In recent years, the Indian welding industry has undergone a significant transformation by adopting advanced technologies such as Industry 4.0, automation, and robotics. These technologies have improved welding processes’ efficiency, accuracy, and safety. As the adoption of these technologies continues to increase, there is a growing demand for skilled professionals who are proficient in working with them. To address this need, the industry has focused on initiatives to develop workers’ skills in the latest welding techniques and technologies.

The welding industry has made significant progress, moving from individual welding machines for each process to 3-in-1 multi-process machines with all functionalities. This technological advancement has resulted in cost savings on capital investments and the ability to choose the most appropriate process for the job by selecting it within a single machine. According to V V Kamath, Managing Director of Fronius India, this has been a significant benefit.

The import Impact

Approximately a decade ago, more than 60% of welding machines used in India were imported from China, while only 40% were domestically manufactured. However, two recent developments have raised concerns among certified producers while supporting India’s progress. According to Amrityoga Mishra, Senior Manager of Marketing at Panasonic Smart Factory Solutions India, Panasonic India, “The implementation of the GST and a crackdown on under-invoicing have led to a significant decline in the import of Chinese machinery. Additionally, China has become stricter with producers who do not meet appropriate quality or environmental standards.”

Satish P. Sawant, the Head of Inspection and Surveyor at the Indian Institute of Welding and Testing Technology, stresses the importance of having more in-house research centres in India. He believes that the country’s continued dependence on technology imports highlights the need for in-house R&D centres that can address the technology gap in Indian industries. He emphasises that R&D will showcase what has been accomplished in India in welding, automation, and the design of special-purpose machines for welding. He also suggests that engineering colleges collaborate on this mission to explore how R&D centres can be related to welding and the metals being used.

Availability of welding training and skill development platforms 

According to Kamath, the welding and cutting industry is turning to automation and artificial intelligence to address the shortage of skilled workers. Advanced welding systems allow robots to detect and correct deviations in the programmed welding path. Additionally, the industry uses data documentation to analyse and compare production costs with budgeted expenses, including consumables and energy consumption.

However, Antree K A, Project Manager at Don Bosco Vocational Training Institute in Raurkela, points out that the need for access to relevant syllabi and engineering skill framework patterns limits exposure to the industry. There are no industry exchange programs currently in place. Although the government has introduced on-the-job training (OJT) for a few hours at the ITI level, supervisors and engineers should also work in the industry during their study time, similar to the German house-building program. This would provide them with industry experience to apply to their studies.

 Advanced welding technologies addressing the skill gap in welding processes

India is grappling with a severe shortage of skilled welding professionals, leading to production issues. Therefore, robotic automation is gaining momentum in the industry. Machine sales are increasing by 7-8 percent, while the robotics market is growing at around 20 percent. Despite this, Mishra is concerned that the industry is trying to minimise the use of the workforce wherever possible, with almost 95 percent of robots being deployed in the automobile sector and only 2-3 percent in construction equipment. However, the need for more skilled welders remains, and they tend to leave during holidays, exacerbating the issue. As a result, robotic automation is rapidly gaining popularity in the welding industry.

On the other hand, Sawant believes that the upcoming generation of engineers will benefit from the advancements in automation and Industry 4.0. They will not have to endure long working hours in the welding process and activities. With the introduction of automation and Industry 4.0, welding is becoming more attractive and can be taught as a hobby class. Welding is a skill that requires precision, and the output differs even with the same machine, electrode, and parameters.

Kamath emphasises the establishment of Centers of Excellence with the latest technologies to improve welding and cutting skills to train the workforce. These centres should provide practical training on advanced equipment, as using outdated equipment would not prepare the workforce for the industry’s current demands.

Maintaining welding safety standards 

Ensuring safety in welding processes involves:

• Taking basic precautions, such as protecting the skin from UV rays and fire hazards.
• Handling high-pressure cylinders with care.
• Managing electrical equipment appropriately.

According to Mishra, Panasonic offers safety practice presentations to welding students, given that the field demands expert knowledge and specific safety measures.

Antree explains that their training program educates students on standard welding safety practices and provides them with necessary equipment such as safety shoes, specific clothing, helmets, glass shield protection, and aprons. Additionally, their industry-based training programs provide the best equipment for safety needs. These skill development programs aim to create a workforce capable of handling advanced welding equipment and technologies.  The forum concluded with a focus on the need for skill development programs to create a workforce capable of handling the latest welding equipment and technologies. This focus on skill development is essential for the growth of the Indian welding industry and for ensuring that it remains competitive in the global market.

Amrityoga Mishra, Sr. Manager Marketing, Panasonic Smart Factory Solutions India
Developing indigenous welding machines and technology will increase the industry’s growth.

V V Kamath, Managing Director, Fronius India Pvt. Ltd.
Technology advancement has led to cost savings on capital investment.

Satish P. Sawant, Head – of Inspection and Surveyor, IIWTT
In-house R&D centres in India to address the technology gap in Indian industries directly.

Antree K A, Project Manager, Don Bosco Vocational Training Institute in Raurkela
We educate students on standard practices for welding safety and best practices for welding equipment.