Vishal Dahiya, Associate Director, Factory Automation System, Panasonic Smart Factory Solutions India (PSFSIN).

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

According to industry estimates, India's industrial automation market, valued at $15 billion in 2024, is likely to grow to $29 billion by 2029, with transformative trends expected to pick up steam in 2025. Artificial Intelligence (AI) and Machine Learning (ML) will be integrated to further improve predictive maintenance, optimise operations, enhance decision-making, and create new use cases across industries as the industry adopts the Industry 5.0 concept, which aims to create a technology-based, human-centered society. With the help of connected devices and sensors, the Industrial Internet of Things (IIoT) will enable intelligent automation through real-time data collection and analytics. Collaborative robots (cobots) are anticipated to see wider adoption, working alongside humans to boost productivity and safety on shop floors. Furthermore, it is anticipated that edge computing will speed up, lowering latency and facilitating quicker data processing at the source for increased effectiveness.

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

We anticipate that the industry will move towards adopting Industry 5.0 conceptualised as “Society 5.0” and Panasonic is deeply aligned with this transformative vision. Devised by the Japanese government, Society 5.0 envisions a technology-driven human-centred “Super Smart Society,” addressing social challenges by integrating IoT, AI, ML, robotics, and big data into every aspect of life and industry. Robotics, including collaborative robots (cobots), are augmenting human capabilities, enhancing safety, and ensuring operational consistency. Connected workspaces enable seamless integration of machines, sensors, and human operators, encouraging real-time communication and decision-making for improved productivity and efficiency. The industrial metaverse is an intriguing frontier, offering immersive simulations and virtual environments for factory planning, training, and monitoring. Combining real-time data with digital twins enables factories to predict outcomes, test scenarios, and implement changes with minimal disruption.

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

Edge computing reduces latency by processing data locally at the production site, facilitating prompt decision-making that improves operational efficiency and reliability. This change makes it possible to monitor manufacturing lines and machinery in real-time, enabling quick reactions to anomalies like equipment overheating or strange vibrations, which abate downtime. Furthermore, real-time analytics enables manufacturers to use massive volumes of sensor-generated data for predictive maintenance and quality control, guaranteeing that only high-quality items make it through the manufacturing process.

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

The major challenge here is legacy system compatibility; outdated systems struggle to communicate effectively with new technologies due to differing communication protocols and data formats. Ensuring interoperability between legacy systems and modern technologies remains a challenge. This leads to difficulties in data integration and standardisation with newer processes. Additionally, there are cybersecurity risks accompanying this integration, as legacy systems may lack updated security protocols, exposing them to vulnerabilities.

The financial aspect cannot be overlooked; integrating these systems can be both costly and resource-intensive, necessitating substantial investments in hardware, software, and skilled personnel. Furthermore, change management poses a strain, as employees may find it challenging to adapt to the substantial changes in processes and workflows introduced by new technologies.

To address these challenges, Panasonic Smart Factory Solution India (PSFSIN) developed a plug-and-play Industrial IoT platform known as Miraie Profactory. This is a one-stop solution for deployment, service and business intelligence needs. It empowers manufacturers to design paperless digitised shop floors, drive machine effectiveness, and maximise plant operations, i.e., monitor production efficiencies right from procurement to finished assembly. The IIoT solution from Panasonic enhances the capabilities through vertical integration i.e. hardware and software to converge operation technology (OT) and information technology (IT) to have one comprehensive view. Data analytics further enhances the OEE by providing real-time insights allowing enterprises to optimise assembly units faster and efficiently through predictive maintenance, real-time monitoring, and quality management processes. Remote monitoring through mobile, and one dashboard for all operations with a unique UI are some of the additional features that will help automate and ensure contactless management.

How are sustainability goals influencing automation strategies in manufacturing?

OEMs are integrating automation to not only enhance efficiency and reduce waste but also align with their broader sustainability goals. This strategic shift is essential for maintaining competitiveness in a market increasingly focused on environmental stewardship. Automation streamlines production processes, minimises human error, and optimises resource use, leading to cost optimisation and improved operational performance. It also supports circular economy practices by enabling modular manufacturing that facilitates product repair and recycling. Additionally, it helps them meet compliance obligations with environmental regulations through accurate tracking and reporting.

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

Smart factories are strategic business investments. They are helping manufacturers jumpstart to digital, offer a competitive edge, innovate and improve Overall Equipment Effectiveness (OEE) while saving major costs. OEMs must prioritise technological advancements like AI, IoT, and predictive analytics to boost efficiency. Moreover, addressing integration challenges, cybersecurity risks, and workforce implications, such as retraining, ensures a smooth transition. Additionally, aligning automation with sustainability goals enhances reputation and compliance.

PSFSIN enables customers to advance from traditional manufacturing and industrial practices to the latest Smart Manufacturing technologies. We use new-age technologies such as machine-to-machine communication and the Internet of Things for increased automation, improved communication and self-monitoring that helps analyse issues without the need of human intervention.

We offer advanced solutions for factory optimisation, including PanaCIM for complete traceability across processes, Integrated Welding Network Box (IWNB) for data-driven welding productivity and quality, and Weld Data Management to enhance machine utilisation, reduce costs, and enable predictive maintenance. Additionally, the Production Management System (PMS) provides real-time monitoring of robotic operations and welding quality from outside the production line. These solutions empower manufacturers to achieve higher efficiency, improved quality, and streamlined operations through data-driven insights and automation.

Further, we work closely with customers to ensure optimum productivity and quality level for their production with our strong technical process knowledge and data analytics skills as the total solution provider. We provide skill development through its state-of-the-art welding training centre in Haryana, on-site training, and collaborations with industry associations and institutes to enhance manufacturing competitiveness.

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

Vishal Dahiya is an Associate Director, Factory Automation System at Panasonic Smart Factory Solutions India (PSFSIN). He is a seasoned business leader with over 26 years of experience in heading businesses and operations. Mr. Dahiya excels in Strategic Marketing, Market Positioning, Key Account Management, and C-level Relationship Building. At Panasonic Smart Factory Solutions India, he adeptly handles P&L management, Service Delivery, and Team Leadership. His proficiency extends to fostering relationships with overseas group companies and associates. His previous tenure at Bergen Electronics has honed his expertise and leadership skills, making him a pivotal asset in driving business. 

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