In an exclusive interaction with Thiruamuthan, Assistant Editor at Industry Outlook, BN Shukla, Managing Director, Jabil India, a seasoned operations and supply chain leader with over 30 years of experience in India's electronics manufacturing sector, discusses how Indian electronics manufacturers are adopting smart factory technologies—real-time analytics, IoT, AI, predictive maintenance and cybersecurity—to improve agility, efficiency and resilience, while workforce upskilling, automation and autonomous systems accelerate India’s transition toward advanced electronics manufacturing.
With recent Indian electronics hubs accelerating smart factory adoption, how are manufacturers leveraging real-time data analytics to boost agility and production efficiency?
Over the years, the markets we serve and the solutions we offer have become increasingly sophisticated. Indian electronics hubs such as Bengaluru, Pune, Noida, and Chennai are rapidly adopting smart factory technologies that leverage real-time data analytics to boost agility and production efficiency. Through IoT networks, manufacturers connect machines, sensors, and ERP systems to capture live data on machine performance, production throughput, and quality metrics. These data streams feed AI-powered dashboards and digital twins, enabling the quick identification of bottlenecks and immediate process optimisations.
According to McKinsey's research on Industry 4.0 digital transformation, the impact is significant, with efficiency gains of 20-30 percent, downtime reduction of up to 30 percent, and enhanced defect detection — all contributing to faster product cycles and greater customisation capabilities. Ultimately, manufacturers are better equipped to respond swiftly to fluctuating market demands and supply constraints while minimising waste and energy consumption.
To elaborate with an example, Jabil continues to evolve its capabilities to meet customers’ demands by investing in harmonising systems, standardising processes across its global network, and leveraging artificial intelligence and machine learning technologies. A further illustration is our computer-vision-based automated optical inspection, which improves first-pass yield, reduces non-value-added inspections and minimises scrap caused by offline debugging and rework. As these solutions mature and integrate more data, they shift from correcting defects to proactively preventing faults across the value chain.
Smart factories in India are moving beyond visibility—using AI, IoT, and predictive analytics to cut downtime, minimise waste, and accelerate production decisions.
Following increased IoT deployments in Indian assembly lines, which real-time monitoring and predictive analytics systems are driving efficiency gains, and how are integration challenges addressed?
The expansion of IoT on Indian assembly lines has introduced advanced technologies such as smart sensors, machine vision, and edge computing, enabling continuous monitoring of equipment health, environmental conditions, and production parameters. Predictive analytics systems leverage this data to anticipate machine failures or quality deviations before they affect output. However, integration challenges persist due to the coexistence of legacy equipment and diverse software platforms. Leading manufacturers are overcoming these hurdles through middleware platforms, standardised APIs, and phased digitisation roadmaps, which facilitate seamless interoperability between machines, ERP systems such as SAP and Microsoft Dynamics, and cloud platforms.
It is essential for organisations to develop a clear strategy for harnessing these technologies effectively within their operations. If we look at Jabil SOPs, we adopt a customer-first approach, being intentional from the outset about how we apply AI and ML to solve business challenges or deliver deep insights that drive transformative improvements in safety, quality, delivery, and cost.
This holistic strategy enables data-driven decision-making, enhances operational transparency, and facilitates timely interventions that improve reliability while reducing maintenance costs.
As predictive maintenance gains traction among Indian electronics firms, how is AI reshaping downtime management in multi-product, high-mix production setups?
AI-powered predictive maintenance is revolutionising downtime management in India's electronics firms, which frequently operate complex multi-product, high-mix lines. AI algorithms can analyse vibration, temperature, and acoustic sensor data alongside historical maintenance records to detect subtle signs of potential equipment failures. This allows maintenance schedules to be dynamically adjusted, avoiding costly unplanned downtime, and maintaining high line availability. Multiple case studies from Indian manufacturers report reductions of 20–25 percent in machine breakdowns and up to a 20 percent cost savings on maintenance. Indian manufacturers are combining AI with digital twins to simulate maintenance scenarios and optimize resource allocation, enhancing asset longevity while supporting frequent product changeovers typical of electronics manufacturing.
Also Read: Advancing India’s Manufacturing Realm Toward Global Resilience
With ransomware and supply-chain cyberattacks rising globally, how are Indian smart factories securing cloud-based automation while maintaining operational efficiency?
Indian smart factories are making significant investments in cybersecurity to safeguard cloud-connected automation systems from cyberattacks. Modern security frameworks now incorporate real-time threat detection, network segmentation, secure access controls, and end-to-end encryption. Automated backup processes and robust disaster recovery plans have become standard practices. Moreover, organisations are placing greater emphasis on employee cybersecurity training to mitigate risks such as phishing and insider threats. These comprehensive, layered security measures ensure operational continuity and data integrity while maintaining the high availability and flexibility demanded by automated production environments.
Cybersecurity is a top priority at Jabil. Leveraging our industry expertise alongside enterprise-wide education and awareness initiatives, we are fostering a strong data protection culture. Our employees are empowered, and our customers and partners have confidence in our ability to conduct business securely in today’s ever-evolving digital landscape.
Jabil’s cybersecurity strategy uses a three-pronged risk-management model under its Defence-in-Depth approach:
This layered system delivers multiple levels of data protection, avoiding reliance on any single tool or policy, and builds redundancy into our systems and processes for resilient security.
Amid government-led workforce skill initiatives, how are smart factory solutions helping operators adapt and reskill in India’s evolving electronics manufacturing landscape?
Government initiatives, such as Skill India, PMKVY, and Samarth Udyog Bharat 4.0, underpin workforce transformation, aligning with the deployment of smart factories. Smart manufacturing solutions complement these by providing operators with augmented reality (AR) tools, mobile apps, and AI-driven training modules that enable hands-on learning and adaptive skill development. These technologies reduce the learning curve for complex machinery and software, supporting continuous upskilling. Industry–academia collaborations are also helping tailor programs to evolving technology needs, ensuring a pipeline of digitally skilled talent that sustains productivity and innovation in India’s electronics sector.
Also Read: Top 10 Women Leaders Shaping India's Manufacturing Landscape
With autonomous manufacturing technologies piloted recently in India, which innovations are poised to define the next generation of agile electronics factories?
India’s pilots of autonomous manufacturing technologies are progressing rapidly with innovations such as AI-driven robotics, automated guided vehicles (AGVs), digital twins for virtual process simulation, and collaborative robots (cobots) that work alongside human operators. These technologies offer enhanced flexibility through modular, reconfigurable production lines that can quickly switch between products. The rollout of 5G networks further enables real-time control and data exchange, which are essential for autonomous operations. Indian electronics factories investing in these advancements stand to achieve significant gains in throughput, safety, and product quality, positioning themselves to compete globally within smart, agile manufacturing ecosystems.
For domestic organisations to successfully transition to high-tech manufacturing, a tech-savvy and committed workforce is critical. At Jabil, we place people at the centre of transformation. Our industry-certified internal training programs, developed in partnership with industry experts and local universities, have expanded our pool of subject matter experts by retaining and deepening technological expertise through customised, application-focused upskilling. Furthermore, by integrating business modules into technical training, we foster workplace diversity, driving innovative decision-making and business differentiation.
We also collaborate with leading equipment providers and government agencies to strengthen the manufacturing ecosystem and cultivate the next generation of talent. Inter-sectoral and global partnerships are vital for the effective transfer of knowledge on new technologies and best practices. These initiatives, including a shift toward practical, skill-based learning, are essential for positioning India as a global innovation hub.
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