Building the smart factory: Al, IoT, and the future of automation

The integration of AI, the IoT, and automation is shaping the future of manufacturing.

This panel discussion on ‘Building the Smart Factory: AI, IoT, and the Future of Automation’, moderated by Sunil David, Digital Technology Consultant and former Regional Director (IoT), AT&T, explored how to transform traditional factories into smart, connected ecosystems.

Data architecture and IT-OT integration

Smart manufacturing requires a strategic approach that integrates advanced technologies, data-driven decision-making, and continuous improvement. David notes, “In many large MSME factories, operations remain manual, with extensive paper use and minimal automation.” He emphasises that creating a smart factory involves connecting every asset: “With IoT technologies, energy management and machine maintenance become easier, enabling condition-based and predictive maintenance. Future factories will be more flexible, using modular setups to produce different products on the same lines.”

Surbhi Gupta, Head of Digital, Birla Opus, mentioned, “Data architecture is the heart of smart factory operations,” and highlighted the need for IT-OT (Information TechnologyOperational Technology) integration, a challenge for many legacy manufacturers. “Grasim Paints has implemented a fully integrated ecosystem connecting ERP systems, MES, and DCS, enabling faster decision-making and operational agility essential for any smart factory.”

Overcoming legacy challenges

NBC Bearings, a 70-year-old company, faced challenges in extracting data from machines with outdated automation systems. Ashish Ranjan, Chief Digital Officer, National Engineering Industries Ltd (NBC Bearings), noted the difficulty of transforming a legacy factory into a smart one: “The first challenge was extracting data from different generations of machines with varying controllers and automation levels.”