In the bustling metropolis of Mumbai, amidst the vibrant energy of AVEVA Day Mumbai 2023 held on October 6, Murali Sundaram, representing Magic Wand Media, engaged in a compelling conversation with Ajit Kulkarni, Vice President Presales – Asia Pacific, AVEVA. The focus of their discussion revolved around AVEVA’s transformative role in shaping sustainability and development trends in the Indian manufacturing sector. This article will delve into their insightful dialogue and explore how AVEVA is revolutionizing sustainability in the Indian manufacturing landscape.

The Winds of Change: The Connected Industrial Economy 

As the conversation commenced, Sundaram posed a question that encapsulated the essence of AVEVA’s mission: “How do you perceive the growing role of the connected industrial economy in transforming operation management in the Indian manufacturing sector?”

Kulkarni responded with astute observations, highlighting the intricate web of challenges faced by manufacturing companies in India. He emphasized that these companies often traverse a cyclical journey encompassing sourcing, manufacturing, and procurement. Yet, the ecosystems they navigate are becoming increasingly complex. External pressures such as fluctuating customer demands, inflation, and volatile raw material costs exacerbate these challenges. The need for sustainable operations adds another layer to the equation.

He delved into specific examples to illustrate these complexities, and noted the substantial growth of the Indian pharmaceutical sector, which is projected to reach US$ 65 billion by 2024 and a staggering US$ 130 billion by 2030. However, with international exports to over 200 countries, pharmaceutical companies in India must adhere to stringent regulatory standards, including good manufacturing practices and compliance with 21 CFR Part 11.

“Now, if we contrast these challenges with some notable incidents, we recall media reports about the export of cough syrup and, a few years back, the accidental inclusion of melamine in baby milk formula,” elaborated Kulkarni. “These incidents underscore the importance of manufacturers expanding their ecosystems and collaborating closely with their suppliers and partners to ensure a consistent supply of raw materials that meet specifications. This collaboration is a vital aspect of the connected industrial economy.”

 Streamlining Stability and Safety: The Unified Digital Platform 

Transitioning seamlessly from the challenges faced by manufacturers, Sundaram inquired about the advantages of adopting a unified digital platform in terms of stability and safety. Kulkarni’s response painted a vivid picture of how digitalization can mitigate disruptions and enhance operational efficiency.

He commenced by sketching a typical value chain within a manufacturing organization, encompassing recipe management, production, packaging, and shipping. Drawing from real-world experience, he recounted the predicament of a biscuit manufacturer whose packaging line broke down. This seemingly minor glitch cascaded into a major disruption, where the oven capacity was overwhelmed, and an entire batch had to be discarded. This scenario epitomized the challenges that manufacturers encounter when their operations are siloed.

“AVEVA’s MES (Manufacturing Execution System) offers a comprehensive solution,” Kulkarni explained. “Our robust Model-Driven MES, coupled with a process-driven MES, initiates with a preflight check, ensuring that equipment is operational, raw materials meet specifications, and the required workforce is available on the shop floor.”

He continued, “What sets AVEVA’s MES apart is its ’plus plus’ approach. In addition to monitoring, it offers practical solutions such as mobile operator rounds, enabling periodic inspections, and a digital twin of the manufacturing plant for pinpointing issues swiftly. This comprehensive integration across AVEVA’s portfolio culminates in enhanced predictability, lower total cost of ownership, and the ability for companies to confidently adhere to their annual business plans.”

 Digital Transformation and Sustainability: A Synergetic Nexus 

The dialogue transitioned seamlessly into the profound impact of digital tools and platforms on optimizing the manufacturing value chain and bolstering sustainability efforts. This intersection is where AVEVA truly shines, and Kulkarni articulated the pivotal role of their tools and technologies.

“The significance of sustainability is paramount,” Kulkarni emphasized. “AVEVA actively engages in global initiatives such as the Paris Accord and COP28, underlining our commitment to sustainability. We offer a suite of solutions that extends far beyond MES.”

“The toolkit empowers organizations not only to track emissions but also to monitor wastage, effluence, and other contributing factors to greenhouse gas emissions and wastage,” he continued.

Kulkarni delved into the intricacies of sustainability within manufacturing organizations, highlighting the common sources of waste, which can range from improper packaging materials to inefficient raw material utilization and flawed effluent discharge treatment.

“AVEVA’s approach begins with a thorough evaluation of a plant’s operations, often the starting point of a company’s digital transformation journey towards sustainability,” he stated. “The process involves identifying the root causes of discrepancies and setting realistic sustainability goals. This collaborative approach with companies operating multiple plants yields substantial benefits.”

“Tracking emissions plays a pivotal role, encompassing Scope 1 (direct emissions by the company), Scope 2 (indirect emissions from purchased electricity), and Scope 3 (indirect emissions in the value chain, including logistics),” he explained. “Understanding and addressing these scopes are critical for manufacturing companies, given their substantial electricity consumption.”

As the conversation unfolded, Kulkarni detailed AVEVA’s multifaceted approach to sustainability. It involves partnering with organizations offering innovative solutions like Aker Carbon Capture, which captures carbon dioxide from the atmosphere and stores it underground. This transformative technology has already demonstrated its potential, with Henkel in Germany reducing its greenhouse gas footprint by an impressive 37 percent.

“The third avenue is exploring renewable and alternative energy sources,” Kulkarni continued. “Manufacturing companies, though not as energy-intensive as some industries, present a golden opportunity to embrace wind, solar, and green hydrogen. Addressing the variability of wind and solar energy, AVEVA offers the AVEVA™ Process Simulation eBook, a tool that simulates the proportion of wind, solar, and hydrogen required for a consistent energy supply, based on historical data.”

In summation, AVEVA’s holistic approach to sustainability and digital transformation is poised to revolutionize the Indian manufacturing sector. With a commitment to sustainability, a suite of cutting-edge solutions, and a visionary outlook, AVEVA is leading the way towards a more sustainable and efficient future for Indian manufacturing.

Kulkarni’s insights underscored AVEVA’s dedication to driving transformative change in the manufacturing sector, aligning businesses with sustainable practices and elevating operational efficiency.