Driving a safety revolution, AI is a key to automated manufacturing today. From precise flaw detection to optimised production, how a technology is redefining high-risk fabric manufacturing? Harshit Sureka of Robro Systems reveals to EFY’s Nitisha Dubey.
Q. What is Robro Systems?
A. Robro Systems was founded in 2018 and began operations in 2019 with a vision to bridge the gap between industrial automation and technological advancements. We use AI and IoT for high-accuracy fabric defect detection and optimisation. Many manufacturing industries still rely on manual labour, leading to inefficiencies, errors, defects, and waste. Our AI-driven solutions for vision, intelligence, and control in process optimisation aim to modernise manufacturing industries with automation.
Q. What products does Robro Systems offer?
A. We have developed the Kiara AI and vision platform, the foundation for various manufacturing solutions. Some of our key products include roll-to-roll inspection systems for detecting defects in technical textiles. We also offer ‘Role-Master-Review’, a tool for in-depth analytics. An AI-powered quality assistant helps assess whether fabric rolls meet specified tolerance levels. Additionally, our automation control system for FIBC fabric cutting machines enables intelligent cutting based on defect identification. These solutions are designed to minimise wastage, improve efficiency, and optimise manufacturing processes.
Q. Which industries does Robro Systems cater to?
A. We primarily serve niche technical textile and fabric manufacturers, including those producing smart fabrics with embedded electronics, medical textiles with motion sensors, and high-risk industries such as tyre cords, parachute fabric, and airbag materials, where defects can lead to significant safety hazards. Instead of targeting mass markets, we focus on industries where the cost of defect is high, the market size is substantial, and the complexity of applications ensures high-value addition.
Q. How did Robro Systems develop its product?
A. By spending extensive time in production facilities, the team identified inefficiencies and gaps, leading to the development of a proof-of-concept system that was continuously refined through agile development and customer feedback. We actively qualify leads by selecting industries where defects result in a higher cost of defect, ensuring their solutions provide measurable value.
Q. What role do AI and IoT play in Robro Systems’ products?
A. The role of AI in our products is crucial in identifying and categorising fabric defects. AI models are trained on thousands of images to distinguish between acceptable variations and actual defects. Internet of Things (IoT) plays an equally important role by collecting real-time machine data, including operating speed, idle times, and defect occurrences. Combining these datasets allows the system to generate valuable insights, such as pinpointing which loom or operator is responsible for a particular defect.
Q. What is the accuracy rate of Robro Systems’ machine vision technology?
A. The accuracy rate of our machine vision technology ranges between 97 per cent and 99.9 per cent, depending on the application. Before taking on any project, we conduct feasibility checks to ensure high accuracy levels can be achieved. Initially, AI models start with an 80–85 per cent accuracy, but through continuous learning and optimisation, they reach higher accuracy over time.
Q. Is Robro Systems’ solution scalable for large-scale manufacturing plants?
A. Scalability is an integral part of the system, and we are already working with large-scale manufacturers processing over 10,000 tons of fabric per month. The platform is designed to handle multi-line and multi-product manufacturing setups through customised applications.
Q. Does the system provide real-time production monitoring?
A. Yes, real-time production monitoring is an integral system feature, enabling manufacturers to track efficiency, defect rates, and machine performance.
Q. How is inspection data stored?
A. Data is stored locally for short-term access, while a server at the customer’s premises synchronises data from multiple machines. Google Cloud storage is also available for backup, analytics, and advanced dashboarding.
Q. What kind of training or expertise is required to use the system?
A. Training is essential, and the company ensures that existing machine operators can easily transition to using the system without requiring specialised technical knowledge. The platform is designed to be intuitive, similar to smartphone apps such as WhatsApp or Instagram, making it easy to operate even for users with minimal technical knowledge. Training is provided through online and offline sessions, instructional videos, and detailed documentation.
Q. What are the maintenance requirements for hardware components?
A. Maintenance requirements are minimal, involving occasional air pressure cleaning for cameras and lights, general PC maintenance, and ensuring mechanical components remain secure.
Q. How does Robro Systems differentiate itself from competitors?
A. It is AI, as I said. We differentiate ourselves by taking an AI and analytics-driven approach, focusing on a product-based model rather than highly customised services. Our solutions are minimalistic, cost-effective, and easy to use. We prioritise customer support and structured training, ensuring smooth technology adoption without overwhelming users. By deeply understanding manufacturing processes, we deliver maximum value at the right stages of production.
Q. Is the solution compliant with industry standards?
A. Our solutions comply with industry standards and are certified by Conformité Européenne (CE). We are also working towards obtaining data protection certifications to comply with European regulations.
Q. What is the typical ROI timeframe for implementing the system?
A. The return on investment for customers varies but typically falls within six to fifteen months, depending on the industry and the impact of defect reduction.
Q. How many live installations has Robro Systems done so far?
A. Our headquarters is located in Indore, Madhya Pradesh, with 72 live installations across India, Bangladesh, and Turkey. India remains our strongest market, with a significant presence in Maharashtra, Gujarat, Karnataka, Tamil Nadu, and Rajasthan.
Q. What kind of after-sales support does Robro Systems provide?
A. To ensure long-term customer satisfaction, we have implemented a modern ticket management system for issue resolution, proactive health monitoring for internet-connected systems, and dedicated support teams for online and on-site assistance.
Q. What is the business model for purchasing the system?
A. The business model includes three purchasing options: a one-time hardware purchase for the optical setup, a software licence where the basic version is included with the hardware, advanced features available through subscription and additional services such as data analytics subscriptions or one-time defect training services.
Q. What challenges has Robro Systems faced?
A. Challenges have been a part of the company’s growth journey. Internally, acquiring the right talent and establishing repeatable processes has been a challenge. Adoption has been a hurdle on the customer side, as manufacturers are often unfamiliar with AI-driven automation. Technical limitations, such as improving accuracy beyond 95% and educating customers about the realistic capabilities of AI, have also been significant challenges. Integrating AI, IoT, programmable logic controller (PLC) systems, and customer machinery requires overcoming communication gaps, technical glitches, and system constraints. To address these, we have adopted structured documentation processes and educational initiatives to help customers understand the possibilities and limitations of automation.
Q. Is Robro Systems looking for vendors or partners?
A. Yes, we actively seek partnerships with machine manufacturers to integrate their or our technology directly into new machinery rather than relying solely on retrofitting existing systems.
Q. What are Robro Systems’ future plans?
A. We aim to expand into other industries through a startup hub and entrepreneurship-in-residence programme, allowing new businesses to leverage AI and vision technology. While the core focus remains on technical textiles for the next five to six years, other industry applications will be explored through collaborations.
Q. What was the company’s fiscal growth in recent years?
A. We grew by 400 per cent over two years, although growth slowed to around 40–45 per cent last fiscal year as we focused on improving internal processes. Looking ahead, we aim to get back on a 400–500 per cent growth path by expanding our product range and entering new markets.
