Onward to Industry 4.0: Adaptive manufacturing nature of universal factories lights the way

Gokul NA, Founder - Design, Product & Brand, Cybernetics Laboratory (CynLr) share insights on how universal factory redefines automation, blending human adaptability with machine precision, revolutionizing labor and manufacturing processes for the future.

Transport yourself back to the 1980s, a nostalgic montage, where a cluttered desk adorned with an array of devices. There sits the typewriter, clacking away diligently; the calculator, with its buttons worn from countless calculations; the fax machine, humming with activity; printers churning out reams of paper; telephones resting beside the bulky television set. Each one a marvel of its time, each one serving a distinct purpose.

Fast forward to today, that cluttered desk has transformed into a sleek, all-encompassing marvel: your mobile phone. It’s the Swiss Army knife of technology, seamlessly integrating all those disparate devices into a single electronic powerhouse. The typewriter’s keys have been replaced by a touchscreen, the calculator’s functions are now apps at your fingertips, the fax machine’s dial tone echoes in the messaging app, printers have gone digital, telephones are now pocket-sized communicators, and the television? It’s streaming your favorite shows on-demand.

In this journey from the cluttered chaos of the past to the streamlined simplicity of the present, technology has woven itself into the fabric of our lives, transforming the way we work, communicate, and entertain ourselves. And as we marvel at the capabilities of our modern devices, we can’t help but appreciate how far we’ve come from those iconic images of desks overflowing with gadgets. That’s how universal factory culture emerged where diverse array of machinery replacing by a standardized visual robot applicable to all tasks in a production line.

Gokul NA, Founder – Design, Product & Brand, Cybernetics Laboratory  says, “This consolidation sparked the software industry, now a $12 trillion sector within an $83 trillion GDP market. The concept of universal factories aims to replicate this transformative consolidation, envisioning factories as the product itself rather than merely a place of production.”

In modern times the rising population may lead to space crunch, to convert a space multifunctional will become the only option. Think of everything we use daily, from the glasses on our faces to the food on our plates, even the air we breathe, filtered by various systems. Each of these items originates from a different factory, with its unique machinery, infrastructure, operational methods, and specialized workforce. What if all the goods be it glass, or food are manufactured under same factory by same machinery. This way the space can be utilized multifunctional.

As these factories can only produce one type of product line and cannot be utilized multifunctional thus, they might bring sophistication and also challenges. According to Gokul, the major bottleneck lies in the inability to efficiently switch between tasks. He adds,“Machines struggle with variability and environmental changes, while humans lack the versatility to adapt quickly between different products. Bridging this gap is key. We need technology that combines the precision of machines with the adaptability of humans.

Addressing technological gaps, such as improving vision systems and robotic dexterity, is essential for realizing the vision of universal factories. It’s about blending the strengths of both humans and machines to create a more flexible and efficient manufacturing process in the long run.”

Here is an excerpt of the conversation with Gokul NA, Founder – Design, Product & Brand Cybernetics Laboratory, to delve deep in the concept of universal factories:

Could you describe the inspiration behind the creation of Cynlr and the visual object intelligence platform? What led to the idea and the focus on achieving universal object manipulation?

Nikhil and I encountered a fundamental issue at National Instruments: the lack of generalized automation. Systems are often highly specialized, requiring specialists for customization, which extends beyond factories to various industries like agriculture. We design machines for specific tasks, overlooking the adaptability inherent in humans. We need to adopt a holistic approach, focusing on tasks as a whole, similar to a human’s ability to perform diverse tasks without formal training. This approach will help us overcome the limitations of machines and improve automation.

Currently, there’s a surge of interest in humanoid robots due to advances in AI, with companies like Tesla entering the fray. However, most focus on physical attributes rather than intelligence. Our approach emphasizes building intelligence first, enabling robots to manipulate various objects without prior exposure. This object intelligence enables robots to adapt to unfamiliar objects, crucial for universal automation.

Traditional machines struggle with variability. For instance, a slight tilt can cause errors due to differences in thickness. Our solution, visual object intelligence, enables robots to perceive, feel, grasp, and manipulate objects, even unknown ones, without damaging them. By imbuing machines with this capability, we pave the way for true universal automation.

How do universal factories aim to simplify the complexity of automation processes in both the technical and business aspects of manufacturing?

In the manufacturing sector, there’s both a technical and a business aspect to consider. Simplifying the business is a primary goal, especially since automation can be complex. When someone enters this field, they’re confronted with a multitude of components and customizations required for each system, hindering scalability and efficiency.

Universal factories seek to streamline this process by shifting the complexity into the software realm. Similar to how a laptop’s hardware can adapt to various software applications, universal factories aim to standardize processes so that they can be easily adjusted for different products. Currently, in traditional automation, if the bottle size changes, for example, the entire system must be reconfigured, leading to lengthy application research and engineering cycles.

Technically, the approach differs from typical automation missions in several ways. Traditional automation systems often rely on a conveyor system to precisely position objects for tasks like picking, orienting, and placing. However, these systems require meticulous engineering to ensure accuracy, and any changes to product dimensions necessitate significant reconfiguration.

Moreover, while robotic arms have been a staple in manufacturing for some time, they lack intelligence and require extensive pre-programming for each task. This limits their versatility and scalability. The robotics market, valued at $48 billion globally in 2019, mostly consists of customized solutions rather than standardized robotic arms.

The challenge lies in digitizing these processes to enable quick adaptation to changing market demands. By providing a platform where systems can be easily trained and reconfigured, universal factories offer a more scalable and efficient solution compared to traditional automation methods. This approach simplifies the business by reducing the need for customization and allowing for greater flexibility in manufacturing processes.

How do universal factories address the challenges associated with traditional industrial automation, such as high costs and the need for specific hardware calibration, to make automation more accessible and adaptable for manufacturers?

Absolutely, your concerns and insights are valid, especially regarding the potential impact on employment in the manufacturing sector due to the implementation of advanced automation technologies. Indeed, it’s essential to address the misconception that automation will completely replace human labor.

Firstly, it’s crucial to acknowledge that while automation can streamline processes and reduce the need for repetitive manual tasks, it cannot fully replace skilled workers. Human expertise is indispensable in teaching and programming robots to perform tasks efficiently and accurately. For instance, a seasoned worker who can assemble a product in minutes possesses valuable skills that are essential in training robots to replicate the task.

As automation becomes more prevalent, there may be a temporary reduction in the number of employees required for repetitive tasks. However, this shift will also create new opportunities for skilled workers to transition into roles focused on robot programming, maintenance, and optimization. These experts will play a vital role in ensuring the seamless operation of automated systems and adapting them to evolving production needs.

Regarding the challenges associated with traditional industrial automation, such as high costs and the need for specific hardware calibration, the approach of universal factories offers a promising solution. By leveraging standardized hardware and software platforms, universal factories simplify the deployment and scalability of automation systems.

For example, off-the-shelf robotic arms and intuitive programming interfaces enable rapid setup and configuration, significantly reducing engineering costs and time-to-market. This streamlined approach also facilitates vertical integration and drives down the overall cost of automation systems, making them more accessible to manufacturers of all sizes.

Furthermore, by promoting standardization and simplification, universal factories foster a more dynamic and adaptable manufacturing ecosystem. This not only encourages widespread adoption of automation but also stimulates innovation and the emergence of new market opportunities.

Ultimately, the transition to universal factories represents a paradigm shift in industrial automation, one that prioritizes flexibility, scalability, and efficiency. Whether led by your endeavors or others in the industry, this approach has the potential to revolutionize manufacturing and create a more sustainable and prosperous future for all stakeholders involved.

Could you provide insights into the specific requirements of Indian factories?Could you elaborate on the applicability of robots across sectors, considering we are sector-agnostic?

Our solutions cater to a wide range of industries, spanning from consumer goods to automotive, electronics assembly to life sciences, and even space technology and warehouse operations. We serve clients globally, including the third largest automotive manufacturer in the US, with growing interest from Indian markets as well.

The evolution of automation is driven by the pursuit of consistency and efficiency in output rather than the intention to replace manual labor. Quality assurance is paramount, especially in industries like electronics where customers expect uniformity despite geographical variations. Our goal is to offer flexibility in automation, addressing complex challenges such as assembling components in a moving car, a task that remains unsolved globally.

Elon Musk’s insights underscore the difficulty in automating tasks that are inherently human. While automating white-collar jobs may seem straightforward, tasks requiring real-time decision-making and adaptation pose significant challenges. Our focus lies in automating tasks that are physically demanding or impossible for humans to perform reliably, such as real-time assembly and inspection in diverse environments.

From watch manufacturing to petrochemical inspections, our solutions target industries where human intervention is strenuous or unfeasible. We specialize in discrete manufacturing and assembly, offering tailored automation solutions to meet the diverse needs of our clients across industries.

How do you anticipate India’s automation market evolving in the coming years, particularly in terms of closing the gap with more established markets like China, and what strategies do you believe will be instrumental in accelerating this growth?

In 2019, 350,000 robots were sold globally for automation, contrasting with India’s annual absorption of an estimated 3,000 to 5,000 robots, predominantly in discrete manufacturing. India’s market growth rate is significant, but still lags behind more established markets like China. The automation landscape reflects a disparity between process industries, which are highly automated, and discrete manufacturing, which remains largely unautomated. However, India’s market is rapidly evolving, with a doubling growth rate compared to other regions.

China leads the global market in both growth and absorption of robotic arms, surpassing other countries. While India’s adoption of robotic arms is increasing, it currently lacks the same level of proficiency seen in more established markets. Factors contributing to India’s growth include rising production volumes and an increasing focus on automation across industries. As India continues to invest in automation and technological advancements, the gap between its market and global leaders may narrow.

The challenge lies not so much in price sensitivity but in the know-how and process adoption. Traditional manufacturing firms lack the infrastructure and expertise to seamlessly integrate visual object intelligence technology into their operations. Companies like GM have dedicated research centers for advanced manufacturing, clear policies, and existing processes to facilitate the adoption of new technologies with minimal disruption. However, industries like electronics assembly, where manual labor still predominates, face unique challenges due to the lack of experience and infrastructure for integrating robotic automation seamlessly.

Our approach involves working closely with customers to understand their specific challenges and tailor solutions to meet their needs. We help define and refine processes to ensure a seamless integration of visual object intelligence technology into their operations.

How do you envision the role of robotics and automation evolving in the manufacturing industry over the next decade, particularly in terms of simplification, adaptability, and rapid reconfiguration to meet changing demands?

In essence, the focus of robotics and automation is not primarily on highly intelligent robots for automotive and traditional manufacturing. Instead, the industry is gearing towards enhancing existing machines, increasing their adaptability, and facilitating quicker training. The goal is to reduce the integration time for robots from months to weeks or even days.

The trend over the next decade is expected to prioritize simplification and uniformity in automation processes. Industries are striving for modular factories that can be swiftly repurposed to accommodate new products or technologies. With the emergence of challenges like electric vehicles (EVs) disrupting traditional automotive production, companies are seeking nimble manufacturing setups capable of adapting rapidly to changing demands.

The aim is to create highly flexible production lines capable of manufacturing multiple product variants with minimal reconfiguration. For instance, manufacturing lines are being redesigned to accommodate different models of mobile phones or other products within the same setup. Companies like GM are exploring the removal of fixed equipment in favor of autonomous mobile robots (AMRs) to enable seamless transitions between product variants.

Ultimately, the vision is to create agile manufacturing environments where floors are on wheels, allowing for easy reconfiguration and adaptation to variable tasks and product specifications. This macro trend towards versatile and adaptable production facilities reflects a strategic shift towards future-proofing manufacturing processes in the face of evolving market demands.

How do you anticipate the balance between increased energy consumption and improved material efficiency in the manufacturing industry as automation becomes more prevalent? What steps can be taken to mitigate any potential negative impacts on sustainability while maximizing the benefits of automation?

While we haven’t explored this aspect extensively, it’s logical to anticipate an increase in energy consumption as automation replaces human labor. Machines typically rely on electricity, unlike humans who don’t consume energy in the same way. This shift will likely lead to a rise in overall energy usage. However, there’s potential for significant improvements in waste management and material efficiency.

The primary goal of automation, including traditional methods, is to streamline production processes, minimize errors, and reduce waste. By replacing manual tasks with automated systems, manufacturing can become leaner and more precise. This could result in reduced material wastage and more efficient utilization of resources.

The balance between increased energy consumption and improved material efficiency will ultimately determine the economic viability of automation. How the energy and materials sectors respond to these changes will play a crucial role in shaping the overall impact on profitability and sustainability.

How do you plan to overcome the challenge of introducing the concept of the Universal Factory, which is still relatively new and not widely accepted in the market, to potential stakeholders and industries? What strategies do you have in place to educate and garner support for this transformative vision of automation and manufacturing?

The concept of the Universal Factory stems from our vision of revolutionizing the notion of automated labor. Currently, automation is largely confined to specific tasks and roles, rather than being a generalized replacement for human labor. What we aim to create is an entirely new industry—one where automation isn’t just about replacing human workers, but about transforming the very nature of labor itself.

This narrative isn’t something that exists yet in the market; rather, we are actively shaping it. We’re not just building a company; we’re laying the foundation for a whole new industry. Our goal is to proactively push this narrative forward and make stakeholders rethink the possibilities of automation.

From the perspective of end-users, what matters most is utility. They don’t necessarily care about the intricacies of robotics or artificial intelligence; they care about the practical benefits these technologies can provide. Our vision aligns with the futuristic ideas often found in science fiction—a world where manufacturing is decentralized and brought closer to consumers, where customization is paramount, and where technology enables seamless adaptation and transformation.

Imagine a future where manufacturing isn’t confined to massive facilities but can happen right at the consumer’s doorstep, leveraging existing infrastructure like service stations. This shift would allow companies to focus more on design and innovation, rather than the heavy investments required for traditional manufacturing setups.

While this vision may still seem far-fetched to some, we’re already seeing interest from forward-thinking companies willing to explore these ideas on a smaller scale. But being a fast mover in this space also comes with challenges; the narrative we’re championing isn’t yet widely known or accepted. However, we’re committed to mobilizing the ecosystem and driving the conversation forward, because we believe that the Universal Factory isn’t just a concept—it’s the future of manufacturing.