With over two decades in the welding industry, Ashok Kumar has been at the center of the energy production sector’s transformation through technology. As a Welding Specialist at Welspun Tubular, he combines deep technical knowledge with hands-on expertise to advance the manufacturing of large-diameter steel pipes for oil and gas. In this interview, Ashok discusses how automation, AI, and inspection innovations are reshaping energy production and shares insights on leading teams through rapid industrial change.
Over your 22-year career in manufacturing, what are the most significant technological changes you have seen, especially in the oil and gas sector?
Throughout my manufacturing career, I have observed significant technological advancements that have reshaped operational processes while enhancing safety measures and environmental regulations. The technological revolution of Industry 4.0 and digitalization has introduced substantial changes through the development of SCADA and DCS systems, cloud computing, and Industrial Internet of Things. Process control has improved through automation and robotics systems, which enable condition-based monitoring and early fault detection through predictive maintenance and AI. Advanced materials, including corrosion-resistant alloys and 3D printing, have enhanced both durability and performance.
The oil and gas industry adopted horizontal drilling and hydraulic fracturing as standard techniques for enhanced recovery and drilling operations. The drive toward sustainability has gained momentum through technological advancements, including carbon capture systems, flaring reduction solutions, and environmentally friendly manufacturing approaches. The rise of connectivity requires cybersecurity to become essential, while remote operations and augmented reality tools enhance team efficiency in complex environments.
Can you share a specific example where adopting new technology led to measurable improvements in safety or productivity?
As a Welding Specialist at Welspun Tubular who works on energy production pipeline projects for the oil and gas industry, I have witnessed how automation, robotics, and advanced processes have improved efficiency, quality, and safety. Our facility’s automated welding systems, PLC-controlled equipment, and high-precision machines ensure weld quality while reducing human errors and rework. The inspection process and material handling operations heavily depend on robotics, enabling robotic NDT systems to conduct ultrasonic and radiographic inspections and automated systems to decrease manual handling to improve precision and worker protection.
Integrating SCADA and MES enables real-time production tracking from raw materials to finished pipes through advanced process control and data analytics. The digital quality management system provides complete traceability throughout all production stages because pipeline integrity requires it. Automated systems for 3LPE, FBE, and internal epoxy coatings in our coating facility enhance both the consistency of applications and the extended lifespan of pipes. Our company focuses on sustainability through energy-efficient furnaces, reduced emissions, and precise cutting tools, which reduce waste and maximize material yield.
You have worked with a wide range of advanced techniques. How has your expertise helped your teams adapt to evolving technology in manufacturing?
Over the past two decades, my experience with advanced manufacturing techniques, including automation, robotics, AI-driven systems, and data analytics, has enabled me to play a key role in guiding teams through technological transitions.
For example, my deep understanding of AI integration in pipe manufacturing helped our teams embrace smart systems for quality control and production monitoring. I focused on three key strategies:
- Hands-on training and knowledge transfer: I organized and led hands-on workshops and simulations to upskill technicians and operators on new tools and platforms. I simplified complex technical concepts into practical, actionable steps, helping frontline teams gain confidence in using new systems.
- Change management and collaboration – Acted as a bridge between engineering, IT, and production teams, aligning their goals and ensuring smooth rollouts of technologies like predictive maintenance platforms and automated NDT systems. Established feedback loops to capture on-ground challenges and adapt technology deployment accordingly.
- Driving a culture of innovation – Established feedback loops to capture on-ground challenges and adapt technology deployment accordingly. My leadership helped build a culture of continuous improvement, where team members felt ownership over new tools rather than resistance to change.
As a result, we’ve seen measurable improvements in process efficiency, workplace safety, and product quality while empowering our teams to be more agile and future-ready.
What role do you think hands-on skill still plays as automation becomes more integrated into industrial workflows?
Hands-on skills continue to play a critical role and in many ways, an elevated one, even as automation becomes more integrated into industrial workflows.
Manufacturing environments with increasing automation require hands-on experience to remain vital. The value of deep process knowledge increases when automation systems are implemented. Practical experience enables welders, operators, technicians, and engineers to detect anomalies, identify root causes that sensors and dashboards cannot detect, and adjust machine settings for unique situations that automation systems cannot handle. The skills are essential for commissioning, calibration, and industrial maintenance because they enable quick recovery and prevent quality issues when equipment deviates from tolerance. The high-stakes oil and gas pipeline manufacturing industry requires skilled workers to be adaptable and judgmental during unexpected situations, including irregular materials and emergency stops. Human oversight serves as the primary safety and compliance protection system, even though automation improves efficiency. Shop floor insights generate the most important innovative developments. The AI-based pipe inspection device emerged from direct feedback received from frontline welding and inspection staff who recognized real-time practical challenges.
What technologies or trends do you believe will most impact manufacturing over the next five to ten years?
In the next 5 to 10 years, I believe these key technologies will shape the future of manufacturing –
- Artificial Intelligence (AI) – Will help make faster decisions, improve quality checks, and predict machine problems before they happen.
- Automation & Robotics – More advanced robots will handle complex tasks, improving speed and safety.
- 3D Printing – Useful for making parts quickly, reducing waste, and speeding up production.
- Smart Sensors & IoT: Machines will be more connected, providing real-time data to improve efficiency and reduce downtime.
- Sustainability & Green Tech – Energy-saving processes and eco-friendly materials will become more important.
- Cybersecurity – As factories get more connected, protecting systems from cyber threats will be a top priority.
These trends will make manufacturing faster, safer, and more efficient while helping meet environmental and customer expectations.
Beyond your technical work, how are you helping prepare the next generation of professionals for a more tech-driven industrial environment?
I mentor and train young professionals by sharing real-world knowledge and hands-on experience.
- I conduct on-the-job training to help them understand new technologies such as automation, AI, and digital inspection tools.
- I simplify complex processes so they can learn faster and feel more confident.
- I also encourage them to ask questions, explore new ideas, and stay open to continuous learning.
By guiding them this way, I help build a strong, tech-ready workforce that can handle the challenges of modern manufacturing.
Photo by Bernd Dittrich; Unsplash
Kyle Lewis is a seasoned technology journalist with over a decade of experience covering the latest innovations and trends in the tech industry. With a deep passion for all things digital, he has built a reputation for delivering insightful analysis and thought-provoking commentary on everything from cutting-edge consumer electronics to groundbreaking enterprise solutions.
