Saturday, 18 January 2025, Magazine : Manufacturing Today: Online, Language: English, Source: Opinion Piece
At a time when a boom in innovation has rendered many technologies to become mere commodities, what sets apart the winners from the laggards is how you deploy technological advancements and for what purpose. At Aequs, a global platform for contract manufacturing, operational transformation to deliver product excellence to customer timelines and expectations is the core objective of technology deployment.
Precision and Excellence in Manufacturing: Headquartered in Belagavi, Karnataka, India, Aequs specialises in vertical-agnostic manufacturing solutions for global customers. It currently caters to the who-is-who in the Aerospace and Consumer industries. The company manufactures thousands of components for global Aerospace OEMs like Airbus, Boeing and Collins, to name a few, at the Belagavi Aerospace Cluster (BAC). Set up in 2009, BAC is India’s first notified precision engineering SEZ. This apart, Aequs seamlessly integrates its operations in France and the USA to deliver products to global OEMs. Likewise, Aequs manufactures cutting-edge products for global consumer electronics and homeware brands out of two more clusters that are also located in the North Karnataka cities of Hubballi and Koppal, respectively.
What distinguishes Aequs from others in the industry is its unique Ecosystems of Efficiency® concept that leverages vertically integrated manufacturing capabilities and processes that cut across industry verticals. It ensures seamless operations from raw material sourcing to finished goods delivery for its customers, thereby delivering the most sustainable manufacturing solutions for its customers. This, apart from Aequs’ strategic global partnerships, further enhances its ability to meet complex demands.
Innovative capabilities and infrastructure Aequs’ integrated facilities boast specialised units equipped with cutting-edge technology and a skilled workforce. These entities include forging, precision machining, surface treatment, and assembly for the Aerospace industry.
- Largest machining capacity for aerospace in India: These machines revolutionise precision engineering, enabling the production of complex components with exceptional accuracy and repeatability while minimising waste.
- Largest aerospace forging press in India: A first in India, at 10,000 tons, Aequs boasts of the largest hydraulic press specialising in manufacturing highly intricate aircraft parts like wheels and landing gear.
- Lights-out manufacturing units: These fully automated factories operate with minimal human intervention, leveraging machine learning and high-frequency data collection for efficiency and reliability.
- Advanced surface treatment units: Aequs operates the most advanced unit in India to provide innovative surface treatment solutions that are not readily available in India. It is India’s first and only third-party facility to be approved by both Airbus and Boeing.
Consumer business: Leveraging its precision engineering experience and expertise, Aequs has marked a significant presence in the consumer industry, particularly consumer electronics, in the recent past. The company caters to industries like toys, cookware, and electronics, where precision and safety are equally critical. For example, the global toy industry demands customisation, safety, and superior quality—parallels to the stringent standards of the aerospace sector. Similarly, cookware and electronics manufacturing require adherence to exacting customer specifications and quality benchmarks.
Industry 4.0 – the glue that binds the platform: Notwithstanding the seemingly diverse industries that Aequs services, what binds the platform together is the integration of the old-world manufacturing ethos with modern-day Industry 4.0 concepts.
Aequs was the first in the country to roll out a flexible manufacturing system for its Aerospace machining operations, practically making possible even a lights-out factory that can operate 24/7 without human intervention. Once set up, these systems can make components on their own. In addition, it has deployed modern IoT solutions on its massive army of standalone CNC machines to make them work seamlessly as one unit. These systems collect real-time data on parameters such as temperature, pressure, and equipment performance. Advanced analytics and machine learning algorithms transform this data into actionable insights, enabling predictive quality and maintenance, energy optimisation, and improved efficiency and sustainability.
Key technical aspects include:
- IoT-Enabled Data Acquisition: IoT sensors installed across production lines collect high-resolution data on machine performance, environmental parameters, and product quality. This data is aggregated in real-time using industrial edge computing platforms, ensuring low-latency analysis and decision-making.
- Advanced Analytics and Machine Learning: Predictive algorithms analyse equipment telemetry to forecast potential failures. Machine learning models optimise production schedules by identifying bottlenecks, reducing downtime, and enhancing throughput.
- Digital Twin Technology: Virtual replicas of physical manufacturing processes allow Aequs to dynamically simulate, monitor, and optimise operations. This facilitates proactive adjustments in parameters such as tool wear, material flow, and thermal characteristics.
- Integrated MES and ERP Systems: Manufacturing Execution Systems (MES) seamlessly integrate with Enterprise Resource Planning (ERP) software to enable end-to-end visibility, from order processing to final delivery. This interconnectivity ensures efficient resource allocation and inventory management.
Lessons from deploying Industry 4.0: Aequs’ technical journey in deploying Industry 4.0 offers valuable lessons for Indian manufacturers:
- Invest in scalable IoT architectures: Begin with modular IoT solutions that can scale across facilities, ensuring interoperability and data standardisation.
- Develop high-fidelity data models: Use edge and cloud-based analytics to generate actionable insights from sensor data, enhancing real-time decision-making.
- Implement digital twins: Create virtual replicas of critical processes to experiment with optimisation and quality improvement strategies without disrupting operations.
- Train for multidisciplinary expertise: Equip the workforce with mechatronics, data analytics, and software integration skills to manage complex systems.
- Adopt cyber-physical security: Ensure robust cybersecurity protocols to safeguard interconnected systems and prevent data breaches.
- Use AI for dynamic optimisation: Leverage artificial intelligence to adaptively adjust production parameters based on fluctuating demands and operational conditions.
- Collaborate on open standards: Collaborate in consortia to develop and adopt standardised protocols for seamlessly integrating Industry 4.0 technologies.
The road ahead: Aequs’ journey reflects its dedication to staying ahead in a dynamic industry. By adopting advanced technologies and fostering innovation, the company is well-positioned to meet the evolving needs of its customers. India’s manufacturing sector, supported by a skilled workforce and favourable government drives like “Make in India,” offers immense growth potential. Aequs stands poised to capitalise on this opportunity, contributing significantly to India’s emergence as a global manufacturing hub.
Collaboration between manufacturers, startups, and research institutions will further drive innovation and enhance the sector’s capabilities. With its strategic vision, robust infrastructure, and commitment to excellence, Aequs is not just meeting the demands of today but shaping the future of manufacturing.