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Annual Report 2017-18

India has more than 40 million SMEs across diverse segments and the Bosch Industry 4.0 team is helping them integrate Smart Manufacturing concepts across processes to become leaner and more efficient. By creating digital solutions, Bosch is actively connecting man and machine in a manner that can boost productivity.


Bosch’s initiatives include the Industry 4.0 Academy, collaboration with robotics, lean manufacturing and Karakuri Kaizen, amongst others; these solutions are successfully implemented and tested at Bosch facilities before being offered to Bosch customers across the value chain.

Bosch’s transformation to Smart Manufacturing in India revolves around the core concepts of technology and connectivity. Large organizations have been the frontrunners in adopting Smart Manufacturing tools;however,Smart Manufacturing solutions are now proving to be affordable and effective for Small and Medium Enterprises (SMEs) as well. Bosch’s objective is to deploy such solutions across the country’s more than 40 million SMEs and give them a priceless advantage – profitability driven by efficiency.

The example of Ind Carb demonstrates this. Located in Bengaluru, Ind Carb is an industrial heat treatment facility and metallurgical consultant. After integrating Bosch’s Industry 4.0 sensors with its machines, the company is now reaping the benefits of Big Data to improve its productivity. It gets real-time insights into temperature, production and power; this facility-level transparency transforms into effective planning and forecasting for the company’s assets. For an SME like Ind Carb, the benefits of power management and benchmarking asset performance are priceless. They can aid expansion to remote project sites and also kickstart new verticals like predictive analytics for Bosch to tap into.

Bosch’s objective is to reach 100 suppliers and 2,500 connected machines by 2020. SMEs functioning under the belief that adopting Smart Manufacturing requires high investment and long execution time are realizing the merits of Bosch’s plug-and-play solutions. Working over the cloud, these IoT solutions provide SMEs with dashboards that display cycle time, productivity, idle time, OEE (Overall Equipment Effectiveness), energy management and other key metrics. All they need is network connectivity for these sensor-based solutions.

SMEs can choose from two monthly subscription models (‘Capex’ with a one-time hardware cost or ‘Opex’ with no upfront charges) for achieving their goals of quality, delivery, revenue and competitiveness. These solutions are capable of handling huge volumes of data at affordable prices and providing logistics visibility into all downstream processes. They can thus change the game for SMEs.




Smart Manufacturing Story Image
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Employee swipes his card to enter the plant

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It is calculated through complex mathematical algorithms that digitize skills and priorities

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Gets notifications about allocated work for the day

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It saves time and boosts productivity by at least 2.5 percent


Smart Manufacturing Story Image

Smart Manufacturing success stories

Through the Digital Shopfloor management system at Bosch Limited’s Jaipur manufacturing facility for instance, the plant has implemented Smart Manpower. So, whenever an associate swipes his card to enter the plant, he automatically gets allocated to a machine and task for the day. This allocation is calculated through complex mathematical algorithms that digitize skills and priorities. Ultimately, it saves time and boosts productivity by at least 2.5 percent.

Another benefit of Bosch’s Smart Manufacturing solutions is the possibility for workers to perform even more complex jobs. For example, thanks to materials being tagged with RFID cards, workers can track materials across plants and actively participate in asset management, logistics and inventory management functions.

The objective is to create digital solutions for legacy problems using Industry 4.0 concepts. Pravin Pathak, General Manager, Project Leader for Industry 4.0, Bosch India, and his team oversee the creation of centers of competence where transformative solutions can be shared centrally and deployed quickly to boost productivity and output for suppliers.

Pravin says, “We aren’t here to reinvent the wheel. The idea is to take an existing solution and improve it to gain more efficiency. Industry 4.0 solutions are enablers and they deliver holistic value. Our dual strategy of becoming a lead user and lead provider of Industry 4.0 solutions is possible because of our competence in manufacturing. In other words, we prepare the cake, taste it and then make it better to offer it to customers.”

Along with Jaipur, Nashik and Bidadi plants are also taking the lead and contributing to the 72 successful Smart Manufacturing projects running across the country. Success stories include CISS (Connected Industrial Sensor Solution) kits for assessing pump vibration signatures for quality checks and predictive maintenance; collaborative robots, or cobots, that complement human workers; and implementation of machine lines that rely on the ancient Japanese concept of Karakuri Kaizen – a way to move parts through momentum generated by gravity.

Mohan N C, Senior General Manager, Project Leader for Smart Automation, Bosch India, says, “Historically, workers have always been afraid of robots in the workplace, but we are changing that. The physical fear is overcome by covering the robots with skin that has inbuilt sensors. Now, these machines can stop or slow down by sensing the proximity with a human. The other fear is mental, and we are changing that by demonstrating the productivity improvements these robots generate.”




Smart Manufacturing Story Image

Going beyond the shop floor

For Bosch, knowledge sharing is just as important. This is being driven through presence at national conferences and government collaborations. For instance, Bosch has partnered with the CII (Confederation of Indian Industry) Industry 4.0 Council to create a National Action Plan – Samarth Udyog. While the government supports SMEs and industrial bodies with Smart Manufacturing policies, Bosch demonstrates working Industry 4.0 solutions at its plants.

The Industry 4.0 Academy also offers top-down training to senior leaders and has already trained more than 250 senior leaders. Now extended to external participants as well, the Industry 4.0 Academy forms an integral part of the BPS (Bosch Production System) philosophy which is driven by the concept of ‘Lean Manufacturing’

With digital tools and analytics in the mix, Lean takes on a whole new meaning. Ramesh S K, Senior General Manager, Project Leader for BPS, Bosch India says, “The most important factor for information and material flow is time. Anything that saves time in value streams is beneficial and deserves to be scaled. The Lean philosophy focuses on this and Industry 4.0 is acting as a critical pillar to support it. Through transparency and analytics, we simply find areas that don’t add value and replace them with more efficient processes.”

Indeed, the speed and agility delivered by Smart Manufacturing are transforming functions and verticals for SMEs. The results are plain to see, and the beneficiaries are associates at the ground level whose lives have become simpler and more productive.

With digital tools and analytics in the mix, Lean takes on a whole new meaning. Ramesh S K, Senior General Manager, Project Leader for BPS, Bosch India says, “The most important factor for information and material flow is time. Anything that saves time in value streams is beneficial and deserves to be scaled. The Lean philosophy focuses on this and Industry 4.0 is acting as a critical pillar to support it. Through transparency and analytics, we simply find areas that don’t add value and replace them with more efficient processes.”

Indeed, the speed and agility delivered by Smart Manufacturing are transforming functions and verticals for SMEs. The results are plain to see, and the beneficiaries are associates at the ground level whose lives have become simpler and more productive.

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Smart Manufacturing is about connecting man and machine with the objective of making man smarter and more productive. China has about 22 times more robots than India, but India is a fast follower and is adopting external success stories and localizing them. I see huge potential in Indian manufacturing as everyone loves staying connected, and with the country’s strong software base, this is a recipe for success.