Modern Machine Tools - January 2011 - Expert Views on Changing Trends

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Editorial

January 2011 - MODERN MACHINE TOOLS 33

At the outset, here is wishing you a Great New Year ahead! More importantly and given the growing maturity of the domestic market,

expanding ecosystem of start-ups, and rising demand from the core sectors, one can fairly look forward to the new decade in which India can potentially become the fastest-growing economy on earth. This in turn promises to present unparalleled opportunities to transform the lives of millions, and thereby attain the much sought-after inclusive growth.

Not withstanding its share of challenges, the year 2010 was an inflection point for the Indian metalworking industry and the economy, in general. Case in point is the global focus on India as a key growth market and a marked shift in the approach – not as a mere vendor but as a strategic partner. In other words, it signifies the country’s leverage not only on better cost proposition, but also lean and efficient business model as well as faster time-to-market capability.

Having said that there is an urgent need to ramp up infrastructure, especially power & land; access to capital & technology; manpower skills as well as provide conducive policy environment for the Indian industry.

With IMTEX 2011 and Tooltech 2011 just around the corner, this Special Edition (in two volumes) reflects all the above and more, with an eclectic mix of the latest news, views and analysis. To begin with, the ‘Curtain Raiser’ offers a sneak preview of this mega event to forge business partnerships & collaborations and chart growth paths. Next to follow are the specially compiled sections such as the ‘Industry Voice’ (expert opinions), ‘Roundtable’ (viewpoints on some of the biggest challenges facing the industry), ‘Expert Zone’ (emerging trends in Best Practices and production strategies) and ‘Future Footprints’ (destination next for diversification of the machine tool sector), among others. Believe, you will value this Volume as much as we enjoyed putting it together. And yes, we will be glad to hear your opinions, observations, etc on this special edition.

At this IMTEX, our co-ordinates are Hall: 3A, Stall: B116A. Hope to see you there!

M Lokeswara RaoPresident, IMTMA & MD, Lokesh Machines Ltd

Vikram SirurVice President, IMTMA & Executive Vice Chairman, Miven Machine Tools Ltd

N K DhandPast President, IMTMA & CMD, Micromatic Grinding Technologies Ltd

R SrinivasanPast President, IMTMA & MD, RAS Transformation Technologies

Gautam DoshiAdvisor, IMTMA & Consultant, Productivity & Quality Improvement Services

S N MishraPast President, IMTMA & Vice Chairman, Bharat Fritz Werner Ltd

Up for the next leap!

Editorial

Advisory Board

Manas R [email protected]

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Contents

MODERN MACHINE TOOLS - January 201134

Highlights of Next Issue:

Carlos M Cardoso, Chairman, President and CEO, Kennametal Inc ............ 236

Sector Watch: Aerospace Machining Industry Update: Test & Measurement Systems

Regular Sections

Leaders Speak

Editorial............................................................. 33National News .................................................. 48World News...................................................... 54Events ............................................................. 264Product Index................................................. 280Advertisers’ List ............................................. 285

Event Focus

Details on page 78, 120, 140, 160

Curtain Raiser .............................................. 62

Industry UpdateTooling systems:Productive partnership for increased efficiency ............................... 228

Sector WatchMetal cuttingFlexibility with refined precision ........... 220

Industry Voice ............................................. 69

Highlights of 2010 - NationalNews snippets................................................................... 36

Highlights of 2010 - InternationalNews snippets ................................................................ 43

Roundtable� Shetmetal working: Ready for the rising demand? ..... 116� Zero prototyping: Is the Indian industry ready?...... 118� Logisitcs: The key to controlling cost? ...................... 124� Managing existing talent: The biggest challenge for decision-makers? ................................................ 128� Indian trade policies: Are these industry-friendly enough?........................................................................ 132

Expert Zone� Proficient Productivity................................................. 136� Automation .................................................................... 144� Manufacturing Excellence .............................................. 154� EPO ............................................................................... 162� Green Manufacturing ..................................................... 166� New Materials ................................................................ 172� New Markets ................................................................. 176

Industry InsightsIndian machine tool sector: Backbone of a booming economy .............................. 181

Global OutlookMetalworking enterprise: The next big leap ............. 186

Future Footprints� Medical ........................................................................ 192� Aerospace ..................................................................... 200� Nuclear .......................................................................... 210� Renewable Energy ......................................................... 214

Facility Visit � Bharat Fritz Werner Ltd .............................................. 240� Pragati Automation Pvt Ltd .......................................... 246

Factory Fundamentals � Rotary tables save time, expand capabilities ......... 254� Long-lasting coolant reduces costs, downtime........... 258

PreviewAdvancing towards seamless: Material handling ....... 262

Report� Engineering Expo Pune 2010 ................................... 272� Engineering Expo Ahmedabad 2010 ........................... 276

Highlights of 2010 - National


(July) The heavy engineering & defence equipment manufacturer, signed an MoU with Karnataka government for establishing a manufacturing complex in Bengaluru for designing and manufacturing of aircraft components/sub-assemblies and MRO activities related to aerospace applications. An area of 25 acre of land has been allotted to BEML in the notified Special Economic Zone (SEZ) near Bangalore International Airport. The complex is expected to generate employment and ample business opportunities for local vendors.

BEML announces aerospace manufacturing unit

(August) The defence and aerospace arm of the Tata Group forged a joint venture with US-based Lockheed Martin Corporation to form a new company - Tata Aerostructures Ltd to design and manufacture aerospace and aero structure products. Lockheed holds 26 per cent stake, while the rest remains with Tata Advanced Systems Ltd (TASL). According to the proposal submitted by TASL to the Foreign Investment Promotion Board (FIPB), Lockheed Martins has invested ` 42.82 crore in the proposed venture.

Lockheed ventures into Indian defence market

Aerospace/Defence

Deals/Contracts

(September) QuEST Global Engineering, one of leading engineering service providers, has extended its agreement with Rolls-Royce till 2015. Under the terms of the agreement, QuEST Global will support the engineering resources of Rolls-Royce across its business divisions through an engineering centre located in Bengaluru. With a workforce of over 500 engineers supporting Rolls-Royce, the relationship has grown significantly and spans civil aerospace, defence aerospace, marine and energy sectors.

Rolls-Royce extends engineering services

(October) Soon after the MoU with South Korean automaker Ssangyong Motor Company, M&M has set out a roadmap to source components worth ` 19,000-23,000 crore over several years from across the globe for Ssangyong. It has set out long-term plan for the same. A substantial portion of this sourcing will come from India, where the company boasts of having a network of about 200-odd component vendors. The sourcing is more focussed on joint product development plan.

M&M-Ssangyong to source $ 4-5 billion worth of components

Expansion/Facilities

(February) The company has established a new manufacturing facility for its Antilock Braking System (ABS) at its Chakan plant in Pune. The production facility has a capacity of 3,00,000 units per year. Bosch had already invested ` 60 crore in the production facility, with a further ` 40 crore earmarked for the period between now and 2012. The new site covers about 4,300 sq m, and is part of the Bosch international ABS manufacturing network. Bosch is the only automotive supplier to manufacture ABS in India for passenger cars and light commercial vehicles.

Bosch sets up ABS facility in Pune

(February) A subsidiary of Tata Steel Ltd and manufacturer of cast iron & steel rolls, the company has put up integrated forging facilities for manufacturing forged rolls and engineering forgings. This makes Tayo the only company in the world to manufacture both cast and forged rolls at a single location through a totally integrated facility, from blast furnace to finished rolls. Apart from producing forged rolls, the new facilities has enabled the company to manufacture engineering forgings to cater to the requirements of oil & gas, power, wind mill, sugar, cement and steel sectors.

Tayo Rolls inaugurates integrated forging plant

(October) The Chennai-based automaker has announced the investment of ` 200 crore to increase its production of two-wheelers to meet the growing demands from the domestic and export markets. The company had targeted to sell 18 lakh of two-wheelers in the domestic market and export 2.5 lakh units this year. A design centre in also planned to come up in Indonesia. The company is targeting growing markets of the ASEAN countries along with Sri Lanka and Bangladesh. Moreover, its facility in Brazil may support the further extension of business markets.

TVS Motor invests ` 200 crore on capacity expansion

(November) The new facility of the auto major for body-building of its city buses within its Chakan plant in Pune is under construction. Considering that the market for high-end city buses is placed at 500 units per annum and is expected to grow at 20 per cent per year, the plant has a capacity of producing 700 buses per year by 2011. Planned to expand into the city bus segment, making luxury travel affordable for public transport users of the urban population, the auto manufacturer has also partnered with MCV for the body- building unit.

First trial run of Mercedez-Benz buses at Pune



Joint ventures

Market watch

(February) Mahindra Yueda (Yancheng) Tractor Company (MYYTCL), a joint venture between Mahindra & Mahindra Ltd and Yueda Group, will set up an R&D centre, a manufacturing plant for engines, and make investments to modernise production facilities for tractors at the new MYYTCL plant site at Yancheng, China. The total investment is about $ 40 million, of which the engine R&D centre and manufacturing plant have an investment of $ 18 million. The investments are aimed to improve performance, quality and reliability.

Mahindra Yueda JV invests $ 40 million

(February) The Ludhiana-based manufacturer of sheetmetal & tubular automotive components and one of the largest suppliers to auto majors entered into a Joint Venture (JV) with Cellino SRL. The JV company - Metalman Cellino manufactures medium-sized sheetmetal components primarily for cars, commercial vehicles and heavy equipment. Metalman Group, with the technical support of Cellino, is setting up a new state-of-the-art manufacturing facility in Aurangabad, Maharashtra with an investment of ` 20 crore.

Metalman markets automotive components in Europe

(April) The two companies signed an agreement for the formation of a JV to establish a final assembly line in India for AW119 helicopters to cater to the global market. The JV will be responsible for AW119 final assembly, completion and delivery while AgustaWestland will retain responsibility for global marketing and sales. The first aircraft is scheduled to be delivered from the new facility in 2011 with production forecast to rise to 30 aircraft per year to meet worldwide demand.

AgustaWestland and Tata form JV

(October) Air Works, one of the leading providers of aviation engineering services, entered into a Joint Venture (JV) with Scandinavian Avionics, a globally recognised avionics player to form a new entity, ‘SA Air Works India’. The JV company provides complete avionics solutions, which include cabin entertainment upgrades, in-flight communications, safety applications, weather systems and other airborne electronics to its customers in commercial aviation, general aviation and for military applications.

Air Works signs JV agreement with Avionics

(June) The company has inaugurated its $ 60-million multi-purpose operations facility located at Oragadam near Chennai. The new 2,03,000-sq ft manufacturing plant is spread over 28 acre in the Sipcot Industrial Park. It imports raw materials and parts to make the components and then manufactures the entire transmission assembly in phases. The facility also serves as regional headquarters of the company in India and has helped expand its presence in India, where demand for Allison’s fully automatic transmissions is steadily growing.

Allison Transmission expands its Indian presence

(June) The global leader in metal injection moulding technology opened a world-class investment casting facility near Tirupathi in Andhra Pradesh. The state-of-the-art precision investment castings production facility, spread across 30,000 sq ft, began commercial production in February 2010 under the name Gowri Ventures Pvt Ltd. The plant is equipped with machinery from reputed manufacturers located in the US, Canada, Australia and India. It manufactures precision investment castings, finish machines them and heat treats the castings to make them ready-for-use.

Indo-MIM foray into investment casting

(October) In a breakthrough for US firms to make headway into the untapped Indian nuclear power market, General Electric, and Pennsylvania-based Westinghouse Electric have partnered to build nuclear power plants in India. Westinghouse, majority-owned by Japan’s Toshiba Corporation, has the world’s largest installed base of operating nuclear plants. Areva and Russian company, Rosatom, are already present in the Indian nuclear energy market, and are partners in major nuclear power projects in the country.

GE & Westinghouse foray into Indian nuclear markets

(October) To reap the benefits of a growing renewable energy market in India, Siemens Ltd began operations of its renewable energy segment by setting up an office in Vadodara, Gujarat. The company views that the market outlook for renewable energies in India is positive and eyes huge potential for the wind and solar businesses in the near future. With a target to generate up to 20 GW of solar power by 2022 as part of the National Solar Mission (NSM), the current renewable energy market in India presents a great opportunity for companies like Siemens.

Siemens commences energy operations in India



New launches

(June) The company announced the launch of its new 2D and 3D design & engineering software line-up for manufacturers seeking to digitally design visualise and simulate their products before they are built. The technology integration offered by Autodesk Inventor 2011 software and the complete Autodesk digital prototyping software portfolio helps enable designers and engineers compete more effectively and do more work in-house.

Autodesk accelerates design process for manufacturers

(November) Mori Seiki Co Ltd announced the debut of the X-class horizontal machining centres that is well-suited for the desired features of high performance and safety. Keeping in view the prevailing demand trends in Indian manufacturing industry, NLX2500 series has been first launched as the X-class by the company. The NLX Series uses the MAPPS IV high-performance operating system for its operation panel. In addition to automatic programming software (standard), ESPRIT CAM software is available as an option.

DMG X-class horizontal machining centres arrive in India

New leadership

(April) A N Chandramouli was recently appointed as the new Managing Director of StarragHeckert Machine Tools Pvt Ltd, the Indian subsidiary of StarragHeckert Group. He leads the greenfield business operations and aims to firmly establish the European machine tool company in India. StarragHeckert had earlier launched manufacturing operations in India at an investment of about ¤ 23.56 million. StarragHeckert India plans to accelerate investment and launch various product groups and brands from Switzerland and Germany.

New MD of StarragHeckert India appointed

(June) The Indian subsidiary of Kennametal Inc, a leading manufacturer and supplier of tooling, has appointed Santanoo Medhi as Managing Director of the company. In his role, Medhi has responsibility for all of Kennametal India’s businesses – metalworking solutions, engineered products and special purpose machines. Medhi joined Kennametal in January 2009 as Regional Director – Sales, for the Asia Pacific region, based out of Singapore. In September, he assumed charge as Interim President of Kennametal India Ltd.

Kennametal India appoints Santanoo Medhi as MD

Research/Technology

(April) Fom Industrie, an Italian machine tool manufacturer, has set up its technology centre in Bengaluru, as a part of its global expansion strategy. The company also plans to set up new centres in the northern and western regions of the country. The technology centre in Bengaluru is equipped with advanced machine tools and staffed with process application engineers. It has a training centre, spare parts and an area dedicated to service & support. It also encompasses a warehouse of assorted machines ready for delivery.

Fom Industrie sets up technology centre in Bengaluru

(June) Carl Zeiss, one of the leaders in metrology solutions, inaugurated its secondtech centre in India. Thismove comes after the good success experienced by the company with its first centre at Bengaluru. The tech centre serves customers in the automotive, auto components, aerospace, machine tools, railways, power generation, general engineering, plastics and education sectors. Measurement strategy for complex parts, part programming, reverse engineering, fixturing solutions among other services is also available.

Second tech centre for Carl Zeiss in India

(September) Bajaj Auto, India’s fastest-growing automobile company launched the new 220cc Avenger DTS-i. The new model has a large capacity engine, torque of 17.5 Nm, is equipped with the patented digital twin spark ignition (DTS-I) technology. The technology employs twin spark plug instead of single spark plug, and coupled with digital CDI, ensures efficient combustion. The flame coverage is high in the combustion chamber leading to complete combustion of air fuel mixture and elimination of any unburned fuel.

Bajaj Auto launches new Avenger with DTS-i technology

(October) BHEL, one of the leading power equipment manufacturers announced an increase in its R&D by around 50 per cent to ̀ 1,200 crore by 2011-12. With cheap products from China offering a competitive disadvantage, BHEL has set out to revamp its production lines and processes to develop low-cost and more efficient equipment as it seeks to counter the threat of cheap imports from China. The company’s capacity to manufacture power equipment with a cumulative generation capacity of 15,000 MW per annum will increase to 20,000 MW by the end of 2011.

BHEL to invest ` 1,200 crore in R&D by 2012

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Highlights of 2010 - International


(July) Adept Technology, a provider of intelligent vision-guided robotics and global robotics services, entered into an agreement to acquire privately held MobileRobots Inc, a provider of industry leading autonomous robot and Automated Guided Vehicle (AGV) technologies. MobileRobots uniquely positions Adept to deliver productivity gains in unstructured environments, many of which reside beyond traditional robot applications.

Adept acquires autonomous mobile robot provider

(June) ABB, the global power and automation technology group, acquired Ventys for more than $ 1 billion from Vista Equity Partners. Ventys is a leading software provider to global energy, utility, communications and other asset-intensive businesses. ABB combines its related network management business within the power systems division, with Ventys to form a single unit for energy management software solutions. This acquisition triples the energy management software market available to ABB.

ABB acquires Ventys

(July) Dürr recently acquired the Germany-based Helmut Rickert GmbH and its subsidiary INT Rickert GmbH. A leading supplier of products for gluing body shell components in Germany, among other things, Rickert develops and supplies gluing systems, especially for the body in white process. According to Ralf Dieter, CEO, Dürr, the company cquired Rickert as a part of its strategy to expand in growth areas through selective technology acquisitions.

Dürr acquires gluing technology specialist Helmut

(August) Essar Steel International BV, a subsidiary of Essar Steel Holdings, owned by Ruias, acquired the UK-based Servosteel (Oakside Solutions). The maiden acquisition of Essar Steel in the UK marks a new chapter for the company and is in accordance with its global distribution strategy. Servosteel, a Dudley-based steel service centre, offers a one-stop service for Smooth Clean Surface (SCS) technology, pickling, slitting, decoiling and various individual custom-tailored services.

Essar acquires the largest independent steel processor

(May) MAG Powertrain recently received an ‘Outstanding Supplier’ award from SAIC-GM-Wulin (SGMW), a leading Chinese automaker at a ceremony in Liuzhou, China, for its XS 211 and XS 321 production lines. The event was held to recognise suppliers for excellent technologies, products and service provided in 2009. This is the second consecutive Outstanding Supplier award MAG has received from SGMW, a leading manufacturer of commercial vehicles, such as minivans and transporters, in China.

MAG felicitated for outstanding powertrain performance

(September) The company overcame tough competition from major competitors to bag the award for ‘Best CAD/CAM or Control System’ for its hyperMILL® system. The award was collected by Adrian Smith, Managing Director - UK, OPEN MIND, who commented, “The award is not only recognition for the exceptional capabilities and functionality of hyperMILL® version 9 and the technical expertise of our German parent company, it is recognition of the extremely hard work the UK team has put into making OPEN MIND a major success story in the UK.”

OPEN MIND Technologies wins MWP Awards

Awards

Acquisition



(September) The British aircraft engine maker Rolls-Royce secured orders worth $ 2 billion at the Farnborough Airshow. The orders included deals for its Trent 700 engine, the leading engine for the Airbus A330. The engines will be used to power 17 Airbus A330s from Russia’s Aeroflot and Garuda Indonesia Airlines. The company also signed new service agreements with Sichuan Airlines, and extended service deals with Garuda and Air Transat at the show in England. These contracts included TotalCare long-term service.

Rolls-Royce books orders worth $ 2 billion

(September) The company delivered to US Navy the first F/A-18 Super Hornet combat jet featuring a gun bay door manufactured by Bengaluru-based Hindustan Aeronautics Ltd (HAL). The two companies are also working on projects for the P-8I multi-mission maritime aircraft for the Indian Navy and for the commercial Boeing 777 airplane. The gun bay door covers the F/A-18’s six-barrel 20 mm, externally powered M61A2 Gatling gun system that can fire 4,000-6,000 rounds per minute.

Boeing deliveres first batch of F/A-18 combat jets

(March) The Japan-based company announced its expansion plans in North America, and is currently studying the possibility to establish a manufacturing base in the region by 2011. The group estimates that adding a new factory in North America would raise its total monthly output capacity by about 100 units to slightly more than 900. It said that this level of increase would prepare it for the global expansion of machine tool sales that it anticipates.

Mori Seiki expands in North America

(March) Hexagon Metrology GmbH in Wiener Neudorf, Austria, unveiled its new precision centre as part of its business strategy to extend its presence across the country. The facility will allow customers to have access to the products offered by the company. In addition to being a demonstration & training centre, the new Wiener Neudorf facility provides an operating base for Hexagon Metrology service and sales staff. Hexagon Metrology now has 59 precision centres spread across 25 countries.

Hexagon unveils precision centre in Vienna

(July) Sandvik Coromant officially opened its first Deep Hole Machining (DHM) Global Application Centre in Gloucestershire, UK. The facility utilises research to develop new, innovative DHM techniques for customers in the power generation, aerospace and oil & gas industries. The centre also serve as an interface for research institutes, machine tool manufacturers and universities to conduct tests & undertake studies on specific components.

Sandvik inagurates its first deep hole machining centre

(August) The company plans to invest $ 450 million for a manufacturing plant in Rayong province of Thailand. Production is slated to start from 2012, with 85 per cent of its output destined for markets in the Asia-Pacific. Although the 7,50,000 sq m assembly plant will build Ford Focus cars with initial capacity of 1,50,000 units a year, it will be able to diversify its production to include the company’s other vehicles.

Ford Motor announces expansion plan in Asia-Pacific

Deals/Contracts

Expansion/Facilities

Investment

(December) Volkswagen AG will invest the amount over the next five years as it focusses on modernising and extending its brands’ product range. The amount will be invested in property, plant and equipment for its automotive division. Fifty seven per cent of the investment will be centred in Germany, where the headquarters of the company is located. The company, whose product range includes brands like Audi, Skoda and Seat, will focus on new models and will launch new generations of engines.

Volkswagen announces $ 70 billion investment plan

(May) GE invested the amount to develop and expand its wind turbine manufacturing, engineering and service facilities in four European countries - the UK, Norway, Sweden and Germany. At the core of GE’s European expansion plans is the development of next generation wind turbine of GE, a 4-MW machine designed specifically for offshore deployment. As the largest wind turbine in the company’s fleet, it incorporates advanced drive train and control technologies.

GE investes ¤ 340 million for wind turbines in Europe



Joint ventures

(April) Following a recent agreement between parent companies, DMG and Mori Seiki combined their operation in the US, since April 1, 2010, and the combined organisation is known as DMG/Mori Seiki USA. As a part of the business collaboration since March 2009, sales/service has been unified in nine countries including Thailand, Indonesia, Taiwan, Turkey, Japan, South Korea, Australia, India and the US, beginning from July 2009.

Mori Seiki and DMG combine US operations

(January) GF AgieCharmilles and Hexagon Metrology, globally renowned technology leaders in manufacturing, stepped up the partnership they began earlier this year by exhibiting complementary laser and metrology technologies at EXPOlaser 2009 in Piacenza, Italy, in November. The co-operation between the two companies was inaugurated by the installation of Hexagon 3D measuring machines in GF AgieCharmilles’s application centres several months ago.

Gf AgieCharmilles and Hexagon extends collaboration

New Launches

(December) China has unveiled its first large domestically produced passenger jet, which aims to compete with Airbus and Boeing in the global aviation market. The C919 prototype made its debut at an aviation exhibition in the southern province of Guangdong. Three major state-owned airlines: Air China, China Southern Airlines and China Eastern are due to sign deals to buy the C919s. The aircraft took to air at the show held in the city of Zhuhai.

China unveils jet to rival Boeing and Airbus

(October) Toyota Motor Corp is in the process of introducing six new hybrids, gasoline-electric vehicles by 2012 on a global basis. The automaker will also launch its new RAV4 electric sport-utility vehicle developed in conjunction with Tesla Motors Inc. The company expects pure electric cars to be a small portion of its overall fleet and will concentrate on small, shorter-range vehicles and motor scooters. The company is planning two new Lexus models and four Toyota models with hybrids.

Toyota to launch six new hybrid vehicles

Research/Technology

(November) The two companies agreed upon a collaborative effort to offer closer integration between CNC and Programmable Automation Controller (PAC) environments. The effort will result in the ability for both companies to deliver integrated automation solutions to key vertical market segments, such as automotive and aerospace. The two companies will work together on connectivity between their respective controller platforms through open communication technologies.

Rockwell and FANUC jointly develop automation solution

(August) The Indian company has collaborated with Arabia Holdings and Ras Al-Khaimah Transport Investments to produce Mahindra Defence Systems’ (MDS) armoured vehicles in the UAE. The JV will launch Mahindra’s Marksman, Scorpio and cash-intransit vans in the Emirates. The JV aims to tap into the emerging markets of Africa and Central Asia. According to M&M, the partnership will facilitate the company’s entry into the UAE market.

Three-way JV for M&M in UAE (August)

(June) Makino’s, manufacturer of CNC machining centres, new Mason, Ohio, facility is designated as Makino’s Global Titanium R&D Centre. It houses a specialised group of engineers, who work to further the development of titanium milling technologies. The facility includes state-of-the-art machine tools, specialised titanium machining and tooling experts, co-ordinate measuring machine, and all necessary tools and talent to further titanium machining technologies.

Makino establishes titanium research centre

(January) Mazak’s state-of-the-art European Technology Centre located at the company’s European headquarters in Worcester, England incorporates a solutions area, highlighting parts manufactured by Mazak technology; an auditorium; a spacious hall, featuring many machine tools under power; plus the corporation’s European manufacturing facility. The investment in the European Technology Centre has significantly improved the support the company can give to its European customers.

Mazak European Technology Centre opens its doors

National News


Essar collaborates for advanced high-strength steelIn its commitment towards technology sharing, Essar Steel Ltd has signed MoUs with Kobe Steel Ltd of Japan for collaboration in the area of technology for manufacturing Advanced High Strength Steel (AHSS) grade sheets used in automotive and other relevant applications.

The MoU states that the companies will explore the possibility to set up a joint venture to design, construct, own and operate a Continuous Annealing Line (CAL) and a Continuous Galvanising Line (CGL) for Galvannealed (GA) steel sheets. The existing agreement between the companies encompasses sharing of advanced technology and resources to manufacture high grade iron and steel products to help address the growing demand for high-grade steel products in India. Malay Mukherjee, CEO, Essar Steel said, “The auto industry is expected to be a major driver for steel demand in the country in the years to come. This MoU will further strengthen Essar Steel’s product portfolio to enable it to produce steel for high-end applications in the auto segment.”

Gildemeister and Mori Seiki invest in a new tech centreGildemeister and Mori Seiki - leading manufacturers of cutting tools, recently combined their activities in India. Both groups are expanding their presence in the fast growing Indian market by jointly investing in a new technology centre with a large showroom. Scheduled to open in May 2011, the technology centre is spread across an area of 8,000 sq m and is located in the industrial area of Peenya, Bengaluru. The city, which is considered the

machine tool capital of India, was selected as it houses major industries related to aerospace die & mould, precision engineering and automotive. Live cutting demonstrations in form of workshops, seminars and training will also take place at the centre. Core business areas of turning, milling, ultrasonic and laser are complemented by automation and software solutions for machine tools and solar tracking systems. DMG Mori Seiki will be responsible for complete service and support of the entire product portfolios of both manufacturers.

Tata Motors developing double-trailer truck and enginesThe company is developing a double-trailer truck in its Prima range of trucks for the overseas market. It is expected to be ready for sale by the end of 2011. The company feels there is no good demand for the range in the domestic market, but has great potential in

the overseas market. The company introduced its Prima range of world trucks in May last year and is now

manufacturing engines for its medium-and-heavy commercial vehicles (trucks and buses). The company has an equal joint venture with US-based Cummins to manufacture engines for commercial vehicles at its Jamshedpur plant.

The auto giant is also developing a set of fuel-efficient engines for light commercial vehicles (trucks), which will help increase its sales in the international market. The engines will have a capacity of three to five litre and are likely to be used on a new vehicle platform for light trucks.

Honda plans a new two-wheeler plantHonda Motorcyle and Scooter India (HMSI) will be investing ` 500 crore to build a new plant in Rajasthan. The plant will have an annual capacity of 6,00,000 scooters and motorcycles that will take HMSI’s total capacity to 2.2 million.

The company is a wholly-owned subsidiary of Japanese automaker Honda Motor Co. Its current facility in the state of Haryana has a peak capacity of 1.6 million scooters and motorcyles, and is close to operating at full capacity. It is also planning to launch at least six ranges of motorcycles in the Indian market in 2011, the first of which – the CBR 250R – will be introduced in April. Naresh Kumar Rattan, General Manager & Operating Head – Sales & Marketing said, “The time is right to expand in the domestic market. The two-wheeler segment still has the potential to grow and we are ready to tap it.”

DMG Mori Seiki technology centre

National News


Cranedge: Support for crane usersPune-based ElectroMech, country’s leading industrial crane manufacturer and customised material handling solutions provider recently announced the launch of Cranedge - a dedicated service organisation exclusively for providing post-sales service support for crane users. It was launched to offer unmatched service and to ensure safe & peak crane performance. Cranedge

through its offering also provides spare support, repairs, services and overhauling, annual maintenance contracts, crane health checks, m o d i f i c a t i o n s & retrofits,

relocation of cranes and crane safety certification. In order to reduce and almost eliminate the variability of such unscheduled breakdowns, experts recommend ‘crane specific’ expertise. Tushar Mehendale, MD, ElectroMech said, “Post-sales service for cranes is an area where we find several lacunae in the Indian industry. Such services are big businesses overseas but not that big in India. However, people are slowly realising the benefits of outsourcing the maintenance of their cranes to specialists, especially where cranes happen to be an integral part of their production process.”

Tata Power to invest ` 5,000 crore in wind-energyRenewable energy is an emerging market for the engineering industry. To tap new business prospects in this sector, Tata Power - India’s largest private sector power utility - aims to produce at least 25 per cent of its total power generation from clean sources by 2017. The company, which ranked 4th as the fastest growing energy company in Asia under the Platts Top 250 Global Energy Company rankings, plans to invest around ` 5,000 crore in wind-energy alone. Banmali Agrawala,

Executive Director-Strategy and Business Development, Tata Power confirmed, “We have set ourselves a target to achieve 25 per cent of our

total generation from clean sources by 2017. These will comprise wind, solar, hydro, geo-thermal and gas. In wind-power alone, we will be investing around ` 5,000 crore.” The company also plans to generate around 8,000 MW of power from renewable energy resources and has decided to give thrust on wind-energy, as it is the most commercially viable and established form of renewable energy.

Lockheed Martin delivers India’s first C-130 aircraftAerospace and defence company Lockheed Martin has delivered the first of six aircraft that the Indian Air Force purchased in a $1.2 billion deal negotiated with the USA.

This is India’s first experience with the C-130 aricraft, therefore, the package provided by the US government is quite comprehensive. The contract includes six aircraft, training of aircrew and maintenance technicians, spares, ground support and test equipment, servicing carts, forklifts, loading vehicles, cargo pallets and a team of technical specialists who will be based in India during a three-

year initial support period. The planes have been modified and specially equipped for mission roles. The IAF requirements included capability for precision low-level flying, airdrops, landing in blackout conditions, and features to ensure survival in hostile air defence environments. The models provided to the IAF are the longer fuselage variant of the C-130J, similar to those used by the US Air Force. The order is the first step in Lockheed Martin’s long-term plan for growth in India, which is an increasingly important market for the company.

Nissan inaugurates first field quality centre in IndiaQuality is the cornerstone of any brand and Field Quality Centre (FQC) continually seeks to improve product quality in the field of automobiles. Taking the next step in its quality mandate, the first FQC and training facility of Nissan Motor India Pvt Ltd (NMIPL) was recently inaugurated at its manufacturing plant in Tamil Nadu. “Quality improvement is a never-ending process, and is well integrated into our product development and production processes. The training centre will also provide product,

process & soft skill trainings for dealership staff located in India and Nissan’s consistent focus on ensuring a quality ownership experience to our customers will be strengthened by this new facility,” said Kiminobu Tokuyama, MD & CEO, Nissan Motor India. The training centre, which is built as per Nissan’s global standards, in terms of facilities, tools & equipment, is aimed at consistently achieving ‘fix it right the first time’ concept.

Tushar Mehendale

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National News


Ministry approves second nuclear power plant in MaharashtraThe Union Ministry of Environment and Forests (MoEF) has granted clearance to the proposed 9,900 MW Jaitapur Nuclear Power Plant slated to come up in Ratnagiri district. The state-owned Nuclear Power Corporation of India Ltd (NCPIL) will now initiate commercial negotiations with Areva for the project, from where power will be progressively available from 2016. The initial work on constructing staff utilities at the site can begin, although ground breaking will take place only after the Atomic Energy Regulatory Board (AERB) approves the plant design.

The approval will be granted subject to 35 conditions and safeguards, including 23 specific to the project and other general conditions. The project is expected to cater to the overall energy requirements of the state for the next 25 years, and in the first phase, two of six proposed units, each with a capacity of 1,650 MW will come up. The first pair of 1,650 MW reactors will be operational by 2019.

Cosmos to set up a hi-tech research & development centre The Vadodara-based supplier of metal cutting machine tools will set up a hi-tech research & development centre to develop and manufacture state-of-the-art machine tools. The company has tied-up for technology alliance with some of the top leaders in the manufacturing industry for the future growth of Indian aerospace, defence, heavy infrastructure, power & steel industry, automotive industry, medical & ortho implants, etc. The company has already completed all the ground-work and is now ready to launch the first phase of very hi-tech grinding machines with European design.

T i t led the ‘Cosmos Technology Park,’ for its second phase the company has collaborated three major manufacturers from Taiwan. In the third phase, the company will work towards technology alliance to research and develop various type of 5-axis machines in India.

By 2014, the park is slated to design, develop & manufacture the most challenging machine tools and complete solution lines for the end-user industry.

V N Nagesh, Director, Cosmos signing a JV agreement with Jimmy Chu,

Chairman, FFG

World News


Daimler selects Siemens for vehicle development Daimler AG has selected CAD-software from Siemens for its worldwide car and truck enhancement. Starting in the summer of 2012, Daimler will integrate work from over 20 development centres and its most important suppliers on a single product development platform. With this decision for the NX CAD software of Siemens, Daimler completes its current implementation of Teamcenter, the company’s product data management backbone. Based on this combination, the automotive manufacturer will establish digital collaboration from initial design concept through simulation during the design process.

The consolidation of digital product information in a single worldwide data pool will facilitate new vehicle development. The introduction of parallel processes in development, design, production, and planning will further optimise the entire value chain.

Amalgamation of cutting excellence at YG1 global meetThe South Korea-based cutting tool company recently concluded its first-ever event catering to its various distributors from across the globe. Representatives from various branch of the ‘YG1 family’ assembled in China to experience YG1 hospitality and acquaint themselves with the company’s wide array of products. Over 1,000 distributors and dealers from India, Saudi Arabia, Iran, Australia, Switzerland, Russia, Turkey, the UK, the US, etc flew in to attend the meet. The four-day summit was punctuated with visits to the company’s R&D centres and manufacturing facilities in China and South Korea.

During the meet, delegates were

privy to the expansion and growth strategies of the company and were provided an opportunity to interact with Hokeun Song, President, YG1. Expressing his view, Song said, “The YG1 meet is our endeavour to bring our buyers closer to us and build the YG1 family. The coming years will

see us grow and expand in terms of business.” In a bid to increase its marketshare and strengthen its production capacity, the leading manufacturer of end mills in the world has even started its production facility in Bengaluru.

German machine tool industry plans expansionThe medical technology is one of the world’s expanding markets for the manufacturing sector with estimated revenue of $ 100-220 billion. Rising life expectancy and a growing demand for high-quality medical care in many industrialised nations are fuelling advances in medical technology.

T a r g e t i n g this growing vertical, the G e r m a n machine tool industry will showcase its c a p a b i l i t i e s exclusively for this customer

grouping at the ‘Metal meets Medical - Manufacturing Potentials’ conference to be held on 17th March 2011 in Karlsruhe, Germany. It is being organised by the German Machine Tool Builders’ Association

(VDW) in conjunction with the Institute for Production Management, Technology and Machine Tools PTW, Darmstadt, Germany.

“Medical technology and engineering science are progressively converging, creating innovative applications, designed to ensure improved and more efficient health care for ill people,” explained Dr Wilfried Schäfer, Executive Director, VDW. He further added, “Without massive deployment of high-technology systems, the future challenges faced by the health care system cannot be met and mastered.”

EuroMold 2010: The flag flies highThe 17th EuroMold wrapped up on a high note. With visitors flying, despite the bad weather, from over 86 countries, the event organised at Frankfurt, Germany was able to retain the number of visitors from last year. The visitor profile constituted countries like Italy, Turkey, Austria, Switzerland, the Netherlands, Spain, China, Belgium, France, and Russia.

Dr Ing Eberhard Döring, Exhibition Manager of Euro-Mold 2010 averred, “The increasing number of trade visitors from abroad was far beyond our expectations. EuroMold has been affirmed as an essential event for the

product development industry by more than 55,000 visitors, among them many decision makers.”

Around 1,384 exhibitors from 38 countries showcased their products and services in different sectors.

Dr Wilfried Schäfer

World News


Rolls-Royce bags order from Hawaiian airlinesIn a contract worth $ 420 million, the global power systems company will provide Trent 700 engines for six Hawaiian Airlines A330 aircraft. The order also includes a TotalCare® long-term services agreement. The airline already has ten Trent 700-powered A330s in service. Chris Cyr, Executive Vice President – Customer Business, America Rolls-Royce, said, “Hawaiian Airlines is a valued customer, and we are pleased that they have again

put their trust in our leading edge technology and support services. This contract underscores the market leading position of the Trent 700, the only engine designed specifically for the A330.”

According to Mark Dunkerley, President & CEO, Hawaiian Airlines, “We are delighted to add new A330s to the TotalCare® programme, having seen the strong benefits with our B717 fleet.”

During 2010, Rolls-Royce has won 13 of the 14 potential A330 engine selections, securing orders totalling over $ 5 billion to supply 73 aircraft.

GM to invest $ 163 million in US plants General Motors Co plans to invest the said amount at plants in Michigan and Ohio to add engine production for Chevrolet Cruze, Chevy Volt and an unnamed new small car. With this investment, the company will protect 184 jobs at the facilities, which include an engine plant in Flint, Michigan; a components plant in Bay City, Michigan; and a casting plant in Defiance, Ohio.

The automaker also plans to increase production of a 1.4 litre

engine used in the Cruze compact car and a variation on that engine used in the Volt plug-in hybrid at the

Flint plant. It is expected to begin producing 400 engines per day at the Flint plant in early 2011, increasing to about 800 per day by late 2011. The added investment allows GM to increase production capacity to 1,200 engines per day by late 2012.

Volkswagen to build cars in MalaysiaThe German automaker recently signed a pact with Malaysia’s DRB-Hicom Bhd to assemble 50,000 vehicles a year in the country, after earlier attempts to enter Southeast Asia’s largest passenger car market failed. The $ 318 million venture will be Volkswagen’s second in the Asean region. DRB-Hicom, which already assembles auto models for Daimler

AG’s Mercedes-Benz, Honda Motor Co, Isuzu Motors Ltd and Suzuki Motor Corp, will contribute about 70 per cent of the initial investment, while Volkswagen will put in the remaining 30 per cent. Mohammed Khamil, Managing Director, DRB-Hicom, said, “The agreement between the parties allows for the production of between 40,000 and 50,000 vehicles a year. We have

plenty of space to accommodate Volkswagen.” The Malaysian company has a plant with production capacity of 96,000 vehicles a year, but currently utilises only a fraction of that capacity. One of Europe’s largest automakers, which had last year agreed to set up a plant in Indonesia that will produce its Touran multi-purpose vehicle, is also eyeing other production hubs in the region to further boost sales in Southeast Asia.

Awareness campaign against product counterfeiting In the last two decades, counterfeiting in general has grown by 10,000 per cent. Globally a far greater risk lies in industrial counterfeiting of items such as tyres, seals and bearings. All these products are critical to safety and fake versions pose a real threat. As a result, the World Bearing Association (WBA) has launched an awareness campaign to inform about safety hazards arising from counterfeit bearings. “Our initiative is aimed at sensitising the public on the dangers associated with counterfeits,” said James W Griffith, President, WBA.

He is also the President and CEO of The Timken Company. “The WBA is thus intensifying its anti-counterfeiting initiatives – that means information for customers on the one hand and consistent prosecution of offenders through competent authorities on the other,” he further added. Premium manufacturers invest continuously to develop their technology and improve the quality and value of their products. And the act of counterfeiting violates intellectual property norms, such as patents and trademarks. To spread awareness, WBA anti-counterfeiting information campaign will reach out to various audiences over the next three years and what branded-bearing manufacturers can do to stop it.

World News


Nissan, Mitsubishi looking for expansion to beat competitionNissan Motor Co and Mitsubishi Motors Corp will deepen business ties to get ahead in the fiercely competitive global car industry, including establishing a mini car joint venture in Japan that could eventually expand to other countries. Under the Original E q u i p m e n t M a n u f a c t u r e (OEM) partnership agreement, the two Japanese automakers will make more cars for each other.

The agreement allows one automaker to supply vehicles to another, to sell under the latter’s brand name, enabling companies to cut down production costs through economies of scale. Nissan will produce a small van to be sold under the Mitsubishi brand in the Japanese market, while Mitsubishi will make an SUV to sell under the Nissan brand in the Middle East. To cope with capacity shortfalls in Thailand, Nissan will shift production of its brisk-selling Navara pickup truck to Mitsubishi’s plant in Thailand. The two companies are also keen to establish a 50:50 joint venture next year and release a new mini car model in 2012. Osamu Masuko, President, Mitsubishi Motors, said, “We hope the JV will fuse this company’s design and production know-how with Nissan’s strong purchasing power.”

Seco Tools makes acquisitions in the US The company recently signed an agreement to acquire two companies in the US - NC Industries (NCI) and Diamond Tool Coating (DTC). NCI is a producer of solid carbide end mills under Niagara Cutters and Arch Micro Tools brands and is among the largest local producers in the US of these products. DTC is a producer of wear-resistant diamond coatings. Its customers consist of aircraft and power generation industries, as well as the general engineering industry.

NCI and DTC have a combined annual sales of around $ 37 million. Sherwood Bollier will remain President of NCI & DTC, after the acquisition and both companies will continue as separate entities to ensure continuity in operations. The acquisition is planned for completion before the end of the year. Kai Wärn, President & CEO, Seco Tools, said, “The end mill product area is regarded as strategically important, among other things for high-speed machining capability and the ability to close tolerance requirements. The acquisitions will strengthen Seco Tools’ position and marketshare in this segment in general, and the important US market in particular.”


Event Focus

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Industry Voice....................................... 69


The year heralds in the much awaited event - IMTEX 2011 and the concurrent show Tooltech 2011. As the metalworking sector gears up to leverage the opportunities presented by the economic upswing, here are the views of some head honchos on how this mega event can help overcome the challenges of the future and accelerate the growth momentum.

Curtain Raiser


IMTEX has earned its name as a watershed for the global machine tool industry by bringing in the latest and best each year. As a gateway to foray into the Indian market, the event is also an opportunity to experience ‘live’ the latest developments in India and across the world.

The global economic slowdown has brought the machine tool industry in the West much closer to the Asian markets,

especially India and China. Today, as these countries gain importance in their business strategies and expansion plans, an opportunity to interact with the best in the industry awaits at IMTEX 2011 and Tooltech

2011 - the largest Indian metal cutting machine tool exhibition. Over the years, the mega trade show has gained international repute in attracting the best and the who’s who of the machine tool industry in India and across the world.

As Bengaluru prepares itself to host the 15th edition of this series scheduled to be held from January 20-26, 2011, the specialised business

World-class experience in metalworking

Rachita Jha

Curtain Raiser


fair will feature recent trends in metal cutting machine tools and manufacturing solutions in India and from across the globe. IMTEX 2011 is a trademark brand and flagship event of the Indian Machine Tool Manufacturers’ Association (IMTMA).

India: At the zenith ofindustrial growthIMTEX 2011 and Tooltech 2011 are scheduled to be held at the apex of India’s economic and industrial advancement. The current business environment in India is immensely bullish, with high growth, enhanced investment, and all-round increase in demand for consumer products & industrial products.

For the Indian manufacturing industry, it is a phase of phenomenal growth. Be it the core infrastructure, automotive, consumer durable, capital goods sectors, the growth momentum continues to accelerate like never before. Simply put, just nothing seems to stop India from achieving a +9.0 per centGDP growth in the current fiscal. In essence, business opportunities are expected to pour – and in plenty – for everyone in the manufacturing sector, around the time when IMTEX 2011 and Tooltech 2011 are scheduled.

Experience the bestSlotted among the five major international machine tool exhibitions world-over, IMTEX series has come to symbolise as a one-stop forum where users and customers are empowered with the display of technologies that give an edge to their manufacturing. IMTEX is no doubt an

enabler to global manufacturing competitiveness and a show-window to the emerging technologies of the future.

Sure to attract visitors from almost all sectors of the manufacturing industry, large team of technocrats/engineers from various companies, institutions and organisations involved in manufacturing, design and assembly will mark their presence here. IMTEX 2011 will spearhead a wide range of opportunities for everyone in the field of manufacturing – manufacturers, users, technocrats, researchers, policy-makers, academia, budding engineers and even technical graduates.

Showcasing latest trendsThe leading exhibition of metal cutting and manufacturing solutions in South and South-east Asia will showcase the very latest trends as well as accomplishments of the already successful technologies from India and across the globe. This makes IMTEX the most sought-after exhibition in this part of the continent.

According to M Lokeswara Rao, President, Indian Machine

The combination of IMTEX 2011 and Tooltech 2011 will be one of the largest fairs organised by IMTMA. More than 800 exhibitors from various parts of India and across the world, which include the leading brands in the global metal cutting machine tool industry will be present at the event.

M Lokeswara Rao, PresidentIndian Machine Tool Manufacturers’ Association

Tool Manufacturers’ Association, “The combination of IMTEX 2011and Tooltech 2011 will be one of the largest fairs organised by IMTMA, and will be held over an exhibition space of around 45,000 sq m. More than 800 exhibitors from various parts of India and across the world, which includes the leading brands in the global metal cutting machine tool industry will be present at the event.”

The event will provide a unique opportunity to witness a wide range of metal cutting machine tools and manufacturing technologies on a single platform. Both exhibitions are expected to receive good response in terms of visitor turnout and business generation, similar to the previous two editions.

Technology highlightsIMTEX 2011 and Tooltech 2011 will showcase value-added innovations as well as technological developments in the metal cutting machine tools and manufacturing solutions domain. The displays will focus on optimising productivity, enhancing quality, increasing reliability and reining competitiveness of world-class standards. These include automatic lathes, gear cutting & finishing machines, machining centres, assembling systems, industrial robots, flexible manufacturing systems, drilling machines, boring machines, milling machines, etc.

Go global at IMTEX 2011There is a growing interest among

Manufacturing Inc at IMTEX 2011

� Aerospace

� Aluminium extrusion

� Auto components

� Automobiles

� Defence

� Energy

� Medical engineering

� Oil & gas equipment

� Nuclear

Key draws at Tooltech 2011

� Finishing and cutting tools

� Abrasive tools and products

� Work and tool holders

� Measuring and testing systems

� Testing machines

� Production control and networks

� Manipulation of parts & tools, and assembly

� Computer application

Curtain Raiser


the Indian and global machine tool manufacturers to forge business partnerships & collaborations and charter growth parts. IMTEX 2011 and Tooltech 2011 will be the facilitators for business-to-business co-operation between manufacturers and users of all hues associated with manufacturing. IMTEX 2011 has representation from 22 overseas countries, including eight country-group participation from People’s Republic of China, Czech Republic, Germany, Italy, Singapore, Spain, Taiwan (RoC) and the US. Other major overseas countries represented at the exhibition include Australia, Austria, Denmark, Finland, France, Israel, Japan, Republic of Korea, Russia, Switzerland, Thailand and the UK.

The exhibition holds tremendous significance for manufacturing professionals – be it CEOs, entrepreneurs, senior executives, corporate planners, strategists, manufacturing managers, shop-floor engineers, technicians, agents and dealers. The event also spans across industries such as aerospace, automotive, defence, medical engineering, railways, and nuclear, among other leading industrial sectors.

Tooltech 2011 The upcoming edition of IMTEX will also host Tooltech 2011 as a concurrent fair. It is India’s premier exhibition showcasing the latest

trends in cutting tools and tooling industry from across the country as well as from various corners of the globe. The event will showcase the lastest range of cutting tools, tooling technologies, production aids, machine tool accessories, metrology as well as Computer Aided Design (CAD) & Computer Aided Manufacturing (CAM) equipment and software.

Exhibition and much moreApart from the exhibition, IMTEX 2011 and Tooltech 2011 are designed to include a new array of technologies in various product segments.

Considering the huge overseas participation – first time in any IMTEX fair with eight country-group participation – the event will open endless opportunities for the machine tool industry over seven days of the show. Technical & technology-specific seminars and workshops have been scheduled for the participating companies to highlight & connect with visitors, forge strategic alliances, enter into new partnerships, as well as provide a unique platform to exchange technology know-how and develop vendor base.

OrganisersConstituted more than 60 years ago for promotional support, Indian Machine Tool Manufacturers’ Association (IMTMA) represents the entire machine tool industry in India. It has a membership of 450 companies from public and private sectors, which are into manufacturing a wide range of metal cutting and metal forming machines, accessories, cutting tools and other ancillary equipment.

The Association has over the years transformed itself to focus on issues of productivity, quality, technology, new product development, design, customer satisfaction, etc for enhancing competitiveness of the industry in domestic and overseas markets. IMTMA plays a key role in the

growth & development of this industry, and it is the reference point for the industry.

Reflections of the pastIMTEX 2009 was 14th in the series and showcased an exhaustive range of innovations & technological refinements in the product segment of metal cutting machine tools. In its 11th edition, Tooltech 2009 featured new trends in cutting tools and tooling systems from across the globe. Both exhibitions featured participation of 940 companies from India and 24 overseas countries.

Almost half of the total participation comprised overseas companies. The response was equally spectacular. Not withstanding the industry slowdown, the exhibition was host to around 80,000 business visitors from across the Indian manufacturing industry. Key highlights of B2B turnouts were high-level delegations from user industries, group visits by manufacturing conglomerates and several Indian & international business delegations. Interaction with business visitors led to a virtual sell-out of all machines displayed at the exhibition and further generated for exhibitors business enquiries to the tune of ` 50,000 million.

Future unlimitedAsia, and India in particular, have become a hot spot for the global machine tool industry. As Indian companies acquire, partner and collaborate with foreign counterparts the future of the Indian machine tool industry will surely be more globalised in its business.

The much-awaited event with new features, more international participation and exciting live demonstration of machining power, will set the trend in the next technology leap in the Indian machine tool industry.

Come, see and experience machining technology at its best!

Key attractions at IMTEX 2011

� Participation of over 800 exhibitors

� Display of new array of technologies in various product segments

� Large overseas participation – first time in any IMTEX fair

� Eight country-group participation – highest at any IMTEX fair

� Exhibition space of nearly 45,000 sq m

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Industry Voice


In this section mavens from the metalworking industry air their views for the future

and express their enthusiasm for one of the biggest events of the Indian manufacturing

industry - IMTEX 2011 & Tooltech 2011.

Industry Voice


India: An ideal machine tool destination…For many, India is the preferred machine tool outsourcing destination because of its low cost. Yet, it is not only the cost factor that continues to make India an attractive outsourcing destination. The quality of manpower combined with an extremely sophisticated vendor base and improvements in local infrastructure have placed the country ahead of other destinations.

The engineering sector in India has been growing on the back of user industries and several new projects being undertaken in various core areas such as railways, power, infrastructure, etc. Capacity creation in sectors such as infrastructure, oil & gas, power, mining, automobiles, auto components, steel, refinery, consumer durables, etc are driving the growth of the engineering industry. The government’s thrust on the power and construction industries is also a key factor.

Growth in the industry…Advancement in technologies has resulted in major changes within the machine tool industry. The computerisation of the industry is leading to rapid improvements in the existing machine tool product

lines and development of new products. Machine tool producers are introducing new ranges with vastly expanded capabilities and significant improvement in precision.

The shortage and relatively high cost of skilled labour are driving the demand for machine tools with greater flexibility that is programmable to replace or reduce the need for more sophisticated operators. The increased competitiveness of major consuming industries such as automotive and job shop is driving the demand for more sophisticated machines. End-users are investing in machine tools that offer increased performance, flexibility and productivity.

Challenges ahead…India has become a growth destination for several global companies. Organisations are becoming increasingly competitive in efficiency & flexibility of their supply chains and not merely on their product features & quality. They have realised that being technology-driven and updated are the keys to compete in the global market.

Currently, manufacturing as a sector in India is warming up to this idea of technology, but the adoption is slow in comparison to its counterparts in developed economies. Lack of

awareness of global technologies has also contributed to this low adoption. There are few areas where the government and the industry need to put in efforts through a well-designed public-private partnership mode.

The manufacturing sector needs to access the vast market possibilities available at the bottom of the income pyramid in the country - the first essentiality for ensuring manufacturing competitiveness is macroeconomic stability. Domestic indirect taxes are often singled out as a major reason why Indian manufacturing is uncompetitive.

IMTEX as a platform…As one of the best exhibitions, it acts as a perfect platform for exhibitors to expand their customer database, in sharing product knowledge and promoting new products for the entire spectrum of industries. Similarly, for the visitors, it is a platform to witness new technologies and trends in the machine tool and allied industries. It enables visitors to keep up-to-date with the industry.

IMTEX has always provided a platform to reach out to potential clients in India, inform them about achievements, brief them of the technologies, and understand specific market needs & requirements.

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Colin Price, Country Head

Renishaw Metrology Systems Pvt Ltd

Government and industry need to form a well-designed public-private partnership mode

Industry Voice


India as a market…Several machine tool manufacturers are looking at India as a potential market for expanding their business. There is a demand for machine tools in India, which foreign companies want to exploit. Currently, global companies are not interested in setting up their manufacturing base in India; instead most of them are utilising the country as their demonstration centres. These companies entering the market are either supplying high-technology machines or low- technology equipment at cheap prices. No country is self-sufficient in machine tools, so there is a need to import machines. Therefore, for any country across the world, there is always going to be a certain quantity of imports.

Challenges…A major challenge for the machine tool industry is to increase its output and keep pace with the increasing demand. After the economic slowdown, a sudden demand for machines has been witnessed. Training and recruitment of highly skilled people remains to be the second major challenge for the industry. While we have to create jobs, there is also a situation where we face lack

of manpower, highly skilled workers, and skilled workforce in design & development of new machines. The third challenge is how to increase productivity, which is much needed as the demand is on a constant rise. There is a need to either develop on our own or buy companies who possess this capability.

Investment…Machine tools is considered as a ‘mother industry’. As long as the manufacturing industry continues to grow, the need for machine tools will exist. Demand for machine tools is rising in the transportation sector, which includes railways and two/four-wheelers.

Also, with the growth of the aerospace sector, the need to have a strong machine tool manufacturing base in India has become important. Germany and Japan are two big machine tool builders in the world, and lately China is gaining strength as well. We are investing in design & development of new products, and are bringing in new types of machine tools. We already have acquisitions in Canada and are in the process of synergising with the company on how to build machines.

IMTEX 2011…At IMTEX, Indian companies will have an opportunity to show what they have accomplished in terms of development. Indian manufacturers will showcase new products, which can be proof of how they are trying to fill the technology gap existing between the markets in India and the West.

We will be presenting a new range of products at the event, with an aim to widen our customer base.

Growth ahead…Nowdays, new avenues have come up for machine tool builders such as aerospace, medical and nuclear sectors. In the coming years, more special applications or requirements will arise from for the above sectors.

Currently, the industry is growing at 50 per cent per annum, so we expect that this tempo will continue. As long as the GDP continues to grow steadily, the manufacturing sector will grow, and therefore the demand for machine tools will also grow substantially. So, we are positive about seeing good times ahead.

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Nirmal Bhogilal, CMD

Batliboi Ltd

Training and recruitment of highly skilled people remains a major challenge for the industry

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Indian industry on a high…The industry in India is scaling new heights every year, emerging from the economic slowdown and rebounding to an impressive annual growth rate of 9 per cent. The overall growth in the industrial sector is exciting with recent Index of Industrial Production (IIP) reports showing return of double-digit growth rates and more specifically leading to growth in automobile & ancillary industries. This has turned out to be a boon for machine tool manufacturers and allied industries.

Local manufacturers are improving capabilities every day to compete on a world-scale and are offering products & services to meet demands from top global automotive & engineering OEMs. The Indian industry is now next to none in terms of quality & systems. Also, availability of skilled human resource in the right age band is proving to be a great advantage for the Indian metalworking industry.

Global and domestic challenges…Indian operative conditions offer unique challenges to the metal working industry driving the need for customisation. In addition, there is an ever-increasing demand on global and local manufacturers to improve precision, energy efficiency,

cost-effectiveness and environmental compliance. These are common to machinery employed and component under process. The synergy effect of these factors is resulting in the usage of more complex technologies and metallurgy. This demands that the metalworking fluid manufacturers need to beequipped not only with fluid technology but also an impeccable technical service to provide solutions on sight.

With the continuous improvement in cutting tools technology to meet the demand from the manufacturers for high feed, speed and improved productivity, the cutting coolant suppliers are now required to be on their toes constantly. The global competition is driving local manufacturers to always improve quality of output and cost of production. This has also made the domestic metal processors conscious about concepts like total cost of operation beyond raw materials and running costs.

Growth drivers…Energy efficiency has become a key success factor due to scarcity and increasing cost of energy & other utilities. The traditional formulae used in calculation of cost efficiency have become redundant. New regulations

such as REACH have put onus on the manufacturer for environmental compliance.

The domestic manufacturers are investing in understanding andcomplying with such regulations to sustain competition and meet global demand. The fluid suppliers are constantlybeing asked to help in understanding finer points of such regulations and provide compliant fluid designs.

IMTEX as an ideal platform…With such a fast-changing industry environment, interactions between industry, government institutions, opinion leaders and technocrats/researchers are becoming critical. IMTEX 2011 provides an ideal platform for such a vast canvas of stakeholders to come together and discuss issues. The intense discussions and large-scale knowledge sharing enables manufacturers to learn about new technologies, concepts and equip themselves to compete globally, and adds great value to the Indian economy.

Participation by global corporates and presence of large country pavilions, especially from the Asian region, makes IMTEX an international exhibition.

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H A Anand, President

Sah Petroleums Ltd

The domestic manufacturers are investing in understanding regulations to sustain competition

Industry Voice


Robotics: The preferred choice for machining…Today’s competitive environment demands high productivity, high quality & high process capability, and needs traceability throughout the production. Manual operations and intervention for loading & unloading of machines reduce throughput, and in the process, can affect process capability through human errors, leading to quality concerns. Also, the usage of single-piece flow utilising robotics results in cost benefits and utilisation of space.

Further, it can tackle auxiliary operations like measurement of parts, correction of tool offsets, part cleaning between processes, deburring & identification marking for traceability, quality check and data capture for MES & MIS, as these are today left to human skills and diligence, resulting in further manufacturing performance degradation.

To achieve the performance expectation, modern machining shops are utilising robots for not only loading and unloading, but also as a turnkey automated system covering all auxiliary processes in the production of machined parts.

Features and functions of robotic technology…We have focussed on integration of line solutions involving complete machining and auxiliary processes in an integrated automated solution. This involves high-performance gantry robots to free up floor space, special conveyors for storage and transport of buffered parts, auxiliary stations for gauging, cleaning, deburring, marking, etc, integrating robotic stations for special machines & processes, upstream software integration for MES & SCADA solutions, which can finally make us a one-stop shop for machining automation.

User segment…Any machining shop that produces high-quality products in significant volumes, needs to drive the performance benchmarks to international levels. In the case of automotive industry, it is now a de facto standard for manufacturing most engine & transmission parts. Sectors like auto ancillaries and engineering components are progressively adopting integrated automation.

Machining on multiple-axis…Automation systems are inherently multi-axis to enable movements required for operations. This not only provides operating efficiency, but also flexibility in reprogramming in case of change of production and part numbers. Using multi-axis programmed manipulations, line set up to run ‘Batch of One’ (single part for each part number), enables just-in-time setups, where manufacturing can be done on the basis of sales orders required to be processed, thereby avoiding inventories.

IMTEX 2011…Today, the manufacturing industry must achieve high productivity of cost & throughput, quality, flexibility and dependability. These requirements are making automated machining the need of the hour. IMTEX provides a central platform for buyers & sellers to meet and share their needs & solutions. It also serves in educating the thinkers and planners to scan available technologies to make their future decisions.

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Dr Ranjit Date, President

Precision Automation & Robotics India

Machining shops need to drive the performance benchmarks to international levels

Industry Voice


India: An ideal destination…India’s economy is growing at around 9-10 per cent. This upbeat growth trend is one of the key factors that has made the country the preferred choice for the engineering industry. Moreover, in pace with the trend, it is becoming an automobile manufacturing hub for several big names from across the world. Growth in aerospace component manufacturing, nuclear power generation equipment, among others makes the country an ideal destination for machine tools.

Latest trends in work-holding tools…According to a latest research, the machine tool market worldwide is around $ 70 billion.And, we expect the work-holding solutions to be around $ 4-5 billion. Moreover, as CNC machines involve high investment, the end-users today are more eager to utilise innovative value-adding solutions to achieve the maximum output of men and machines.

The global trend is to move away from expensive, dedicated and highly customised transfer lines and opt for CNC machines, which can adapt to

flexible work-holding solutions that are quickly changeable, practical and repeatable to meet the needs of applications. Simple but rugged quick-change ball lock systems ensure fixture changeovers in less than a minute. It also locates and clamps fixture plates to sub-plates in one single action.

Application areas…Our products are designed for the growing user segment of VMCs and HMCs to cater to their unique work-holding needs. Five-axis work-holding is designed for multi-face machining with a single clamping operation. It is ideal for machining complicated workpiece in a single clamping operation such as in-mould making. These vises are small but have a large holding capacity. In addition, a variety of jaws increase the range of applications.

The benefits of the new products include consistent quality, dimensional stability, and ensuring high productivity of costly machine tools. Work-holding technology such as our 5-axes compact vises complements the latest advances in new machining technology and manufacturing methods.

Challenges ahead for the manufacturing industry…For the manufacturing industry in India, the challenges are many and universal. To enumerate a few, these include attaining shorter lead times, ensuring less inventory, deskilling of fixture changeover operations, and flexible scheduling of job work, among others. Overcoming these hurdles is possible with the usage of new and better work-holding solutions.

Role of exhibitions like IMTEX…IMTEX is a mega event that offers many opportunities for the Indian machine tool industry. Over the years, it has evolved as a huge trade exhibition that brings the users & providers of the machine tool industry to interact, partner and grow as a robust entity. Active participation at the event is one among the many ways by which the machine tool companies can leverage the event to enhance their business & knowledge base.

It is an ideal platform where the industry can utilise innovative ways to mark its participation as the exhibition draws a large number of engineers, managers & decision-makers.

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Joseph Kilukan, Managing Director

Jergens India Pvt Ltd

Global trend is to opt for CNC machines that can adapt to flexible work-holding solutions

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Industry Voice


India as a machine tool destination…With India’s strong and growing domestic consumption as well as its capability to manufacture world-class products at low cost, it is undoubtedly the most preferred destination for all industrial sectors. Also, the young talent in India, combined with its approach with frugal engineering, is aiding the cause.

With this growth, the machine tool industry is bound to witness a boom in India, so it is no surprise that majority of the machine tool companies are in talks to enter India through a direct subsidiary or own a manufacturing set up.

Importance of exhibitions…Exhibitions like IMTEX give the best opportunity for people who make and seek various technologies to come together and share their views. This is important for both the parties – customers as well as exhibitors. These exhibitions are emerging as important platforms for creating an overall awareness in the market.

With major participants arriving from across the globe, this is one of the best destinations for all B2B & B2C business transactions. IMTEX is attended by

buyers, users and decision-making people – from across India and Asia, so the coverage, visibility & access to the latest developments in the segment is welcoming at IMTEX.

IMTEX 2011…We have changed our entire approach towards IMTEX, from only showcasing products to being a solution provider. We will be displaying a wide range of products with a special focus on our high-technological range of solutions.

In this edition, we will be showcasing our unique and world-renowned products like NC boring & facing heads, angular heads, high-precision tool presetters, rapid prototyping machines, high-performance cutting tools (specifically targeted for aerospace & power generation segments etc.

We will also be showcasing a wide range of our products, along with products from our recent foray into EDM wire manufacturing. We will be holding seminars on aerospace machining, NC toolings and rapid prototyping solutions.

The decade to come…The industry in India is bound to show an upward trend in the coming decade.

We expect to see a huge movement in the aerospace, power generation and infrastructure segments. This may be witnessed in both the civil as well as defence segments. The auto industry, as always, will have fluctuating trends in the global scenario, but the increase in spending power of the huge Indian middle-class will certainly help the country’s auto industry in seeing positive trends in the near future. Global and domestic demand scenario will play a major role in boosting the growth of the industry. Also, we cannot ignore the importance of government policies pertaining to the industry.

Challenges ahead… The manufacturing industry in India has seen its worse year in 2008-09. The main challenge is to make the right products at the lowest possible cost and on appropriate time schedules.

Manpower, infrastructure, operating costs, technology costs, etc are adding up to the pressure on the ultimate product cost. As India is perceived to have a frugal approach towards manufacturing, we need to keep the growth pace intact, and at the same time, improve overall efficiency.

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Nickunj Shah, CMD

Nickunj Group

India is undoubtedly the most preferred destination for all industrial sectors

Industry Voice


IMTEX 2011…IMTEX is without a doubt, one of the biggest machine tool exhibitions, and customers from all over the world would be present.

India is the fastest growing economy and its GDP rate is also high. So, the scope for the event also is huge. There are plenty of buyers, and demand in the country has always exceeded supply.

Further, the future of the Asian machine tool industry is bright, with growing potential of manufacturers and buyers.

Challenges ahead…The biggest challenge is infrastructure development. Among the many roadblocks, the key area of concern for the industry remains power, roads and water. These are some of the fundamental facilities that need to be supplied throughout the industry to ensure maximum productivity from manufacturing. In addition, with changing trade environment, the tax system should be given a relook. In the case of the coolant industry, the first and foremost challenge faced in India is the ever-increasing raw material prices,

especially crude oil. Raw material prices are increasing by the day, making it difficult for companies to manufacture and sell coolants & related products at competitive prices.

Ways in which the industry can leverage this event…Communication has become an important tool in building awareness in the market about the latest products and their unique features. And, trade events such as IMTEX are an ideal place to update oneself on the latest developments in the machine tool industry, under one roof.

Latest trends in metal cutting fluids…The rise in demand has pushed the metalworking industry to find innovative ways to increase its production. By raising the lubricity level of metalworking fluids, one can increase the production, and simultaneously save the cost of cutting tools. Increasing the sump life means reduction in downtime of a machine, thereby, achieving more productivity. New broad-spectrum biocides and fungicides

have lately entered the market, which when added to the baths can prolong the life of metalworking fluids.

Benefits and expectations from IMTEX…The platform offered by IMTEX is huge. To enhance the base for business and knowledge, one needs to meet & communicate with more people. This exhibition provides manufacturers, dealers and consumers a chance to interact with each other, share ideas and issues, if any. This way, manufacturers can work on the issues specified by a visitor. The visitor, in turn can seek the solution for the hurdle faced by him. The whole exercise is good for the industry, as it not only enhances the knowledge of the people involved, but also increases business prospects.

We expect to meet more potential buyers in India and across the world. The event is definitely a platform to gain popularity. As the number of visitors would be high, the chance of achieving good business is more as well.

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Pratap Marathe, Managing Director

Pratap Tex-Chem Pvt Ltd

For the coolant industry, the challenge is increasing prices of raw material

Industry Voice


India: A machine tool destination…We are lucky to be around at a time when the world seems to be looking at India as an attractive machine tool market. The sheer demand of domestic infrastructure alone is a key driver to some of the opportunities available to the global machine tool industry. Also, the presence of a mature engineering community in India has largely contributed in making the country a popular destination. The aspiration of a large percentage of the population to pursue engineering or technical careers is a huge resource as well.

Some of the recent Government policies like the Automotive Mission Plan (AMP) and the Micro, Small and Medium Enterprises Development Act (MSMED) have set a tone for the development of the domestic manufacturing industries resulting in some of the momentum we see in the market today. These two separate policies had a dominant effect in developing competent enterprises right through the supply chain of which the machine tool industry is an integral part.

India in the next decade…Today, no one questions if anything can be done in India anymore. Substantial growth is a matter of government policy and funding. Growth is also a matter of implementing scale, and adequate funding is required to achieve the same. Growth of the industry is assured, provided that government policies are favourable. There seems to be a plan in place till 2016 with the AMP and the subsequent snowball effect it will have on the supply chain. Still, if we are to be competitive against countries like China, our government has to streamline taxation and bureaucracy.

The huge inflow in capital markets is proof that the world believes in the Indian story, although cost continues to be high for manufacturing industries. Our bankers need to be more involved in the manufacturing industry, and while progress has been made with several SME policies, much more can be done.

Trends and demands…The significant trends are in scales of operation and localisation. Several years ago, it was rare to see turnkey projects being implemented or discussed as possibilities. Today, several companies

have examples of complicated installations being implemented to meet very complex requirements.

Today, Indian manufacturers are developing high-quality products for the global market, seeking efficient solutions on a fast note. It is not enough to simply transplant a solution from Europe, the US or the Far East, but it is necessary to adapt the same to the local conditions. This has called for increased investments in localisation of technology, spares and service, which can create its own momentum as demand increases.

Leveraging IMTEX…Several machine tool companies will benefit from the publicity that IMTEX generates, and the exposure it provides in showcasing products. Every year, there seems to be new companies exploring the possibilities of India as a manufacturing base.

IMTEX is the ideal place for key personnel to meet suppliers and get a feel of what is available in the industry. It lends credibility to some extent but this is not always the case. It is the main event organised by the official industry body, Indian Machine Tool Manufacturers’ Association, and it pays to be a part of it.

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Nikhil Nayak, Managing Director

Combined Engineering Agencies Pvt Ltd

Growth of the industry is assured,provided that government policies are favourable

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Industry Voice


Current trends and demands… The latest trend in the machine tool industry is to offer high-productive & multi-functionality production centres, which can complete machining of components in a single production centre and also have provision for automation.

The purpose is to offer machines, which are consistent in quality, productivity and flexibility. The Indian machine tool industry has a huge demand from auto component companies and specialised industries like aircraft/aerospace, wind energy, power equipment & off-road equipment.

While catering to the aircraft/aerospace industry, these machines have to provide high accuracy and productivity. At the same time, the size of the machines also matters while catering to the wind energy segments.

Future technologies for machining centres…In the near future, the machining centres will witness a lot of development on the technology front. The top three technologies to look out for are mono-block design, multi-spindle technology, high-performance spindles and guide-way systems.

New application gaining prominence in VMC/HMC…Any design that imparts productivity, quality, and reduce cost of production will gain prominence. Most of the HMCs/VMCs in the market world-over come with features like multi-spindle machining, pallet system, fast tool changing systems, high rapids, etc.

Technological gaps…The Indian market does have a technology gap in certain areas where high volumes are involved, where labour is utilised instead of fully automated lines. Machines produced by Indian machine tool makers also lack in the quality of technology compared to the machines produced elsewhere in the world. Collaborative efforts are necessary to bridge this gap.

An approach that allows a domestic company to access the latest technological developments existing across the world will help the industry in the long run. This will also support the growth of the industry in terms of exports.

IMTEX as a platform…The Indian Machine Tool Manufacturers’ Association, which

organises IMTEX, has done an excellent job over the years in bringing modern technologies available across the world into the Indian market through this event. IMTEX has provided an ideal platform for the manufacturing industry.

As a converging place for all, the event is a good base for the industry to forge strategic alliances, enter into new partnerships, exchange technology know-how and develop vendor bases. In the past, this exhibition has also proved be a breeding ground for entrepreneurs and innovations that have helped the industry. Many enthusiastic youngsters have learnt from the event and developed their own enterprises.

Leveraging the event to enhance business…IMTEX is an ideal place to attract new customers and renew acquaintance with the old ones. Through the years, a large number of customers who visited the event have been convinced of its importance, with the various machines/systems demonstrated, and other technological solutions. Also, interaction with industry leaders keeps one updated and geared up for the future.

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J Prasanna, Managing Director (Technology Centre)

EMAG India Pvt Ltd

Collaborative efforts are necessary to bridge the gapin technology

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Industry Voice


India: A partner for growth…India has been counted as a strong business option by global players in the machine tool industry to partner with, as it provides a link for these companies to introduce their advanced technologies and latest machining solutions. Updated technologies provide the domestic machine tool market with an edge in their journey to face challenges of the growing global competitive market that the industry is exposed to. New opportunities for partnerships and collaborations await the Indian machine tool industry, especially after the dynamic & challenging market scenario, since early 2010.

Upcoming applications…With an experience to sustain over 50 years of fruitful partnerships with machine tool technology leaders from Europe, Japan and the US, we have always tried to introduce product ranges that represent the most well-known global market leaders providing cutting-edge technology to the manufacturing industry.

The emerging sectors for the industry include automotive component machining, gear cutting & grinding, bearing manufacturing,

aerospace part manufacture and high-precision tool room applications. Indian machine tool manufacturers have also developed to a level from where they can compete with and address a large section of manufacturing needs using controls and components of acceptable quality. This has brought in challenges for the technology leaders to be cost-effective to suit industry needs.

Choice for companies across the globe…The quest for development and acquiring the capability of the most advanced nations have been the driving factors for Indian manufacturing industry and entrepreneurs, using the best machines with domestic creativity & skills to churn out a blend of quality products at low costs compared to the developed world.

Indian engineers and technicians have a unique combination of skills & hands-on ability to conceptualise and put into practice home-grown solutions utilising advanced technologies, which has seen a constant demand for high-performance machine tools. It is this appreciation of technology and Indian engineering capability that has made

the country a preferred destination for the global machine tool leaders to successfully deploy new technologies.

IMTEX 2011…At the event, we will be showcasing a 5-axis machining centre that comes with powerful built-in motors and rigid construction to achieve jig boring class accuracies and finish. The Fehlmann 5-axis machine is a reference standard for the highest class of machines required in defence, aircraft and aerospace tool rooms where the mother machine itself is sometimes more relied on accuracy than the measuring machine.

German engineering & technology is represented by Kapp-Niles gear grinding for aerospace, high-end automotive, power & infrastructure industry and Supfina high-performance, super finishing technology for automotive and bearing industry. Domestic component suppliers and original equipment manufacturers now have a better choice with high-performance products at competitive prices compared to offerings from domestic and the established overseas sources.

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Philip Mascarenhas, MD

Chrystec Machine Tools Pvt Ltd

Engineering capability in India has made it a preferred destination

Industry Voice


India: A favoured choice...India is fast emerging as a global manufacturing hub with a large number of automotive, electronic and other companies shifting their manufacturing base to the country. The key factors that add to India’s popularity as a manufacturing destination include frugal engineering and price competitiveness. Global OEMs can use these to cater to the growing domestic demand as well as international markets.

In addition, well-established and constantly innovating supply chains can be leveraged for sourcing of raw materials and other components. The strong push by the government via various existing policies and new ones in the offing are conducive to setting up of large manufacturing hubs in India. With an aim to increase contribution from the manufacturing sector to the country’s GDP, opportunities are abound, so the OEMs should utilise the same.

Developments in the manufacturing sector…While various trends are driving the development of controllers towards giving the user a more productive asset, the universal need of any manufacturing set up cannot be refuted, and that is focussing towards bringing down the ‘cost of ownership’ of assets.

Today, customer expectation is increasingly focussed on transparency around the machine. We mean monitoring of the entire production process chain. Integration of the machines into the IT production environment is a key requirement to achieve maximum productivity. The pioneering example of this is the MotionControl Information System (MCIS).

Need for the industry…India is a big consumer of machine tools. However, when it comes to production of machine tools, the country is ranked far behind at the 18th position. The huge gap between consumption and production indicates that we have a long way to go. This also translates into a huge growth opportunity for the Indian machine tool industry, provided that we focus on the right objectives. Strong R&D and innovation is the need of the hour to keep pace with dynamic requirements of a growing market. While continuing the pace of catering to the standard segment, we also need to diversify into advanced, high-end segments, which are being largely catered to by imported machines.

Of course, the focus of this segment has to be on improving flexibility, efficiency, reliability and durability of

the equipment. A possible avenue can also be a close co-operation with academia to come out with innovations to foster new technological trends. The machine builders should also focus on creating competitive advantage based on value creation over the complete life cycle of their machines.

The coming decade…In a developing economy like India, the capital goods manufacturing segment always shows a sustained growth. With urbanisation and the burgeoning middle-class, India’s demand for everything from power to cars to consumer goods, will continue to multiply rapidly.

IMTEX: Aiding the industry…IMTEX is the right avenue for machine tool users, builders, as well as the entire chain of suppliers to interact and showcase various trendsetting technologies. These interactions, coupled with various seminars and expert-speak, assist in knowledge sharing on important parameters such as innovation in productivity, energy efficiency and the likes. Such events are a platform to bring out strengths of the Indian machine tool industry, and at the same time, set the tone for the future.

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Satish Godbole, Business Head – Motion Control

Siemens Ltd

Strong R&D and innovation is the need of the hour

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Trends in tooling systems…The current trend in tooling system is in providing solutions to manufacturing industries. This can be for any sector – automobile, aerospace, defence, medical or general-purpose engineering. The machine tool industry creates awareness for cost-effective solutions by recommending the right tools, thus bringing down the cost per component. There is much focus on end-to-end solutions rather than just providing a specific solution.

When it comes to productivity improvement, faster production or providing tooling solution to the manufacturers, design plays an important role. The industry is moving towards creating ideas and concepts utilising software, and later developing the products. By using CAD/CAM solutions, companies have improved designs, especially for customised solutions/special tooling, which is different than that of the set standards.

Whether it is the business outlook for tooling or customised solution, some important points that need to be considered are: volume of production, common tooling for different models, simplicity of design, quality aspect of tools and faster development of customised tools.

Technology update…India has a large young population and has more than 3,000 engineering colleges, churning out thousands of young engineers every year. This makes the country a more attractive destination, coupled with stable political and economic situation. Further, India is a growing economy and creates substantial domestic consumers.

The growth will continue in the next five years, and demand is expected throughout. All state governments in India offer various subsidy and ready infrastructure like Special Economic Zones (SEZs) to start the industries, which attract the corporate to set up manufacturing plants in India. Considering the growth in infrastructure and logistics, most of the multinationals are setting up their manufacturing hub in India to cater to the world market.

The English language, being widely taught in the Indian curriculum, also enables multi-national companies to invest in key sectors like aerospace, defence and automotive, which has created huge potential for the supporting units. The advent of MNCs is helping in the growth of the industry in terms of access to technological know-how and research

& development opportunities. The industry is also utilising new materials for manufacturing products, which is seeing the development of technology to work with them.

We are exhibiting our newly developed special end-mills and drills like: viper – the variable helix endmills; super viper – double variable helix endmills; krait – high-feed endmills; aluma endmills, dies & moulds endmills; blackmamba – the coolant-fed drills, burrs & inserts, in addition to PCD & CBN tools to cater to industries like aerospace, automotive, dies & moulds and medical & general engineering. The challenges ahead are related to capacity and the need to adapt to the advanced technology in tool design.

IMTEX advantage…IMTEX is the biggest event for machine tool and cutting tool manufacturers. This is a place where one can showcase products and spread brand awareness. This exhibition is being visited by most of our customers from all over India and abroad.

For cutting tool manufacturers, this may not be a platform to book big orders, but for the machine tool industry, this is the place where big business can be achieved.

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Shivaji Salagode, COO

Cobra Carbide

Multi-nationals are setting up their manufacturing hub in India to cater to the world market

Industry Voice


Manufacturing - post the economic downturn…The global market for manufacturing has witnessed significant turnaround after the slowdown, especially in the automotive sector. China, India, Japan and Korea are rapidly emerging as key markets for the global automotive industry.

India has emerged as a major production hub for global auto companies. The cost advantage, coupled with high-engineering skills, has made India a preferable choice for automotive and component manufacturing.

Progressive policies…The current government policies are good. Since the government is focussing on the emergence of ‘green technologies, this will be one of the strongest forces over the next two decades, offering challenges and opportunities in green and new technologies for Indian manufacturing. We also believe that a strong manufacturing sector is an essential component of the Indian economy.

The Indian customs tariff rates have been brought down. India’s vast domestic market and availability of low-cost workers with advanced

technical skills has been instrumental in attracting an ever-expanding number of multinationals who are setting up their manufacturing base in the country.

Future belongs to young India…Young demographic profile, coupled with the unshackling of Indian economy, is having a tremendous effect on the Indian economic outlook.

Today, India is perceived as the most favourable investment destination. The global economic growth is becoming more dependent on Asia’s growth, in which India is playing an increasingly important role. While the sector has undergone a period of change, the resulting structural adjustment has ensured the sector’s continued relevance as a contributor to the country’s GDP.

To compete internationally, the Indian manufacturing sector now has the strategic vision. A strong manufacturing sector warrants a superior level of operational freedom and integrated programmes between industries and the government.

Promising outlook…The next decade will witness the emergence of a phase in business

value chain that is completely knowledge-driven and is sustained by rapid innovation & quick delivery of new or improved solutions to markets. Therefore, the creation, protection, effective exploitation and leveraging of existing and new knowledge in the marketplace will differentiate the winners from the others. Also, engineering expertise on design, CAD, documentation, testing and evaluation is needed.

Further, the pool of skilled workforce specialising in assembly, design and software development should be broadened, as well as efforts to further strengthen its design and innovative skills is needed.

IMTEX: Array of opportunities…The leading machine tool show in India will showcase an exhaustive range of innovations and technologies in the complete product segment of metal cutting machine tools.

As a business-oriented exhibition, IMTEX signifies a world of opportunities as well as exponential growth & development for all its participants and the manufacturing sector as a whole.

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Techtronics (India) Ltd

A strong manufacturing sector is an essential component of the Indian economy

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Industry Voice


Demand trends...Today, the machine tool sector in India is facing a unique scenario. An unexpected surge in demand of products, especially from auto, power and infrastructure industries, has resulted in many manufacturers looking outward for supply of machine tools as the industry in India is unable to cope with the demand.

The investment in machine tool industry is static, barring a few new investors. The existing manufacturers cannot suddenly increase production capacity in such a short period. Hence, the situation is critical unless Indian machine tool manufacturers change the mindset to become a part of this growth by introducing out-of-the-box strategies.

Need of the hour...An uncertain global economic environment with no clear directional trend regarding the financial stability has led to fluctuating currency, resulting in variable returns to the service industry. Thus, the recent economic slowdown across the globe has paved the way for companies to target the top-level technology products either in India or abroad

to stay afloat in this fast-changing scenario. Development of advanced products at economically viable investments is the need of the hour for the machine tool industry in India.

Impact of slowdown...Despite the fact that the industrial production never actually fell during the period, it still managed a double-digit growth in the first half of 2010. Investment by key industries is also expected to recover strongly after registering negligible growth in 2009.

For the year as a whole, investment is forecast to rise by 12.25 per cent, with the machinery and automotive industries growing by 20 per cent. The machine tool consumption, as a whole, is predicted to rise by 15 per cent this year, after a steep 34 per cent drop in 2009.

Forecast for the industry...Activities in key customer industries is expected to grow at a robust pace over the next two years, in the background of a growing domestic and export market. As a result, investment is projected to accelerate by 14.50 per cent in 2011, and 16 per cent

in 2012, boosted by the upturn in the investment cycle and the opening up of new capacities. The machine tool consumption is anticipated to grow 25.75 per cent in 2011, and 30.50 per cent in 2012, with a strong double-digit growth also expected over the rest of the period.

Currently, the manufacturing output is still a relatively small part of the Indian economy. We continue to expect rapid growth in machine tool sales over the next few years.

Challenges ahead...One of the main hurdles faced by the manufacturing industry in India is in delivering products with innovative designs on time and in small batches, and more importantly, at reduced costs, to remain competitive in the global market. This has put pressure on the manufacturers to utilise the latest technologies, Lean manufacturing processes and enhance quality as per the market demand.

Machine tool manufacturers face the uphill task of raising the technology level to top-class, to deliver quality, performance, reliability, and backup service at the doorsteps of end-users.

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S V Joshi, Director

Danobat Group Machine Tools India Pvt Ltd

Development of advanced products at economically viable investments is the need of the hour

Industry Voice


India: An ideal machine tool destination… The country has emerged as the preferred destination for manufacturing. The machine tool industry has also matured and is poised to offer quality machines at affordable prices.

Leveraging IMTEX…The current boom in the Indian manufacturing sector has created huge demand for various machines. IMTEX is the biggest platform for the machine tool companies to showcase their products and interact directly with prospective clients. Also, they are exposed to various domestic as well as international vendors who are into selling of machine tools and components.

Expectations from current edition…Precihole is already an established machine tool company, but at this IMTEX, we are planning to promote it as a reputed and preferred brand in the field of deep hole drilling technology. Our aim is to showcase deep hole drilling as a highly productive, cost-effective and reliable process of producing high-quality drill holes.

Machines/technologies at the event…We will be displaying our new series of micro gun drilling machines, various state-of-the-art deep hole processes like skiving and burnishing, twin bore barrel machining, bottle boring, draw boring, small hole honing, deep bore key way machining, deep boring with tuned boring bar, etc.

Challenges ahead for the manufacturing industry… There are many challenges ahead for the manufacturing industry. The crucial one is to find skilled & even unskilled manpower, while retaining qualified and experienced engineers. The soaring price of raw materials is another challenge. The industry needs to look at cheaper alternatives or ways to reduce cost. Lack of proper infrastructure, ie, shortage of power, lack of good roads, etc, increasing cost of finance, and exorbitant land prices pose additional challenges.

Growth and expansion plans…In the current global environment, the market is dynamic and consumers are more demanding. We are competing with the global players, and we need to offer more innovative product & solutions to our customers. Looking

at the rising demand for large hole drilling machine in sectors like heavy engineering, oil field and nuclear power, in domestic as well as international market, we have already started building a new facility for manufacturing of large deep hole drilling machines. These are capable of drilling up to 200 m diameter and length up to 15 m, along with tube sheet drilling machines and skiving & burnishing machines.

Future of the Asian machine tool industry...Currently, India and China are the countries with huge growth potential followed by Taiwan, Singapore, etc. Both countries have become hub for global manufacturing.

There are many factors, which clearly indicate that the coming decade will be good for the machine tool industry. There is a continuous growth in local consumption because of the burgeoning Indian middle-class. In fact, trade analysts have predicted that the Indian middle-class will prove to be beneficial for the automobile sector, as in the coming decade, they will form a huge consumer base for the small-car segment. There will also be huge investments in power and renewable energy sectors.

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Precihole Machine Tools Pvt Ltd

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Industry Voice


Growth of the manufacturing sector…Over a period of time, the manufacturing industry in India has gone through various phases of development. Currently, it is on par with the global competition. The journey to this position had started right through the early days of independence, ie, the first phase of building the industrial foundation in late 50s.

Later in the 70s, the second phase saw the manufacturing sector moving towards the license-permit Raj, and the next phase of liberalisation was the major step for India in the global market.

Overall, the Indian manufacturing sector has grown at a good rate, considering the global environment.

Government policies…For the policies framed for this industry, ie, the steps taken by National Manufacturing Competitiveness Council (NMCC), the question that comes under scanner is not the individual satisfaction because the

policies are again based on the global scenario.

Since 1991, the Indian economy is being progressively liberalised and its integration to the global economy is deepening. There is a need to benchmark the Indian manufacturing sector against the best in the world and enhance competitiveness of the manufacturing sector.

India: A favoured destination…As of today, India is a favourable destination for setting up of manufacturing units due to many reasons such as skilled and economical labour, development of IT/ITES sectors & many more. But, besides skilled manpower, the major factor that is drawing companies to India is the immense potential of the market and the burgeoning middle-class with its buying power.

Forecast for the next decade…By seeing the robust growth in the sector for the last 10 years, we may witness the economy grow threefold in the coming decade.

The growth in the future is expected, first due to the increasing domestic consumption, and second because of the acceptance of India as a manufacturer of reliable and quality products in the global marketplace. Other factors leading to the growth of the industry can be summed up as increasing focus on R&D and easy availability of raw materials & skilled manpower.

Importance of IMTEX for the industry…IMTEX is expected to witness a large international participation, and is one of the most beneficial exhibitions for medium & large-scale segments in the Indian market. It provides a path to interact with a spectrum of machine tool users and to display technologies & products to both - users as well as manufacturers.

For us, IMTEX helps us demonstrate our capabilities/products and understand the requirements of the market, so that we can provide the customer with better products and services.

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S S Tools India Pvt Ltd

There is a need to benchmark the Indian manufacturing sector against best in the world

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India as a machine tool destination…The biggest reason for anybody to consider India as a choice for machine tool destination is because of our engineering skills. For decades, we were at the receiving end of the talent exodus, but for the past few years, the case has reversed. Indian companies have now started developing new products as well. And, we are witnessing an increase in number of patents for new products in the machine tool industry from India.

We now also have instances when machine tool builders in India have acquired foreign companies, thereby bringing their technology to India. Our innovation, which got us through the ‘Jugaad Raj’, will be the driving force of our future.

The biggest challenge for the manufacturing industry is manpower. The government has made policies to secure the job of the workmen, but not the workmen themselves.

Government support for the industry…The government does not have any specific policy for the machine tool industry. Unlike Japan and Taiwan, the industry is a small contributor to our

economy, and hence the government has neglected the sector.

The government should have a special task force for the machine tool industry. One of the biggest hurdles faced by the industry today is lack of quality manpower. The government should also subsidise exhibitions for the machine tool industry, so that our products can have more exposure worldwide.

IMTEX: A platform for the machine tool industry…IMTEX is an important part of our marketing strategy.

IMTEX is a platform for companies to demonstrate their new developments and products. The companies participating should focus on showcasing their latest products. This is the time to make sure that new technologies are being developed and how one can complement them with new products.

Building a global brand…We are planning to expand our business, and modernise our existing two plants as well. The main additions will be CNC machines and lifting arrangement. We have entered

into arrangement with DOCMAGNET Inc, USA, for sales and distribution of our products in North America. We have tied up with Seyconel, Brazil, for sales and distribution of our lifting equipment range in that country.

We have strengthened our ties with Assfalg Gmbh for sales of our magnetic lifters in Germany and work-holding magnets across Europe. We have also signed an agreement on technology development with Lifton Magnets Intl Pte for the development and sales of our products in South & South East Asia, including China. We are now looking for partners for our product range in Africa.

IMTEX 2011…At the event, we are showcasing our new products and technologies. We would be demonstrating our work-holding magnets in a CNC machine, along with our latest patented products. We will also be showcasing the new range of magnetic lifters with live demonstrations on a crane. The focus will be on the new products, which we have designed over the past few years, and on a new range of elift & A4 range of battery-operated EPM lifters.

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Dhiruj Sarda, GM Marketing

East Coast Enterprises Ltd

We are witnessing an increase in number of patents in the Indian machine tool industry

Industry Voice


Current scenario in the machine tool industry…The machine tool sector is unanimously recognised as a strategic industry for the development and growth of a country. Machine tools are important and critical in the manufacturing sector for precision engineering. They can transform prime materials, metals and other components to obtain the required shapes. Processes like cutting, stamping, milling and drilling are utilised to create tools and dies required for the production of parts for the automobile or aerospace industry.

India: A global sourcing base…The machine tool industry in Asia will soon be equipped to cater to the global manufacturing industry, by delivering quality and maintaining the cost. After registering a quick bounce-back in the economy, the engineering industry in India has gained global recognition. The factors that promise to make the country emerge as a global sourcing base include the competitive cost in manufacturing. This has been a major advantage for Asia, especially India, in attracting the global machine tool industry.

IMTEX: A global platform…The leading trade exhibition is the largest, and dedicated to the machine tool industry in India. It plays a crucial role in bringing all machine tool companies together, which in turn helps the industries in sharing products and technologies. The capability to deliver short time-to-market cycles has become a need for many companies to gain a competitive edge. Even as companies strengthen and upgrade their production units, the availability of a good working environment for trained manpower has become a determinant for success.

With regular technology advancements, adaptability to new technology has proved successful for the industry. A major challenge lies in enabling factories with manufacturing automation & time-to-market.

Machines/technologies to be showcased…India plays a vital role in our product development and expansion strategy. It is a testing ground for our flagship product, CAMWorks. It addresses the need of today’s SME market by providing value-packed CAM solution,

which is easy to learn and easy to use. And, with the basic machining knowledge, a machinist can produce high-speed efficient tool paths within 1-2 weeks of training.

We will be showcasing Geometric’s flagship products and technologies. The main focus will be on our CAM product, CAMWorks, which comes with new additions like VoluMill for high-speed machining in reducing machining time.

IMTEX: Enhancing business & knowledge base…The mega trade show will help machine tool companies come together on a common platform where they can showcase their products and technologies & also learn the latest developments in the machine tool industry globally.

An exhibition like IMTEX provides the right platform for the industry. It plays a crucial role in bringing all machine tool companies together, which in turn helps the industries in sharing products & technologies. We surely expect that this edition will help in providing us a platform for our products to meet the end-users.

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Geometric Ltd

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Industry Voice


India as a manufacturing destination…India has a fast growing and robust economic environment. Also, there is a significant demand from rural and urban areas. Availability of abundant, cost-effective engineering talent makes India an ideal destination for manufacturing.

Today, Europe and the US markets are struggling to be back on the growth curve, while markets in India and China are the only vibrant ones. It is this reason that is attracting global manufacturers to focus their attention on these two countries.

While India holds tremendous potential as a manufacturing destination, we need to urgently address challenges in infrastructure, especially power & land; access to capital & technology; manpower skills and conducive long-term stable policy environment for the industry, to flourish and be globally competitive.

Trends and demands…From an auto component manufacturing perspective, in the year 2009-10, the turnover of the industry was $ 22 billion, and this year we are looking to grow by at least

20-25 per cent. In the last two years, the exports had stagnated to $ 3.8 billion, but in the current fiscal, we expect the exports to be around $ 4.75 billion as there is revival in the US and European markets, albeit a little slow in the latter.

The imports in auto components stood at $ 8.2 billion last year, which was a growth of around 20 per cent over 2008-09, and we except a similar growth in the current fiscal.

Capacity addition to meet the growing needs of the auto component industry will create a significant demand for the machine tool industry. The auto component industry alone needs to invest $ 33-38 billion over the next 10 years.

ACMA is working closely with IMTMA, which represents the machine tool industry, to address the challenges of rapid rise in demand for machine tools and equipment by ACMA members.

Technology gap…Spending on R&D for new technologies and products by companies in India is negligible, & many of these are imported. Ours has traditionally been a ‘build-to’ industry.

There is an urgent need to create an environment for technological development. We have requested the government to set up a fund for ‘technology upgradation and development’, which could be utilised for facilitating the industry to move up the value chain and stay competitive.

Industry growth in the coming decade…The auto component industry in India would reach around $ 60 billion by the year 2015. By 2020, it is estimated that the size of the industry would be around $ 110 billion. As the growth of Indian automobile and auto component sectors is increasing rapidly, it is both an opportunity and a challenge for the machine tool industry.

IMTEX as a platform…IMTEX is the showcase of prowess of the Indian machine tool industry, which provides an insight into the capabilities of the sector. The event also gives an idea of the technology roadmap of the industry. It is a much sought-after meeting ground for the trade and indeed a very happening event.

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Industry Voice


India: A destination for metal cutting companies...India is an emerging manufacturing hub for the automotive industry due to high consumption in the domestic market and increase in automotive exports. As a result, the cutting tool market is expected to grow at a high rate. Also, we have witnessed a huge increase in the machining of power sector components, which is capable of further triggering the growth of the metal cutting industry.

Highlights at IMTEX...We have adopted a revolutionary concept in coatings technology that has been now implemented across many of our carbide grades. This development in coating increases tool life by 30-40 per cent over conventional grades. The technology enables us to provide a shining appearance on the inserts and also reduce micro-chipping of inserts while machining. We are converting our regular grades to the new improved ones, which will be a highlight during IMTEX.

Challenges...The market is in a fast-emerging phase; machine tool builders have recovered and are close to record production levels attained in 2008. The market needs high-productivity tools for increasing the feed rates to satisfy the modern machining requirements.

Indian customers are also investing in high-powered machines. For all new products to be displayed at IMTEX, one will find the tools focussed for this requirement. We have milling cutters, which can work on high-feed rates, with more number of teeth to enable faster machining. Also, we are launching new cutters to enable high-speed machining for dies & moulds sector, with low depth of cut and high-feed capabilities.

IMTEX: A mega show of machining solutions...Participating in IMTEX is important, as it helps us in increasing our reach to the customers. We get a chance

to find many new opportunities and meet new customers.

This is a platform where we can showcase the entire product range and increase brand awareness. For companies like us who are in the nascent stage of marketing, it helps us find new customers and increase our reach to the users. Customers can come and understand our capabilities for providing machining solutions.

Leveraging opportunities... The exhibitors can demonstrate their product strengths in such large-scale exhibitions. The presence of leading companies of the machine tool industry can give customers a chance where they can have proper technical discussions with the exhibitors, and a solution can be worked out for any machining issues.

This also enables customers to visualise how such tools can be used at their work place. The customers can have the latest know-how on cutting technologies to help improve their machining.

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Tungaloy India Pvt Ltd

The market needs high-productivity tools for increasing feed rates

Roundtable


Will Rogers, the famous philosopher once said - ‘A difference of opinion is what makes horse racing and missionaries’. And this difference of opinion is represented in the section, where industry insiders address myriad issues - right from latest trends in sheetmetal working, future of zero prototyping in the country to managing and retaining skilled workforce & whether the government policies are conducive enough to the growth of manufacturing industry? Read on to find out…

Shetmetal working: Ready for the rising demand? ................................... 116

Zero prototyping: Is the Indian industry ready? ........................................ 118

Logisitcs: The key to controlling cost? ....................................................... 124

Managing existing talent: The biggest challenge for decision-makers? ...... 128

Indian trade policies: Are these industry-friendly enough?...................... 132

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Roundtable


The sheetmetal sector has been witnessing increasing demand. Along with the auto industry, infrastructure, construction, and telecom sectors are fuelling the growth of the industry. Besides adopting the latest technologies, the sheetmetal industry is moving towards the usage of environment-friendly applications. Here, some experts note the trends in technology and future prospects of the industry in meeting rising demand.

Ready for the rising demand?

SHEETMETAL WORKING

In the sheetmetal industry, companies are now consciously moving towards green technologies. There is a move from oil and hydraulic controlled systems to electrically-driven machines. The software used for the machines is also evolving and has become more user-friendly. The graphical user interface has become much more operator-friendly making it easy to use and requiring limited amount of training. Customers

are increasingly demanding value propositions and are accepting new technologies.

In addition, there is a need for top line machines, which provide high-end solutions. The fully automated one-stop line eliminates the need for many operators to do the job. Considering the manpower issues that the industry is facing, such a solution can be an answer to the existing issues.

Riddhish JalnapurkarCountry Sales Manager, Salvagnini India

Currently, the automobile industry is registering growth, which has led to rise in demand for the metal forming industry. To improve production and speed, the technology too is evolving.

The waterjet cutting process allows flexible processing of virtually all materials with consistent high quality. Nowadays, the usage of CAD/CAM is increasing in the industry, which allows close linking with the CAD/CAM programming system. One of the advantages of waterjet cutting is that it can cut many materials, while laser cutting can be limited. Waterjet machines generate high-speed jet, which can cut thick materials with good accuracy and good finishing surface. The machine cuts any material with no heat-affected zone.

The focus of the industry is fast moving towards eco-friendly technologies. One such method is the increasing usage of CNC technology. Also, to ensure accuracy and high-production capability, many companies are now implementing automated processes such as CNC machines. Further, the waterjet cutting technology is environment-friendly and gives clean production without poisonous gases. The waterjet cutting machine is widely employed in cutting metal, glass, marble, ceramic tile and granite. Besides auto sector, aerospace, food processing sector and the medical industry too are supporting the demand for the metal forming industry.

Hardik ShahHead - Marketing, A Innovative International Ltd

Shivani Mody

Roundtable


The industry is increasingly adopting CNC controlled machines. There is major growth opportunity for the same nationally and internationally. A major advantage of a CNC machine is that it can be programmed to produce a particular part, accurately, repeatedly without variation. It also reduces scrap, prevents mistakes, and makes production faster and more efficient.

Besides these machines, there is also a demand for laser, waterjet and plasma cutting machines. These are more beneficial when used in profile cutting. Currently, multifold growth opportunity exists within the industry. The economy as a whole is booming, leading to increase in demand for goods and development of infrastructure. This will also fuel growth of the sheetmetal industry.

A A ChandavarkarVP-Marketing, NuGen Machineries Ltd

There is a definite move towards ‘green’ technologies, which will continue to be the dominating trend. Machines using hydraulic oil are being replaced with environment-friendly technologies. These machines are easy to operate, which is an advantage for the industry. With a focus on reducing the size of machines, there is a move towards producing compact machines. The focus on running cost of operations and process integration in making its way in the machine

purchase decisions. There is an increased focus on high productivity by companies.

Currently, machines employed in the infrastructure, construction and telecom industries are much in demand. There is a major need for steel components used for manufacturing, panels, switch gears, kitchen set up for food joints. These will pose demand in the years to come. Further, the growth in the metal cutting industry is supported by the rise in demand for automation solutions.

A V SrinivasanCEO, Meiban Engineering Technologies Pvt Ltd

With the advent of new materials such as high-strength steels, automakers are faced with the challenge of understanding the formability aspects of such materials, which at times can be unpredictable, necessitating the use of a formability solution. The software solutions catering to the auto sector are defined by the complexity of the component. Companies are also looking at producing robust components, which can functin with a variety of materials. Nowadays, there is a need to employ steel with low-carbon content.

With competition growing rapidly in the Indian automotive sector, manufacturers are increasingly considering the adoption of formability solutions to keep tooling & stamping costs under control and generate a robust stamping strategy for optimised production of stamped parts. With many innovative developments in such software

solutions, a platform for conclusive validation of the entire sheetmetal production process is available now.

Software solutions address the need of manufacturers to introduce new products and reduce time to market. This can also help the domestic industry in tackling the competition from global players as well.

Software solutions are thus becoming an important element in this process for a manufacturer. Besides, MNCs are currently undertaking engineering in their headquarters and carrying out the final assembly in the country. When these MNCs bring in the engineering capability into the country, local manufacturers will find it tough to compete. Thus, it is necessary that companies integrate the latest software technology in their process, which will prove beneficial for the future.

Ramesh PonnuriIncharge – Sales & Marketing, AutoForm Engineering India Pvt Ltd

Roundtable


Since the recent past, the West has adopted the practice of zero or rapid prototyping. This enables it to simulate an entire range of products, and enter into direct mass production stage. In comparison, manufacturers in India have still to make do with the traditional method. With growing demand and shorter time-to-market, the adoption of Rapid Prototyping Technology (RPT) seems set to witness increased momentum in the country. Presenting some expert opinions from the domain…

Is the Indian industry ready?

ZERO PROTOTYPING

Shivani Mody

We refer to the term ‘rapid prototyping’ as ‘digital prototyping.’ In our view, Indians are quite receptive to new technologies & products, and are early adopters. In the past decade, the country saw a significant increase in manufacturing activities, which many termed as a resurgence in India. Efforts have been made to fine-tune state policy and enable the Indian manufacturing industry to realise its potential to the fullest.

Automotive has been the most visible of these sectors, and years of sustained efforts by the auto component firms & proactive government policy framework have transformed a relatively small and unsophisticated domestic industry into one with world-class manufacturing practices and a global footprint. None of this would have been possible had it not been for the increased usage of IT in the manufacturing processes.

With manufacturing becoming innovative day by day, SMEs play a crucial role in the economy. In a world that demands speed, accuracy & flexibility, it is vital that these SMEs in the manufacturing sector adopt world-class engineering processes, powered by the most advanced technologies. And, digital prototyping holds the key here.

Digital prototyping offers even greater promise for the future, and design software will become an increasingly important tool in an effort to improve the sustainability of manufacturers. By allowing designers to make better decisions in the early stages of product development, when they are most effective, future product capabilities may make it even easier and faster for manufacturers to design products that are resource-efficient, carbon neutral, healthy and safe.

Jayant Keswani Head - Marketing, Autodesk India & SAARC

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Roundtable


While the manufacturing industry and technology providers move ahead with the concept of zero prototyping, it would not be fair to claim that zero prototyping is a possibility in the visible future. Having said that, hand-made prototyping has been considerably reduced by rapid prototyping techniques and CAD/CAM/CAE technologies, for digital or virtual prototyping had a dramatic impact on reducing physical prototyping. Indian manufacturers too have adopted such technologies, and there has been a reduction in physical prototyping; although, it is nowhere close to zero.

The Indian manufacturing industries have adopted RPT considerably in the last decade. From the early 2000s, we have seen consumer electronics, industrial design houses/studios for FMCG, medical equipment and defence technology companies adopt RPT. Followed by automotive and their tier I & II suppliers, jewellery design houses in the mid-2000s to large multi-national captive centres are now adopting RPT in India.

As manufacturers in India carry out more design and core product development, further adoption of RPT will be witnessed, as it primarily helps in decreasing product development time significantly.

Nitin Tappe Vice President - Software Services, Geometric Ltd

Any technology that is well-accepted in the West does have a chance of being implemented in India too. But this depends on how well it is customised as per the applications and needs of the industry.

Rapid prototyping can help in reducing the cycle time and costs. This can be helpful for the manufacturing industry in the long run. The only issue is that any new technology, if it has to be adopted in the manufacturing sector, needs to prove its usefulness. Also, adoption of the same

for manufacturing is complex, as the projects are varied and cannot have a general solution.

For all projects, there needs to be customisation and flexibility. One needs to re-develop the solutions to cater to the application. If it gives flexibility, it can be adopted for the sector. The technology will have a future, if these issues are addressed. Further, it is used for manufacturing of parts, which are in small numbers. The issue of repeatability for the industry is critical, which needs to be rectified.

Ramji Singh Country Head - EPLAN Division, Rittal India Pvt Ltd

The concept of rapid prototyping has been in India for sometime. It is an advantage for the manufacturing industry where there is a need for modification or working with various parts. The physical prototype can help in generating a 3D model. Using the CAD tools, companies can then do in-depth analysis and see the actual working or get an idea about the operation.

The rapid prototyping technology is utilised extensively in India for producing shafts, blades, etc, which might be limited when compared to international standards, but it is significant considering the applications. In India, even the reverse application of rapid prototyping is being employed. A physical prototype is scanned, and later digital modelling is carried out. Although,

the application is common, it is not extensively utlised for further analysis.

One of the main advantages of using this technique is that it helps in doing the feasibility analysis. While carrying out the feasibility studies, companies can check the defects and see if the final product is fit to be produced. Eliminating the defects in the initial stages itself, reduces the trial and errors for manufacturers, thus saving valuable time. The digital analysis also helps manufacturers reduce overall material wastage and cost & in the bargain it also addresses manpower issues. With the current demand and growth prospects of the manufacturing industry, the adoption of these technologies is sure to increase in the future.

Dr S ShamasundarManaging Director, ProSIM R&D Pvt Ltd

Roundtable


Logistics plays a critical role in the overall cost of manufacturing products and delivering them on schedule. By creating a proper logistics system, companies can reduce their costs and meet customer demands efficiently. The logistics set up of a company also acts as an evaluation parameter when customers are scouting for probable manufacturers. Here are the views of some industry experts pertaining to it...

The key to controlling cost?LOGISTICS

The costs pertaining to logistics can add to the overall expenses and delay the production if not handled properly. Gearing up our supply chain management in the recent years has paid off for us. This has helped us in improving our efficiency and productivity.

Besides reducing cost on an annual basis, we have achieved flexibility in our operations. The material flow synchronisation has helped us reduce the time taken to manufacture and deliver machines. Nowadays, there are many IT systems, which when implemented brings in transparency and real-time information flow

for all concerned managers. Implementing SAP has allowed us to streamline our system and improve the process.

To meet the rising demand for machines, it is necessary that companies have an efficient supply chain process. Logistics becomes an important factor while customers are evaluating manufacturers. Also, while tapping international opportunities, companies need to bank on a robust supply chain to meet the expectations. Working together with suppliers and managing an efficient internal supply chain practice will help a company reach out to a wider market.

H K BirlaSenior Vice President – Operations, Bharat Fritz Werner Ltd

Logistics plays a vital role in manufacturing and even during the final delivery. The costs pertaining to logistics are not clearly visible, and hence it is necessary for companies to study them in detail. With the current economic scenario and growing demand, it is necessary for every organisation to look at its logistics capability and take appropriate steps in improving it. One such method is implementing ‘5–S’ and Lean system, which becomes an advantage for the production line.

The benefits can be realised while managing the process as it becomes easier. With such systems in place, a company can plan better and enhance its decision-making ability. With a strong

logistics system in place, companies can keep a check on costs and even be effective & efficient in handling customer demands. Such systems can give the organisation an advantage in tapping new opportunities and new geographies.

During the economic slowdown, we improved our own logistics capability, and now we are witnessing the benefits of that exercise. By improving our logistics system in the plant, what earlier used to take around 15 working days to build a machine, can now be produced in 12 days. The system has a scope for further improvement. Further, the machine can be built in eight working days with a more efficient system.

Rolf GrossenbacherGlobal Sales Director, Fritz Studer AG

Shivani Mody

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Logistics plays a vital role, considering trading operations and the shop floor processes. It is a critical aspect for operations. Customers expect the product to reach them in a particular time so as to carry on with their operations. The commitment and delivery of products is what a customer seeks from the manufacturer. Even if the customer is present in a remote location, the delivery schedules have to be adhered to. If not, this affects the overall performance of the customer, and hence it is critical to meet the schedules. Based on the delivery performance, customers evaluate the manufacturer, which is a benchmark for future business opportunities.

Looking at the scope of improvement in the logistics sector, it has largely reached the optimum

level. Today, the need is for better services and updating the technological capability. Some of the major hurdles with logistics sector are witnessed during import and export transactions. The customs clearance is still a tricky process and their systems are not as updated as desired.

The products from Japan reach India in three days, while it takes nearly 10 days to avail a custom clearance. This is a major issue that needs to be addressed. Further, there is a need to educate the third party logistics service providers (3PLs) regarding the service requirements. The industry still has a long way to go before we can see the best-in-class service levels, which can be comparable to some of the developed countries.

N Gopinath Vice President, MMC Hardmetal India Pvt Ltd

For any manufacturing company the input-sourcing and distribution costs form a significant part of the overall cost. For instance, instead of having 10 large distribution centres across the country, a company can have 2-3 large distribution centres connected with other smaller depots - a hub & spoke model. A properly planned model will help companies reduce the cost by 0.5-2 per cent, depending on the final plan. Companies can bring down costs significantly by improving their logistics capability. And, passing on the cost benefit to the customer will depend on the practices of an individual manufacturer.

In many cases, companies are reducing the number of middlemen, or outsourcing the logistics capability to 3 PLs. Since they are eliminated and there is no asset maintenance or overheads, a company can cut down its expenses. With specific annual contracts and fixed costs, manufacturers can plan better and save themselves from mental turmoil. Depending on the model, any firm can realise around 1-2 per centcost benefit, which is huge considered over a period of time. There is potential in improving the sourcing and distribution patterns, which can be explored by the industry.

With the GST that is to be implemented, one can envision statewise large distribution centres

across the country. These can be big warehouses with the latest facilities and strategically located so as to serve 2-3 states at a time. This will reduce the need for individual transportation and distribution centres, thus impacting the overall costs.

In addition, following the best practices adopted in developed countries, the service providers have begun to implement the latest technologies. Tools such as warehouse management system, transportation management system, and Radio Frequency Identification (RFID) for track & trace mechanisms are being used by the industry. In case of movement of parts from tier 2-3 regions, remote locations can be traced and the loss can be accounted for. The visibility of the movement of products can help companies take better decisions. The information from the RFID tags can ensure the availability of genuine parts.

Overall, such systems help in better control, improved productivity, and ensure quality of products & decision-making. Identifying problem areas become possible and easy to manage. The only issue is that technology adoption is limited owing to its high cost. There also needs to be a change in the mindset of the management towards adopting a technology.

Srinath MandaProgram Manager, South Asia, Middle East & North Africa, Automotive & Transportation Practice, Frost & Sullivan

Roundtable


The current crop of engineers and technical professionals are well equipped to take on any industrial challenge at hand. However, the problem is that the machine tool industry is not getting enough of them. With the level of competition rising in the industry, it is difficult to find a workforce, which is industry-ready. On the other hand, the existing talent is changing jobs in a hurry. The government is doing its bit, but a lot more needs to be done, considering the needs of the machine tool industry.

The biggest challenge for decision-makers?

MANAGING EXISTING TALENT

The industry is facing an acute shortage of skilled engineers. Most of the students who complete their engineering courses prefer to join the IT industry because of the big salary offered by this industry. They are quickly absorbed by IT companies, thereby leaving the machine tool industry with no options.

While we build training institutes for young engineers, we must have a strategy to retain them in the machinery sector as well.

The government is supportive of our endeavours towards skill development, but we need to do more, or else, innovation through improvisation will be hard to achieve for the machine tool industry.

If the government can come up with its own training institutes, it will instill confidence in the minds of youngsters willing to join the industry and ensure that the final human capital that enters the job market is upto industry standards.

Vikram SirurVice President, Indian Machine Tool Manufacturers’ Association

Skill management is becoming increasingly important in the current scenario in India because there is a gap between what the industry demands and what the academic institutions are churning out.

Though the government is taking proactive steps towards creating parity between this demand and supply mismatch, what is required is the development of vocational training for students.

Industrial training for under-graduates at all levels should be arranged so that before entering the industry, they have an idea of what is expected from them. Though we are producing lakhs of engineers and technical graduates, all cannot be considered as ready-for-the-market. However, the scenario has changed, as institutions providing further education are partnering with companies to provide industrial training to students.

Prof Sanjay Govind DhandeDirector, IIT Kanpur

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Today, we train people in the manufacturing sector, but after 2-3 years, they leave the company to wherever they find a better monetary arrangement. This is the current key problem facing the manufacturing industry. The amount of money and expertise spent within a company towards an employee is substantial, but when these skilled people leave, it creates an acute shortage within an organisation.

There needs to be an understanding among the current crop of engineers that to create stability, they must stay with one organisation.

Yes, there are initiatives being taken by the industry with constant support from the government, but we would require more understanding from the engineers themselves to set this problem right.

Due to shortage of skilled workforce, there is a demand-supply mismatch in the industry, which can only be overcome if young engineers value the investment made in them by their current organisation. This will not only add value to their skills but also reduce the burden on the company.

Girish Mahajani Country Sales Manager (India), Industrial Automation, Kollmorgen

The retaining and training of skilled workforce in India is a challenge. On one hand, we would like to have global standards for our education system, but on the other, the reality is different. The issue is with skill orientation in educational institutions. Transformation induction in our engineering institutions is not satisfactory. This is not the responsibility of only teaching institutions but also of the manufacturing industry. The industry needs to specify to

institutions what its requirements are. Training for future employees needs to be in tandem with the current industry demands.

While the government is supportive, no concrete measures can be identified. A national committee must be set up and its findings need to be implemented in a multi-stratum manner within the industry. The industry has veterans at the top level. What we require is appropriate training at the middle-level.

T R Gopalakrishnan NairDirector, Research & Industry Incubation Centre, Dayananda Sagar Institutions

The unorganised sector forms a large part of the existing structure within the manufacturing industry. The issue with this is that entry barriers for manpower is less, so unskilled workforce can be absorbed easily. This creates a hurdle for skill development. Skilled workforce is required at all levels in the manufacturing industry. The industry is like a pyramid where the top level remains the same but the mid and low levels go through constant shuffling.

Companies provide training initiatives when they recruit labour, but this trained manpower leaves the company as and when

they see a better opportunity, little realising that the organisation needs their dedication on a sustained basis for wealth creation. For long-term training and skill development, a Private-Public Partnership (PPP) model needs to be followed, which delivers to the industry what it demands.

Currently, there is an issue of attrition, and the measures taken towards skill development are insufficient. India has talent that is ready to be explored. And, while countries in Europe have the required infrastructure, India needs to tap its large existing workforce and cash in on this advantage.

Avra MitraSenior Manager - Key Accounts Web Fed, Bobst India Pvt Ltd

Roundtable


The machine tool industry in India is pegged to achieve great heights. According to the industry observers, while Indian machinery is well-accepted globally due to its high quality, a key area that requires attention is the tax policy. This will allow the industry to better absorb the competition from China, and will complement the excellent after-sales service provided by the Indian machine tool industry. More than a revision of policies is needed, what the experts say.

Are these industry-friendly enough?

INDIAN TRADE POLICIES

Though the government has recently begun focussing on helping the manufacturing sector across the country, there are various states, especially in the East, which needs more attention from the Central Government. In states like West Bengal, there was a time when large entrepreneurs were present, but most of them have either shut

down their units or are planning to do so, due to lack of government support.

We are receiving orders, but most of them are from outside the state. While this is positive, we would also like to see our local markets developing. Interest rates for procuring loans are high and we do not see them coming down in the near future.

Debdeep KoleDirector, Koley Converting Machinery (P) Ltd

The current government policies for the manufacturing sector are quite conducive for growth. We are exporting plant & machinery on a significant scale and our machine tool manufacturers are in compliance with global standards. The growth rate in the manufacturing sector itself speaks volumes about the support received from the Indian machine tool industry.

The machine tools manufactured by the Indian companies have brought in significant change in technology, accuracy and reliability. We have also witnessed that many companies are moving away from just machine tool manufacturing to systems manufacturing, which

is the right direction, so that the customers can choose a single-stop solution provider.

The government policies offer a good environment for innovation and growth. This helps the machine tool industry to strengthen itself and improve their competency on par with global machine tool manufacturers. In fact, the Indian Machine Tool Manufacturers’ Association (IMTMA) is doing a commendable work in benchmarking machine tool industries in India with world-class manufacturers and enabling innovation. Also, the Indian economy is growing year-on-year and we will be witnessing an accelerated growth in the machine tool industry.

Dr N RavichandranCEO, Lucas-TVS Ltd

Anwesh Koley

Roundtable


The current industrial policies in the country are supportive of the domestic machine tool industry. And, we are satisfied with the government’s efforts on the same. However, we would want more support for manufacturers to compete in the international market.

Policies for procuring raw materials and for the supply of electricity should be revised so that manufacturers can be more competitive

in the international markets. We are facing strong competition from the machinery industry in China; as our products are more expensive compared to the ones manufactured in that country. While the government has come forward to help the manufacturers, we expect more tax benefits so that our products can be priced low in the global market.

Hitesh ShahManaging Director, H G Shah & Co

The quality of Indian machinery is appreciated worldwide. Our products are known for their performance and the companies offer good after-sales service as well. However, the excise duty in the country is high, hence we fall short on the pricing factor. The delay with the Goods and Service Tax (GST) does not help matters either.

Infrastructure for intra-state movement of goods should be made smoother and a policy should be in place for smoother mass-transport system.

While Chinese products do pose a threat for Indian machine tool manufacturers, the truth remains that Chinese machinery is not trusted for quality.

We need more training institutes in place to aid this industry, and while there are private institutions, a government initiative will instill confidence among the industry players. There is a general consensus within the industry that with a little more government support, Indian machinery can probably become the best in the world.

Kinjal ShahDirector, Hi-Life Machine Tools Pvt Ltd

If we compare India with other countries that have a well-developed manufacturing sector, we are still lagging behind substantially. For instance, if we have to import industrial equipment, we have to pay an import duty or customs duty of around 25 per cent. Not only is this high, but also it adds to the final price of the product. This makes our products more expensive in the domestic as well as the global markets, thereby making us uncompetitive, despite our products being of superior quality. Companies in China and the UAE do not have any excise duties, and therefore are at an advantage. If the government wants the manufacturing sector in India to evolve, such issues must be tackled at the earliest.

Even the tax structure in the country is very complex. Very few are aware of the entire gamut of taxes that we have to pay. Besides, the payment methods are also complex and require a heavy drain of time & money. From direct to

indirect taxes, there are more than 30 variables of taxes a company needs to pay. Also, the licensing of products and the steps involved in setting up units require heavy bureaucratic involvement, which is often cumbersome. Corruption in government departments is also a cause of concern as it delays projects and causes unnecessary hurdles. The rules for the manufacturing sector should be clearly defined and applying for permits should be made more clear.

The government should encourage the growth of technology if it wants the Indian machine tool industry to match the global standards. This would require not only reducing taxes on our imports but also developing research centres, which will allow indigenous technology to be developed and used in the domestic sector. The system of investing through FDI in India is also not conducive, and requires similar levels of transparency as with other forms of investment.

Pradeep ShoranAGM, KUKA Robotics (India) Pvt Ltd

Expert Zone


With increasing competition in the metalworking sector,

manufacturers are compelled to seek cutting-edge solutions to

lead the race. Presenting several solutions to complex challenges,

this section contains a series of articles by industry experts, on

topics ranging from productivity, automation, Lean product

development to EPOs, green manufacturing, new materials and

emerging markets.

Expert Zone - Proficient Productivity


DFSDFSD

As Indian machine tool companies collaborate and partner with their global counterparts, it has become essential for them to achieve and adhere to the international standards of quality & productivity to ensure growth in business and trust of partners. Overall, to be Lean has become a need for the machine tool industry to maximise gains.

The measure of productivity is the amount of output per unit of input that includes components of labour, equipment and

capital. There are many different ways of measuring productivity. For example, in a factory, it might be measured, based on the number of hours it takes to develop a product. In recent times, especially following the downturn last year, quality has become an important aspect of the corporate strategy across the manufacturing sector.

Many companies have set out on their path to increase productivity by adopting 5S – Lean manufacturing, visual management, KAIZEN, KANBAN, single-minute exchange of ideas, total productive maintenance with continuous improvements and quality management systems.

Importance of certificationsIncreasingly, more companies across the world find it wise to avail ISO certification. This conveys that the organisation is following best production and managerial

Increasing productivity through quality management

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practices. It is important to have ISO standards becasue following the certification process, the required quality of products & services is established in the market.

And, with the reliability standards established, we can know what to expect from the products. In addition, whenever a company attains an ISO certification, it reflects as a company policy that the required safety rules & regulations are followed and are complied within the organisation. With increasing awareness and importance given to the ecological footprint of various industries, an ISO merit is evidence of a company’s commitment towards environment, and that environment-friendly manufacturing methods are strictly followed.

Moreover, having standards in place increases manufacturing efficiency and reduces overall costs. And, as global markets open up for the Indian machine tool industry, it becomes easier to expand businesses across global markets, aided by an ISO certification.

Lean manufacturingDue to the recent economic slowdown, companies revisited their manufacturing processes to make production lines Lean. With the help of global partners, Indian machine tool companies are focussed on understanding the importance of quality by the method of inspection, manufacturing and material handling & storing to meet expectations. Lean manufacturing is a systematic approach of producing goods and delivering services that creates precise value for the customer – with minimum amount of waste through identifying and eliminating non-value-added activities. Thereby, the maximum degree of quality is attained through a culture of continuous improvement.

The 5S philosophy focusses on standardising, organising and simplifying the work environment to reduce waste and improve quality & safety.

KAIZEN means ‘change for the good’ and is an intensive and focussed approach in process improvement. KANBAN signifies ‘signal’ and is a device for indicating the need to replenish materials. A KANBAN or pull system controls the flow of resources during a production process and replaces only what has been consumed by the customer, delivering the right amount of material to the right place exactly when it is needed.

Total Productive Maintenance (TPM) is a team-based initiative for optimising the effectiveness of manufacturing equipment. Sharing information through visual tools that describe workplace safety, production throughput, material flow, quality metrics, etc helps the production run smoothly and safely.



Investing in qualityThe ever-changing customer demands require areas of investment in production & suppliers/vendors units for upgrading quality of the products. To begin with, some key areas of investment include multi-pallet machines of VMC/HMC, special-purpose milling, grinding and honing machines.

Inventory and convenient stores can also benefit a company. Information technology such as Enterprise Resource Planning (ERP) starts from screw to assembly drawing, which is visible from assembly table that can streamline all processes for a holistic approach towards manufacturing and ensure quality at each step. Sophisticated tool crib, CMM, profile projectors, etc can also contribute to significant quality improvements.

Talented workforceBy definition, productivity is the

amount of output per unit of input and has a direct co-relation with labour or workforce. This stands as the primary and most significant contributor to quality & productivity in manufacturing processes.

Hence, the role of workforce is necessary for any organisation. It is therefore pertinent that a company must identify the high-impact critical workforce. To strengthen the overall capabilities of the company, it needs to continuously invest in its own people to upgrade performance and productivity. Based on the analysis of the workforce, an organisation can conduct training to reduce the workforce-capability

gaps. It must adopt different solutions such as increasing knowledge of the workforce, enhancing skill sets, and including mandate through performance & talent management solutions.

While knowledge solutions mitigate the risks of knowledge loss, and performance solutions cut down the risks posed by inexperienced employees who replace retiring workers in critical jobs, talent management solutions address the challenge of accelerating the pace at which companies move people through the entire employee lifecycle - from acquisition to development to performance management.

Ranganath K is Manager - Production at Sphoorti Machine Tools Pvt Ltd. He has 14 years of experience and has served in different capacities in the machine tool industry. E-mail: [email protected]

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Many companies in the machine tool industry employ tool-holders, milling cutters, drills, insert grades, geometries and machining techniques that have been superseded. A well-developed practical software can enable customers to utilise latest tooling systems and leverage relationships with their tool supplier.

The rate at which people and organisations learn & apply new technologies usually lags far behind the actual pace of development. The result - an

increase in the so called ‘technology gap’, which has a detrimental effect on a company’s ability to compete, with productivity often falling well-behind. A well-developed and practical programme designed to familiarise users with the latest tooling systems and metal cutting techniques, enables companies to overcome

this hurdle and achieve maximum machining productivity.

Keeping pace with technologyIncrease in productivity is essential for every company’s growth. Some cornerstones are crucial in this respect such as reliable machinery, good quality tools and high-quality products. Leading global tooling companies are constantly focussing on innovation in introducing a range of tooling solutions to help customers increase

Ways to expand knowledge

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their productivity. Many customers are already reaping in the benefits of latest technologies, although a small initiative in orientation can act as a catalyst. With added information and training, companies can find out how best they can utilise these in their business and be more competitive.

Reducing downtimeTo be truly competitive in the modern marketplace, companies need to take control of production and stock, making sure that the amount of money spent is put to maximum usage. To get this competitive edge, companies should opt for a single solution that could make the difference between average and good results, waste & control or even profit and loss. There is a compelling movement well underway across the world – towards automating transactions at the ’point-of-use’.

A web-enabled solution automates the processing of tool crib and storeroom transactions at the ’point-of-use’ itself. It controls and automates the dispensing and returning of high-use, high-cost or mission-critical tools and supplies; it automates the replenishment process, calculating just the right amount of inventory required for

each turn. It streamlines inventory management, reduces fixed costs and has a positive impact on productivity and information flow. A technology platform for inventory control ensures that this functionality is available for the users directly and automatically.

Increasing qualityCompanies with extensive experience in metal cutting should work towards developing a system that enables measurement, control and management of manufacturing processes. A new concept called Productivity and Cost Analysis (PCA) has been introduced to help tooling customers achieve cost reductions and enhance efficiency. Using PCA, we can take a wider view of the user’s manufacturing methods, focussing not only on the cost of tooling, but also on the total cost of production. The PCA system can evaluate a single machine tool process or the complete path

a workpiece takes on its journey through a manufacturing plant.

The latter takes bottlenecks or restraint operations into consideration, where more in-depth studies are necessary. The PCA software provides a comprehensive report with both process information such as tooling & cutting data, and cost information such as cost per part, output per hour, tool consumption and investment cost. According to reports from different industries, reductions in total costs of 15-30 per cent with improvements in productivity of up to 40 per cent has been gained by companies who have adopted PCA.

Training and developmentCurrently, there exists a gap between technology awareness and its application. A comprehensive technical education programme that is well-developed and practical can be designed to familiarise users with the latest tooling systems and metal cutting techniques. This enables companies to combat the ‘technology gap’ and achieve maximum machining productivity. Such orientation programmes should be regularly designed to keep users in touch with a rapidly changing industry.

W i t h o u t a n i n - d e p t h understanding of new technologies in the market, many customers find the decision-making process more difficult as the range of tooling system expands. Courses can be designed to cover customer-specific requirements, so that machine operators, manufacturing engineers, programmers and company owners can begin to understand the simplest way to choose the correct tooling and machining strategy.

Implementing point-of-use technology in inventory management

Sashi Menon is Deputy General Manager - Technical Support at Seco Tools India (P) Ltd. The company provides cutting tools, technical support, demonstrations, technical advice, new ideas and practical experience. Email: [email protected]

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Expert Zone - Automation


DFSDFSD

Strong R&D and innovation have helped bridge technology gaps in building products and processes, ensuring sustained growth and long-term survival of industries across the globe. Automation becomes unmanagable and expensive when more parts are handled and processed. However, costs related to purchasing, stocking and servicing come down when the number of parts are reduced.

The machine tool sector is unanimously recognised as a strategic industry for the development and growth of a country. Over the years,

machine tools have experienced many technological developments. However, the most beneficial has been the introduction of Computer Numerical Control (CNC). Today, a vast majority of machine tools produced are equipped with CNC.

CAM for consumersSeveral industries rely on the machine tool sector, and thus there is a constant

pressure to deliver the best, which is achieved through R&D and innovation. Consumers, who employ these improved machine tools, experience the benefits of increased productivity, shorter product cycle times, and improved product quality.

The latest technologies in Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) tools are utilised in assisting the machining process. For example, Design For Manufacturability (DFM) is an important tool for a manufacturer, as it helps minimise the cost of production and time-to-market, without compromising

Knowledge-based manufacturing

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on the quality of the product. A DFM review tool can be effortlessly integrated within the CAD environment, and can easily support features extracted from imported materials.

Knowledge-Based Machining (KBM)There has been a growing trend towards KBM. In a world where faster and cheaper production is critical, CAM systems that incorporate KBM provide a competitive edge to manufacturers as they offer automation, while still retaining control over the machining process. Moreover, systems that incorporate KBM come with a generalised database of standard tools, pre-programmed speeds, as well as feeds and information on standard material characteristics. These may also be supplemented by a set of pre-defined machining features and processes that can be tailored to preference.

Such a system has the ability to recognise the machining features; and by using available data, the software automatically retrieves process & cutting information from the database for cutting the part in a most effective way. Such pre-definitions can help manufacturers considerably shorten programming cycles, especially for highly repeated machining processes.

A CAM system that delivers the entire capabilities of KBM is a feature-based system that utilises Automatic Feature Recognition (AFR) technology. AFR is an automated method that analyses the solid model geometry and identifies regions to be machined. As a CAM software evolves along the KBM curve, it needs to take a broader view of what constitutes knowledge.

Today, that definition is focussed around machining practices and tools. It is increasingly expected that such systems will also take into account factors such as machines available on the shop floor, capacities of these machines, and more complex material information, including those related to cost and availability. These advances will enable users to evaluate between multiple machining approaches that can be applied to a particular task, not just from the perspective of quality outcome, but also in terms of manufacturing time and cost efficiency.

Integration with the systemAnother milestone to look forward to in CAM evolution is tighter integration with CAD systems. CAM systems can retain the design knowledge & information already inherent in a CAD model, and therefore apply the same intelligence, and vice versa.

One line of such integration work has been centred on seamless integration between CAD and CAM products so that a part designed in a CAD system can be opened directly in a CAM application without the need for translation software. With the issues and errors associated with data translated in & out of IGES or STEP formats, these partnerships completely eliminate the need for any kind of file translation.



Recent technological developments are also impacting the utility of CAD/CAM systems. For example, the progress towards establishing a single CAD/CAM standard, so that different data packages can be exchanged without manufacturing & delivery delays, unnecessary design revisions, and other problems, continue to hinder CAD/CAM initiatives.

Design For Manufacturability (DFM)Good design guidelines exist in the industry for frequently used manufacturing processes. These guidelines are systematic statements of good design practices, derived over the years of design and manufacturing experience by trial & error. Ensuring that the given product design conforms to each guideline specific to the selected process results in better manufacturability.

To meet the objectives of the DFM approach, design and manufacturing planning activities have to be combined into a single engineering effort and applied throughout the life cycle of a product. CAD systems offer powerful features such as the ability to develop complex solid models and perform engineering analysis.

However, a prominent limitation faced by designers in CAD systems is the lack of ‘intelligence’. DFM is a

methodology that involves designing with an intent to minimise the cost of production and time-to-market, without compromising on quality of the product. Various studies have proved that an error detected and rectified during the design stage costs almost 100-1,000 times less than when rectified at the manufacturing stage.

Elimination of errorsAlthough the advent of CAM software represents a leap in machining productivity, an integrated 3D design system with DFM tools can increase efficiency gains. No matter what process one uses – milling, drilling, punching, laser/waterjet cutting, multi-access machining, or wire EDM – the critical requirements are starting with accurate 3D geometry and using machining technology that best fits the needs. Over a period of time, manufacturing companies have realised the benefits of implementing a design for manufacturability tool. The tool helps identify critical manufacturing errors at the design stage itself, thereby eliminating errors and increasing the manufacturing yield.

Implementing the DFM toolDFM proponents advocate concurrent engineering teams consisting of engineers from various departments like design, manufacturing, quality among others. However, managing the teams is not easy. Additionally, in the

existing global manufacturing scenario, teams are likely to be widely dispersed. Therefore, it is important to have an easy-to-use, yet simple and powerful tool that allows quick validation of designs for easy manufacturing, while automating the DFM reviews to a large extent. DFM can be implemented by drawing on a number of concepts and techniques that collectively – allow the organisation to achieve its design goals.

The main thrust of the DFM approach is a designer’s ability to not only perform functional analysis of a product design but also to improve its manufacturability by selecting a combination of processes based on first-order cost estimates and evaluation. Effective implementation of DFM will greatly facilitate the process of reviewing a design against an organisation’s set of DFM guidelines as well as provide interactive feedback to the design engineers to take immediate corrective actions, if any.

Benefits of DFM automationA DFM tool integrated within a CAD environment can alert the designer regarding any violation of DFM guidelines. This, reduces the chances of costly design mistakes. Using DFM automation and rule customisation, best practices can be captured and disseminated. A systematically deployed DFM automation solution can provide a framework to enforce and improve the manufacturability of an organisation. Identifying areas in a design that are difficult, expensive or impossible to manufacture is one of the key features of the DFM tool. It helps an organisation save considerable cost, time & effort by improving productivity and reducing waste.

Sambit Pradhan is Business Development Manager at Geometric Ltd. He manages the Asia-Pacific region and has more than 10 years of expertise in the dies & tools industry. His primary focus area is expanding the business potentials for CAMWorks® & DFMPro® in the Asia-Pacific region, and also exploring new markets to promote business. E-mail: [email protected]

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DFSDFSD

The machine tool industry has always followed the concept of automation for manufacturing and production. After India’s call for high-volume production, developments in this field are focussed on better productivity and flexibility with integrated automation.

The growth of the machine tool industry has always been associated with automation. Machining and SPC & handling activities

are now clubbed, and total solutions are offered by most of the machine tool manufacturers. They integrate various machining operations & allied processes along with its quality control.

It is also planned simultaneously with automation in handling & sub-processes, before or after. This provides total solution to the customer, and enables ease of operation with a common strategy and

optimised layout. Simulation software provides advance estimates, possible alternatives online balancing, product mix and throughputs.

Automate for flexibilityMachines today are designed with automation in mind. This has been mainly witnessed in the automotive sector, which among other manufacturing sectors, remains to be one of the largest buyers of machines. These industries need high-production volumes with consistent quality output through automation. Provisions are made for gantries

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and/or robots to handshake through planned interface for exchange of input/output and relevant data for total online monitoring.

Today, companies demand not only the manufacturing of parts at the lowest possible cost, but also to have the flexibility in adapting to the production lines for changing volumes and new parts. Shorter production cycles & various components running in batches are taken care while designing new types of fixtures and flexible gripping systems, which allow quick change. Automation can manage multiple programs with CNC & CAM and different operation sequences with ease.

Ready-to-use modulesMany manufacturers are also planning to produce small handling units for machine tending, along with the system. This reduces the complications of accessibility to human being,

and the requirement of high safety for them, besides elimination of any chance of wrong loading/unloading.

Automation solutions in ready-to-use modules from leading service providers are available with ready design data and ease in adaptability. These can be clubbed with the main machine through a common controller to give a total solution for high productivity in a production concept similar to a cell or for the total production line. Quick and ready solutions for holding a variety of components are available as ready data.

Linking multiple operationsAdditional machines can easily expand the production cells. As parts are primarily conveyed by gantries, if one machine shuts down, other machines in the cell can carry out the operation. If a machine from a cell of five machines shuts down, the output reduces by only 20 per cent. Agility itself is characterised by parallel processes, ie, several pieces of machinery within the system perform the same processing content together, and are combined into a manufacturing cell.

The base machines are designed for high-cutting performance. Each cell is optimised to perform one task.

Companies demand not only the manufacturing of parts at the lowest possible cost, but also to have the flexibility in

adapting to the production lines.

An invite that rewards as well...

Dear Reader,

‘MODERN MACHINE TOOLS’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the machine industry.

You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words.

The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format.

The final decision regarding the selection and publication of the articles shall rest solely with ‘MODERN MACHINE TOOLS’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque.

Published by Infomedia 18 Ltd, ‘MODERN MACHINE TOOLS’ is the leading monthly magazine exclusively meant for manufacturer and user fraternities of the machine trade. Well supported by a national readership of over 1.25 lakh and strong network of 25 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of machine products, machinery and allied sectors. Also, by virtue of tie-ups with global

media majors, it ensures that advertisers are able to promote their products and services across the globe at no extra cost.

So get going and rush your articles, write-ups, etc…

Thanking you,

Yours sincerely,

Manas R BastiaEditor

Infomedia 18 Limited

‘A’ Wing, Ruby House,J K Sawant Marg, Dadar (W)Mumbai 400 028India

T +91 22 3024 5000F +91 22 3003 4499E [email protected] www.infomedia18.in

D +91 22 3003 4669



Several cells linked in the series process the pieces completely. Several options are available to link the individual machines and various cells. Automation service providers can now offer circular or straight gantries and in different combinations.

Better supervisory controlIn the production lines, with Supervisory Control And Data Acquisition (SCADA), monitoring and traceability can be automated. Screens are developed with appropriate representation of processes for more clarity. With proper feedback systems, tool wear compensations can be triggered in machines. Rejection data is analysed, and maintenance schedules can be planned with shutdowns for the machines one turn after the other. Various logistics are pre-planned to take care of different production constraints and conditions. Production lines can be handled from the office, and controlled output can be achieved with high flexibility.

Machine utilisation has been optimised like never before with the usage of handling automation. Machine tending times are controlled and consistent. It often helps in bringing down the cost per piece of a particular operation. Large investments in

costlier machines become economical propositions, with suitable automation matching the needs of various processes.

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Future of automationThough slightly expensive at this stage, the idea of having fully automated factories with high flexibility has been a part of the vision for many industry leaders. Requirements to integrate and optimise business processes across global supply chains, to improve utilisation of assets, to operate in a Lean environment, to be able to build anywhere, and to do more with less, are driving the need for improved automation technology.

Customer orders are received online, and accordingly automated design is generated, which is processed through fully automated production lines with the help of highly sophisticated interacting machines and intelligent robots. Unmanned night shifts are also planned to cater to customer needs with high utilisation of resources. All systems, designing, ERP, communication, fabrication, production machines, inspection units, material handling, and storing & retrieval should have easy adaptability to each other for better handshakes. These sophisticated automations need highly reliable sub-systems like control elements, mechanical units, communication units along with sensors to make it possible.

Diagnostic software and remote access make the possibility of error correction being done from supplier’s base. A few changes, if necessary, can be done remotely as per the application. However, mechanical modules have limitations to remote maintenance and will always demand much high degree of reliability. While designing such automation lines besides flexibility, focus is given to product reliability and on quick maintainability. Modular concept gives scope for adding as per demand at any stage. Extensions, expansions, process changes, etc need to be addressed with basic modular designing, even if marginally high investment in the beginning. But, this gives a large advantage to shift to new production without becoming obsolete.

New factories being planned for full automation require these features for being agile. Besides, its conceiving time and time from concept to realisation should be quick, not to miss the opportunity. Fully developed and off-the-shelves proven modules are thus becoming more popular. In the 21st century, those who are quick and agile to adapt to the changing demand and fast to process an order at globally competitive rates will survive.

Shirish Thatte is COO at Gudel India Pvt Ltd. He is an alumni of IIT Madras with over two decades of experience in manufacturing, machine design and automation. Email: [email protected]

Expert Zone - Manufacturing Excellence


Today’s manufacturing units are facing far more challenges than ever before, mainly due to ever-increasing complexities in product design as well as more stringent time, cost, regulatory and quality requirements. The right approach to efficient manufacturing in this scenario revolves around concepts, which have been talked about from time immemorial. However, it is only recently that the Lean manufacturing and enterprise concepts have been given a serious look as businesses combat the pressures of customer satisfaction, cost reduction, globalisation, compliance, time-to-market, growth, profitability, etc.

Lean manufacturing aims to ’do it right the first time’ while minimising waste (this refers to not just physical waste but importantly to non-value add

processes as well) and being open to change. Toyota led this effort by what is now the well-known Toyota Production System (TPS). The global manufacturing industry went about researching, learning or adopting similar practices only to find that they did not achieve significant business

success, such as gaining a competitive advantage.

The reason most probably lies in the fact that emulating only manufacturing practices is not enough. This can put a company’s manufacturing practices at par with other leaders, but what about the products themselves? If quantum improvements are needed in areas such as competitive advantage and marketshare – which can lead to high-revenue growth and profitability – companies need to build winning

An enabler for Lean product development

PLM

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products. Therefore, Toyota, being the leader today, is not only because of TPS.

Leading companies around the world recognise this fact and are applying ‘Lean’ principles to other activities of the value chain like planning, parts sourcing, purchasing and so on. It is in this context that most companies are realising Lean Product Development (LPD) as the next frontier, since it provides a greater level of opportunity for improvement. Lean manufacturing still delivers significant value but is no longer a competitive differentiator.

Product developmentAs enterprises become more customer-driven, the focus has shifted to product development. They are now beginning to realise that an even greater level of opportunity for improvement is possible by better managing the digital product definition at every stage in a product’s life. There are ever-increasing demands to improve innovation, quality and time-to-market while reducing costs. These circumstances have forced businesses to re-engineer their product development processes.

Global Product Development (GPD) has become a reality through offshoring and outsourcing in leveraging the benefits of costs and talent availability across the world. However, new challenges have emerged. There is a need to collaborate effectively across geographies, various participants, including customers & suppliers, time zones, cultures and languages. Developing the organisational ability to manage projects, product information, protect Intellectual Property (IP), deploy consistent processes, communicating the right thing to the right person at the right time, managing change or have version control in a distributed environment are complex tasks.

Lean product developmentMany enterprise solutions – such as Enterprise Resource

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Planning (ERP), Customer Relationship Management (CRM), and Supply Chain Management (SCM) – focus on optimising the flow of physical products and transactional information. These applications work best for processes that involve doing

the same thing, the same way, over and over again. The fact is, they are not suited for the kind of rapid iteration and innovation necessary for successful product development. This gave birth to Product Lifecycle Management (PLM).

To consistently produce products, companies need a product development process that becomes in itself a competitive differentiator. While some see product development as synonymous with engineering, a truly effective product development process engages a variety of cross-functional participants from marketing, engineering, procurement, manufacturing, sales and service departments. Ever-increasing levels of outsourcing have driven suppliers and manufacturing partners into direct roles in the process. At the same time, a strong customer focus has necessitated the customer’s direct involvement. As a result, attempts to optimise product development evolve from a departmental focus within engineering, to an enterprise focus, and ultimately to a distributed value chain focus.

Developing digital products in a value chain environment – and under

Commitment to total customer value

Leadership by example

Flowing processes

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and tracking

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Manufacturing & supplier partnering

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Integral product development system

Visualisation & mockup

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intense time and cost pressure – is certainly not easy. While many manufacturers have made great strides by improving operational effectiveness across their enterprise & supply chain as it relates to manufacturing and logistics, most companies will admit that their product development processes are rife with issues. The digital content that describes products during the development process becomes fragmented across organisational boundaries, with each group having different forms of product definition stored in different systems, and many with incompatible formats. No easy-to-use capability exists to share information among these enterprise systems in a controlled manner.

PLM describes a comprehensive framework of technologies and services that permit manufacturing companies and their partners & customers to collaboratively conceptualise, design, build and manage products

throughout the entire lifecycle. PLM solutions must enable companies to create detailed, intuitive and realistic digital product information; collaborate by incorporating early input from the various participants in order to identify & resolve critical issues; and control & automate critical processes such as release to manufacturing, change and configuration management throughout the product’s lifecycle. PLM has emerged as the primary means by which manufacturing companies can achieve step-change improvements in their product development process.

Architecture mattersA superior product development system must be based on a leading technology that tightly links footprint

and architecture. A comprehensive set of capabilities on an inadequate architecture, or a good architecture that lacks critical capabilities, does not deliver an effective product development system. A comprehensive footprint must offer the capabilities necessary to improve product development processes. These processes involve the entire enterprise and are further extended to include suppliers, partners and customers.

The footprint of Product Development System (PDS) must provide five essential capabilities:� Create detailed digital product

information (MCAD, ECAD, software, documentation, etc)

� Collaborate with distributed

To consistently produce products, companies need a product development process that becomes in itself a

competitive differentiator.

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Rafiq Somani is Country Manager – India Operations at PTC, Product Development Company. He is responsible for driving growth of PTC India’s Product Life Cycle Management (PLM) solutions across key verticals such as automotive, industrial, aerospace & defence, consumer, infrastructure and publishing.Email: [email protected]

project teams, customers, suppliers, and partners� Control content and automate processes and

product quality� Configure content to match products and services� Communicate via dynamic publications But, this footprint of capabilities must align with the sensible system architecture. Without an integral, Internet-based architecture that knits together, and with these five interdependent capabilities, manufacturers cannot effectively optimise their product development processes. Therefore, leading technologies must ensure that the footprint of capabilities are built from the ground-up on an optimised architecture that addresses the needs of the digital product value chain, what PTC calls the ‘3 Is’. The architecture must be:� Integral in the sense that it shares a common

database scheme, common business objects & web-based user interface

� Internet that it deploys seamlessly across existing Intranet and Internet infrastructures to accommodate a distributed value chain as well as provide a seamless user experience across applications

� Interoperable that it integrates easily with other systems (ERP, SCM, CRM, as well as a variety of MCAD/ECAD and software applications) using standard protocols and integration approaches

Today, the emerging need of a PLM system is to have a strong capability to define & automate processes, and not just tie those tools together, which help engineers create a product with a set of capabilities. A competitive value can emerge when organisations focus on not just ‘what’ they develop, but ‘how’ they develop. Examples of processes involved would be concept development, change management, quality management, manufacturing process management, component sourcing, to name a few.

In general, the goal of Lean techniques is to define processes, which allow people – individuals, functions or organisations – to operate as one entity to create breakthroughs in a continuous value stream to raise the whole chain to a high level. PLM system is the technology, which ties people and processes across the supply chain to help create winning products.

Expert Zone - EPO


Two of the industry domains that are causing growth wave in India are aerospace and automotive. A lot of multi-national companies tend to set up their captive centres for engineering services, but over time, many companies have realised that engaging with the right Engineering Services Outsourcing (ESO) company adds value and helps them sustain & improve their cost structure.

In the era of fast-moving products that need to be developed within a stipulated timeframe, manufacturing has undergone a major revolution

in the engineering of products. The aerospace industry is expected to grow significantly in India, driven by offset requirements and the need for smart sourcing to gain cost and time benefits. The automotive industry is also growing significantly in India, driven by the need for sourcing components faster and cheaper for international as well as for the expanding domestic market.

Hence, engineering services and manufacturing sectors in India are on a rapid growth path. The latter’s growth has translated into demand for high-end and sophisticated machinery like three/four/five axis milling and turning machines for metal cutting, special purposes, electro discharge, wire cutting/laser cutting/waterjet cutting, bending & forming, etc. Hence, machining and machine tool companies are seeing increased demand for their products in India.

Helping handOutsourcing is an emerging market, as

Reach peak productivity levels easily

ENGINEERING OUTSOURCING

Expert Zone - EPO


an Engineering Process Outsourcing (EPO) company can work with some of the top machine tool industry leaders across the globe and address their engineering technical requirements while providing cost-effective solutions.

Global Product Development (GPD) methodology can be deployed to provide services ranging from concept design through product re-design, drafting, detailing and modelling, engineering analysis to simulation, verification & validation, application engineering, machine layout detailing, design of tools & gauges, fixture designs, process planning, CNC programming, cost excellence programs, cycle time estimation, etc. Modular design and creation of standard parts libraries are also available, thereby saving engineering and manufacturing costs.

Global product developmentA strategy to leverage the cost advantage and engineering resource availability offered by various locations in low-cost and high-cost areas is to set up GPD centres. These assist OEMs, which want GPD as a framework/methodology for engineering that leverages labour arbitrage and time zone differences to develop products faster, better and cheaper.

With the intent of penetrating into a market created by the growing demand for high-end and sophisticated manufacturing machinery, one can engage with the machine tool industry by offering engineering services using CAD/CAM/CAE tools, and develop a few strategic relationships with some OEMs & their suppliers.

The presence of the outsourcing service company in global markets such as North America and Europe can offer services to the machine tool industry, including assisting it in identifying the core and non-core engineering processes within the company and moving non-core engineering processes & work packages to India for

offshore execution. The machine tool industry has evolved significantly since the 19th century, and is highly cost-conscious, with a need for delivering at the right time with the required quality levels.

Hence, any engineering outsourcing company that caters to this industry needs to have good

EPO solutions and services

� Design and detailing

� Engineering analysis

� Manufacturing engineering

� Technical publications

� Sustenance engineering

� Embedded systems

� Special services

� Plant and process

Expert Zone - EPO


offshore engineering processes, and a high level of domain knowledge in the machine tool area.

Experience and expertiseApplication engineering plays an important role in the entire product development lifecycle; expertise is required in bringing engineers having extensive manufacturing experience, who can take decisions from the grass-root level on process planning, simulation of cutting process and fixture designs & tooling. These engineers then work collaboratively

within a team to arrive at the right design, which would yield the required end-results like reduced cycle time & tool changeover time, and so forth.

By bringing in the right talent under one umbrella makes the difference. It also lends support to customers by leveraging its vendor management and supply chain skills for helping customers in manufacturing components and providing them with low-cost, high-quality fixtures and tooling.

Improve time to marketCollaboration with a leader in the engineering outsourcing space will enable the machine tool company

to avail unmatched support across the entire product life cycle – right from design and modelling through analysis, prototyping, automation,

data documentation, manufacturing support, vendor management, and in-house precision machining. Also, some of the steps that can be taken are to: cut product development costs, shorten lead times, extend capacity, maximise engineering resources, and finally, outsource engineering requirements to receive better, faster & more value-optimised solutions.

Courtesy: Quest Global Inc

Benefits

� Focus on core activities

� Flexibility of manpower

� Faster time-to-market

� Reduced product development costs

� Knowledge retention

� Move to a variable cost mode

Collaboration with a leader in the engineering outsourcing space will enable the machine tool company to avail

unmatched support.

Expert Zone - Green Manufacturing


DFSDFSD

The cornerstones of sustainable productivity goals are to work more efficiently, economically and more safely in ways that minimise the impact on the environment. To attain these objectives, one needs to constantly challenge as well as find new ways of working, utilising a balance of the resources available to us – human, natural and capital.

The key is to focus on whole-life costs instead of short-term profitability. This makes it possible to maximise returns on investment.

The other priority is to save energy. Finding new ways of reducing the amount of energy our tools utilise while increasing productivity is the challenge.

One example of this is the CO2

neutral tightening that is possible with battery tools. Another is an airline audit that allows monitoring the efficiency of compressors in airline facilities and how much pressure is delivered to the pneumatic tools being used. It is solutions such as

these, and many more that provide a world of opportunities for improving and sustaining productivity over time.

Investing in quality toolsTo help improve productivity and sustain it over a longer work-life, a strong emphasis should be made on the benefits of preventative maintenance. As a result, the increase in uptime over many more years of usage directly translate into low-operating costs. New ways of designing tools that have better power-to-weight ratios should be adopted. The usage of strong and light materials such as carbon-fibre is one way to accomplish this. Tools should also be properly

Reducing the environmental footprint

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aligned and balanced. This makes them easier to aim and more safe to work over a longer period. Also, incorporating solutions that dampen vibration is another alternative to save energy. These factors work together to increase productivity.

The right optionsSometimes, the answer to a seemingly simple question can make an enormous difference. For example, design engineers at a major truck manufacturing company wondered what might result from using electric tools to assemble the chassis of its trucks and buses with smaller bolts instead of pneumatic tools and larger bolts that were used. The results were eye-opening. The company discovered that by migrating from pneumatic to electric tools and smaller bolts & screws in the process, the weight of every chassis assembled could be reduced by up to 200 kg.

The facts behind this story can be found in ‘The Weight Loss Method,’

which is the result of German VDI2230 standard. Initially, large European truck and bus manufacturers began utilising electric tools because vibrations are minimised, and quality

can be monitored, along with more precision and control. However, in the recent years, the ability to save weight by using smaller bolts and screws has drawn more attention.

Carl Carlin, Head – ‘Advanced Fastening Technology’, Atlas Copco, believes that this gives advantages to manufacturers. By multiplying the effects of saving 200 kg on every large truck or bus, it is an area that can result in big savings for the environment. From the usage of natural resources for manufacturing, to the costs of

transporting vehicles, to the energy savings that result from operating lighter vehicles, the utilisation of electric tools can make an enormous impact in a multitude of ways.

Reducing environmental footprintFrom specialty shops to large, high-volume global manufacturers are required to reduce their environmental footprint in ways that will show on the bottom line, while improving competitive edge and corporate social responsibility. Some of the ways to comply to this are:

Migrate to electric tools: A good leap one can take in terms of energy efficiency is to migrate to sophisticated electrical tools with

From specialty shops to large, high-volume global manufacturers, all are required to reduce

their environmental footprint in ways that will show on the bottom line.



built-in intelligence. As a bonus, one can receive constant positive feedback in quality control. Tools powered by compressed air have a lot of positive benefits too, including proven durability and easy operation. However, these also consume up to 20 times more energy than their electrical counterparts, which is why migrating to electric tools makes sense in both short term and the long run. Electric tools are more comfortable to work

with, they vibrate less and make less noise. Larger, advanced industrial production facilities also offer quality monitoring. These add up to achieve sustainable productivity.

Optimise air line: A huge amount of energy is wasted due to leaks in compressed air systems. Capacity losses of up to 15-20 per cent are common in many installations. There is a huge amount of energy wasted by leakages due to less than optimal

installation. In fact, this can be prevented quite easily. For example, using high-flow couplings attached to the correct size of hoses, and having the correct regulators in place, can result in significant energy cost savings and increased productivity. Utilising only one bar more of pressure than what is needed unnecessarily increases air pressure by 16 per cent, which directly translates into high energy consumption and costs. Having the correct regulators alone can go a long way towards reaching peak efficiency and energy savings. In addition, good installation also improves overall productivity by allowing workers to accomplish more in few hours.

Achieve CO2 neutral tightening: The biggest impact on energy savings is by powering the production line with solar panels or windmills. The evolution of tools from those that are powered by air and electricity to ones that operate on batteries makes this possible and translates into

New areas for ergonomic improvement

Perfectly balanced tools: Tools that fit comfortably in hand and are perfectly balanced increase productivity and make working conditions much safer in the long runReduce vibrations: Vibration from tools is by far the greatest threat for an operator’s health. The European Union has published guidelines regulating exposure to vibration in the workplaceRisk-reducing accessories: Torque arms, reaction bars and other accessories can help prevent injury caused by prolonged usage by reducing the weight of a tool for individual operators. And, each accessory is engineered with an emphasis on safe & reliable operationHigh power, low weight: The continuous journey to pack more power into lighter tools is a top priority

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greater savings. By developing such tools, with renewable energy, the savings are immediately evident and lasting. In addition, these advanced tool solutions mean that sustainability can be put in place without sacrificing practicality or productivity.

Good ergonomics means a better work lifeOperators are the key to achieving high quality and a sharp competitive edge. Focus should be on developing tools that allow people to work throughout the day at a consistent level of high quality without giving up a rewarding personal life. Good ergonomics are also important for maintaining a healthy bottom line for businesses, which are into manufacturing. In workplaces where power tools are employed, injuries may be common if safety standards are not in place – not to mention the cost involved. Scientific reports indicate that the cost of productivity losses and quality issues are at least three times more than the disorder itself.

High quality leads to better economyOne of the biggest threats to our society and the environment is over-consumption and the short-term perspective many people have for manufactured goods. Simply put, we have to stop throwing away things and make the most of our resources. Therefore, each tool has to be of the highest quality possible. To achieve this, manufacturers need to constantly look at how they can refine details, while also considering the bigger picture.

For example, by designing tools that employ spiral angle gears with an improved contact area instead of conventional gears, the life of each tool is lengthened. As a result, tools that are used for a short time have to be discarded for recycling. Innovations such as carbon fibre instead of lightweight plastics can add years to the durability of the tools. It all starts by having the right tools for the job at hand.

First, invest in better quality tools that will last. Then, make sure they last even longer by following a proper maintenance programme. It is invaluable to put practices and tools in place that are better for the environment today, tomorrow and far into the future.

Courtesy: Atlas Copco (India) Ltd

Ways to save energy

� Switching to smaller bolts can reduce the weight of cars by 20 kg per vehicle

� The lighter the vehicle, the less the fuel needed to drive it, and CO2 emissions are released into the atmosphere

� If every vehicle was manufactured using smaller bolts, it would cut fuel consumption by 12,000,000,000 litrea year (the equivalent of five oil tankers) and dramatically reduce CO2 emissions on a global scale

Expert Zone - New Materials


For an uninterrupted turning of steel, the latest advancements in coatings technology promise faster, precise and cleaner metalworking for the manufacturing industry. By providing excellent wear-resistance and tool-life improvement, the new grade of carbide tools promise to deliver productivity benefits and cost reductions to the end-user.

During the recent past, the metalworking industry has seen launches of many new tooling products in India and across the world.

The main focus has been in providing high-productivity solutions for modern high-powered machines. The industry has witnessed new lines of milling machines for cast iron and steel rough milling, and round cutters for the dies & moulds market, turning lines that enable high depth-of-cut application and a modified range of indexable drills, among others. The market has

also seen the arrival of a combination of standard and customised cutting tools that can optimise production for the automotive industry.

The advanced range of new-generation Cubic Boron Nitride (CBN) inserts can machine high-hardness components up to 65 HRc. In many cases, these tools have eliminated grinding with CBN turning, offering shorter cycle times and cost advantage to the user.

Designed for futureThe tooling industry invests a lot

Coating technology for new-age tools

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in the R&D and in improving new & advanced range of tools to constantly keep pace with the changing demand trends. One revolutionary concept is a premium range of carbide grades for machining performance. The technology enables tooling suppliers in providing a shining appearance on the inserts and also enables to reduce the micro chipping of the inserts while machining.

These carbide grades provide a substantial increase in insert life, due to the most advanced coating technology followed by a special surface treatment. This development in coating increases tool life by 30-40 per cent over conventional grades. The durable coatings offer ease in machining all types of materials. The newly designed process improves toughness & chipping resistance, and thus reduces friction & built-up edge.

Columnar crystalsWith the combination of a Chemical Vapour Deposition (CVD) coated layer with fine and hard columnar crystals of Ti (C, N), and strong carbide substrate, the cutting performance for a variety of cast iron turning is improved manifold. These columnar crystals offer chipping resistance when turning steel. These are most suitable for various applications in steel and stainless steel machining.

These upgraded carbide grades feature a tough substrate with a (Ti,Al) N PVD coating layer, that provides triple force with additional features of well-balanced fracture resistance. Superior performance for turning of high-temperature alloys is also an advantage due to high wear and oxidation resistance. These are generated from the (Al,Ti) N Physical Vapour Deposition (PVD) coated layer and the fine grain cemented carbide substrate with diffused Co.

ChallengesThe metal cutting industry in India is changing at a fast pace with arrival of new sectors and materials on the shop floor for metalworking. Constant advancements are made in carbide tools in providing the right tooling solution to ensure quality and productivity at the same time. The market is in an aggressive phase, while the machine tool builders are recovering and are close to the record production levels attained in 2008, the market needs high-productivity tools for increasing

Advantages of coating technology in inserts

� Substantial increase in insert life � Easy machining � Improves toughness � Reduces friction and built-up

edge � Increases productivity



the feed rates to satisfy the modern machining requirements.

High-technology toolingIndian customers are also investing in high-powered machines that demand tools focussed for a specific requirement. With customised milling cutters, which can work on high-feed rates, with more number of teeth to enable faster machining, the latest range of cutters enable high-speed machining for dies & moulds sector with low-depth cut and high-feed capabilities.

Such machining was not possible on low-powered machines, but now a new range of tools have been designed that can function on smaller machines and enable customers to work on high-feed rates. New drilling solutions, with a revolutionary design feature to function on high-feed rates, have more gullet space to enable better chip evacuation through coolant applications that can be used in machining as well as turning centres.

Today, the machine tool builders are increasingly developing new generations of multi-function and multi-tasking machines, which enable reduction of production lead times, improvement in machining accuracy, and reduction of floor space & initial costs, expenses, etc. New-generation multi-functional tools are most efficient on multi-tasking machines that reduce cycle times. They are new trends in the machine ool industry.

Yoshito Uehara, President and CEO, Tungaloy Corporation, is heading the company worldwide. He is the driving force behind the phenomenoal growth of Tungaloy, witnessed in the last 3 years. Email: [email protected]

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Expert Zone - New Markets


In the current market scenario, customers need a wide variety of processes and tools for designing, manufacturing and marketing of products. As more & more companies place their trust on simulation and prototyping software for product development, IT-enabled manufacturing technologies are becoming crucial for manufacturing transformation that can drive efficiency, high productivity, competitiveness and sustainability.

To keep pace with changing trends in the manufacturing industry, the machine tool sector has to constantly design and re-

design products to ensure quality, performance and shortest time-to-market lifecycle. Powered with some of the most widely used tools for digital design documentation – electrical & mechanical design,

manufacturing & production layout and facilities design & process plant design – these digital design solutions are becoming popular with each passing day. In addition, when combined, these capabilities are able to help drive tremendous improvements, not just in the design process, where our industry has so far traditionally focussed, but way beyond.

Competitive edge for new markets

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Digital advantageRather than building physical prototypes, the performance of a product can be digitally simulated, saving time and money required to build multiple physical prototypes. The optimised design can be tested and broken before spending on materials or labour. After being manufactured, the digital prototype can assist with accurate documentation of material and design data, which is important for compliance with environmental regulations.

Digital prototyping solutions are employed extensively in the manufacturing environment. Industrial designers utilise latest software to digitally sketch design ideas and create 3D digital concept models for validation that can be shared with the engineering or manufacturing team. Engineers utilise these designs to explore ideas with simple, functional representations that help generate a digital prototype for best bi-directional inter-operability between 2D & 3D mechanical and electrical design applications in the market.

Integrated stress analysis and motion simulation help engineers

optimise and validate entire designs digitally and confirm that customer requirements are met even before the product is built. Manufacturing teams benefit from accessing the most current and accurate data, avoiding mistakes caused by using outdated documents. Going digital is definitely moving one step closer to paperless manufacturing processes.

Digital prototypingA digital prototype saves time and money for the design team, as it analyses & tests alternative options. In many cases, the digital prototype can help predict the impact of the proposed change on product’s characteristics and the energy consumed during its manufac¬turing. Armed with such data, the design team can quickly and cost-effectively experiment with different materials and process variables until it discovers the optimal combination. Multiple options for the same product can be saved at any stage, from concept through manufacturing, allowing the team to pursue multiple strategies parallely.

If the market or regulatory environment changes, the product can quickly be optimised to meet the latest conditions. The digital prototype reduces risk by allowing the design team to incorporate changes much later in the process, increasing flexibility to design sustainable product strategies.

Competitive edgeThe powerful 3D modelling tools come at affordable prices that most manufacturers can easily utilise. Small & Medium Business (SMB)

segments across manufacturing verticals like industrial processes & machinery, automotive and consumer goods are attaining a major boost through this increasing range of digital prototyping products. There are more nimble and powerful 3D modelling tools now available in the market at extremely affordable prices that most SMBs can easily avail.

Further, the software for digital prototyping is also scalable, which in turn means that a manufacturer can move from 2D to 3D at his/her own pace. In fact, products available today in this field include products that are attainable and cost-effective. With solutions available for digital prototyping, it is easier for manufacturers to stay competitive in an increasingly intense global marketplace.

Fast market reachUsing a single digital model throughout the design process helps product development teams boost the level of communication with different stakeholders while having more innovative products to be marketed. By using a digital prototype, manufacturers can visualise and simulate the performance of the design with less reliance on costly physical prototypes.

Digital prototyping gives conceptual design, engineering and manufacturing departments the ability to virtually explore a complete product before it becomes a reality. With digital prototyping, manufacturers can create, validate, optimise and manage designs from the conceptual design phase through the manufacturing process.

Jayant Keswani is Head of Marketing at Autodesk India & SAARC. He is a management graduate from Institute of Management Technology, Ghaziabad. With over 19 years of experience in sales and marketing, his tasks involve developing brand strategy, cre-ating marketing programmes/campaigns, customer relationship management, database management and overseeing marketing research. E-mail: [email protected]

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Industry Insights


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Considered as the backbone of India’s huge and diverse manufacturing sector, the machine tool industry has enormous growth potential. It is one of the segments that has recovered faster from global economic slowdown, compared to other manufacturing segments. Geetha Jayaraman highlights the growth seen by the industry in 2010, and the opportunities ahead.

Currently, the machine tool industry in India is estimated at around ` 1,700 crore. It provides strategic support for the growth of key

manufacturing sectors such as capital goods, automotive and white & brown goods. The machine tool industry plays a vital role in development of strategic sectors such as railways, airlines and defence.

To transform India into a global manufacturing hub, local

manufacturers are constantly striving to produce high quality and cost-competitive goods. The domestic machine tool industry plays a significant role in propelling this growth trajectory, provided the industry starts exporting its goods. Shrikant Savangikar, Vice President & Factory Manager - Pune, SKF India Automotive Division, says, “Great opportunities are waiting for the Indian manufacturing segment. But, from our perspective, we are

Backbone of a booming economy

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still required to go outside India for special purpose machines like cost-effective solutions for grinding machines for bearing industry, auto assembly machines, etc.”

After flat growth for two years, the Indian machine tool industry is experiencing boom times again. Inclusive of imports, it grew by 47 per cent to ` 1,923 crore in the first quarter of 2010-11 (April-June), comparedd to the corresponding quarter of last year. This is due to the rise in demand from automobile and auto components sector. Domestic machine tool output grew by 143 per cent over the corresponding quarter of last year, to ` 502.7 crore. The Indian manufacturers have taken advantage of this positive swing and have tapped into new opportunities in overseas markets, leading to a 9 per cent increase in exports in the first quarter.

According to Vikram R Sirur, Executive Vice Chairman, Miven Machine Tools Ltd, “The country is set to become a key player in the global machine tool industry and is likely to see substantial high-end machine tool manufacturing. Demand is so huge this year that several companies are unable to cope with it. Many are facing shortage of materials like castings, forgings and bearings. The industry

in India needs to expand capacities significantly to meet the demand from the domestic manufacturing sector.”

At the same time, industry experts are positive that this will be achieved, as several international firms have entered the Indian machine tool domain, or have announced plans for joint ventures or wholly-owned subsidiaries in India. This shift from the developed market to the emerging market is due to the stagnation of manufacturing capacity and the constant fall in growth rate of the machine tool industry in the western economies. The other reason behind the shift is emerging economies like India are considered as low-cost and high-skill geographies.

Domestic marketThe Indian machine tool industry comprises around 150-160 players in the organised sector and around 400 units in the small ancillary sector. Ten major Indian companies constitute

almost 80 per cent of the total production. While large organised players cater to India’s heavy and medium industries, the small-scale sector meets the demand of ancillary and other units. Many machine tool manufacturers have also obtained CE Marking certification, keeping with the requirements of European markets.

Opportunities are clearly visible in every sector. After facing a downturn, everybody is buying machines this year. Sunil Mehta, AGM - Automotive, Messung Automation, avers, “This year, the ancillary industry has witnessed huge growth, as there is a rise in orders from the automobile industry and the power sector, especially nuclear power.” Companies like BHEL and L&T are manufacturing large number of power equipment. The industry expects to get multiple orders from these companies.

Although, the Indian machine tool industry has its fair share of domestic manufacturers, it still remains a net importer of machine tools. Import in this sector has increased by 3.6 times in the fiscal 2008-09 over fiscal 2004-05. The major export suppliers include Japan, Germany, Italy, Korea, China and the US. There are no restrictions on the import of machine tool equipment to India and the total duty for importing is 8.1 per cent. According to Mehta, one of the basic problems faced by a manufacturer in India is the unavailability of trained/skilled manpower.

The metal cutting CNC machines contributed nearly 66 per cent of the total revenue for the Indian machine tool industry in 2009-2010. Within these, the major categories are Numerically Controlled

The country is set to become a key player in the global machine tool industry and is likely to see substantial high-end machine tool manufacturing.

Vikram R Sirur, Executive Vice Chairman Miven Machine Tools Ltd

Highlights of the Union Budget 2009-2010

Export development incentive� ` 124 crore allocation for market development assistance scheme� ` 4,000 crore provided as special fund to Small Industries Development Bank

of India (SIDBI) – to lend to micro and small enterprises� Adjustment assistance scheme to provide enhanced export credit and

guarantee corporation cover at 95 per cent to badly hit sectors, extended up to March 2010

� Service tax exemption till 31 March 2010 for export promotion councils and Federation of Indian Export Organisations (FIEO) on membership and other fees

Tax considerations� Increase in centre’s tax to GDP ratio at 11.5 per cent � Introduction of dual Goods and Services Tax (GST) from 01 April 2010� Release of new direct taxes code � Early introduction of SARAL - II forms

Industry Insights


(NC) machines and Flexible Manufacturing Systems (FMS). In the metal cutting conventional segment, there are General Purpose Machines (GPMs) and Special Purpose Machines (SPMs). In the metal forming sector, conventional machines are preferred and these contribute around 9 per cent of the revenue, in comparison to 4 per cent for metal forming CNC machines. Sirur confirms that the industry’s prospects mainly depend on growth of the engineering sector.

OpportunitiesThe Indian machine tool sector offers several opportunities for investment and trade purpose. Given the current gap between demand and supply, there is a need for adding capacities in this sector. Mehta says, “The industry is moving towards increasingly sophisticated CNC machines, driven by demand from key user segments, such as automobiles and consumer durables. Machine tool manufacturers need to develop capabilities to cater to this demand, and investments in this area could yield long-term benefits. At the same time, R&D and design capabilities are also gaining importance, as they are critical factors for future success and are areas that could see increased investment from Indian and global players.”

A few global automotive players have already leveraged India as a design hub and this trend could extend to other manufacturing sectors, such as, machine tools. Savangikar says, “Several Indian states offer attractive locations for setting up manufacturing and R&D facilities in the country. SKF has also

expanded its base in the country, with plans for three more plants in place, along with expansions in existing two plants. The expectations are no more only in terms of less cost of manufacturing, but world-class quality and world-class environment in manufacturing is also expected. For this, there is a need to bring about cultural change in day to day working practices, new paradigms in union-management relations and show good trends in productivity and quality.”

Future trendsA burgeoning Indian market and a capacity-constrained Indian machine tool industry resulted in a zoom-phase for importers. Most of the machines imported comprised metal cutting machine tools. And, within this segment, machining centres, turning centres and grinding centres form the largest chunk of imports. These three machine tool categories captured 40 per cent of the total machine tool imports in 2009.

The rise in import can also be pointed to increase in the number of international companies setting base in India. “Of late, there are many international companies trying to set their base in India. The reason behind this shift is that the emerging market has huge growth potential, and everyone is seeking a share of the same,” states Mehta.

In future, one will witness many big international companies setting up base in India. This will lead to rise in demand for the best-in-class production and increase in competition among the domestic players.

Great opportunities are waiting for the Indian manufacturing segment. Several Indian states offer attractive locations for setting up manufacturing and R&D facilities in the country.

Shrikant Savangikar, Vice President & Factory Manager - Pune SKF India Automotive Division

Global Outlook


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Riding high on the upbeat economic outlook for India and its manufacturing sector, the metalworking industry in the country is also striving towards strengthening its machining capabilities, productivity benchmarks and quality standards. The future holds many opportunities for growth and expansion for the industry as it registers a parallel growth curve in sync with the manufacturing sector.

After the economic downturn of the recent past, the industry has been registering a turnaround in the current fiscal. Demand

has seen strong growth. This trend is expected to continue at least for the next two to three years based largely on new investments in auto and auto-component industries. There is also a strong demand for large machine tools from power and infrastructure industries. Given the large outlays in

infrastructure, this demand is also likely to be strong for the next few years. This will be largely led by technology upgradation that will support quality and productivity for the industry.

Among leading technologies pertaining to machine tool industry, CNC turning and machining centres will be top draws in coming years. In addition, new machining technologies with the combination of processes on single & multi-functional machines will grow rapidly in the near future.

The next big leap

METALWORKING ENTERPRISE

P J Mohanram

Global Outlook


As a foundation framewrok, metal forming technology is also likely to be an important component of growth among machine tools.

Product design and applicationDesigns for multi-function machines are the latest to reach the market. While earlier these machines combined various machining processes, the recent developments enable these new machines to combine metal forming processes with metal cutting and finishing processes to drastically increase productivity and make operations Lean. In the case of metal forming, servo presses and hot forming technologies are emerging. Micro-machining and surfacing technologies are becoming cutting-edge due to their applications in electronics, medical, instrumentation, sensorics, micro and nano technologies. These are considered to be the growth engines of the future.

Technology gap between India and rest of the worldThere is a vast gap between Indian and international markets when it comes to technology. However, the user industries in India are rapidly adopting the latest technologies, which is reflected in increasing imports of the latest metalworking machines. This gap can be bridged only through a strong R&D effort through participative approach by machine tool industries, its users, academia and R&D institutions. The government is actively encouraging the development of an eco-system that supports such initiatives.

It will be necessary for the government to fund R&D expenditure initially and then recover it through royalty on the technologies developed. Another important step could be to insist on technology transfer and local content of manufacturing when machine tools are imported in a substantial quantity. Development contracts from large users to machine tool companies can spur technology

development. The Offset Trade Policy could be utilised as an instrument to bring new technology into India.

The government can also facilitate the acquisition of select foreign machine tool companies - both to obtain technology and markets. Some

private machine tool companies have already adopted this route successfully. China is reported to have acquired around 15 high-technology machine tool companies in Europe and the US to get the latest technologies. Our government must consider a mix of these policies to bridge the technology gaps in the shortest possible time.The Indian Machine Tool Manufacturers’ Associaion (IMTMA) has requested the government to allocate an amount of ` 2,000 crore for technology development in the industry.

Leading investment destinationAt present the top three destinations would appear to be China, India and South-East Asia as these are the growing economies. There is also a gradual shift of manufacturing from advanced countries to these regions to take advantage of lower costs. As a result, machine tools will be required in large numbers in these markets. China already leads the world in both production and consumption of machine tools.

Future role of the machine tool industry The manufacturing sector in India is heading for a healthy growth in the

coming years. The government itself has targeted a 25 per cent contribution to GDP from manufacturing, from the current 16 per cent. The encouraging success of the local auto industry in becoming a manufacturing hub for small and perhaps medium cars

both for domestic and international consumption is sure to push the demand for machine tools substantially.

The vision document and perspective plan 2010 prepared by the sub-committee of the Development Council for Machine Tools constituted by the government has projected a minimum demand growth of 15 per cent Compounded Annual Growth Rate (CAGR) for machine tools. On this basis, the demand for machine tools is expected to rise to around ` 30,000 crore by 2020. The machine tool industry should be looking at a production target of around ` 23,000 crore by 2020, to have a 60-65 per cent domestic marketshare and also have an export content of 20-25 per cent, realising that these targets will require fresh investments in capacity creation and expansion.

The industry has requested the government to support it by creating a seed-capital corpus fund and through the proposed capital goods industry support scheme for the establishment of integrated machine tool parks and common facility centres. These measures would help a focussed expansion of the industry with technology upgradation.

PJ Mohanram is the Director - Technology Division at Indian Machine Tool Manufacturers’ Association (IMTMA). He has been an active member of the machine tool industry in India and has taken on the task of improving the level of technology implementation under the aegis of the association. Email: [email protected]

There is a gradual shift of manufacturing from advanced countries to these regions to take advantage of lower costs.

Future Footprints


With changing dynamics of the metalworking industry, time has come for machine tool manufacturers to explore new avenues of growth. This section presents four promising sectors - medical, aerospace, nuclear and renewable energy - which are poised to become key growth drivers for the industry.

Future Footprints - Medical


The medical devices market is growing substantially in a worldwide perspective. For leading builders of high-end, laser machining systems for super-precision cutting, drilling and welding of micro parts & laser cutting of tubes, medical devices is an upcoming market.

The usage of lasers as a tool for micro-machining in high-precision cutting and drilling of medical devices such as stents,

canulas, needles, among many others, is fast becoming the trend. On a worldwide basis, growth in the field of laser cutting of tubes for medical devices is expected to rise by more than 20 per cent per year.

However, this trend is predicted to accelerate, especially in the fast-growing economies like India, China, Russia and a few Latin American countries, resulting in establishing local production for the growing local needs. In these countries and in small Asian countries, governments have identified medical device manufacturing as a key industry segment of the future.

Lasers for micro-machiningMost of our machines are used for producing stents from various materials. Stents are tubular shaped implants similar to mesh, to be placed mostly in arteries to ‘repair’ and prevent further blockages. These stents are cut from tubes with diameters less than 2 mm. Once

placed in the patient’s body, it will expand to its real size – a multiple of its original diameter. These structures are fine and the materials are often delicate that only the accuracy of a laser can fullfil these requirements.

This is possible with minimal heat affected zones and high speed. Here, it is not only the laser but also the system where it is integrated, which plays an important role. Only a robust and precision-oriented laser machining system can deliver consistent quality – a top priority in medical device manufacturing.

Laser sourcesIn the last couple of years, systems with complicated laser sources were replaced by handy fibre laser technology. These laser sources now are more reliable, with incomparable efficiency and best quality. This technology will be suitable for most cutting applications of stents or needles. But, medical device manufacturers have identified polymers as one of the future materials for stents. To cut these, new laser sources are necessary. These ultra-short pulse lasers can now cut any material,

Georg Dobler

Laser machining for medical devices



using cold ablation instead of hot-cutting.

Another advantage is their excellent cutting quality, which offers new options when cutting traditional stent materials like cobalt chrome, stainless steel or nitinol. Due to its capability to cut without heat-affected zones and completely dross-free, a large portion of conventional cleaning process can be eliminated.

Machine designDevices that demand micro-machining include needles, stents and encoscopic devices, among other mass products. Once the design and production methods are decided, the production numbers developed per year of a single device can reach millions. These machines therefore have to be made for continuous mass production. Sometimes, this involves fully automated systems that have to be as reliable as the laser cutting system itself. Also, it has to be user-friendly.

During production, all input parameters – not only of laser but also gas & water supply, and of the motion system – have to be under control. If this is fulfilled, cutting speed up to 3,000 mm/minute can be achieved without any defects. As a consequence, another important requirement is traceability. Input parameters have to be under control, but they also have to be reproducible, and records have to be maintained.

Hurdles in growthA successful launch of a medical product requires ample research and development. Especially in China and India, some companies lose a lot of time and money by not investing in already tested & proven equipment. With continuous efforts, it may be possible to create a stent with an experimental laser set up. But, once it comes to production, these systems fail in producing consistent quality in being safe & easy to operate, and

more importantly, in producing fast. Thus, many companies eventually invest in replacing their home-made machine by a purpose-built stent cutting system.

The demand is coming from start-ups and university spin-offs in these countries, which replaces expensive imports by indigenous products. Therefore, a huge emphasis is placed on research and development in these countries. The market trend indicates that replacing imports is only the first step, and exports to former supplying countries in the west will outnumber imports.

Business outlookIn the field of laser micro-machining, medical device markets are driven by research, improved expectancy of life, new diseases caused by increased wealth, and economic strategies. So, the need for stents in the future will increase in Asian countries with large populations.

The advantage of these countries in tapping the medical devices market will be useful only if they introduce the latest technologies available in the market. The medical

machining industry expects large volumes to become competitive in India & China, and has the potential to emerge as the number one stent producing region within five to ten years. These will not only benefit large companies, but also small units, as there will always be some small-scale productions needed as well.

Automation toolA major trend in micro-machining of medical devices is automation. Of course, this started in regions where labour is expensive. But, one important factor is the elimination of human errors. Medical implants are bound to be of 100 per cent good quality and are expected to be safe. Each company spends millions of dollars in designing, prototyping, testing and marketing of stents.

Also, to avail government approval, and later for fullfilling the specifications in export markets, manufacturers have to prove a plausible process description. Very often this is only possible without having the highest grade of automation.

Stainless steel stents and polymer stent cut with pico laser

Georg Dobler is International Sales Manager with Swiss Tec Technology GmbH. He has extensive knowledge in the domain of laser-micromachining processes for the medical device industry, and has been actively involved in the product devel-opment cycle of the company. Email: [email protected]

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Recent advancements in dental engineering have led to the arrival of new materials that demand high precision and extreme machining environment. Ultrasonic multi-axis machines designed to machine difficult-to-machine materials for dental prostheses promise speed, precision and quality to the growing demands from the dental industry.

Currently, the dental technology industry is in the midst of a revolution; there is a rising tendency to replace manual jobs in the manufacturing

of dental prostheses with automated processes. The leading high-speed high-performance machine manufacturers have recognised this market trend early, and have responded to it with the introduction of special machines catering to the needs of this emerging market. The state-of-the-art ultrasonic range of machines that is compact and applicable for all materials is promising.

Need for changeFaster and more accurate machining capabilities on a variety of new materials in the dental prostheses are a requirement for this specialised field in the medical industry. This demand has led to the rapid modernisation of dental prosthetic production processes. The solution now on offer is a technology integration that enables the combination of 5-axis milling with ultrasonic hard machining of advanced materials – the new ultrasonic range of compact 5-axis milling machine.

The dental sector is registering a rise in demand for high-technology machines

that derives a transition from manual to industrialised CAD/CAM manufacturers of dental prostheses. At the same time, there is a growing demand for high-quality crowns, bridges and inlays – linked to a trend towards new materials such as zirconium oxide.

Within the scope of the market-oriented strategy, leading machine tool companies have entered this market with the intention of actively shaping the technology development, taking place in the dental sector with tools of design and innovation. The technical contribution is centred on the expertise in both high-speed milling and the unique ultrasonic processing technology.

Dental process chainCNC machining of dental prostheses is more cost-effective, moreover, it offers high degree of precision that is practically unattained with traditional methods. Digital dental models and ultra-modern 5-axis milling machines allow pinpoint precision and open an almost infinite array of possibilities for the user. The dental process chain begins with dentist diagnosis, the type of prostheses that is required. Later, a digital scan of the tooth or the jaw creates the basis for an

Maximum precision and productivity for the dental technology

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efficient CAD/CAM production. The digital image of the tooth is now ready to be processed by the respective CAD software. This eliminates the need for a plaster model of the dental prosthesis. This generates a data set that is prepared for CNC machining.

The special CAM software can then generate a milling strategy from the CAD data of the dental prosthesis. Therefore, the software defines which tools and tool paths are necessary to produce the dental crown, bridge or implant according to the digital data. This makes it possible to produce several models in one cycle, the post-processor adjusts the milling strategy to the machine control. Once the final programme has been written, the machine, depending on the equipment and level of automation, takes over a major part of the remaining work.

The ultrasonic linear machine can then be equipped with a linear magazine or a robotic system, so, all that remains for the user to carry out is to place the raw materials - the so-called blanks in the machine - and later remove the finished milled product at the end. Digital processing of the data along with 5-axis milling guarantees economical as well as high-quality production of dental prostheses.

Milling for dental industryThis technology saves time compared to traditional processing methods. In the case of a combination of ultrasonic technology and high-speed cutting, the machine-milling can process all applications in the material right from soft plastics to hard sintered zirconium oxide. The result is that the patient receives a dental prosthesis that fits perfectly within a few days time, which is identical to the original.

The success of these machines demand a joint-based approach with dental technicians to assess the requirements in the industry as high-performance milling machines would only be successful in the dental sector if these can be used to machine all materials.

Ultrasonic chip removal, in combination with HSC milling, has proved to be the key. This mix of technologies enables the user to machine the whole range of materials commonly used in dental technology. And, 5-axis simultaneous machining means even complex geometries can be milled - one that is normal part of day-to-day operations in the field of dental technology.

Ultrasonic technologyThe usage of an ultrasonic technology makes machining of materials for any dental application possible. Ever since advanced materials such as zirconium oxide and glass ceramics have entered dental technology development, high-capacity CNC milling machines have been a part of daily production. Modern milling centres have allowed industrial production of dental crowns and bridges.

The technology also gives the small dental laboratories the opportunity for structuring their process chain in a more profitable manner while increasing the quality of dentures they produce. The high-frequency 20-50 HZ is transferred from the spindle to the ultrasonic actuator tool holder via induction. Custom piezo-elements in the tool-holder results in a directed super position of the tool rotation with an additional oscillation in the longitudinal direction. The usage of ultrasonic technology in precision machining has successfully broken into the dental industry, due to its innovative machine concept and ingenious strategy.

Flexible solutionThe latest ultrasonic milling machines are compatible with other systems, as they function with open STL data sets that are passed through the whole dental process – from the scanner, right

through the actual milling. It is vital to remain flexible in this continuously growing market to keep a competitive edge. More labs have recognised this fact, which is also reflected in the loss of marketshare for large providers of closed systems.

As is the case with ultrasonic machines, other components must be compatible with each other, ie, they must go hand-in-hand with the open system. The process begins with high-resolution 3-D scanner encompassing the CAD/CAM software and ultrasonic machine. The availability of such high-end technology integrated machines means that dental laboratories can retain their competitive edge in the international market instead of being forced to manufacture in low-wage countries for cost-efficiency reasons.

Future forecastAs technological innovations and design improvements continue in high-speed machining to keep pace with the dynamic development taking place in the engineering market, the combination of ultrasonic machining offers new benchmarks in speed and precision in milling processes for the dental industry.

Dynamic 5-axis milling of high-end dental prostheses and implants

Christian Thones, CEO, SAUER Gmbh leads the new tech-nologies within the Gildemeister Group. With his extensive experience in the field, he guides the activities to ensure the technology know-how is for economical machining. Email: [email protected]

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Future Footprints - Aerospace


Though the Indian machine tool manufacturers mainly focus on automotive, general engineering and dies & moulds industries, the perception now is that sky is the limit for them. One has to be imaginative and resourceful to break the mental barrier, find new avenues, and enter into more sectors. One such emerging avenue is the aerospace segment.

Today, foreign investors eye India as an attractive destination, as India has become an indispensable contributor to world

economy. It is estimated to have a working population of 882 million within the next ten years. Most of this population will fly too, promising sustained growth to the aerospace sector. Past reflections of the trend show that it was merely three years ago that the aerospace industry had 25 per cent of the cumulative orders from the global airline manufacturer Airbus, which originated from Asia.

In recent times, the country has witnessed a rise in air travel. The increasing number of airlines operating in the country, along with many new airports that have come up, coupled with those proposed in various cities, underline the growth of air travel in India.

Machine tools for the aerospace sectorAerospace component manufacturers must consistently produce high-

quality products. They must meet tight delivery schedules, and constantly devise ways to reduce cost. Exacting standards for aerospace machining make it mandatory for each part to be machined with precision, regardless of the complications involved.

Aerospace components withstand extremities in temperature, pressure and velocity, and yet serve for decades. They are often constructed from special but difficult-to-machine materials such as titanium, invar or exotic plastic. The machine tool industry plays an important role in this endeavour. It supports the aerospace sector by churning out products that save on resources and meet stringent quality requirements.

The advantage of currency equation of Indian rupee compared with US dollar and/or euro, increases interest of the global engineering industry towards India for manufacturing and selling their products for worldwide distribution. In addition, India also serves as a buyer of military

A smooth take-off for Indian manufacturers

Ramesh Babu



aircrafts and as a user concerned in upgrading existing military aircrafts and buying parts for them.

Technology demandsAerospace sector demands accurate, fast and economical machining of difficult materials. Time-consuming multiple setups and out-of-tolerance errors are unacceptable. Therefore, it is wise to avoid multiple setups and save time on multiple inspections. Strict conformance must be observed throughout part run at all times. Simultaneous multi-surface, multi-axis machining is a quest that continues to be pursued by machine tool manufacturers world-over, including those in India.

Multi-tasking is another quest. The most efficient ways of machining,

usage of cooling medium, and environment-friendly machining processes are other avenues that attract machine tool builders. Sophisticated 5-axis machining centres are of help in this endeavour. These machines perform multiple machining tasks with minimum setup, part transfer and part handling, while eliminating multiple setup-associated with human errors.

Strategies for succeeding in aerospace machiningThe vendor must exercise complete

control over production. Companies should ensure that operations must be performed correctly, and parts produced must meet specifications. The vendor should be able to demonstrate integrity of tools and machines deployed. In addition, the vendor should install a foolproof method of overseeing the entire process.

The component traceability programme should be efficient. All manufacturing and testing equipment should be well-calibrated. The track record of calibration should be readily available. Further, the system should be open to internal quality management audit by qualified personnel. Acquisition of the AS9100 certificate helps towards this cause.

Business outlookThe aerospace market in India is expected to register good growth in the coming years. For the Indian market, commercial and military aircraft exist on the shopping list. As a progressive policy, the Indian defence sector is also opening up, and the offset policy gives the growth prospects in this sector further impetus. Proof of this emerging market is the healthy growth of HAL and ISRO, which improves the prospects further.

However, the full potential of the aerospace sector can be exploited with more systematic and consistent development of the aerospace support system, regular review of techno-commercial policies, and ready availability of key resources.

Aerospace components demand accurate machining of materials

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� Accurate, fast and economical machining

� Strict and consistent adherence to quality standards

� Difficult-to-machine materials - aluminium, titanium, special grades of steel

� Demand for multi-axis Vertical Machining Centre (VMC) and Horizontal Machining Centre (HMC)

� Tight delivery schedules

Ramesh Babu is General Manager at Bharat Fritz Werner Ltd. The Ministry of Commerce and Industry recently granted a licence to BFW to manufacture parts and sub-assemblies for aircraft, engines, and accessories. He has been actively involved with the team that machine these components in the company. Email: [email protected]



Futurists speculate endlessly about the subject ‘globalisation’. Fortunately, a new metaphor for its impact – ‘The world is flat’ – does not apply to travel plans. Globalisation, in fact, is transforming travel demands and expectations, bringing sweeping changes in airline operations, aircraft design and manufacturing.

The dot-com wiring of the world has turned it into the global village popularised by Marshall McLuhan, facilitating and accelerating trends in

global sourcing, but it has not changed the imperative behind business travel. Many new global business relationships are still established and managed in face-to-face negotiations, creating travel demands by executives for the fastest, most direct transport between origin and destination.

Reliable optionsToday, one can fly non-stop from the east coast of North America to Japan or China. The number of city pairs served by non-stop flights has grown since 1985, from under 6,000 to more than 10,000, and is accelerating as China, India and other developing nations continue rapid industrialisation.

A similar trend is being witnessed in the case of air freight. Global sourcing, selling and just-in-time logistics require that producers receive and ship smaller quantities more frequently, quickly and reliably over long distances, driving long-term growth for air freight. While around 20 per cent of today’s

manufactured goods cross borders, experts predict the volume will grow to 80 per cent by 2020.

Responding to these trends, companies are engineering new aircraft range that can operate economically on both long-range routes and shorter & point-to-point/quick turnaround routes. This is leading to innovations in airframe materials, manufacturing methods and engines. Manufacturers have created a new class of aircraft, the Very Light Jet (VLJ), which is ushering in the era of the personal jet and air taxi. Designed for short haul routes (1,000 miles or less), VLJs can operate out of virtually any airfield, providing time-saving point-to-point access to thousands of locations not served by airlines today. The US expects 1,000 VLJs to be flying in the country by 2012, and 8,000 by 2025.

Latest trendsOn the manufacturing side, aircraft manufacturers are investing in composite fabrication technologies, fast and more precise metalworking equipment, Lean manufacturing methods, and greater application of automation. They are also more widely

Attaining a new high

Eswari Prasad



outsourcing component production, while specifying & qualifying the machinery and processes to be employed.

Boeing leads the way on composite fuselage construction with the new 787 Dreamliner - the first commercial aircraft with composite fuselage, wing and tail construction. The Dreamliner replaces millions of parts joined by armies of assemblers with large, pre-fabricated sections produced on automated CNC composite lay-up machines. Programmable, near-net-shape lay-up optimises structural integrity, reduces material waste up to 65 per cent, and minimises the need for subsequent machining and hand finishing.

Composites will reduce weight and fuel consumption by nearly 20 per cent, Boeing estimates, while delivering best-in-class comfort and useable passenger space. Machinery makers are facilitating composite production with automated CNC fibre placement systems for large 3-D structures and tape layers for flat and low-profile structures, as well as the required machine tools to trim, drill and rout composite parts.

On the metal cutting side, airframe and engine makers seek faster, more productive & precise machining across the material spectrum from aluminium to steel, titanium and tough nickel alloys. The latest machine design for aerospace work - the horizontal profiler - achieves metal removal rates of 8,066.5 cc/min (500 in3/minute) on aluminium plate or forgings. The industry’s drive to achieve ‘snap-together’ fit on large components imposes accuracy requirements that were unheard of a decade ago.

Components connected with rivets and fasteners must be predrilled so accurately that shimming and machining at assembly are eliminated. These improvements in part accuracy lead directly to

assembly cost savings through reduced labour. There is also a direct impact on fuel costs over life of the aircraft. According to Boeing, the variation between the minimum and maximum tolerance on a wide body aircraft can translate into a weight savings of 10 passenger seats.

Composite construction greatly expands the usage of titanium. Utilised for large, critical monolithic components that join composite sections together, titanium offers a coefficient of expansion similar to composites, and avoids aluminium’s corrosion problems from galvanic reaction with carbon fibres. These new applications are in addition to titanium’s traditional ones in high-stress landing gear and high temperature engine areas.

Defining factors According to world-class producers

of aircraft and the related components, cost savings and accuracy improvements can be achieved by utilising manufacturing practices adopted from automotive manufacturing. Automated assembly, system integration and testing are quickly gaining acceptance as necessary elements for productive aerospace manufacturing.

Helping the globalisation of aircraft manufacturing, long-time equipment makers can provide comprehensive machinery, process engineering and integration capabilities on a worldwide basis, accelerating the entry of new companies and nations into the aerospace industry.

Just as surely as time will always be money, the world will keep growing closer, riding the wings of aircraft design and manufacturing advances.

High-end precision machining

Eswari Prasad is President of MAG India Industrial Automation Systems (P) Ltd, is a leading machine tool and systems company serving the durable goods industry worldwide with complete manufacturing solutions. Key markets served include aerospace, automotive, heavy equipment, oil and gas, rail, solar energy, wind turbine production & general machining. Email: [email protected]

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Future Footprints - Nuclear


It is predicted that in the next decade, the Indian nuclear industry will grow at a faster pace compared to any other industy in the world. This necessitates an in-depth understanding of the regulatory regimes, licensing requirements and waste & decommissioning strategies, which is an important front-end activity of any new nuclear programme.

The growth of the nuclear sector in India is going to be spectacular because in the next 25 years, India is planning to build its nuclear capacity,

on the lines of the world’s total nuclear capacity today. It is undoubtedly an ambitious programme. The country is taking bold steps to meet the huge demand for electricity. Following this all major engineering and technical support group, want to be in a position to provide local support to the country’s extensive nuclear power programme that is already underway. Given the emphasis on accelerating the civil nuclear power programme in India and the political encouragement on international collaboration, companies are committed in establishing significant bases in India through which to offer engineering & technical support services and range of specialist products to the global nuclear market.

Nuclear safetyIt is a multi-staged approach. Safety begins at the design stage and continues from concept to

commissioning. This is a rigorous and systematic approach. The potential hazards and mitigation strategies of the plant are considered at an early stage. The design concepts must be carried through at every stage of the project, ensuring that all structures are built strictly as the designer intended, with the highest quality standards. Finally, one has to train everyone involved in commissioning the plant so that the design philosophy is adhered to. A quality assurance system is followed throughout the life of the power plant from concept to decommissioning.

Latest technologies and application featuresThe reactor designs available today are new-generation ones that incorporate passive safety features. In case of any components or equipment failure, the reactor remains safe, and it does not require human intervention to maintain safety. This is a feature in the latest designs. Nuclear plants should be advised properly on how to upgrade to modern engineering standards as fast as possible. Specialist products that

Lifecycle approach to nuclear reactors

Kenneth G Jackson

Future Footprints - Nuclear


offer fire & earthquake-resistance can be incorporated with existing plants to make them compliant with global regulations and requirements.

Hurdles aheadThere are political and cultural hurdles that originate from the fact that India and its nuclear industry had been isolated from the rest of the world for a number of years. There has been a positive side to this that the country has developed a high degree of indigenous competency in the sector. The challenge remains to become more open to acceptance and adoption of external knowledge and know-how from companies that today have an advanced engineering expertise in nuclear technology.

It is going to be a progressive change from an industry that has been completely under the

government domain to one that involves constructive partnerships from the private sector. It will need the willingness of decision-makers in the government to build a consensus and allow more active participation of the private companies in the nuclear industry. This includes action from the regulatory authorities to asses the values of foreign technology and include them in the nuclear industry.

Demand outlook for equipment With the growing demand for

energy and the increasing awareness of the benefits of nuclear power as a key part of a low-carbon sustainable economy, the demand for new reactors is increasing rapidly. Moreover, India plans to grow its nuclear power capacity to 63,000 MW by 2032 from the current 4,500 MW. Therefore, there is going to be a high demand for heavy fabrication of equipment such as large reactors, heavy heat exchanger vessels, pipe work, turbines, hardware, etc.

There are speculations on the availability of special type of steel, which is a raw material in the nuclear sector – a hurdle for the fabricators. A lot of fabrication requires much machining, and many companies in India are expanding their facilities. This can translate into new and emerging opportunities for the machine tool industry in the country. The sustainable nuclear future rests on the pillars of modern plants that meet stringent operational safety and environmental requirement while being cost-effective over the operational life cycle.

Kenneth G Jackson is Managing Director of Nuvia India Pvt Ltd. He spent his early years in project management, design and plant operations in the petrochemicals industry in the UK and Spain. In the mid 1990s he went back into the chemical industry until 2002 when he joined Nuvia UK as Engineering and Projects Director. For the last two years he has been advising the Board of the Nuvia Group on its international strategy. Email: [email protected]

Various stages of operational process

Optioneering

Waste strategy

Concept

Decommissioning strategy

Safety justification

Specialist civil engineering

Specialist nuclear engineering

Seismic protection

Heavy lifting

Fire protection

Civil engineeringmaintenance and upgrading


Fire protection improvement

Heavy lifting

Radiation protection & outage support

Global decommissioning project


Waste management

Decontamination & dismantling

Pre-construction Construction Operation Decommissioning

Plan and non-plan expenditure of nuclear power schemes

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Future Footprints - Renewable Energy


Wind farms promise to generate more electricity compared to solar, prompting many countries to invest in wind energy for electricity generation. To build reliable wind power solutions and easy transportation & handling of wind turbines, prototyping of designs is now gaining increased attention from wind turbine builders worldwide.

The popularity of wind turbines is growing rapidly. This trend is most likely to continue, and perhaps become more widespread, because of the

advantage of more electricity generation from large turbines in wind farms. For the Indian market, where wind strengths are usually low-to-medium, suitably designed turbine with large motor and a powerful generator is ideal to reap maximum rewards from these conditions.

A recent advancement based on hydraulic technology when incorporated in wind turbines ensures that the rotor gathers the maximum power available from the prevailing wind, while minimising loads and controlling output. This technology will help to push current handling technology of these huge turbines to its limits.

Prototyping of turbinesTransportation of a large component such as the wind turbine requires special design solutions as well as thorough planning. Therefore, transport engineers start working on the solutions beforehand when design engineers start working on the design of the turbine itself. Companies in the wind power solutions sector are aware of the importance of

transport & handling, and are usually used to the daunting task of moving abnormal loads.

Form study prototyping is a new approach towards addressing the many issues that arise during transportation and handling of turbines. This type of prototype allows designers to explore the basic size, look and feel of a product, simulating the concepts, without exact function & visual appearance of the product. They can help assess ergonomic factors and provide insight into visual aspects of the final product.

Form study prototypeCommonly intended for internal decision making, these prototypes are models of the final product, without simulating the actual function or exact visual appearance of the product. Form study prototypes are often carved or machined models, from easily sculpted, inexpensive materials such as urethane foam, without representing the intended colour, finish, or texture.

A major usage of solid foam is proofing CNC machining paths and milling details, composites & tooling. In this case, the non-abrasive rigid urethane foam board is a perfect choice. It is less expensive than machinable plastic, poly boards, metal and most other plastics. Moreover,

Powering a green future

Dobrica Brajkovic

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MMT Jan-2011 Ad Name: Arhan Pg No. 216

Future Footprints - Renewable Energy


non-abrasive material saves on tool changes also, as coolants are not required during machining such materials.

As a step forward, the tranport and handling department of a leading wind turbine manufacturer has developed the scale model of hub that can test the likely function of a particular process & design at an early stage of development without incurring the entire expense of a full-sized prototype. These models are also used to evaluate and verify a new construction before it is built. This allows the designers to see and interact with a prototype allowing them to provide better and more complete requirements and specifications.

Rapid prototypingAs an alternative, ‘rapid-prototyping’ or ‘rapid application development’ technique is intended to be used for the initial prototypes, which implement part but not the complete design. This allows designers & manufacturers to rapidly and inexpensively test the parts of the design issues to be solved, and later build the full design.

Prototyping has proven to be a useful tool in both designing of the product and in showing those to customers in an impressive way. An idea that started by looking for a more efficient way to do one’s job, and what’s turned into an innovation, now saves money, time & resources. That is smart thinking!

Dobrica Brajkovic is the Director of Design Department, Special Tools, Operations (STO) at Vestas Technology R&D Chennai Pvt Ltd. Email: [email protected]

Form study prototyping

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Sector Watch


An integrated aspect of manufacturing process, the metal cutting industry has evolved from manual-driven to one that involves sophisticated technologies. The latest developments have the potential to lead the industry towards more accurate, fast and high-end precision cutting. This article focusses on the related developments, essential software, challenges and demand for high-end precision cutting technology.

Metal cuttingFlexibility with refi ned precision

Nishant Kashyap

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While developing a product, minimising time and cost, yet maximising efficiency & productivity are crucial

factors for surviving in the competitive world of manufacturing. Today, the Indian machine tool industry, which had a technology-dependent status, is successfully developing products out of its own R&D efforts. Speed and finishing are the two factors that make any metal cutting process robust & repeatable.

Today, the industry is looking at high-cutting parameters and reduction in cycle times. “The demand is to develop new cutting geometries, adopt advanced technologies, special super hard coating, better spindle power, etc to facilitate easy cutting and better tool life,” says V S Ravishankar, CEO, Sheasha Tools Services.

Technological evolutionDue to high cost, less speed and adverse side-effects of traditional metal cutting methods, chipless machining processes and technologies such as automation, Numeric Control (NC) technique, electro discharge, waterjet, plasma cutting system and laser machining techniques have been developed. The implementation of computers has increased the precision and efficiency of metal cutting tools, as it is the best and most effective

technique for machining complicated parts and complex shapes. Nowadays, NC controls have become more sophisticated as the concern for environment has increased in the manufacturing sector.

However, new metal cutting advancements are gaining acceptance and applicability in the industry. These advances could again bring significant

changes in the methods employed to cut metal. “There is a demand for high-performance tools for machining titanium and nickel alloys, which are the preferred materials in the aerospace industry. The automobile industry also is moving towards utilising special composite materials because of their toughness and low density, which again requires special tools for machining,” elaborates Ravishankar.

These advances could again bring significant changes to the methods employed to cut metal to achieve a desired shape. According to Praveen Koti, Country Head, CGTech India, “The implementation of multi-tasking machines has increased significantly in the past few years. A large portion of our customer simulation projects are for multi-tasking machines, along with their more conventional simple 5-axis machining & turning centres.”

Role of simulation Metal cutting is one of the most common metal shaping processes. The latest enhancement of manufacturing technologies such as metal cutting requires better modelling and analysis. The Finite Element (FE) technique is a method for analysing a metal cutting process that can contribute to a high level of understanding of this process. This simulation can also predict chip shape and behaviour, cutting zone temperature, tool wear and surface effects such as residual stressin workpieces.

Computer simulation engineers can analyse various effects on the computer. Process modelling also provides a window into temperature and stress, which are important to process performance. “During the cutting simulation, the software

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Advantages of waterjet cutting

� Does not produce any dust or particles that are harmful if inhaled

� Reduces waste

� Can be easily automated for production

� Reduces other machining operations such as finish sanding and grinding

� Does not leave a burr or a rough edge

� Reduces the issues in accelerating and decelerating the robot head

� Reduces the energy consumption

� Is fast, cheap and accurate

Virtual CNC and machining simulation

The demand is to develop new cutting geometries, adopt advanced technologies, special super hard coating, better spindle power, etc to facilitate easy cutting and better tool life.

V S Ravishankar, CEO, Sheasha Tools Services

Sector Watch


automatically detects issues such as fast feed errors, gouges and collisions that could potentially scrap the part, break the cutter or crash the machine. If an error is discovered, the programmer easily identifies the offending NC program record by clicking the mouse on the error. The issue can then be fixed in the CAM software so that an error-free NC program is sent to the machine,” says Koti.

Traditionally, the analysis of metal cutting process has relied on orthogonal approximations. FE analysis predicts material behaviour based on the fundamental physics of the process. These qualities have attracted more manufacturers in utilising simulation for specialised processes and complex machines.

Waterjet technologyIn the current scenario, where saving the planet has become the most popular mantra, companies are adopting technologies that are more environment-friendly. As one of the most valuable and extensive green manufacturing methods of metal cutting process, waterjet has gained acceptance in the metalworking industry. This technology has proven to be a highly effective method for cutting any flat material, including stainless steel and aluminium.

According to Koti, waterjet tool has parameters to define minimum and maximum cutting lengths, and the simulation checks for errors such as jet cutting through multiple sections of the workpiece, cutting through fixtures when it should not, and cutting either too close or far from the jet nozzle. In this regard, waterjet is considered as an ideal green technology. In the case of waterjet cutting, there is no hazardous waste produced. It can cut large pieces of reusable scrap material

and prevent unnecessary waste that results when using traditional cutting methods. There are many more reasons why waterjet cutting is preferable over other cutting methods in stainless steel and aluminium.

Plasma cutting Speed, accuracy and the range of materials that plasma cutting system can cut have attracted automobile and steel companies to utilise it on a large scale. Plasma arc cutting is cheaper than oxyfuel and even faster, especially for cutting steel up to 2-inch thickness. It also provides greater speed than those of laser cutting systems for thickness over 0.125 inch. The plasma cutter has many advantages such as: it is equipped with latest techniques to cut metal; it prevents the warping & paint damage that occur while cutting; it is faster & cost-effective than other equipment; and it cuts the metal accurately. These aspects make plasma cutting one of the best options in the industry for cutting metal.

Role of laser cutting technologyLaser technology is known for its accuracy and speed. It is one of the best cutting methods, as it is accurate and saves time. Laser cutting is mostly employed in metalworking and medical industry; it is considered as the best method for making complex shape in the metal cutting industry and micro-level marking in medical and electrical & electronics industries. Ramasamy Elavarasan, Chief Technical Officer, Treo Laser Machines Pvt Ltd, states, “In many metal cutting processes, it is difficult to achieve the required shapes and clarity. This can be resolved by the laser cutting technology, which gives proper shape and accuracy in comparatively less time. Fibre laser and disc laser are the two technologies that are extensively employed in the metal cutting industry as they are able to cut almost any metal.”

The implementation of multi-tasking machines has increased significantly in the past few years. A large portion of our customer simulation projects are for multi-tasking machines, along with their more conventional simple 5-axis machining & turning centres

Praveen Koti, Country Head, CGTech India

Advantages of laser technology

� High bandwidth of possible materials

� Easy operation by automation

� Flexibility in geometry

� Outstanding precision and reproduction

� Choice of contour in various applications

� Contact-free cutting without any impact

� Constant cutting quality without wear of tool

� High-functioning speed

� Excellent for complex shape and material

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Sector Watch


Emerging marketAs the manufacturing industry in India is witnessing double-digit growth, this is a challenge as well as an opportunity for the metalworking industry. The demand for the metal cutting industry is to provide high-precision, quality and cost-effective products. “Nowadays, companies have become more demanding – they seek high accuracy and better productivity in less time. These aspects have increased the demand for laser technology in industries like metalworking and medical. This is because laser technology provides high-precision

machining and is cost-effective,” says Elavarasan.

The demand from the industry is to develop a technology that can save cost and reduce waste during machining. This has forced companies to invest in R&D and develop innovative & cost-effective technologies. “Manufacturers constantly face the hurdle of having to do more with less. And, the pressure seems even greater this year, on a global scale. Finding new and creative ways to improve the efficiency and quality of jobs that has been running the same-old way for years in the workshop may be critical to the

survival of many businesses. And, they may have to do it with less resource (people, skills, consumable tools, etc). Thus, a general hurdle is in learning & implementing new manufacturing methods and new tools to help improve the existing processes,” elaborates Koti.

Currently, multi-fold growth opportunities exist in the industry, and will continue to rise in the coming decade. While the Asian machine tool industry is on its way to become one of the biggest machine tool markets with the emergence of China and India, it is also continuously upgrading its technology, and challenging the world in innovation & development. The industry as a whole is closely attached to national and worldwide economic conditions. With the growth of the Asian economy, this is the time for companies to grab every opportunity in the emerging geography.

Nowadays, companies have become more demanding - they seek high accuracy and better productivity in less time. These aspects have increased the demand for laser technology in industries like metalworking and medical. This is because laser technology provides high-precision machining and is cost-effective

Ramasamy Elavarasan, Chief Technical Officer Treo Laser Machines Pvt Ltd

Industry Update


As the manufacturing sector charts a growth trend, the need for customised tooling has gained importance in job shops. Tooling systems that can perform multiple operations, and at the same time adapt to quick-change, have become a necessity for the machine tool industry. Today, toolmakers are collaborating with their customers to design tools for the next levelof performance.

The economic slowdown had changed the volume of job work that usually used to arrive at a metalworking factory. During the period,

many in the industry witnessed arrival of small orders that required customised tooling for a specific application. Taking cue from this trend, machines had to be loaded with a

tooling system that could be changed as defined by the customers. These included capabilities to machine for different geometries and job materials. Thus, many companies invested in customised tooling systems that helped perform multiple operations on a single machine, utilising tools made of advanced materials, designs and performance parameters.

Productive partnership for increased effi ciency

TOOLING SYSTEMS

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Industry Update


Changing trendsThe Indian manufacturing sector is on the fast-paced growth track. With many new projects being announced each month in infrastructure and general engineering, this trend is sure to continue in the coming years. The order books are full, and companies are trying to meet deadlines & reduce delivery time. This has resulted in demand for high-performance, high-speed machining system that offers repeatability and quality consistently.

Says Santosh M Prabhu, Managing Director, Tool Grinding Technologies Inc, “We find that the manufacturing sector is switching over to latest designs of machining centres, thus moving away from the regular special purpose machines in the auto sector. Now the challenge for tool manufacturers is design fixturing and tools, to suit machines of the particular task. This combination of operations is the new trend in reducing cycle time and increasing accuracy & productivity.”

Customised toolingWith the emerging sectors opening up new business avenues for the machine tool manufacturers, the capability for multiple operations is much in demand. For example, in aerospace component manufacturing, the shop floor requires precision processes like turning, milling, drilling, jig boring, grinding, polishing, etc in multiple setups. Large in-process inventory, requirements of several jigs & fixtures and large cycle time are some of the common issues that arise during the execution of orders.

An all-in-one multi-tasking machine offers a convenient solution to overcome these hurdles by limiting all operations to a single multi-tasking machine. “Machine Tool Builders (MTBs) are increasingly developing new-generation multi-function & multi-tasking machines, which enable reduction of production lead times, improvement in machining accuracy, and reduction of floor space, less expenses, etc. “We have developed a new-generation of multi-functional tools that are efficient on multi-tasking machines, which reduce cycle times and number of tools in the magazine,” says Samir Kumar, Regional Manager – West, Tungaloy India Pvt Ltd. Thus, modular and quick-change tooling system are the latest trends in customer-centric metalworking solutions.

Quick-change tooling systemTo utilise the right tool for a job, holds utmost importance in metalworking as a wrong tool can not only damage the job material but also the toolholding setup within the machine. The adoption of a quick-change tooling strategy can help many in the business of manufacturing parts & components for multiple industrial sectors in increasing flexibility and coping with the ever-changing manufacturing environment.

“We have developed a combination of standard and customised cutting tools to optimise production for the automotive industry. The market is in an aggressive phase; the MTBs have recovered and are close to the record production levels attained in 2008. The market needs high-productivity tools for increasing feed rates and to satisfy modern machining requirements. Indian customers are also investing in high-powered machines that have special tooling needs,” says Kumar.

Coatings technologyThe recent advancements have changed the dynamics of the tooling industry. Performance-driven carbide inserts are today designed to offer properties & performance tailored to respond to the needs of milling, turning & drilling applications and to provide maximum productivity & optimal machine-tool usage.

“We have introduced an advanced range of new-generation Cubic Boron Nitride (CBN) inserts to machine high-hardness components up to 65 HRc. In many cases, we have eliminated grinding with CBN turning, offering shorter cycle times and cost-advantage to the user,” says Kumar. Milling of modern cast iron requires good resistance to abrasion and excellent edge toughness.

Some important aspects of customised tooling that any tooling company should adopt include simple design, ease of manufacturing, low cost and modular design.

Santosh M Prabhu, Managing DirectorTool Grinding Technologies Inc

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Economical facemilling solution with 12 cutting edges neutral inserts

Key aspects of customised tooling

� Multi-functional tools� Ease of manufacturing� Multi-tasking machines� Quick-change tooling systems� Low cost of manufacturing

Industry Update


The new range of carbide inserts come with multi-layer coating, especially designed to resist high temperature and abrasion. The surface properties of the coatings protect the cutting edge against heat transfer, oxidation and abrasion. “This development in coating increases tool life by 30-40 per cent over conventional grades. The technology enables us to provide a shining appearance on the inserts and also to reduce micro chipping of inserts while machining,” avers Kumar. The growing popularity of these coated inserts is evidence of its many advantages and improvements in the overall productivity and performance of machines.

Going greenThe green movement has also entered the tooling industry, as some of the global companies have joined hands for a recycling effort in the carbide-based tooling system. Approximately 75 per cent of the cemented carbide content consists of a finite resource – tungsten – that can be recycled many times. With the ever-growing demand for cemented carbide inserts, currently there is a demand-supply gap and accelerated depletion of tungsten reserves. This is the strongest known

metal and has the highest melting point than any other element. It is next to only carbon, thus making it ideal for carbide inserts.

Approximately 30 per cent of this metal is recycled. As a green initiative, SECO Group has adopted the tungsten carbide recycling programme, thereby reducing the company’s reliance on mined tungsten ore. The cutting tool manufacturer aims to recycle 50 per centof the carbide inserts it sells by 2014. Based on its research, the company estimates that when an operator replaces carbide insert, less than 5 per cent of the tool is actually worn out, leaving the rest intact and capable of being recycled. “The trend for dry drilling is also fast catching-up with the metalworking industry. This is more in sync with the environment-friendly approach to reduce the generation of effluents when coolants are employed. The latest technological developments in coatings and tool geometries have made it possible to execute dry drilling, as the chips generated during the process are reduced significantly,” says S C Agarwal, CEO, Indian Tool Manufacturers.

CAD/CAM advantageModular fixtures and jigs are gaining importance in customised tooling solutions. Taking cue from this trend, computer-aided fixture design technique is being rapidly developed to reduce the lead-time involved in manufacturing planning. An automated fixture configuration design system has been developed to select modular fixture components automatically and place them in position with satisfactory assembly relationships. Increased number of machine tool builders & tool manufacturers are today using the design and development of tools & fixtures to meet various requirements.

Powered by multiple product development options and design features, CAD/CAM software also validates tool paths for the new product. “The design software is an important tool to adapt and execute the variations in tooling options in accordance to the job work on the machining centre. The verification and validation of tool performance on the software help ensure that the customisation in tool design will increase the flexibility and productivity of tools. Overall, CAD/CAM helps in designing the modular fixtures, tool path, and optimisation of tools,” says Prabhu.

Future outlookCustomisation and modular fits are the need of the hour. “Some important aspects of customised tooling that any tooling company should adopt includes simple design, ease of manufacturing, low cost and modular design,” states Prabhu.

Keeping pace with the new demands, the manufacturers of tooling systems are introducing tool materials and geometries of the future. As they also begin to think green for their designs, the future of the tooling industry will be in sync with the environment.

The trend for dry drilling is also fast catching up with the metalworking industry. This is more in sync with the environment-friendly approach to reduce the generation of effluents when coolants are employed.

S C Agarwal, CEO, Indian Tool Manufacturers

The market is in an aggressive phase; the MTBs have recovered and are close to the record production levels attained in 2008. The market needs high-productivity tools for increasing feed rates to satisfy modern machining requirements.

Samir Kumar, Regional Manager – West, Tungaloy India Pvt Ltd

Leaders Speak


…avers Carlos M Cardoso, Chairman,

President & CEO, Kennametal Inc

- a leading global supplier of tooling,

engineered components and advanced

materials consumed in production

processes. A certified Six Sigma

Green Belt, Cardoso has been

named one of the ‘Best Chief

Executive Officers’ in the US by

Institutional Investor magazine.

He is a Member of The Stanley

Works Board of Directors,

and Vice Chairman of the

Executive Committee of

Manufacturers Alliance/

MAPI, to name a few.

In a freewheeling

conversation with

Manas R Bastia,

he speaks on a

range of topics

from transformational

strategies during the

economic slowdown to

meeting the ‘new set of customers’,

from breakthrough products/

technologies to the road ahead for

Kennametal. Excerpts…

This year is going to be one of the most innovative years for us

Leaders Speak


Looking back into the unprecedented economic slump of last year, was there any window of opportunity, as well? We looked at our whole global business and felt that we had a cost structure that was competitive within the industry. But, one needs to benchmark against companies not only in his own industry, but also best-in-class companies. When this was done, we found good opportunities in two areas - the cost structure and the business model per se.

We saw the economic downturn as a good opportunity to address these issues on a fast-paced basis. The organisational simplicity has allowed us to grow at a tremendous level; we are seeing growth and profitability that we did not experience before. For instance, our fourth quarter (last July) was one of the most profitable in the history of the company in India. We just announced this fiscal’s first quarter - the best so far in the first half of our year - with 34 per cent top-line growth globally. We are already establishing profitability & growth records and are still not at the peak of our business. We see a lot of that as a result of the changes that we made in the previous 18 months.

Tell us about the transformational strategies that Kennametal pursued during this phase. The slowdown had a relatively modest, short-lived impact on India. The depth was not as high as the rest of the world. On a macro level, the Indian economy is doing well, and there is a lot of demand.

We have consistently been meeting our goal of 40 per cent sales resulting from new products - which have been in the marketplace since five years or less and are at least 20 per cent better than those being replaced. We have done this for seven years in a row, which is impressive. We have also grown significantly on a global scale and could take the best practices around the world effectively.

India provides much greater opportunities than what we witness today. We have invested more in Kennametal India during this period than probably two or three decades put together. Besides, as a percentage of sales, we invest a significant amount here.

We are close to quadrupling the size of this business since acquiring it in 2002 (ie, less than 10 year), and the team here has responded effectively. Quadrupling the business in 10 year stretches everything - from talent to training to dealing with customers and so forth.

Did you offer any specialised product/service during this phase? We made a commitment to invest and not slow down our efforts in R&D despite the restructuring. This is going to be one of the most innovative years for Kennametal. Many of our competitors slowed down their R&D because of the downturn. But, we decided to achieve the savings from elsewhere and continued to innovate. As a result, a part of our current growth owes not only to the market, but also to some of our latest products, which are well-accepted.

How do you plan to win the new set of customers, and meet their requirements & priorities? Part of the growth in India is because of the global competition, as the level of products in the marketplace goes up. Before the slowdown, some good Indian companies may have focussed on buying on ‘price versus value’, having more suppliers versus less, and so on. Today, they are saying - ‘I have orders for stuff I cannot deliver. I need more efficiency and productivity, because even if I want to buy more machines, they may not be available’.

We have a great opportunity, especially with the new structure where we offer an automotive solution to the automotive customer. If one is developing a new engine, we

would probably have done the same somewhere else in the world, thereby we can help the customer now. This has positioned us better with the new ‘after the slowdown’ customer. Also, we are a better partner for customers who are becoming more global, as we are global in nature too.

What kinds of breakthrough products/technologies are going to shape the metalworking world? The growth of composites for aircraft is going to require different machining techniques, types of toolings and so forth. So also are the electric type cars and the wind/solar energy sectors. This is the reason why we have incorporated a market segment structure. For one of the world’s leading aerospace manufacturers, for instance, we were developing tooling for a specific type of composite way before the design of the aircraft was finalised. Consequently, we were part of the solution, of the OEM being able to make this aircraft. And, we have special tooling designed from ground-up only for that application. In the automotive business, we must focus this way on transmissions, because even an electric car needs transmissions and brakes.

So, what are your new USPs?First would be quality of our people and training them. We spend a significant percentage of our sales revenue in people development and training. Next one would be our global culture and solutions. One of our major competitive advantages is that our salesperson has eleven thousand people behind him when he faces a customer, ie, the ability to leverage the whole corporation.

How do you plan to leverage the WIDIA brand name? When we took a long-term view of our business, we realised Kennametal was good at direct sales; that is how the company was structured. But, carrying

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Leaders Speak


out the same around the globe was not feasible, which left several gaps. We saw WIDIA as an opportunity to fill this. WIDIA was known in India and Germany, but not in countries like the US or China. We are now launching it worldwide, the latest being in Japan. Our goal is to double the sales from WIDIA in the next five years.

Here is another unique point. Some of our competitors re-brand the same product and put it through a different channel. Their distributors have to watch out because another distributor next door may be selling a different brand, but the same product. In our case, WIDIA products are completely different from Kennametal - all the way to their metallurgical structure. In fact, they are different value propositions.

How do you envision the road ahead for Kennametal India?We quadrupled this business in

10 years; we are planning to quadruple it again in the next five years. We will continue to invest in our people, products and in the growth this country is going to witness. With the size of the population, there is plenty of room to grow here.

One of our global IT centres is located in India, which is on a growth path. We added around 30 engineers this year. Also, we have a training centre here. Further, we will continue to invest around $ 80 million a year in capital.

Tell us about the key challenges faced here. The only pitfall is the talent. The challenge is how one continues to train and keep pace with this growth through graduating people who are capable of doing the jobs and so forth. Added to this is how to keep this pipeline full.

What will be some of the highlights at Kennametal booth during IMTEX 2011? IMTEX 2011 is the right time for showcasing & discussing manufacturing technology, and this year promises to be particularly exciting as the industry begins to slowly recover from one of the worst global slowdowns in decades.

With regard to advancing innovation, ‘Beyond Blast’, making its debut here at IMTEX 2011, is a good example of what we mean by commitment to new products and different thinking. It presents a quantum leap in productivity for our customers, delivering up to 300 per cent productivity improvement, depending on the application.

The game-changing ‘Beyond Blast’ will not only improve part-production processes but also decrease power consumption & improve coolant management and a manufacturing company’s environmental standing - an obvious benefit to protecting our planet and a clear case of where different thinking can take our customers.

What are the growth strategies for Kennametal over the next 1-2 years?One is to focus on WIDIA. The other is to drive our growth-based on segments, as we get closer to the customer. The third is to continue to achieve 40 per cent of our sales from new products. The fourth is globalisation, ie, to continue to grow in the developing economies, add more infrastructure and have a bigger presence.

Any specific acquisitions, plans, etc in the pipeline?We have been a good acquisitive company and have a strong balance sheet with our debt to equity being less than 20 per cent. In the next 12 months, a lot of activities are being planned. Certainly, as we do globally, we are always looking for and evaluating growth strategies in India, if we have them.

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Executive mantras

Qualitative leadership: Leadership is all about having a clear vision and then being able to inspire the team to take ownership of that vision to turn it into reality. It is also about taking the long-term view of what is good for the organisation, and then making the tough decisions in the short-term that will get one there.Effective delegation: It is perhaps the least understood or properly implemented word in management lexicon! Effective delegation comes first from proper understanding of a person’s abilities, then setting the right expectations & providing the appropriate resources, and, finally holding the individual accountable. Talent management: To attract and retain the best people, we have to provide them with challenges that they will relish, and we have to let them know how important they are to the success of the company. It is important to have the right compensation and rewards in place; but that is not enough. Organisational culture: The best organisations have a single work culture permeating throughout – one which enables every employee to understand the company’s goals in the context of his or her everyday work and provides the motivation to act as if he or she is facing the customer. Spurring innovation: The most successful companies partner with their customers to drive innovation, because all manufacturing innovations are in the interest of making the customer more productive, profitable and green. Work-life balance: Time management and discipline are the keys to achieving work-life balance. Corporate social responsibility: Companies are an interdependent part of society, and each one of us – corporation or individual – has a duty to give back to the community that supports us. Social responsibility is actually an important component of being a sustainable organisation over the long term, and that is in everyone’s best interest.

Facility Visit


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Moving towards next-generation solutions, Bharat Fritz Werner Ltd (BFW) is now focussing on manufacturing machines that are accurate, precise and function at high speed. Also, as the demand for new machines and automation is on the rise, the company is tapping opportunities in strengthening internal practices.

Celebrating its Golden Jubilee this year, BFW has come a long way since its inception in 1961. In the past, the comapny

has exported a good number of milling machines to the erstwhile USSR. Incorporated with German-Fritz Werner in a techno-commercial collaboration, Bharat Fritz Werner is a 100 per cent Indian company with a subsidiary in Germany. The move saw

Fritz Werner taking interest in BFW’s milling machines and producing machines with an identical design. It was in 1966 when BFW became a part of the Kothari Group that the company embarked on a journey, which later created waves in the machine tool industry. The difference that BFW set out to provide has now become its strength and is earning laurels for the company in international markets.

Tapping new frontiers

BHARAT FRITZ WERNER LTD

Shivani Mody

Facility Visit


Over the years, BFW has developed expertise, and its product portfolio includes CNC machining centres – Vertical & Horizontal Machining Centres (VMCs & HMCs), milling machines, CNC vertical turning lathes, Special Purpose Machines (SPM) and machining cells & lines. The products suit a wide range of sectors such as aerospace, automobile, defence, dies & moulds, forging, general engineering, machine tool, medical implants, off-highway products, pharmaceuticals, power generation, printing, railway, textile, training and education.

Since the last four years, BFW has emerged as a strong industry player. Currently, it produces around 400 variants of machines for prismatic component manufacturing. These include CNC and non-CNC machines, milling machines, HMCs & VMCs, 5-axis machines, automation solutions and sophisticated equipment.

The company has recently ventured into manufacturing vertical lathes. BFW also manufactures spindles & castings and has produced around 800 SPMs to provide customised solutions. H K Birla, Senior Vice President - Operations, Bharat Fritz Werner Ltd, says, “We are now focussing on next-generation solutions and requirements. One such move is modernisation of our workshop. This will see us producing machines that are accurate, precise and high-speed solutions for the automation era.”

Manufacturing capabilityThe three manufacturing plants have formed biggest divisions in BFW since 2007. The plant focusses on manufacturing VMCs, HMCs and SPMs. Currently, running with 90 people, the VMC manufacturing plant is geared up to make 100 machines per month. To improve its production capacity, BFW adopted the concept of lean manufacturing in 2008, and improved their overall efficiency & capability. To meet increasing demand, the shop floor machine layout has been re-laid to save space and improve capacity. As a result, machines that could be earlier manufactured in 24-27 days, can now be carried out in seven days. Even the supply chain management has been reconfigured to deliver for today’s growing market requirements.

Says Birla, “With the new workflow, we have become flexible. An HMC can now be manufactured in one month as opposed to two-and-a-half months, which was the case earlier. Besides, operators are regularly sent

for training programmes and skill updating courses for CNC efficiency.”

Eliminating wasteTo be competitive, efficient and reduce costs, BFW is looking at waste elimination exercises. Birla informs, “We are working on the design, material flow, power consumption, usage of accessories to eliminate waste and reduce power consumption. One of the ways is by looking at the internal practices and receiving feedback from employees.”

He further adds, “For instance, when we made changes in the CNC systems, we were able to save ` 5-6 lakh per machine. Focussing on value-engineering for manufacturing VMCs with a material focus, we saved ` 2 lakh. These savings and close monitoring have helped us save nearly ` 40-70 lakh annually with the benefits reaching our customers. Currently, we are working on designing a compact chip conveying system and looking at guard design of the machine.”

BFW has been the single largest machine tool manufacturing single company (not a group) for the last four consecutive years. We at BFW are confident that we will grow and efficiently meet the need of the manufacturing industry in India and abroad.

S N Mishra, Vice Chairman

Automation solution

Facility Visit


Adding new featuresWith growing demand, customers are looking at minimum cutting time for production of machines at low cost. There is a need for fast machines with high productivity, precision and accuracy. Birla avers, “Nowadays, there is a major need for high-speed and accurate machines. Also, our efforts are directed towards reducing the non-cutting time, which takes up nearly 75 per cent of the procedure. We are also working on developing a technology to support the growing speed of machines. The speed of motorised spindles is going up from 15,000-20,000 rpm.”

He further adds, “We are also developing 5-axis machining centres, which are now less in demand in the country. In two-three years, these will become fast-moving products. In addition, we have tied up with technical institutes in India and Europe for new design and training initiatives.”

Environment-friendly campusAs a socially responsible company,

BFW has implemented environment-friendly practices at its campus. Preserving nature, the campus houses several gardens, a nursery and a pond with fish & geese. To practise rainwater harvesting, the company removed eucalyptus trees and planted silver oak trees in the campus. Till now, it has planted 40,000 trees in and around the factory. The dead leaves, residual food

articles & other waste are collected and treated organically to create manure, which is later used for growing more than 100 varieties of flowers, fruits, spices and aromatic plants in the premises.

Also, as an endeavour to save trees, BFW has reduced the usage of wood frames for its packaging requirements. Birla says, “Since last one year, we have started utilising plywood wherever possible instead of thick wooden frames. We have changed the packaging of smaller machines and components to cardboard instead of wooden boxes.”

Hosting a garden of medicinal plants, the company has won many awards from the horticulture department in Bengaluru for its efforts. Birla says, “We have 10 people maintaining the garden each day, and taking care of the greenery is a full-time effort. Also, for our garden of medicinal plants, we have been winning the award for the ‘best garden’ from the horticulture department since last 20 years.”

New shop floor

N N Upadhyay, Director, on BFW’s current strength, growth potential and future prospects:

Growth of the company...From the beginning itself, BFW has maintained a low-key profile and concentrated on the main function of manufacturing machines. Most of the imported machines are catalogue products, where the motive is to provide customised solutions.

Our machines have been well-accepted internationally, as we have supplied some SPMs to Honda Japan, a few fast vertical machining centres to Renault, a huge horizontal machining centre to Magtec GmbH, and machining centres to Peugeot. With our company in Germany, we will look to expand in that region as well.

Future outlook...Until now, the domestic demand has grown steadily for the company, forcing us to cater to domestic markets. Catering to the local requirements left us with little time to focus on exports. Seeing the market trends in the past few years, we have decided to diversify our portfolio & risks and tap into international opportunities. The plan is to target European market through its subsidiary in Germany - Bharat Fritz Werner GmbH, which has an international network of agents

and dealers. The company is also planning to reserve about 10 per cent of the turnover for exports.

Apart from export plans, our R&D centres in Singapore and Bengaluru are continuously working for developing new machine designs. Bengaluru is the talent hub, while Singapore provides latest information flow, international trends and a view of what the company’s competitors are

moving towards. Further, the vertical machining centres have become

a commodity product and from the current production capacity of 800 per year the company plans to reach more than 1,200 per year. It is also considering to expand into three large bases. The company has identified nearly 100 acre in Hosur for production purposes. There will be an exclusive foundry in Hosur acting as supplier for us. We are also planning to sell a complete production line, inclusive of SPMs, VMCs, HMCs and milling machines arranged one after the other on the shop floor.

To carry out future plans and meet the rising demand - national and international - we are expanding our facilities and have devised a five-year business plan for the future.

Facility Visit


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Focussing on the growing automation market, Pragati Automation Pvt Ltd is all set to provide tools, which are accurate and precise. A part of the company’s growth strategy includes expansion of its facility and setting up units in other countries. Targeting future demand, the company is also banking on its design expertise and R&D might.

Established in 1976, with an aim to manufacture machine tool accessories, Pragati Automation Pvt Ltd is part of the Ace Micromatic

Group. Spread across an area of 12,105 sq m, the manufacturing campus comprises two facilities measuring 4,055 sq m and 8,050 sq m, respectively.

Today, riding on the back of experience, core design strength and production, Pragati is looking to make inroads into new geographies. Having established service centres in China, Germany, Poland and the UK, the company is now planning to set up an assembly plant in China.

Manufacturing for the futureThe manufacturing unit at Pragati consists of Automatic Tool Changer (ATC) assembly plant, turret production unit and gear production facility. Over the years, the company has established a name for its design and production. Banking on its 250 employees and 60 engineers, Pragati is now looking forward to make a name in the area of automation and expand its market overseas. Complying with its expansion plans, the company has added 40 new CNC machines on the shop floor and is busy building new assembly and production areas in Belgaum, Kolhapur and China. The total investment for expansion is

PRAGATI AUTOMATION PVT LTD

Shivani Mody

Broadening manufacturing horizons

Facility Visit


` 50 crore and is slated to be completed within the next six months. Also, by the end of July 2011, the company will have production capacity of 1,000 turrets and 500 ATCs per month at its Bengaluru facility. On the other hand its Belgaum unit has developed a range of square turrets for flat- bed CNC lathes, while the Kolhapur unit has developed a range of umbrella ATCs. The company is planning to up its production volume for these new products. Currently, the annual production capacity of the company is 10,000 tool turrets and 6,000 ATCs. A V Sathe, Chairman, Pragati Automation Pvt Ltd, claims, “There are no competitors for these products, as most of the machines are imported. Our expertise lies in the design of products, because for us, engineering is the top priority. The turret technology is at par with international brands. This is a next-generation technology providing quality & reliability and that too at a competitive price.”

The finished parts, which are of varying sizes are stored in a vertical storage unit. According to Atul S Bhirangi, Managing Director, Pragati Automation Pvt Ltd, “Most of the assembly work is carried out manually while the storage unit utilises automation. These parts are stored in the form of stacks inside trays. We have 72 trays, and the shop floor

workers can remove parts from any section as and when required.”

Subsidiary manufacturing facility The turrets and ATCs of the company require a large number of gears. The running of these products depend on the quality of gears. Unfortunately, it is very difficult to outsource these gears, because most of the gear shops in India work on second hand, re-conditioned machines. New modern CNC machines are highly productive, but at the same time prohibitively costly. The company did not find it economical to install these machines in-house; and use them only for 10 or 15 per cent of the time. Therefore, the subsidiary Pragati Transmission Pvt Ltd was established in 2006. With an investment of ` 20

crore, the subsidiary acts as a supplier of gears and shafts for Pragati’s tool turrets and ATCs. The manufacturing facility built on a total area of 20,000 sq ft comprises of a design and testing unit, as well. Says Bhirangi, “The gear manufacturing facility is a major investment, as each machine costs about ` 70 crore, and we have seven of them. The gear manufacturing unit ensures that our end-product is accurate and precise. The high quality of gears also leads to reduced noise and maintenance issues in the end-product. The accuracy of gears also helps in improving the long life & performance of our turrets and ATCs. Currently, we are using 10 per cent capacity of the machines. We also undertake outsourcing work for our gear facility, which helps us in capacity utilisation of the machines.”

Our expertise lies in the design of products, because for us, engineering is the top priority. The turret technology is at par with international brands.

A V Sathe, Chairman

ATC assembly

We are investing heavily in machines and capacities. What holds us from growing is the production capacity. Also, our next target market is China, where we are witnessing a rise in demand.

Atul S Bhirangi, Managing Director

Facility Visit


Luckily this strategy has paid off for Pragati, as the subsidiary is manufacturing at full capacity and thinking of further expansion.

‘On-the-job’ R&DTaking design and R&D as ‘on-the-job’ process, Sathe says, “Customer demand and feedback is an important element for technology evolution of our products. Even in the prototype stage, we have many companies working with us, and some of them have even placed orders with us. We carry out customised designs for specific requirements. For instance, we have 32-50 tool changers in our ATCs. But, there is a need for special ATC design for high-volume products. This requires customisations as well as R&D for the system to run smoothly during the on-the-job production process.”

Pragati is also evaluating a new design for turrets, especially for the Chinese market. “The demand for turrets is high as the need for automation is rising in various markets,” informs Sathe. He further adds, “One of the units in manufacturing campus is the assembly unit. We plan to double our assembly capability to cater to demand from the Chinese market. The companies in China need low-cost turrets in square design and large volumes. Providing 1,000 turrets a month at a particular price is the challenge.”

Looking at future demand, the company is planning to work with servos and better controls for the

products. Currently, experiments are on in the unit for improving performance. Sathe says, “We are getting used to the employment of servos and controls for which R&D is being carried out. We will get a breakthrough by next year, after which we will start manufacturing.” Some of the products under development are servo turret, servo turret with single motor and ATCs for horizontal machining centre.

Focus on qualityTo ensure overall quality and precision in the end-product, Pragati believes in making Special Purpose Machines (SPMs) for operations, which helps it in maintaining precision for each part of the final product, from start to end. Bhirangi claims, “With the usage of SPMs, we can reduce the cost of products by nearly 50 per cent, which can be passed onto the customers. At each step, we carry out quality checks for the desired accuracy of the products.”

In the assembly plant, the company tests products before final packaging. Each ATC is put through rigorous cycles to test for wear & tear and raw material changes. Each ATC is run on test stand for 8 hours before dispatch, while each turret is run for 3 hours before dispatch.

Future outlookCurrently, seeing the international demand, Pragati is in an expansion mode. Starting from 2010, the company is on track to double its production capacity. To achieve this,

the company plans to expand facilities in India and abroad, by investing ` 50 crore in the next six months.

Bhirangi reveals, “We are investing heavily in machines and capacities. What holds us from growing is the production capacity. Also, our next target market is China where we are witnessing a rise in demand. By having a facility in China, we will be able to carry out the assembly there, with manufacturing in the Indian unit. A part of our expansion plan also includes a new facility at Belgaum, additional land & building near Kolhapur & Bengaluru, and a new facility at Shanghai, China. The Belgaum plant is built over an area of 16,200 sq m and we are adding 2,750 sq m to it.”

With expansion strategy, the manufacturing capacity of tool turrets is expected to go up to 1,000 units per month from 500 units per month. The production capacity of tool changers, which is the second major product from Pragati will also increase from 150 units per month to 500 units per month. Nearly 70 per cent of sales of ATCs is generated from exports. Also, production of power chucking cylinders will go up from 250 per month to 500 units per month.

Bhirangi further adds, “Our domestic sales constitutes 60 per cent, and the rest is exports. During 2010-11, we expect our sales to be ` 85 crore, up from ` 34 crore in 2009-10. Our exports are mainly to countries such as Germany, Spain, Brazil, Poland, Italy, Russia, Taiwan and China. Although more than 50 per cent of the export is to Europe, China is the growing market for us.” By the end of next year, the company also plans to start manufacturing lathes.

With strategies and design capability well in place, Pragati is well on its way to achieve new targets. Having planned for the next five years, the company is also in a position to tap growing potential and be ahead of the curve compared to its competitors.

SPMs used for machining

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Factory Fundamentals


Technox Machine and Manufacturing refused to accept the notion that large, complex parts necessarily require multiple, time-consuming setups. Rotary tables from Lyndex-Nikken have saved time and expanded capabilities to the point where the shop can take on new work and bring previously outsourced jobs back in-house.

“A35-year old business like ours is like a person – one is never too old to learn

new things,” says Jason Herff, Sales Manager, Technox Machine and Manufacturing. At least for Technox,

Herff’s analogy is close to the mark, as evidenced by one lesson the shop has taken to heart. That is, there is no reason to assume that machining large parts requires multiple setups, and there is no reason to accept as a given the extra time and labour required to complete those setups. Challenging these assumptions by equipping machines with rotary tables from Lyndex-Nikken (Mundelein, Illinois) enabled the shop to cut production time by half and bring in new work as well as jobs that were previously outsourced.

Technox employs more than 30 machinists and occupies two Chicago facilities totalling 75,000 sq ft.The full-service machine shop specialises in parts ranging to 28 ft long. Common jobs include rings, dial plates, drums, shafts, segments and castings for industries ranging from steel mill to food processing.

The turnaroundUntil five years ago, such work required multiple setups on the shop’s three-axis machines, and parts often had to be rotated by hand. However, the shop’s problems extended beyond just time-consuming setups. The size and intricacy of the parts also created challenges in maintaining accuracy and consistency. Nikken rotary tables have changed this.

Built for rigidity, the tables integrate fine casting material with a patented, ground, carbide worm screw mechanism. The screw is paired with an ion-nitrided worm wheel, as

Rotary tables save time, expand capabilities

This drive shaft, constructed of heat-treated 4140 steel with a hardness of 269/321 BHN, requires machining four 0.375 by 0.75-inch keyways in exacting locations. In addition to time-consuming setups, maintaining accuracy was a challenge on this part before the shop could take advantage of positioning via a Nikken CNC601 rotary table

It has been our persistent effort to provide incremental value to our readers with ‘cutting-edge’ information. As a part of this endeavour, we have this feature - ‘From Modern Machine Shop’, in an exclusive arrangement with the premier metalworking and machine tool publication in North America. Modern Machine Shop (MMS), published by Gardner Publications, US, offers exceptionally high editorial features and circulation standards that have become a hallmark of its operating philosophy and worldwide reputation. We strongly believe that the information provided in this feature will keep our readers updated about the latest global developments in business strategies & technological innovations, the quintessential ingredients for competitive manufacturing.



opposed to a conventional bronze or bronze alloy actuation mechanism. According to the company, this can reduce friction and wear by a factor of eight. The worm screw consists of a less-brittle V-grade form of carbide, while the worm gear is ion-nitrided to a depth of 0.1 mm and an external surface hardness of 68 Rc. When paired with a steel way hardened to 58-60 Rc, these features enhance system rigidity and longevity, the company says.

One job that exemplifies the benefits the shop has gleaned from the tables involves cutting four 0.375- by 0.75-inch keyways into a heat-treated, 4140 drive shaft that is rated for hardness at 269/321 BHN. Required tolerances are +0.001 inch/-.000 inch.Integrating Nikken’s CNC601 rotary table into a Mori Seiki MV1003 VMC has taken manual part rotation out of the equation. This not only saves time for operators, but also improves accuracy, Herff says. Ensuring that the keyways are perfectly aligned with the drive shaft is critical, and using a rotary table rather than manually rotating the shaft eliminates the risk of misalignment resulting from human error.

Expanding possibilitiesImproving efficiency on existing jobs was not the only impetus for the shop’s investment. “We bought the rotary tables with more opportunities for us in mind, as well as more opportunities for our customers,” Herff says. By expanding the shop’s range of machining capabilities, the tables have enabled it to bring in new work.

A key advantage is that the Nikken tables provide three-axis machines with the same performance and precision as dedicated four-axis models, Herff says. Moreover, they provide the flexibility to perform both three- and four-axis work on the same machine. “Technox can do full four-axis, simultaneous machining exactly like, and to the same accuracy as,

factory-built four-axis machines - at a fraction of the cost,” says Steve Baier, Regional Manager, Lyndex-Nikken.

Herff cites a ribbon screw used in underground boring applications as an example of where these capabilities come into play. The screw is designed to push cutter heads forward and engage the tunnel face. Every tunnel-boring machine uses several screws, one for each cutter head. They begin as 26-inch-long, forged HR 1020 steel cylinders with 16-inch ODs and 8-inch IDs. After machining, each screw is reduced to a 15.75-inch OD, 8.25-inch ID and 25.875-inch length, with 2.5-inch flights. Tolerances are ±0.005 inch, and a great deal of material removal is involved - the original 1,200-pound workpiece is machined to a final weight of about 300 pound. Without the additional axis provided by the CNC601 rotary table, the shop could never have machined such a large, complex part, Herff says.

Changing scenarioIn addition to pursuing new work, the rotary tables enabled the shop to bring previously outsourced jobs back in-house. One example is the machining of a flesh-stripping ring for the meatpacking industry. The part is machined on the shop’s OKK VM7III VMC, which is equipped with a Nikken CNC401 rotary table. The table operates in conjunction with a Nikken angle head and a mimetic indexable cutter to machine teeth into the ring of D-2 tool steel, and no finishing work is required. Technox produces 600 of these parts per year in segments of 100 for customers worldwide, saving thousands of dollars compared to when the job was outsourced.

“Nikken rotary tables have opened up our capabilites. They have allowed me to find more work & different types of work, and they have definitely helped us increase sales,” Herff concludes.

A close-up of one driveshaft keyway

Installing Nikken rotary tables enables the shop to pursue new, more complex work, such as this ribbon screw used in underground boring applications

This part, a flesh-stripping ring for the meatpacking industry, was previously outsourced. Now equipped with Nikken rotary tables, Technox has brought this part back in-house, saving thousands of dollars, the company says

A Lyndex-Nikken CNC401 rotary table installed on Technox’s OKK VM7III VMC



Precision Methods Incorporated (PMI) provides a case in point of the substantial savings that can be realised with the proper coolant formulation. Rustlick Ultracut Pro, available from ITW Rocol North America, lasted twice as long in the sump than the shop’s previous coolant, leading to significant operating and maintenance cost savings.

Although costs resulting from changing coolant can be substantial, they are frequently overlooked. That was not the case at

contract manufacturer PMI, where the management realised how quickly these costs can compound. Last year, the company began searching for a new coolant formulation that would reduce expenses associated with downtime during change-outs and the disposal & replacement of old coolant. Ultracut Pro from Rustlick, a brand of ITW Rocol North America (Glenview, Illinois), ran at a low concentration and

lasted longer in the sump, leading to significant savings in maintenance and operating costs.

Operating at a 10,000 sq ft facility in central Connecticut, PMI supplies parts to the medical, aerospace, electronics, fibre optics and control industries. Although the shop specialises in Swiss screw machining, it says it excels in producing precision-threaded components; it also includes in-house facilities for CNC milling, CNC turning, centreless grinding, screw captivation, thread rolling and assembly operations. Capacity is sufficient for machining parts in most metals as well as plastics. Products manufactured here range from 3/64 inchto 10 inch in diameter, and tolerances range to ±0.0001 inch.

Transformation phaseImplementing Ultracut Pro throughout the shop was easy, says PMI’s Tim Cocchiola. “We started using the new coolant on one of our CNC turning centres, a Hyundai-Kia KIT450. It has a small sump, maybe 20-25 gallon, and the transition from the former coolant went smoothly,” adds Cocchiola.

Introduced in 2009, Ultracut Pro is available in 5- or 55-gallon containers with chlorinated EP additives or chlorine-free EP additives, with the latter recommended for use on titanium. The coolant consists of long-lasting, water-soluble oils with new additives formulated specifically

Long-lasting coolant reduces costs, downtime

PMI’s Hyundai-Kia Kit 450 CNC turning centre was the first of the shop’s machines to use Rustlick Ultracut Pro. The coolant lasts twice as long in the sump, and less coolant is used because it runs at a low concentration. In addition, its lubricity and rust-protection make it suitable for light- & heavy-duty cutting and grinding applications



to provide maximum biostability and performance.

Specifically, these additives prevent fungal and bacterial growth. In fact, the manufacturer says independent lab studies performed during the past 12 month show that compared to previous-generation products, the formulation improves resistance to bacteria and fungus by factors of three and five, respectively. The additives also make the coolant safe for a wide range of materials, including steel, aluminium, brass, bronze and copper, without the risk of staining. Further contributing to versatility is the coolant’s high lubricity and rust protection, which make it suitable for improving performance on both light- & heavy-duty cutting and grinding applications.

Change agentDon Beyer of DGI Supply, a Rustlick distributor, introduced PMI to the coolant and helped with its implementation. “Their main concern was cost savings,” Beyer recalls about PMI’s impetus for converting to a new coolant formulation. He further adds, “In 2009, plant managers looked closely at all costs, and they began scrutinising coolant change-overs & the costs associated specifically with that.”

Beyer began by doing a simple analysis, comparing the cost of the shop’s previous coolant with Ultracut Pro,revealing a total potential savings of more than 20 per cent. He then explained the formulation’s performance benefits, including the fact that the coolant could run at a low

concentration for some applications. On average, Ultracut Pro runs at 25:1,compared to a 15:1 ratio for most other coolants. That translates to less coolant usage and additional savings.

So far, the coolant has been implemented in two sumps at PMI, and the company intends to expand that to a range of other CNC machines in 2011. Cost savings from the longer-lasting formulation have been substantial. For example, the shop cites the minimum cost of changing coolant in a machine’s sump at $ 373, so it has saved at least that amount per machine this year (the previous coolant would have been changed once already).

Cutting costsImproved coolant life translates to other benefits as well. Few change-overs mean less machine downtime, saving the shop an estimated $ 124 per machine (based on an average of 2 hour of downtime at a cost of $ 50 per hour, as well as a $ 12 per hour labor rate). Likewise, the shop saves on coolant disposal costs estimated at approximately $ 180 per change-over (based on an average per-gallon disposal cost of $ 3 for a 60-gallon sump). The shop also spends less on coolant replacement, which costs $ 69 per 60-gallon sump (when running the coolant mixture at 20:1 and taking into account a $ 23 average cost per gallon of concentrate). Moreover, the formulation’s resistance to bacteria and fungus saves money because tools do not need to be changed as frequently compared to the previous solution.

“The major benefit is the coolant life improvement, which I originally sold to be at least 30 per cent,” Beyer says. In fact, that figure is actually closer to 100 per cent. “PMI used to change the coolant every six months. The new coolant has been in the sumps for a year now, and it is still running strong,” he adds.

In addition to direct cost savings from longer coolant life, the shop changes tools less frequently because additives in the formulation help resist bacterial and fungal contamination

PMI produces these small, plastic parts for an aerospace customer. Rustlick Ultracut Pro is flexible enough for use on parts made of a wide variety of materials without staining

Preview


Material handling industry in India is growing at a steady pace along with stable manufacturing intensification. The advancements in this industry are moving in line with its growth. But with the progress, there is a need to create awareness about innovative solutions and technologies available. In this regard, HiTech Material Handling Show promises to serve as a fertile ground for the entire industry to converge and display technology, innovation and futuristic material handling solutions.

Material handling

Shibani Gharat

India is moving steadily on a smooth growth trajectory. This has shifted the focus from cost-cutting to expanding capacities in the market which directly results into more

factories and warehouses. In this era, material handling is

an inevitable phenomenon for any manufacturing unit. Material Handling Equipment (MHE) may not directly contribute towards production of goods but they bring about efficiency in handling, transport and storage of goods. In fact, the MHE industry just about harmonises the entire process in a manufacturing set up by ensuring smooth and efficient distribution of goods. This makes these equipments one of the most vital ingredients of a manufacturing unit. “Any manufacturing unit, in any sector, requires equipment to handle materials in its factory. Different verticals need different solutions to cater to their MHE needs. Chemical industry, pharmaceutical, construction, electronics, energy, food & beverage, metalworking, metal-casting, plastics, aerospace manufacturing, automotive industries – all are dependent on the MHE industry,” avers Tushar Mehendale, MD, ElectroMech.

Technological advancementsToday, the MHE industry offers a plethora of products to various industry verticals as per the needs of a particular industry. There have been several advancements in the industry to cater to the customised requirements

Mumbai | 17-19 Feb, 2011

functions with greater mobility,” notes Rajesh Sharma, VP & Head – Marketing, Escorts Construction Equipment (ECEL).

With the arrival of a variety of new, innovative and advanced products in the market, the problem of creating awareness among the users about the same also emerges. In order to create this awareness about innovative material handling solutions for the industry, Network18 Group is organising HiTech Material Handling Show in February 2011. The event aims to provide a conducive platform for showcasing best-in-class solutions that aid in attaining manufacturing efficiency. HiTech Material Handling Show will be held concurrently with HiTech Automation, under the umbrella show HiTech Manufacturing. Elaborating on the role of this show in creating awareness in the MHE industry, Jategaonkar avers, “There are various products that the MHE industry offers but the manufacturing industry is unaware of. Thus, there is a need to create awareness about these products. An ideal platform to achieve this is the futuristic show – HiTech Material Handling. At the show, latest manufacturing, distribution and supply chain solutions that will help the entire industry stay afloat will be showcased”.

From forklift trucks to automated logistics systems, HiTech Material Handling will showcase innovative and cost-effective solutions in racking and shelving, storage solutions, pallets and palletising equipment, third party logistics, transport and distribution, handling system design and warehousing.

of various industry verticals. There are specialised equipment available for movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal.

“Material handling, with each passing day, is becoming more complex and novel. It is rapidly evolving as well. The present market offers a variety of equipment and systems that help in moving materials in and out of a warehouse. The equipment is selected based on the type of products to be moved and the volume to be handled,” asserts Sudhanva Jategaonkar, Associate Vice President – B2B Publishing, Infomedia18.

Right equipment drives growthA combination of appropriate and well-organised material handling is considered a key to determining the economies of operation. The correct selection would not only bring down the overall cost of operations, but also enhance the safety and comfort of operators, resulting in less fatigue and consequently more productivity.

“Recently, we have seen the need for more robust equipment with high demand on uptime and capabilities. The equipment manufacturing industry has met these expectations with technologically advanced products, marking a shift towards more versatile and capable equipment. We, for example, have launched TRX series of cranes, which are higher capacity cranes with higher reach and have versatile

ADVANCING TOWARDS SEAMLESS

Events - National


IMTEX 2011 & Tooltech 2011The 15th Indian Metal-cutting Machine Tool Exhibition, with international participation, will showcase the exhaustive range of innovations and technological refinements in the complete product segment of metal-cutting machine tools and manufacturing solutions. The concurrent event - Tooltech 2011 - the 13th international exhibition of cutting tools, tooling systems, machine tool accessories, metrology and CAD/CAM, will feature the latest trends in cutting tools and tooling systems from across the globe; January 20-26, 2011; at Bangalore International Exhibition Centre (BIEC), Bengaluru

For details contact:Indian Machine Tool Manufacturers’ AssociationBangalore International Exhibition Centre, 10th Mile, Tumkur RoadMadavara Post, BengaluruTel: 080 6624 6600 Fax: 080 6624 6661Email: [email protected]: www.imtex.in

Fabtech India 2011The event will highlight technologies, products, systems and services for industrial sheetmetal processing; January 21-24, 2011; at Codissia Industrial Centre, Coimbatore

For details contact:P E Schall GmbH & Co KG

MesseunternehmenGustav-Werner-Straße 6D-72636 Frickenhausen Tel: +49 7025 9206 0Fax: +49 7025 9206 620Email: [email protected]: www.fabtec-messe.com

MMMM - MINERALS, METALS, METALLURGY & MATERIALS 2011 One of the most significant events in the Indian minerals, metals and materials market, it will serve as an ideal B2B platform for industries; February 11-14, 2011, at Pragati Maidan, New Delhi

For details contact:ITEI (International Trade & Exhibition India Pvt Ltd)1106-1107, 11th Floor, Kailash Building, Kasturba Gandhi Marg, New Delhi Tel: 011 4082 8282 Email: [email protected]: www.mmmm-expo.com

DIEMOULD India 2011International exhibition for industries including dies & moulds, press tools and machine tools; April 7-10, 2011; at Chennai Trade Centre, Chennai

For details contact: Tool & Gauge Manufacturers Association of India (TAGMA)A-33, NandJyot Industrial Estate Safed

Pool, A K Road, Mumbai Tel: 022 2852 6876, 2850 8976Fax: 022 2850 3273 Email: [email protected]: www.tagmaindia.org

BLECH India 2011The event will be focussing on industrial technology, sheetmetal working, handling, cutting, forming, automation and robotics; April 14-17, 2011; at Bombay Exhibition Centre, Mumbai

For details contact: Inter Ads - Brooks Exhibitions (India) Pvt LtdPlot No 859, Phase-V, Udyog Vihar, Gurgaon, Haryana Tel: 0124 475 1600Fax: 0124 475 1601Email: [email protected]: www.blechindia.com/english

Automotive Engineering Show International exhibition on technologies for automotive manufacturing; June 10-12, 2011, at Chennai Trade Centre, Chennai

For details contact:

Focussed Event Management Pvt LtdPlot No. F/11 & F/12, Camlin Fine, WICEL, Andheri (E), Mumbai Tel: 022 3201 9137Email: [email protected]: www.focussedevents.com

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging

& Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details

Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028.

Tel: 022 3003 4651 Fax: 022 3003 4499 • Email: [email protected]

INDOREMadhya Pradesh

Jan 7-10, 2011Poddar Plaza, M G Road, Near Gandhi Hall

CHENNAITamil Nadu

Mar 11-13, 2011Chennai Trade Centre

For details

Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W),

Mumbai 400 028. Tel: 022 3003 4650 Fax: 022 3003 4499

Email: [email protected]

Concurrent Shows

One of the largest advanced design and manufacturing events in India featuring

Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation

& Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material

Handling and Safety Equipment.

MUMBAIMaharashtraFebruary 17-19, 2011,Bombay Exhibition Centre

Events - International


Pacific Design & ManufacturingThe 13th annual trade show will showcase custom moulding, custom CNC metals processing CAD/CAM & rapid prototyping; February 08-10, 2011; at Anaheim Convention Centre, Anaheim CA

For details contact:Canon Communications LLC 11444 W Olympic BlvdLos AngelesCA 90064, USTel: +310 445 4200Fax: +310 445 4299Email: [email protected] Web: www.ubmcanon.com

TIMTOS 2011The 15th TIMTOS will be focussing on the latest developments in machine tools and technologies; March 01-06, 2011; at Taipei World Trade Centre, Taiwan

For details contact:Taiwan External Trade Development Council (TAITRA)5-7 Fl, 333 Keelung road, Section 1 Taiwan ROCTel: +886 2 2725 5200 Fax: +886 2 2757 6245Email: [email protected] Web: www.timtos.com

BLECH RussiaThe event, an ideal platform for decision makers and business partners within the sheetmetal industry in Russia, will focus on sheetmetal machinery, tools and service; March 15-17, 2011; at Pavilion 7 of Lenexpo Vasilievsky Island, St Petersburg, Russia

For details contact:Mack Brooks Exhibitions Romeland House Romeland Hill St Albans, UK

Tel: +44 1727 814 400 Fax: +44 1727 814 501Email: [email protected]: www.blechrussia.com

MTA2011The event will focus on the technology and quality required to machine parts and components in metals and composites; March 23-26, 2011; at Singapore Expo, Singapore

For details contact: Singapore Exhibition Services Pte Ltd1 Jalan Kilang Timor09-02 Pacific Tech CentreSingaporeTel: +65 6233 6638Fax: +65 6233 6633 Email: [email protected]: www.mta-asia.com

MATERIALS HANDLING 2011International event on material handling equipment; March 30-31, 2011; Birmingham, UK For details contact:easyFairs UK Ltd3rd Floor, Regal House70 London RoadTwickenham, UK Tel: +44 (0) 20 86 22 44 11Fax: +44 (0) 20 86 22 4412 Email: [email protected] Web: www.easyfairs.com

JAPAN METAL STAMPING TECHNOLOGY EXHIBITION 2011The exhibition will highlight the latest technologies in metal stamping, press forming machines, forging press machines and accessories & tools for forming machines; April 20-23, 2011; at Tokyo Big Sight, Japan

For details contact:Japan Metal Stamping Association Shiba-koen 3-5-8 Kikai Shinko Kaikan 212Minato-ku, Tokyo, Japan

Phone: 3 3433 3730 Fax: 03 3433 7505Email: [email protected]: www.nikkin.or.jp

SHEETMETAL ASIA 2011The 15th international exhibition will showcase the latest developments in sheetmetal fabrication technology and machinery; May 12-15, 2011; at Bangkok International Trade Exhibition and Convention Centre (BITEC), Thailand

For details contact:UBM Asia (Thailand) Co Ltd503/23 KSl Tower, Sri Ayuthaya Road Thanon Phayathai, Rajathewee Bangkok, ThailandTel: +6600 2642 06911Fax: +660 2642 6919-20Email: [email protected] Web: www.sheetmetal-asia.com

BlechexpoInternational trade fair for sheetmetal processing, June 06-09, 2011, Stuttgart, Germany

For details contact: P E Schall GmbH & Co KGMesseunternehmenGustav-Werner-Straße 6D-72636 FrickenhausenTel: +49 7025 92060Fax: +49 7025 9206620Email: [email protected]: www.blechexpo-messe.de

The information published in this section is as per the

details furnished by the respective organisers.

In any case, it does not represent the views of

invites you to

CHENNAI | 11 - 13 Mar ‘11

Chennai Trade Centre, Nandambakkam 10 am - 7 pmInv

itatio

nInv

itatio

n

Machine Tools & Acc. | Process Machinery & Eqpt | Material Handling Eqpt | Hydraulics & Pneumatics | Automation & Instrumentation | Electrical & Electronics | IT Products & Services | Light & Medium Engineering | Safety & Security

| Packaging Machinery

Exhibitor Profile

Engineering Expo organized by Infomedia18 is one of the engineering industry’s biggest events in country. The 2009-10 edition of Engineering Expo saw business transactions worth over Rs. 150 crores. Launched in Ahmedabad in the year 2002, the event today boasts of a fabulous visitor turnout. The Expo is a preferred destination for SME’s and manufacturing & engineering companies to transact, network, tie-up and

exchange ideas for the growth of the industry.

Report


Reigning in the legacy of creating an ideal platform for profit, Engineering Expo Pune 2010 kept its promise of generating business, well beyond expectations. But even the envious ` 85 crore worth of business that the edition generated, faded in comparison to the prospects that it procured; not only for the visitors and the exhibitors, but also for the entire Pune region...

Creating a perfect trade ecosystem

B ooming economy and buoyant industrial prospects refl ect an unprecedented growth that India is all set to witness.

With innovation as the guiding light, companies are putting their best foot forward to strengthen tie-ups, establish

strong networks and harness the most lucrative deals. Generating 8,123 business leads, the Pune edition of Engineering Expo provided an ideal ecosystem of growth to exhibitors and visitors. During the four power-packed days, from November 19–22, 2010, the Expo succeeded in conveying the message that the time was ripe for the

companies to reap maximum benefi ts and fructify potential business.

The unveiling ceremony witnessed industry stalwarts vouching for the fact that India has emerged as a major trade economy and companies should make most of these opportunities. Through their inspiring speeches, industry biggies reiterated the fact that trade fairs like

The four-day extravaganza began with an inspiring note from industry leaders on the critical importance of trade fairs in building a perfect ecosystem for growth. Here’s the glimpse of what the who’s who of the industry had to say…

Inspiring thoughts @ unveiling ceremony

The SME advantage that the Pune region enjoys should be pursued and leveraged for bigger growth of the region. The developmental policies and the relentless work that has gone into making Pune region as a preferred choice for the manufacturing companies to establish their base here and grow is for all of us to see. But the need of the hour is to take these developmental work and policies to the next level to make our success a lot bigger and achieve a much higher success scale.

Sadashiv Survase, General Manager, District Industries Centre, Pune

Design-led companies carry a distinct edge and are highly differentiated. Design helps improve your product & services, powers sustainability credentials that make people happy and has positive benefi ts on bottom line. Design innovation helps you move up the value chain and has become the new source of competitive advantage. With India positioning itself as an innovation-led manufacturing hub, design becomes a key strategic tool for enterprise success.

Ashish Deshpande, Co-founder, Director & Head – Product Innovation, Elephant Strategy + Design

Trade shows are the best way to introduce your business to your customers. This is one place where you can meet all your customers at one go. In short, trade shows are the enabling vehicles to make success a surety. We grew our business only on trade shows, and my journey of being an inventor, an entrepreneur and now a proud part of a very successful organisation, would not have been so enriching without these trade shows being our enabling medium. That is the precise reason why I am here today.

Farook Merchant, Chairman & MD, Messung Group of Companies

Report

272 MODERN MACHINE TOOLS - January 2011

ENGINEERING EXPO PUNE 2010

Sumedha Mahorey

Report


Engineering Expo provide an ideal ecosystem for companies to put forth their innovative offerings for prospective buyers and aid in taking the growth trajectory forward. The awe-inspiring and thought-provoking insights of the leaders resulted in garnering business worth ` 85 crore with a total visitor footfall of 20,397. What added to the cheer was the presence of SMEs as well as government organisations along with multinationals, which provided a conducive atmosphere for the manufacturing ecosystem to grow and fl ourish.

Engineering Expo: A success storyThe Engineering Expo provided exhibitors the opportunity to reach out to global giants who are visiting India

to look out for prospective partners. Elaborating on the role of Engineering Expo in generating business leads, Pankaj Kanherkar, Senior Territory Manager, Aventura Components, said, “Engineering Expo has offered Indian companies a good opportunity to promote their products, especially at a time when MNCs are visiting our country. The Expo offers scope for tremendous exchange of ideas. We not only get inputs from customers but also from other participating companies, which help us upgrade and improvise our products to meet the demands of our clients.”

With the vast expanse of products & services on display, the event proved to be a one-stop-solutions-shop for exhibitors & visitors alike. Some of the leading companies that showcased their

innovative solutions included Atlas Copco (India), Autotech CNC, Boge Compressed Air System, Igus India, Misumi India, Nilkamal, Tussor Machine Tools India and S&T Engineers, amongst others.

Thus, weaving an entire industrial ecosystem on a single centrestage, the Expo opened up multiple lucrative opportunities for the industries in this region and brought to the fore the criticality of metworking and understanding customers’ needs in a better way.

India has emerged as one of the fastest growing economies, but its growth story will be incomplete if the bottom of the pyramid is not a part of this story. So, while we should cheer for what we have achieved, we must also strive to make India’s success story a holistic one and that will only happen when there is enough & more networking platforms being created, and technology transfer happens more often. Engineering Expo is one such platform, so utilise it to the fullest.

Raja Kochar, MD – India, Eaton Corporation

Since last year, we have worked very closely with the Engineering Expo team in providing clean and green power for the show. This Expo provides opportunities where one can see a variety of engineering products & services and that too, under a green roof. Events like this not only offer new business opportunities but also give boost to the overall economy of the region. As we travel to other locations with the Expo, our own understanding of our customer requirement is enhanced and this provides valuable inputs to our R&D team.

Sanjay Jain, AVP – Sales, Kirloskar Oil Engines

This is the fi rst time we are taking part in Engineering Expo and I must congratulate the organisers and the team for putting up this extraordinary show. The manufacturing sector is the probable growth engine of the Indian economy and as its economy progresses; the sector will have a bigger role to play. But as the economy and sector progresses, there is a need to collaborate more than ever. Engineering Expo is the place where you can collaborate with the right companies and fi nd right partners & products.

Guy Amoroso, MD, 123 Insight India

Exhibitions and trade shows have been used as an effective marketing medium to fi nd new customers, improve business relationships with existing customers, introduce new products & services, and deliver many other meaningful & tangible business outcomes. Engineering Expo is one such event that has become a principal platform for product launches and business growth for several SMEs in this region. Over the years, The Expo has helped foster trade & commerce in the region and has helped the local industry’s interface with prospective investors.

Sandeep Khosla, CEO - Publishing, Infomedia 18

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Growth phase S Chandrasekhar, Senior Manager (Western Region), S&T EngineersWe are optimistic about the growth of our sector with increase in the number of start-ups. Various sectors like automobile, dies & moulds and component manufacturing are showing good performance. As a result, the demand for our machines will increase to match their requirements.

Sohrab Daver, Executive Director, Masibus Automation and InstrumentationWe have set up an additional system integration unit in our Gandhinagar plant and already have a manufacturing plant in Goa. We are expanding and plan to set up plants all over the country to keep pace with the manufacturing industry. We expect our company to witness a 30-40 per cent compounded growth in the next fi ve years.

A P Singhal, MD, Emtex Marketing We are growing by 100 per cent in terms of turnover. We are also consolidating our market position by investing in new products.

Amit Shah, Manager - Sales, East India Bearing CoOur engineering products are unique in the world. While others produce ball or spherical bearings, we have split roller bearing equipped for the mining or steel industry. Companies using our equipment can reduce upto 90 per cent of downtime, thereby signifi cantly improving shop fl oor effi ciency.

Delighted visitors Maulik Desai, MD, Unique Industrial ServicesI was expecting Engineering Expo to be organised on a much smaller scale. But the Expo was so well organised that it surpassed my expectations. I could easily fi nd all the products I was looking for.

Santosh Patil Kulkarni, Manager, AnsysThe Engineering Expo is good for the industry, especially the SMEs. I was able to get the products I needed. The good part is that there are electronics-related products available at the Expo.

Shireesh P Lawate, CEO, Parth EnterprisesEngineering Expo has a wide range of engineering products on display. The organiser took steps to ensure that only quality visitors attended the show. To make it better, the Expo can be made more vertical-specifi c.

Animesh Kumar, AVP & Branch Head, Axis BankMy experience at Engineering Expo has been quite good. There were a number of engineering tools and forging products available at the exhibition. However, a better variety was needed. On the whole, the Expo was very informative. D R Gadakh, Manager, New Aniket Packing Industries Engineering Expo was well-organised. The stalls were well- arranged and properly segregated.

Business transaction of over ` 85 crore in 4 days

90 per cent of downtime, thereby signifi cantly improving shop fl oor effi ciency.

Engineering Expo was well-organised. The stalls were well- arranged and properly segregated.

Business transaction

235 exhibitors

participated

in Engineering

Expo Pune 20108,123 are

the total

business leads

generated

88% exhibitors

showed

willingness to

partner with

Engineering Expo

again

Total weight of

the machinery

moved in

80,000 kg

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Alluring alliances @ Engineering Expo Pune 2010

Arun Vijay, Director - Marketing, Autotech CNCEngineering Expo has helped us fi nd a good number of references. We are a Pune-based company and most of our visitors were our clients. I am sure that if we participate in Engineering Expos held in other cities, we will defi nitely get a good response. Prashant Joshi, Business Head, Hi-Tech Group We have participated in Engineering Expo to reach out to emerging markets like Pune, Ahmedabad, Chennai, etc, which are usually not covered by other trade exhibitions.

Preeti Nagarkar, Managing Partner, MapynEngineering Expo has provided us a platform to display our products to our target customers. It gives us the chance to interact with customers and visitors, who give us valuable inputs on how we can upgrade our products.

Hemang K Ghelani, Product Manager – Control Components, Omron Industrial AutomationEngineering Expo helps us reach out to our customers. We look at the Expo as a marketing tool or a promotional activity to create brand awareness.

Demands trends witnessed

Milan Supanekar, Owner, Welding Technologies IndiaThe need of the hour in the manufacturing sector is to upgrade existing technology to stay ahead of competitors.

Pawan Wadhwan, Manager (Business Development), Sipcon Instrument IndustriesNowadays, customers have become more demanding. They want the best product at the lowest cost. Therefore, companies should focus more on providing the highest quality products & services to their customers, at the lowest possible cost.

Nimesh Karlya, Director, Jay Equipment System Customers always track the market for the latest technology, high-quality and low-cost products. Hence, it is important that companies work on their branding and offer good quality products, which will enhance the company’s overall productivity.

Dinesh Chaudhary, Director, Energy Mission EngineersCustomers want NC and CNC machines. This means that automation is in demand. At the same time, customers have also been demanding bigger and special machines.

82% visitors were from Pune

66% of the visitors have visited the Expo in previous editions

activity to create brand awareness. special machines.

20,397 visitors

visited

Engineering

Expo Pune

82% visitors

were happy

with the

product range

displayed

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Creating history, Engineering Expo Ahmedabad 2010 registered over 250 exhibitors and generated business of over ` 100 crore, the biggest ever since its launch in 2002. Taking the triumph forward and playing the role of an enabler, this year’s Engineering Expo Ahmedabad edition kept up with its promise of generating envious business deals and maximum returns on investment for exhibitors and visitors alike. A report…

Taking the triumph forward

Having established their mettle in facilitating growth, trade shows have been proven to be success platforms for

companies to form business alliances and transactions. This was evident from the grand success of the 9th edition of Engineering Expo Ahmedabad.

Apart from being a good promotional vehicle for brands and

products, trade shows offer lucrative business prospects and a platform for business generation. Engineering Expo Ahmedabad 2010 proved to be one of the biggest shows in the history of Engineering Expo Ahmedabad, since its inception in 2002. It has managed to generate business amounting to over ` 300 crore in the past nine years; moreover, this year it managed to generate business transactions worth ` 100

crore. Talking about the returns the exhibitors get from the expo, Shirish Vyas, Marketing Manager, Cranoist Material Handling Equipments, said, “About 15-20 per cent of our business is done at the Engineering Expo. But, we do not set any sales target for the expo, as these sales are just an incentive of the investments we make while participating in the expo. We spend a substantial amount of money on exhibitions and expos.”

Report

ENGINEERING EXPO AHMEDABAD 2010


Engineering Expo - Ahmedabad basks in glory The four-day Engineering Expo at Ahmedabad was fl agged off on December 10, 2010, with a traditional lamp-lighting ceremony followed by a ribbon cutting ceremony. Industry torchbearers BB Swain, IAS, Industries Commissioner, Government of Gujarat, and Pradyumna Vyas, Director, National Institute of Design, bestowed an auspicious momentum to the event. Both Vyas and Swain were overwhelmed with the strength displayed by the industry. Serving as a perfect platform for profi t, the Expo managed to converge the entire manufacturing and engineering industry of Gujarat under one roof. Manufacturing forms the core of the state’s industrial profi le, according to Swain, with Gujarat contributing 40 per cent to the total engineering export of India. The manufacturing industry helps provide employment to over 18 lakh people in the state.

Engineering Expo - Ahmedabad basks in glory The four-day Engineering Expo at Ahmedabad was fl agged off on December 10, 2010, with a traditional lamp-lighting ceremony followed by a ribbon cutting ceremony. Industry torchbearers BB Swain, IAS, Industries Commissioner, Government of Gujarat, and Pradyumna Vyas, Director, National Institute of Design, bestowed an auspicious momentum to the event. Both Vyas and Swain were overwhelmed with the strength displayed by the industry. Serving as a perfect platform for profi t, the Expo managed

BB Swain, IAS, Industries Commissioner, Government of Gujarat

inaugurating Engineering Expo Ahmedabad

Purna Parmar

Meanwhile, Nurul Vora, Marketing Manager, Hydro Pneumatic Equipments, explained, “The conversion rate at the Engineering Expo is over 50 per cent. We sold a machine on the fi rst day of the exhibition and generated business of about ` 10 lakh by the end of the expo. Trade fairs easily gather all Original Equipment Manufacturer (OEM) customers and process-related customers under one roof, and this is what makes the Engineering Expo unique.”

Highlighting the glorifying success achieved by the Expo year after year, Sandeep Khosla, CEO - Publishing, Infomedia18, averred, “Engineering Expo Ahmedabad has managed to withstand the test of time, and for

nine consecutive years it has been a vital platform for forging trade ties. Right from new product launches to substantial business transactions, the Engineering Expo Ahmedabad has established itself as a trendsetter of innovative offerings.”

Similarly, Mehul Gajjar, CMD, Heena Equipment, says, “Apart from meeting prospective clients, we see latest technology and machinery displayed by the industry. We sold four welding machines on the fi rst day of the exhibition. We have launched a new product at the expo. It is a three-in-one machine that can do all types of welding and cutting work.”

While Ahmedabad serves as a perfect trade centre for the industry, smaller

cities like Rajkot have now emerged as a manufacturing hub, especially for the machine tools industry. Tushar Shaparia, MD Jamnagar Machine Tools, commented, “The machine tools industry is growing by 15-20 per cent. Rajkot is emerging as a manufacturing hub for the machine tools industry, and this is mainly due to the presence of other machinery and related companies in Rajkot. Trade shows like the Engineering Expo play a vital role in our growth, as we get an opportunity to meet prospective clients and create a good brand presence in a big city like Ahmedabad. ”

In all, Engineering Expo Ahmedabad managed to successfully take this legacy forward, proving to be the biggest ever expo in the history of Ahmedabad and the second biggest in the history of the Engineering Expo. While the expo managed to serve as a lucrative business platform and the biggest product showcase vehicle, it also managed to give the best Return On Investment (ROI) to the exhibitors.

Report


Creating a business environEngineering Expo - Ahmedabad managed to generate business worth ` 100 crore. The Expo witnessed the participation of more than 250 exhibitors from various industry verticals and a visitor turnout of over 19,759. To facilitate the enterprising spirit of the industry and provide a platform, The Gujarat government is coming up with two new conventional centres in Gandhi Nagar, both of which will be used for the next Vibrant Gujarat slated to take place in January.

Further, talking about how trade fairs help the industry grow, Shirish Vyas, Marketing Manager, Cranoist Material Handling Equipments, said, “Trade fairs like the Engineering Expo are helpful in displaying our products on a single platform where all our potential customers can come and have a fi rst-hand experience of the product.”

Similarly, Shrikesh Mehta, Bearing and Tool Centre, said, “A trade fair is one of the best opportunities a company can have to showcase its products to its customers. It is diffi cult for us to show our products door-to-door, but in a trade fair, the customer comes to you, and thus it helps us create a good database of customers.”

Engineering Expo - Ahmedabad managed to generate business 100 crore. The Expo witnessed the participation of more

than 250 exhibitors from various industry verticals and a visitor turnout of over 19,759. To facilitate the enterprising spirit of the industry and provide a platform, The Gujarat government is coming up with two new conventional centres in Gandhi Nagar, both of which will be used for the next Vibrant Gujarat slated to

Further, talking about how trade fairs help the industry grow, Shirish Vyas, Marketing Manager, Cranoist Material Handling Equipments, said, “Trade fairs like the Engineering Expo are helpful in displaying our products on a single platform where

us to show our products door-to-door, but in a trade fair, the customer comes to you, and thus it helps us create a good database of customers.”

Market scenario Paresh Patel, Executive Marketing, Masibus Automation and InstrumentationGujarat, particularly Ahmedabad, is a new market for us and so it is a good opportunity to explore this market. Rajkot in particular is an emerging hub and has a large number of manufacturing companies, while Ahmedabad is a trade hub.

Tushar Shaparia, MD, Jamnagar Machine ToolsThe machine tools industry is growing by 15-20 per cent per year. About 20 per cent of our business is generated through trade fairs.

Amit Gosai, Sales Engineer, S & T Engineers Ahmedabad is one of our target markets, we also plan to have a footprint in the surrounding areas like Rajkot, Baroda and Anand. We see a good potential in these markets as well.

Ashish Sengupta, GM, Atlas Copco The compressor market in India is not very competitive nature. And as we are not in a price battle. Looking at the way the market is developing, compressors will become a necessity for all industries. Gujarat is the only state in India that is fully developed compared to other states. Moreover, in Gujarat even smaller cities like Vapi are highly developed. So the scope of economic development is far better in the state. We see a huge geographical advantage in Gujarat, as means of transportation is high.

Innovative products

Madhur Mehrotra, Head – Chemical Division, Earth Water Group We mainly offer purifi cation and fi ltration services for the water and waste water management industry. We have launched a new range of softeners in the Engineering Expo this year. This is a very convenient and easy to use product. It does not have many time-consuming functions. These can be used in large homes, industries and even large institutions.

Ashish Vij, Executive – B D, Bry-Air We deal in air treatment systems and moisture control systems. The Indian manufacturing industry is moving up the growth curve, and we are very optimistic about this growth. Trade fairs like these help us display our products to the right audience, as the visitor profi le of these trade fairs is focussed.

Manish Raval, VP Sales, Mobienturbo Trade fairs are a platform where we can display our technology and explain to customers about the design and technical aspects of the product. We have conducted several technical sessions in trade fairs, where we demonstrate the importance of design and other technical aspects of the product. Mangesh Agarwal, GM, Cleaning and Filtration Systems IndiaThe Ahmedabad market for cleaning and fi ltration equipment is still at a nascent stage. At trade fairs we get to know the kind of technologies and products available in the market.

Report

2010 edition was the

biggest show in the

history of Engineering

Expo – Ahmedabad, be it

the number of exhibitors,

visitors, area occupied,

revenue generated for

the company or amount

of business transacted

More than 100,000 kg machinery were brought in by exhibitors at the Expo, which is again the highest in the history of the Engineering Expo

85 per cent exhibitors

found Engineering

Expo Ahmedabad

2010 better than

other trade shows


250+ exhibitors

Creating a business environment

Manish Chandrani, B E Elect, Kumarpal Kantilal and Co, Kirloskar oils Trade fairs are mainly seen as an opportunity to showcase products. We have been participating in the Engineering Expo for the last four years and have generated many leads, out of which 40 per cent of our leads get converted into business. Shreepad Deshpande, Regional Manager – West, Kulkarni Power ToolsWe are fi rst time exhibitors at this expo but the response has been very good for us, as we have sold two machines at the expo.

Pratik Bhatt, Slaes & Service, Komet India The manufacturing industry is growing at a fast pace and Gujarat has been on the forefront. Over 8 per cent of our marketing budget is spent on trade exhibitions and shows, while 20 per cent of our business is generated from these exhibitions.

Jagadish Patel, Sales Manager, Neutron Power Tools We have been participating in the engineering expo since the last fi ve years. Although we did not concentrate on making any actual sales, we manage to generate several business leads for our dealers spread across the state.

Enchanted visitors

Rajesh Panchal, MD, Ambica EngineeringGenerally, we see products only in company brochures, and it is diffi cult for us to understand the product and other features of the equipment. However, at the Expo we had fi rst hand experience of the products and also saw a demo of the machine. I have booked a welding machine here as well.

Deepak Shah, Manager, SpartexI am not from engineering background, but the kind of products displayed were interesting and I learnt a lot about manufacturing and CNC machines at the Expo.

Jaiprakash Gala, Sales Engineer, Mamta Engineering The Expo was well organised, especially the venue chosen was very good. It looks like an international event. The exhibitors from power tools industry were helpful, as they offered guidance regarding the applications. The equipment displayed could be used at home as well as in industrial shop fl oors.

Manish Sangla, Manager, Tasyani Traders The organisers have chosen a very good venue, and the expo was also grand. I got the tools I needed at the expo. I plan to come back next year as well.


More than 100,000 kg machinery were brought in by exhibitors at the Expo, which is again the highest in the history of the Engineering Expo


found Engineering

Expo Ahmedabad

2010 better than

other trade shows


83 per cent exhibitor were happy with the quality of visitors at the show

Report

Business of over `100 crore 19,759+ Visitors

Product Pg No Product Pg No Product Pg No

Product Index


Abrasive blast rooms ...........................................32Abrasive blasting machines.................................................. 32Abrasive brush technologies.............................................BGFAbrasives ............................ 42, 47, 49, 51, 53, 55, 57, 59, 63Abrasives and pneumatic tools................................................................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63AC drives ....................................................................................129Aerospace materials....... 42, 47, 49, 51, 53, 55, 57, 59, 63Air hammer & screwdriver.................................................. FGFAir impact & rachet wrench............................................... FGFAir treatment ............................................................................225Air-conditioning hose ...........................................................174Air-die grinder ......................................................................... FGFAirless paint spray hose........................................................174Aluminium endmills...........................................................12-13Angle encoders.........................................................................BICAngle grinder............................................................................164Angle head & live tool .. 42, 47, 49, 51, 53, 55, 57, 59, 63Angular boring machine......................................................245Antivibration tools..................................................................150APFC panels ..............................................................................221Appliance switches................................................................... 17Association ................................................................................229Automatic drilling machine ................................................177Automatic tapping machine ..............................................177Automation ..........................................................................20, 41Automation accessories .......................................................201Automation and testing equipment ...............................213Automation solutions............................................................193Automobile workshop trolley ............................................158Automotive oils .......................................................................249Balance systems ...................................................68Ball screws .................................................................................165Bandsaw machines................................................................... 29Bar feeders.................................................................................193Bearings ......................................................................................130Bed-type milling machine ...................................................183Billet shearing machines ........................................................ 16Blades ................................................................................171, 195Blasting media ........................................................................... 32Bolts, screw & nuts .................................................................171Boring bars/boring heads...................................................... 22Boring heads...................................................................171, 247Boring heads & accessories.................................................169Boring machines............................................................171, 183Boring tools...............................................................................171Braided & spiral high pressure flexible hose................174Building automation................................................................ 20Burrs .........................................................................................12-13Cable carriers ..................................................... 130Cable connectors ....................................................................130CAD software............................................................................137CAD solution - Hypercad ....................................................... 26CAD system ...............................................................................137CAD/CAM programs ..............................................................137CAD/CAM software .................................................................. 26Camshaft ..........................................................................216, 223Camshaft/crankshaft grinding machines.......................207Carbide burrs ........................................................................12-13Carbide endmill tools ..............................................................BCCarbide helical endmill .........................................................100Carbide rods................................................................................ 99Carbide routhing endmills ..............................................12-13Carbide tools.........................................................................12-13Castings .......................................................................................FICCED coating machines............................................................ 20Cement grouting hose..........................................................174Centralised lubrication systems ........................................217Centre hole grinding machine...........................................133Centreless grinding machines ............................................. 25Ceramic .......................................................................................299Ceramics and refractories .. 42, 47, 49, 51, 53, 55, 57, 59, 63Cermet.........................................................................................299C-frame power press ............................................................... 16

Chain pulley block .................................................................... 83Chains ..........................................................................................130Chamfer machines..................................................................171Chemlok coating machines .................................................. 20Chuck jaws................................................................................... 41Chucks .........................................................................................171Clamping series .......................................................................175Clamping tools...........................................................................BCCleaners ......................................................................................139CMM probe systems ..............................................................161CNC.......... 7, 14, 15, 42, 47, 49, 51, 53, 55, 57, 59, 63, 259CNC automatic lines ..........................................................80-81CNC controls .............................................................................. 97CNC cutting machines ............................................................ 20CNC die-sinking EDM .............................................................. 60CNC drilling machines...........................................................171CNC equipment ......................................................................... 19CNC gear hobbing machines .............................................231CNC gear shaping machines ..............................................231CNC grinding machines ...................................................80-81CNC guillotine shear ................................................................ 24CNC hob regrinder .................................................................241CNC horizontal boring and milling machines .............171CNC horizontal boring machines..................................80-81CNC horizontal machining centres .................... FIC, 80, 81CNC hydraulic press brake .................................................... 24CNC laser cutting machines...........................................20, 24CNC lathes ........80, 81, 109, 147, 171, 235, 261, 184, 185CNC lathes/turn mills.............................................................169CNC machine............................................................................158CNC machine probe................................................................. 97CNC machine simulation ....................................................... 97CNC machine solution ...............................30, 143, 218, 219CNC machine tools.............................................................80-81CNC machines ............................8, 9, 15, 125, 184, 185, 283CNC machining centre............................................................ 15CNC milling machines.................................................. FIC, 171CNC oxy-fuel cutting machines........................................... 20CNC plasma cutting machines............................................. 20CNC punch press....................................................................... 24CNC robodrills ......................................................................80-81CNC systems (open & closed PLC type) .........................201CNC tool grinders ...................................................................241CNC tool holders .....................................................................247CNC toolings ...................................................................171, 195CNC turning centres .........................................................15, 86CNC turning machines......................................................80-81CNC turn-mill centres.............................................................. 86CNC vertical chuckers........................................................80-81CNC vertical machining centres................... FIC, 15, 80, 81CNC VMC machines ....................................... 87-90, 121, 123CNC wire-cut EDM .................................................................... 60CNC wire-cutting machines ................................................171Coating machines ..................................................................... 20Coating plants............................................................................ 20Coating systems ........................................................................ 20Cold forming machines ........................................................213Collets......................................................................................10-11Combination boring ..............................................................150Combination boring bars ....................................................247Combined drills & countersinks ....................................12-13Composite applications.......................................................... 97Composite processing equipment...................................213Compound machines.... 42, 47, 49, 51, 53, 55, 57, 59, 63Computer-aided design machines.......................................... ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Computer-aided manufacturing systems............................. ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Conduits and connector systems ....................................... 17Connectors ......................................................................105, 130Control cabinets ......................................................................105Control panel accessories...................................................... 17Control panels..........................................................................105Control systems .......................................................................105

Control valves...........................................................................180Controlling machine tools....................................................BICCoolants......................................................................................159Cooling tower...........................................................................225Copper brass tubes ........ 42, 47, 49, 51, 53, 55, 57, 59, 63Corrosion preventives ................................................... 23, 139Counters & power supplies................................................... 67Countersinks ...........................................................12-13, 72-73Crabs .............................................................................................. 83Crane.............................................................................................. 83Crankshaft.............................................................. 211, 216, 223Crankshaft machines .............................................................213C-type power press ................................................................156Custom design cutting tools ................................................ 22Customerised software development .............................. 39Customised product ..............................................................267Customised solutions ............................................................150Cut-off machine.......................................................................164Cutter/grinder verification & machine simulation ....... 97Cutters...............................................................................171, 195Cutting fluids ............................................................................139Cutting machines...................................................................... 20Cutting oils ................................................................................159Cutting speed optimisation.................................................. 97Cutting tools ......31, 35, 37, 42, 45, 47, 49, 51, 53, 55, 57, 59, 63, 65, 99, 119, 197, 198, 233, 234, 263, 299, 300CV joint machines...................................................................213Cyclinders.................................................................................. FGFCylinder block...........................................................................216Cylinder head ...........................................................................216Cylindrical & internal grinding machines ........................ 95Cylindrical grinders ................................................................109Cylindrical grinding machines ................................... 25, 169Deburring machines ......................................... 223Decimal endmills.................................................................12-13Deep-hole drilling machines ..............................................169Deep-hole drilling solutions ..............................................BGFDemagnetisers ........................................................................... 18Diamond cutters......................................................................171Diamond superabrasives ...................................................BGFDiamond superfinishing tools .........................................BGFDiamond tools......................................................................72-73Didactic equipment for training .......................................105Die-mould machines ........................................................... COCDigital readout systems..............................................110, 227Disposable toolholder bits ..................................................171Distribution transformer ......................................................221Double-column bandsaw machine .................................. 29Double-coulmn milling machines .................................. COCDrawer cupboard....................................................................158Drawing & forming compound .........................................139Drill machine.............................................................................203Drill tap centres ........................................................................FICDrill tools ......................................................................................BCDrilling & milling tools ..........................................................150Drilling head .............................................................................177Drilling machines ..........................................................138, 183Drilling tools........................................................31, 72, 73, 119Drills ........................................ 12-13, 100, 138, 164, 171, 267Drills and centre drills ...........................................................267Drive technology......................................................................BICDrives............................................................................................. 14Dust collectors ........................................................................... 32Dye polishing stones ..... 42, 47, 49, 51, 53, 55, 57, 59, 63Edge preparation machine........................208-209EDM ..............................................................................................259EDM accessories and consumables ........................................................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63EDM spares........................ 42, 47, 49, 51, 53, 55, 57, 59, 63EDM wires .......................... 42, 47, 49, 51, 53, 55, 57, 59, 63Ejector systems .......................................................................BGFElectric discharge machines ................................................. 21Electrical CAD/CAE software................................................. 52Electromagnetic lifter .............................................................. 18

SOURCE AUTOMATION & INSTRUMENTATION PRODUCTS @www.engg-expo.com


Product Index


Electromagnetic separators .................................................. 18Electropermanent magnetic chuck/tools/lifter ............. 18Encoders ....................................................................................... 67Endmill cutter ...........................................................................155Endmills .................................................................. 100, 168, 267Endmills/facemills ..................................................................... 22Enterprise application development................................. 39EOT/HOT cranes ........................................................................ 83Exhibition - Engineering Expo...78, 120, 140, 160, 269, 270Exhibition - HiTech Manufacturing Show ...........251, 252Export interfaces ....................................................................... 97Exposed linear encoders .......................................................BICFactory automation..................................... 20, 179Fire-reel hose ............................................................................174Fittings ....................................................................................... FGFFixturing systems ....................................................................145Flame-proof hoist ..................................................................... 83Flex hone tooling...................................................................BGFFlexible shaft grinding machines ............................................ ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Floor automation ....................................................................205Fluidised bed coating machines......................................... 20Fly wheel ....................................................................................216Forging press.............................................................................. 16Form measurement......................................................Box, 215Forming milling cutter..........................................................155Friction drop hammers........................................................... 16Friction screw press ................................................................. 16FRP - movable cross-rail .......................................................296FRUF - movable cross-rail ....................................................296Fully automatic bandsaw machine.................................... 29Gantry automation............................................ 205Gauges ....................................................................................... FGFGear boxes................................................................................... 83Gear cutting machines.............................................. COC, 169Gear grinding machines.............................................127, 169Gear grinding technology ...................................................189Gear hobbing machines.............................................127, 207Gear inspection centres........................................................169Gear pumps...............................................................................180Glass .............................................................................................113Glide coating machines.......................................................... 20Goliath crane .............................................................................. 83Goods lift ...................................................................................... 83Graphite & high temperature insulation .............................. ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Greases........................................................................................249Grinding machines ...................25, 113, 133, 152, 207, 223Grinding tools for hard materials ...........................113, 152Grooving & parting tools ....................................................... 99Ground rods..............................................................................267Guillotine shear.......................................................................... 24Gun drills ................................................................................72-73Hammers ...............................................................16Hanlding system modules...................................................105Hard alloy turning cutter .....................................................155Hardened & ground drill blanks........................................100Head face milling ....................................................................245Heavy duty drill .......................................................................164Heavy duty drill machine.....................................................203Heavy duty magnetic drill stand.......................................164Heavy duty radial drill machine ........................................203Heavy-duty machine toolos.......................................208-209H-frame power press ............................................................... 16High performance drills....................................................12-13High performance endmills ............................................12-13High precision roll shop machine ...........................208-209High pressure gear pumps..................................................180High pressure hydraulic clamping elements ..............BGFHigh-speed and high-performance milling centres.... 21High-speed machining centre ............................................. 15HMC.......................................................................... 184, 185, 283HMC machines .........................................................................245Holders........................................................................................168

Horizontal & vertical machining centres .......................207Horizontal bandsaw...............................................................153Horizontal boring machines ...............................................213Horizontal boring mill ......................................................... COCHorizontal machining centres.......................................7, 213Horizontal milling machines............................................. COCHorizontal pipe & tube bending machine ...................... 85Horizontal section bending machine................................ 85Horizontal turning centres ..................................................213Hot & cold forming ................................................................169Hot water hose ........................................................................174HSK ...........................................................................................10-11HSK holders ...............................................................................247HSS tools ....................................................................................267Hydraulic accessories ........................................................... FGFHydraulic bandsaw machine ................................................ 29Hydraulic gear pumps...........................................................180Hydraulic hoses ...................................................................... FGFHydraulic power tools...........................................................171Hydraulic press brake.................................................... 24, 156Hydraulic press machine ....................................................... 85Hydraulic shearing machines ..................................... 85, 156Hydraulic variable rake angle shearing machine .......156Imaging & vision systems....................................20Impact wrenches............. 42, 47, 49, 51, 53, 55, 57, 59, 63Incise dental CAD/CAM ........................................................161Indexable angle cutter..........................................................168Indexing machine ..................................................................... 32Indo-German trade promotion services.........................295Induction pipe bending machine............................208-209Induction vacuum casting machine ....................................... ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Inductive proximity switches ............................................... 17Industrial brushes ..................................................................BGFIndustrial connectors.............................................................173Industrial control & sensing devices.................................. 67Industrial coolers.....................................................................225Industrial oils ............................................................................249Industrial robots ........................................................................ 93Industrial safety products .....42, 47, 49, 51, 53, 55, 57, 59, 63Integrated CNC turning-cum-machining centre .......... 86Interface connectors ..............................................................173Interface electronics................................................................BICInternal grinding machines......................................... 25, 133Invertor/variable frequency drives..................................... 67Iron worker ...........................................................................24, 85Isolation transformer .............................................................221Jack hose ........................................................... 174Jib crane ....................................................................................... 83Jig grinding ...............................................................................169Jobber length drills ............................................................12-13Keys & wrenches................................................ 247Lapping & flat honing machines ..................... 169Large plano millers.................................................................169Large size machining centres........................................... COCLaser calibration and telescoping ballbar .....................161Laser cutting machine ............................................................ 24Laser interferometer encoders ..........................................161Laser shaping ................................................................113, 152Laser tools..................................................................................107Laser welding machines.......................................................207Lathe chucks ............................................................................... 41Lathe machines........................................................................283Lathes ...............................................................................................7Lathes - automatic........................................................171, 235Lathes - heavy-duty ...............................................................171Lathes - high-speed ...............................................................171Lathes - turret...........................................................................171Lathes - vertical........................................................................171LED.................................................................................................. 17Length gauges ..........................................................................BICLevel controllers ........................................................................ 67Light duty drill..........................................................................164Limit switches............................................................................. 17

Linear motor thread & gear grinders ................................ 43Linear way vertical machining centre.............................125Load break switches ................................................................ 17Lubes ...........................................................................................159Lubricants .......................................................................... 23, 255LV motors...................................................................................129Machine condition monitoring systems .........BGFMachine measurement system ..........................................BICMachine simulation ................................................................ 97Machine simulation - multi-axis .......................................... 97Machine tool accessories ....................................................... 58Machine tool accessories & vices............................................. ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Machine tool probe systems ..............................................161Machine tools ............................................................................. 45Machining & grinding fluid.................................................139Machining centres ......................................................42, 47, 49 51, 53, 55, 57, 59, 63, 157, 169, 171, 184-185, 231, 296Machining tools............... 42, 47, 49, 51, 53, 55, 57, 59, 63Magnetic crack detectors ...................................................... 18Magnetic encoders.................................................................161Magnetic modular encoders ...............................................BICMagnets for billet handling/coil handling ...................... 18Maintenance trolley ...............................................................158Manual feed drilling machine ............................................177Marine oils .................................................................................249Material testing..............................................................Box, 215Measurement equipment..........................................Box, 215Measurement systems ............................................................ 58Measuring & monitoring relay ............................................ 67Measuring accessories ..........................................................145Measuring equipment... 42, 47, 49, 51, 53, 55, 57, 59, 63Mechanical & penumatic shearing press.......................156Mechanical clutch press brake ..........................................156Mechanical shear ...................................................................... 24Mechanical/hydraulic press brake...................................... 85Metal cutting bandsaw machine ........................................ 29Metal cutting technology ................................................10-11Metal cutting tools .................................Booklet, 10, 11, 149Metals and alloys ............ 42, 47, 49, 51, 53, 55, 57, 59, 63Metalworking fluids ....................................................... 23, 271Metric endmills ....................................................................12-13Metrology equipment.................................................Box, 215Micro ball nose endmills ........................................................ 45Micro boring kits ............. 42, 47, 49, 51, 53, 55, 57, 59, 63Micro drills ................................................................................... 45Micro endmills............................................................................ 45Micro rotary tools...................................................................... 45Micro tools .................................................................................. 45Microbore tools ......................................................................... 22Microboring cartridges .........................................................247Micrograin solid carbide twist drills ................................100Milling centres...............................................................................7Milling cutter ...................................72, 73, 99, 155, 168, 247Milling machines ..................... FIC, 171, 183, 184, 185, 296Milling solutions ......................................................................239Milling tools ...............................................................31, 119, BCMilling/drilling machines .....................................................169Mill-turn centres ......................................................................169Millturn machining centres................................................... 97Mobile drawer system...........................................................158Mobile equipment & earthmoving hose .......................174Model export interfaces ......................................................... 97Modelling machines ...... 42, 47, 49, 51, 53, 55, 57, 59, 63Modmachine simulation ....................................................... 97Modular boring........................................................................150Modular tooling system ...................................................72-73Molecular diagnostics ...........................................................161Monorail trolley ......................................................................... 83Motion controls ..................................................................14, 67Motor protection circuit breaker ........................................ 17Motorised chain pulley block............................................... 83Motors ........................................................................................... 14Mould changing systems.....................................................163

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Product Index


COC - Cover On Cover FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover BGF - Back Gate Fold BC - Back Cover

Moulds.........................................................................................183Moving-column machining centre .................................245Mtad catalogue 2009 (full) ......................................................... ................................................ 42, 47, 49, 51, 53, 55, 57, 59, 63Multi-axis waterjet cutting operations ............................. 97Multi-channel programming/synchronisation .............. 97Multifunctional tools ............................................................... 99Multi-spindle drilling and tapping head........................177NC boring & facing head ..... 42, 47, 49, 51, 53, 55, 57, 59, 63NC spotting drills ................................................................12-13Offline hydraulic clamping systems ................BGFOptical absolute encoders ..................................................161Optical incremental linear/rotary encoders..................161Optical measurement..................................................Box, 215Orbital motors ..........................................................................180Orbital sander...........................................................................164Over crank shearing press ...................................................156Paint shop equipment .........................................20Paint shop machines ............................................................... 20Paint spray booth ..................................................................... 32Pallet monitoring solutions................................................BGFParallel kinematic machines ................................................ 97Part ejectors ..............................................................................281PCD & CBN tools......................................................................299Permanent magnet tools....................................................... 18Permanent magnetic chucks................................................ 18Permanent magnetic lifter .................................................... 18Permanent magnetic separators......................................... 18Petrol disprnsing hose ..........................................................174Photoelectric sensors .............................................................. 67Pillar drilling machine .................................................138, 203Pilot lights .................................................................................... 17Pipe bending machine.................................................208-209Pipe cutting machine ...................................................208-209Piston...........................................................................................216Piston pumps............................................................................167Plasma cutting machine......................................................... 24Plate bending machine .......................................................... 85Plate cutting machine..................................................208-209PLCs...................................................................................... 67, 129Plugs and sockets ..................................................................... 17Pneumatic clutch press brake............................................156Pneumatic hydraulic clamps ..............................................171Pneumatic tool hose..............................................................174Pneumatic tools & accessories.......................................... FGFPnuematic grinders........ 42, 47, 49, 51, 53, 55, 57, 59, 63Polishing machines ................................................................223Portable blaster ......................................................................... 32Portable coolant purifying system...................................281Portable oil skimmer ............................................................281Position display units .............................................................BICPost processors .......................................................................... 26Power chuck..............................................................................175Power chucking cylinders....................................................109Power pack................................................................................180Power press....................................................................... 85, 156Power saver...............................................................................221Power sources ..........................................................................187Power tools ..............42, 47, 49, 51, 53, 55, 57, 59, 63, 164Powrgrip system......................................................................226Precise electrochemical machining .................................259Precision gear cutting tools.............................................. COCPrecision parts machining..................................................... 22Precision steel ................................................................113, 152Precision switches..................................................................... 17Precision switches ................................................................... 17Press brake ........................................................................ 24, 156Pressure blaster ......................................................................... 32Pre-tereatment systems ......................................................... 20Process automation and control equipment...............105Process monitoring sensors................................................107Profilers and gantry machines ...........................................213Program verification ................................................................ 97Programmable boring bar..................................................... 97Programmable terminals ....................................................... 67Programming of tool axis ..................................................... 97Propeller hub.............................................................................. 77Protection systems ...............................................................BGF

Proximity sensors...................................................................... 67Pumps..........................................................................................180Push buttons............................................................................... 17PVC braided clear hose.........................................................174PVC steel wire hose............................................................... FGFQuick die change system.................................. 163Quick mould change system..............................................163Radial driling machine...................... 138, 183, 203Reamers .............................................................. 72-73, 263, 267RFID ................................................................................................ 67Robotic automation...............................................................205Robots ........................................................................................... 93Roll forming machine.............................................................. 85Rolling oils .................................................................................139Rotary cam switches ................................................................ 17Rotary cylinder .........................................................................175Rotary encoders........................................................................BICRotary feed back ....................................................................... 14Rotary tables ...................................................................171, 253Rough & fine boring bars ....42, 47, 49, 51, 53, 55, 57, 59, 63Router ..........................................................................................164Rubber.........................................................................................174Rust preventives......................................................................139Safety and security ......... 42, 47, 49, 51, 53, 55, 57, 59, 63Safety light curtains ................................................................. 67Safety protection devices ...................................................... 17Saw blade...................................................................................168Sawing machines ....................................................................153Saws .............................................................................................153SCADA & DCS implimentaion .............................................. 20Screws .........................................................................................247Sealed linear encoders...........................................................BICSection bending machine ..................................................... 85Sensitive part loading/unloading.....................................281Services ......................................................................................... 21Servo motors & drives...........................................................201Servo stabiliser (air-cooled & oil-cooled) .......................221Sewer jetting hose..................................................................174Shaft loading ............................................................................281Shearing press..........................................................................156Shot blasting hoses.................................................................. 32Single-speed gear machine ................................................164Sinking EDM..............................................................................299Sleeves ....................................................................................10-11Software - 3D modelling......................................................137Software - Solid Edge............................................................137Software outsourcing.............................................................. 39Software, 2D to 3D conversion..........................................137Solenoid valve..........................................................................167Solid carbide drills ................................................ Booklet, 149Solid carbide drills with IC................................. Booklet, 149Solid carbide mills ................................................ Booklet, 149Solid carbide reamers.......................................... Booklet, 149Solid carbide reamers with IC .......................... Booklet, 149Solid carbide tools...........................100, 267, 233, 234, 300Solutions for heavy-duty industry....................................211Spade drills ............................................................................12-13Spare parts................................................................................... 21Special hydraulic expansion technology......................... 41Special induction hardening machine............................187Special machines.....................................................................213Special purpose machines................................ FIC, 231, 245Spin window systems...........................................................BGFSpindle nose tooling................................................................ 99Spindle probes.........................................................................107SPMs.............................................................................................283Stainless steel ...........................................................................174Standard endmills...............................................................12-13Standard induction hardening machine........................187Standard mobile drawer ......................................................158Stationary workholding.......................................................... 41Steam hose................................................................................174Steep-taper............................................................................10-11Stepper motors & drives ......................................................201Stereotactic neurological systems....................................161Straight flute drills ..............................................................12-13Straight grinder .......................................................................164Stub length drills.................................................................12-13

Styli for touch probes............................................................161Suction blaster ........................................................................... 32Superior collision checking................................................... 97Surface & profile grinding ..................................................... 95Swiss precision tools..............................................................226Switching relays......................................................................... 67Tapping head..................................................... 177Taps ............................................................................... 72, 73, 267Telecom ......................................................................................221Telescopic covers ..................................................................BGFTemperature controllers......................................................... 67Thermoplastic hose................................................................174Thread milling cutters.................................................170, 265Thread rolling systems............................................................ 27Threading tools..........................................................................BCThunder spring hose .............................................................174Timers ............................................................................................ 67Tool balancing and shrinkfit machines ................................................................................. 42, 47, 49, 51, 53, 55, 57, 59, 63Tool grinders............................................................................... 95Tool holders .........................................................10-11, 22, 226Tool holding system .... 41, 42, 47, 49, 51, 53, 55, 57, 59, 63Tool monitoring sensors ......................................................107Tool monitoring systems ....................................................BGFTool presetting machine...... 42, 47, 49, 51, 53, 55, 57, 59, 63Tool setting systems................................................................ 58Tooling and fixtures....... 42, 47, 49, 51, 53, 55, 57, 59, 63Tooling systems.........................................................................BCToolroom machine .................................................................125Tools trolley...............................................................................158Tool-trolley for VMC/HMC ...................................................158Top drill...................................................................................10-11Touch probes.............................................................................BICTransfer trolley ........................................................................... 83T-slot milling cutter................................................................168Tubing accessories .................................................................105Tungsten carbide burrs .... 42, 47, 49, 51, 53, 55, 57, 59, 63Tungsten coppers........... 42, 47, 49, 51, 53, 55, 57, 59, 63Turbine blade ............................................................................. 77Turbine shaft............................................................................... 77Turning centres...............................................................184-185Turning holders ......................................................................... 99Turning machine solutions .................................................103Turning machines ..42, 47, 49, 51, 53, 55, 57, 59, 63, 207Turning tools .............................................................31, 119, BCTurnkey projects (energy)....................................................221Turnkey solutions....................................................................211Turnmill centres...................................................................80-81Turret punch press ................................................................... 24Turrets .........................................................................................109Twin-edge rough boring head ..........................................247Ultra micro drills...................................................45Under crank shearing press ................................................156Universal grinding machines................................................ 25UPS ...............................................................................................221Vacuum blaster.....................................................32Vacuum products................................................................... FGFValve terminals.........................................................................105Valves.................................................................................FGF, 105Vane pumps..............................................................................167Vertical machining centres............. 7, 8, 28, 109, 213, 257Vertical turning centers ..............................................213, 231Vertical turret milling machine................................110, 227Vises .............................................................................................171Vision sensors............................................................................. 67VMC .................................................................184, 185, 216, 283VTL machines ...........................................................................245Wear parts.............................................................99Wear parts and consumables ............................................. 21Wheel balancers and acoustic emission .......................BGFWire-cut EDM.................................................................... 28, 299Wire-rope hoist .......................................................................... 83Wiring trolley ............................................................................158Work holding system..... 42, 47, 49, 51, 53, 55, 57, 59, 63Work shop table ......................................................................158Wrenches....................................................................................171

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No

Advertisers’ List


A3 Logics 39

T: +91-141-2771816

E: [email protected]

W: www.a3logics.com

ABB Ltd 129

T: +91-80-22949560


W: www.abb.co.in

Acumac Machine Tools Pvt Ltd 133

T: +91-80-28360016


W: www.acumacmachines.com

Agie Charmilles 21

T: +91-80-40798019


W: www.gfac.com/sg

Ann Way Machine Tools Co., Ltd 171

T: +886-4-2563-1259


W: www.annwaytools.com.tw

Arhan Technologies Pvt Ltd 216

T: +91-20-65603200


W: www.arhan.co.in

Autogrip Machinery Co., Ltd 175

T: +886-4-822-8719


W: www.autogrip.com.tw

Autotech Machine Tools Sales & Services 8-9

T: +91-20-25690044


W: www.autotechcnc.com

Basic Engineers 158

T: +91-9825344527


W: www.basicengineers.in

Batliboi Ltd 283

T: +91-22-66378200


W: www.batliboi.com

Bharat Fritz Werner Ltd FIC

T: +91-80-28395745


W: www.bfwindia.com

Blaser Swisslube India Pvt Ltd 159

T: +91-124-4994000


W: www.blaser.com

Castrol 23

T: +91-44-42198885


W: www.castrol.com/industrial

Ceratizit India Pvt Ltd 99

T: +91-33-24947146


W: www.ceratizit.com

CGTECH India Software Solutions (P) Ltd 97

T: +91-9845212147


W: www.cgtech.com

Changhua Chen Ying Oil Machine Co., 217

T: +886-4-2639-3751


W: www.chenying.com.tw

Chrystec Machine Tools Pvt Ltd 169

T: +91-80-40927021


W: www.chrystec.com

CNC India Tools & Services (P) Ltd 22

T: +91-80-42602119


W: www.cnc-india.com

Coatec India 20

T: +91-172-5063436


W: www.coatecindia.com

Cobra Carbide 12-13

T: +91-8110-415003


W: www.cobracarbide.com

Cosmos Impex (India) Pvt Ltd 30, 143, 218, 219

T: +91-265-3927000


W: www.cosmos.in

Drake Manufacturing 43

T: +330-847-7291

W: www.drakemfg.com

Drass Mechatronics 28

T: +91-80-23478764

E: [email protected] /

[email protected]

W: www.drassautomech.com

East Coast Magnets (P) Ltd 18

T: +91-40-23098262


W: www.sardamagnets.com

EFD Induction Ltd 187T: +91-80-7820404

E: [email protected].

W: www.efd-induction.com

Electronica Hitech Engineering Pvt Ltd 121, 1236T: +91-20-30435400


W: www.electronicahitech.com

Electronica Machine Tools Ltd 259T: +91-20-24232900


W: www.ElectronicaEMT.com

Electronica Mechatronic Systems India Pvt Ltd 110, 227T: +91-20-24224440


W: www.electronicaems.com

Emag India Pvt Ltd 207T: +91-80-42544400


W: www.emag.com

Emuge India Pvt Ltd 170, 265T: +91-20-39310000


W: www.emugeindia.com

Engineering Expo 78, 120, 140, 160, 269, 270T: +91-9920401226


W: www.engg-expo.com

Ermaksan Machine Ltd, Sti 24T: +90-224-2947500


W: www.ermaksan.com.tr

Etxe-Tar S. A 211T: +34 943740600


W: www.etxe-tar.com

Euro (India) Hose System 174T: +91-79-26890788


W: www.euroindiahose.com

Everising Machine Co 153T: +886-4-2359-3178

E: [email protected] [email protected]

W: www.everising.com

Fagor Control Systems Pvt Ltd 14T: +91-80-42682828


W: www.fagorautomation.com

SOURCE AUTOMATION & INSTRUMENTATION PRODUCTS @www.engg-expo.com


Advertisers’ List


Ferrocare Machines Pvt Ltd 167T: +91-20-26830655


W: www. ferrocare.com

Festo Controls Ltd 105T: +91-80-22894100


W: www.festo.com

Forging Machinery Manufacturing Co 16T: +91-161-5011755


W: www.nkhhammers.com

Forwell Precision Machinery Co., Ltd 163T: +886-4-834-5196

E: [email protected]; [email protected];

[email protected]

W: www.forwell.com

G W Precision Tools India Pvt Ltd Booklet, 149T: +91-80-40431252


W: www.gwindia.in

Galaxy Machinery Pvt Ltd 86T: +91-80-26625771


W: www.galaxymachinery.com

Gem Equipments Ltd 225T: +91-22-3267800


W: www.gemindia.com

Godson Bending Systems Pvt Ltd 85T: +91-281-2361467


W: www.godson-india.com

Grind Master Machines Pvt Ltd 223T: +91-240-2376262


W: www.grindmaster.co.in

Gudel India Pvt Ltd 205T: +91-20-25459531/32


W: www.gudel.com

GSK CNC Equipment Co. Ltd 19T: +91-9886835186


W: www.gsk.com.cn

Haas Automation India Pvt Ltd 7T: +91-20-32935433E: [email protected]: www.HaasCNC.com

Harting India Pvt Ltd 173

T: +91-44-43560415


W: www.harting.com

Heidenhain Optics & Electronics (I) BIC

T: +91-44-30234000


W: www.heidenhain.in

HiTech Manufacturing Show 251, 252

T: +91-09820373804


W: www.hitechmanufacturing.in

Hittco Tools Ltd 267

T: +91-80-28392265


W: www.hittco.com

HOFLER Maschinenbau GmbH 127

T: +49 7243 5990


W: www.hofler.com

Huen Chen Machinery Co., Ltd 183

T: +886-4-2561-6338


W: www.huenda.com.tw

IEMCA Division of IGMI S.P.A. 193

T: +91-9986337038


W: www.iemca.com

Igus India Pvt Ltd 130

T: +91-80-39127800


W: www.igus.in

Indian Machine Tool Manufactuers’

Association 114

T: +91-80-66246600


W: www.imtma.in

Indian Machine Tool Manufactuers’

Association 268

T: +91-80-66246600


W: www.imtma.in

Indian Oil Corporation Ltd 249

W: www.iocl.com

Indo German Chamber Of Commerce 295

T: +91-11-26111730


W: www.indo-german.com

Indo-Nihon Technologies 77

T: 044-65611352


W: www.indonihon.co.in

Ind-Sphinx Precision Ltd 45

T: +91-1792-232860


W: www.axis-microtools.com

Jay Shakti Machine Tools 156

T: +91-281-2367804


W: www.jayshaktimachines.com

Jyoti CNC Automation 15

T: +91-2827-287081


W: www.jyoti.co.in

Jytra Engineering Services 137

T: +91-40-66663747


W: www.jytra.com

Kennametal India Ltd 10, 11

T: +91-80-22198341


W: www.kennametal.com / www.widia.com

Korber Schleifring Gmbh 95

T: +91-80-41554601


W: www.schleifring.in

Kuka Robotics (India) Pvt Ltd 93

T: +91-124-4635774


W: www.kuka.in

Larsen & Toubro Ltd 65, 197, 198

T: +91-22-67051093


W: www.larsentoubro.com

Laxmen Metal Sawing Co 29

T: +91-2752-220246


W: www.laxmanbandsaw.com

Liang Lih Machine Co., Ltd 177

T: +886-4-2426-1151


W: www.ktk-tpm.com.tw

Lico Machinery Co., Ltd 235

T: +886-4-2563-0950


W: www.licomachinery.com


PRODUCT INQUIRY FORM

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Use this form for free additional Information on product write-ups and advertisements published in this issue.

We will send your inquiries to the advertisers and ask them to send you the details or contact you directly.

How to use this form:� Please tick against the box of product(s) you are interested in: � Mention specific product/service you need, against

the product’s name � Complete all the details on this form. � Tear the form & mail it to us. (It is a prepaid mail)

Tel.: +91-22-3003 4684 � Fax: +91-22-3003 4499 � Email: [email protected]

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Drilling headDrilling machinesDrilling toolsDrillsDrills and centre drillsDrive technologyDrivesDust collectorsDye polishing stonesEdge preparation machineEDMEDM accessories and consumablesEDM sparesEDM wiresEjector systemsElectric discharge machinesElectrical CAD/CAE softwareElectromagnetic lifterElectromagnetic separatorsElectropermanent magnetic chuck/tools/lifterEncodersEndmill cutterEndmillsEndmills/facemillsEnterprise application developmentEOT/HOT cranesExhibition - Engineering ExpoExhibition - HiTech Manufacturing ShowExport interfacesExposed linear encodersFactory automationFire-reel hoseFittingsFixturing systemsFlame-proof hoistFlex hone toolingFlexible shaft grinding machinesFloor automationFluidised bed coating machinesFly wheelForging pressForm measurementForming milling cutterFriction drop hammersFriction screw pressFRP - movable cross-railFRUF - movable cross-railFully automatic bandsaw machineGantry automationGaugesGear boxesGear cutting machinesGear grinding machinesGear grinding technologyGear hobbing machinesGear inspection centresGear pumpsGlassGlide coating machinesGoliath craneGoods liftGraphite & high temperature insulationGreasesGrinding machinesGrinding tools for hard materialsGrooving & parting toolsGround rodsGuillotine shearGun drillsHammersHanlding system modulesHard alloy turning cutterHardened & ground drill blanksHead face millingHeavy duty drillHeavy duty drill machineHeavy duty magnetic drill stand

Heavy duty radial drill machineHeavy-duty machine toolosH-frame power pressHigh performance drillsHigh performance endmillsHigh precision roll shop machineHigh pressure gear pumpsHigh pressure hydraulic clamping elementsHigh-speed and high-performance milling centresHigh-speed machining centreHMCHMC machinesHoldersHorizontal & vertical machining centresHorizontal bandsawHorizontal boring machinesHorizontal boring millHorizontal machining centresHorizontal milling machinesHorizontal pipe & tube bending machineHorizontal section bending machineHorizontal turning centresHot & cold formingHot water hoseHSKHSK holdersHSS toolsHydraulic accessoriesHydraulic bandsaw machineHydraulic gear pumpsHydraulic hosesHydraulic power toolsHydraulic press brakeHydraulic press machine Hydraulic shearing machinesHydraulic variable rake angle shearing machineImaging & vision systemsImpact wrenchesIncise dental CAD/CAMIndexable angle cutterIndexing machineIndo-German trade promotion servicesInduction pipe bending machineInduction vacuum casting machineInductive proximity switchesIndustrial brushesIndustrial connectorsIndustrial control & sensing devicesIndustrial coolersIndustrial oilsIndustrial robotsIndustrial safety productsIntegrated CNC turning-cum-machining centreInterface connectorsInterface electronicsInternal grinding machinesInvertor/variable frequency drivesIron workerIsolation transformerJack hose Jib craneJig grindingJobber length drillsKeys & wrenchesLapping & flat honing machinesLarge plano millersLarge size machining centresLaser cutting machineLaser interferometer encodersLaser shaping Laser toolsLaser welding machinesLathe chucksLathe machinesLathes

Lathes - automaticLathes - heavy-dutyLathes - high-speedLathes - turretLathes - verticalLEDLength gaugesLevel controllersLight duty drillLimit switchesLinear motor thread & gear grindersLinear way vertical machining centreLoad break switchesLubesLubricantsLV motorsMachine condition monitoring systemsMachine measurement systemMachine simulation Machine simulation - multi-axisMachine tool accessoriesMachine tool accessories & vicesMachine tool probe systemsMachine toolsMachining & grinding fluidMachining centresMachining toolsMagnetic crack detectorsMagnetic encodersMagnetic modular encodersMagnets for billet handling/coil handlingMaintenance trolleyManual feed drilling machineMarine oilsMaterial testingMeasurement equipmentMeasurement systemsMeasuring & monitoring relay Measuring accessoriesMeasuring equipmentMechanical & penumatic shearing pressMechanical clutch press brakeMechanical shearMechanical/hydraulic press brakeMetal cutting bandsaw machineMetal cutting technologyMetal cutting toolsMetals and alloysMetalworking fluidsMetric endmillsMetrology equipmentMicro ball nose endmillsMicro boring kitsMicro drillsMicro endmillsMicro rotary toolsMicro tools Microbore toolsMicroboring cartridgesMicrograin solid carbide twist drillsMilling centresMilling cutterMilling machinesMilling solutionsMilling toolsMilling/drilling machinesMill-turn centresMillturn machining centresMobile drawer systemMobile equipment & earthmoving hoseModel export interfacesModelling machinesModmachine simulation Modular boringModular tooling systemMolecular diagnosticsMonorail trolleyMotion controls

Abrasive blast roomsAbrasive blasting machinesAbrasive brush technologiesAbrasivesAbrasives and pneumatic toolsAC drivesAerospace materialsAir hammer & screwdriverAir impact & rachet wrenchAir treatmentAir-conditioning hoseAir-die grinderAirless paint spray hoseAluminium endmillsAngle encodersAngle grinderAngle head & live toolAngular boring machineAntivibration toolsAPFC panelsAppliance switchesAssociationAutomatic drilling machineAutomatic tapping machineAutomationAutomation accessoriesAutomation and testing equipmentAutomation solutionsAutomobile workshop trolleyAutomotive oilsBalance systemsBall screwsBandsaw machinesBar feedersBearingsBed-type milling machineBillet shearing machinesBladesBlasting mediaBolts, screw & nutsBoring bars/boring headsBoring headsBoring heads & accessoriesBoring machinesBoring toolsBraided & spiral high pressure flexible hoseBuilding automationBurrsCable carriersCable connectorsCAD softwareCAD solution - HypercadCAD systemCAD/CAM programsCAD/CAM softwareCamshaftCamshaft/crankshaft grinding machinesCarbide burrsCarbide endmill toolsCarbide helical endmillCarbide rodsCarbide routhing endmillsCarbide toolsCastingsCED coating machinesCement grouting hoseCentralised lubrication systems

Centre hole grinding machineCentreless grinding machinesCeramicCeramics and refractoriesCermetC-frame power pressChain pulley blockChainsChamfer machinesChemlok coating machinesChuck jawsChucksClamping seriesClamping toolsCleanersCMM probe systemsCNCCNC automatic linesCNC controls CNC cutting machinesCNC die-sinking EDMCNC drilling machinesCNC equipmentCNC gear hobbing machinesCNC gear shaping machinesCNC grinding machinesCNC guillotine shearCNC hob regrinderCNC horizontal boring and milling machinesCNC horizontal boring machinesCNC horizontal machining centresCNC hydraulic press brakeCNC laser cutting machinesCNC lathesCNC lathes/turn millsCNC machineCNC machine probeCNC machine simulationCNC machine solutionCNC machine toolsCNC machinesCNC machining centreCNC milling machinesCNC oxy-fuel cutting machinesCNC plasma cutting machinesCNC punch pressCNC robodrillsCNC systems (open & closed PLC type)CNC tool grindersCNC tool holdersCNC toolingsCNC turning centresCNC turning machinesCNC turn-mill centresCNC vertical chuckersCNC vertical machining centresCNC VMC machinesCNC wire-cut EDMCNC wire-cutting machinesCoating machinesCoating plantsCoating systemsCold forming machinesColletsCombination boringCombination boring bars

Combined drills & countersinksComposite applicationsComposite processing equipmentCompound machinesComputer-aided design machinesComputer-aided manufacturing systemsConduits and connector systemsConnectorsControl cabinetsControl panel accessoriesControl panelsControl systemsControl valvesControlling machine toolsCoolantsCooling towerCopper brass tubesCorrosion preventivesCounters & power suppliesCountersinksCrabsCraneCrankshaftCrankshaft machinesC-type power pressCustom design cutting toolsCustomerised software developmentCustomised productCustomised solutionsCut-off machineCutter/grinder verification & machine simulationCuttersCutting fluidsCutting machinesCutting oilsCutting speed optimisationCutting toolsCV joint machinesCyclindersCylinder blockCylinder headCylindrical & internal grinding machinesCylindrical grindersCylindrical grinding machinesDeburring machinesDecimal endmillsDeep-hole drilling machinesDeep-hole drilling solutionsDemagnetisersDiamond cuttersDiamond superabrasives Diamond superfinishing tools Diamond toolsDidactic equipment for trainingDie-mould machinesDigital readout systemsDisposable toolholder bitsDistribution transformerDouble-column bandsaw machine Double-coulmn milling machinesDrawer cupboardDrawing & forming compoundDrill machineDrill tap centresDrill toolsDrilling & milling tools

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Omron Automation Pvt LtdOpen Mind Technologies Asia Pacifi cP Parmar Machine ToolsPalmary Machinery Co., LtdPramet Tools India Pvt LtdPremier LtdQuaker Chemical (India) LtdRajasthan UdyogReishauer AG, CH-WallisellenRenishaw Metrology Systems Pvt LtdRittal India Pvt Ltd - Eplan DivisiS&T EngineersSah Petroleums LtdSandeep EnginnerSAP Technical & Marketing ConsultanSBS Precision (India) Pvt LtdSchunk Intec India Pvt LtdSeco Tools India Pvt LtdServomax India LtdSigma EngineersSodick Technologies India Pvt LtdStarragheckert Machine Tools Pvt LtdTaegutec India LtdTagmaTaiwan Association of Machinery Industry (TAMI)Taiwan Takisawa Technology Co., LtdTal Manufacturing Solutions LtdTechno IndustriesTeknicTJR Precision Technology Co., LtdTool Grinding Technologies IncToss Kurim - OS, a.s.Tungaloy Singapore (Pte) LtdTussor Machine Tools Ind P LtdTyrolit India Superabrasive Pvt LtdUniversal CorporationU-Tech AssociatesVBC HydraulicsVora ToolsWalson & CompanyWalter Tools India Pvt LtdWendt India LtdWexper India LtdYamazaki Mazak India Pvt LtdYG Cutting Tools Corporation Pvt LtdYih Troun Enterprise Co., LtdZen Wu Zheng Sun Tool Co., Ltd

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MODERN MACHINE TOOLSJa

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MODERN MACHINE TOOLSJa

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2011 - V

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Reg No: MH / MR / WEST / 235 / 2009 – 2011 RNI No: MAHENG / 2008 / 24347 WPP Licence No: MR / Tech / WPP – 359 / West / 2009-2011

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