Shaping the Future of CNC Manufacturing: Intelligent, Sustainable, and Digitally Driven Solutions from Ace Designers Limited

 What does “intelligent manufacturing” mean to you, and how is your organization contributing to this transformation?
Mr. Muralidhara Rao – Intelligent manufacturing represents the seamless integration of advanced technologies such as IoT, automation, data analytics, and AI into the production process to create smarter, more efficient, and adaptive manufacturing environments. It transcends traditional manufacturing by enabling real-time decision-making, predictive maintenance, and enhanced productivity, thereby driving innovation and competitiveness.

As India’s largest CNC machine manufacturing company and a market leader in this sector, we view intelligent manufacturing as the cornerstone of the future industrial landscape. Our organization is uniquely positioned at the intersection of manufacturing expertise and cutting-edge technology through our dedicated IoT division. This division develops innovative IoT-based solutions tailored specifically for CNC machines, empowering our customers to monitor, control, and optimize their machining operations remotely or locally, and in real time.

By embedding IoT sensors and connectivity into our machines, we enable predictive diagnostics, reduce downtime, and facilitate data-driven decision-making, which collectively enhance machine performance and lifecycle. Our commitment to intelligent manufacturing not only advances the efficiency and precision of our CNC products but also helps drive the broader industry transformation towards smarter factories, ultimately supporting India’s vision of becoming a global manufacturing powerhouse.

Can you share a recent breakthrough or initiative that helped empower your customers or channel partners in a significant way?

Mr. Prakash G – One of our most significant recent breakthroughs is the launch of our next-generation CNC machines equipped with integrated basic IoT capabilities as a standard feature and custom IoT features for advanced needs as an optional offering for interested customers.

This initiative has empowered our customers and channel partners by providing real-time machine monitoring, predictive maintenance alerts, and remote diagnosis capabilities through a user-friendly digital platform. Information is made available down to the operator level, enabling them to be part of their company’s efficiency improvement programs.

By enabling proactive issue detection and minimizing unplanned downtime, our solution has drastically improved operational efficiency and reduced maintenance costs for our customers. Additionally, channel partners benefit from enhanced service support and data-driven insights, allowing them to deliver superior value and build stronger customer relationships. Along with our IoT division, AmiT, we are able to provide smart factory solutions by connecting all applicable assets or delivering total solutions as required by our customers.

This breakthrough exemplifies our commitment not just to manufacturing world-class CNC machines but also to driving digital transformation that empowers our entire ecosystem to thrive in today’s competitive landscape.

How is your company embracing sustainability in machining — from materials to energy and lifecycle design?
Mr. Muralidhara Rao – Sustainability is a core value at our company, and we are proud to have recently been recognized with the CII GreenCo Platinum Award, an upgrade from the Gold Award we obtained four years ago — a testament to our commitment to environmentally responsible manufacturing.

In machining, we embrace sustainability through a holistic approach that spans materials, energy consumption, water consumption, and lifecycle design. We prioritize the use of eco-friendly and recyclable materials in our CNC machines wherever possible, reducing environmental impact from the very start. Our manufacturing processes are optimized for energy efficiency, employing advanced technologies and IoT-driven monitoring to minimize power consumption without compromising performance.

We also have real-time water consumption monitoring, STP (sewage treatment plants), recycling units, and various initiatives implemented as part of our sustainability journey towards a green factory. Additionally, we design our machines with longevity and ease of maintenance in mind, extending their lifecycle and reducing waste.

By integrating IoT-enabled predictive and preventive maintenance, OEE tracking, and other productivity improvement features, we help customers avoid unnecessary part replacements and reduce material and energy wastage. This approach not only conserves resources but also lowers the total cost of ownership.

Through these efforts — including sustainability-related initiatives such as CII GreenCo programs at the factory level — we are advancing sustainable machining practices that align with global environmental goals while delivering high-quality, reliable CNC solutions that empower our customers to operate responsibly.

What role are MSMEs and local suppliers playing in your machine tool ecosystem, and how are you enabling their growth?

Mr. Muralidhara Rao – As the largest CNC machine manufacturing company, we view our suppliers not merely as vendors but as strategic partners integral to our success and innovation. MSMEs and local suppliers form the backbone of our machine tool ecosystem, providing specialized components, timely support, and innovative solutions that help us maintain high standards of quality and reliability.

We actively engage with MSMEs and local suppliers by fostering long-term relationships based on mutual trust, collaboration, and shared growth objectives. Our approach includes:

• Capacity Building: Providing technical support, knowledge sharing, and training opportunities to help local suppliers upgrade their capabilities and meet our stringent quality, sustainability, and delivery standards.
• Collaborative Development: Involving MSMEs early in the product development cycle, encouraging innovation and customization that benefits the entire supply chain.
• Financial Support and Fair Practices: Maintaining transparent, fair procurement practices and assisting MSMEs in streamlining operations through timely payments and, when necessary, financial guidance.
• Sustainability and Localization: Prioritizing local suppliers to reduce lead times and carbon footprint, strengthening regional economies, and promoting sustainable growth.

Through these initiatives, we empower MSMEs and local suppliers to enhance their competitiveness and scalability, which in turn strengthens our machine tool ecosystem, driving industry-wide growth and innovation.

 How do you see digital technologies (like AI, IoT, or digital twins) redefining machine tool applications in the next 3–5 years?
Mr. Prakash G – Digital technologies such as AI, IoT, and digital twins are poised to fundamentally redefine machine tool applications over the next three to five years, ushering in a new era of smart manufacturing.

• AI-powered Automation and Predictive Maintenance: In CNC machines, AI algorithms can analyze cutting forces, vibration patterns, and tool wear in real time to automatically adjust machining parameters for optimal performance and surface finish. Predictive maintenance models help detect early signs of spindle or motor wear, enabling proactive servicing and minimizing costly downtime. Troubleshooting time is also reduced with AI-enabled algorithms built into the controller or additional interfaces.
• IoT-enabled Connectivity: Beyond advanced CNC controller features, IoT sensors embedded in CNC machines facilitate continuous monitoring of operational health and energy consumption. This data can be aggregated across production lines to optimize workflows, reduce idle times, and enhance supply chain responsiveness through real-time inventory updates.
• Digital Twins for Simulation and Optimization: Digital twin technology allows us to create virtual replicas of CNC machines and simulate machining processes with different materials and tool paths before actual production. This leads to faster process, PLC, and parameter optimization, reduced trial-and-error, and shorter time-to-market for customized parts.
• Enhanced Customization and Flexibility: Using AI and IoT together, CNC machines can rapidly switch between different programs and tooling setups, supporting just-in-time manufacturing and catering to the increasing demand for personalized, small-batch production runs.

At our company, we are already integrating these technologies by deploying IoT-based platforms, implementing AI initiatives at the factory level, planning applicable product features, and initiating digital twin models — all aimed at helping our clients reduce cycle times, improve tool life, and boost overall equipment effectiveness (OEE).

 Talent is a core driver of future-ready manufacturing. How are you re-skilling or upskilling your workforce for the new era?
Mr. Muralidhara Rao – Talent is indeed the cornerstone of future-ready manufacturing, especially as we integrate advanced technologies like AI, IoT, and digital twins into our CNC machine manufacturing processes. To ensure our workforce is fully prepared for this new era, we have implemented a comprehensive upskilling and reskilling strategy focused on both technical and digital competencies.

• Continuous Learning Culture: Offering employees access to specialized training programs such as AI-based CNC programming workshops, IoT integration courses, and industrial visits. We also encourage online learning opportunities for all employees, with reimbursement options for applicable courses.
• Collaboration with Industry and Academia: Partnering with premier technical institutes like IITs, external startups, and consultants to co-develop courses on smart manufacturing, AI, and CNC automation, ensuring our teams stay updated with the latest technological advances. Our software division, AmiT, also provides support as needed.
• Hands-on Training and Digital Tools: Utilizing in-house digital software tools, feature simulators, and digital twin platforms where design trainees, operators, and engineers can practice before implementing changes on actual machines. Our software division, AmiT, also helps trainees gain the required knowledge. CAM software with tool-path optimization, programming support, and CNC simulators enable engineers to learn machine performance without interrupting live production.
• Cross-functional Skill Development: Rotating employees through departments to build versatile skill sets.
• Leadership in Change Management: Running leadership development programs that focus on digital transformation and change management, preparing managers to lead agile teams through technology adoption and process innovation. A dedicated team works closely with user departments and our software division to implement digital transformation initiatives across all our plants and products.

By investing in these targeted programs and technologies, we ensure our workforce remains highly skilled, motivated, and ready to drive innovation, quality, and operational excellence in the future of CNC machine manufacturing.

 What values or leadership principles guide your decision-making in balancing innovation, business growth, and social impact?
Mr. Prakash G – Our decision-making is firmly rooted in a set of core values and leadership principles that harmonize innovation, business growth, and social impact, ensuring sustainable success for all stakeholders.

• Customer-Centric Innovation: Prioritizing the creation of value for our customers by innovating with purpose, ensuring every technological advancement improves performance, reliability, and user experience. Customer-specific customizations are implemented as per various needs in both our products and IoT software offerings.
• Integrity and Transparency: Upholding ethical conduct and openness in all business practices, fostering trust with partners, employees, and communities.
• Sustainable Growth: Focusing on long-term business growth that balances profitability with responsible resource use, minimizing environmental impact through energy-efficient manufacturing, and promoting circular economy practices where applicable.
• Empowerment and Collaboration: Empowering our workforce, customers, and supplier partners, fostering inclusive collaboration that drives collective progress and innovation.
• Social Responsibility: Contributing positively to society by supporting local communities, enabling MSMEs through partnerships, and investing in initiatives that uplift education, skills development, and environmental stewardship.
• Agility and Learning: Encouraging agility and continuous learning, enabling us to adapt rapidly to changing market needs while staying aligned with our ethical and social commitments.

By embedding these principles in every strategic decision, we create a balanced ecosystem where innovation fuels growth and social impact strengthens our industry and communities.

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