Synetics aims to be in the top league in automation
Coimbatore-based Synetics Automation Solutions Pvt. Ltd. is in the forefront of automation, providing innovative and cost-effective solutions to the manufacturing sector. Six years down the line, the company has proven its engineering prowess and innovativeness in the areas of its core competence namely CNC auto-loading, assembly automation and robotic solutions, and added an impressive list of customers to its portfolio. Reduced dependence on labour, reduced overheads, increased throughput, increase in quality and consistency and ultimately increased customer satisfaction are some of the benefits of automation the user-industry should take advantage of, says the top brass of Synetics in an interview with
Mr. P.K. Balasubramanian. Excerpts:
Q. Could you explain the beginnings of Synetics?
Vijayaram Balasundaram : Synetics is the brainchild of two engineers – me and Karthik Soundararajan. We both have done our Masters in Automation & Robotics from the Rochester Institute of Technology, in the US. After my MS, I joined General Motors and worked there for 10 years and got rich experience in automated car and truck body welding lines. Karthik joined Alliance Automation Systems as a Controls Engineer handling electrical design of machines, PLC and robot programming. After working for five years, he moved to Assembly & Test Worldwide (ATW) and stayed there for 1 ½ years. In 2007 he came to India to start and head their Indian Operations. Synetics was started by us jointly in the year 2010 with a view to serve manufacturing companies who wanted to reduce their dependence on labor and at the same time improve their quality and productivity. We started the factory with just two employees and today we have a dedicated workforce of 43 people.
Q. Who was your first customer and what’s your present range of manufacture?
Vijayaram: Our first customer was Adulon Polymers based in Coimbatore. For them we developed a painting line using robots. After the initial order, we did two more projects for them – naturally because they were quite happy with our first project. Our current range includes robotic solutions, assembly automation solutions and CNC auto-loaders.
Q. So, what is your niche in automation today?
Karthik Soundararajan: We are primarily full-fledged system integrators and machine builders providing end-to-end solutions. We have a very strong mechanical design team with experience in 3D modeling and analysis, backed up by a controls team with vast PLC & robot programming knowledge. We do the entire assembly, integration and testing in house to achieve ultimate customer satisfaction.
Q. What are your capabilities and major strengths in turnkey automation?
Vijayaram: We are highly creative and we apply our automation experience to come up with innovative solutions that address the customers’ problems. We use high quality and reliable automation components for our systems integration. We focus on building operator-friendly systems also taking care of ergonomics. We have a thorough understanding of OSHA safety standards and lay greater emphasis on the safety of our systems. Our systems are also designed with serviceability in mind and are very maintenance-friendly. When it comes to aesthetics, our products are world-class.
Q. Which are the major projects you have executed recently?
Vijayaram: We have executed five robotic projects – one for machine tending, a large overhead gantry system for welding and two for painting. We have a steady stream of orders for our CNC Auto-loaders.
Q. Which are the innovative products you have developed for automation?
Karthik: Our CNC Auto Loader needs special mention. With auto-loaders attached to 4 CNC’s, one operator can run four (4) machines. So across three 8 hour shifts, the auto-loaders can replace 9 operators. They are less expensive(40% less) when compared to robotic solutions and can be easily retrofitted to existing machines. Another revolutionary product is our Carbide Insert Vending Machine – Pro-Crib, which is a boon to machine shops. Inserts are costly and hence their issue and proper usage should be monitored and controlled. We have come up with two versions. The smaller version is designed for single insert vending to be used for turning centers, while the larger one is meant for machine shops with vertical & horizontal machining centers which need supply of more inserts. Our prototypes are ready and are getting perfected. We shall be launching these machines in a couple of months. The ASRS we have developed for food vending is also a novelty in retail outlets and public places. We have already supplied about 20 such systems. They are now being launched in Singapore.
Q. How do you convince the prospect of the fast realization of ROI.
Vijayaram: When it comes to automation and calculating the return on investment, the customer should consider reduction in manpower, and also the improvement in productivity. With automation one can expect at least 15-30% improvement in productivity. The savings can be worked out as follows: Suppose you have 7 CNC machines. If you attach auto-loaders to 6 machines and achieve a 15% improvement in productivity per machine, you can achieve a cumulative 100% increase. So instead of running 7 machines, for instance, you can achieve your production with 6 machines. This obviates a capital investment of Rs.20 lakhs and also saves on floor space and power required for the 7th machine. On the other side, with manpower, one can achieve only 85% efficiency. When you implement Automation, you can get closer to 95% efficiency and realize several tangible and intangible benefits. And most important, you have peace of mind. One of our customers has realized a huge increase in production. In 12 hours, with manual loading they used to get 1100 components. Now with an Auto Loader, they get 1440, a gain of 30%. At this rate, the 4th CNC machine can be used to produce other components!
Q. What are the do’s and don’ts in Automation?
Karthik: People generally have a bad impression about Automation. This is because the requirements are not defined and customer may not be aware of the Do’s & Dont’s. In order to reap the full benefits of Automation, the end-user should work very closely with the supplier and have a complete understanding of what they will get. Both should get involved and make things happen.
For implementing Automation, the following factors should be considered:
- Identify areas that provide maximum value addition.
- Select areas which are easier to implement and bring ROI faster.
- Select projects where the process is stabilized and less complex
- The input component quality should be consistent, automation cannot handle parameter variations
- Areas where cost of labour is more (or) hazardous environments.
- Take time to define the scope thoroughly.
Q. These days all are talking of low cost automation. What are your views?
Vijayaram: Yes. People say they have achieved low cost automation. But in effect, it may not be true. While working out the cost, one should also include the cost of time invested by their employees and the cost of failures. People should go for cost-effective automation, based on ROI calculations.
Q. How do you keep yourselves abreast of the latest trends?
Karthik : We interact with various vendors who keep us informed of the product developments. We read technology journals, attend seminars and conferences, meet people, visit exhibitions and also access Internet for knowledge and information.
Q. Which are the major industry segments you serve and who are your major customers?
Karthik: Automotive industry, pump industry and materials handling are some of the key industry segments we serve. We want to get into assembly automation in a big way. That’s our core strength.
Q. Which is the most challenging development you have handled?
Karthik: It is the food vending machine we have developed. First we developed with pneumatic automation. Later it was switched to all electric. It is materials handling in a different form. The development was quite exciting and satisfying.
Q. What’s your vision for Synetics and how do you look at the future of automation vis-à-vis Synetics?
Vijayaram: We want to be one of the top 10 players in the automation industry in India by 2025. Our national agenda is to make India a manufacturing hub for the world. But this is possible only if we implement automation and take our manufacturing to the next level. Look at Ford. They have put up a plant in Gujarat with 85% automation in their bodyshop, the highest in Asia-Pacific. Automation has to be taken seriously and implemented by our tier-2 and tier-3 companies. The fact remains that China is way ahead in automation in manufacturing. That is why they are able to mass produce components at cheaper prices. In the days to come there will be more compulsions to go in for automation. The semi-skilled labour cost which stands at a level of Rs.350/- per day is likely to touch at least Rs.800/- per day by 2025.
Today most of the components for automation are imported – PLC’s, servo motors and robots for instance. With the “Make in India” campaign gaining momentum, some of these products will also be manufactured in India and their prices will come down. A combination of increased labour costs and reduced automation component prices will be a big enabler and ROI will be much quicker. In the 80’s the machine tools industry was comfortable with conventional lathes. There was inertia on the part of manufacturers to go in for CNC machines. But in 90’s transition did take place. Today everyone wants only CNC’s because they realize the benefits. Similarly automation is also going through a transition phase in India and the country has to embrace it on a much larger scale so as to keep pace with the industrial growth envisaged.
