Gautam Doshi, Advisor, Indian Machine Tool Manufacturers’ Association (IMTMA)
What are your views on “Let the technology take over manual process”
I am very clear about one thing, if you want to become competitive in terms of quality and productivity, it has to be through technology only. There is no short cut to this. Having said that – it has to be an appropriate technology in a balanced way. If we go overboard with technology, we will also have issues on the cost front. So, the exact or required technology that we can use, is the only way to make ourselves stand out in the competitive global market.
When you say that it has to be an appropriate way, how can we justify the cost factor? Also where do you see India when it comes to the adoption of the latest technologies?
The Indian businessman is very smart and therefore has been using appropriate technology. So, it is not that the Indian businessman is an alien to the advanced technology. Over the years markets are opening up. Therefore, if Indian companies want to do business outside India, they have to make products matching their global counterparts. It can be done by the use correct technology.
For Indian market, they may still be able do business, the way they are doing it today in the conventional way .i.e using a combination of technology solutions and certain amount of labour inputs. But to match the global standards the companies will have to come forward to use the correct technology. On the other hand, Indians are very innovative, they will find solutions which are technologically sound but at the same time they will not dispense completely with the labour to bring around good balance between the two. This balance is very important for India. We dont need to do everything what the West is doing or what the developed world is doing. If we do it their way, Indian made will become as costly as them. We have to find good technological solutions, keeping in mind the cost.
Basically, around 60% of the technology is imported and if you go for high-end technology, the percentage of cost is even higher. And when we talk about investing in technology, it means investing in high-end equipment. What are the challenges faced by the SMEs?
According to me, the biggest challenge that the SMEs face is importing high-end technology and the ability to use it at optimum level. The usage is very poor in terms of OEE (Overall Equipment Effectiveness). Most of the SMEs would be working at 40-50% of OEE. So if one uses this technology at such a low usage level, they will not get the best outcome, in the Indian market or anywhere in the world. So the only way they can get fully utilise the technology is to use it 365 days X 24 hours and only then they will realize the benefits and the real economics of the investment.
So the Indian companies have to the find answers to do that, which means not just buying the best of machines but also buying all the peripherals around the machines. Ensure that the machines are utilised fully and high level training is provided to the people who are operating them. Many a times we lack trained manpower, therefore usage of technology suffers. So skill development for the appropriate use of technology is very important. So, OEM manufacturers have to package the training as a part of the supply of equipment. It increases the chances of successfull use of a technology/ solution.
Coming to training, what should be done to address the issue of shortage of unskilled manpower? Do you think industry and academia collaboration can help?
We have an industry who wants readymade solutions and we have academia who is working on research, but there is no intermediate agency or body, which connects the two. That is where we lag. For example, in Germany, there is Fraunhofer Institute, which plays a vital role of bridging the gap between the academia and industry. I have been to Fraunhofer Institute. I spoke to people who are working on research there. The person works for five years in the university and spends five years in the industry, again he comes back to university. This is a continuous process there. Therefore, the connectivity between the industry and academia is very good. Unfortunately, we don’t have such institutes in place. For example, our professors hardly have any industry experience and the industry people have never gone to the institute for imparting their knowledge. So, unless this reciprocal relationship is properly established, we will not be able to create an environment for developing new technologies.
What could be the solution to combat the above mentioned mismatch?
From Association side, we at IMTMA are working towards it. We have, what is known as ‘finishing school’ for production engineers, where engineers are sent for one month training about the basics of manufacturing, so that they become ‘industry ready’. Many companies like Maruti, Honda etc. are sending their people regularly to this finishing school. They recruit engineering graduates and send them here for a month. So at least they have some practical training before hand.
More companies should come forward to do this, larger companies in particular. But the problem is, it does trickle down on the SMEs. In most cases, a fresher joining a SME is directly put on the job and he is only taught on site by a senior, who is working there. So, all the things which the senior doesn’t know, the trainee will also not know. In short the trainee will not only learn the work but might also adopt wrong practices.
Of course we have the National Skill Development Council (NSDC) trying to develop and help skill development. Let’s see and hope for the best.
Do you think initiatives like E-manufacturing Technology can help the industry?
Yes, definitely. It will spread awareness which is the most important thing. We are a price sensitive nation, so it is a challenge to convince people about the cost effectiveness, but if we can prove it to them how a technology will help them in the long run, I think it will help.
What would be your message to the Indian machine tools professionals especially to the users?
Irrespective of which machine you opt for or which technology you opt for, find out how can you use your machine. Use it to its maximum capacity. Can you do that? if you can do that, you will make money. You have to find out where you are losing, where is the waste in your process or in the system. For example, there are 30 CNC machines working, just take a quick round and take a look at spindle knitter. How much percentage power of the total capacity of the spindle motor is being used? And 99% times you will find that on most machines it is being used either at 10% or 15% – 20% of the needed power. Just follow a cursory step, just go around the shop floor – just see the spindle power %. This is the kind of picture you get. So utilise the machines to its fullest.
Only 20%?
Yes, generally you find it in this range. Just go around and note down, see the percentage. Do this exercise and more often than not, this will help.
What could be the reason for this?
Either we are not concerned about it or we don’t know much about it. Even if we know, nobody on the shop floor is really bothered about it.
You mean to say, if it is just 20%, we are working with the less feed rate?
Either the feed rate is less or depth of cut rate is less. But something is not right.
There is still 70% or 60% capacity to be utilised..
No, I would say, if you bring it to about 50%, you are adding 75% capacity. I am not saying go to 100%, you cannot. There are semi-finishing cuts where you will never be able to use 100% power, but at least in roughing there should be 100%. There is no reason it should not be 100% in roughing. How many machines out of 30 are doing roughing? You will realise once you see it.
many times, we go outside and give the material to the vendor for roughing and bring the material inside and do the finishing work. We think we are preserving our machine. Don’t preserve your CNC machine – utilise it fully for five years. However, we want our machine to last for 20 years. Therefore, by doing roughing outside, we are saving a great deal. This is, I would say, a ‘penny wise pound foolish’ approach, because you are not thinking about the logistic costs, communication, paper work and other factors like material handling and time involved in this process.
Nobody is bothered about the hidden or indirect costs. Besides, there could be various threats, like vendor may botch up with the quality of roughing, timely delivery and so on. To get over this why not use our own machine? Therefore, I would say, use your CNC machine 24×7. Make full use of it for five years, take it out and buy the new one with more advanced technology.
Do you think the Indian companies are happy catering to the domestic demand and not keen to look elsewhere for opportunities, are that why they fall behind?
That has been the case so far, but there are some companies who are venturing into the world market with a fresh approach. They will change and they will adopt new technologies.
Historically speaking, why countries like Japan and Germany have progressed? Simply because they were so destroyed in the second world war, that they had to do something drastic, to get on their feet once again. If don’t feel that you have a problem, you will never look for solution. Simply because you get used to the problem, you learn how to live with it and manage somehow. We have to come out of our comfort zone to look for the overseas market and only then we will be able to uplift out technology level.
