The Make in India movement proves the government’s intent of making India a global manufacturing hub in the near future. With a prime focus on 25 sectors, ranging from automobile to Information Technology, this initiative will boost India’s position as a global leader while facilitating job creation, encouraging foreign direct investments, improving skill development, and fostering innovations.

Such initiatives and ground-level government involvement require competency and connectivity enhancements across industries. Bosch understands the need to create factories aligned with the vision of the future by innovating and implementing solutions for our own manufacturing units first and then offering these solutions to third parties. Hence, becoming a leading user and leading service provider.
We have implemented smart moves in all our manufacturing facilities. The success of three of our recent in-house solutions clubbed with our skilling initiatives is a testimony to that. It has helped Bosch Limited’s manufacturing units minimize errors and improve the quality of the products. We’ve optimized processes through superior data analytics; ensuring better man-machinery connect; empowering the workforce; and digitizing processes.

India has a huge advantage of a strong IT base for driving digitization, but a smart factory also needs smart people. People are at the core of building factories of the future. Before machines talk to machines in the factory, people need to talk to people

 

 

Andreas Wolf

Joint Managing Director
Bosch Limited

Optimizing efficiencies through intelligent data analytics

Bosch, across its units, has stringent quality check mechanisms that combine multiple testing points. The same holds true for our Common Rail Injector Assembly Line, wherein the process identifies defects in the first go and then accepts or rejects the part accordingly. But each rejection comes at a high cost.

To ensure the highest quality levels across assembly and testing, we used machine learning and algorithm integration to expedite processes and drastically reduce human errors.

“One of the important objectives at Bosch is to match footsteps with the changing times. Through analysis of the current factory scenario, we’ve identified obsolete human-dependent processes to be a bottleneck in the overall scheme of things. To address this concern, the team created the Smart Adjusting Assembly Lines with the help of in-house intelligence,” said Pravin Pathak, Project Leader for Industry 4.0, Bosch Limited.

The CRI Data Analytics system has pre-processed raw data fed on the server to identify quality hindrances across stations, simulates close to a thousand iterations in less than five seconds, and automatically chooses the correct setting. The system also provides early warnings, and gives suggestions for corrections through automated iterative procedures.

With a strong intent to create efficient factories of the future, the CRI Data Analytics system is another example of how we have made systems more intelligent, minimized manual dependency, and explored data to take preemptive measures.

Overview

At Bosch, we understand the need to match steps with new technological advancements and ever-changing times. As the world moves toward Industry 4.0, we realise the need to expedite the process of manufacturing and reduce human errors.

We introduced Smart Adjusting Assembly Line to make manufacturing systems more intelligent and minimize manual dependency.

Benefits of the Smart Adjusting Assembly Line

Bridging the gap between old and new

India is sprinting on the path of digitization. From a factory perspective, many existing machines used in manufacturing units are old and cannot be connected to the Internet of things (IoT) platforms. Since connectivity is an integral part of digitization, we recognized the need to devise a smart solution that could bridge the gap between old machinery and connected platforms without the need to invest in a new set of machines.

Our manufacturing unit in Bidadi exhibited a strong need to forge a machinery-platform connect. The answer to which was the Device Bridge, a software that integrates into the existing Manufacturing Execution System (MES). Since Bosch already has coveted industry-wide manufacturing capabilities, the software enabled transforming them to digitized manufacturing machines.

The software fetches real-time machine status and production information through its multiple drivers and interfaces, which is then uploaded to the MES. This results in leveraging and analyzing existing real-life data to analyze and improve processes.

Device Bridge is an economical, flexible, and scalable solution that is already being deployed across Bosch plants, and not just in Bidadi, India, but also in Germany, the US, and China.

Ensuring superior product quality through artificial intelligence

Bosch keeps customer centricity at the centre of everything it does. And to ensure a higher level of customer satisfaction and delight, we constantly strive towards bringing out the highest quality offerings. A visual inspection solution is not only faster but also does away with human errors by automating the process.

Bosch has been manufacturing inline pumps for more than 75 years in India.

To further improve the quality of these pumps, the team developed the Automated Visual Inspection System (AVIS) that uses high-resolution cameras mounted on robots. The robotic integration ensures that the quality of the image remains unaffected despite the product being on a conveyor belt.

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AVIS clicks up to 40 images in just a few seconds and comes in-built with intelligence based on a thorough learning program. This intelligence further identifies the images as ‘good’ or ‘bad’, enabling quick and error-free decisions. With the capabilities of capturing a high number of product variants, AVIS has boosted productivity and ensured better quality consistency across products.

The scalability of AVIS makes it perfect for being replicated across other Bosch locations as well.

Educating Bosch employees and other players to match steps with changing technologies

To support the Government’s Make in India and Digital India initiatives, Bosch laid the foundation of the Industry 4.0 Academy in 2017 with centres in North, South, and West India. Bosch Limited and Confederation of Indian Industry signed a Memorandum of Understanding (MoU) to conduct sessions on Connected Industry at various Bosch locations. These sessions utilize Bosch plants as a live case scenario to highlight various projects and the ways in which we implement new and innovative technologies.

The academy also makes Bosch employees more technologically sound and up-to-date with new developments in the constantly changing technology landscape.

With a top-down approach to educate and skill across hierarchies, the academy’s knowledge sharing initiative now also extends to external partners. At the time of writing, we have educated more than 300 external leaders on digital technology.

We believe that, for us to transform thoroughly, we need to transform collectively. In line with this vision, our efforts not just ready Bosch to cater to altering needs of the industries but also ensure newer revenue generation models and secure our growth.

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