Accelerating APAC manufacturing with Rockwell Automation's strategies for smart tech success

By: Kathryn Gerardino-Elagio

In an insightful interview by International Metalworking News for Asia, Marcelo Tarkieltaub, Southeast Asia’s Regional Director for Rockwell Automation, delves into the burgeoning trends of smart manufacturing in the Asia Pacific region.

As the 2024 State of Smart Manufacturing Report reveals a significant shift towards increased automation, Tarkieltaub discusses the driving forces behind this movement, including the quest for higher efficiency, productivity gains, and solutions to labor shortages. His expert perspective sheds light on how these trends are shaping the future of manufacturing in one of the world's most dynamic regions.

 

IMNA: What trends or drivers are propelling the 48% increase in automation investment by APAC manufacturers, as noted in the 2024 State of Smart Manufacturing Report?

The 2024 State of Smart Manufacturing Report reveals that nearly half of APAC manufacturers are boosting automation investments. This trend is driven by the need for cost efficiency, productivity gains, and addressing labour shortages. Automation enhances production cycles, reduces operational costs, and decreases errors. An IDC report predicts that 60% of APAC manufacturers will use automation to improve operational roles, leading to a 50% increase in worker efficiency. Additionally, the ageing workforce is accelerating automation adoption to maintain or improve productivity levels amidst labour challenges.

 

IMNA: What critical factors are driving 69% of APAC manufacturers to adopt smart manufacturing in the next 6 to 11 months?

Rapid adoption is driven by accessible advanced technologies like AI and IoT, as highlighted at Rockwell Automation's ROKLive event in Kuala Lumpur. Sustainability is another key factor, with 91% of APAC manufacturers having ESG policies, aiming to improve efficiency and competitiveness. Cybersecurity is also critical, with 35% of companies citing it as a major challenge and it being a top skill sought in 2024 and a leading use case for AI/ML over the next three years.

IMNA: How is smart manufacturing enhancing product quality for the 43% of APAC manufacturers aiming for this outcome?

Quality remains a top priority for manufacturers, with 43% of APAC respondents aiming to improve it through smart manufacturing technology adoption. This desire is followed by reducing costs and enhancing overall equipment efficiency. Smart manufacturing achieves this through real-time monitoring, advanced automation, AI-driven process optimisation, and integrated quality management systems, ensuring consistent and reliable products and enhancing competitiveness in the dynamic market.

 

IMNA: What technologies are being implemented by the 36% of APAC manufacturers to track and quantify sustainable practices, and how do they contribute to sustainability goals?

APAC manufacturers are embracing various technologies to track and quantify sustainable practices. They utilise IoT devices and sensors for real-time monitoring of energy usage, emissions, and waste, enabling optimisation of operations and reduction of resource consumption and emissions. AI and Machine Learning analyse data to enhance efficiency, predict maintenance needs, and optimise supply chains, thereby minimising downtime and environmental impact. Energy Management Systems oversee energy usage, pinpointing areas for improvement and ensuring energy-efficient operations. Data analytics tools offer insights into production processes, aiding in identifying inefficiencies and implementing sustainability measures. Automation reduces human error, enhances precision, and promotes energy efficiency in manufacturing, resulting in reduced waste and resource consumption.

As an example, the largest pet food manufacturer company in Australia found that with the rapid growth of the production and the business, standardisation of data became vital to ensure ongoing process improvements. With the IoT feature developed as the basis for FactoryTalk® InnovationSuite, they have managed to collect, visualise and analyse data easily through a standardised data platform, easing the business to better contextualise the overall consumption of energy, therefore aiding them in achieving their sustainability goals.
 

IMNA: How is Rockwell Automation addressing cybersecurity concerns in smart manufacturing for APAC manufacturers, where it's cited as the top external challenge by 35%?

Rockwell Automation addresses cybersecurity concerns in smart manufacturing by providing a robust OT cybersecurity capability. This includes a blend of specialised in-house cyber expertise and strategic partnerships tailored to customer needs. Solutions encompass firewalls, intrusion detection/prevention systems, secure remote access, and data encryption to safeguard manufacturing systems. Additionally, Rockwell Automation offers training and awareness programs to instil cybersecurity best practices and foster a security-conscious culture within manufacturing organisations. Through these strategies, Rockwell Automation aids APAC manufacturers and global clients in mitigating cybersecurity risks and safeguarding their smart manufacturing operations.

 

IMNA: What are the main benefits APAC manufacturers gain from implementing smart manufacturing solutions? Can you share some case studies or examples?

APAC manufacturers benefit significantly from smart manufacturing solutions, seeing increased efficiency, improved quality, cost savings, and enhanced flexibility. Automation and robotics boost production speed and accuracy, while predictive maintenance and real-time monitoring reduce downtime and maintain consistent product quality. For instance, a leading Chinese polymer manufacturer successfully integrated Rockwell Automation's FactoryTalk® Analytics™ Pavilion8® software to stabilise production, reduce quality fluctuations, and increase yield. This advanced process control system minimised labour intensity and material consumption, showcasing the transformative impact of smart manufacturing in the petrochemical industry.

 

IMNA: What are the key gaps or challenges that businesses must tackle to fully harness the potential of smart manufacturing in the APAC region, despite its benefits?

Rockwell Automation’s State of Smart Manufacturing Report identifies significant barriers for APAC manufacturers in adopting smart manufacturing, including employee resistance to technology, skill gaps, and infrastructure readiness. To overcome these challenges, empowering employees with digital skills through training and upskilling is essential. AI and ML tools facilitate experiential learning, while AI-powered systems optimise manufacturing processes in real-time for enhanced efficiency and quality. Machine learning algorithms analyse sensor data to detect defects, ensuring consistent product quality and waste reduction.

 

IMNA: What are the primary barriers to adopting smart manufacturing in the APAC region, and how can they be addressed?

The main barriers to smart manufacturing adoption in the APAC region include high costs, skill gaps, cybersecurity concerns, and infrastructure limitations. Overcoming these barriers necessitates technological advancements and strategic interventions. Addressing skill gaps requires investments in training and education, with collaboration between organisations, governments, and educational institutions. Effective change management strategies are essential to foster continuous learning and innovation. For instance, Rockwell Automation signed an MOU with the USAID HEPI project in Indonesia to develop advanced automation teaching labs at universities, preparing students for careers in manufacturing. Rockwell Automation also supports manufacturers through programs like ROKLive and PartnerNetwork, offering education and tailored solutions to kickstart and sustain their digitalisation journey.

 

IMNA: What emerging technologies will be crucial for smart manufacturing evolution in the APAC region?

The Asia-Pacific Smart Manufacturing Market is projected to grow significantly, from USD 54 billion in 2024 to an estimated US$80.38 billion by 2029, with a CAGR of 8.28%. Emerging technologies such as blockchain, Industrial IoT, AI, and 5G connectivity are driving this transformation, enhancing efficiency and sustainability as we transition from Industry 4.0 to Industry 5.0.

 

IMNA: What strategies or programs does Rockwell Automation offer to assist APAC manufacturers in addressing smart manufacturing challenges like cybersecurity and sustainability?

At Rockwell, we host ROKLive, a regional event series offering insights into our latest solutions, including AI, AR, and robotics, and showcasing successful technology implementations. The recent Southeast Asian event in Kuala Lumpur focused on aiding businesses in adopting smart technologies, with another planned in Surabaya, Indonesia. Our PartnerNetwork program connects customers with leading companies to design, build, and maintain automation solutions, streamlining supply chains and maximising investment value.

An inside look at Chen Ying's market leadership and customer commitment

 By: Kathryn Gerardino-Elagio

International Metalworking News for Asia had the opportunity to sit down with Miranda Tsai, International Sales Manager of Chen Ying Oil Machine Co. Ltd., to discuss the company's journey and their unique position in the market.

Miranda Tsai began by sharing the company’s humble origins. "We started very small in 1971 with the CNC machine tool holder," she recounted. "Later, we realised that Taiwan lacked a proper lubrication system. My father decided to address this by implementing a notification system." At that time, Taiwanese CNC machines heavily relied on expensive Japanese lubrication products. Recognising the need for a cost-effective alternative, her father saw an opportunity to develop their own brand products to support local CNC machinery manufacturers.

 

Chen Ying Oil Machine has since grown significantly. In 1997, they were the exclusive agent in Taiwan for renowned brand of Willy Vogel products. "Willy Vogel was quite well-known and were ranked number one in the world for lubrication systems," Tsai noted

The founder of Willy Vogel was particularly impressed during his visit to the Chen Ying factory. "He was pleased with how optimised our operations were and the effectiveness of our product testing system," Tsai said. This visit led to a significant partnership, with the founder choosing Chen Ying as their representative in Taiwan. "He also welcomed us to learn their system, openly sharing knowledge on how to improve our lubrication systems. We greatly appreciated this," she added.

 

Tsai emphasised the importance of this collaboration, noting that it takes a confident company to share such valuable insights. "Strong leaders are not afraid of any competition," she concluded, reflecting on the mutual respect and trust that has defined their partnership.

 

Leading the Market with Confidence

When asked about the threat of competitors copying their products, Tsai confidently replied, "If your product is good, you shouldn’t worry about copies. Competitors will always chase after you because you’re leading the market."

 

Discussing the standout features of their industrial lubrication system, Tsai emphasised their commitment to quality. "Nowadays, people are concerned about costs, but our company’s philosophy is to always provide the best for our customers. CNC machines are expensive, and using a cheap lubrication system to cut costs can lead to damage and greater losses. It’s a small part but crucial, like a heart in a machine."

 

She further elaborated that their lubrication systems are not limited to CNC machines. "It’s also for press machines and any machinery that relies on lubrication. Our main goal is quality, not reducing costs to compete on price."

 

Regarding their manufacturing practices, Tsai proudly stated, "The majority of our supplies are local, except for one. We prefer local sources to support local businesses and ensure quality control. Some suggest using cheaper materials to cut costs, but that compromises quality and longevity."

 

Tsai also highlighted their stringent quality control processes, saying, "We conduct thorough checks during QC and test every part before shipment. We aim for our products to last many years, reflecting responsible manufacturing."

 

Through this insightful conversation, it became clear that Chen Ying is dedicated to maintaining high standards and supporting local businesses, setting them apart in a competitive market.

 

Commitment to Sustainability and Carbon Footprint Reduction

When asked about their focus on green initiatives, Tsai shared, "Yes, we’re actively working on sustainability programs and reducing our carbon footprint. We’re implementing ISO standards and other environmental measures." She emphasised that they are deeply committed to carbon footprint reduction. "Absolutely. In Taiwan, there’s a push to reduce carbon emissions, so we’ve hired consultants to help us calculate and reduce our carbon footprint. It’s a new initiative for the industry."

 

Tsai affirmed that they are aligning with Taiwan’s efforts to promote sustainability in businesses. "Correct. We’re awaiting a report to see the impact of our efforts." She acknowledged that contributing to the environment is a widespread goal, especially in a small country like Taiwan where green initiatives are a priority. However, she also highlighted the challenges they face, such as a low birth rate leading to fewer future engineers. "We’re addressing this by automating our factories," she explained.

 

Discussing the incorporation of automation, Tsai noted, "Indeed. Despite having only 55 employees, we produce a large volume of products thanks to automation, which helps us maintain high quality and reduce reliance on labour."

 

On the topic of exports, Tsai confirmed that they have a broad international reach. "Yes, we export to many countries, including those in South East Asia, Europe like Switzerland and Hungary, and virtually all over the world." She identified Thailand and Indonesia as their largest markets in Southeast Asia, reflecting the company's significant presence in the region.

 

Throughout the interview, Tsai’s insights illustrated Chen Ying Oil Machine's proactive approach to sustainability, automation, and global expansion, positioning them as a forward-thinking leader in their industry.

 

When asked about the introduction of their products outside of Taiwan, Tsai confirmed, "Yes, we’re currently showcasing them at trade shows. We’ve launched a green lubrication system for customers who prefer not to recycle oil due to environmental concerns. This year, we’ve seen a shift towards grease-based systems." This indicates a tailored approach to meet specific customer needs. "For example," she continued, "we’ve designed a system that allows customers to change only the discharge valve instead of replacing the entire unit. This makes maintenance more cost-effective and environmentally friendly."

 

Tsai emphasised the economic benefits of the new model, saying, "Yes, it’s designed for customisation. Companies can easily adapt it to different types of valves as needed." However, she noted that older machines would need an upgrade to the new system if only a part replacement is desired. She highlighted the best feature of the new pressure relief system: "It uses a grease cartridge system, which is simpler for employees to replace without mixing up different types of grease." Moreover, Chen Ying provides additional cartridges, ensuring that after-sales support is robust, with responses to customer inquiries within three days, often sooner.

Commitment to Customer-Centric Lubrication Solutions

On encapsulating the company’s ethos, Tsai mentioned, "We’re still finalising our slogan, but it will reflect our commitment to customer-based lubrication solutions." She emphasised that Chen Ying is more than just a machine parts supplier. "We sell our knowledge to help customers design better lubrication systems for optimal machine performance. It’s not just about selling accessories; it’s about providing comprehensive solutions," she stated.

 

Tsai elaborated on their consultative approach, explaining, "Many customers don’t realise the complexity of lubrication systems. They might think it’s as simple as replacing a part, but it’s not. We aim to educate and provide tailored solutions, not just products." This approach includes assisting customers who are unsure of their needs. "Absolutely," she affirmed. "We often find that customers are confused by the variety of options available. Our role is to guide them to the correct choice for their machinery, ensuring compatibility and functionality."

 

Customer education and support are key aspects of Chen Ying’s business philosophy. Tsai concluded, "I’m not interested in just selling our product for a one-time purchase; I want to cultivate long-term relationships with our customers, spanning 5 to 10 years or more. Our customers stay with us not only because of our products but also because of our service-oriented attitude. That’s crucial for us." Through this interview, it’s evident that Chen Ying Oil. prioritises quality, innovation, and customer relationships, setting them apart in the industry.

🚗🌏 Indonesia: The Biggest Market for Automotive in Southeast Asia!

 

Are you involved in vehicle, motorcycle, or auto parts manufacturing? Indonesia offers incredible opportunities for growth in this booming sector! Don't miss your chance to be part of the action at the 2024 ASEAN Advanced Automotive Manufacturing Summit – Flexible Production & EV Solutions taking place on November 5-6 in Cikarang.

This international conference brings together top industry professionals based in Indonesia who are eager to learn and share the latest trends and advancements in the entire auto parts manufacturing process.

🌟 Key Topics:

• High-performance materials
• Machine & precision tools
• Metal & plastics machinery
• E-mobility and electric vehicles (EV)
• Robotics & automation for automotive and motorcycle production
• Testing machines

🎯 Why Attend? Meet influential decision-makers, exchange insights with expert speakers, and connect with industry leaders in the automotive manufacturing sector. Don't miss out on this opportunity to stay ahead of the curve in Southeast Asia's largest automotive market!

📅 Save the Date: November 5-6, 2024 📍 Location: Cikarang, Indonesia