Some More IIoT Case Studies Showcased at ARC’s Fourteenth India Forum – Part 2

By Amruta Kanagali

In continuation with the IIoT Case Studies Part 1, below follow some more IIoT Case Studies. These case studies are based on information shared during the recently concluded Industry Forum titled “Industry in Transition: Navigating the New Age of Innovation” in India. This blog focuses on the case studies presented by R. S.  Kulkarni & Jeetendra Bhavrani (Nuclear
Fuel Complex, Hyderabad), Lokesh Payik, Head of Smart Manufacturing (General Manager Bosch) and R. Sarangapani (Additional General Manager, NTPC).

Case Studies:


In their joint presentation, R. S.  Kulkarni & Jeetendra Bhavrani gave a joint presentation on the application of modern techniques in manufacturing. They spoke about the company’s activities from “ore to core.” Showing the fuel assemblies and structural manufactured at NFC, they explained the architecture of the modernized system, and the efficacy of their e-cam solution in overcoming irregularities and eccentricities. They discussed a new concept of electronic-camming NFC has employed, while carrying out retrofitting of obsolete dc servo motors & drives with AC servo motors & drives, in this manufacturing process. This electronic-CAM runs as a virtual master in a motion controller software and electronically generates the position set points for each axis and transfers them to networked AC Drives. The designer now enters the data in an excel file or CAM table with a feasibility of entering 1000 points for linear interpolation.

The technology delivers

  • better accuracies,
  • smoother profile due to more number of points,
  • faster design to delivery times,
  • Improved safety and reliability of the manufacturing process
  • Electronic compensation of mechanical errors.


Mr. Lokesh Payik, Head of Smart Manufacturing, General Manager, Bosch shared his views on  Industrie 4.0 and how it
facilitates smart and sustainable manufacturing. A survey conducted by Bosch, a chair member of the Industrie 4.0 framework, reveals that projects that have deployed the approach have improved KPIs in the manufacturing environment. Mr. Payik said that Industrie 4.0 is the “Internetting of all Things and cyber-physical systems.” Bosch’s seven criteria for Industrie 4.0:

    • Fast integration and flexible configuration
    • Open standards
    • Virtual real-time representation
    • Digital lifecycle management
    • Secure value creation network
    • Distributed intelligence; and
    • People at the center of all the above

In a case study, an agricultural pump manufacturer deploying Industrie 4.0 improved productivity by 25 percent; reduced downtime by 20 percent; and provided real-time visibility and performance monitoring.  In another case study shared by Mr. Payik a large automotive OEM was facing issues with its warrant analytics. Every time a product was released, they
needed to predict a warranty claim.  when they worked with automotive OEM. They were unable to predict it properly and
the deviation was 60-70 percent. Bosch provided warranty analytics and helped realize almost 6 million worth saving. Bosch helped in ensuring that the deviation came down to 4-5 percent.

Mr. Payik also spoke about the APAS family, robots that work in tandem with the humans. These robots are made specifically to ensure human safety and consist of 180 sensors. To explain further, he showcased a video demonstration
of the robot. The robot comprises of a sensor skin which stops the robot when it detects a human being in 5 cm radius. Also, once the human is outside the danger zone (about a meter radius) the speed switch in the robot gets activated it proceeds to operate faster.


Mr. R. Sarangapani, Additional General Manager, NTPC, explained how connectivity and interoperability can be enhanced through unified HMI. NTPC had a TG package of 650 MW. This had 2 DCS – one for integral control and one to balance the TG package. One was provided by Siemens and one by maxDNA through BHEL. NTPC needed a unified HMI. The scheme was discussed extensively by Siemens, BHEL and NTPC. All the signals of Siemens were then transferred to BHEL systems and the native HMI of the Siemens Systems was kept separately in the programmer room. This scheme was extensively tested at Siemens, Germany. There were two very important parameters in the testing – due to different HMI they ensured that the latency response time remained undisturbed and the redundancy of links. It was ensured that the TG system was commissioned by the unified HMI only and not the native HMI. Encouraged by this success, NTPC has specified that the future projects should have unified HMIs.

End-users of technology must be aware of what is available in the market and make informed Choices accordingly. 

Case studies, such as these presented at this forum, provide insightful information and feedback to all parties as to what to expect, how to implement, and the quantifiable benefits of deploying new technologies.

About ARC Advisory Group ( Founded in 1986, ARC Advisory Group is a Boston based leading technology research and advisory firm for industry and infrastructure.

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