Rajaneesh Kini, SVP and CTO, Cyient, tells us how digital control is critical to enhancing this foundation through automated orchestration of critical processes.
How would you lay the foundation—connectivity and a unified IT/OT digital platform—for Industry 4.0 use cases?
The foundation for Industry 4.0 use cases has five aspects to put in place.
- Machine and sensor connectivity (L2 layer) – adding eyes and ears to the systems to gather data and process at the early stage.
- Application connectivity (L3 and L4 layer) – Integration through APIs, interoperability, and ability to process data between systems.
- Edge to Cloud – Edge intelligence, plug-and-play analytics, data to the cloud data lake.
- Digital platform – a platform that is capable to handle the above 3 and provide orchestration and monitoring.
- Cyber security – safe envelope for data exchanges.
We also add automation capabilities. Digital control is critical to enhancing this foundation through automated orchestration of critical processes.
What are you doing to decrease tooling costs and lead time?
We are doing a lot of things. We use shared tools and common frameworks. It is important that there is a defined framework for tooling and collaboration driven through a COE.
Appropriate assignment and action of data analysis will bring down the tooling cost and time as it will be a closed-loop decision system. We are making people competent and capable of using new ways of working is key to decreasing tooling costs and lead time.
How are you creating shortening changeovers and creating simpler process instructions to reduce training time?
For this, we have several steps.
Streamlined knowledge acquisition process – Using intuitive knowledge capture tools, experienced employees can share their wisdom and experience quickly from the shop floor. As a result, it is easy to author and revise documentation, and approval processes can be automated before changes to procedures are released.
Increased accessibility – Referencing and using the standards becomes challenging if changeover procedures are contained solely in paper binders. With rugged cases, EWIs can be used in a variety of environments on tablets and smartphones. With no binders to prevent your workers from using standards during changeover procedures, mobile tablets promote a culture of continuous improvement among your workers. Using QR codes, operators can scan machines to instantly access the relevant setup procedures.
Operational twin can be used for complete changeover programming remotely.
Simpler process instruction can be provided for training through:
- Intuitive applications and platforms using platforms like AR/VR
- Self-support systems guide stakeholders only if something is wrong/not done.
What are you doing to meet complex customer requirements and improve delivery timing?
We are doing this in various ways.
- Solution approach – build comprehensive solutions and accelerators to improve realization time; customer to select features rather than custom develop wish lists
- Use of open platforms – flexibility and modularity; access to latest upgrades without licensing (open-source technology); no feature locking
- Optimal engineering – decide how much is optimal, e.g., high availability vs. BCP; analysis on 1-second data vs. 1-hour data. The simplified approach helps in adoption as well.
- Re-use of learnings and standards developed for implementation captured through earlier experiences and projects.
Give at least two examples of any recent Industry 4.0 deployments.
We have several To summarize:
- Asset Lifecyle Management implemented in global manufacturing company — making data actionable and providing solutions on all levels.
- Implemented a mobile workforce management solution for an oil and gas company providing real-time mobility integration, optimal resource assignment, and better staff utilization.
Rajaneesh Kini, SVP and CTO, Cyient
By Pradeep Chakraborty