dependency on centralised data centres, which in turn minimises delays and enhances the responsiveness of automated systems. This is crucial in environments where real-time decisions need to be made quickly to maintain continuous production flows and optimise operational efficiency.

Furthermore, real-time analytics play a complementary role by enabling immediate insights into the production process. This capability allows factory managers and decision-makers to monitor operations instantaneously and make adjustments on the fly. For instance, if a potential issue is detected in a component of the production line, real-time analytics can prompt immediate corrective actions, thus avoiding potential downtimes or quality issues.

Combined, these technologies foster a more resilient manufacturing environment. They empower factories to not only react swiftly to issues but also to anticipate and mitigate potential disruptions before they occur. This predictive capability, powered by real-time data, is what I see as a game-changer for the industry. It not only streamlines operations but also enhances quality control and reduces waste, aligning with broader sustainability goals within the sector.

In my role as a consultant, integrating these technologies has been a key recommendation for clients aiming to future-proof their operations and maintain competitiveness in a rapidly evolving industrial landscape.

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

Integrating legacy systems with new automation technologies presents a significant challenge, yet it's a crucial step for factories looking to modernise without disrupting ongoing operations. There are a few key hurdles that stand out.

First and foremost, compatibility issues often arise. Legacy systems were not always designed with interoperability in mind, particularly with the latest technological advancements. This can lead to significant integration challenges where new systems are unable to communicate effectively with older ones, resulting in data silos or operational inefficiencies.

Another major challenge is the risk of downtime. Upgrading or integrating new technologies often requires taking parts of the production process offline. For many manufacturers, the potential loss of productivity during this period can be a daunting prospect, especially in high-throughput environments where downtime translates directly into lost revenue.

Moreover, there's the skill gap in the workforce. Legacy systems often require specific knowledge that might be scarce in the current labour market, where newer talents are more versed in advanced technologies. Bridging this gap involves either retraining existing employees or attracting new talent capable of managing modern automation technologies, both of which require time and investment.

Lastly, the financial investment required for integration can be substantial. Upgrading legacy systems to be compatible with the latest technologies often requires not just new software, but sometimes complete hardware overhauls, which can be cost-prohibitive.

Addressing these challenges requires a strategic approach, combining careful planning with phased implementations to minimise disruption. At Frost & Sullivan, we emphasise to our clients the importance of a thorough needs assessment followed by a tailored integration strategy that aligns with both the technological objectives and the business goals of the factory.

How are sustainability goals influencing automation strategies in manufacturing?

Sustainability is increasingly becoming a non-negotiable in the manufacturing sector, profoundly influencing automation strategies. From my standpoint, the integration of sustainability goals with automation is not just about compliance or public relations; it’s about fundamentally enhancing operational efficiency and securing long-term viability.

Firstly, automation technologies are pivotal in optimising resource use. For instance, advanced predictive maintenance systems can dramatically reduce energy consumption and minimise waste by ensuring equipment operates at peak efficiency. This not only aligns with sustainability goals but also reduces operational costs, which is a significant incentive for manufacturers.

Moreover, automation is enabling the transition to more sustainable manufacturing practices through improved process controls. For example, automated systems can precisely control the input of raw materials and chemicals, reducing overuse and spillage. This precise control is crucial in industries like chemicals and pharmaceuticals, where minimising environmental impact is a critical concern.

Another area where automation intersects with sustainability is in data collection and analysis. Automation systems equipped with IoT technologies provide detailed insights into every aspect of the manufacturing process, allowing companies to identify areas where sustainability goals are not being met and make necessary adjustments. This data-driven approach ensures that sustainability is not just a checkbox but a core operational focus.

Lastly, there’s a growing trend towards the circular economy in manufacturing, which automation supports by enabling the efficient disassembly and sorting of products for recycling at the end of their lifecycle. This not only helps reduce waste but also feeds back into the supply chain, reducing the need for new raw materials and decreasing the overall environmental footprint.

It’s not merely about adopting new tools; it’s about rethinking processes to make them more sustainable, which in turn enhances the brand reputation and aligns with global environmental objectives.

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

Vijay Mathew is Director, Industrial Technologies, at Frost & Sullivan. With over 18 years of experience, Vijay is a seasoned advisor known for providing strategic, unbiased, and objective advisory services across a variety of industries. His areas of expertise include automation, process control, industrial sensors and instrumentation, and electronic test and measurement. Always on the forefront of technological evolution, Vijay is committed to tracking and understanding the latest trends in Industry 4.0, data analytics, predictive maintenance, smart factories, and blockchain technologies. 

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