In 2024, the manufacturing industry is set to undergo a revolutionary transformation driven by cutting-edge technologies. Automation, machine learning, and AI will play pivotal roles in optimizing production processes and boosting overall efficiency. The transition from Industry 4.0 to 5.0 will underscore the significance of human-machine collaboration, focusing on creativity and complex decision-making. Sustainability will take centre stage with a commitment to reducing carbon footprints, embracing cleaner energy sources, and implementing circular economy principles. Anticipated trends include the rise of industry-specific cloud solutions and the expansion of generative AI technologies. Despite the promising opportunities, challenges such as ensuring responsible AI use will need careful navigation for a successful evolution in this dynamic manufacturing landscape.
What significant trends and innovations do you foresee shaping the manufacturing industry in 2024, and how will they impact your specific sector?
The year 2024 will be all about leveraging the power of automation, machine learning, and AI to optimise production lines in the manufacturing industry. These technologies are maturing at a fast pace, making it the best time for organisations to incorporate them and reap the benefits of robust and seamless functioning in every manufacturing vertical.
In the current manufacturing setup, where precision and accuracy are paramount, IoT-enabled instrumentation plays a vital role in ensuring meticulous precision in every cycle. IoT-enabled advanced and smart instrumentation technology collects real-time data from sensors in pressure, level, flow, temperature, vibration, position, and analytical devices and strategically analyses them to predict the performance of the process. This also allows for on-time corrective measures and predictive maintenance that maintain the overall health of the machines and devices while enhancing the quality of the process.
This automation helps organisations reduce downtime, minimise waste, and enhance operational efficiency in every process. Real-time data analysis also helps in identifying any bottlenecks or inefficiencies in the entire process and addresses them accordingly for the seamless functioning of every device and instrument.
Can you share insights into the role of smart factories in your industry and how they are revolutionising manufacturing processes, from data analytics to real-time decision-making?
Smart factories are highly digitised shop floors with self-adapting manufacturing capabilities achieved by connecting different devices and processes to continuously collect data. The data collected from the connected machines can be used to proactively address issues, improve manufacturing processes, and respond to future demands and requirements.
These smart factories, connected with advanced AI technology and artificial vision, are revolutionising quality inspection in various manufacturing processes. Continuous data collection enables real-time analysis to achieve accurate monitoring of the process, forecast the need for maintenance, and avert major breakdowns of any machinery or parts.
Manufacturers are increasingly embracing automation with artificial vision to enhance real-time data and analytics for process optimisation. Furthermore, connecting devices using technology like cloud computing and smart sensors increases transparency and flexibility in various operations.
Considering the unpredictability of global events, what strategies have you put in place to ensure business continuity and resilience in the face of unforeseen challenges?
WIKA, as a global instrumentation giant, is always at the forefront of technology and innovation. The organisation’s forward-thinking capability consistently keeps it ahead of the curve, allowing it to assess and gauge market situations and organise its operations accordingly. During volatile market conditions, WIKA is proactive in addressing unprecedented situations and develops strategies to cope with them. While constantly assessing market environments, we also simultaneously train our staff and test our plans to promptly address situations and adapt to the changing dynamics of the market.
Every year, the world encounters a myriad of unforeseen circumstances. WIKA, with its extensive global footprint, possesses the capability to assist individuals across diverse regions in a multitude of situations while also capitalising on various opportunities. We ensure that we adeptly navigate each situation, ensuring minimal negative impact on our business operations.
How are technological transformations reshaping the manufacturing landscape?
Today, automation is emerging as a key player in revolutionising the manufacturing industry. Automation, driven by smart technologies, is reshaping traditional manufacturing processes with increased efficiency, reduced operational costs, and enhanced precision in production. For instance, the implementation of Robotic Process Automation (RPA) is addressing the challenges of automating labour-intensive manufacturing processes, workforce shortages, and repetitive tasks. Advanced sensors with machine learning capabilities are optimising intricate tasks with speed and precision, thereby improving the overall productivity of the manufacturing process.
These technologies have also allowed manufacturers to collect and analyse real-time data, leading to predictive maintenance and better quality in manufacturing. This has also enhanced decision-making and timely addressal of downtime, creating an efficient and sustainable manufacturing environment.
Many manufacturers have adopted cutting-edge technologies like IoT, 3D printing, and AI to enhance operational efficiency. How have these technologies been successfully integrated into manufacturing processes in your sector?
Smart instrumentation is an integral part of the measuring instrumentation market. Products like smart sensors have been integrated into pressure, level, flow, temperature, and a diverse range of advanced measuring devices to increase precision, efficiency, and the quality of products.
Cutting-edge technologies like IoT, 3D printing, and AI have become necessary in manufacturing processes today. Their integration into the manufacturing sector revolutionises and enables the monitoring of various machines to ascertain the health and quality of processes.
IoT enables real-time monitoring of production processes, optimising resource utilization. 3D printing accelerates prototyping and custom manufacturing, reducing costs and waste. AI-driven automation enhances decision-making, predictive maintenance, and quality control, ensuring higher product quality. Collectively, these technologies streamline operations, minimise downtime, and foster quick and easy production.
Furthermore, these IoT and AI-enabled smart solutions also foster a smart manufacturing ecosystem to be in sync with the advanced machines used in various manufacturing sectors.
How do you see the transition from Industry 4.0 to Industry 5.0 unfolding, and what role do humans play in this new era of manufacturing? And how has your sector adopted this trend?
Industry 4.0, also known as the Fourth Industrial Revolution, introduces the automation and digitalisation of industrial processes and is characterised by the interconnection of systems such as cloud computing and the Internet of Things (IoT) using data. On the other hand, Industry 5.0, also known as the Fifth Industrial Revolution, is more value-driven and focuses on human-machine collaboration on tasks that require creativity, complex decision-making, and emotional skills.
While Industry 4.0 is all about the automation of manufacturing using AI, robotics, and IoT, Industry 5.0 is focusing more on integrating the human workforce with robots and smart machines. As described by the European Commission, Industry 5.0 will be ‘a vision of industry that aims beyond efficiency and productivity as the sole goals and reinforces the role and the contribution of industry to society.’
We are moving towards an era where machines will help humans work better and faster while leveraging IoT, big data, and other smart technologies. It will be more about adding a human touch to Industry 4.0 to improve efficiency in production processes. This enhanced version of Industry 4.0 will leverage technologies while enhancing the role of the human workforce to bigger functionalities. For instance, Industry 5.0 will free employees from repetitive and mundane workloads so that they can focus on bigger developments of the operation and solve the broader challenges of the industry. The use of advanced technology will not just ensure enhanced precision and efficiency but also improve work safety on the shop floor. All this will drive towards an inclusive and diverse manufacturing environment.
Sustainability is a growing concern in manufacturing. What sustainable practices and initiatives do you anticipate gaining prominence in 2024, and how will they affect your business operations?
Rising environmental concerns are a pressing issue that the industry is addressing. A major impetus is being given to adopting sustainable practices that will reduce the carbon footprint in every operation. Manufacturers are increasingly investing in cleaner energy sources to power their various manufacturing operations while mitigating the environmental impact. This will drastically reduce reliance on non-renewable resources, enhancing sustainability.
Furthermore, advanced technologies like smart manufacturing, IoT, and AI play a key role in optimising production processes. They also ensure precision in manufacturing, minimising wastage, and achieving energy efficiency. Organisations, big and small, are heavily investing in smart technologies to leverage their manufacturing processes and achieve sustainability.
To further strengthen sustainability and reduce the net carbon footprint, organisations must focus on adopting gas-based generators instead of diesel-based systems. This is because these generators are much more efficient and cleaner. Waste management is also crucial in sustainable manufacturing. Organisations are implementing the principles of the circular economy in waste management processes to reduce wastage while improving the overall efficiency of the process.
As a globally responsible organisation, WIKA incorporates sustainability principles into all its operations. The company has implemented an integrated management system and sustainability impact management, encompassing environmental, social, governance (ESG), and economic dimensions. WIKA constantly assesses the impact of its business activities on both the environment and stakeholders and incorporates necessary measures to reduce the impacts.
Being at the forefront of technological advancements, WIKA’s adoption of automation-enabled measuring devices minimises the overall environmental footprint, embedding sustainability across the value chain. The advanced devices address the issues of energy efficiency, minimise wastage, and facilitate energy-efficient decisions. These measures further improve employee productivity as well as employee and product safety. Furthermore, WIKA ensures that all its processes, ranging from vendor management to raw material sourcing, align with the principles of green manufacturing. This reinforces the company’s unwavering commitment to sustainability.
As we look towards 2024 and beyond, what are the key challenges and opportunities that manufacturers should be prepared to navigate in this rapidly evolving technological landscape?
With the maturity in technology, this is the best time for manufacturers to experiment, innovate, and invest in smart technologies. In the years to come, the evolution of industry-specific cloud solutions will be on the rise. This will help address industry-specific needs and requirements and provide definite solutions to every problem.
Further, the expansion of generative AI-based technologies will boost the efficiency and effectiveness of various operations. This will help in achieving the desired efficiency, precision, and cost-effectiveness in processes. Unfortunately, there is growing concern about the misuse of AI-based technologies, posing a threat not only to organisational well-being but also to individuals in forms like unauthorised access to different accounts, online banking, and lack of emotions, to name a few.
The concept of smart factories and supply chain digitalisation too is ripe and will witness widespread adoption across all manufacturing verticals. This will not only enhance operations but will also bring in an organised and sustainable way of functioning. Last but not least, the adoption of various technological solutions will allow organisations to embark on their journey towards decarbonisation and meet their sustainability goals.
The Indian government is striving to achieve a net-zero carbon footprint in the near future. However, many organisations currently lack specific goals or objectives to align with this ambitious target. It is, therefore, imperative for industries to establish clear directives and focused goals to actively contribute to and attain the predefined national net-zero objective.
