Achieving excellence in Automation and Enterprise convergence

Transcription

1 ISAB/F&B Symp/ /Slide No. 1 National Symposium on Automation & Digital Transformation of Food & Beverage Industry 26 th & 27 th February 2016 Achieving excellence in Automation and Enterprise convergence Standards Certification Education & Training Publishing Conferences & Exhibits Mr. Kanchan Chakraborty GM Technology & Engineering ITC Limited, Foods Division, kanchan.c@itc.in

2 ISAB /F&B Symp / /Slide No. 2 Mr. Kanchan Chakraborty 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)

3 ISAB /F&B Symp / /Slide No. 3 Agenda 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)

4 ISAB /F&B Symp / /Slide No. 4 What does FMCG business demands? Dynamic Market requirements Low Product lifetime (including SKU) High Flexibility Highly cost competitive Low Margins Multiple Local players High productivity Economical (Overall Project Cost) Quality Consciousness Consistency Low Defective generation Defective detection and rejection systems Efficient

5 ISAB /F&B Symp / /Slide No. 5 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 Efficient: Higher machine productivity Least response time w.r.t troubleshooting High Reliability and reproducibility Cost Effective: Optimal Capital Investment Optimal Maintenance cost

6 ISAB /F&B Symp / /Slide No. 6 Need of Automation : WHY? Value to customer Product Cost Process Consistency and Reliability Resource (Man & Material) Deliverables of Automation: Process consistency and reproducibility with minimum possible resource

7 ISAB /F&B Symp / /Slide No. 7 Need of Automation : WHY? Manpower Dependency Process efficiencies are driven by skill level Quality of production Production throughput Operational and equipment safety Online reliable data capturing Implementation of SPC modules Networking WHY? Availability of Manpower Plethora of Job Opportunities Scarcity of skilled Manpower Rate of increase in Wages (>10% YOY) Upswing of minimum wages across states Cost of Manpower

8 ISAB /F&B Symp / /Slide No. 8 Scope of Automation: Where Manpower Deployment: Manufacturing Process 31% 19% 23% 7% 2% 6% 5% 9% Raw Material Handling Raw Material Processing Quality and Hygiene Driven Packing Sections Manpower productivity, quality and hygiene Driven

9 ISAB /F&B Symp / /Slide No. 9 Scope of Automation: Plant and Machinery Monitoring and maintenance Utilities Air compressors, boilers etc Production Machineries Store Management Instance: Use of CMMS(computerized maintenance management system )

10 ISAB /F&B Symp / /Slide No. 10 Achieving Excellence in Automation Process Knowledge Complete knowledge on process variabilities and control points High Repeatability and reproducibility of performance Cost and competent technology partner base Automation Technology driven approach System design and fabrication System stabilization Quality High Repeatability and reproducibility of performance

11 ISAB /F&B Symp / /Slide No. 11 Enterprise Convergence How automation technology is changing the way industries work. Effectiveness of a technology on a customer/end user Awareness Customer experience Update on advanced technologies Capabilities of technologies Reliability of technology Lead time: Installation to production Cost of technology Periodic Technology induction Challenges faced by Customer

12 ISAB /F&B Symp / /Slide No. 12 Challenges faced by customer Types of Automation Projects 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.

13 ISAB /F&B Symp / /Slide No. 13 Challenges faced by customer 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

14 ISAB /F&B Symp / /Slide No. 14 Challenges faced by customer Feedback and Expectations 1. Mutual Organizational tie-ups. Building up process knowledge pool Appreciate the shop floor constraints 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 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

15 ISAB /F&B Symp / /Slide No. 15 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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