AI-powered anti-collision system for our forklifts detects humans, preventing accidents: Vininder Baweja, CDIO, Saint Gobain

The manufacturing sector undoubtedly forms the foundation of multiple big and small industries. As per the India Brand Equity Foundation (IBEF), India’s manufacturing sector is poised to leapfrog to US $1 trillion mark by 2025-26 fueled by investments in automobile, electronics, and textile industries. Saint Gobain, one of the leading names in designing, manufacturing, and the distribution of materials for construction and industrial markets, has brought forth innovation in its operations and workforce management. Vininder Baweja, Chief Digital and Information Officer at Saint-Gobain India opened up on how the company is leveraging advanced technologies like AI and much-valued data to enhance its digital footprint, while swiftly upscaling productivity and building a secured work environment.     

With the onset of advanced technologies, how do you see the manufacturing industry has evolved? How is Saint-Gobain embracing digitalisation in their manufacturing facilities?

In India and across the globe, advanced technologies are transforming the industrial landscape, enabling businesses to boost efficiency while reducing their environmental footprint. By using Industry 4.0 tools such as automation, IoT, and AI, the manufacturing industry has become smarter. This helps reduce waste and make better decisions based on accurate data, which saves energy and boosts productivity. As technologies advance, machine learning models will optimise energy usage with greater precision.

Saint-Gobain is also adopting advanced technologies like the NEO program which leverages real-time data from sensors and programmable logic controllers (PLCs) and optimises manufacturing processes. This helps in minimising energy consumption. Another program, INDEC 4.0 Smart Devices Factory connects devices and systems that make the work process safer and efficient. Apart from these, we have also implemented AI-enabled solutions like visual inspection for deviation capture towards quality improvements; anti-collision system and immobiliser for fleet management or forklifts at the shop floor towards overall safety. These AI-enabled safety solutions at the World Glass Complex, Sriperumbudur reduces accidents, near-miss incidents, minimising the need for energy-intensive repair and replacement processes.

NEO is your customisable IIoT platform. How is it effectively managing your data and driving operational excellence?

NEO is our versatile IIoT platform which is designed to optimise data management and drive operational efficiency. Developed by the Regional IT team, the platform offers a customisable and secure solution for gathering near real-time data from sensors and programmable logic controllers (PLCs). By leveraging IoT technologies and advanced machine learning algorithms, NEO provides valuable insights into key performance indicators, allowing better decision-making, optimised operations, and proactive maintenance.

NEO also addresses market challenges by providing a more affordable and user-friendly approach compared to traditional IIoT solutions. With a focus on cutting-edge technology and knowledge transfer, it ensures long-term sustainability and operational excellence.

INDEC 4.0 is another innovative arm of Saint-Gobain. How is it helping you modernise your infrastructure and processes?

Saint-Gobain is committed to transforming its manufacturing operations through various digital innovations. INDEC 4.0 is a key part of this effort, focusing on using Industry 4.0 technology to make processes more efficient, safer, and sustainable. By integrating digital solutions, we aim to modernise our infrastructure and streamline production. The Smart Devices Factory in Sriperumbudur is a splendid example of our advanced technologies. This facility uses connected devices and advanced tools like workstations for assembly, a circuit lab for design, and 3D printing for prototyping which help improve our operations.

Another solution by INDEC 4.0 is the ProBHM system which provides real-time monitoring of EV battery health, enhancing safety and extending battery life. Moreover, AI-enabled safety systems, such as anti-collision technology for forklifts, reduce accidents and improve workplace safety. INDEC 4.0 also supports predictive maintenance, which minimises equipment downtime and boosts reliability. These are innovations that are helping Saint-Gobain build a smarter and safer manufacturing environment.

In what ways are you leveraging AI to enhance safety and prevent any possible hazards while making your facilities and operations future-proof?

Employee safety and risk prevention are paramount for manufacturing organisations, and Saint-Gobain is at the forefront of this effort. As operations evolve, modern technologies such as AI will play an increasingly key role in achieving these objectives. We are incorporating AI into our daily operations to offer a secure and future-proof working environment.

One such breakthrough is an AI-powered anti-collision system for our forklifts. This system uses cameras and sirens to identify the presence of humans on the shop floor, averting collisions and notifying drivers in real-time. Since its implementation, we have observed a substantial reduction in near-miss incidents by 2/3rd.

Also, to prevent glass breakage caused by sudden braking or harsh acceleration of forklifts, immobilisers equipped with RFID, gyroscopic, and acceleration sensors have been installed in our fleet. This has resulted in a remarkable improvement in safety scores, increasing from 71 percent to 99 percent on site. All these innovations underscore the positive impact of AI-driven solutions on our operations.

Data plays a key role in driving major functions at any organisation today. How are you gathering and managing your data? What innovations have you put in place to fetch actionable insights and leverage your data?

In modern organisations, effective data management is important for improving operations and making better decisions. At Saint-Gobain, we focus on gathering and managing data efficiently to monitor key areas like energy use and equipment performance. We have implemented a robust data management strategy that the organisation leverages to gather and analyse data, extracting valuable insights that help with better decision-making.

One key innovation is the NEO platform which collects near real-time data from sensors and PLCs. This data is then analysed to provide actionable insights that improve operational efficiency. The platform’s user-friendly interface and scalability make it a good option for businesses seeking to implement IIoT solutions. Additionally, INDEC 4.0’s Smart Devices Factory at World Glass Complex utilises connected devices to support business operations and optimise productivity. This has enabled the organisation to implement other innovative solutions such as ProBHM, a real-time EV battery health monitoring system, and ProEdge, a computing device that helps with data collection and processing.

How does Saint-Gobain foresee market trends in the manufacturing sector? What are your future plans and strategies in India? Can we expect any new launches?

India’s manufacturing sector is poised for a renaissance driven by the strategic integration of Industry 4.0 technologies. This digital transformation journey holds immense potential to propel India to the forefront of global manufacturing. At the heart of this revolution are trends like smart factories, digitalisation, AI, and sustainability. Saint-Gobain is staying ahead of the curve by developing digital-enabled solutions that meet the evolving needs of its customers while contributing to making the world a better home.