The Indian industrial automation market is projected to grow from $13.23 billion in 2023 to $25.76 billion by 2028, at a CAGR of more than 14 percent. The market’s growth is being fueled by manufacturers’ demand for efficient and tailored smart factory solutions to boost competitiveness amid industry evolution. They expect the solution’s integration with existing systems to be smooth and look for customization as per their unique requirements.
Fulfilling these expectations is AMIT (AceMicromatic Manufacturing Intelligence Technologies), a part of AceMicromatic Group (AMG), the largest machine tool group in India. The company is India’s first mover in Industry 4.0 solutions market with over a decade of experience in deploying IoT solutions. It has executed Industry 4.0 initiatives for hundreds of customers successfully, and connected over 20,000 machines, largely in the discrete manufacturing sector – Automotive, Industrial Equipment, Aerospace & Defense, Tool & Die Mould and Medical.
“As we build high technology platforms and products, we prioritize a client-centric approach, dedicating ourselves to comprehending and serving the distinct needs of each customer. By closely collaborating with our clients and evaluating their requirements, production processes, and objectives, we deliver last-mile solutions to precisely address the unique challenges encountered on each shop floor,” says Chandrashekar Bharathi, Managing Director, AMIT.
Digitalization Solution from A Global Machine Tool Group
AceMicromatic Group is renowned for its ability to personalize machine tools according to the exact specifications of customers. Whether it involves altering machine configurations, incorporating specialized features, or developing entirely new solutions, their engineering prowess enables them to craft machines that seamlessly align with the distinctive workflows and production requirements of individual clients. Rather than adopting a one-size-fits-all approach, they engage in consultative sales processes. This entails in-depth dialogues with customers to gain insights into their specific needs and challenges, subsequently recommending suitable machine tools and solutions, including those pertaining to Industry 4.0.
Leveraging its deep domain expertise, AMIT has devised various tailored approaches and solutions for interfacing with CNC machines, aligning them with the specific controller type and manufacturing application. Their proprietary IP-based data acquisition systems seamlessly connect across multiple industrial protocols like MODBUS, PROFIBUS, RS- 232, RS-485 etc. Furthermore, the firm has a dedicated team for understanding and uncovering customer needs, solution architecting, PLC programming and automation, embedded programming, software development, mobile app development, ERP integration, installation and post implementation customer adoption.
Since its inception, AMIT’s IIoT platforms and solutions have evolved, providing invaluable insights that have enabled its customers to achieve a rapid return on investment within months. Beyond CNC machines, the enterprise has successfully digitalized an array of other equipment, including Presses, Gravity Die Casting, HPDC, Injection Moulding, Welding, Foundry machinery, etc. This expansion is a testament to its profound understanding of both the manufacturing domain and information technology. Adding to this is the unique advantage of having service engineers stationed at over 65+ physical locations across India, ensuring responsive on-site support.
Comprehensive Suite of Industry 4.0 Solutions
Today, AMIT offers a comprehensive suite of Industry 4.0 solutions, encompassing eight modules applicable across diverse components, industry sectors, and machine categories. These solutions are versatile, capable of independent deployment or collective implementation, allowing customers to scale their operations incrementally.
Production & OEE Analytics: Through real-time data capture, the organization provides insights into shop floor performance, including part count, downtime reasons, cycle time, and load/unload time variations. It enhances Overall Equipment Effectiveness (OEE) and production analytics, optimizing efficiency and asset utilization.
Real-time SPC and Automated Offset Corrections (AWOC): Integrating metrology equipment with production machines, it offers real-time Statistical Process Control (SPC) and automated tool wear offset corrections. This reduces manual errors, identifies dimensional deviations, and ensures superior quality.
Energy Monitoring: It provides insights into energy consumption relative to part production, electrical parameters like RYB line voltage, and power factors. This enables organizations to benchmark their energy usage and reduce greenhouse gas emissions.
Traceability and Genealogy: It enables tracking of raw materials to final products using barcodes, RFID, or serial numbers. Manufacturers can capture critical process parameters, ensuring comprehensive traceability and product genealogy.
Digital Factory: It allows transition to a paperless factory through machine-mounted displays, tablets, or computers, all driven by a centralized knowledge repository. Strict access controls ensure data authenticity.
Process Parameters: Manufacturers can capture intrinsic CNC controller data and external sensor data (vibration, flow, pressure, temperature) to monitor equipment health and ensure process traceability, yielding valuable insights and predictability.
Assembly & Line Monitoring: It helps manufacturers achieve end-to-end visibility into assembly processes, enforcing digital poka-yoke and workflows to boost line availability and performance.
Visual Factory: It offers real-time visualization of shop-floor status via industry-standard Key Performance Indicators (KPIs) presented in rich dashboards and graphs, facilitating quick decision-making and actionability.
Benefits of Digitalization Services
AMIT enhances efficiency and utilization via digitalization services, reducing component costs. Its solutions empower manufacturers to leverage data insights and enhance maintenance. Through automated data capture and reporting, the company's solutions allow customers to concentrate on productivity enhancements, ultimately boosting profitability.
Today, amg is positioned as one of india's foremost vertically integrated producers of precision cnc machines, automation products, & industry 4.0 software
Improving Competitiveness, Delivering Bottom Line Impact
One of AceMicromatic Group's clients, a prominent global turbine manufacturer, was grappling with a low Overall Equipment Effectiveness (OEE) of approximately 35 percent. The primary impediment they faced was their reliance on paper-based workflows, which led operators to reference outdated versions of drawings and process documents, ultimately resulting in rework and rejection issues.
To address this challenge, AMIT implemented a tailored solution for them, utilizing TPM-Trak Production Monitoring, eSHOPx, and Energy Monitoring. As a result, the manufacturer successfully elevated its OEE from 35 percent to an impressive 66 percent. Moreover, they were able to completely eliminate rejections and rework caused by outdated document references. The solution also made a significant impact from an environmental standpoint by saving over 500 sheets of paper and prints each month. After these improvements, the manufacturer now enjoys consistent annual savings of more than Rs 1.5 crore through the utilization of AMG’s Industry 4.0 solutions.
Connecting Every Aspect of Manufacturing Value Chain
Staying at the forefront of technology and innovation, AMIT drives productivity and transforms customer engagement and revenue models through its AMG-mIoT platform. The AMG-mIoT advanced platform seamlessly connects every aspect of the manufacturing value chain, spanning from the sourcing of raw materials to the final product delivery. This comprehensive connectivity enhances traceability and visibility throughout the manufacturing process. By digitizing this manufacturing backbone, companies can achieve complete "vertical integration" of their crucial business processes. This, in turn, results in processes that are not only faster, but also more efficient and cost-effective. It empowers decentralized decision-making through knowledge-based, predictable, and resilient frameworks.
In order to harness the advantages of Industry 4.0, the AMG-mIoT platform leverages a three-dimensional convergence of business processes, smart Initiatives, and enabling technologies. This convergence is instrumental in identifying specific business outcomes and tangible outputs. Putting information, digital workflows, metrics, and Key Performance Indicators (KPIs) into the hands of both blue-collar and white-collar workers empowers them to operate autonomously while minimizing risks. Importantly, AMG-mIoT is a versatile platform that can be utilized by end-users, machine manufacturers, and service providers alike. The platform enables and delivers outcomes that translate into heightened productivity and increased profits.
The Next Frontier
Today, AMG is positioned as one of India's foremost vertically integrated producers of precision CNC machines, automation products, and Industry 4.0 software. “Our aspiration is to secure a place among the world's top 10 global leaders in our industry. We are committed to achieving this goal by offering cost-effective solutions that yield substantial returns on investment, thereby aiding our customers in enhancing their productivity and boosting their profits,” signs off Madhusudan Kestur, Director, AMIT.
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