Smart automation and data-driven controls enhance manufacturing efficiency

Manufacturing industries are increasingly adopting smart automation and intelligent control systems to improve operational efficiency, product quality, and profitability. By moving beyond simple monitoring, these technologies allow for real-time insights that maximize yields, minimize waste, and reduce equipment downtime.

In Ahmedabad, India, the Grainfuel Distilleries Pvt Ltd ethanol facility, commissioned in November 2024, utilizes an integrated biorefinery approach. This system converts by-products into valuable goods, such as turning residues into distiller’s dried grains with solubles (DDGS) and capturing carbon dioxide for the beverage industry. The facility also employs a zero liquid discharge (ZLD) approach to recycle wastewater.

Addressing manufacturing variability, research from the National Institute of Standards and Technology (NIST) highlights the importance of using numerical measurements rather than simple pass/fail classifications to track equipment deterioration. Industry experts suggest three primary strategies for intervention: using measurement feedback to prevent scrap, connecting production and maintenance records for faster diagnosis, and implementing process controls or redesigns to reduce persistent variability.