As manufacturing moves beyond the constraints of traditional, linear production systems, flexibility has emerged as a defining priority for industry leaders navigating volatile demand and rising complexity. In this conversation, Jhankar Dutta, regional managing director – Southern and Eastern Asia at B&R Industrial Automation, outlines how adaptive, software-driven automation is reshaping production, enabling manufacturers to balance customization, efficiency, and resilience in an evolving industrial landscape.

The Packman: The traditional production line has been the backbone of manufacturing for decades. Why is it being rethought today?

Jhankar Dutta: The traditional production line was designed for stability – high volumes, minimal variation, and predictable demand. But today’s market dynamics are very different. Customers expect customization, faster turnaround, and consistent quality. At the same time, manufacturers are dealing with supply chain volatility and cost pressures. This is pushing organizations to rethink rigid systems and move toward more adaptive, responsive production models.

The Packman: How do you define ‘flexibility’ in modern manufacturing?

Jhankar Dutta: Flexibility is the ability to respond quickly to change – whether it’s a shift in demand, a new product variant, or an external disruption – without compromising efficiency or quality. It’s about designing systems that are modular, intelligent, and connected. Importantly, flexibility is not about adding complexity; it’s about simplifying operations through smarter design and technology.

The Packman: How is B&R Industrial Automation enabling this shift?

Jhankar Dutta: At B&R, we see flexibility and efficiency as complementary, not conflicting goals. Our approach focuses on creating software-driven, modular automation systems. By integrating hardware and software into a unified ecosystem, we enable machines and processes to communicate and adapt in real time. This allows manufacturers to reconfigure production lines quickly, introduce new variants, and scale operations with minimal disruption.

The Packman: Can you elaborate on the concept of an ‘adaptive line’?

Jhankar Dutta: An adaptive line represents a fundamental shift from traditional sequential production systems. Instead of rigid, fixed processes, it enables dynamic product routing and real-time adjustments based on demand.

To illustrate this with a real-world example, consider a personal care company producing shampoos. Today, the market demands a wide variety of bottle shapes, sizes, formulations, and packaging formats – often in smaller batch sizes. In a conventional production line, each variation would require significant changeover time, leading to inefficiencies and downtime. An adaptive line, however, can seamlessly handle this variability. Products are routed dynamically, and the system adjusts on the fly – allowing multiple variants to be produced at full speed with minimal or no changeover. This ensures continuity, maximizes asset utilization, and significantly enhances productivity.

At the core of this capability is a software-driven automation approach. Platforms like B&R’s enable manufacturers to configure, scale, and reconfigure production lines rapidly. Using modular software frameworks such as mapp Technology, OEMs can design machines where functionalities – motion, safety, robotics, and recipe handling – are standardized, reusable, and easily adaptable.

Taking this further, modern mechatronic innovations enable true flexibility at the physical level. Advanced product transport systems – such as linear motor-based tracks and planar magnetic levitation systems – allow individual prod-ucts to move independently through the production process. Technologies like ACOPOStrak, SuperTrak, and ACOPOS 6D decouple product flow from fixed mechanical timing. Each product carrier (or shuttle) can follow its own path, speed, and process sequence.

This means an adaptive machine can instantly switch between product formats without sacrificing efficiency. It also enables parallel processing, intelligent load balancing, and flexible routing – where products can be split, merged, or redirected in real time. Combined with digital twins, manufacturers can even simulate and implement new product variants or line configurations with minimal disruption.

The result is a highly flexible production environment where a single line can efficiently handle a wide range of product variants. Manufacturers achieve mass customization while maintaining high throughput, consistent quality, and optimal resource utilization – making adaptive manufacturing a key enabler of modern industrial competitiveness.

The Packman: What role does digitalization play in enabling flexibility?

Jhankar Dutta: Digitalization is a key enabler. Technologies such as real-time analytics, digital twins, and connected systems provide visibility across the production process. This allows manufacturers to anticipate issues, optimize performance, and make data-driven decisions. At B&R, we leverage these technologies to create systems that are not just automated but also intelligent and self-aware.

The Packman: How does this transformation impact the workforce?

Jhankar Dutta: The role of the workforce is evolving significantly. Operators are no longer just executing tasks – they are managing and optimizing systems. This requires new skills and a stronger focus on upskilling and reskilling. At the same time, user-friendly interfaces and advanced diagnostics make it easier for teams to interact with complex systems and make faster decisions.

The Packman: Is there a trade-off between flexibility and efficiency?

Jhankar Dutta: That’s a common misconception. When implemented correctly, flexibility actually enhances efficiency. It reduces downtime, minimizes waste, and improves resource utilization. The key is to strike the right balance – standardizing processes where necessary while building in the ability to adapt when needed.

The Packman: Beyond operations, how does flexibility impact the broader value chain?

Jhankar Dutta: Flexibility must extend across the entire value chain – from design and engineering to supply chain and service. Integrated digital systems enable better coordination, visibility, and resilience. This end-to-end approach ensures that manufacturers can respond to market changes more effectively and deliver consistent value to customers.

The Packman: How does flexibility contribute to sustainability goals?

Jhankar Dutta: Flexible systems inherently support sustainability. They enable manufacturers to produce closer to actual demand, reducing overproduction and waste. They also optimize energy and resource usage. In this way, flexibility not only drives business performance but also supports environmental responsibility.

The Packman: What is your outlook for the future of manufacturing?

Jhankar Dutta: We are moving toward a world where production systems are increasingly autonomous, driven by AI, industrial IoT, and advanced robotics. The concept of the ‘line’ itself will evolve into a flexible, intelligent network of processes. Manufacturers who embrace this shift will be better positioned to navigate uncertainty and capture new opportunities.

The Packman: One key takeaway for industry leaders?

Jhankar Dutta: The future is not about choosing between the discipline of the line and the agility of flexibility – it’s about combining both. Organizations that can successfully integrate these elements will define the next era of industrial growth.