ZEISS considers automation to be the bedrock of future-proof production

By Staff Report August 16, 2025 5:40 pm IST

Integrating AI and advanced automation is essential for businesses to stay competitive globally. While challenges like initial investments and workforce upskilling exist, the benefits, such as improved productivity, reduced waste, and quick market responsiveness, are substantial. Aveen Padmaprabha, Head of Industrial Quality Solutions at ZEISS India and Neighbouring Markets, highlights how they are adopting these technologies for sustainable growth in manufacturing.

Stepping into a contemporary factory reveals a subtle yet profound transformation. Machines now anticipate issues proactively, rather than awaiting breakdowns. Robots are no longer confined to rote tasks; they adapt and respond to changing conditions. This signifies the evolving landscape of manufacturing, where Artificial Intelligence (AI) is fundamental in reshaping production, logistics, and material handling processes.

Across India, from cutting-edge greenfield facilities to established plants, AI is being seamlessly integrated into every stage of production. Manufacturers are harnessing AI to optimise productivity, minimise waste, adapt to dynamic market demands, and refine product designs. National policies and escalating enterprise ambition are pushing Indian factories to achieve unprecedented levels of precision, agility, and global competitiveness.

The bedrock of future-proof production

Automation will be the bedrock of future-proof production. Its significance extends beyond mere speed; it’s about taking quality and consistency to unprecedented levels. ZEISS’s advanced automation solutions support this transformation. These systems facilitate critical inline and 100% component inspection, ensuring flawless output.

ZEISS has observed remarkable reductions in cycle times, falling from hours to mere minutes. This includes automated loading, unloading, and the precise segregation of “OK” and “Not OK” parts, virtually eliminating manual errors. Such capabilities give maximum output across multi-shift operations and increase productivity by removing human intervention from repetitive tasks. The inline auto-correction for EDM machines is a prime example of intelligent, adaptive manufacturing in action.

From an implementation standpoint, success is based on a thorough understanding of customer processes for seamless integration of solutions with existing infrastructures. ZEISS prioritises minimising deviations. Addressing customer concerns regarding data storage for comprehensive traceability is paramount. ZEISS foster trust by developing robust systems that guarantee data integrity and accessibility, thereby underpinning reliable automation.

Operational and environmental challenges in automation adoption

Clients primarily seek automation to enhance productivity from existing setups, curtail cycle times, and eliminate manual errors. Their objectives include improving equipment utilisation and augmenting the traceability of rejected parts to refine overall production processes. However, a significant obstacle remains the high initial investment.

From an environmental perspective, increased energy consumption is a valid concern. Nonetheless, this challenge is being effectively managed through the deployment of innovative, energy-efficient technologies, demonstrating that sustainability and automation can advance synergistically. Automation also exerts pressure on supply chains, making the development of resilient networks necessary. On Indian shop floors, the safe integration of advanced automation is important. Worker safety amidst sophisticated machinery demands rigorous protocols and comprehensive training for handling these technologies, making safety a shared priority among all stakeholders.

ZEISS India’s role in supporting digital transformation and Industry 4.0 adoption in India

ZEISS offers specialised automation systems like ZEISS ScanBox and SCANCOBOT, alongside equipment-agnostic software such as ZEISS PiWeb. New solutions, including ZEISS INSPECT, Smart Services, and Remote Health Check, improve operational capabilities. Crucially, all the system software by ZEISS supports CAD-based measurement planning and execution, streamlining critical processes for modern manufacturing environments.

The ongoing transformation of the manufacturing sector, propelled by AI, shifts how goods are produced, moved, and managed. This is fundamental in reimagining industrial processes, leading to the highest levels of precision, efficiency, and adaptability.