“We provide Safety Solutions for robot applications. And we leverage Industry 4.0 technologies such as IoT, IIoT, AI, and automation to enhance industrial safety and optimize operational efficiency at customer end. We are providing software as a solution and we will continue to focus keenly on the growing needs of customers, all with the aim of designing more secure and more efficient processes for them and developing new services together,” elucidates Kunal Sharma, Schmersal India, in an exclusive interview. Excerpts:
Q1. Schmersal is a well-known name in the industrial safety sector. What’s the pivotal role you play in robotics automation in the manufacturing sector where safety is of paramount importance?
We provide Safety Solutions for robot applications.
We have a wide range of products and services available for the protection of industrial robots, from simple safety components to programmable safety controllers. We offer a variety of solutions for access control and area safeguarding that are suitable for a range of different robot systems. The product range satisfies the requirements of C standard ISO 10218-1 (robots and robotic devices) and ISO 10218-2 (robotic systems and integration).
Depending on the complexity and number of safety circuits, Schmersal provides solutions for reliable signal evaluation based on safety relay modules and safety controllers with an array of visualisation and diagnostic options.
In addition, our manufacturer-independent service team tec.nicum has a wealth of safety-related expertise in all areas of robot safety, from consultancy services to risk assessments of robot workstations
Q2. Please elaborate on the use of Industry 4.0 technologies in your automation solutions.
Schmersal India is leveraging Industry 4.0 technologies such as IoT, IIoT, AI, and automation to enhance industrial safety and optimize operational efficiency. Here’s how:
- IoT-Based Energy Management Systems
Schmersal India integrates IoT-enabled energy management solutions to monitor and optimize energy consumption across industrial setups. These systems provide real-time insights into energy usage, helping manufacturers reduce wastage, lower operational costs, and support sustainability goals. By aligning energy management with safety systems, the company ensures compliance with safety standards while improving efficiency. - OEE Monitoring Solutions
To optimize machine efficiency, Schmersal offers Overall Equipment Effectiveness (OEE) monitoring solutions. These IoT-enabled systems track key performance indicators (KPIs) like availability, performance, and quality in real time. With OEE monitoring, manufacturers can identify bottlenecks, minimize downtime, and ensure maximum productivity across operations. - AI for Predictive Maintenance
Schmersal utilizes Artificial Intelligence (AI) to implement predictive maintenance strategies. By analyzing data from connected machines and safety devices, the system can predict potential failures and schedule maintenance proactively. This minimizes unexpected downtime, extends machine life, and reduces maintenance costs. - Enhanced Machine Safety with IIoT
Schmersal’s IIoT-enabled safety solutions provide real-time monitoring and control of safety systems across industrial facilities. Devices such as safety interlocks, light curtains, and safety controllers communicate through IIoT platforms, ensuring seamless integration with automation systems. This results in higher safety standards and improves operational workflows. - Automation for Process Optimization
The integration of automation in Schmersal’s solutions allows manufacturers to streamline processes while maintaining safety. Automation solutions combine safety data with operational metrics, enabling manufacturers to optimize workflows, reduce human errors, and enhance overall efficiency. - Smart Factory Alignment
Schmersal India’s focus on Industry 4.0 aligns with the vision of smart factories, where interconnected systems enable decentralized decision-making. By leveraging data-driven insights, manufacturers can enhance agility, improve resource utilization, and maintain high levels of safety compliance.
Through these innovative solutions, Schmersal India is not only advancing industrial safety but also enabling manufacturers to achieve higher levels of operational efficiency and sustainability, making them well-positioned in the evolving Industry 4.0 landscape.
Q3. How does your tec.nicum Business Unit add value to safety training and customer education?
Machine safety is the basis for safe cooperation between man and machine – and at the same time a complex field of tasks. This is because a large number of standards and guidelines have to be taken into account.
tec.nicum is the Schmersal Group’s safety engineering division and comprises a global consultancy network of TÜV certified Functional Safety Engineers and Machinery CE Experts. Services can be called upon around the world. tec.nicum’s core philosophy is to offer consultancy according to ISO standards that is independent of product manufacturers and as objective as possible.
The aim is to develop and implement the objectively best possible safety solution for the individual application – true to the slogan: “neutral approach everywhere.”
tec.nicum services cover four areas, which can be obtained as individual modules or as complete packages:
tec.nicum academy – Awareness & education to customers on all the aspects of machinery safety.
tec.nicum consulting – Assess the machine for relevant legislation and standards for machine safety and provide recommendations.
tec.nicum engineering – Design complete Safety engineering solutions by selecting appropriate safety devices.
tec.nicum integration – Retrofitting of old machines & upgrade them to the maximum possible safety level.
We have customers for whom we developed Safety Book which they give to their machine suppliers. For machine suppliers willing to export machine to Europe we have developed TUV recognised safety courses like Functional Safety Engineer (FSE ) / MCEEXPERT, we are have provided practical oriented training to understand assessment process and how to develop safety circuit. Those who have followed the right approach like awareness, understanding of function safety, safe design engineering, risk analysis, mitigation & verification are benefitted the most.
Q4. How do you envision driving innovations in IIoT-enabled safety solutions?
The Industrial Internet of Things is a concept that aims to make data and information from industrial production more accessible and usable. Its principal objective is to improve efficiency and productivity in industrial processes.
One of the most important requirements for the IIoT is that all devices, sensors and actuators involved in communication can communicate. Digital networking of devices is essential to being able to intelligently monitor production processes.
Schmersal’s IIoT concept essentially offers four solution approaches: energy management, calculation of key performance indicators (KPIs), such as overall equipment effectiveness (OEE), condition monitoring and predictive maintenance. We will continue to expand the range of services around our products.
Nowadays the ‘digital transformation’ marches on and we envision the same. Topics such as the digital twin, combined with the structure and communication of administration shells, as well as simulation, are topics of current focus.
We are providing software as a solution; we will continue to focus keenly on the growing needs of customers, all with the aim of designing more secure and more efficient processes for them & developing new services together.
