Enhancing Quality Control with Automated Systems in Manufacturing

In an exclusive interview with Asia Business Outlook, Sameer Gandhi, MD, OMRON Automation, India, shares his views on the measures for data protection and monitoring systems, how businesses reduce downtime and production delays, implementation measures to streamline the integration process, and more. He has 30 years of experience in marketing, sales, operations, service, and managing profit centers in a multi-cultural matrix structure for product and project businesses. 

Considering that automation relies on digital systems and networks, the manufacturing industry becomes more vulnerable to cybersecurity threats. What robust measures can be adopted for data protection and monitoring systems to ensure the automation is secure and compliant?

Ensuring the security and compliance of automation in the manufacturing industry is crucial, especially as it becomes more interconnected and reliant on digital systems. Whilemost automation products come with cyber security protection, malicious software is continuously evolving, and new threats are emerging. Thus, firmware upgrades are released, and the users must keep their firmware and software up to date. Some of the other robust measures that can be adopted for data protection and monitoring systems are regular assessments to evaluate the current state of cybersecurity practices and identify areas for improvement; implementation of stronger security controls across the network infrastructure like all end points and encryption. Employee training and awareness is another important step that the users can take to prevent breaches.

Amidst concerns regarding the complexity of integrating new automated processes with existing infrastructure, which requires additional modifications to ensure compatibility and smooth functioning, what effective measures can be implemented to streamline the integration process and minimize disruptions to operations?

Integrating new automated processes with existing infrastructure can be complex but need not be very challenging. It’s vital to approach integration with a strategic mindset, focusing on long-term goals and the overall efficiency of the production line. One should start with a comprehensive planning and try to consider using modular systems that can be easily integrated with existing infrastructure, allowing for flexibility and scalability. This should be followed by standardizing processes and interfaces to ensure compatibility and simplification of the integration of new technologies. A close collaboration with technology vendors to ensure that their solutions are compatible with the existing systems and rigorous pilot testing to evaluate the integration of new processes on a smaller scale before full deployment must also be done. By taking these steps, manufacturers can effectively integrate new automated processes with minimal disruption to their operations. 

With machinery or systems, industrial automation systems can with time breakdown or malfunction, leading to costly downtime and delays in manufacturing production and impacting the bottom line of a business; how can businesses reduce the downtime and production delays caused by breakdowns, ensuring the manufacturing process is streamlined?

While with advancing technologies downtime due to automation systems is reducing, there may still be some occasional failures. To further reduce unscheduled downtime, most automation companies are working towards solutions that can predict failures. OMRON is also geared up towards finding solutions to these challenges. For instance, our smart sensors coupled with IO Link can detect anomalies due to aging which can then be used to predict failures. 

Amidst concerns that implementing automation may require adherence to specific standards and compliance with safety regulations, how can the industry navigate this complex landscape and what measures can be taken that meet regulatory requirements, contributing to innovation and efficiency within the industry?

Firstly, it’s essential to view compliance not as a barrier but as an enabler of higher standards and better practices that can lead to a competitive advantage in the global market. Unsafe operations or equipment can lead to injuries or even fatalities and hence it is in the interest of manufacturers to have operations that meet regulatory requirements. To ensure safe operations we need to consider the entire machine or line operation and not just the automation piece. Certified professionals are available to provide such safety assessment services and provide recommendations and to carry out subsequent remediation activities. Omron also provides these services. And off course any change in operations or machine design triggers another safety assessment.