achieving excellence in automation and enterprise...

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National Symposium on

Automation & Digital Transformation of

Food & Beverage Industry26th & 27th February 2016

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Mr. Kanchan ChakrabortyGM Technology & Engineering

ITC Limited, Foods Division,

[email protected]

Achieving excellence in Automation and

Enterprise convergence

Basics of Modern Industrial Automation

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Academic

- B. E. (Mechanical Engineering), Jadavpur University, Kolkata

Worked in:

- Union Carbide India Ltd in Battery Products Division as Maintenance Engineer (5 Years)

- Britannia Industries Ltd as Corporate Head of Engineering (21 years)

Currently working with:

- ITC Ltd in Foods Division as General Manager, Technology & Engineering (contd. Last 10 years)

Mr. Kanchan Chakraborty


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• Automation: FMCG Business requirement(WHAT?)

• Need of automation: WHY?

• Scope for automation: WHERE?

• Achieving excellence in automation

• Enterprise convergence

• Kind of automation

• Key Challenges faced

• Expectations (of end user)

Agenda


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What does FMCG business demands?

Dynamic Market

requirements

• Low Product lifetime (including SKU)

Highly cost competitive

• Low Margins

• Multiple Local players

• High productivity

Quality Consciousness

• Consistency

• Low Defective generation

• Defective detection and rejection systems

High Flexibility

Economical

(Overall Project Cost)

Efficient


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What do we need?

A highly flexible, efficient and cost effective solution

Flexible:

• Capability to handle multiple formats with minimum possible

• Change over time and Cost

• Stabilization time and Cost

Cost Effective:

• Optimal Capital Investment

• Optimal Maintenance cost

Efficient:

• Higher machine productivity

• Least response time w.r.t troubleshooting

• High Reliability and reproducibility


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Need of Automation : WHY?

Value to

customer

Product Quality

@

Cost

Process Consistency and Reliability

Resource (Man & Material)

Deliverables of Automation: Process consistency and reproducibility with minimum possible

resource


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Need of Automation : WHY?

WHY?

Manpower Dependency

Availability of

Manpower

Cost of Manpower

Networking

• Process efficiencies are driven by skill

level

• Quality of production

• Production throughput

• Operational and equipment safety

• Plethora of Job

Opportunities

• Scarcity of skilled

Manpower

• Rate of increase in Wages (>10%

YOY)

• Upswing of minimum wages

across states

• Online reliable

data capturing

• Implementation of

SPC modules


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Scope of Automation: Where

Manpower Deployment: Manufacturing Process

Raw

Material

Handling

Raw Material

ProcessingPacking

Sections

Manpower productivity, quality and

hygiene DrivenQuality and Hygiene Driven

7% 2% 6% 5%

19%

31%

23%

9%


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Scope of Automation: Plant and

Machinery

Production Machineries

Store Management

UtilitiesAir

compressors, boilers etc

Monitoring and maintenance

Instance: Use of CMMS(computerized maintenance management system )


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Achieving Excellence in Automation

Automation

Process Knowledge

Technology driven

approach

Quality

Cost and competent technology

partner base

• Complete knowledge on process

variabilities and control points

• System design and

fabrication

• System stabilization

• High Repeatability and

reproducibility of

performance

• High Repeatability

and reproducibility

of performance


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Enterprise Convergence

How automation technology is changing the way industries work.

AwarenessCustomer experience

Effectiveness of a

technology on a

customer/end user

• Update on advanced

technologies

• Capabilities of

technologies

• Reliability of technology

• Lead time: Installation to

production

• Cost of technology

Challenges faced by CustomerPeriodic Technology induction


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Challenges faced by customer

Innovation

• Developmental Projects

• Scope: Complete conceptualization and commercialization

• High Time and resource consuming

Customization

• Partial developmental Projects

• Needs customization in material flow and process as per specific requirement

Adoption

• Plug and play projects

• Mostly replication projects

• Swiftly executable projects w.r.t. time and resource.

Types of Automation Projects


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Innovation

1. Swift transition from conceptualization to commercialization

2. Technical competency across functions in

3. Cost of development

4. IP rights

Customization

1.Cost of customization

2.Technical competency of local service support

Adoption

Cost of Installation

• Stabilization time and

cost: Completely borne

by end user.

• One stop economical

solution provider

• Smooth Handshaking

with upstream and

downstream equipment

• Certified machine

training programs


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1. Mutual Organizational tie-ups.

• Building up process knowledge pool

• Appreciate the shop floor constraints

4. Definitive estimation and commitment towards stabilization cost and time.

Instance: Setting of high speed packing machines

Reduction of stabilization time through use of technology:

• Use of high speed camera

• Use of parchment paper to identify pressure variations across jaw

• Use of linear strain gauges to set the and replicate the pressure in rollers

Feedback and Expectations

2. Building technically competent vendor base in every vertical of an automated

solution. Or Development of aggregated solution providers.

3. Project Identification and facilitation team: Task Force approach


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Feedback and Expectations

5. Training modules/workshops OEM’s

6. Local sourcing of imported parts and services

7. Complete transfer of technical knowledge pool from OEM to service provider


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achieving excellence in automation and enterprise...

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