Revolutionising Welding: How Udhyog 4.0 is Bringing Industry 4.0 Technologies to Metal Fabrication

The global metal fabrication (welding) market, valued at USD 20.25 billion in 2022, is growing at a CAGR of 5.6% through 2030. This growth is driven by industrial expansion, infrastructure development, and technological advancements across key automotive, aerospace, and construction sectors.

While large manufacturers are rapidly adopting advanced technologies like robotic welding and AI/ML systems, a significant portion—70-80%—of small and medium fabricators face challenges in accessing these transformative tools.

Udhyog 4.0 LLP, a government-funded startup established in 2019, is Bridging this technological gap. Specialising in Industry 4.0 technologies, Udhyog 4.0 is making strides in transforming traditional manufacturing with IoT-enabled devices, process monitoring, and intelligent inspection systems.

With a strong foundation in revolutionising metal casting processes, the company is now applying its expertise to the metal fabrication sector, thanks to insights and guidance from welding expert Himanshu Thaker.

The integration of IIoT (Industrial Internet of Things) and AI/ML technologies is at the forefront of Udhyog 4.0's mission to modernise welding. With a deep understanding of the challenges faced by small and medium-sized fabricators, Himanshu Thaker, a seasoned expert in welding and fabrication technologies, has played a pivotal role in driving this transition.

His extensive knowledge has helped the company tackle critical issues in traditional welding processes, such as inconsistent quality, inefficiencies, and high defect rates.

As per Thaker, the process's first and arguably most essential part is data acquisition, which includes collection, digitisation, and storage. "Data collection, digitisation, and storage are fundamental to optimising welding parameters," he explains. The goal is to enhance the most basic welding parameters influencing weld quality. However, he acknowledges the complexities of real-time welding, where dynamic factors constantly evolve and impact the quality and consistency of the weld.

The solution? A sophisticated blend of advanced sensors and edge computing. Udhyog 4.0 is developing systems that monitor these changes in real time, analyse them, and make adaptive suggestions to correct motion and process parameters.

Udhyog 4.0 also leverages predictive analytics to transform quality control in welding. By analysing welding data, the company aims to identify inefficiencies and trends, enabling real-time adjustments and forecasting weld quality before a project is completed.

"This predictive approach reduces defects and ensures proactive quality management," says Thaker. Such innovations enable fabricators to shift from reactive to proactive methods, addressing issues before they escalate.

A key innovation is the development of retrofitting technologies that convert traditional welding equipment into smart machines. This patented technology offers an affordable and minimally disruptive way for smaller fabricators to adopt innovative manufacturing practices. "Our goal is to make these solutions accessible to even the smallest players, helping them remain competitive in a rapidly evolving industry," Thaker adds.

Udhyog 4.0 and its founding member, Dr. Amit Sata, along with Thaker's expertise, have been instrumental in this transformation. Dr. Sata, a dean at Marwadi University and an alumnus of IIT Mumbai, credits Thaker for providing the technical depth needed to navigate the complexities of welding processes.

"Himanshu has been invaluable in helping us understand the intricacies of welding and designing systems that address real-world challenges," says Dr. Sata. Together, the team has developed predictive maintenance systems capable of detecting anomalies in welding parameters early, reducing equipment downtime and enhancing overall efficiency.

As Udhyog 4.0 continues its journey in smart welding, its commitment to advancing the metal fabrication industry remains steadfast. The company is setting a new benchmark in the field by combining Thaker's specialised knowledge with Udhyog 4.0's innovative technologies.

"We're not just improving efficiency and quality; we're laying the foundation for the future of automated, data-driven industries," remarks Dr. Sata. With its groundbreaking work in IIoT, AI, and data analytics, Udhyog 4.0 is redefining what's possible in welding and metal fabrication, positioning itself as a leader in the Industry 4.0 revolution.

The efforts of Udhyog 4.0, bolstered by the expertise of Himanshu Thaker, highlight the transformative potential of smart manufacturing in welding. As the industry embraces automation and AI-driven processes, this collaboration exemplifies how innovation and expert insight can bridge gaps and drive sustainable growth. The future of welding is brighter, more efficient, and more connected—thanks to pioneers like Udhyog 4.0 and the visionaries behind its success.