Low cost Labour intensive production vs New Product Development and Innovative Manufacturing Which path is suitable for

r India?

GROUP 4
13P183-Abhinay Abhilash 13P193-Ankita Shrivastva 13P203-Debopam Sarkar 13P222-Pratik Panwala

13P223-Praveen Kumar
13P233- Sahil Vij

Challenges in India

One of the major strengths of India has been its diversified industrial base with plants based on different technologies Most of the old plants had outmoded equipment and a large labor force Requirement of up-gradation to match global standards of productivity Problem of managing excess labor which has a significant cost implication Need to focus on developing competitive advantages to have an edge in global manufacturing Slow growth in the past two years after a strong growth in the previous decadeMost of the spending on R&D is by Government Indian companies spend lesser on Industrial R&D as compared to global companies( 8 percent)

WAY FORWARD

New Product Development (NPD)

Innovative Manufacturing Need to move from INTENT to IMPLEMENTATION Need to involve the Private sector

New Product Development(NPD)

Process of bringing a new product to market Two parallel paths involved in the process

Idea Generation, Product design and Detail Engineering

Market Research and Market Analysis

EIGHT STAGES OF NPD

Idea Generation Idea Screening Concept Development and Testing Business Analysis Beta Testing and Market Testing Technical Implementation Commercialization New Product pricing

NPD Strategies

Design for Six Sigma Flexible Product Development

Quality Function Deployment

User Centered Design

Need for Innovation

Has set an agenda to become Germany of the East Right mix of engineering talent and strengthening quality systems Evident by a string of Deming Awards Building R&D centers both at company and sector levels

Manufacturing is critically important to both the developing and the advanced world In the former, it continues to provide a pathway from subsistence agriculture to rising income and living standards and in the latter, it remains a vital source of innovation and competitiveness, making outsized contributions to research and development, exports and productivity growth. Innovations spark additional demand and this accompanied by the emergence of a new global consuming class will create greater opportunities for firms When economies industrialize, manufacturing employment and output both rise rapidly, but once manufacturing share of GDP peaks at 20 to 35 percent of GDP it falls in an inverted U pattern, along with its share of employment. This wages rise, consumers have more money to spend on services, and that sectors growth accelerates, making it more important than manufacturing as a source of growth and employment

In the long run, manufacturings share of employment will remain under pressure as a result of ongoing productivity improvements, faster growth in services, and the force of global competition, which pushes advanced economies to specialize in activities requiring more complex skill The largest segment by output (gross value added) includes industries such as autos, chemicals, and pharmaceuticals. These industries depend heavily on global innovation for local markets they are highly R&D intensiveand also require close proximity to markets. The second-largest segment is regional processing, which includes industries such as printing and food and beverages. The smallest segment, with just 7 percent of global manufacturing value-added, produces labor-intensive tradable In established markets, demand is fragmenting as customers ask for greater variation and more types of after-sales service. A rich pipeline of innovations in materials and processesfrom nanomaterials to 3-D printing to advanced roboticspromises to create fresh demand and drive further productivity gains across

Manufacturing Excellence

Singapore Success
Precision Engineering Centre of Innovation (PE COI) Manufacturing Productivity Technology Centre (MPTC) Sustainable Manufacturing Centre (SMC) Growing Enterprises through Technology Upgrade (GET-Up) operation and technology roadmapping (OTR) initiative Industry-oriented research centres Samsung is ranked fourth among the worlds most innovative companies Highest R&D intensity (3.36% of GDP) South Korean National Science and Technology Council Presidential Advisory Council on Science & Technology (PACST)

South Korean Success

Japanese Success
Kanban Muda, Mura, Muri, SMED, Kaizen Poka-yoke, Just-in-time, Heijunka,Taguchi Loss Function, Jidoka,Gema, Gembutsu, Genjitsu

ROBOTICS Applications & development

Material Handling: material transfer and machine loading and unloading. Material-transfer applications require the robot to move materials or work parts from one location to another Processing operations: robot manipulates a tool to perform a process on the work part Assembly: assembly is expected to increase because of the high cost of manual labour common in these operations Inspection: area of factory operations in which the utilization of robots is growing. the robot positions a sensor with respect to the work part and determines whether the part is consistent with the quality specifications.

NANO-MANUFACTURING

Nano-Manufacturing involves scaled-up, reliable, and cost-effective manufacturing of nanoscale materials, structures, devices, and systems Chemical vapour Deposition is a process in which chemicals react to produce very pure, high-performance films Nanoimprint Lithography is a process for creating nanoscale features by "stamping" or "printing" them onto a surface

RAPID PROTOTYPING

Sterolithography: Optical fabrication Cladding: Cladding is the bonding technique used for producing models together of dissimilar metals and production parts

Additive manufacturing or 3D printing: process of making a 3Dobject of virtually any shape from a digital model 3D printing is achieved using an additive process, where successive layers of material are laid down in different shapes3D printing is also considered distinct from traditional machining techniques, which mostly rely on the removal of material by methods such as Laser Sintering: Technique used for cutting or drilling the low volume production of (subtractive processes). prototype models and functional components.

For India to be the Manufacturing Giant NFD and Innovative manufacturing is the Way Forward Thank You