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NEXT GENERATION MANUFACTURING
WINNING THROUGH TECHNOLOGY & INNOVATION
November 2016
CII 15th Manufacturing Summit 2016
Confederation of Indian Industry
The Boston Consulting Group (BCG) is a global management consulting firm and the world’s leading advisor on business
strategy. We partner with clients from the private, public, and not-forprofit sectors in all regions to identify their highest-
value opportunities, address their most critical challenges, and transform their enterprises. Our customized approach
combines deep insight into the dynamics of companies and markets with close collaboration at all levels of the client
organization.This ensures that our clients achieve sustainable competitive advantage,build more capable organizations,
and secure lasting results.Founded in 1963,BCG is a private company with 85 offices in 48 countries.For more information,
please visit bcg.com.
The Confederation of Indian Industry (CII) works to create and sustain an environment conducive to the development
of India, partnering industry, Government, and civil society, through advisory and consultative processes.
CII is a non-government, not-for-profit, industry-led and industry-managed organization, playing a proactive role in
India‘s development process. Founded in 1895, India‘s premier business association has over 7400 members, from
the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 100,000
enterprises from around 250 national and regional sectoral industry bodies. In its 120th year of service to the nation,
the CII theme of ‘Build India – Invest in Development, A Shared responsibility’, reiterates Industry’s role as a partner
in national development.
With 64 offices, including 9 Centres of Excellence, in India, and 7 overseas offices in Australia, China, Egypt, France,
Singapore, UK, and USA, as well as institutional partnerships with 300 counterpart organizations in 106 countries, CII
serves as a reference point for Indian industry and the international business community.
NEXT GENERATION MANUFACTURING
WINNING THROUGH TECHNOLOGY & INNOVATION
| Arindam Bhattacharya
| Arun Bruce
| Anirudh Tara
| Mani Singhal
November 2016 | The Boston Consulting Group
CII 15th Manufacturing Summit 2016
Confederation of Indian Industry
3
06
16
28
40
05
STATE OF THE SECTOR
THE RISE OF GLOBAL MANUFACTURING SUPERSTARS
INDUSTRY 4.0: TECHNOLOGIES TRANSFORMING MANUFACTURING
INDUSTRY 4.0: IS INDIA READY?
50
AT A GLANCE
59 NOTE TO THE READER
58 FOR FURTHER READING
WAY FORWARD: IMPERATIVES FOR INDIA
Contents
5
Over the long term, the Indian manufacturing sector has performed exceedingly well. During the last three decades, the
sector has grown at a steady annual rate of 13% (nominal), surpassed by just one other country over this time–China.
However, considering its potential and the country's promise in terms of job creation, India still has a long way to go–both
the government's target of 25% contribution to economy and 100 million new jobs are still a far cry from where we are.
While a lot has been said about the sector's potential, we examine a few central areas critically.
We start by taking a look at the government initiatives that aim to promote manufacturing. We recognize the magnitude of
progress already achieved across several areas, from infrastructure, to 'ease of doing business', to labour reforms. We
conducted a poll of industry leaders to record their feedback on government performance (which is quite positive, overall).
We then distil the lessons learnt from fast growing manufacturing economies from across the world–China, the USA,
Switzerland, Vietnam, Mexico, and the UK. Lessons learnt and their implications vary from the obvious “given” (e.g. fixing
infrastructure) to the evolved (R&D investments, niche-sector focus, FTAs, etc.).
We also study the accelerating trend of technology in manufacturing–otherwise called Industry 4.0. We observe that there
are many more Indian examples now than before of “Industry 4.0", and we recognize that the advanced adoption of
technology trends could be a major differentiator as we evolve into a manufacturing powerhouse.
Finally, we synthesize and lay down the implications for the government and the industry–both to promote the sector in
general, and to specifically drive technology adoption. We strongly believe that the industry is at a tipping point. How
Indian manufacturing reacts to technology adoption could be the difference between gaining its rightful prominence in the
global manufacturing stage and getting stuck in a catch-up game as early adopter economies take the lead and realize
huge productivity dividends.
Happy reading!
At a Glance
STATE OF THE
SECTOR
7
“Nourish your hopes, but do not
overlook realities.”
– Sir Winston Churchill
8 | NEXT GENERATION MANUFACTURING
The Indian manufacturing sector has performed well
over the long term
Source: Euromonitor; World Bank.
One Rupee
Output in
1990 has today
grown to…
he Indian manufacturing sector is a perfect example of a reliable, steady workhorse. The sector has shown steady results with a Compounded
Annual Growth Rate (CAGR) of 13% (in nominal terms) over 25+ years. In the process, it has grown faster than most other economies, with 1 rupee
of output in 1990 increasing to 21 rupees today. The only notable exceptions are the Chinese manufacturing and Indian service sectors.
T
₹16
₹21
South Korea
Manufacturing
₹14
Agriculture
India
₹11
Mexico
Manufacturing
India
Manufacturing
Thailand
Manufacturing
₹34
Services
India
₹96
Manufacturing
China
₹5
South Africa
Manufacturing
Germany
Manufacturing
₹5
USA
Manufacturing
₹8
₹21
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 9
There is significant untapped potential for Indian
manufacturing
Source: Euromonitor; WTO; World Bank; Government of India; BCG Analysis.
Global Trade Share
12%
3%
2%
4%
12%
7%
U.S.A.
Mexico
India
S. Korea
China
Germany
GDP Share
16%
India
20%
Mexico
25%
GoI Target
27%
China
28%
S. Korea
Employment Share
10%
18%
29%
Germany
Mexico
India
S. Korea
GoI Target
China
17%
20%
20%
22%
Germany
hile historical growth has been impressive,benchmarks indicate an even greater potential ahead. Many government initiatives have targeted a
25% GDP share; China's manufacturing sector is already at 27%. Covering only 2% of global trade and 10% of formal employment, India's
manufacturing holds enough potential to drive a new era of inclusive economic growth for the country.
W
10 | NEXT GENERATION MANUFACTURING
The slowdown in global trade is exerting pressure on
manufacturing economies
Source: World Trade Organization.
Note: Merchandise trade to GDP ratio is estimated as merchandise trade (average of exports and imports values) divided by GDP, measured in nominal dollar terms at market exchange rates.
T
30
25
20
0
Ratio of world merchandise
trade to GDP (%)
2015
2010
2005
2000
1995
1990
Collapse in consumer
demand during
financial crisis
Negative growth driven
by trade restrictions
and reshoring
20 years of secular growth
driven by deconstruction of
supply chains and outsourcing
he global manufacturing sector is likely to face obstacles over the next few years. Economies seem to be getting increasingly isolated and the
gains from globalization seem to be reversing.Many developed countries have started implementing restrictive trade policies, including the US
with their 200%+ anti-dumping duty against steel from China, and 90%+ from other countries.Political developments such as Brexit is another sign of
de-globalization. Countries with strong local markets, including India, will likely continue to do well, while export-oriented manufacturers could face
challenges.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 11
India's recent manufacturing performance has been
below par
12
6
0
-6
Manufacturing production growth
year-on-year change (%)
Aug’16
Apr’14
Jun’14
Apr’15
Jun’15
Feb’16
Apr’16
Feb’15
Dec’14
Dec’15
Jun’16
Oct’14
Aug’14
Aug’15
Oct’15
Source: Ministry of Statistics & Program Implementation; Government of India.
The last 12 months have been quite poor for the Indian manufacturing sector. After starting off well in the first half of FY16 and peaking in
October 2015 with an output growth of ~10%, the sector has seen a decline. The maximum growth since October last year has been only 2% with 7
out of 11 months showing a negative y-o-y growth.
12 | NEXT GENERATION MANUFACTURING
Slowdown in the capital goods has been most
concerning
Basic
Goods
Capital
Goods
Intermediate
Goods
Consumer
Goods
Petroleum fuel, Cement,
Basic metals etc.
Commercial vehicles, Light
and heavy machineries etc.
Metal products, Cotton yarn,
Plywood etc.
Electronic products,
Passenger cars, Two
wheelers, Apparel, Processed
food products etc.
FY12-15
FY16
FY17
(Apr-Aug)
4%
4%
4%
2%
3%
21%
2%
3%
4%
0%
3%
1%
Source: Ministry of Statistics & Program Implementation; Government of India.
While the overall performance has been poor, what could hurt manufacturing most overtime is the contraction in capital goods. Capital goods, an
indicator of economic investment has de-grown by over 20% so far this year. Over 40% of demand in capital goods was fulfilled through imports,
while capacity utilization across sectors was only 60-70%. While private consumption in the capital goods sector saw an even sharper fall, public sector
and government demand provided much needed respite through investments in the infrastructure sectors of power, rail, oil & gas, and roads.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 13
"Make in India": Government initiatives in place to
drive manufacturing growth
Apr 2015 Apr 2017
Apr 2016
Passed in Lok Sabha
GST Passed in Rajya Sabha Slated to be implemented
Power UDAY scheme passed
Tariff Policy–
Electricity for all
FDI FDI norms relaxed
for 15 sectors
FDI norms further relaxed for 9 sectors
Transport Sagar Mala project initiated–
ports led development
Construction of 15,000 km of
new roads by 2017
Industry
specific
Package launched for textile industry
Labour
reforms
Finance Bankruptcy code passed Repo rates lowered to 6.25%
A lthough the recent rate of growth has been a concern, the long term business environment is improving. Make in India has been more than just
a buzzword. The government has made good on its commitments to drive the manufacturing sector by introducing a set of initiatives to improve
manufacturing performance. Infrastructure, policy and taxation efforts across have resulted in landmark reforms.
Not Exhaustive
Solar power increase
by 66% anticipated
Source: Press articles.
Apprentices rules
amended
Shram Suvidha
Portal launched
Labour reforms; easy hiring &
retrenchment, flexible female participation
14 | NEXT GENERATION MANUFACTURING
Results visible along with increased optimism
in the industry
Industry view: Expected growth in
manufacturing in the next 5 years
2014 2015 2016
8.1% 8.6% 8.8%
Ease of
Doing
Business
ROADS
built
PORTS
capacity
RAIL
tracks
2014
12
km/day
27
km/day
800
MT
965
MT
4
km/day
7
km/day
Infrastructure
2016
142 130
Energy
Gap
Peak
Power
Gap
Power
Getting
Electricity
Rank
2014
-4.2%
-4.5%
2016
-2.1%
-3.2%
51
2017
estimate
1.1%
2.6%
26
$40Bn
$25Bn
FDI
2014 2016
111
Source: World Bank; Ministry of Power; Ministry of Road Transport & Highways; Ministry of shipping; Department of Industrial Policy & Promotion; CII–BCG Manufacturing Leadership Survey.
The results are visible. Ease of doing business rankings, power availability, infrastructure, and FDI inflows have all seen significant improvement
over the past 2 years. The impact is also evident on the mood and optimism of the industry with key industrial leaders today having higher growth
expectations.While this is a good start, how this optimism translates into growth on ground remains to be seen. It will require continued efforts from
both industry stalwarts and policymakers alike in order to reverse the current trend.
Rank Rank
actual
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 15
Two structural shifts shaping global manufacturing
While the Indian manufacturing sector is steadily growing, it is equally important to keep an eye out for global shifts. Two such shifts are outlined
in the next few chapters –
• Rise of other manufacturing economies: the global manufacturing superstars
• Technological changes: The Fourth Industrial Revolution also known as Industry 4.0
The Fourth
Industrial
Revolution
Rise of
Manufacturing
Superstars
THE RISE OF GLOBAL
MANUFACTURING
SUPERSTARS
17
"It's not enough to do your best, you must know
what to do and then do your best."
– W Edwards Deming
18 | NEXT GENERATION MANUFACTURING
20
6
2
0
-4
-6
2,250
1,000
500
250
-2
0
4
United Kingdom
Netherlands
Italy
France
South Korea
Indonesia
United States
Germany
China
Brazil
Russian Federation
Vietnam
Sweden
Austria
Japan
Thailand
India
Canada
Manufacturing
Exports (US$ Bn)
Spain
Switzerland Mexico
Belgium
Growth rate in the last Five Years (%)
Seven manufacturing superstars have shown growth in
exports over the past five years
n a period where the world trade in manufactured goods has been on the decline, there are several countries that have still managed to consistently increase their exports.
As we evaluate the ways in which India can boost its manufacturing sector and progress towards its 'Make-in-India' targets, it is worthwhile to learn from these
manufacturing superstars. These superstars consist of six large manufacturing economies (above $250Bn of export) that have shown positive export growth in the past five
years. They are Switzerland, Mexico, United Kingdom, South Korea, United States of America and China. An addition to this list is Vietnam with its extraordinary 20% growth.
I
Source: World bank; World Development Indicators data; BCG Analysis.
Small Medium Large
Under
Pressure
Accelerated
Growth
Growing
Exports Value (manufactured goods)
Export
Growth
(manufactured
goods)
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 19
Mexico: Building on location advantage
9.7%
5.1%
0.6%
3.9%
100
50
0
% Share of exports
Others
Machinery
Electronics
Automotive
2015
2014
2013
2012
2011
2010
2009
2008
2007
2006
2005
2004
% Share of exports
89%
2004
11%
USA
RoW
2015
81%
19%
USA
RoW
Canada
China
Brazil
1.8%
0.5%
0.5%
Canada
China
Brazil
2.8%
1.3%
1.0%
0% Duty on Mexican goods in USA
44 Free Trade Access to developed markets
including USA, EU, Canada
1 USD vs Peso
Peso vs USD
depreciation
Electricity
(c$/KWh)
Labour
($/h, productivity
adjusted)
4
20
29%
45%
45%
2004
7.33
37
2015
exico's proximity to the USA, the world's largest consumer market, is the cornerstone of its early success. Taking advantage of its low labour
costs, Mexico targeted the US market and inked free access to the United States with a Free Trade Agreement(FTA) in 1994. The maturing of
this agreement (phasing out of trade barriers) led to export growth in the ensuing decade. While the USA still gets the largest share of exports, Mexico
has diversified by increasing exports of automotive and machinery to other countries. The government has continued to focus on manufacturing
exports,establishing FTAs with 44 countries, the highest in the world. With continued labour cost advantages, depreciating currency and falling energy
costs due to shale gas, Mexico is one of the cheapest manufacturing destinations in the western world. Skilled and hardworking labour force coupled
with free access to most developed markets makes Mexico a very attractive destination to set up manufacturing units.
M
Source: Sener; EIU; BCG Analysis.
Note: Though not all sectors have duty free access through NAFTA, duties and tariffs have been phased out by 2009 for select sectors (e.g. Auto).
11.3 15.9
20 | NEXT GENERATION MANUFACTURING
Vietnam: Export-oriented economy on its way to
becoming a global star
120
90
60
30
0
Others
Machinery
Footwear and
Apparel
Electrical and
Electronics
2014
2013
2012
2011
2010
2009
2008
2007
2006
2005
2004
2003
2002
2001
2000
1999
1998
1997
• Investment law–Incentives for FDI
in multiple sectors formalized
• Vietnam joins WTO
• Apparel industry boom: Strong
focus on low wage, low skilled work
• Post 2009 financial crisis, Vietnam an
attractive low cost hub
• Government push: sweeteners for electronics
companies (e.g. Samsung)
• Intel invests $1Bn, LG $1.5Bn, Samsung
$2.5Bn; commitments for another $9Bn
• Investment law amended in 2014 to
encourage companies to expand facilities
Exports (US$ Bn)
19%
20%
27%
tarting from the reforms in 1986, Vietnam has come a long way in the global economy. The first phase of growth came after the quota system ended and Vietnam
became an attractive destination for labour intensive industries given its labour cost advantage. This started the apparel manufacturing boom with factories shifting away
from China to Vietnam. Access to the USA through a bilateral trade agreement and to the EU through LDC norms created the right ecosystem for growth. The second phase of
growth has come by means of change in Investment laws and incentives in 2004 which promoted FDI. During the financial crisis, as companies looked to cut costs and restructure
supply chains, Vietnam aggressively attracted electronics manufacturers like Intel, Samsung and LG. Electronics now forms 32% of all manufactured exports, moving away from
labour intensive to more value added manufacturing goods.
S
Source: UN COMTRADE; trademap.org.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 21
The UK: A low cost manufacturing center in Western
Europe witnessing a resurgence in manufacturing
30
40
50
1995 2000 2010
2005
1990
10
0
2015
20
United Kingdom
Spain
France
Germany
Switzerland
Corporate Tax 20%
Productivity Adjusted Wages
($/hour)
Exports
64
51
36
29
$ billion
$ billion
$ billion
$ billion
CAGR
(2010-15)
2%
6%
1.5%
-2%
Machinery
Automotive
Pharma
Electronics
32% 33% 37%
he investment by Jaguar into a $740 million facility at Wolverhamptom is indicative of the course that manufacturing will be taking in the UK.
With the lowest corporate tax rates in the G7, highly flexible labour laws, highly skilled workforce and a strong R&D support system from
academia, the UK is seeing a spurt in manufacturing. Free access to the European market along with wages that continue to be competitive against
that of it's neighbours have made this country a regional superstar. With Brexit threatening to curb free access while the depreciating pound enhances
competitiveness,it could be interesting times ahead for the UK.
T
Source: EIU; COMTRADE; trademap.org.
22 | NEXT GENERATION MANUFACTURING
China is reinventing itself as a high-tech manufacturer
as labour costs rise
Exports
2011 2015
5%
1.7 2.1$ trillion
100
80
60
40
20
0
% of manufactured exports
2015
2014
2013
2012
2011
2010
2009
2008
2007
2006
2005
2004
2003
2002
2001
Electronics
& Electrical
Machinery
Apparel
3%
8%
7%
R & D Spend
(% GDP) 1.2% 2.1%
Infrastructure
Competitiveness
Rank
521 39
Cost Advantage
v/s USA 13% 3%
2004 2015
% Population
Enrolled in Higher
Education
18% 31%
t the time of induction into the World Trade Organization (WTO), China was largely a destination for low cost goods with cheap labour geared
towards the export market. But as the country became more prosperous, wages nearly quadrupled between 2004-2014 bringing the low-cost
manufacturing tag under attack. China, over the last decade and half, invested in R&D, infrastructure and education, to move away from labour intensive,
low value-added goods like apparel to R&D intensive high-tech goods such as Electronics and Machinery. While it is still one of the most cost-competitive
manufacturing locations, with export subsidies being gradually phased out, a new wave of competition from other countries could be on the horizon.
A
1 2006 number. WEF rankings start from 2006.
Source: UN Comtrade; WEF competitiveness rankings; EIU; World Bank Trade Indicators; BCG Analysis.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 23
South Korea: Maintaining a strong position in high-tech
manufacturing
Labour
Productivity
between 2005-2015
39%
R&D
spend
(% GDP)
2.1%
4.3%
Population with
college degree
(% 25-34 years old)
2.7%
46%
3.6%
59% 18%
68%
$Bn
Machinery 62 3.6%
Plastics 22 3.3%
CAGR
2010-2015
Automotive 69 5.3%
Electronics 138 4.5%
ver the past decade, labour productivity in South Korea has increased by 40%, driven in large part by rapid technology adoption. The
government, through its policies and funding for smart factories, is driving Industry 4.0 adoption aggressively. South Korea has an impressive
track record in terms of R&D, investing as much as 4.3% of GDP in R&D–higher than most developed countries.The country also has a very educated
workforce, making technology adoption and innovation easier. Besides automotive,high value added goods such as electronics and machinery make
up the bulk of its exports,and are likely to continue growing given the efforts to drive productivity.
O
Source: EIU; COMTRADE; Trademap.org.
24 | NEXT GENERATION MANUFACTURING
Switzerland: Focused on winning in niches
Global
competitiveness
ranking
8th
R&D
spend
(% GDP)
1st
Intellectual
Property Rights
Protection
3rd
Fostering
Innovation
1st
Watches
Precision
instruments
23
15
8%
2%
Pharmaceuticals 61 6%
(12% of world exports, non-generics)
CAGR
2010-2015
Exports
$Bn
Headquarters
(41% of world exports)
nnovation has been the key driver of Switzerland's growth. The pharmaceuticals and watchmaking industries are unparalleled in the world and are
niche segments that Switzerland focuses on. The strong ties between academia and industry, accompanied with the ability to attract and retain top
talent enables Switzerland to succeed. Extremely efficient IP processes (11 months for a patent) and significant R&D spend on pharmaceuticals by the
government,helps them stay ahead of the curve. Pharmaceuticals and chemical products have a tax benefit of 2.5%, further encouraging these
industries to grow.
I
Source: WEF competitiveness index; EIU; World Bank Trade Indicators; BCG Analysis.
Pharma
Watches
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 25
The USA: Manufacturing resurgence around the corner
(10th)
Exports
teady wages, and gradual increases in productivity,have made USA manufacturing in the world competitive.With Chinese costs verging those of
the USA over the past decade, USA has again become a viable choice for manufacturing locations. Strong IP laws, flexible labour laws and rapidly
falling energy prices due to the shale gas boom are making the USA cost effective.A culture of innovation and high investments into innovation help
ensure that USA remains competent in the high tech market.
S
Aerospace
& Defense
Automotive Electronics
Precision
Instruments
2%
CAGR
(2010-2015)
2%
11%
5%
1,200
900
600
300
0
2015
2010
2005
2000
1995
1990
1985
1980
USA manufacturing Exports (US$ Bn)
Energy cost
(2010-2015)
Productivity
(2009-2014)
Wages
(2010-2015)
R&D spend
(Rank as % GDP)
Federal Interest
Rate
(% Interest)
11%
$60 Bn
6%
9%
Source: EIU; US energy agency; US Treasury; BCG Analysis.
0.25%
(2009-2015)
8%
0%
4%
Manufacturing
resurgence due
to reshoring
China
joins
WTO
26 | NEXT GENERATION MANUFACTURING
Three key lessons to be learnt from the manufacturing
superstars
Exploit natural
advantages
Identify natural advantages in comparison with competing
countries
Advantages can be based on geographical location, labour, energy
costs, etc. (e.g. Mexico for geographical advantage and China for
low-cost labour)
Create strong barriers for competition to break into a sector.
Significant spend on R&D and innovation can create a knowledge
barrier for other countries to compete with (e.g. South Korea &
USA)
Invest in infrastructure and human capital to keep a competitive
advantage over other countries–Spend on education,
infrastructure (e.g. China & South Korea)
Strategic policy interventions to promote target sectors for the
future (e.g. FDI promotion in Vietnam, export promotion
incentives in China & tax breaks in Switzerland)
Select target markets and promote trade (e.g. Free Trade
Agreements for Mexico and Vietnam with the US and the EU)
Invest to create
competitive
advantages
Introduce policy
interventions
in target sectors &
markets
INDUSTRY 4.0:
TECHNOLOGIES
TRANSFORMING
MANUFACTURING
29
"As all these trends happen, the winners will be
those who are able to participate fully in
innovation-driven ecosystems by providing new
ideas, business models, products and services,
rather than those who can offer only low-skilled
labour or ordinary capital."
– Klaus Schwab
Founder and Executive Chairman of
the World Economic Forum
30 | NEXT GENERATION MANUFACTURING
We are already in the era of Industry 4.0,
The Fourth Industrial Revolution
Industrial
Revolution
eras
ith every industrial revolution we have seen labour and asset productivity multiply and structural shifts emerge in the manufacturing world
order. From the steam and water power in the 1700s to the electric and automation revolutions in the 19th century, we have already seen three
big shifts.We are now in the midst of The Fourth Industrial Revolution where digital technology is transforming traditional manufacturing to give rise
to connected cyber physical systems. This latest revolution is fittingly called Industry 4.0.
Late 18th century
Early 20th century
Today and in the near future
Early 1970s
Mechanized production
Water and steam power
Fusion of technologies
straddling physical,
digital and biological
worlds
Automated production
Robots, IT &
electronics
Mass production
Electrical energy
Increasing complexity & labour productivity
W
1.0 4.0
3.0
2.0
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 31
Technological megatrends have created conditions ripe
for this revolution
Infrastructure
as a
Service (IaaS)
Platform as
a Service
(PaaS)
Software as
a Service
(SaaS)
Applications
served to
customers
on-demand
via web
Virtualised
computer
infrastructure
(e.g. server,
storage)
Scalable
platform for
developing/
hosting web
applications
Business
Process
as a Service
(BPaaS)
Business
processes (e.g.
payroll)
delivered as a
service
"Cloud"
(metaphor for internet)
So why is Industry 4.0 relevant now? Technology breakthroughs in the past 10 years have made the cost of key technology enablers like
bandwidth, processing power, cloud storage, sensors, and robots, crash to a fraction of what they were 10 years ago. The performance, size and
availability of these cyber-physical systems have also dramatically improved, making them accessible to manufacturing shop floors. Cloud services
have made connected enterprise management systems available to even small and medium enterprises (SMEs). These structural changes in the
ecosystem have created conditions for efficiency and productivity gains and the momentum for the widespread adoption of Industry 4.0.
40x
Over the past ten years
Avg. cost over the past ten years
20x
Cost per MB over the past ten
years
30%
Avg. cost of robots over the
past ten years
50x
Over the pas ten years
50%
Cost of
Bandwidth
Cost of Data
Storage
Cost of
Sensors
Cost of
Robots
Cost of
Processing
Power
Source: Goldman Sachs; Deloitte; BCG Analysis.
Abundant and cheap
computing power
Availability of low cost on-demand
cloud platforms
32 | NEXT GENERATION MANUFACTURING
Several core technologies are driving Industry 4.0
Few core technologies combine to create multiple use cases across the manufacturing value chain. Many of these have already been in use
standalone. With Industry 4.0, these technologies are getting used together and transforming the conventional manufacturing value chain.
Industry 4.0
Augmented Reality
• Real time information in
semantic context
• Assistance in navigation,
diagnostic, repair etc.
Additive manufacturing
e.g. 3D printing
• On-demand manufacturing
• Mass customization
• Rapid prototyping and tooling
Big data and analytics
• Real-time data processing
• Data driven decision making
Simulation
• Upfront optimization of
products / processes
Autonomous robots
• Self learning industrial robots
• Integrated sensors
• Standardized interfaces
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 33
Core performance impacted across all
production elements
Overall, these technologies have transformed value chains into more flexible (through programmable machines and robots),more efficient
(through higher automation and shorter set up times),higher quality (through real time monitoring using sensors and actuators) and quicker to
market (using data and simulation based modeling systems). Beyond these core benefits,manufacturing conditions are also improving with greater
workforce safety, better working conditions,increased collaboration opportunities across production cells with greater data availability and increased
resource utilization. The result has been a better environment for production.
Flexibility
Productivity
Speed
Quality
34 | NEXT GENERATION MANUFACTURING
Example: Autonomous robots in assembly lines
hop floors across the world, especially in developed economies like the USA, Germany and South Korea are already seeing this transformation.
For example, autonomous robots like Baxter by Rethink Robotics are configurable, designed to work safely with humans and are highly adaptive.
Tasks such as packing, loading and handling that were not possible with traditional robots are now coming into the ambit of automation. With costs as
low as $22,000,payback for such automation is now in months rather than in years. This particular technology is already being used by firms in North
America, including small enterprises with less than 20 employees, to compete effectively with China and Mexico.
S
Low cost $22,000
Can replace
$15~$20 / hour
jobs for <$ 3/ hour
Cobot
(collaborative
robot) designed
to co-work with
humans
Trained through
demonstration
rather than
programming
Continuously
improving
through remote
software
upgrades
Source: Press article search.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 35
Example: Warehouse guidance systems
using augmented reality
ugmented Reality (AR) is another technology that is transforming manufacturing and warehousing operations.An example is the DHL warehouse
where AR glasses show operators the exact location and quantity for the next pickup, provide indoor navigation and also scan barcodes to report
pickup and drop operations. Estimates suggest a ~2% cost reduction in the steady state due to a reduction in human errors, lower training costs,
increased productivity, plus an increased speed of freight loading.
Beyond warehousing, AR has found applications in hands-on training, real-time operator guidance during manufacturing, and guiding repairs on
complex machinery. The use of augmented reality empowers low skilled workers to execute tasks that typically require higher skilled workers.
A
Glasses show location,
quantity
and handling information
Indoor navigation for
shortest route
Object recognition and
barcode scanning for
paperless pickups
Linked to ERP for real-time
updates and order
completeness checks
Source: Press article search.
Images are representative
36 | NEXT GENERATION MANUFACTURING
Example: Lot size of one in
semi-automated production
nother example is of the German auto component manufacturer Bosch which has managed to achieve flexible production with a lot size of one.
This is done through the use of RFID codes on components, smart workstations and real time instruction to workers through work screens. With
no set up times and machine guided real-time assembly, production time has seen up to a 30% decrease. Errors are also minimized. The ability to
handle complexity has multiplied with little to no scale disadvantage. Traditional cost-complexity tradeoffs are being made irrelevant, ultimately
leading to higher line utilization and lower costs.
A
Auto-adjusting working station as per
product requirements and workstation
capabilities
RFID tagged products with the information
on which tasks have to be carried out
Self adapting workstation to worker's
height and ergonomic needs, skills,
language and instruction requirements
Visual board to collect, filter and visualize
production data, highlight potential
problems, auto-alert function
Semi-automated production
for making 200 variations of
six basic models with 30%
decrease in production time
Source: Press article search.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 37
Example: Use of 3D printers to increase flexibility,
speed and cost competitiveness
E has realized benefits from using additive manufacturing for jet engine components. With the acquisition of two European companies for
$1.4 Bn, capability gaps in additive manufacturing were filled. Now instead of large warehouse networks and inventories of huge components, the
company is producing components on demand close to the consumption center. Beyond the inventory and logistics cost advantages, more complex
designs are leading to lower weights, reduced wastage and greater speed.
With more than 400 3D printers already in use, plans are in place to produce over 100,000 components through additive manufacturing by 2020.
High precision part created by
additive manufacturing
G
GE acquired 2 companies
with advanced 3D printing
capabilities to fill
capability gap in 3D
printing
400+ 3D printers in use
with plans to add 1,000
more in next decade
Plan to expand use to
manufacture 100,000
components by 2020
On-demand production
to replace conventional
safety stock inventory and
warehouse network
Source: Press article search.
Images are representative
38 | NEXT GENERATION MANUFACTURING
Example: Multiple technologies are coming together to
challenge status quo in auto manufacturing
esla, the twelve year old electric auto manufacturer, is competing aggressively with the century old auto giants and gaining ground too.Since the
early days, Tesla has relied on heavy use of technology in its product development and production processes to keep costs low, improve speed to
market while maintaining high quality. They have revolutionized auto manufacturing with greater use of simulations to cut down on development
times and use of physical crashing models, use of additive manufacturing to create low cost components in-house, and high use of automation in its
factories. Extensive use of technology allows Tesla to have better margins (24% gross margin versus 17% for GM) and better quality reflected in its #1
ranking for customer satisfaction.
T
Simulations and
Big Data
Autonomous
Robots
Additive
Manufacturing
Simulations for crash testing
reducing need for physical
tests
1,000+ robots
including 160 specialist robots
Additive manufacturing for
rapid prototyping and low cost
components
Source: Press article search.
Images are representative
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 39
Structural shifts will change sector dynamics
The last three decades saw the emergence of global supply
chains as large pools of low cost labour in developing
countries took to factory floors. However the fourth manufacturing
revolution could fundamentally alter this trend.
As trade-off between labour and automation swings in the favour of
the latter, manufacturing is returning to highly automated factories
in developed countries. Small scale plants closer to the market are
becoming more competitive than large off-shore plants. Digital
technologies are driving consistent growth in labour productivity of
developed nations, reducing competitiveness gap with emerging
countries facing wage inflation.
The CEO of a leading manufacturing conglomerate quotes
frequently that "Every Company Has to be a Service Company".
The servicification of manufacturing is rapidly evolving as
manufacturers disrupt their business model to capture shifting
value pools. For example, GE has transformed itself from
manufacturer to service provider, with digital revenues crossing
$15Bn this year.
Rise of digital trading platform, digital supply chain and global
services will fundamentally enhance the skills expected of the
worker. Even the traditional manufacturer will need talent with new
skills such as data scientist,robot supervisor and virtual reality
designer.
Shift in skills of
labour force
'Servicification' of
manufacturing
Re-shoring of
manufacturing closer
to consumption centers
INDUSTRY 4.0:
IS INDIA READY?
41
“The art of war teaches us to rely not on the
likelihood of the enemy's not coming, but on our
own readiness to receive him; not on the chance of
his not attacking, but rather on the fact that we
have made our position unassailable.”
– Sun Tzu
42 | NEXT GENERATION MANUFACTURING
India Inc. is already adopting Industry 4.0 technologies
Question : Which pillar of Industry 4.0 are you investing in?
Today
In next
5 years
Big Data and
Analytics
Autonomous
Robots
Additive
Manufacturing
Augmented
Reality
Simulation
79% 58% 65% 52% 71%
56% 38% 23% 15% 54%
As the adoption of Industry 4.0 technologies accelerates in other countries, Indian manufacturers are drawing a roadmap to incorporate these
technologies. Our CII–BCG survey reveals that more than 50% of manufacturers have either already invested in or are in the process of investing
in the majority of the Industry 4.0 technologies.Big data and simulation are technologies that almost two-thirds of companies are expected to adopt
within the next 5 years.
Source: CII–BCG Manufacturing Leadership survey 2016.
THE BOSTON CONSULTING GROUP  CII | 43
One in two respondents expects greater than 50%
process automation in the next 10 years
Question: What percentage of your processes are currently automated and
how much is expected to be automated in the next 5 and 10 years?
s the adoption of these technologies increases, the automation of manufacturing processes is also expected to steadily increase. While more than
60% of survey respondents have less than 20% of current processes automated, this number is expected to fall below 20% in 10 years time. At the
same time, more than half of the respondents expect to have 50%+ of their processes automated. This trend shows that Indian manufacturers are
actively thinking about investing in automation technologies and planning to catch up to their global peers.
A
At
present
23%
15%
In
5 years
19%
37%
In
10 years
33%
50%
20-50% > 50%
38% 56% 83%
Source: CII–BCG Manufacturing Leadership survey 2016.
44 | NEXT GENERATION MANUFACTURING
Quality improvement and cost reduction are primary
objectives of adoption
Question: What are the benefits that you see resulting from
Industry 4.0 advancement?
28%
19%
17%
16%
10%
6%
4%
Improved
quality
Lower
cost
More
flexibility
Reduced time to
market
Reduced
production time
Improved
product availability
No
benefit
Although cost and productivity have been the primary drivers of the accelerated adoption of Industry 4.0 in developed countries, quality is the
most prominent benefit in India. Despite low labour costs,the availability of skilled and quality-conscious labour is a major pain point for Indian
manufacturers. As Indian manufacturers move up in the value chain and aim to capture the export market, they need to fill quality gaps through
automation and technology adoption. Cost, flexibility and reduced time to market are the second order benefits that Indian manufacturers target
beyond quality.
Identified as either Top 1 or Top 2 reasons
Source: CII–BCG Manufacturing Leadership survey 2016.
THE BOSTON CONSULTING GROUP  CII | 45
Example: Availability of low-cost IIoT solution is
accelerating the adoption of Industry 4.0 in India
o far the Industry 4.0 revolution has been led by western companies. Established industrial companies as well as startups have been dominating
market share in these technologies.Most of their solutions are aimed at developed market, on the other hand Indian manufacturers operate in
different operational environments–with lower labour costs, lower skilled labour, inconsistent digital infrastructure and a limited capacity to pay.
Varroc, an automotive component manufacturer with $1.3 billion revenue was looking for an effective,scalable solution to improve their
competitiveness.After comparing various global solutions,Varroc decided to implement Altizon's IIoT platform as it met their diverse requirements
better than competing solutions.Altizon's innovative system combined global functional benchmarks, competitive pricing, and flexibility to connect
with legacy machines. Today, operational status of connected machines in Varroc's Uttarakhand plant are visible on the Datonis Platform within
minutes. Rather than taking reactive measures on old data, supervisors on shop floors are empowered with real-time decision making, improving
effectiveness and creating real impact on the bottom line.
S
Fast RoI
• ~20% improvement in efficiency
• 5% decrease in product defects
Real-time monitoring and instant
decisions enabled shop floor
workers to take proactive decision
Plan to implement solution in all 35
plants and develop algorithm for
real-time decision making
Altizon's solution was selected due
to flexibility, scalability and low cost.
Other solutions couldn't connect
with our legacy machines
– Mr. Narinder Singh,
DGM ,IT , Varroc
Device collecting
data on legacy
machines
Analytics engine providing
real-time visibility of plant
utilization
Source: Industry interview.
46 | NEXT GENERATION MANUFACTURING
Example: Collaborative robots (cobots) can automate
high precision labour-intensive tasks
Universal Robot's cobots assisting
women factory workers
7
Processes automated by
cobots
110+
Cobots operating on
assembly line
raditional robots were designed to perform specialized tasks and operate from a cage. They require significant upfront capital and skilled staff for
programming. The rise of collaborative robots,also called Cobots, are changing the game. They can work safely with humans, are easy to deploy
and cost fraction of the traditional robot's cost. Today a cobot can be purchased at a cost of mid-size sedan, requires no annual maintenance contract
and have payback within 24 months, even at Indian salaries. Bajaj Auto, world's 3rd largest two wheeler manufacturer, has been an early adopter of
cobots made by Universal Robots.Bajaj has automated physically taxing processes that require high-end precision and today 110+ cobots operate with
workers to provide flexibility, reliability and productivity gains. For Indian SMEs, capital expense and operating expense are of major concerns for
adoption of any technology. Availability lower cost, versatile cobots can accelerate automation among SMEs as well.
T
Source: Industry interview.
Payback period
<24
months
THE BOSTON CONSULTING GROUP  CII | 47
ndustry characteristics are expected to drive the adoption of Industry 4.0 technologies.Impact of any Industry 4.0 lever varies by sector given their
unique characteristics. Industry characteristics may differ across geographies due to regulation, customer needs,labour intensity, etc. The results of
CII–BCG Manufacturing survey reveal that Indian manufacturers are most optimistic of Industry 4.0 impact on auto, electrical & electronic machinery
and precision equipment sectors, while metal and non-metallic products are expected to be least impacted.
Industry characteristics to drive adoption
T
CII–BCG Manufacturing survey:
Top 3 sectors with Industry 4.0 potential
CII–BCG Manufacturing survey:
Sectors with least Industry 4.0 potential
Logistics Complexity
Complexity (number of parts, number of
SKUs)
Speed of new product development cycle
Supplier-aided smart design
Product complexity: material, form,
technology
Precision & Quality
Need for integrated supplier management
On-demand configuration
Share of manual activities in production
Setup times & product variance
Industry characteristics Industry 4.0 levers
Automobile and
transport equipment
Electrical and
electronics machinery
Medical, optical and
precision equipments
Metal products
Metals and mining
Non-metallic products
Integrated
work-flows
Virtual
design
Flexible
manufacturing
Autonomous
logistics
Self-
optimization
I
Source: CII–BCG Manufacturing Leadership survey 2016.
48 | NEXT GENERATION MANUFACTURING
Adoption of Industry 4.0 could create a step change in
Indian manufacturing competitiveness
he size of the prize for adoption of these technologies for Indian manufacturing is large. Based on currently deployed solutions,manufacturers
can expect to gain advantages in raw material, labour and energy costs.This in addition to benefits in quality delivered, speed to market and asset
utilization. The impact of adopting Industry 4.0 is clearly visible through the magnitude of the numbers involved. It is now up to the policy makers and
industrial leaders to ensure that India actively participates in this revolution and reap the benefits in global competitiveness.
T
Labour
Productivity
30-100%
Increase
Quality
6 sigma levels
Responsiveness
From days to
hours
Energy Costs
10-30%
decrease
Inventory in
Value Chain
Up to 75%
reduction
Source: BCG client experience; Industry interviews; BCG Analysis.
WAY FORWARD:
IMPERATIVES FOR INDIA
51
“In strategy it is important to see distant things as
if they were close and to take a distanced view of
close things”
– Miyamoto Musashi,
legendary Japanese swordsman
52 | NEXT GENERATION MANUFACTURING
India needs to reinforce the sector's foundation and
leverage Industry 4.0 to improve competitiveness
As Indian manufacturing shifts gear to catch-up with manufacturing superstars,action is required on two fronts. First, policy makers need to
continue reinforcing the foundation by delivering on Make-in-India objectives.This will allow Indian manufacturers to effectively compete in
global markets by removing inefficiencies and fully leveraging our competitive advantages. Second, with the fourth industrial revolution unfolding,
Indian manufacturers need to proactively start adopting Industry 4.0 technologies.Here, government can play a key role in promoting Industry 4.0 by
increasing awareness, providing incentives and building the necessary ecosystem.
Reinforce foundation: Continue to
deliver on Make in India objectives
Improve competitiveness
through technology adoption
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 53
Reinforcing the foundation:
9 point agenda for government
any recommendations have been made in the past about reviving manufacturing growth and government has already taken action in right
direction. Indian government should continue fixing the building blocks by accelerating the infrastructure execution, improving ease of doing
business through structural reforms and increasing capital availability. It is critical to keep a steady focus on gaining global competitiveness by
building global scale, developing world-class clusters and easing trade barriers to improve export competitiveness.To ensure sustainable competitive
advantage, policy makers also need to promote development of capabilities by accelerating technology transfer, promoting innovation and improving
workforce skill base.
M
Building blocks
Ease of doing business
Improve labour flexibility, faster
and simplified clearance and
approvals (e.g. land acquisition,
environment clearance)
Capital
Ease capital constraint by
relaxation of FDI limits and
increase in credit availability
Infrastructure
Establish world-class
infrastructure in ports, rail
and road
Competitiveness
Build
global scale
Develop cluster-
based ecosystem
Ease
trade barriers
Leverage domestic demand to
nurture and develop global
scale
Build world class clusters
containing core infrastructure
for supporting operations,
common facility centres etc.
Prioritize FTA with key
importing nations
Expand export promotion
schemes with tax breaks to
more sectors
Capabilities
Accelerate
technology transfer
Promote R&D
and innovation
Improve
workforce skill base
Support systematic
indigenization of technology
Incentivize R&D and
innovation to develop it into
key pillar of sustainable
competitive advantage
Skill improvement program to
improve quality of labour and
engineering workforce
54 | NEXT GENERATION MANUFACTURING
Reinforcing the foundation:
5 point agenda for manufacturing leaders
n a fast evolving global manufacturing landscape, Indian manufacturers are competing against leading manufacturers with bigger scale, superior
productivity, superior employee skill base, R&D capabilities and quality capabilities. To win market share from these competitors,Indian
manufacturers need to act on each of these fronts to fill key gaps and become globally competitive.
I
Think Big–think long-term, think global
• Create and defend competitive advantage across whole value
chain, focusing on an 8 to 10 year path to success
Relentlessly focus on productivity
• Significant productivity gap with other manufacturing countries
needs to be filled to become globally competitive
Fortify and further improve quality
• Indian auto component industry has set a perfect example of
steadily improving quality to become world class. Other
industries need to replicate this success story
Bet on R&D and innovation
• Indian manufacturers need to increase investment in R&D and
innovation to build competitive advantage beyond low cost
labour
Invest in lifelong learning of employees
• As labour cost advantage diminished over long-term,
manufacturers should proactively invest in lifelong training of
employees to build highly competent workforce
No. of Fortune 500 companies:
103 Vs. 7
India
China
1.5x
China's labour productivity as
compared to India
22 Vs. 28
India Rest of World
Cumulative No. of Deming prizes (2002-15)
1,100 Vs. 190
No. of R&D professionals per million
India
China
5%Vs. 2%
Training spend as % of labour cost
India
China
Source: EIU; Oxford economics; BCG Survey.
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 55
Technology adoption: Government agenda to promote
and enhance competitiveness
roactive adoption of Industry 4.0 can take India to the league of top manufacturing countries.We need to sustain a bold vision of becoming a top 3
manufacturer. To realize the existing target of 10% annual growth in manufacturing, India needs to consistently improve labour productivity by 5%
every year. To realize these ambitious goals, the government needs to build world class digital infrastructure and carry out education reforms required to
make the Indian workforce future ready. CII–BCG leadership survey reveals that industry leaders expect the government to play a role in increasing
awareness about Industry 4.0. This can be achieved by developing a dedicated Industry 4.0 innovation centers that will also support the SME sectors in the
adoption process. Development of low cost indigenous solutions can be accelerated by allocating part of startup India funds for Industry 4.0 startups.
As other developed and developing countries provide productivity linked incentives to local SMEs, India also needs to create a level playing field by
matching such incentives and additionally promoting import duty and tax breaks for companies that adopt these technologies to enhance competitiveness.
P
India as global top 3 manufacturing economy
• Annual labour productivity growth of 5% for next 10 years leveraging technology
• Technological readiness rank (WEF competitiveness index): 120 (2016) ⇒ 30 (2025)
• Develop high bandwidth
network for smart factories
• Develop Industry 4.0
Innovation Center to
support technology
adoption
• Allocate part of 10,000 Cr
startup India fund for
Industry 4.0 startups
Build world class
digital infrastructure
Improve support
system
Education reform to
train future workforce
• Overhaul education system
to impart skills required for
future jobs
• Productivity linked incentives such as tax breaks, capex subsidies
• Exemption of import duties on Industry 4.0 related technologies
• Reward companies leading in Industry 4.0 maturity index
Promote
adoption
Set Clear
Vision
Create
supportive
ecosystem
Source: World Economic Forum.
56 | NEXT GENERATION MANUFACTURING
Technology adoption: CEOs need to challenge status
quo and develop an adoption strategy
he CEO's role is central in any technology adoption journey. It is the CEO's responsibility to challenge the status quo of all key processes, and set
a bold vision for competitiveness through technology adoption. A change of this kind is always driven from the top, with the CEO chairing the
steering committee meetings.An often missed area in such journeys, is that of people. Having technologically capable mid-managers and key front-
line staff is critical to ensuring a successful transformation but is not always easy to do. It is important to define the capability gap and draw out a clear
roadmap to plug key gaps–through a mix of training/hiring levers. In driving the detailed transformation agenda, it is prudent to carry out a diagnostic
that identifies the key processes across the organization that are conducive to step-improvement through technology-adoption.And, having done so, it
is always helpful to drive a mix of 'quick wins' and a set of long-term initiatives that could involve higher investment and experimentation.A balanced
approach such as this, ensures early momentum while retaining the focus on big-ticket items.
T
CEOs to own and drive the Industry 4.0 transformation
• Assess status quo with respect to existing technological changes, competitor's
positioning and existing capabilities
• Set ambition level for company to achieve across 4 categories–Productivity,
Quality, Speed and Flexibility
• Drive the transformation journey
Embed
Industry 4.0 in
CEO's agenda
Develop strategic roadmap to fill the capability gap
• Invest in developing and acquiring talent equipped with future-ready skills
• Develop a culture of innovation, experimentation, collaboration and continuous
improvement
• Evaluate M&A as potential option to fill key capability gap
Build the
foundation
Re-engineer value chain and re-imagine offerings, starting from high impact
use cases
• Generate quick wins by implementing limited use cases with proven impact
• Proactively invest in long-term initiatives that will create sustainable competitive
advantage.
• Manage data as a valuable strategic asset
Setting right
priorities
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 57
Make-in-India: The need for concerted multi-pronged
action agenda to realize vision
Top 100 in
Ease of Doing
Business
FDI
reforms
Top 50
in Ease of
Doing
Business
Invest in level
technology
adoption
Implement
GST
Debottleneck
ports, road, rail network
FTAs
with major
global
importers
Develop
Industry 4.0
immersion
centers
I
ndian manufacturing sector is at a cusp of a new dawn. Many factors such as government-led structural reforms, infrastructure growth, increasing
foreign investment,and increasing domestic demand have potential to create a long-term growth momentum for Indian manufacturing. To
maintain growth momentum,government needs to accelerate the pace of infrastructure development,policy reforms and trade agreement
negotiations. Indian manufacturers also need to aggressively adopt advanced technologies to transform themselves into globally competitive
manufacturers. To achieve ambitious targets set as part of Make-In-India initiative, manufacturing sector needs to grow by double digits and we have
more favorable factors than any other time in recent history. The time has come for India to transform itself into a manufacturing powerhouse.
Today
Vision
58 | NEXT GENERATION MANUFACTURING
The Boston Consulting Group
publishes other reports and
articles on related topics that
may be of interest to senior
executives. Recent examples
include:
Industry 4.0: The Future of
Productivity and Growth in
Manufacturing Industries
A focus by the Boston
Consulting Group, April 2015
Man and Machine in Industry
4.0
A report by the Boston
Consulting Group, September
2015
Time to Accelerate in the
Race Toward Industry 4.0
A perspective by The Boston
Consulting Group, May 2016
Three Ways for Companies to
Succeed in the Fourth
Industrial Revolution
A perspective by The Boston
Consulting Group, January 2016
Manufacturing for the 21st
century
An article by the Boston
Consulting Group, November
2016
Why Advanced Manufacturing
Will Boost Productivity
A report by The Boston
Consulting Group, January 2015
Make in India: Turning Vision
Into Reality
A report by The Boston
Consulting Group in association
with Confederation of Indian
Industry, October 2014
Acting on the Digital
Imperative
An article by The Boston
Consulting Group, September
2016
The Proximity Paradox:
Balancing Auto Suppliers'
Manufacturing Networks
A report by The Boston
Consulting Group, March 2015
People Productivity: Key to
Indian Manufacturing
Competitiveness
A report by The Boston
Consulting Group, March 2013
The shifting Economics of
Global Manufacturing–How
Cost Competitiveness Is
Changing Worldwide
A report by The Boston
Consulting Group, August 2014
Future of Indian
Manufacturing: Bridging the
Gap
A report by The Boston
Consulting Group in association
with Confederation of Indian
Industry, August 2015
Forks in the Road: Navigating
Industry Disruption
A report by The Boston
Consulting Group, May 2016
The Robotics Revolution: The
Next Great Leap in
Manufacturing
An article by the Boston
Consulting Group, September
2015
The Evolution of Robotics
An interactive by The Boston
Consulting Group, November
2014
The Rise of Robotics
An article by The Boston
Consulting Group, August 2014
3D Printing Will Change the
Game: Prepare for Impact
An article by the Boston
Consulting Group, September
2013
For Further Reading
THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 59
About the Authors
Dr. Arindam Bhattacharya is a Senior Partner
and Director in the New Delhi office of The
Boston Consulting Group.
Arun Bruce is a Partner and Director in the
Mumbai office of The Boston Consulting Group.
Anirudh Tara is a Principal in the New Delhi
office of The Boston Consulting Group.
Mani Singhal is a Principal in the New Delhi
office of The Boston Consulting group.
For Further Contact
If you would like to discuss the themes and
content of this report, please contact:
BCG
Dr. Arindam Bhattacharya
Senior Partner and Director
BCG New Delhi
+91 124 459 7093
bhattacharya.arindam@bcg.com
Arun Bruce
Partner and Director
BCG Mumbai
+91 22 6749 7101
bruce.arun@bcg.com
Anirudh Tara
Principal
BCG New Delhi
+91 124 459 7178
tara.anirudh@bcg.com
Mani Singhal
Principal
BCG New Delhi
+91 124 459 7146
singhal.mani@bcg.com
CII
Dr. Saugat Mukherjee
Regional Director
CII–Western Region
+91 22 2493 9747
s.mukherjee@cii.in
Alpa Antani
Head–International & Special Projects
CII–Western Region
+91 22 2493 1790
alpa.antani@cii.in
Acknowledgements
This study was undertaken by The Boston
Consulting Group (BCG) with support from the
Confederation of Indian Industry (CII).
We would like to thank the members of CII related
to Manufacturing and allied sectors for their
valuable inputs and insights. Special thanks to Mr.
Jamshyd N Godrej, Chairman, 15th Manufacturing
Summit and Chairman and Managing Director,
Godrej & Boyce Manufacturing Company Limited;
Mr. Sudhir Mehta, Chairman, CII Western Region
2016-2017 and Chairman & Managing Director,
Pinnacle Industries Limited and Dr Saugat
Mukherjee, Regional Director, CII Western
Region, for their valuable contribution.
We would also like to thank the respondents to
the CII–BCG Manufacturing Leadership Survey
2016 for their valuable inputs.
We gratefully acknowledge the contribution of
Vinayak Tendulkar, Ayush Bohra in the firm's
Mumbai office and Akshay Devalla in the Chennai
office in writing this report.
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and Jasmin Pithawala for managing the marketing
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India's manufacturing sector shows steady growth but faces challenges

  • 1. NEXT GENERATION MANUFACTURING WINNING THROUGH TECHNOLOGY & INNOVATION November 2016 CII 15th Manufacturing Summit 2016 Confederation of Indian Industry
  • 2. The Boston Consulting Group (BCG) is a global management consulting firm and the world’s leading advisor on business strategy. We partner with clients from the private, public, and not-forprofit sectors in all regions to identify their highest- value opportunities, address their most critical challenges, and transform their enterprises. Our customized approach combines deep insight into the dynamics of companies and markets with close collaboration at all levels of the client organization.This ensures that our clients achieve sustainable competitive advantage,build more capable organizations, and secure lasting results.Founded in 1963,BCG is a private company with 85 offices in 48 countries.For more information, please visit bcg.com. The Confederation of Indian Industry (CII) works to create and sustain an environment conducive to the development of India, partnering industry, Government, and civil society, through advisory and consultative processes. CII is a non-government, not-for-profit, industry-led and industry-managed organization, playing a proactive role in India‘s development process. Founded in 1895, India‘s premier business association has over 7400 members, from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 100,000 enterprises from around 250 national and regional sectoral industry bodies. In its 120th year of service to the nation, the CII theme of ‘Build India – Invest in Development, A Shared responsibility’, reiterates Industry’s role as a partner in national development. With 64 offices, including 9 Centres of Excellence, in India, and 7 overseas offices in Australia, China, Egypt, France, Singapore, UK, and USA, as well as institutional partnerships with 300 counterpart organizations in 106 countries, CII serves as a reference point for Indian industry and the international business community.
  • 3. NEXT GENERATION MANUFACTURING WINNING THROUGH TECHNOLOGY & INNOVATION | Arindam Bhattacharya | Arun Bruce | Anirudh Tara | Mani Singhal November 2016 | The Boston Consulting Group CII 15th Manufacturing Summit 2016 Confederation of Indian Industry
  • 4.
  • 5. 3 06 16 28 40 05 STATE OF THE SECTOR THE RISE OF GLOBAL MANUFACTURING SUPERSTARS INDUSTRY 4.0: TECHNOLOGIES TRANSFORMING MANUFACTURING INDUSTRY 4.0: IS INDIA READY? 50 AT A GLANCE 59 NOTE TO THE READER 58 FOR FURTHER READING WAY FORWARD: IMPERATIVES FOR INDIA Contents
  • 6.
  • 7. 5 Over the long term, the Indian manufacturing sector has performed exceedingly well. During the last three decades, the sector has grown at a steady annual rate of 13% (nominal), surpassed by just one other country over this time–China. However, considering its potential and the country's promise in terms of job creation, India still has a long way to go–both the government's target of 25% contribution to economy and 100 million new jobs are still a far cry from where we are. While a lot has been said about the sector's potential, we examine a few central areas critically. We start by taking a look at the government initiatives that aim to promote manufacturing. We recognize the magnitude of progress already achieved across several areas, from infrastructure, to 'ease of doing business', to labour reforms. We conducted a poll of industry leaders to record their feedback on government performance (which is quite positive, overall). We then distil the lessons learnt from fast growing manufacturing economies from across the world–China, the USA, Switzerland, Vietnam, Mexico, and the UK. Lessons learnt and their implications vary from the obvious “given” (e.g. fixing infrastructure) to the evolved (R&D investments, niche-sector focus, FTAs, etc.). We also study the accelerating trend of technology in manufacturing–otherwise called Industry 4.0. We observe that there are many more Indian examples now than before of “Industry 4.0", and we recognize that the advanced adoption of technology trends could be a major differentiator as we evolve into a manufacturing powerhouse. Finally, we synthesize and lay down the implications for the government and the industry–both to promote the sector in general, and to specifically drive technology adoption. We strongly believe that the industry is at a tipping point. How Indian manufacturing reacts to technology adoption could be the difference between gaining its rightful prominence in the global manufacturing stage and getting stuck in a catch-up game as early adopter economies take the lead and realize huge productivity dividends. Happy reading! At a Glance
  • 9. 7 “Nourish your hopes, but do not overlook realities.” – Sir Winston Churchill
  • 10. 8 | NEXT GENERATION MANUFACTURING The Indian manufacturing sector has performed well over the long term Source: Euromonitor; World Bank. One Rupee Output in 1990 has today grown to… he Indian manufacturing sector is a perfect example of a reliable, steady workhorse. The sector has shown steady results with a Compounded Annual Growth Rate (CAGR) of 13% (in nominal terms) over 25+ years. In the process, it has grown faster than most other economies, with 1 rupee of output in 1990 increasing to 21 rupees today. The only notable exceptions are the Chinese manufacturing and Indian service sectors. T ₹16 ₹21 South Korea Manufacturing ₹14 Agriculture India ₹11 Mexico Manufacturing India Manufacturing Thailand Manufacturing ₹34 Services India ₹96 Manufacturing China ₹5 South Africa Manufacturing Germany Manufacturing ₹5 USA Manufacturing ₹8 ₹21
  • 11. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 9 There is significant untapped potential for Indian manufacturing Source: Euromonitor; WTO; World Bank; Government of India; BCG Analysis. Global Trade Share 12% 3% 2% 4% 12% 7% U.S.A. Mexico India S. Korea China Germany GDP Share 16% India 20% Mexico 25% GoI Target 27% China 28% S. Korea Employment Share 10% 18% 29% Germany Mexico India S. Korea GoI Target China 17% 20% 20% 22% Germany hile historical growth has been impressive,benchmarks indicate an even greater potential ahead. Many government initiatives have targeted a 25% GDP share; China's manufacturing sector is already at 27%. Covering only 2% of global trade and 10% of formal employment, India's manufacturing holds enough potential to drive a new era of inclusive economic growth for the country. W
  • 12. 10 | NEXT GENERATION MANUFACTURING The slowdown in global trade is exerting pressure on manufacturing economies Source: World Trade Organization. Note: Merchandise trade to GDP ratio is estimated as merchandise trade (average of exports and imports values) divided by GDP, measured in nominal dollar terms at market exchange rates. T 30 25 20 0 Ratio of world merchandise trade to GDP (%) 2015 2010 2005 2000 1995 1990 Collapse in consumer demand during financial crisis Negative growth driven by trade restrictions and reshoring 20 years of secular growth driven by deconstruction of supply chains and outsourcing he global manufacturing sector is likely to face obstacles over the next few years. Economies seem to be getting increasingly isolated and the gains from globalization seem to be reversing.Many developed countries have started implementing restrictive trade policies, including the US with their 200%+ anti-dumping duty against steel from China, and 90%+ from other countries.Political developments such as Brexit is another sign of de-globalization. Countries with strong local markets, including India, will likely continue to do well, while export-oriented manufacturers could face challenges.
  • 13. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 11 India's recent manufacturing performance has been below par 12 6 0 -6 Manufacturing production growth year-on-year change (%) Aug’16 Apr’14 Jun’14 Apr’15 Jun’15 Feb’16 Apr’16 Feb’15 Dec’14 Dec’15 Jun’16 Oct’14 Aug’14 Aug’15 Oct’15 Source: Ministry of Statistics & Program Implementation; Government of India. The last 12 months have been quite poor for the Indian manufacturing sector. After starting off well in the first half of FY16 and peaking in October 2015 with an output growth of ~10%, the sector has seen a decline. The maximum growth since October last year has been only 2% with 7 out of 11 months showing a negative y-o-y growth.
  • 14. 12 | NEXT GENERATION MANUFACTURING Slowdown in the capital goods has been most concerning Basic Goods Capital Goods Intermediate Goods Consumer Goods Petroleum fuel, Cement, Basic metals etc. Commercial vehicles, Light and heavy machineries etc. Metal products, Cotton yarn, Plywood etc. Electronic products, Passenger cars, Two wheelers, Apparel, Processed food products etc. FY12-15 FY16 FY17 (Apr-Aug) 4% 4% 4% 2% 3% 21% 2% 3% 4% 0% 3% 1% Source: Ministry of Statistics & Program Implementation; Government of India. While the overall performance has been poor, what could hurt manufacturing most overtime is the contraction in capital goods. Capital goods, an indicator of economic investment has de-grown by over 20% so far this year. Over 40% of demand in capital goods was fulfilled through imports, while capacity utilization across sectors was only 60-70%. While private consumption in the capital goods sector saw an even sharper fall, public sector and government demand provided much needed respite through investments in the infrastructure sectors of power, rail, oil & gas, and roads.
  • 15. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 13 "Make in India": Government initiatives in place to drive manufacturing growth Apr 2015 Apr 2017 Apr 2016 Passed in Lok Sabha GST Passed in Rajya Sabha Slated to be implemented Power UDAY scheme passed Tariff Policy– Electricity for all FDI FDI norms relaxed for 15 sectors FDI norms further relaxed for 9 sectors Transport Sagar Mala project initiated– ports led development Construction of 15,000 km of new roads by 2017 Industry specific Package launched for textile industry Labour reforms Finance Bankruptcy code passed Repo rates lowered to 6.25% A lthough the recent rate of growth has been a concern, the long term business environment is improving. Make in India has been more than just a buzzword. The government has made good on its commitments to drive the manufacturing sector by introducing a set of initiatives to improve manufacturing performance. Infrastructure, policy and taxation efforts across have resulted in landmark reforms. Not Exhaustive Solar power increase by 66% anticipated Source: Press articles. Apprentices rules amended Shram Suvidha Portal launched Labour reforms; easy hiring & retrenchment, flexible female participation
  • 16. 14 | NEXT GENERATION MANUFACTURING Results visible along with increased optimism in the industry Industry view: Expected growth in manufacturing in the next 5 years 2014 2015 2016 8.1% 8.6% 8.8% Ease of Doing Business ROADS built PORTS capacity RAIL tracks 2014 12 km/day 27 km/day 800 MT 965 MT 4 km/day 7 km/day Infrastructure 2016 142 130 Energy Gap Peak Power Gap Power Getting Electricity Rank 2014 -4.2% -4.5% 2016 -2.1% -3.2% 51 2017 estimate 1.1% 2.6% 26 $40Bn $25Bn FDI 2014 2016 111 Source: World Bank; Ministry of Power; Ministry of Road Transport & Highways; Ministry of shipping; Department of Industrial Policy & Promotion; CII–BCG Manufacturing Leadership Survey. The results are visible. Ease of doing business rankings, power availability, infrastructure, and FDI inflows have all seen significant improvement over the past 2 years. The impact is also evident on the mood and optimism of the industry with key industrial leaders today having higher growth expectations.While this is a good start, how this optimism translates into growth on ground remains to be seen. It will require continued efforts from both industry stalwarts and policymakers alike in order to reverse the current trend. Rank Rank actual
  • 17. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 15 Two structural shifts shaping global manufacturing While the Indian manufacturing sector is steadily growing, it is equally important to keep an eye out for global shifts. Two such shifts are outlined in the next few chapters – • Rise of other manufacturing economies: the global manufacturing superstars • Technological changes: The Fourth Industrial Revolution also known as Industry 4.0 The Fourth Industrial Revolution Rise of Manufacturing Superstars
  • 18. THE RISE OF GLOBAL MANUFACTURING SUPERSTARS
  • 19. 17 "It's not enough to do your best, you must know what to do and then do your best." – W Edwards Deming
  • 20. 18 | NEXT GENERATION MANUFACTURING 20 6 2 0 -4 -6 2,250 1,000 500 250 -2 0 4 United Kingdom Netherlands Italy France South Korea Indonesia United States Germany China Brazil Russian Federation Vietnam Sweden Austria Japan Thailand India Canada Manufacturing Exports (US$ Bn) Spain Switzerland Mexico Belgium Growth rate in the last Five Years (%) Seven manufacturing superstars have shown growth in exports over the past five years n a period where the world trade in manufactured goods has been on the decline, there are several countries that have still managed to consistently increase their exports. As we evaluate the ways in which India can boost its manufacturing sector and progress towards its 'Make-in-India' targets, it is worthwhile to learn from these manufacturing superstars. These superstars consist of six large manufacturing economies (above $250Bn of export) that have shown positive export growth in the past five years. They are Switzerland, Mexico, United Kingdom, South Korea, United States of America and China. An addition to this list is Vietnam with its extraordinary 20% growth. I Source: World bank; World Development Indicators data; BCG Analysis. Small Medium Large Under Pressure Accelerated Growth Growing Exports Value (manufactured goods) Export Growth (manufactured goods)
  • 21. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 19 Mexico: Building on location advantage 9.7% 5.1% 0.6% 3.9% 100 50 0 % Share of exports Others Machinery Electronics Automotive 2015 2014 2013 2012 2011 2010 2009 2008 2007 2006 2005 2004 % Share of exports 89% 2004 11% USA RoW 2015 81% 19% USA RoW Canada China Brazil 1.8% 0.5% 0.5% Canada China Brazil 2.8% 1.3% 1.0% 0% Duty on Mexican goods in USA 44 Free Trade Access to developed markets including USA, EU, Canada 1 USD vs Peso Peso vs USD depreciation Electricity (c$/KWh) Labour ($/h, productivity adjusted) 4 20 29% 45% 45% 2004 7.33 37 2015 exico's proximity to the USA, the world's largest consumer market, is the cornerstone of its early success. Taking advantage of its low labour costs, Mexico targeted the US market and inked free access to the United States with a Free Trade Agreement(FTA) in 1994. The maturing of this agreement (phasing out of trade barriers) led to export growth in the ensuing decade. While the USA still gets the largest share of exports, Mexico has diversified by increasing exports of automotive and machinery to other countries. The government has continued to focus on manufacturing exports,establishing FTAs with 44 countries, the highest in the world. With continued labour cost advantages, depreciating currency and falling energy costs due to shale gas, Mexico is one of the cheapest manufacturing destinations in the western world. Skilled and hardworking labour force coupled with free access to most developed markets makes Mexico a very attractive destination to set up manufacturing units. M Source: Sener; EIU; BCG Analysis. Note: Though not all sectors have duty free access through NAFTA, duties and tariffs have been phased out by 2009 for select sectors (e.g. Auto). 11.3 15.9
  • 22. 20 | NEXT GENERATION MANUFACTURING Vietnam: Export-oriented economy on its way to becoming a global star 120 90 60 30 0 Others Machinery Footwear and Apparel Electrical and Electronics 2014 2013 2012 2011 2010 2009 2008 2007 2006 2005 2004 2003 2002 2001 2000 1999 1998 1997 • Investment law–Incentives for FDI in multiple sectors formalized • Vietnam joins WTO • Apparel industry boom: Strong focus on low wage, low skilled work • Post 2009 financial crisis, Vietnam an attractive low cost hub • Government push: sweeteners for electronics companies (e.g. Samsung) • Intel invests $1Bn, LG $1.5Bn, Samsung $2.5Bn; commitments for another $9Bn • Investment law amended in 2014 to encourage companies to expand facilities Exports (US$ Bn) 19% 20% 27% tarting from the reforms in 1986, Vietnam has come a long way in the global economy. The first phase of growth came after the quota system ended and Vietnam became an attractive destination for labour intensive industries given its labour cost advantage. This started the apparel manufacturing boom with factories shifting away from China to Vietnam. Access to the USA through a bilateral trade agreement and to the EU through LDC norms created the right ecosystem for growth. The second phase of growth has come by means of change in Investment laws and incentives in 2004 which promoted FDI. During the financial crisis, as companies looked to cut costs and restructure supply chains, Vietnam aggressively attracted electronics manufacturers like Intel, Samsung and LG. Electronics now forms 32% of all manufactured exports, moving away from labour intensive to more value added manufacturing goods. S Source: UN COMTRADE; trademap.org.
  • 23. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 21 The UK: A low cost manufacturing center in Western Europe witnessing a resurgence in manufacturing 30 40 50 1995 2000 2010 2005 1990 10 0 2015 20 United Kingdom Spain France Germany Switzerland Corporate Tax 20% Productivity Adjusted Wages ($/hour) Exports 64 51 36 29 $ billion $ billion $ billion $ billion CAGR (2010-15) 2% 6% 1.5% -2% Machinery Automotive Pharma Electronics 32% 33% 37% he investment by Jaguar into a $740 million facility at Wolverhamptom is indicative of the course that manufacturing will be taking in the UK. With the lowest corporate tax rates in the G7, highly flexible labour laws, highly skilled workforce and a strong R&D support system from academia, the UK is seeing a spurt in manufacturing. Free access to the European market along with wages that continue to be competitive against that of it's neighbours have made this country a regional superstar. With Brexit threatening to curb free access while the depreciating pound enhances competitiveness,it could be interesting times ahead for the UK. T Source: EIU; COMTRADE; trademap.org.
  • 24. 22 | NEXT GENERATION MANUFACTURING China is reinventing itself as a high-tech manufacturer as labour costs rise Exports 2011 2015 5% 1.7 2.1$ trillion 100 80 60 40 20 0 % of manufactured exports 2015 2014 2013 2012 2011 2010 2009 2008 2007 2006 2005 2004 2003 2002 2001 Electronics & Electrical Machinery Apparel 3% 8% 7% R & D Spend (% GDP) 1.2% 2.1% Infrastructure Competitiveness Rank 521 39 Cost Advantage v/s USA 13% 3% 2004 2015 % Population Enrolled in Higher Education 18% 31% t the time of induction into the World Trade Organization (WTO), China was largely a destination for low cost goods with cheap labour geared towards the export market. But as the country became more prosperous, wages nearly quadrupled between 2004-2014 bringing the low-cost manufacturing tag under attack. China, over the last decade and half, invested in R&D, infrastructure and education, to move away from labour intensive, low value-added goods like apparel to R&D intensive high-tech goods such as Electronics and Machinery. While it is still one of the most cost-competitive manufacturing locations, with export subsidies being gradually phased out, a new wave of competition from other countries could be on the horizon. A 1 2006 number. WEF rankings start from 2006. Source: UN Comtrade; WEF competitiveness rankings; EIU; World Bank Trade Indicators; BCG Analysis.
  • 25. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 23 South Korea: Maintaining a strong position in high-tech manufacturing Labour Productivity between 2005-2015 39% R&D spend (% GDP) 2.1% 4.3% Population with college degree (% 25-34 years old) 2.7% 46% 3.6% 59% 18% 68% $Bn Machinery 62 3.6% Plastics 22 3.3% CAGR 2010-2015 Automotive 69 5.3% Electronics 138 4.5% ver the past decade, labour productivity in South Korea has increased by 40%, driven in large part by rapid technology adoption. The government, through its policies and funding for smart factories, is driving Industry 4.0 adoption aggressively. South Korea has an impressive track record in terms of R&D, investing as much as 4.3% of GDP in R&D–higher than most developed countries.The country also has a very educated workforce, making technology adoption and innovation easier. Besides automotive,high value added goods such as electronics and machinery make up the bulk of its exports,and are likely to continue growing given the efforts to drive productivity. O Source: EIU; COMTRADE; Trademap.org.
  • 26. 24 | NEXT GENERATION MANUFACTURING Switzerland: Focused on winning in niches Global competitiveness ranking 8th R&D spend (% GDP) 1st Intellectual Property Rights Protection 3rd Fostering Innovation 1st Watches Precision instruments 23 15 8% 2% Pharmaceuticals 61 6% (12% of world exports, non-generics) CAGR 2010-2015 Exports $Bn Headquarters (41% of world exports) nnovation has been the key driver of Switzerland's growth. The pharmaceuticals and watchmaking industries are unparalleled in the world and are niche segments that Switzerland focuses on. The strong ties between academia and industry, accompanied with the ability to attract and retain top talent enables Switzerland to succeed. Extremely efficient IP processes (11 months for a patent) and significant R&D spend on pharmaceuticals by the government,helps them stay ahead of the curve. Pharmaceuticals and chemical products have a tax benefit of 2.5%, further encouraging these industries to grow. I Source: WEF competitiveness index; EIU; World Bank Trade Indicators; BCG Analysis. Pharma Watches
  • 27. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 25 The USA: Manufacturing resurgence around the corner (10th) Exports teady wages, and gradual increases in productivity,have made USA manufacturing in the world competitive.With Chinese costs verging those of the USA over the past decade, USA has again become a viable choice for manufacturing locations. Strong IP laws, flexible labour laws and rapidly falling energy prices due to the shale gas boom are making the USA cost effective.A culture of innovation and high investments into innovation help ensure that USA remains competent in the high tech market. S Aerospace & Defense Automotive Electronics Precision Instruments 2% CAGR (2010-2015) 2% 11% 5% 1,200 900 600 300 0 2015 2010 2005 2000 1995 1990 1985 1980 USA manufacturing Exports (US$ Bn) Energy cost (2010-2015) Productivity (2009-2014) Wages (2010-2015) R&D spend (Rank as % GDP) Federal Interest Rate (% Interest) 11% $60 Bn 6% 9% Source: EIU; US energy agency; US Treasury; BCG Analysis. 0.25% (2009-2015) 8% 0% 4% Manufacturing resurgence due to reshoring China joins WTO
  • 28. 26 | NEXT GENERATION MANUFACTURING Three key lessons to be learnt from the manufacturing superstars Exploit natural advantages Identify natural advantages in comparison with competing countries Advantages can be based on geographical location, labour, energy costs, etc. (e.g. Mexico for geographical advantage and China for low-cost labour) Create strong barriers for competition to break into a sector. Significant spend on R&D and innovation can create a knowledge barrier for other countries to compete with (e.g. South Korea & USA) Invest in infrastructure and human capital to keep a competitive advantage over other countries–Spend on education, infrastructure (e.g. China & South Korea) Strategic policy interventions to promote target sectors for the future (e.g. FDI promotion in Vietnam, export promotion incentives in China & tax breaks in Switzerland) Select target markets and promote trade (e.g. Free Trade Agreements for Mexico and Vietnam with the US and the EU) Invest to create competitive advantages Introduce policy interventions in target sectors & markets
  • 29.
  • 31. 29 "As all these trends happen, the winners will be those who are able to participate fully in innovation-driven ecosystems by providing new ideas, business models, products and services, rather than those who can offer only low-skilled labour or ordinary capital." – Klaus Schwab Founder and Executive Chairman of the World Economic Forum
  • 32. 30 | NEXT GENERATION MANUFACTURING We are already in the era of Industry 4.0, The Fourth Industrial Revolution Industrial Revolution eras ith every industrial revolution we have seen labour and asset productivity multiply and structural shifts emerge in the manufacturing world order. From the steam and water power in the 1700s to the electric and automation revolutions in the 19th century, we have already seen three big shifts.We are now in the midst of The Fourth Industrial Revolution where digital technology is transforming traditional manufacturing to give rise to connected cyber physical systems. This latest revolution is fittingly called Industry 4.0. Late 18th century Early 20th century Today and in the near future Early 1970s Mechanized production Water and steam power Fusion of technologies straddling physical, digital and biological worlds Automated production Robots, IT & electronics Mass production Electrical energy Increasing complexity & labour productivity W 1.0 4.0 3.0 2.0
  • 33. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 31 Technological megatrends have created conditions ripe for this revolution Infrastructure as a Service (IaaS) Platform as a Service (PaaS) Software as a Service (SaaS) Applications served to customers on-demand via web Virtualised computer infrastructure (e.g. server, storage) Scalable platform for developing/ hosting web applications Business Process as a Service (BPaaS) Business processes (e.g. payroll) delivered as a service "Cloud" (metaphor for internet) So why is Industry 4.0 relevant now? Technology breakthroughs in the past 10 years have made the cost of key technology enablers like bandwidth, processing power, cloud storage, sensors, and robots, crash to a fraction of what they were 10 years ago. The performance, size and availability of these cyber-physical systems have also dramatically improved, making them accessible to manufacturing shop floors. Cloud services have made connected enterprise management systems available to even small and medium enterprises (SMEs). These structural changes in the ecosystem have created conditions for efficiency and productivity gains and the momentum for the widespread adoption of Industry 4.0. 40x Over the past ten years Avg. cost over the past ten years 20x Cost per MB over the past ten years 30% Avg. cost of robots over the past ten years 50x Over the pas ten years 50% Cost of Bandwidth Cost of Data Storage Cost of Sensors Cost of Robots Cost of Processing Power Source: Goldman Sachs; Deloitte; BCG Analysis. Abundant and cheap computing power Availability of low cost on-demand cloud platforms
  • 34. 32 | NEXT GENERATION MANUFACTURING Several core technologies are driving Industry 4.0 Few core technologies combine to create multiple use cases across the manufacturing value chain. Many of these have already been in use standalone. With Industry 4.0, these technologies are getting used together and transforming the conventional manufacturing value chain. Industry 4.0 Augmented Reality • Real time information in semantic context • Assistance in navigation, diagnostic, repair etc. Additive manufacturing e.g. 3D printing • On-demand manufacturing • Mass customization • Rapid prototyping and tooling Big data and analytics • Real-time data processing • Data driven decision making Simulation • Upfront optimization of products / processes Autonomous robots • Self learning industrial robots • Integrated sensors • Standardized interfaces
  • 35. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 33 Core performance impacted across all production elements Overall, these technologies have transformed value chains into more flexible (through programmable machines and robots),more efficient (through higher automation and shorter set up times),higher quality (through real time monitoring using sensors and actuators) and quicker to market (using data and simulation based modeling systems). Beyond these core benefits,manufacturing conditions are also improving with greater workforce safety, better working conditions,increased collaboration opportunities across production cells with greater data availability and increased resource utilization. The result has been a better environment for production. Flexibility Productivity Speed Quality
  • 36. 34 | NEXT GENERATION MANUFACTURING Example: Autonomous robots in assembly lines hop floors across the world, especially in developed economies like the USA, Germany and South Korea are already seeing this transformation. For example, autonomous robots like Baxter by Rethink Robotics are configurable, designed to work safely with humans and are highly adaptive. Tasks such as packing, loading and handling that were not possible with traditional robots are now coming into the ambit of automation. With costs as low as $22,000,payback for such automation is now in months rather than in years. This particular technology is already being used by firms in North America, including small enterprises with less than 20 employees, to compete effectively with China and Mexico. S Low cost $22,000 Can replace $15~$20 / hour jobs for <$ 3/ hour Cobot (collaborative robot) designed to co-work with humans Trained through demonstration rather than programming Continuously improving through remote software upgrades Source: Press article search.
  • 37. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 35 Example: Warehouse guidance systems using augmented reality ugmented Reality (AR) is another technology that is transforming manufacturing and warehousing operations.An example is the DHL warehouse where AR glasses show operators the exact location and quantity for the next pickup, provide indoor navigation and also scan barcodes to report pickup and drop operations. Estimates suggest a ~2% cost reduction in the steady state due to a reduction in human errors, lower training costs, increased productivity, plus an increased speed of freight loading. Beyond warehousing, AR has found applications in hands-on training, real-time operator guidance during manufacturing, and guiding repairs on complex machinery. The use of augmented reality empowers low skilled workers to execute tasks that typically require higher skilled workers. A Glasses show location, quantity and handling information Indoor navigation for shortest route Object recognition and barcode scanning for paperless pickups Linked to ERP for real-time updates and order completeness checks Source: Press article search. Images are representative
  • 38. 36 | NEXT GENERATION MANUFACTURING Example: Lot size of one in semi-automated production nother example is of the German auto component manufacturer Bosch which has managed to achieve flexible production with a lot size of one. This is done through the use of RFID codes on components, smart workstations and real time instruction to workers through work screens. With no set up times and machine guided real-time assembly, production time has seen up to a 30% decrease. Errors are also minimized. The ability to handle complexity has multiplied with little to no scale disadvantage. Traditional cost-complexity tradeoffs are being made irrelevant, ultimately leading to higher line utilization and lower costs. A Auto-adjusting working station as per product requirements and workstation capabilities RFID tagged products with the information on which tasks have to be carried out Self adapting workstation to worker's height and ergonomic needs, skills, language and instruction requirements Visual board to collect, filter and visualize production data, highlight potential problems, auto-alert function Semi-automated production for making 200 variations of six basic models with 30% decrease in production time Source: Press article search.
  • 39. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 37 Example: Use of 3D printers to increase flexibility, speed and cost competitiveness E has realized benefits from using additive manufacturing for jet engine components. With the acquisition of two European companies for $1.4 Bn, capability gaps in additive manufacturing were filled. Now instead of large warehouse networks and inventories of huge components, the company is producing components on demand close to the consumption center. Beyond the inventory and logistics cost advantages, more complex designs are leading to lower weights, reduced wastage and greater speed. With more than 400 3D printers already in use, plans are in place to produce over 100,000 components through additive manufacturing by 2020. High precision part created by additive manufacturing G GE acquired 2 companies with advanced 3D printing capabilities to fill capability gap in 3D printing 400+ 3D printers in use with plans to add 1,000 more in next decade Plan to expand use to manufacture 100,000 components by 2020 On-demand production to replace conventional safety stock inventory and warehouse network Source: Press article search. Images are representative
  • 40. 38 | NEXT GENERATION MANUFACTURING Example: Multiple technologies are coming together to challenge status quo in auto manufacturing esla, the twelve year old electric auto manufacturer, is competing aggressively with the century old auto giants and gaining ground too.Since the early days, Tesla has relied on heavy use of technology in its product development and production processes to keep costs low, improve speed to market while maintaining high quality. They have revolutionized auto manufacturing with greater use of simulations to cut down on development times and use of physical crashing models, use of additive manufacturing to create low cost components in-house, and high use of automation in its factories. Extensive use of technology allows Tesla to have better margins (24% gross margin versus 17% for GM) and better quality reflected in its #1 ranking for customer satisfaction. T Simulations and Big Data Autonomous Robots Additive Manufacturing Simulations for crash testing reducing need for physical tests 1,000+ robots including 160 specialist robots Additive manufacturing for rapid prototyping and low cost components Source: Press article search. Images are representative
  • 41. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 39 Structural shifts will change sector dynamics The last three decades saw the emergence of global supply chains as large pools of low cost labour in developing countries took to factory floors. However the fourth manufacturing revolution could fundamentally alter this trend. As trade-off between labour and automation swings in the favour of the latter, manufacturing is returning to highly automated factories in developed countries. Small scale plants closer to the market are becoming more competitive than large off-shore plants. Digital technologies are driving consistent growth in labour productivity of developed nations, reducing competitiveness gap with emerging countries facing wage inflation. The CEO of a leading manufacturing conglomerate quotes frequently that "Every Company Has to be a Service Company". The servicification of manufacturing is rapidly evolving as manufacturers disrupt their business model to capture shifting value pools. For example, GE has transformed itself from manufacturer to service provider, with digital revenues crossing $15Bn this year. Rise of digital trading platform, digital supply chain and global services will fundamentally enhance the skills expected of the worker. Even the traditional manufacturer will need talent with new skills such as data scientist,robot supervisor and virtual reality designer. Shift in skills of labour force 'Servicification' of manufacturing Re-shoring of manufacturing closer to consumption centers
  • 43. 41 “The art of war teaches us to rely not on the likelihood of the enemy's not coming, but on our own readiness to receive him; not on the chance of his not attacking, but rather on the fact that we have made our position unassailable.” – Sun Tzu
  • 44. 42 | NEXT GENERATION MANUFACTURING India Inc. is already adopting Industry 4.0 technologies Question : Which pillar of Industry 4.0 are you investing in? Today In next 5 years Big Data and Analytics Autonomous Robots Additive Manufacturing Augmented Reality Simulation 79% 58% 65% 52% 71% 56% 38% 23% 15% 54% As the adoption of Industry 4.0 technologies accelerates in other countries, Indian manufacturers are drawing a roadmap to incorporate these technologies. Our CII–BCG survey reveals that more than 50% of manufacturers have either already invested in or are in the process of investing in the majority of the Industry 4.0 technologies.Big data and simulation are technologies that almost two-thirds of companies are expected to adopt within the next 5 years. Source: CII–BCG Manufacturing Leadership survey 2016.
  • 45. THE BOSTON CONSULTING GROUP  CII | 43 One in two respondents expects greater than 50% process automation in the next 10 years Question: What percentage of your processes are currently automated and how much is expected to be automated in the next 5 and 10 years? s the adoption of these technologies increases, the automation of manufacturing processes is also expected to steadily increase. While more than 60% of survey respondents have less than 20% of current processes automated, this number is expected to fall below 20% in 10 years time. At the same time, more than half of the respondents expect to have 50%+ of their processes automated. This trend shows that Indian manufacturers are actively thinking about investing in automation technologies and planning to catch up to their global peers. A At present 23% 15% In 5 years 19% 37% In 10 years 33% 50% 20-50% > 50% 38% 56% 83% Source: CII–BCG Manufacturing Leadership survey 2016.
  • 46. 44 | NEXT GENERATION MANUFACTURING Quality improvement and cost reduction are primary objectives of adoption Question: What are the benefits that you see resulting from Industry 4.0 advancement? 28% 19% 17% 16% 10% 6% 4% Improved quality Lower cost More flexibility Reduced time to market Reduced production time Improved product availability No benefit Although cost and productivity have been the primary drivers of the accelerated adoption of Industry 4.0 in developed countries, quality is the most prominent benefit in India. Despite low labour costs,the availability of skilled and quality-conscious labour is a major pain point for Indian manufacturers. As Indian manufacturers move up in the value chain and aim to capture the export market, they need to fill quality gaps through automation and technology adoption. Cost, flexibility and reduced time to market are the second order benefits that Indian manufacturers target beyond quality. Identified as either Top 1 or Top 2 reasons Source: CII–BCG Manufacturing Leadership survey 2016.
  • 47. THE BOSTON CONSULTING GROUP  CII | 45 Example: Availability of low-cost IIoT solution is accelerating the adoption of Industry 4.0 in India o far the Industry 4.0 revolution has been led by western companies. Established industrial companies as well as startups have been dominating market share in these technologies.Most of their solutions are aimed at developed market, on the other hand Indian manufacturers operate in different operational environments–with lower labour costs, lower skilled labour, inconsistent digital infrastructure and a limited capacity to pay. Varroc, an automotive component manufacturer with $1.3 billion revenue was looking for an effective,scalable solution to improve their competitiveness.After comparing various global solutions,Varroc decided to implement Altizon's IIoT platform as it met their diverse requirements better than competing solutions.Altizon's innovative system combined global functional benchmarks, competitive pricing, and flexibility to connect with legacy machines. Today, operational status of connected machines in Varroc's Uttarakhand plant are visible on the Datonis Platform within minutes. Rather than taking reactive measures on old data, supervisors on shop floors are empowered with real-time decision making, improving effectiveness and creating real impact on the bottom line. S Fast RoI • ~20% improvement in efficiency • 5% decrease in product defects Real-time monitoring and instant decisions enabled shop floor workers to take proactive decision Plan to implement solution in all 35 plants and develop algorithm for real-time decision making Altizon's solution was selected due to flexibility, scalability and low cost. Other solutions couldn't connect with our legacy machines – Mr. Narinder Singh, DGM ,IT , Varroc Device collecting data on legacy machines Analytics engine providing real-time visibility of plant utilization Source: Industry interview.
  • 48. 46 | NEXT GENERATION MANUFACTURING Example: Collaborative robots (cobots) can automate high precision labour-intensive tasks Universal Robot's cobots assisting women factory workers 7 Processes automated by cobots 110+ Cobots operating on assembly line raditional robots were designed to perform specialized tasks and operate from a cage. They require significant upfront capital and skilled staff for programming. The rise of collaborative robots,also called Cobots, are changing the game. They can work safely with humans, are easy to deploy and cost fraction of the traditional robot's cost. Today a cobot can be purchased at a cost of mid-size sedan, requires no annual maintenance contract and have payback within 24 months, even at Indian salaries. Bajaj Auto, world's 3rd largest two wheeler manufacturer, has been an early adopter of cobots made by Universal Robots.Bajaj has automated physically taxing processes that require high-end precision and today 110+ cobots operate with workers to provide flexibility, reliability and productivity gains. For Indian SMEs, capital expense and operating expense are of major concerns for adoption of any technology. Availability lower cost, versatile cobots can accelerate automation among SMEs as well. T Source: Industry interview. Payback period <24 months
  • 49. THE BOSTON CONSULTING GROUP  CII | 47 ndustry characteristics are expected to drive the adoption of Industry 4.0 technologies.Impact of any Industry 4.0 lever varies by sector given their unique characteristics. Industry characteristics may differ across geographies due to regulation, customer needs,labour intensity, etc. The results of CII–BCG Manufacturing survey reveal that Indian manufacturers are most optimistic of Industry 4.0 impact on auto, electrical & electronic machinery and precision equipment sectors, while metal and non-metallic products are expected to be least impacted. Industry characteristics to drive adoption T CII–BCG Manufacturing survey: Top 3 sectors with Industry 4.0 potential CII–BCG Manufacturing survey: Sectors with least Industry 4.0 potential Logistics Complexity Complexity (number of parts, number of SKUs) Speed of new product development cycle Supplier-aided smart design Product complexity: material, form, technology Precision & Quality Need for integrated supplier management On-demand configuration Share of manual activities in production Setup times & product variance Industry characteristics Industry 4.0 levers Automobile and transport equipment Electrical and electronics machinery Medical, optical and precision equipments Metal products Metals and mining Non-metallic products Integrated work-flows Virtual design Flexible manufacturing Autonomous logistics Self- optimization I Source: CII–BCG Manufacturing Leadership survey 2016.
  • 50. 48 | NEXT GENERATION MANUFACTURING Adoption of Industry 4.0 could create a step change in Indian manufacturing competitiveness he size of the prize for adoption of these technologies for Indian manufacturing is large. Based on currently deployed solutions,manufacturers can expect to gain advantages in raw material, labour and energy costs.This in addition to benefits in quality delivered, speed to market and asset utilization. The impact of adopting Industry 4.0 is clearly visible through the magnitude of the numbers involved. It is now up to the policy makers and industrial leaders to ensure that India actively participates in this revolution and reap the benefits in global competitiveness. T Labour Productivity 30-100% Increase Quality 6 sigma levels Responsiveness From days to hours Energy Costs 10-30% decrease Inventory in Value Chain Up to 75% reduction Source: BCG client experience; Industry interviews; BCG Analysis.
  • 51.
  • 53. 51 “In strategy it is important to see distant things as if they were close and to take a distanced view of close things” – Miyamoto Musashi, legendary Japanese swordsman
  • 54. 52 | NEXT GENERATION MANUFACTURING India needs to reinforce the sector's foundation and leverage Industry 4.0 to improve competitiveness As Indian manufacturing shifts gear to catch-up with manufacturing superstars,action is required on two fronts. First, policy makers need to continue reinforcing the foundation by delivering on Make-in-India objectives.This will allow Indian manufacturers to effectively compete in global markets by removing inefficiencies and fully leveraging our competitive advantages. Second, with the fourth industrial revolution unfolding, Indian manufacturers need to proactively start adopting Industry 4.0 technologies.Here, government can play a key role in promoting Industry 4.0 by increasing awareness, providing incentives and building the necessary ecosystem. Reinforce foundation: Continue to deliver on Make in India objectives Improve competitiveness through technology adoption
  • 55. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 53 Reinforcing the foundation: 9 point agenda for government any recommendations have been made in the past about reviving manufacturing growth and government has already taken action in right direction. Indian government should continue fixing the building blocks by accelerating the infrastructure execution, improving ease of doing business through structural reforms and increasing capital availability. It is critical to keep a steady focus on gaining global competitiveness by building global scale, developing world-class clusters and easing trade barriers to improve export competitiveness.To ensure sustainable competitive advantage, policy makers also need to promote development of capabilities by accelerating technology transfer, promoting innovation and improving workforce skill base. M Building blocks Ease of doing business Improve labour flexibility, faster and simplified clearance and approvals (e.g. land acquisition, environment clearance) Capital Ease capital constraint by relaxation of FDI limits and increase in credit availability Infrastructure Establish world-class infrastructure in ports, rail and road Competitiveness Build global scale Develop cluster- based ecosystem Ease trade barriers Leverage domestic demand to nurture and develop global scale Build world class clusters containing core infrastructure for supporting operations, common facility centres etc. Prioritize FTA with key importing nations Expand export promotion schemes with tax breaks to more sectors Capabilities Accelerate technology transfer Promote R&D and innovation Improve workforce skill base Support systematic indigenization of technology Incentivize R&D and innovation to develop it into key pillar of sustainable competitive advantage Skill improvement program to improve quality of labour and engineering workforce
  • 56. 54 | NEXT GENERATION MANUFACTURING Reinforcing the foundation: 5 point agenda for manufacturing leaders n a fast evolving global manufacturing landscape, Indian manufacturers are competing against leading manufacturers with bigger scale, superior productivity, superior employee skill base, R&D capabilities and quality capabilities. To win market share from these competitors,Indian manufacturers need to act on each of these fronts to fill key gaps and become globally competitive. I Think Big–think long-term, think global • Create and defend competitive advantage across whole value chain, focusing on an 8 to 10 year path to success Relentlessly focus on productivity • Significant productivity gap with other manufacturing countries needs to be filled to become globally competitive Fortify and further improve quality • Indian auto component industry has set a perfect example of steadily improving quality to become world class. Other industries need to replicate this success story Bet on R&D and innovation • Indian manufacturers need to increase investment in R&D and innovation to build competitive advantage beyond low cost labour Invest in lifelong learning of employees • As labour cost advantage diminished over long-term, manufacturers should proactively invest in lifelong training of employees to build highly competent workforce No. of Fortune 500 companies: 103 Vs. 7 India China 1.5x China's labour productivity as compared to India 22 Vs. 28 India Rest of World Cumulative No. of Deming prizes (2002-15) 1,100 Vs. 190 No. of R&D professionals per million India China 5%Vs. 2% Training spend as % of labour cost India China Source: EIU; Oxford economics; BCG Survey.
  • 57. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 55 Technology adoption: Government agenda to promote and enhance competitiveness roactive adoption of Industry 4.0 can take India to the league of top manufacturing countries.We need to sustain a bold vision of becoming a top 3 manufacturer. To realize the existing target of 10% annual growth in manufacturing, India needs to consistently improve labour productivity by 5% every year. To realize these ambitious goals, the government needs to build world class digital infrastructure and carry out education reforms required to make the Indian workforce future ready. CII–BCG leadership survey reveals that industry leaders expect the government to play a role in increasing awareness about Industry 4.0. This can be achieved by developing a dedicated Industry 4.0 innovation centers that will also support the SME sectors in the adoption process. Development of low cost indigenous solutions can be accelerated by allocating part of startup India funds for Industry 4.0 startups. As other developed and developing countries provide productivity linked incentives to local SMEs, India also needs to create a level playing field by matching such incentives and additionally promoting import duty and tax breaks for companies that adopt these technologies to enhance competitiveness. P India as global top 3 manufacturing economy • Annual labour productivity growth of 5% for next 10 years leveraging technology • Technological readiness rank (WEF competitiveness index): 120 (2016) ⇒ 30 (2025) • Develop high bandwidth network for smart factories • Develop Industry 4.0 Innovation Center to support technology adoption • Allocate part of 10,000 Cr startup India fund for Industry 4.0 startups Build world class digital infrastructure Improve support system Education reform to train future workforce • Overhaul education system to impart skills required for future jobs • Productivity linked incentives such as tax breaks, capex subsidies • Exemption of import duties on Industry 4.0 related technologies • Reward companies leading in Industry 4.0 maturity index Promote adoption Set Clear Vision Create supportive ecosystem Source: World Economic Forum.
  • 58. 56 | NEXT GENERATION MANUFACTURING Technology adoption: CEOs need to challenge status quo and develop an adoption strategy he CEO's role is central in any technology adoption journey. It is the CEO's responsibility to challenge the status quo of all key processes, and set a bold vision for competitiveness through technology adoption. A change of this kind is always driven from the top, with the CEO chairing the steering committee meetings.An often missed area in such journeys, is that of people. Having technologically capable mid-managers and key front- line staff is critical to ensuring a successful transformation but is not always easy to do. It is important to define the capability gap and draw out a clear roadmap to plug key gaps–through a mix of training/hiring levers. In driving the detailed transformation agenda, it is prudent to carry out a diagnostic that identifies the key processes across the organization that are conducive to step-improvement through technology-adoption.And, having done so, it is always helpful to drive a mix of 'quick wins' and a set of long-term initiatives that could involve higher investment and experimentation.A balanced approach such as this, ensures early momentum while retaining the focus on big-ticket items. T CEOs to own and drive the Industry 4.0 transformation • Assess status quo with respect to existing technological changes, competitor's positioning and existing capabilities • Set ambition level for company to achieve across 4 categories–Productivity, Quality, Speed and Flexibility • Drive the transformation journey Embed Industry 4.0 in CEO's agenda Develop strategic roadmap to fill the capability gap • Invest in developing and acquiring talent equipped with future-ready skills • Develop a culture of innovation, experimentation, collaboration and continuous improvement • Evaluate M&A as potential option to fill key capability gap Build the foundation Re-engineer value chain and re-imagine offerings, starting from high impact use cases • Generate quick wins by implementing limited use cases with proven impact • Proactively invest in long-term initiatives that will create sustainable competitive advantage. • Manage data as a valuable strategic asset Setting right priorities
  • 59. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 57 Make-in-India: The need for concerted multi-pronged action agenda to realize vision Top 100 in Ease of Doing Business FDI reforms Top 50 in Ease of Doing Business Invest in level technology adoption Implement GST Debottleneck ports, road, rail network FTAs with major global importers Develop Industry 4.0 immersion centers I ndian manufacturing sector is at a cusp of a new dawn. Many factors such as government-led structural reforms, infrastructure growth, increasing foreign investment,and increasing domestic demand have potential to create a long-term growth momentum for Indian manufacturing. To maintain growth momentum,government needs to accelerate the pace of infrastructure development,policy reforms and trade agreement negotiations. Indian manufacturers also need to aggressively adopt advanced technologies to transform themselves into globally competitive manufacturers. To achieve ambitious targets set as part of Make-In-India initiative, manufacturing sector needs to grow by double digits and we have more favorable factors than any other time in recent history. The time has come for India to transform itself into a manufacturing powerhouse. Today Vision
  • 60. 58 | NEXT GENERATION MANUFACTURING The Boston Consulting Group publishes other reports and articles on related topics that may be of interest to senior executives. Recent examples include: Industry 4.0: The Future of Productivity and Growth in Manufacturing Industries A focus by the Boston Consulting Group, April 2015 Man and Machine in Industry 4.0 A report by the Boston Consulting Group, September 2015 Time to Accelerate in the Race Toward Industry 4.0 A perspective by The Boston Consulting Group, May 2016 Three Ways for Companies to Succeed in the Fourth Industrial Revolution A perspective by The Boston Consulting Group, January 2016 Manufacturing for the 21st century An article by the Boston Consulting Group, November 2016 Why Advanced Manufacturing Will Boost Productivity A report by The Boston Consulting Group, January 2015 Make in India: Turning Vision Into Reality A report by The Boston Consulting Group in association with Confederation of Indian Industry, October 2014 Acting on the Digital Imperative An article by The Boston Consulting Group, September 2016 The Proximity Paradox: Balancing Auto Suppliers' Manufacturing Networks A report by The Boston Consulting Group, March 2015 People Productivity: Key to Indian Manufacturing Competitiveness A report by The Boston Consulting Group, March 2013 The shifting Economics of Global Manufacturing–How Cost Competitiveness Is Changing Worldwide A report by The Boston Consulting Group, August 2014 Future of Indian Manufacturing: Bridging the Gap A report by The Boston Consulting Group in association with Confederation of Indian Industry, August 2015 Forks in the Road: Navigating Industry Disruption A report by The Boston Consulting Group, May 2016 The Robotics Revolution: The Next Great Leap in Manufacturing An article by the Boston Consulting Group, September 2015 The Evolution of Robotics An interactive by The Boston Consulting Group, November 2014 The Rise of Robotics An article by The Boston Consulting Group, August 2014 3D Printing Will Change the Game: Prepare for Impact An article by the Boston Consulting Group, September 2013 For Further Reading
  • 61. THE BOSTON CONSULTING GROUP  CONFEDERATION OF INDIAN INDUSTRY | 59 About the Authors Dr. Arindam Bhattacharya is a Senior Partner and Director in the New Delhi office of The Boston Consulting Group. Arun Bruce is a Partner and Director in the Mumbai office of The Boston Consulting Group. Anirudh Tara is a Principal in the New Delhi office of The Boston Consulting Group. Mani Singhal is a Principal in the New Delhi office of The Boston Consulting group. For Further Contact If you would like to discuss the themes and content of this report, please contact: BCG Dr. Arindam Bhattacharya Senior Partner and Director BCG New Delhi +91 124 459 7093 bhattacharya.arindam@bcg.com Arun Bruce Partner and Director BCG Mumbai +91 22 6749 7101 bruce.arun@bcg.com Anirudh Tara Principal BCG New Delhi +91 124 459 7178 tara.anirudh@bcg.com Mani Singhal Principal BCG New Delhi +91 124 459 7146 singhal.mani@bcg.com CII Dr. Saugat Mukherjee Regional Director CII–Western Region +91 22 2493 9747 s.mukherjee@cii.in Alpa Antani Head–International & Special Projects CII–Western Region +91 22 2493 1790 alpa.antani@cii.in Acknowledgements This study was undertaken by The Boston Consulting Group (BCG) with support from the Confederation of Indian Industry (CII). We would like to thank the members of CII related to Manufacturing and allied sectors for their valuable inputs and insights. Special thanks to Mr. Jamshyd N Godrej, Chairman, 15th Manufacturing Summit and Chairman and Managing Director, Godrej & Boyce Manufacturing Company Limited; Mr. Sudhir Mehta, Chairman, CII Western Region 2016-2017 and Chairman & Managing Director, Pinnacle Industries Limited and Dr Saugat Mukherjee, Regional Director, CII Western Region, for their valuable contribution. We would also like to thank the respondents to the CII–BCG Manufacturing Leadership Survey 2016 for their valuable inputs. We gratefully acknowledge the contribution of Vinayak Tendulkar, Ayush Bohra in the firm's Mumbai office and Akshay Devalla in the Chennai office in writing this report. Special thanks to Jamshed Daruwalla, Pradeep Hire and Zaufer Sadiq for their contributions to the editing, design and production of this report and Jasmin Pithawala for managing the marketing process. Note to the Reader
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  • 63. © The Boston Consulting Group, Inc. 2016. All rights reserved. For information or permission to reprint, please contact BCG at: Email: bcg-info@bcg.com Fax: +91 226749 7001, attention BCG/Permissions Mail: BCG/Permissions The Boston Consulting Group (India) Private Limited Nariman Bhavan 14th Floor, 227, Nariman Point, Mumbai 400 021 India For information or permission to reprint, please contact Confederation of Indian Industry at: Email: ciiwr@cii.in Web: www.cii.in Tel: +91 22 24931790 Fax: +91 22 24939463/ 24945831 Mail: Confederation of Indian Industry Western Region 105, Kakad Chambers 1st floor, 132, Dr Annie Besant Road, Worli, Mumbai – 400 018 India To find the latest BCG content and register to receive e-alerts on this topic or others, please visit bcgperspective.com. Follow bcg.perspectives on Facebook and Twitter. 11/2016