Automation is an ideal go to productivity : S.A. Mohan
Over the last couple of years several types of automation systems have been developed to govern the flow of materials in warehouses. The scope of automation is immense. Every aspect of warehousing can be automated including entry and exit operations, inventory management, updating & control, etc. This way one can eliminate manual handling errors, while saving space and time enormously, says Mr. S.A. Mohan, CEO, Maini Materials Movement P. Ltd, in an interview with Mr. P.K. Balasubramanian. Excerpts:
Q. What’s the significance of automation in the manufacturing sector in today’s context?
Automation has a notable significance in manufacturing sector as it improves the quality and productivity of manufacturing, whilst consuming less energy and generating less waste. It also helps to connect engineering design, manufacturing and enterprise systems, enabling a customer-driven responsive production environment.
The operational benefits of automation include speed, repetition, accuracy, safety, efficiency, adaptability and reduced utility and labour costs.
On humane front, automation replaces human operators in tasks that involve hard physical work. Thus, automation is an ideal go to improve productivity, quality and measure the performance as well.
Q. How does ‘automation’ contribute to operational efficiency in the industry?
Business success depends on one’s ability to employ your assets in a way that delivers maximum returns. Automation helps to use existing systems and infrastructure to enhance plant-centric processes and operations for stronger business performance, thus guaranteeing greater efficiency, reliability and predictability in manufacturing.
The main advantages of automation are:
- Increased throughput & productivity
- Reduced lead times
- Simplified production
- Reduced handling
- Consistency of quality
- Increased consistency in processes
- Improved work flow
- Precision in the resulting output
- Reduced direct human labour costs and expenses
Q. Where does materials handling figure in this spectrum?
The role of an effective material-handling system is to ensure that a given material in the right quantity is safely delivered to the desired destination at the right time and at minimum cost – an integral part of any manufacturing activity. A great opportunity for reducing non-productive time in manufacturing exists in the use of the right material handling and storage systems. In most manufacturing plants, materials spend more time being moved and stored than being processed. In some cases, the majority of the labour cost in the factory is consumed in material handling, movement and storage. Benefits of using advanced MH equipment include reduced work-in-process and shorter manufacturing lead times. It is therefore important that this function be carried out as efficiently as possible.
Q. What’s the level of automation one can achieve in materials movement?
Role of AGVs (Automated Guided Vehicles) and Robots have become strategic with respect to the automation and modern material handling practices followed in the present day industry. AGVs are driverless equipment and are increasingly turning out to be an important part of automated manufacturing system. They belong to a class of versatile material handling systems used to transport materials at various locations throughout the facility.
AGVs have fully automated various material handling functions. They are used as towing vehicles, unit load transporters, pallet trucks, forklift trucks, light load transporters; order pickers, assembly line vehicles. Industrial robots have taken automation in material handling to a new level of commercial and technological importance by their ability to perform their work cycles with consistency and repeatability that cannot be attained by humans. They are mainly used for material transfer and material loading/ unloading applications.
AGVs and robots are flexible, reliable, inexpensive to operate, easy to interface with systems such as FMS’s (Flexible manufacturing systems), AS/ RS (Automated storage and retrieval systems) and other material handling systems.
Q. When it comes to storage and warehousing what’s the scope for automation?
Over the last couple of years several types of automation systems have been developed to govern the flow of materials in warehouses. The scope for automation is immense – every aspect of warehousing can be automated including entry and exit operations, inventory management, updating & control, etc. This helps in elimination of manual handling errors, savings in space and time devoted to storage tasks, etc.
Q. How modern are today’s warehouses?
Modern and automated warehouses is an upcoming phenomenon in India. In recent years, warehouse operations in most organizations have undergone significant changes. Warehouses have transitioned to making more frequent inventory transactions in a greatly compressed time frame; storing and handling smaller loads; implementing more value-added services such as labelling, customized packaging and supplier-managed inventories; using less storage space; and integrating more computer technology in warehouse. Automation systems and modules being used in modern warehouses include Automated Storage & Retrieval Systems, automatic guided vehicles, carousels, computer integrated warehouse control systems. Modern warehouses help in reducing costs, improving productivity and accuracy, while giving complete visibility of the inventory data. Both SMEs and larger players can ensure higher accuracy and efficiency in their inventory tasks leading to cost optimization of firms.
Q. Are they making best use of technology for their operational efficiency and inventory management?
Large players are making the best use of technology for their operational efficiency and inventory management. However, as the need for efficient warehousing and traceability grows, even smaller warehouses are being compelled to adapt newer technologies into their processes to stay competitive by cost optimization and accurate and efficient inventory tasks.
Q. What’s Maini’s role, as an enabler, in enhancing operational efficiency in the industry?
Maini Materials has completed over 28 years in its journey of design, manufacture & supply of material handling equipment & electric buggies. The company has pioneered many equipment much ahead of its time and seeded the industry with mechanized products which improved productivity and efficiency of user industry segment.
At present, Maini Materials leads the market in this space and is adding many new products to its offerings. The strategic alliance with NACCO Material Handling Group, USA to manufacture Yale-Maini co-branded forklifts and reach trucks in India is a significant step forward.
Armes Maini, a JV with Ferretto Group, Italy is another enabler to build large format modern warehouses in today’s times where real estate is becoming scarce and expensive. Embassy Maini, a JV with Embassy Group is a thoughtful step to establish logistics parks and build ready-to-use warehouses.
Q. What’s your vision for Maini and how do you look at the future of your company vis-à-vis materials handling & warehousing in India?
My vision for Maini Materials is to continue to be at the forefront of driving sustainable development in the growing warehousing and material handling industry. We are in business of providing products and solutions to our customers. We need to ensure that we continue to offer solutions that are superior in quality, competitive in price while having lowest possible environmental footprint.
In my view, the future of Maini Materials and that of material handling & warehousing industry can be and should be interlinked. As a part of the materials handling and warehousing industry we have a collective responsibility to educate user industry segments on use of modern practices. That is the only way we can be truly sustainable.
