We're boosting R&D in our technology centers for innovation in construction machinery
Seshan Iyer, President, Bearings & Industrial Solutions, Schaffler India
What steps has Schaeffler India taken to meet the increasing demand for construction equipment and machinery in India?
The construction equipment industry has experienced significant growth, and Schaeffler is fully committed to meeting the rising demand for such equipment in India. The company is actively taking several strategic steps to achieve this goal:
- Capacity expansion at the Savli Plant, Gujarat: Schaeffler India has been continuously ramping up its local manufacturing footprint through significant capex investments. In June 2023, the company inaugurated a new manufacturing hall at its Savli facility in Vadodara, adding over 10,000 sq m of production space. This expansion entails localisation of certain global manufacturing lines together with addition of new lines, which will enable the plant to produce mid- and large-sized roller bearings. This enhancement strengthens Schaeffler’s ability to serve the growing needs of the construction equipment sector.
- Investment in new facilities: As committed, Schaeffler India has invested more than Rs 15 billion in last three years to bolster its manufacturing capabilities and ensure Schaeffler India is well equipped to cater to the growing demands of its customers. This includes the establishment of a new plant in Hosur, Tamil Nadu, which aims to producing transmission components and systems for segments of automobile that are integral to the construction machinery industry.
- Focus on localisation and export growth: Schaeffler India’s strategic investments are aimed at localising a wide range of bearing products, which will aim at reducing dependence on imports and will help us align with the Make in India initiative. The Indian construction equipment industry operates in a fiercely competitive market and with enhancing the local manufacturing capacities, Schaeffler India will be able to offer Schaeffler’s worldclass quality and superior technology to meet the specific needs of the Indian construction equipment industry more effectively Through these initiatives, Schaeffler India is well-positioned to contribute significantly to the growth of the construction equipment industry in India.
How is Schaeffler India planning to grow its presence in the industrial and machine tools sector, especially in construction equipment?
Schaeffler India recognises India’s strategic importance and is actively taking steps to strengthen its footprints and grow its presence in the Indian construction machinery industry:
- Collaboration with leading OEM: Schaeffler collaborates closely with OEMs and other industry stakeholders to align its solutions with the rapidly changing needs of the Indian market. Our innovative and customer?first approach has resulted in Schaeffler India becoming the preferred partner for India’s biggest automotive and industrial OEMs.
- Capacity expansion and localisation: As mentioned, Schaeffler India has been ramping up its manufacturing to meet the market demands and grow with the Indian market. The company inaugurated a new manufacturing hall at its Savli facility in Vadodara, adding over 10,000 sq m of production space. This expansion entails Localising certain global manufacturing lines and addition of new lines, which will enable the plant to produce mid- and large-sized roller bearings. This enhancement strengthens Schaeffler’s ability to serve the growing needs of the construction equipment sector.
Schaeffler India has a very diverse product portfolio. Our strong customer partnerships and worldwide operations enable us to have deeper understanding of customer challenges and their complex, diverse operating environments. This understanding of motion technology helps us excel in manufacturing high quality motion technology products and solutions that are better suited to meet the needs of our customers.
- Technological innovation and electrification: The industry in India is undergoing a significant transformation, with the shift towards electrification and adoption of predictive maintenance, industry 4.0 and other are driving the change. Our goal is to offer our customers products and technologies that enhance motion by making it smarter, cleaner, and safer. With our innovative and extensive product range, we position ourselves as a forward-thinking partner for construction equipment manufacturers.
- Research and development: Schaeffler India is investing significantly in expanding manufacturing facilities to cater to the increasing demand across industrial segments. Additionally, we are also enhancing our technology centers to focus on R&D for cutting-edge solutions to drive continuous innovation in the construction machinery sector.
Through these strategic initiatives, Schaeffler India is solidifying its presence in the Indian construction machinery industry.
With mobility changing rapidly worldwide, what role do you see Schaeffler India playing in the future of mobility in both automotive and industrial sectors?
Schaeffler is actively shaping the developments of the future as we leap ahead with solutions that are founded on quality, technology, and innovation. We are actively positioning ourselves to influence the future of mobility within the industrial sector through several strategic initiatives:
- Schaeffler India has set up a state-of-the-art Mechatronics centre at Pune while through the in organic route, also has an electronics and hardware design centre at Bangalore. While both these centres are catering majorly to the needs of Europe, specific projects for India needs are being worked upon. This brings in the capability of designing and developing solutions for both the IC engines as well as for the E Mobility and chassis applications.
- Showcasing advanced mobility solutions: At the Bharat Mobility Global Expo 2025, Schaeffler India presented a range of products and services tailored for combustion engines, hybrid vehicles, and electric vehicles. All these technologies will be contributing to the construction machinery segment as well.
- Emphasis on sustainable and efficient technologies: Schaeffler globally is investing heavily to develop products and solutions that contribute to CO? reduction, electrification, and the development of intelligent motion technologies.
How are Schaeffler India’s products designed to meet the needs of construction equipment makers and their customers?
Schaeffler India designs its products to meet the rigorous demands of construction equipment OEMs by prioritising durability, efficiency, and tailored solutions. Some of the key offerings include:
- Comprehensive bearing solutions: Schaeffler India has a very comprehensive bearings solution. The product spectrum includes rolling and plain bearings, linear and direct drive technology, as well as service features such as maintenance products and monitoring systems.
- Tailored application support: Schaeffler India provides tailored application support to meet the unique needs of construction equipment manufacturers.
- A robust product portfolio: Schaeffler India’s product portfolio is designed to meet the diverse needs of the construction industry. It includes a variety of components, all engineered for the construction equipment industry. This robust portfolio ensures that Schaeffler can offer solutions for a wide array of applications.
By combining advanced engineering techniques with a deep understanding of the construction industry's needs, Schaeffler India delivers products that improve the performance, safety, and efficiency of construction equipment.
How is Schaeffler aligning its operations with global sustainability goals, and what steps is the company taking to support the green transition?
Schaeffler India is committed to the sustainability and has taken significant strides towards achieving these goals. Schaeffler India aims to:
- Achieve climate neutral production by 2030 by focusing on reduction measures
- Achieve climate-neutral supply chain by 2040
- Target to source all purchased electricity from renewable sources by 2024
- Implement measures to achieve cumulative annual energy efficiency(Link: https://www.schaeffler-sustainability-report.com/2023 )
- targets reduction in Freshwater Withdrawal by reducing its freshwater usage by 20 per cent compared to the 2019 baseline, aiming to minimise water-related production risks.
How is Schaeffler India using condition monitoring systems to improve the performance and lifespan of construction equipment?
Scheffler India combines smart condition monitoring and lubricant management to form one predictive maintenance solution. Key solutions from Schaeffler for condition monitoring solutions include:
- OPTIME Ecosystem: This comprehensive system combines smart condition monitoring and lubricant management to form one predictive maintenance solution. It utilises battery-powered vibration sensors to continuously monitor machinery health, providing early warnings of potential issues such as imbalances or misalignments. The system’s intuitive mobile app offers maintenance teams real-time insights, facilitating timely interventions and reducing unplanned downtimes. Schaeffler will continue to develop and add new elements to the OPTIME Ecosystem based on the experience gained in successful customer projects in various sectors and applications. In this way, the OPTIME Ecosystem will continue to optimally support the smooth operation of machines and facilities in the future by providing all relevant information at a glance.
- SmartCheck: A compact, modular online measuring system, SmartCheck is designed for continuous monitoring of machinery and process parameters. It’s particularly effective in early detection of rolling bearing damage, imbalances, and misalignments in components like electric motors, pumps, and gearboxes. By providing real-time data, SmartCheck enables maintenance teams to address issues before they escalate, thereby extending equipment lifespan.
Data analytics is key in condition monitoring. What key metrics should manufacturers track to improve equipment performance and reliability?
Condition monitoring entails tracking a variety of parameters due to the complexity of the equipment and processes. There are several key metrics that must be evaluated to enhance equipment performance and reliability. These metrics are crucial for identifying inefficiencies, predicting potential failures, and optimising maintenance schedules. Some of them are mentioned below:
Reliability Metrics
- Mean time between failures (MTBF): It measures the average time equipment operates before failing. Higher MTBF indicates better reliability.
- Mean time to repair (MTTR): The average time needed to repair equipment after a failure. Lower MTTR means faster recovery.
- Failure rate: The frequency at which equipment fails over a specific period.
Maintenance metrics
- Planned vs. unplanned maintenance ratio: A high ratio of planned maintenance ensures fewer unexpected failures.
- Preventive maintenance compliance: Measures adherence to scheduled maintenance tasks to avoid breakdowns.
- Condition monitoring alerts: Tracking the number of early warnings from condition monitoring systems like vibration analysis or thermal imaging.
Performance metrics
- Overall equipment effectiveness (OEE): Combines availability, performance, and quality into a single measure of efficiency.
- Equipment availability: Percentage of scheduled time the equipment is available for operation.
- Performance efficiency: Measures actual vs. expected production speed.
- Quality rate: The percentage of defect-free products produced.
There are numerous additional metrics that can be considered for evaluation. By regularly monitoring and tracking these metrics, manufacturers can enhance reliability, extend the lifespan of equipment, and optimise overall performance.
With the growing need for skilled workers in the construction equipment industry, how is Schaeffler India helping address skill gaps?
While Schaeffler does not directly contribute to skill development within the CE Industry, it plays a significant role in supporting skill enhancement across various industries by:
Schaeffler Technical Enhancement Program (STEP)
- Technical training centres: Launched in 2018, STEP focuses on enhancing the technical skills of underprivileged youth by providing state-of-the-art training facilities. The various STEP Labs help students gain technical skills on CNC Programming, Simulation - Turning, Milling, Hydraulic and Pneumatic trades mechatronics, equipping students with industry-relevant skills.
- Collaboration with Don Bosco training centres: In partnership with Don Bosco, Schaeffler India has established training hubs in Pune and Hosur. These centers offer six-month intensive courses, which culminate in certifications from the National Skill Development Corporation (NSDC). This initiative enhances employability, particularly in sectors such as construction equipment manufacturing.
REPXPERT Training Vans
- This programme is designed to upskill mechanics nationwide, with a special focus on the commercial vehicle segment. To reach mechanics and technicians in remote areas, Schaeffler India introduced mobile training vans, fully equipped with advanced tools and spare parts. These vans provide hands-on training in vehicle maintenance, diagnostics, and repairs, ensuring that even those in far-flung locations have access to the latest technical expertise.
Schaeffler Technology Centre: Modular training programmes
- This center offers a variety of courses, ranging from basic to advanced levels, in areas such as rolling bearings, mechatronics, and condition monitoring. The programs are tailored to meet the specific needs of both technical and commercial employees in the construction machinery and other industries, enhancing their skills and overall performance.
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