Seeing Green in Blue - IMTMA

Seeing Green in Blue

Print • Digital • Events • Services Volume 1 · No. 1 · January 2013

Partnered by:

MAIN FEATURE

Spearheading the Growth Momentum

CUTTING TOOLS

Tailored to Meet Micro-machining Requirements

MACHINING CENTERS

Combining all the Right Elements

The official magazine of Indian Machine Tool Manufacturers‘ Association

S SANDILYA

Chairman, Eicher Group & President, SIAM

“Manufacturing Can Hope for Better Days Ahead”

Extraordinary Accuracy - when ordinary won‘t cut it

MIKROMAT GMBHNiedersedlitzer Strasse 37

D 01239 DresdenFon: + 49 (0) 351 / 2861 0

Fax: + 49 (0) 351 / 2861 107www.mikromat.net

Hall 3A, Booth B 109

C OM PA NY IN DEX

4 MODERN MANUFACTURING INDIA - JAN 2013

3Cap… . . . . . . . . . . . . . . . . . .20

AAce Designers… . . . . . . . . . . . .34Ace Micromatic… . . . . . . . . . . .88Audi… . . . . . . . . . . . . . . . . . . .47Automation Industry Association… . . . . . . . . . . . . . .44Axcend Automation… . . . . . . . .45

BB&R Automation… . . . . . . . . . .45Bharat Aluminum Company… . .22 Bharat Fritz Werner… . . . . . . . .55

CCII… . . . . . . . . . . . . . . . . . . . .74Cummins Generator Technologies… . . . . . . . . . . . . .74C-Weld Technology… . . . . . . . .60

DDassault Systèmes SolidWorks Corp… . . . . . . . . . .56Delcam Software India . . . . . .27, 84DMG / MORI SEIKI India… .27, 53Drake Manufacturing… . . . . . . .88DVS Sales & Service India… . . .86

EEaton India… . . . . . . . . . . . . . .25EEPC India… . . . . . . . . . . . . . .25Eicher Group… . . . . . . . . . . . . .32ElectroMech Material Handling Systems India… . . . . . . . . .24, 80EMO Hannover 2013… . . . . . .24EMUGE India… . . . . . . . . . . . .52Essar Steel… . . . . . . . . . . . . . .22

FFaiveley Transport Rail Technologies… . . . . . . . . . . . . .22Fanuc India Pvt Ltd … . . . . .27, 47Faro Business Technologies… . .60Faurecia… . . . . . . . . . . . . . . . .63Festo Controls… . . . . . . . . . . . .80

Fiat India Automobiles… . . . . . .22 Frost & Sullivan… . . . . . . . . . . .22

GGeiss AG… . . . . . . . . . . . . . . . .86Geometric Ltd… 20, 27, 66, 80, 87Godrej & Boyce Mfg… . . . .34, 74Granada Software… . . . . . .22, 40Grind Master Machines . . . . . . . .84GSPMA PPA… . . . . . . . . . . . . . .20Güdel India Pvt Ltd… . . . . . . . .27

HHaas Automation India Pvt Ltd… . . . . . . . . . . . . .84Hardinge Inc… . . . . . . . . . .24, 88Hindustan Unilever… . . . . . . . .22Hyperthem… . . . . . . . . . . . . . .84

IICPCI… . . . . . . . . . . . . . . . . . .20IEEMA . . . . . . …16,20, 22, 34, 78IPF . . . . . . . . . . . . . . . . . . . … .20IPI… . . . . . . . . . . . . . . . . . . . . .20

JJyoti CNC Automation Pvt Ltd … .27, 80, 84

KKennametal India Ltd … . . . . . .27Keyence India… . . . . . . . . . . . .86Kuka Roboter… . . . . . . . . .47, 58

LLaguna Clothing… . . . . . . . . . .22Larsen & Toubro . . . . . . . . . . . . .74Lupin . . . . . . . . . . . . . . . . . .…22

MMAG India Industrial Automation Systems Pvt Ltd… .87Martin Aircraft… . . . . . . . . . . . .56Mazak… . . . . . . . . . . . . . . . . .68Mercedes . . . . . . . . . . . . . . .…47Metrol Corporation India . . . .…88

Micro Labs… . . . . . . . . . . . . . .22 Mikromat Gmbh . . . . . . . . . .…86Miven Machine Tools… . . . .34, 80

NNational Instruments . . . . . . .…25NTMA . . . . . . . . . . . . . . . . . .…68

OOPPI… . . . . . . . . . . . . . . . . . . .20

PPlexcouncil… . . . . . . . . . . . . . . .20

QQuaker Chemicals… . . . . . . . . .80

RReata Engineering and Machine Works… . . . . . . . . . . .68Reliance Industries Ltd… . . . . .20

SSABIC… . . . . . . . . . . . . . . . . . .20Sandvik Coromant . . . . . .…50, 86Seco Asia Pacific . . . . . . . . . .…27Seco Tools India… . . . . . . .80, 84Sescoi International… . . . . . . . .22Shriram Pistons & Rings… . . . .34Signalion . . . . . . . . . . . . . . . .…25Society of Plastic Engineers . .…20SPI… . . . . . . . . . . . . . . . . . . . . .20

TTaegutec India… . . . . . . . .34, 78Tata Motors… . . . . . . . . . . . . .22Toyota Kirloskar Auto Parts… . .34Trumpf India… . . . . . . . . . . . . . .62Tungsten Carbide Metal… . . . .86

UUsach Technologies… . . . . . . . .24

VVero Software… . . . 22, 46, 53, 62

YYuken India… . . . . . . . . . . . . . .34

Company DirectoryCompanies that are mentioned editorially in this issue

October 9-11, 2013

ADVISORY BOARD

Mr. Jamshyd N. GodrejChairman and Managing Director Godrej & Boyce Manufacturing Company Limited

Mr. Vikram KirloskarVice Chairman Toyota Kirloskar Auto Parts Pvt Ltd

Mr. A. K. TanejaManaging Director & CEOShriram Pistons & Rings Ltd

Mr. Vikram Sirur President (IMTMA) Chairman Miven Mayfran Conveyors Pvt Ltd

Mr. L Krishnan Vice President (IMTMA) Managing Director TaeguTec India Private Limited

Mr. Shailesh ShethCorporate Strategy Advisor

Mr. Shrinivas G. ShirgurkarManaging Director Ace Designers Limited

Mr. C. P. RangacharManaging Director Yuken India Limited


Print • Digital • Events • Services

Volume 1 · No. 1 · January 2013

Partnered by:

MAIN FEATURE

Spearheading the

Growth Momentum

CUTTING TOOLS

Tailored to Meet

Micro-machining

Requirements

MACHINING CENTERS

Combining all the

Right Elements


S SANDILYA

Chairman,

Eicher Group &

President, SIAM

“Manufacturing Can

Hope for Better

Days Ahead”

Indian machine tools goes global with a bi-monthly publication MODERN MANUFACTURING INDIA (MMI), brought to you in partnership by IMTMA

Its comprehensive editorial contents cover the following topics...

Turning, Milling, Cutting Tools, Tool Holders, Measurement, EDM, Drilling,CAD/CAM Software, CNC Machine Controls, Forming Machines, Sawing, Laser Cutting, Welding, Joining, Stamping, Sheet Metal Handling, Fastening, Drilling.

1 Year ` ______

2 Years ` ______

Successful together The official magazine of Indian Machine Tool Manufacturers‘ Association

Partnered by:

SUBSCRIBE NOW!

Advertising Contact:

Bala [email protected] Thakur [email protected] Dinesh Mishra [email protected]

Contact:Vogel Business Media India Pvt. Ltd. 32, New Unique Industrial Estate, Dr. R.P. Road, Opp. Jawahar Talkies, Mulund (W), INDIA Tel.: +91 22 256 444 69

Yes, I wish to subscribe MODERN MANUFACTURING INDIA for

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EVENTS

MODERN MANUFACTURING INDIA - JAN 2013 5

FOREWORD


Welcoming the year with new beginning‘sWishing you a very Happy New Year!

As we look back, we feel proud that the machine tool industry has come a long way. In the last one decade it has become an important industry in the manufacturing sector. The machine tool industry has developed rapidly with the advancements in technologies, innovations and products in the recent years and we find the growth is really exponential.

Since independence, Indian Machine Tool Manufacturers’ Association has been supportive of the machine tool industry as it pursues to become a global industry of repute. The machine tool industry is quite aware that IMTMA has been pursuing various activities for its benefit.

“Modern Manufacturing India (MMI)” is a new magazine that IMTMA is bringing out, keeping in view the interest of manufacturing and machine tool industry stakeholders. I am happy that IMTMA has taken an important initiative to launch this magazine in association with two globally reputed media houses, Vogel Business Media from Europe and Gardner Business Media from USA. MMI will be the official magazine and voice of the Indian machine tool industry. This is an effort from the association specially for the benefit of the user industry in manufacturing technology.

MMI takes a measured approach to the big picture: rather than telling readers everything that happens in technology it goes beyond technology and its value added topics will benefit those who love manufacturing and machine tools. In addition to offering the global content and focused columns with beautifully designed cover page, the magazine will feature product launches, exclusive articles on technological developments in machine tool sector, corporate news, to enable the Indian manufacturing industry experts to gather the latest happenings in the sector.

The magazine is published bi-monthly with a mission to provide information on the latest happenings in the Indian manufacturing context.

It’s a great beginning… subscribe to MMI and enjoy reading.

Vikram Sirur President, Indian Machine Tool Manufacturers‘ Association (IMTMA) and Chairman, Miven Mayfran Conveyors Pvt Ltd

Indian Machine Tool Manufacturer's Association

th

PUBL ISHER / CH I EF ED I TOR ‘S NOTE


Emotions initiate everything...Emotions always initiate actions. Awareness of emotions help to identify the presence of need, its nature, and label those actions which are to be intentionally initiated – excerpt from the book titled ‘Brain Experience-Neuroexperiential Perspectives of Brain-mind’ by C R Mukundan.

It was some such emotion/s which originated in the minds of the powers that are within IMTMA, Gardner Business Media and Vogel Business Media and a valuable partnership was formed to create Modern Manufacturing India (MMI).

As you are reading this first, inaugural issue of Modern Manufacturing India released at IMTEX 2013 at Bengaluru, I wish to thank you, the Reader for your time and attention, and thank the entire team from all the partnering organizations for their support: our advertisers, the advisory board, internal teams of management, content, design, administration and sales.

While the list is extensive for the scope available here, allow me to mention a special thanks to the management committee of IMTMA; Mr. J N Godrej, Chairman, IMTMA; Mr. V Sirur, President, IMTMA; Mr. Abhijit Mukherjee, MD, BIEC and Mr. Shailesh Seth, Corporate Strategy Advisor, IMTMA. I would also like to extend my thanks to Mr. V Anbu, CEO, IMTMA; Mr. Rick Kline, Owner, Gardner Business Media, USA and Mr. Ken Fouhy, Member of Management Board & Editor-in-Chief, Vogel Business Media, Germany; Mr. Bala, Senior Director IMTMA, and Mr. Jens Otte, Director International Marketing & Sales, Vogel Business Media, Germany, for their support.

Without you all this would not have been possible!

Our focus in MMI is towards You, our Reader and we will strive to address your knowledge needs, as we go along. Your success and the success of the enterprise that brings this to your table is our singular, overriding goal.

While we have our experts from the Reader community, advisory board and machine tools industry to guide us and address the topics of technology, allow me to touch upon a strange paradox that is staring at the media industry in the face. On one hand we have these leaps in technology that enable the knowledge seeker to choose between various mediums on which the content is delivered using tablets, smartphones, smart TV’s. This gives us the impression that this is the most convenient method and the way forward. On the other hand, the media market analysis reports from various regions globally (& India) and our observations in the global markets we operate in, has clearly shown that print is still strong and growing; at a pace that electronic mediums are hard pressed to match or overtake, at this point. We as one of the most trusted media groups in USA and Europe, will ofcourse consider both scenarios. Our electronic platform for MMI will soon be rolled-out, to the market, in a phased and logical manner with due information and notice to you.

Going forward, we seek your co-operation and support, which will guide and enable us to raise the bar higher.

With this and coming back to the starting point, the emotions that triggered our origination and this partnership, my experience is that one must emote, express ones feelings & aspirations, in business and personal environments…it works!

And God forbidding it doesn’t work you will be content with the knowledge that you tried all means available to you.

We trust you will find our first issue interesting and informative.

Signing off at the end of a beginning.

Happy reading!

NB: Your feedback and suggestions are very valuable to us. Please send your comments on [email protected]. We promise you that we shall consider and give our best, to address as many as we can.

Paresh Navani Managing Director (India) / Publisher


Soumi Mitra Editor, [email protected]

Think, Act, Go... Global!With the Indian machine tool sector exploring the global space, the challenge posed is to accelerate

growth and improve competitiveness. It is pertinent for these brands to understand the pulse of the market and come up with innovations in this competitive business environment. We know in fact very few companies or organizations that are going global or associating with foreign companies and integrating themselves in to global world. Therefore, it is time to ponder why are they shrugging and shying away.

What drives today to beat competition is sharing of information and transfering knowledge to excel. As a country we have held back ourselves out of our own inhibitions. Yet, the need of the hour is a strong mechanism of information flow between users, domestic companies, academia and global firms.

In the midst of this interesting challenging economic environment where the industry is adopting a cautious approach and wearing an optimistic outlook at the same time, I am thrilled to work for two global media moguls Gardner Business Media and Vogel Business Media, Germany!

Today’s winning mantra lies in quality, consistency, cost, lowered delivery cycles and research resulting in innovation and thereby leading the market. The need is to work diligently, tirelessly focussed entirely towards the needs of the customer. Higher the exchange of knowledge, greater is the success quotient.

Providing a medium to exchange knowledge, I am pleased to present - Modern Manufacturing India, which will always look foward to hearing from you, understanding your first-hand experiences, and will strive to share the latest technological advancements with our global view and high quality content.

As we all know the time has arrived to think, act, go... global! Without any further ado, I leave you to think and perhaps act.

Wishing you all a happy read!

ED ITOR IAL

www.mazakindia.inwww.mazak.com


THE BIG INTERVIEW

32 “Manufacturing can hope for better days ahead” A one-on-one with S Sandilya, Chairman, Eicher Group & President, Society of Indian Automobile Manufacturers (SIAM)

TALE-TALK

34 Putting ideas to work: Strategies to emerge as the next manufacturing superpower Industry veterans’ opinion on the current industry environment of the manufacturing sector and their recommendations for a better future

BUSINESS ANALYTICS

40 Tackling efficiency through operations software

A look at an ERP software

INDUSTRIAL AUTOMATION

44 The changing face of automation Read to know how system engineering

and automation technologies synergize to change the face of manufacturing

FACILITY VISIT

46 Seeing green in blue Exploring the journey of Volkswagen India Pvt Ltd

CUTTING TOOLS

50 Cutting tools tailored for micro-machining requirements A sneak-peak into micro-machining

52 Industry Mavens “Cutting tools has not been given its

deserved status by the academia” A one-on-one with Sanjay Baljekar, Director, EMUGE India Pvt Ltd

MACHINING CENTERS

53 Combining all the right elements A case study on milling and turning operations at Volvo Aero: using technlology from DMG / MORI SEIKI

55 Industry Mavens “Tough periods make one

stronger, wiser and better” A one-on-one with S N Mishra, Vice

Chairman, Bharat Fritz Werner Ltd

MANUFACTURING SOFWARE

56 Developing the world‘s first practical jetpack

Get to know how by using SolidWorks Premium design software, the Martin Jetpack, a jetpack for the masses, was made

▶ COVER FEATURE/FACILITY VISIT: The plant has futuristically designed state-of-the-art equipment at its Pune plant in Chakan 46

CONTENT | MMI - 1 . JANUARY 2013

FOREWORD

6 Message from Vikram Sirur, President, IMTMA

8 Message from Paresh Navani, Managing Director, Vogel Business Media India

ECO-BUZZ

20 An update on the latest happenings in the manufacturing space

MAIN FEATURE

26 Spearheading the growth momentum An insight into the different facets of

innovation and the change that it brings into an organization

▶ TURNING CENTERS: Features on the front and back of the part make this an example of true six-sided machining 68

▶ INDUSTRIAL ROBOTS: Direct integration of a CNC kernel on the robot controller 58

▶MANUFACTURING SOFTWARE: Martin Jetpack is the first jetpack created for the mass market 56

Mastercam, the worldwide standard in CAM software gives you the ultimate toolkit for fast, effi cient machining done the right way. Your way. Call or click today to see what Mastercam can do for you.

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INDUSTRIAL ROBOTS

58 A direct approach A read on how through direct

integration of an CNC kernel on the robot controller turns the industrial robot into a machine tool

MEASURING SYSTEMS

60 Practical metrology solutions Faro Business Technologies enables

C-Weld Technology to move on from legacy systems to address current customer needs

LASER TECHNOLOGY

62 The dancing photons 3D scanner optics add the Z motion of

a focusing lens to the X-Y motion of the mirror. A read on how users will benefit from this three-dimensional dance.

CLOUD COMPUTING

66 Will the cloud ever cast its shadow on engineering?

Get to know how cloud computing can take engineering to new heights

TURNING CENTERS

68 Moving to multitasking Implementing a done-in-one approach

to production, Reata Engineering and Machine Works adopts Mazak’s five-axis multitasking machine

EVENT REPORT

74 Throwing open the window of opportunities

A report on CII’s 11th edition of its flagship event, the Manufacturing Summit 2012

78 A mega factory in operation A preview on the 16th edition of

IMTEX 2013 & 15th edition of Tooltech 2013 from January 24 – 30 at its eco-friendly exhibition center, Bangalore International Exhibition Centre (BIEC) promoting the entire machine tool, cutting tool and accessory industry

INNOVATIONS & SOLUTIONS

84 A special section on new technologies and solutions to enhance business leads

REGULAR

04 COMPANY INDEX

10 EDITORIAL

12 CONTENT

16 FROM IMTMA‘S DESK

72 EVENT CALENDAR

90 IMPRINT

▶MACHINING CENTERS: Central Tool Storage (CTS) as a closed cabin unit offers space for 1,250 tools. 53

▶ INDUSTRIAL AUTOMATION: Automating at every step 44

▶ CUTTING TOOLS: High-performance tooling is vital for shops processing micro-components or parts with micro-features 50

▶ THE BIG INTERVIEW: S Sandilya, Chairman, Eicher Group & President, SIAM 32

▶MEASURING SYSTEMS: The FaroArm is used to align a fixture and ensure accurate positioning 60

CONTENT | MMI - 1 . JANUARY 2013

B E A R B E I T U N G S T E C H N O L O G I E N F Ü R H Ö C H S T E P R Ä Z I S I O NP R O C E S S T E C H N O L O G I E S F O R U L T I M A T E P R E C I S I O N

Die Welt der Bearbeitung vom Standard bis zur Individual-lösung – machen wir Ihre Anforderung zu unserer Heraus-forderung.

Mit Innovation, Inspiration & Creativität.Innovation, Inspiration & Creativity.

• Beste Qualität mit den härtesten Schneidstoffen der Welt.• Höchste Qualitätsstandards.• Modernste Fertigungstechnik durch Automation.• Rundum-Service und Beratung durch qualifiziertes

Fachpersonal.

In the world of processing from a standardized to an individualsolution – we turn your requirements into our task.

• Best quality due to the use of the hardest cutting materialin the world.

• Highest quality standards• State-of-the-art production engineering by means

of automation systems.• All round service and consultancy carried out by

highly qualified staff.

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Fortschritt Entwicklung:HEUTE...

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…for the technology ofTOMORROW!

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FROM IMTMA’S D ESK


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Indian Machine Tool Manufacturers‘ Association

Indian Machine Tool Manufacturers’ Association (IMTMA) is neither a new name in the machine tool industry nor does it require any introduction. However, on the occasion of the introductory issue of Modern Manufacturing India (MMI), IMTMA gives an overview of the association and its contribution towards the machine tool industry.

technology, productivity, quality, design, product development and greater customer interface, so as to enable its membership to enhance its competitiveness, advancement and growth. This enabled IMTMA to become a single point of contact for the entire machine tool industry in India.

IMTMA- IMTEX 2013

IMTEX is the flagship event of IMTMA,

which is South and South East Asia’s largest B2B exhibition on machining technologies. This is now organized every odd year (IMTEX Forming is conducted every even year) at IMTMA’s state-of-the-art Bangalore International Exhibition Center (BIEC).

IMTEX is a one-stop forum where users and customers are empowered with display of “Live” technologies that give an edge to their manufacturing. It is an

Leading Machine Tools to Greater Heights

Since its inception in 1947, the Indian Machine Tool Manufacturers’ Association (IMTMA) is in the forefront

to assist the country to be jotted among the progressive industrialized economies of the world. The nationalistic cause has clearly been the inherent characteristic of IMTMA and its membership.

IMTMA, has over the years, transformed itself to look beyond and focus on issues of

A view of IMTEX exhibitions, the flagship event of IMTMA

F RO M IMT MA’S DESK


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

Along with IMTEX, “Tooltech 2013” is held as a concurrent fair. Tooltech series of exhibition showcases latest range of cutting tools, tooling technologies, production aids, machine tool accessories, metrology as well as Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) equipment and software.

Highlights of IMTEX 2013

IMTEX 2013 and Tooltech 2013 will be one of the largest fairs by IMTMA and will be held over an exhibition space of around 48,000 sq mt divided into five exhibition halls. The exhibition will have over 900 exhibitors from various parts of the country and all across the world which represent the leading brands in the global machine tool industry.

IMTEX has representation from 25 countries including nine group participations from Republic of China, Czech Republic, Federal Republic of Germany, Italy, Republic of Korea, Singapore, Spain, Taiwan (ROC) and USA. Other major overseas countries represented at the exhibition include Australia, Austria, Belgium, Denmark, France, Israel, Japan, Sweden, Switzerland, Thailand, Turkey and UK.

The training program is structured systematically to provide participants in-depth machine tool knowledge on machine tool design

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Technology on 23 January 2013 at BIEC, Bangalore. International experts from Germany, Italy, Israel, USA, Austria and India will share their experiences and latest developments on metal cutting solutions. Spread over three keynotes and six concurrent sessions, the two day seminar will cover technology areas related to machine tools & machining, tools & tooling, metrology & controls, CAD/CAM, work holding & fixturing, emerging trends, grinding & finishing processes etc.

IMTEX and Tooltech hold tremendous significance for all levels in manufacturing organizations - be it CEOs & entrepreneurs, or shop-floor engineers and supervisors.

International seminar on machining technologies

With a view to highlight evolving trends in the metal-cutting machine tool Industry from all over the globe, IMTMA has organized the Fifth International Seminar on Machining

FROM IMTMA’S D ESK


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Indian Machine Tool Manufacturers‘ Association

Machine tool parkIMTMA signed a MoU with Government of Karnataka on 8 June 2012 for the establishment of a Machine tool industry park for the Southern region near Tumkur. The park will co-locate machine tool producing companies, along with the supply chain units, and service providers. The park has received an enthusiastic response from the industry. It is planned to be developed to international standards, meeting high infrastructural standard and facilities.

Growth prospects for Karnataka

The report of the 12th Plan Working Group on capital goods constituted by Dept of Heavy Industries, Govt of India has projected a substantial growth of the industry by 2016-17. Karnataka accounts for approximately 50 per cent of the machine tool production in the country, which is around ̀ 2000 crore. By 2016-17, this amount is believed to reach `5000 crore in line with the overall growth of the industry in India. To achieve this growth through an integrated development of the industry, IMTMA and its members have conceived setting up the machine tool industry park. The project will be taken up by a new non-profit company registered for this purpose. The organization structure of the non-profit company will be:

▶ Named as “IMTMA Machine Tool Industry Park” under Sec.25 of Companies act▶ Promoters: IMTMA along with member companies as a cluster of machine tool and related companies▶ Will be managed through an Executive Committee▶ 50 units have been provisionally signed up for the project. More are expected once project approval is given.

▶ The company also invites foreign manufacturers of important components items to join▶ Infrastructure development: Will be developed by the company on bulk land to be procured from Karnataka Industrial Areas Development Board (KIADB)

The location of the machine tool park is planned to be at Vasanthanarsapura Phase II, KIADBA area in and around 500 acres. The total number of units is approx 120-130 large to small machine tool, supply chain and service providers. The project cost is estimated to be `250 crore towards infrastructure in addition to the cost of land. The project is expected to receive the approval from the Government shortly.

Training programs- Technology center

According to the National Manufacturing Competitiveness Council (NMCC) the biggest concern at present is having highly skilled manpower to run the manufacturing sector. The sector is slated to require around 12 million people and what we have now is just one-tenth as documented by the Confederation of Indian Industry (CII). One of the major reasons why engineers, even from reputed institutes, are not easily employed is because they lack hands-on skills and the biggest challenge Indian educational system faces today is employability. Though India has the largest pool of educated youth, they are unemployable. Identifying this concern, with the active support of the industries, IMTMA – the apex body of the machine tool industry in India – has established a Technology Center at BIEC. The objective is to increase competitiveness, enhance efficiency and improve productivity of machine tool

builders and the CNC users across the country, by providing technology inputs and state-of-the-art training.

The Technology Center is fully equipped with the latest equipment and other required resources to impart training in all aspects of machine tools and production technology. The facilities include production CNC machinery – CNC turning centre & CNC VMC, CNC and PLC training modules, CAD/CAM solutions, Cutting tools, Tool pre-setter, setting probes and other metrology equipment.

The training programs are designed for professionals ranging from CEOs to shop floor. IMTMA now conducts about 150 short term training programs across the centers in Bangalore, Pune and Gurgaon. The topics are decided based on the present industry demand and is designed in order to sharpen the skills of the industry professionals. IMTMA also conducts custom made training programs as per requests from companies. A multitude of training programs are organized on wide ranging topics covering the entire manufacturing space – including design, CAD/CAM programming, CNC machining, tooling management, metrology and measuring instruments, peripherals, CNC maintenance, etc.

Finishing school in production engineering

The latest inclusion in the long list of training program is the Finishing School on Production Engineering focused at training fresh engineers through hands on training program and making them industry employable. This

IMTMA‘s 4th international seminar on machining technologies

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is a one month long course conducted at the Technology Center in Bangalore.

Design institute

Design is everything and everywhere. It is innovative, creative, communicative, embody, plan, and much more. Design is a complex activity and has both a process and an outcome. It is the process of turning ideas into tangible things. A good designer should be a good artist, a good technocrat, a logical thinker, a practical person who can correlate technology with innovativeness at reasonable cost. Also when it comes to manufacturing industry, machine design plays a vital role on right product development. Systematic design approach is the best tool for the product success. Machine design, validation, optimization, Design for Manufacture and Assembly (DFMA), design for simplicity, low cost, higher reliability and quality, ease of maintenance, safety, ergonomics are the key knowledge to be developed for the machine tool designers. To meet the industry’s need for trained engineers on the machine design and to create an excellency pool, the IMTMA Design Institute is established at BIEC, Bangalore.

Sighting the importance of designing technology in the manufacturing industry, IMTMA further developed the concept of a Design Institute. It has been conceived as a hi-tech training center for the machine tool industry. The institute focuses on providing intensive training in all aspects of machine tool designing and technology to engineers from the industry. It is equipped with the latest design infrastructure. The institute enables participants to strengthen their knowledge in

machine tool technology. The latest design practices are imbibed by participants who have the opportunity to utilize high powered 2D and 3D CAD work stations, which are commonly used for design and analysis.

The course

The training program is structured systematically to provide participants in-depth machine tool knowledge on machine tool design. This is complimented by hands on group projects that emphasize the development of practical design skills. Experienced design faculty will guide the participants and will also enable them to achieve high standards of professional expertise. The course also incorporates visits to machine tool industries to expose all facets of machine tool designing and practical applications.

Faculty

The faculty of the training program consists of industry experts specialized in machine tool design and theoretical specialists from leading institutions. Also CAD/CAM software experts from various design software industries present the demo and practices. An interactive learning process will be adopted to enable participants to build practical skills on a solid theoretical knowledge base.

Training methodology

▶ Sophisticated and advanced spacious class room with audio - visual presentations▶ Independent computer with 3D and 2D latest version design software▶ Experienced industrial professional faculty

to share knowledge and experience▶ Machine design curriculum blended with latest design trends▶ Course includes hands on experience on solid modeling, FEA, design calculations, design validations▶ Hands on experience in CAD/CAM software▶ Mechanical laboratory to show the real machine parts and functions▶ Industrial visits and project work

Course envelope

Machine tool design training program is modularized into many different courses to facilitate the industry and participants to focus on the specific requirements. Below are the main modules classified:

Course 1: Machine Tool Design (Basic Machine) 4 WeekCourse 2: Machine Tool Design (Accessories) 4 WeeksCourse 3: Electronics Design For Machine Tools 1 WeekCourse 4: Mechatronics 2 WeeksCourse 5: Comprehensive Machine Tool Design 10 WeeksCourse 6: Design Of Machine Tool Spindles 1 WeekCourse 7: Design Of Machine Slides 1 Week

All the training programs will be conducted in the state-of-the-art facility Technology Centre at BIEC, Bangalore. The facility currently includes audio visual digital class room, 22” LED monitor with high configured work stations, Auto CAD 2D software, SolidWorks 3D and Analysis software, Pro Engineer software, Ansys Digital Analysis software, mechanical laboratory, machine carcass of CNC lathe and machining center, CNC lathe and machining center, Siemens and Fanuc program simulation kits, hydraulic and pneumatic teaching models, cutting tools and holders, CMM and digital height gauge. MMI

The Technology Center is fully equipped with the latest equipment and other required resources to impart training in all aspects of machine tools and production technology

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Raising Awareness on Revised StandardsMumbai – International Copper Promotion Council India (ICPCI) recently organized an interactive workshop in association with Indian Electrical and Electronics Manufacturers‘ Association (IEEMA). This initiative was taken to create awareness on the revised IS12615:2011 standard for energy efficient motors. The

workshop was flagged off by an expert panel comprising – Ajit Advani, Director, International Copper Association, A M Naik, Chairman – RM Division, IEEMA, and K N Hemanth Kumar, Chief Manager, Electric Motors & Motor driven Systems, ICPCI. The event was well received by industrial project consultants and other present industry experts.

Commenting on this association with ICPCI, Naik mentioned, “Through this association with ICPCI we aim to educate industrial project consultants and encourage them to adopt the revised standard for energy efficient motors in their technical specifications.” He further added, “There is a need for more such workshops to educate industries to develop and create a pull for energy efficiency motors.”

Vijay Boolani, Technical Programme Chair & President Elect 2013-14; SPE Global addressing the audience at ANTEC conference

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India Finally Witnesses ANTECMumbai – The ANTEC conference was for the first time held in Mumbai, India. Organized by Society of Plastic Engineers (SPE), USA, this is the first time that ANTEC has been held outside North America. The two day long conference saw a presentation of 178 papers across seven parallel tracks.

The most interesting session during the conference was the New Technologies Forum, where six invited eminent speakers from across the globe presented a paper on the Future of Plastics and Plastic Processing in the areas of Carbonaceous nano-materials, including, graphenes and carbon nano-tubes. This was concluded with a panel discussion.

Along with the conference, SPE had also organized a special workshop on Plastics. Key areas of plastics engineering, such as thermoforming, injection molding and medical plastics devices were discussed at the

workshop. The conference and workshop was attended by over 450 delegates.

The conference hosted a special plenary session where Manohar Parrikar, Honorable Chief Minister of Goa and a Materials

Geometric Europe Takes Over 3CapMumbai – Geometric Europe has acquired German based 3Cap Technologies, a specialist in electronics engineering, primarily for the automotive industry. It has seven customers, which are mostly tier I automotive suppliers. 3Cap offers a multitude of services to its customers ranging from embedded systems development

verification and validation, and calibration in the areas of powertrain and chassis.

Announcing the acquisition, Manu Parpia, Managing Director & Chief Executive Officer, Geometric Ltd said, “This acquisition represents an important step in our strategy to provide greater capability and more comprehensive solutions in the digital product realization space to our customers.”

Parpia continued, “The use of embedded systems is increasing in all our customer products. This acquisition fills a major gap in the solutions we offer to our customers, while at the same time strengthening our presence in Europe. Thus, in taking this action, we address two main needs of our customers - the ability to deliver embedded systems based solutions and a stronger presence in Europe.”

A M Naik, Chairman – RM Division, IEEMA

Manu Parpia, MD & CEO, Geometric Ltd

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Science Engineer from IIT Mumbai was the Guest of Honor. The event was also attended by Jim Griffing, SPE Global President, 2012-13; Ken Braney, Sponsorship Chair; Vijay Boolani, Technical Programme Chair & President Elect 2013-14; SPE Global. Dr Ernesto Occhiello, Executive Vice President, Technology & Innovation, SABIC, delivered a special plenary address on Plastics for Sustainability. Dr Ajit Sapre, Group President, Research & Technology, Reliance Industries Ltd gave his plenary address on Business and Technology –Trends and Challenges for the Indian industry.

The event was supported by PlastIndia Foundation, AIPMA and associations like IPI, OPPI, Plexcouncil, IPF, GSPMA, PPA, SPI. ANTEC will be hosted in India again in December 2014.

The powerful CNC platform for machine tools

With SINUMERIK, Siemens offers you an integrated and seamless system platform for machine tool automation used in various metal cutting industries and technologies. The SINUMERIK concept brings you “one CNC system, many options - from the CNC through drives and motors”.

SINUMERIK is easy-to-operate and offers you innovative functions and technology cycles for cost-

SINUMERIK

effective manufacturing. SINUMERIK CNC is used globally to machine simple as well as complex parts in individual and series production. It is an industry benchmark for ruggedness, optimum usability and flexibility, as well as outstanding performance.

For more details, please contact:Email: [email protected]

siemens.com/sinumerik

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IEEMA Presents a Pre-budget Memorandum

Mumbai – Indian Electrical and Electronics Manufacturers’ Association (IEEMA), the apex representative body of manufacturers of electrical equipment, professional electronics and allied equipment in India has presented a Pre-budget Memorandum 2013-14 to the Ministry of Finance.

IEEMA believes that the Union Budget is a tactical and direction setter and therefore more focus should be given on encouraging domestic manufacturing and creation of level playing field for the industry in order to maintain its competitiveness.

The pre-budget memorandum has cited extension of service tax exemption to important infrastructure sector, power generation, Transmission and

Distribution (T&D) related services as their wish from the Union Budget 2013-14.

The generation equipment sector is 26 per cent of the total industry and the T&D equipment sector comprises of 74 per cent of the industry. Growth rate of electrical equipment sector decelerated to 6.9 per cent in 2011-12 as compared to 11.3 per cent and 13.7 per cent in 2009-10 and 2010-11 respectively. For the first time in 10 years, the electrical equipment industry has seen a negative growth of 3.9 per cent in the first five months of the current fiscal (2012-13).

In its pre-budget memorandum, IEEMA has appealed to the Government for the refund of excise duty paid by the domestic manufactures as a deemed export benefit.

Raghavendra Rao, Vice President, Frost & Sullivan

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Frost & Sullivan Organizes Manufacturing Summit 2012Mumbai – Frost & Sullivan organized a Manufacturing Summit 2012 in Mumbai on 14 December 2012. The 7th edition of this annual event provided an ideal platform for knowledge exchange and industry networking. At the beginning of the summit, Raghavendra Rao, Vice President, Frost & Sullivan delivered a keynote address. This summit was an excellent opportunity for participants to learn about proven practices and hear industry experts speak on factors that contribute to the successful deployment of these practices.

Participants appreciated

presentations by Essar Steel India on Sustaining a safe culture and business analytics

by Granada Software. Furthermore, the audience was also pleased with presentations

Vero Software Acquires Sescoi

Mumbai – Vero Software has taken over industry specialist for 2D to 5-axis NC machining with its WorkNC product suite, Sescoi International. The acquisition will provide the platform to Vero to build stronger products across the range through a significantly enlarged development team and distribution channel with experienced, time served, industrial knowledge.

Commenting on the acquisition, Richard Smith, CEO, Vero Software says, “Across the enlarged Group, the complementary products address the worldwide need for efficient and innovative CAD/CAM/CAE technology. With an unrivalled breadth of market leading solutions for specific manufacturing techniques and an expanded distribution capability, we will continue to provide excellent service and support to both existing and new customers and further extend a growing influence on the global market.”

He further added, “We fully recognize the importance of product branding and customer loyalty. It is important to emphasize that we will continue to invest in the WorkNC product suite and welcome the existing Sescoi partners and resellers into the Vero network. We will move forward together with the expertise, knowledge and resources necessary to deliver even higher levels of productivity to our customers.”

Richard Smith, CEO, Vero Software

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from Hindustan Unilever on New product development and Laguna Clothing on Skill development - A structured approach. Other companies that delivered noteworthy presentations, were Bharat Aluminum Company, Fiat India Automobiles, Lupin, Faiveley Transport Rail Technologies, Micro Labs and Tata Motors.

This Manufacturing Summit 2012 offered a platform to the audience and participants to discuss the constraints and ways to overcome them. It also suggested ways to deploy, discuss best practices in their respective organizations.

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EMO Hannover 2013 Attracts Machine Tool IndustryFrankfurt, Germany – EMO will be hosted this year at Hannover during 16 -21 September 2013 under the motto “Intelligence in Production.” At the beginning of the year, more than 1,600 companies from 34 different countries registered their participation. The exhibition will be spread over around 145,000 m² of net space.

Talking about the tremendous response to the event, Carl Martin Welcker, General Commissioner, EMO Hannover 2013, said, “Everyone wants to be there. That’s why once again the EMO Hannover is well set to continue its success story.”

ElectoMech Displays Range of Cranes at Vibrant Gujarat 2013Gandhi Nagar – ElectroMech recently showcased its entire range of products and services at Vibrant Gujarat 2013. The exclusive range of cranes and hoists along with the other customized products by the company received immense amount of admiration by industry experts from all over the world.

The products on display were specifically meant for the various industries operating out of Gujarat and to suit the material handling needs of the Gujarat market. Stahl CraneSystems’ range of explosion protected hoists and cranes that is available in India through ElectroMech received a huge interest from companies in the oil and gas sector. Zoomlion tower cranes, the latest offering by the same company through its Joint Venture (JV) with Chinese partner Zoomlion also received a huge response from the real estate and construction companies that visited the event.

Commenting on the huge response witnessed at Vibrant Gujarat 2013 this year, Tushar Mehendale, Managing Director, ElectroMech Material Handling Systems (India) Pvt Ltd said, “The interest shown by companies in Gujarat towards our products has been phenomenal in this year’s summit. We consider Gujarat as one of the most crucial market for our business. Global leaders from all over the world have

made huge investments in the past few years in this region. Our company’s products showcased at the event are meant for all the global and domestic companies that are based out of Gujarat and operate across various sectors and industries. We are certain that this year’s participation will help us tap the potential of the Gujarat market and provide them customized solutions.”

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how they have taken these issues and requirements proactively on board and translated them into intelligently efficacious engineering, thus establishing for themselves a secure position in a fiercely competitive environment,” says Welcker.

He further adds, “Further registrations from international market leaders are arriving every day. We are accordingly confident that we can seamlessly build on our record event size of 2011. We can already guarantee our international trade visitors a top-class, comprehensive exhibition program.”

Carl Martin Welcker, General Commissioner, EMO Hannover 2013

As new trends are emerging, customers are seeking ideas and solutions for efficient production operations at widely dispersed locations with highly disparate prerequisites. What counts is innovation not only on the machine, but also for the components, in the production process and for the services involved. Aspects like communication between and networking of machines and lines, new materials, flexibility, quality, innovative production concepts, and much, much more play an important role.

“Internationally operating machine tool vendors will be showing at the EMO Hannover

5 tonne wire rope hoist on display at ElectroMech stall at Vibrant Gujarat

Hardinge acquires UsachElmira, USA – Hardinge has taken over Usach Technologies, a provider of high-precision, computer-controlled ID and OD grinding machines and grinding systems. Strengths of Usach are designing and configuring products specific to a customer’s unique requirements and equipping the machines with fully automatic loading systems.

“This acquisition complements our strategy to maintain our competitive edge by continually advancing and enhancing our product portfolio. Importantly, Usach strengthens our reach into high profile OEM’s (original equipment manufacturers) in the U.S. and expands our opportunities in the highly diversified end markets we serve,” stated Richard L. Simons, Chairman, President and Chief Executive Officer.

ECO-BUZZ


Eaton Names New MD

Pune – Nitin Chalke has been named as the new Managing Director, Eaton India. In his new role, Chalke will be responsible for developing and executing a broad based,

Indo-Czech trade partnership to get boost

Mumbai – The slowdown has affected the manufacturing industry world over. However, the bright side for industry giants is that India is showing positive growth even in the unenthusiastic scenario. Hence, the whole western side is turning towards India for investment. In this regards, the Czech companies are seen to be interested in investing in India particularly in Maharashtra. This trend is expected to continue and the state is anticipated to have investment around 400 million euros in couple of years. This investment is expected to be majorly in the defense, automobile, manufacturing, energy and heavy industries.

Therefore, various platforms are created to

facilitate foreign companies expand their businesses in India. EEPC India is one of such events that focuses on the engineering sector. This year EEPC has been organized in Mumbai in association with Czech Republic from 14-16 March 2013. Over 100 Czech companies are participating in the event with the view of expanding their reach in India. As a result this event is expected to give a boost to Indo - Czech trade partnership.

Apart from Czech Republic, international delegation from other continents like Europe, Africa and South America are also visiting the show. However being the partner country, the biggest delegation comes from Czech Republic.

NI acquires SignalionBanglore – National Instruments (NI) has acquired Germany-based Signalion. The acquisition delivers strong wireless communications talent and technologies to the NI platform, which are critical to NI’s goal to continue to drive long term growth in the communications test industry. Signalion founders, Dr Tim Hentschel and Dr Thorsten Dräger, will remain with the company as Co-managing Directors, and work closely with NI R&D. Signalion will continue to operate as a wholly owned NI subsidiary and to sell and support its products through its direct, distributor and OEM channels.

“NI continues to invest in the strategic areas of RF research, design and test,” said Dr James Truchard, President, CEO and Co-founder of National Instruments. “Signalion has assembled a top team of researchers and developers through its close relationship with Technische Universität Dresden (TU Dresden) working on the latest standards such as

LTE, LTE-advanced and even fifth-generation wireless research. This expertise combined with a strong product portfolio strengthens our market position while laying the foundation for continued innovation using the NI PXI RF platform and LabVIEW for mobile communications and infrastructure test,” he added.

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Nitin Chalke Managing Director, Eaton India

Arun Maira, Member Planning Commission, Government of India

Dr James Truchard, President, CEO and Co-founder, National Instruments

Government to set up Institutes of Design Mumbai – “Government has intentions to set up several institutes of design across the country to improve productivity and outcomes for the products and services offered including governance,” said Arun Maira, Member Planning Commission, Government of India. Maira was addressing the 2nd CII Global Strategic Design Summit 2013 organized by Confederation of Indian Industry (CII), which was organised on the theme, ‘Design as strategy to steer through turbulence.’

Stating that design is all about architecture, Maira said that there is a flaw in governance in

proactive strategy to support Eaton’s growth objectives in India. He will continue to lead the India hydraulics business until a successor is appointed.

Chalke joined Eaton in 2009 and most recently served as Managing Director, India and South East Asia – Hydraulics. Prior to Eaton, he held various positions at Schindler, Structural India and Ingersoll-Rand. Chalke holds a Bachelor of Engineering and an MBA – both from Mumbai University.

“I am very pleased to announce the appointment of Nitin as Managing Director of Eaton in India,” said Curt Hutchins, President – Asia Pacific, Eaton.

our country and called for the need of public participation to ensure that governance architecture must be much more local than centralized.


MAIN FEATURE

Acknowledged by all of us is the fact that innovation is not an innovation until it translates into invention plus

commercialization. Indeed we are becoming known for a certain type of innovation termed as “Jugad”. India has vast unmet

Soumi Mitra Editor [email protected]

With the Indian machine tool industry slated to play an important role in achieving 12-14 per cent manufacturing growth over the mid-term during the 12th Five Year Plan, the subcontinent is said to emerge as a global manufacturing hub of machine tools. In this context, we explored the different facets of innovation and how it changes the face of an organization, which ultimately will lead to India emerging as an international hub.

Spearheading the Growth Momentum


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“Our machine tool industry has been growing from strength to strength. We now stand at the cusp of being not just competitive but also innovative.”

Sonali Kulkarni, President & CEO Fanuc India Pvt Ltd

needs and challenges. Overcoming challenges is the source of innovation. Touching upon how the innovation movement has not only created more global brands from India, but also taken India to the next level, Sonali Kulkarni, President & CEO Fanuc India Pvt Ltd, underscores, “Our machine tool industry has been growing from strength to strength. We now stand at the cusp of being not just competitive but also innovative. It is merely a matter of time before we see game changing innovation from India.”

Brand India

The innovation movement has helped create at least half a dozen global machine tool brands from India in the past decade. With most of these machine tools being exported to developed as well as emerging economies, it is also enabling the Indian manufacturing industry by reaching out to every corner of the country. By understanding the pulse of the market,

these brands have also come up with innovations that are affordable while being at par with the required standards. Quoting an example, Vineet Seth, Managing Director, India & Middle East, Delcam Plc, UK, states, “An Indian machine tool company of repute also has acquired a well-known global machine tool brand in the recent past, and is now in a position to

address a wide spectrum of requirement in the machine tool

business.” In the automotive domain, quite a few cars indigenously

manufactured in India are now running on roads in Europe, Australia, Africa and the Americas. Other than bringing in the obvious revenue in the country, these products among many others, are also building brand-India. Reliability, affordability and adaptability are spelt in bold letters on these products and that is there for the whole world to see. Further, it is because of these innovations, that there is no great divide between the west and our country – in terms of contemporary

technologies. Not only is the sector in India growing rapidly; but experts believe that it is very well-positioned to lead globally, because India possesses the crucial combination of fast-paced growth with the technical talent required to serve it. Andreas Fritz, President, Seco Asia Pacific & Vice President, Seco Tools says, “Innovation is the driver for any society and industry and India, as the world’s biggest democracy has the unique opportunity by combining European or American with Indian know-how to become a leading country and economy.”

Jugaad is a way of life for Indians. In their book Jugaad Innovation, the authors Navi Radjou, Jaideep Prabhu and Simone Ahuja translate Jugaad as “an innovative fix, an improvised solution born from ingenuity and cleverness”. “800 million Indians are at subsistence levels, but we all desire cell phones,” says Kulkarni. Tapping into this, Reliance and Airtel innovated, resulting in the cheapest talk time and cell phones for less than `1000. The mobile revolution touched 700 million. Arvind Eye hospital conducts surgeries at 1/20th the cost and global quality. Tata captured the world’s imagination by offering the Nano at `100,000. Increasingly academics cite reverse innovation, where innovation from India will flow back to the West. Our

“We believe in trend setting rather than following. With a very open mindset our young team is keen on learning, experimenting, adapting and fine tuning the technology to stay well ahead of competition.”

Parakramsinh Jadeja, CEO Jyoti CNC Automation Pvt Ltd

machine tool industry has been growing from strength to strength. We now stand at the cusp of being not just Competitive but also Innovative. It is merely a matter of time before we see game changing innovation from India.”

Innovating constantly

Innovation has become the industrial religion of the late 20th century. Businesses see it as the key to increasing profits and market share. Governments automatically reach for it when trying to fix the economy. B C Rao, Additional Director & Managing Director, Kennametal India Ltd, elaborates, “We expect to realize substantial growth in India in the coming years serving a heightened level of production and development throughout the country. We see many opportunities to serve this need, bringing our advantage of the latest technology, including the most advanced materials and total tooling solutions to meet the most demanding needs.” India is a dynamic and diverse market, and marketing a single brand in such a market is a big challenge. Constant innovation and customisation of products is needed to stay in business while remaining profitable. Apprising on this front Sridhar Ramisetti, Managing Director, DMG / MORI SEIKI India comments, “The global co-operation


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between leading machine tool companies like DMG (GILDEMEISTER) from Germany and Mori Seiki from Japan is in itself an innovative move. DMG / MORI SEIKI India brings the latest technologies and applications from both manufacturers to India. The most obvious innovations are jointly developed machines, such as the MILLTAP 700 compact machining center, but the benefits and innovations go far beyond. They include premium level manufacturing technologies, engineering, innovative machine tools and high quality application expertise.” Representing the new age entrepreneurs and professionals who come from a clan where the thought process starts from innovating in the existing technologies to bring about a change, Parakramsinh Jadeja CEO, Jyoti CNC Automation Pvt Ltd stresses that they are keen enough to take India to the next level through gradual but firm efforts. At the same time he believes that innovation process in machine tool industry should obviously be developed through cross functional attributes.

Cross-functional process

A cross-functional team is a group of people with different functional expertise working

towards a common goal. It may include people from finance, marketing, operations, and human resource departments. Typically, it includes employees from all levels of an organization. They can be also from outside the organization such as suppliers, key customers, or consultants. Sharing his experience, Sunil Raibagi, Managing Director, Güdel India Pvt Ltd avers, “Our every project needs cross functional teams. We need good discipline while managing innovation processes. Without proper processes, it is not possible for R&D to be efficient. Creative efforts to introduce new ideas, processes or products decide the through put. We can build innovative technologies based on existing or newly invented technology and try to find profitable applications to use this technology.” Sometimes the innovation process tries to find areas where customer’s needs are not met, and the focus is on development efforts to find solutions to those needs. To succeed with either method, an understanding of both the market and the technical problems are needed. “By creating multi-functional development teams, containing engineers and marketers, both dimensions can be solved,” adds he. In this day and age, it is extremely important

to adopt cross-functional processes in innovation because these processes help to bring in experts from diverse domains, different skill sets and different approaches to the innovation goal. Drawing an example, Seth elucidates, “Our dental and orthotic CAD/CAM software innovation is the result of cross functional innovation process between our professional services group, the core software development department, central marketing and the country managers. What started as a custom project is now a full-fledged open CAD/CAM system that is sold across the globe. Without the right processes, tools and collaboration the innovation process becomes lengthy and at times outdated.”

Improving manufacturing

Improvements in manufacturing are taking place as a result of continuous developments in all related fields - input materials, machining processes, machine tools, cutting tools, automation, process controls and all related activities. In this context, Ramisetti mentions, “The modern machine tools use innovative configurations and developments in mechatronics offering immense capabilities. Multi-tasking and multi-axis machines are developed by participation of teams from machine builders, suppliers and even the customers. This makes the machines highly productive, accurate, flexible, and reliable. The users of such high-tech machines can extract the benefits of the capabilities of these machines by re-aligning their production methods and systems in an innovative way.” Innovation is a pervasively cross-functional process. Although innovation is driven by technology, required competence extends beyond technical know-how. According to Jadeja, one has to learn and adapt various cross functional skill sets to have a breakthrough innovation. Various attributes to innovations may come from different individual processes and paradigms which finally with the mutual efforts may convert into innovations.

Dysfunctional processes and systems

Like every coin has two sides, the flip side of this is whether the hype of innovation creates dysfunctional processes and systems? Fritz says, “As long as we keep our product, process and service development close to our customers; listen, understand and address their needs; we don’t see this risk. Our customers together along with sales and technical engineers develop solutions which increase our customer’s

“We have plans in place to localize high-consumption tools and wear solutions in India, which would mean ongoing technology transfer initiatives and supporting investments to build competencies to further offer Indian customers indigenously produced items supporting accelerated growth.”

B C Rao, Additional Director & MD, Kennametal India Ltd

“The vast demand of the Indian population will drive domestic consumption, which will increase the industrial production in India and as a result will create even more global Indian companies exporting their goods.”

Andreas Fritz, President, Seco Asia Pacific & Vice President, Seco Tools


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competitiveness.” Dysfunctional processes or systems are created mostly due to shortcomings in planning or implementation. If we really see, no process goes waste. Agreeing Seth adds. “Most often sub processes and systems can be re-cycled to fit in into other larger systems. There is always some small amount of risk involved in ending up with a dysfunctional system but this can often be managed with the right tools and approach. Learning is a by-product as well as an end product of innovation and hence, while a so-called dysfunctional process cannot be used in a certain project, the learning acquired as a result of building such a process will most certainly be helpful for a completely unrelated project.”

A good organization has the necessary review mechanisms which will check the effectiveness of any changes, and keep on correcting the course in the direction of continuous improvement. Agreeing Ramisetti adds, “This is why it is mandatory to ensure innovations are a result of systematic generation, collection, evaluation and implementation. Continuous and extensive testing as well as customer feedback is a very important indicator of success of any innovation, which is

implemented and also gives rise to new innovations.”

Fostering innovation

Corporate culture, entrepreneurial skills, and technical leadership are important elements in fostering innovation in a company. Updating about his company’s initiatives, Rao apprises, “we introduced the Kennametal Value Business System (KVBS) in 2003 and are implementing it consistently to global business execution processes. Within KVBS, there are six core business execution processes which we use to create value for our customers and stakeholders: Strategic planning, innovation, customer excellence, talent development, portfolio management, and operational excellence.”

He further adds, “Innovation is one of our core business processes. With the help of entrepreneurial skills, and technical leadership, we can ensure the successful execution of innovation.” Innovations not only break the mold, they also yield far better returns than ordinary business ventures. “We do run global research and development centers in many places in the world, such as India, China, US, Germany, France, Netherlands, Czech and Sweden. This ensures closeness to our customers as well as ‘out of the box’ thinking by utilizing our global resources,” asserts Fritz. For Geometric, the strategy is to look for disruptive innovations in their space, which may not happen often, and to simultaneously ensure that they achieve incremental

“Following a cross functional approach can sometimes even lead to the re-design of a component in view of the new machining possibilities, giving tremendous advantage in the reduction and simplifications of parts, functional performance, manufacturing cost and cycle times.”

Sridhar Ramisetti, Managing Director, DMG / MORI SEIKI India

Six issues and worlwide e-paper in 2013

Official showdaily at IMTEX & EMO

Global partnership of IMTMA, Gardner & Vogel

V. ANBUCEO, Indian Machine Tools Manufactuerers‘ Association (IMTMA)

IMTMA Launches New MagazineIndian Machine Tools Go Global

Print • Digital • Events • Services No. 1 · January 2013 · Volume 1 · www.modernmanufacturing.in

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MAIN FEATURE

innovation regularly. “We have a dedicated business unit that focuses on generating new technology and product ideas based on internal research as well as customer requirements. The innovations from this business unit help to differentiate our engineering and software solutions. Some of the innovations of this business unit have been recognized by various awards from bodies like Frost & Sullivan, IIT Bombay, and NASSCOM,” affirms Vivek Kotru, Director, Global Marketing, Geometric Ltd. Recounting on how being single-mindedly focused on customers is important for Fanuc and is equally critical for improvement, Kulkarni shared an interesting anecdote when after the Tsunami in March 2011 the company was facing a challenge to source a type of microcomputer critical for its CNC. The company deployed the entire R&D team, worked round the clock and completed the design changes within two months (instead of the normal time period of 12 months) and protected the customers from delays on CNC delivery. Raibagi takes pride in having serviced more than 10000 units world-wide in a highly diverse range of applications. “The integration of the control technology led the development of gantry robots and system solutions which have been completely tailored to fulfill the customers‘ needs.

Without culture of innovation and technological leadership it would not be possible. Every project of ours has a novelty dimension and we built the function package based on our technology together with our customer.”

Beating competition

Corporations can no longer just rely on the old formula that sustained innovation and growth for decades: a mix of top-down strategies, expensive R&D projects and rigid, highly structured innovation processes. “We continue to make strategic investments in R&D and reinforce the value of this practice by consistently generating sales from new products of nearly 40 per cent or more each year since 2003,” apprises Rao. With the global economy undergoing a metamorphosis of galactic proportions, companies are strategizing their stream of innovations to stay ahead of competition. “Our success lies in a decentralized organization where each and every individual gives his/her 100 per cent and personal commitment to our customers.” Having always applied the strategy of innovating across a spectrum of functionality and technology, Delcam has come a long way. Seth shares, “As a CAD/CAM software company, we are unique in

having our own advanced manufacturing facility where we test our software products, as also use it as a commercial manufacturing facility. This additional factor has helped us innovate much faster than our competition and is one of the key factors that have helped us to continue to stay ahead.” At Geometric in order to encourage idea generation across the organization they have an ongoing initiative for ‘Innovation and Incubation’ headed by a Vice President. “Through this initiative employees are encouraged to add their ideas into a company-wide ideas database. Such ideas are periodically reviewed by cross functional teams and promising ones are taken up for development through the innovation process,” avers Kotru.

The process continues

Innovation is the key factor facilitating companies to stay afloat and beat competition. Hence, it is pertinent to continuously thrive to innovate and create technological solutions. It is the only way leading to learning, experimenting, adapting and fine tuning technological refinements to stay upbeat. MMI

“Dysfunctional processes or systems are created mostly due to shortcomings in planning or implementation. If we really see, no process goes waste. Most often sub processes and systems can be re-cycled to fit in into other larger systems. There is always some small amount of risk involved in ending up with a dysfunctional system, but this can often be managed with the right tools and approach.”

Vineet Seth, Managing Director - India & Middle East, Delcam Plc, UK

“Innovation needs to be a measurable, focused activity. There is nothing wrong with innovation “for the sake of it”; many of the best ideas emerge that way. But to sustain its growth a business needs to find ways of making innovation a managed process.”

Sunil Raibagi, Managing Director, Güdel India Pvt Ltd

“We continuously invest towards innovation. The strategy is to look for disruptive innovations in our space, which may not happen often, and to simultaneously ensure that we achieve incremental innovation regularly.”

Vivek Kotru, Director, Global Marketing, Geometric Ltd

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THE B IG INTERV I EW


S Sandilya, Chairman, Eicher Group & President, Society of Indian Automobile Manufacturers (SIAM) draws an optimistic picture on the contemporary Indian manufacturing, automotive and machine tools sector, while elaborating on how the sector can thrive and stand out in the global competitive space.

“Manufacturing Can Hope for Better Days Ahead”

”The National Mission on Electric Mobility being launched by the Honourable Prime Minister of India in January 2013 will give us the impetus for catching up on Green mobility with the rest of the world” -S Sandilya

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As India‘s New Manufacturing Policy aims for manufacturing to grow about 3 per cent faster than GDP, how plausible do you think this would be taking into account the current market scenario?

S Sandilya: Current market scenario should not distort the long-term outlook for the Indian economy and in particular the manufacturing sector. Ours is a demand led economy and therefore I am very optimistic about the future. Manufacturing policy envisages manufacturing to contribute 25 per cent of the GDP while currently it is around 16 per cent. The achievement of this target may get delayed but is definitely feasible. For this government has to speed up

implementation of the policy initiatives. The automobile sector would be a driving force to achieve this target. Currently it contributes to around six per cent of the GDP and as per the Auto Mission Plan we should reach around 10 per cent. Considering the ratio of number of vehicles per population in comparison with the developed economies the headroom is very high which makes the achievement of the target definitely feasible. The growth in the auto sector brings with it significant additional investments in manufacturing capacity, design and development and supply chain investments. The additional employment generation will be significant which again increases the demand generation

potential. On the whole the manufacturing sector can hope for better days ahead.

With machine tools being the backbone of most of the industrial activities in the country, how can the sector increase its volume to leverage maximum benefits while meeting cost competitiveness?

Sandilya: The machine tool sector has to focus on technology and quality to meet global standards. Being cost competitive is fundamental. The whole approach has to be one of co-creating with the customers. The sector has to focus not only on its direct customers who will be in the manufacturing sector but the ultimate users of the products being produced by first level customers. Offering value to customers to enable them in turn to offer value to their ultimate customers will be the key for significant growth. This approach will not only help in domestic growth but also in globally competing with the best in the world. This can be achieved only with a high focus on product design and development and constant innovation. Our country has enough engineering talent to support this effort but the challenge is in training and channelizing the efforts in the right direction.

What measures should be implemented in terms of deploying exceptional productivity practices?

Sandilya: The sector has to start thinking and practising lean. The focus should be on lean management in all areas of the company. Identifying the non-value added activities and eliminating / avoiding waste in all the value streams will bring in extra-ordinary results. It is startling to know how much ‘waste’ is there in all our operations. A proper scientific study through value stream mapping will help identify potential areas for

T HE B IG IN TERV IEW


“The machine tool sector has to focus on technology and quality to meet global standards. Being cost competitive is fundamental. The whole approach has to be one of co-creating with the customers. The sector has to focus not only on its direct customers who will be in the manufacturing sector but also the ultimate users of the products being produced by first level customers.”

S Sandilya, Chairman - Eicher group & President, SIAM

PERSONALimprovement. Then acting on each of the potential areas with a lot of perseverance will yield results in significantly improving the overall productivity of the entire organization, and not just in manufacturing. It is not a magic wand but a continuous journey. However, to achieve progress in this area, the lead and focus has to come from the top management. Experience shows that the momentum slows down if the top management does not constantly monitor and encourage the people in the organization.

Please share your thoughts on how participation across the value chain in manufacturing can accelerate growth.

Sandilya: It is a simple spiral and a positive one. Improvement has chain reaction. Each segment of supply chain becoming competitive enables the segment to explore opportunities elsewhere to increase the demand for their products and services. Just taking the auto sector as an example, the tier I manufacturers improving their competitiveness to meet the needs of the OEMs will force the tier II to be competitive or else tier 1 will look for sourcing from other sources even globally. The chain goes through to tier III and IV and so on. Thus the overall competitiveness will improve enabling all participants in the supply chain to explore growth opportunities domestically and globally. This will have an impact for the machine tool industry as well because the entire auto sector depends on it for its equipment needs. This will impact the downstream suppliers to the machine tool industry. Thus, there will be a cascading effect enabling acceleration of growth.

According to recent reports, the auto industry numbers reflect economic slowdown. Please share your thoughts on how long do you think this situation will last and what are the strategies to deal with this?

Sandilya: The slowdown in the auto industry is due to a combination of various factors which include high inflation, high interest rates, slowdown in infrastructure spending, high fuel prices, drying up of government demand for vehicles, overall economic slowdown, etc. However, the auto industry has continued to invest in additional capacity creation both in OEM and component sectors. There is some rescheduling of investments because of the current economic scenario but the long-term outlook is fairly optimistic because of high headroom in terms of demand for vehicles. A number of global players have entered the Indian market because of the domestic demand potential for all types of

vehicles be it two wheelers, cars, utility or commercial vehicles. The government is also concerned about the economic slowdown and therefore planning a number of structural changes including policy reforms. The auto industry has also requested for extension of the Auto Mission Plan by another 5 to 10 years so that the policy initiatives arising there from will enable significant growth in the auto industry, which in turn will help the auto component sector and the machine tool industry as well. We have probably reached the bottom of the cycle and can look forward in the upward direction soon.

With the automotive industry being one of the drivers of economic growth, how will the evolving global trends such as green cars, electric vehicles, etc, (EV) impact the sector?

Sandilya: Globally automotive industry is exploring greener mobility options with increasing concerns on energy security, environmental impact of fossil fuel usage and global warming. Governments all over the world including the US, Europe, Japan, China, etc are investing billions of dollars along with the industry for developing green technology. These solutions include electric vehicles, hybrid vehicles, fuel cell vehicles, etc including the investment in the infrastructure to enable use of these vehicles. The challenge is in making them cost-effective and

affordable. India cannot be left behind. The National Mission on Electric Mobility being launched by the Honourable Prime Minister of India in January 2013 will give us the impetus for catching up on Green Mobility with the rest of the world. Till the time comes where the greener technologies become affordable for larger sections of the population, the challenge will be to continuously improve the fuel efficiency of these vehicles and also meet the future demands of emission standards. The government will have the challenge of making available the required quality of fuel compatible with the emission standards being implemented.

Please elaborate on how the joint venture between Eicher Motors and Polaris Industries Inc will facilitate to market new products in India and other emerging markets. When will the production activities start out of the new manufacturing facility to support this JV?

Sandilya: The joint venture company will design, develop, manufacture and sell a new range of personal vehicles suitable for India and other emerging markets. The manufacturing facility will be located in India and the JV partners are currently evaluating locations to set up the facility. The expected start of production is 2015.

How do you perceive the contribution of shows like IMTEX in boosting confidence among the manufacturers?

Sandilya: The IMTEX Show has been a showcase of our country’s strength in the machine tool industry for more than three decades. It is a show that is perhaps rated the highest in the calendar of events in the automotive industry after the Auto Expo. It has evolved as a major international event where machine tool companies from all over the world participate. Thus, this show has gained significant importance for manufacturing companies especially the auto and auto component manufacturing companies who are looking for state-of-the-art manufacturing solutions. It not only boosts the confidence of the domestic machine tool industry but also enables the user industries to explore opportunities to improve their competitiveness on a sustainable basis. The technological prowess being displayed in the show is a great learning experience for the domestic machine tool industry, which will trigger ideas for further innovations. MMI

The interview was conducted by: Soumi Mitra E-mail: [email protected]


India’s strong talent pool in science, technology and research, and the lowest labor rates in the world are certain factors

that give the country a lot of scope to propel its manufacturing sector immensely. According to industry reports, Deloitte’s global index, 2013, for 38 nations, has ranked India the fourth most competitive manufacturing nation, behind China, the US

and Germany. Also, The Global Manufacturing Competitiveness Index, 2013, based on a survey of CEOs, executives and other officials of 550 global manufacturing companies, has positioned India as second five years down the line, next only to China.

The above news is intended to spread some optimism in this uncertain gloomy climate that engulfs the Indian manufacturing industry. While there might be a lot of positive things to look forward to in the coming months of this New Year, one cannot deny that the current state of Indian manufacturing is disappointing. Discussing these very issues, are industry stalwarts, Jamshyd N Godrej, Chairman & MD, Godrej & Boyce Mfg Co Ltd; AK Taneja, MD & CEO, Shriram Pistons &

Informed investment and business planning decisions require timely analysis of key Indian government economic data and manufacturing industry trends. An accurate view of the manufacturing economic outlook is essential for policymakers to make informed and supportive decisions that promote the competitiveness of manufacturers. This discussion takes a look at the current industry environment of the manufacturing sector and presents an outlook for the year ahead.

Putting Ideas to Work: Strategies to Emerge as the Next Manufacturing Superpower

Rings Ltd; Vikram Kirloskar, Vice Chairman, Toyota Kirloskar Auto Parts Pvt Ltd; Vikram Sirur, President IMTMA & Chairman, Miven Machine Tools Ltd; CP Rangachar, MD, Yuken India Ltd; L Krishnan, MD, Taegutec India Pvt Ltd; Shailesh Sheth, Past President, IMTMA, Corporate Strategy Advisor and Shrinivas Shirgurkar, MD, Ace Designers Ltd.

Facing tough times

“Growth in the manufacturing sector and its contribution to the GDP is a little disappointing,” says Kirloskar straight away into the conversation. Suggesting ways to better this situation, he talks about various factors that could lead to the increase in the manufacturing growth rate. “The first issue

Indira Rao Deputy Editor [email protected]

Tale-Talk

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is that it is difficult to set up Greenfield manufacturing plants due to permissions and red tape and lack of power and proper infrastructure. It is difficult to get good returns and there are other avenues with higher potential returns for investment. Leaner manufacturing process offers potentially more returns and I think that is the key. India has a huge domestic market, high-quality capital goods are available here, and we have good manpower. All these are the plus points. However, despite all of this, somewhere along the way, we are missing the boat.”

Acknowledging similar sentiments are Taneja and Sheth. “The manufacturing sector is in pain. After a few years of high double digit growth, it seems the Indian growth story has lost momentum. There are several issues that need to be addressed: our manufacturing competitiveness is eroding, there is infrastructure deficit - particularly the availability of power, is hurting growth and cost competitiveness. There seems to be no long-term strategy to make India a manufacturing hub even for items where we have skill sets and resources,” avers Taneja.

“There has been a slowdown in growth and investment and many sectors are actually quite stressed”, states Godrej. “Take the power sector for example, there is a shortage of power because the power sector is in huge debt and hasn’t utilized all the money borrowed. The automobile sector which was growing rapidly has slowed down too. I think

what has happened is because investment is not taking place; we are not witnessing that much growth in manufacturing. A lot of manufacturing growth will depend on the growth of the economy.”

Talking along the same lines is Sheth who avows, “While there is a perceptible slowdown in investments in creating new capacity all ‘discretionary’ investments are put ‘on hold’. Only major projects which have already invested substantially would complete their projects. The general mood is apprehensive and far from ‘feel good’,” admits he.

Taneja proposes that with a little handholding, the manufacturing sector can become India’s trump card for inclusive and sustainable growth. “I cannot think of any country that became a manufacturing powerhouse without a strong machine tool industry. Unfortunately, we continue to import more machine tools than we manufacture and there is no serious game plan to change this.”

The big debate

It’s been a forever trend to compare India and China when one talks about manufacturing. While we have always spoken about how India should match up to China with they becoming mightier day–by-day, the story this time around comes across a little differently. According to the latest industry reports, while over the past two decades, China‘s manufacturing sector has proven to

be a great growth story relying primarily on its strength in the manufacturing sector, today China‘s competitiveness declines – due to Yuan appreciation and wage inflation. With their investment dropping as a percentage of its GDP, there is a universal expectation that Chinese manufacturing‘s growth is unlikely to continue unabated. In fact, this very topic was also discussed at the recently held, Manufacturing Summit 2012 organized by The Confederation of Indian Industry (CII).

Opportunity India

Presenting his take on the subject, Krishnan states, “All major multinational competitions are certainly looking for new growth engines. India with its large rising middle-class population is certainly a good long term bet. Many companies are very seriously looking at broad basing their business if India is one of the focused markets for future. Current economic conditions and currency of China may be favorable to us. However, we need to build our strength based on our own domestic demand and global competitiveness.”

“Definitely, the decreasing cost competitiveness of China is opening up a window of opportunity and India is well positioned to capture this”, exclaims Sirur. “Sectors such as automotive are already competing with the best across the globe. The investment in infrastructure and implementation of GST will enable India to

“GST has to be implemented, ensuring that the total tax incidence is lower than at present. Better compliance in any case will lead to higher revenue for the Government.”

AK Taneja, MD & CEO, Shriram Pistons & Rings Ltd

“The aspiration for India should be to not become Factory to the West, but Germany of the East.“

Jamshyd N Godrej, Chairman & MD, Godrej & Boyce Mfg Co Ltd

“It is important that we increase manufacturing share in GDP so that we can increase employment prospects.”

Vikram Kirloskar, Vice Chairman, Toyota Kirloskar Auto Parts Pvt Ltd

TALE -TALK


achieve targets of National Manufacturing Policy. The National Manufacturing Competitiveness Council (NMCC) in various reports to PMO has identified sectors which have the potential for global competitiveness, their problems and constraints in terms of structure and size of industry, technology gaps and modernization needs. Evolving sector specific strategies will enable substantial increase in manufacturing sector and develop the country as a manufacturing super power. Machine tool is one of the prominent ones among the identified sectors.”

Rangachar also is of a similar opinion and avers, “There are good techno, economic, political factors for success if we put our act right. Apart from rising costs, China has a socio- economic time bomb, which is difficult to defuse. Most countries are afraid of over dependency on an aggressive China. US manufacturing has been hollowed out by the shrewd Chinese. India is an ideal alternate, along with other counties like Vietnam, Burma etc. Action required – India is recognized as one of the worst countries in the world to do business with and we keep sliding down the scale. We need to exterminate bureaucracy; bring in investor friendly policies; and proclaim that manufacturing is the only avenue to create employment for 80 per cent of Indians, who are struggling to eke out a living on fragmented farms.”

Looking beyond low costSheth however has a counter opinion to share, “There is no doubt that China is a major competitor and its escalating economic problems do provide us with an opportunity. But who in India has the capacity to match the volumes of China? Our manufacturers are also domestic market centric. So, to what extent we can take advantage of the Chinese predicament is a matter of doubt. What will China do to counter its increasing un-competitiveness? It will most probably move up the value chain, vacating low end volume driven markets to others. This is not India’s core competency. So, all in all, I doubt if India can benefit significantly from Chinese downturn.”

Taneja states that India cannot and should not bank on China losing its competiveness due to appreciation of Yuan or wage inflation for growing the Indian manufacturing sector. Germany, for example, has a strong currency, but continues to be the largest exporter of manufactured goods in the world. Similarly, Korea does not rely on weak currency or low wages to dominate the manufacturing sector globally. India has abundant manpower, but it is not plug & play.

Seconding, he adds, “We have good engineers, but they need enormous amount of training before they are able to become production or design engineers. We need to correct this for becoming a design and

manufacturing hub and not rely on a weak currency. There are five things that we need to do to make India the manufacturing powerhouse, irrespective of how China’s currency moves or their wage inflation:

▶ Manufacturing sector cannot become competitive without reliable infrastructure. Availability of good quality power, at reasonable rates, is the first requirement.

▶ We have multiplicity of taxes. This needs to converge into simple goods and service tax (GST). Most countries in the world have adopted this system and it is disheartening to see the delay in adopting a similar structure in India.

▶ China provides direct and indirect incentives to its manufacturing sector, to promote exports. There is enough evidence of this, based on number of antidumping cases in WTO against China. Steel is available to manufacturers in China at lower prices than if we were to buy the same steel. On top of this, there are incentives in one form or the other, to promote exports. We need to find a way to neutralize this.

▶ We should not merely leverage lower labor cost to manufacture labor intensive products. This advantage will disappear sooner than later. Instead, we must invest in design and development capability and focus on manufacturing high value added products. Instead of assembling mobile phones, it is better we invest in design and manufacture of precision auto components.

▶ There is a need to simplify. Doing business in India is very complex and complexity is very costly. Single window clearances, simple compliances and realistic labour laws can provide sustainable advantage to India’s manufacturing. Simultaneously, companies have to find a way to de-bureaucratize, uncomplicate and rely on simple but robust processes. Complexity is as much a cost for an enterprise as it is for a nation.

While Godrej agrees that the decreasing cost competitiveness of China does indeed open up a window of opportunity for India, the country should look at developing ways and means to increase in competitiveness rather than just look at low cost. “Over the last two decades, labor rate arbitrage was the main driver for off shoring of production to China and provided substantial costs savings of 20–40 per cent, in spite of lower productivity levels. However, since 2009,

“We need to exterminate bureaucracy; bring in investor friendly policies and proclaim that manufacturing is the only avenue to create employment for 80 per cent of Indians, who are struggling to eke out a living on fragmented farms.”

CP Rangachar, Past President, IMTMA, Managing Director, Yuken India Ltd

“Definitely, the decreasing cost competitiveness of China is opening up a window of opportunity and India is well positioned to capture this.”

Vikram Sirur, President Indian Machine Tool Manufacturers‘ Association (IMTMA) and Chairman, Miven Mayfran Conveyors Pvt Ltd

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production worker wages have inflated at almost four times the rate of Indian wages. Add to this the relatively low productivity as compared to the US standards, and China’s competitiveness in low cost labour is clearly eroding”.

Godrej emphasized that the challenge now lies in our readiness in developing and enhancing the Indian manufacturing ecosystem. “A low cost focus alone will not be able to drive the differentiation, India needs to also focus on developing other sustainable competitive advantages in order to create a footprint on the global manufacturing landscape”. He mentioned, “The aspiration for India should be to not become Factory to the West, but Germany of the East.” India is lagging behind its peers in R&D and innovation – less than one per cent of the country’s GDP is invested in R&D; there are only 190 R&D professionals per million population, as compared to 1,100 for China and more than 5,000 for Germany. Godrej therefore affirmed, “Manufacturing quality along with R&D and innovation depth will be key focus areas for India to become a top quality and high technology manufacturing destination.

Government’s helping hand

In order to emerge as a manufacturing superpower, while the lion’s share of the improvement must come from India’s

manufacturers, there should be some share of proactiveness from the government too. Hence, we asked the industry experts what some of the imperatives were that the Indian government should do to foster growth in manufacturing.

Infrastructure glitches

Implementation of GST and clearing roadblocks related to infrastructure, sorting out power issues were the common pointers mentioned by all the experts. “The government has to get the roadblocks out of the investment in infrastructure whether it’s got to do with the roads, railways, seaports, airports. There’s a lot of hard infrastructure building required. Take railways for example, the maximum people in India today travel

“Current economic conditions and currency of China may be favorable to us. However, we need to build our strength based on our own domestic demand and global competitiveness.”

L Krishnan, Vice-President, Indian Machine Tool Manufacturers‘ Association & Managing Director, TaeguTec India Pvt Ltd

by rail. Railways haven’t seen investments for a long time because of which there is no increase in capacity. Railways can give a huge boost to manufacturing because there is a need for locomotives, wagons, rails, etc.,” avers Godrej.

“The government needs to enable the industry to make investments through proper incentives. It needs to reduce the hassles to set up industry by truly single window clearances. For instances one of our group companies has set up a plant in China, the land was allocated to them in one week flat,” states Shirgurkar. Adding on the same lines, Godrej opines, “I think the critical aspect for the administrative government is to make sure that every permission that is required for the industry

TALE -TALK


“The Indian cost structure is definitely lower than Chinese and there is every possibility that we can be more competitive if we scale up our manufacturing base.”

Shrinivas Shirgurkar, Managing Director, Ace Designers Ltd

“The five point agenda for Government - Enhance outlay substantially for technical education, ensure fast track implementation of approved projects, simplify archaic laws governing manufacturing, invest significantly in infrastructure development and quickly roll out GST.”

Shailesh Sheth, Chairman –Media Indian Machine Tool Manufacturers‘ Association

is given on time; that all permissions do not take more than 30 or maximum 60 days of time. Companies get frustrated because of the time delays that it takes to get things done. We do not have the luxury of time, we need speed and that is what the government should ensure.”

“The government recently cleared the proposal to set up the Cabinet Committee on investment, which will expedite projects over `1,000 crore by setting timelines for concerned ministries. I hope this Committee clears a lot of the past projects especially power and infrastructure projects. The government should also look at power seriously. Power is a major issue and fuel supply to the new power plants is critical and ofcourse without power one cannot run factories,” avows Kirloskar.

GST

“I think the five point agenda for government is very clear. Enhance outlay substantially for technical education, ensure fast track implementation of approved projects, simplify archaic laws governing manufacturing, invest significantly in infrastructure development and quickly roll out GST,” suggests Sheth. Sharing similar opinions are Godrej and Taneja. Taneja says, “Firstly, the government should correct the inverted duty structure. For example, it is

possible to import several auto components from Thailand at zero duty under the FTA, whereas there is import duty on raw material! GST has to be implemented, ensuring that the total tax incidence is lower than at present. Better compliance in any case will lead to higher revenue for the government.”

“GST has to be implemented. Issues regarding labour, environment, etc. need to be taken care of and dealt with. Government should support all legislation and infrastructure projects that make manufacturing more competitive and build skill development centers all over the country. It is important that we increase manufacturing share in GDP so that we can increase employment prospects”, asserts Kirloskar.

Other measures

“The Prime Minister’s vision of creation of additional jobs is not possible if we do not grow aggressively in manufacturing. If we need to grow from the current contribution of 16 per cent GDP to a level of 25 per cent, we need to grow our manufacturing industry many times over. Following are some of the key factors that will determine our growth and success in future: world class industrial infrastructure; quality and reliable power supply; road, port and airport connectivity for imports and exports; land availability and availability of skilled labor,” states Krishnan.

Suggesting further ideas is Rangachar, who says, “The government needs to eliminate bureaucracy; enact business friendly laws - regulate, and not control; facilitate finances at reasonable rate including risk capital for the start up ventures for the manufacturing industry; provide infrastructure - logistics, ports, roads, power, land etc. at reliable and reasonable costs; focus on health, education, sanitation, and nutrition.”

Holistic development of the manufacturing industry must be facilitated by the government through cluster development that includes developing industry parks and common facility centers. Agreeing Sirur adds, “Government funding may be allocated to set up these parks and for its infrastructure. There should be faster implementation of the National Manufacturing Policy and GST. The government should create an enabling environment for companies to invest more in R&D and innovation and perhaps use the vast network of academia institutions. The government should introduce the scheme of Revolving Corpus Fund at a low interest rate to promote investment (both expansion and fresh) in the manufacturing sector.”

Implementing to witness change

If the government seriously listens to the suggestions coming forward from the industry and looks at implementing it then the Indian manufacturing could witness a sea change. Companies that are able to provide end-to-end solutions including design, development and testing at competitive prices will emerge as winners in the next years. “Also, companies that are able to identify India like markets for India-specific products will be able to expand their businesses faster. For example, there are several markets in the world for affordable good quality rugged automobiles suitable for not-so-good roads or with non-so-good driving habits. India is best positioned to service such markets,” emphasizes Taneja.

Having placed suggestions on board and seeing how the Indian manufacturing industry can apply certain measures to make itself better, the future does not seem grim at all. However, the unwillingness to implement ideas will not only will weaken the industry but also have a counter effect on the country’s GDP. After all, the true worth of an idea is through its implementation. So, maybe one day we could see the Indian industry emerging as a manufacturing superpower, if and only if suggestions are heard and primarily implemented. MMI

BUS INESS ANALYT I C S


The software like Enterprise Resource Planning (ERP) plays an important role in improving the business. Though companies have to pay the initial installation cost, its a smooth ride later because of software‘s problem indicating feature.

Manufacturing Requirements Planning (MRP), manufacturing dashboards are explored in some detail here.

MRP and MRPII

MRP is a tool used for production planning and inventory control system. It is used to increase efficiency by making material available for production so ship dates to customers are honored. It assists in reducing inventory and production costs. Several customers are using it successfully and others are new to it.

Prior to the evolution of MRP, industry used reorder-point/reorder-quantity type

methods for manufacturing and inventory management. In 1964, Toyota started the move towards MRP and several companies jumped on it. In 1981, MRP evolved into Manufacturing Resource Planning (MRPII), which included scheduling of equipment/operators and capacity planning into the mix. By 1989, many companies adopted MRPII and this addressed the majority of manufacturing challenges that they had faced earlier.

MRPII includes capacity or resource planning and assists in planning/allocating the production resources to meet customer demand. Here machine and operator

Tackling Efficiency through Operations Software

There is a lot of information in an Enterprise Resource Planning (ERP) software system that will assist in

taking manufacturing operations up a notch or two. This article focuses on several efficiency enhancements and the use of dashboards to attain that. Concepts like

Kishore Tarachand Chief Executive Officer Granada Smart ERP [email protected]

Business analytics enabling efficient manufacturing operationsSo

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BU S I NESS A NA LY T ICS

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loading can be reviewed and allocation/scheduling can be done for production.

Dashboards

In this global competitive environment, it is imperative to be highly efficient to survive and prosper. By quantifying and visualizing a host of information in real-time, it is possible to address the challenges of lean manufacturing, predictive analytics (to assist in learning about trends as they occur and to take appropriate action prior to them becoming problems), improve production quality (lower defects), and improve agility and capacity in the plant.

These can pull in a variety of current and historical data/KPIs to increase the productivity of manufacturing operations − information like work order requirements, quantity, items on order, shipment during the last three months, whether production is on schedule, downtime VS plan, production VS plan, etc.

Kanban or lean manufacturing

Kanban is a system for lean manufacturing or “Just-in-time” production. It is a scheduling system that helps in synchronizing what, when and how much to produce. The need to optimize production led Toyota to utilize Kanban to run the production system as a whole and thereby minimize their parts inventories and rely on their suppliers to provide parts as needed.

Kanban uses the demand to drive the production and supply chain. While the supply chain cannot keep up with fluctuating demand, inventory levels are maintained to take the buffer. This is particularly deployed by auto parts manufacturers all over. Several other industries are also starting to deploy this system.

Smooth production flow

Let us take the case of a FMCG company that is manufacturing fruit products. The production flow chart (Fig 1) includes the key steps for MRP to enhance the planning process.

Putting the smarter heat to smarter use

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can be localized and repeated over and over again.

Of course, the technology behind induction heating

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And at integrating them into existing or planned produc-

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EFD Induction is Europe’s no. 1—and the world’s

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can devise a solution. And since we’re present in the US,

Europe and Asia, your solution is probably closer than

you think. Contact us, let’s see how induction can boost

your business.

FIG.1: Production flow chart

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If Stock Avialable

No

Yes

Purchase Requistion

Other Request

Purchase Order Vendor

Vendor Shipin

Material Receipt

Work Order

Process List

MRP

Material Transfer to Shop Floor

Production

Material Transfer

Warehouse

Every Process Batch / Sl. No. for the Input parts and for the WIP FG – Serial No.

Plan

POSO

BUS INESS ANALYT I C S


In the top table, the first row in red indicates a WO (Work order) that has an estimated completion date that is beyond the promised date. This work order can be drilled down to show where the problem is at the shop floor process level. In addition, in row one, if you look at the quantity on

order (demand) VS work order quantity (Supply), the supply (500 units) is <= demand (1200) and hence indicates a problem or delay in shipping. A case of business analytics is flagging a problem with the order quantity shown in red. This creates the need to create another WO (1000 units) for the item to catch up with the demand (row 2).

The bar charts below show five days of production and downtime for the selected WO in question and shows the fifth day in red indicating that the benchmark was not met for that day. The red bar can be drilled down to indicate what the problem is on that day compared to bench mark for total production scheduled for that day.

In the right hand bottom corner is the output of a CCTV camera that enables the shop floor view from anywhere as the product is 100 per cent web-based.

This dashboard gives a visual indication of the problem areas instantaneously to a Manufacturing Director or VP. Of course, the green items indicates that the operation is well within/exceeds the benchmarks for that day.

Better resource planning

The key resources in manufacturing are machines and operators – this greatly enhances the efficiency of a manufacturing operation – the utilization for both is shown in the figure 3.

Higher efficiencies are attained due to the following:▶ Procuring and maintaining the right

(least) inventory levels to meet customer contractual delivery requirements at the least cost-effective level

▶ Improved scheduling of equipment and operators to maximize their utility, thereby reducing costs and increasing profits

▶ Better planning improves relationships with customers and suppliers

▶ Improved design control▶ Improved quality▶ Reduced working capital due to optimum

inventory control▶ Better cash flow due to on-time deliveries

Conclusion

As the global competitive challenges have grown, manufacturing software systems have risen to the occasion and we should be prepared for continued improvement in this area. The area of business analytics and dashboards is only just being tapped. Capacity planning is available to larger companies at this point and software systems are becoming more cost-effective for mid-market companies. MMI

Manufacturing dashboard

We will review the attached example (Fig 2) of a dashboard (screen shot from the product) that extracts several KPIs (Key Performance Indicators) to present visual information to review the state of the manufacturing operations.

FIG.3: Operator & machine utilization

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FIG.2: Manufacturing dashboard

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INDUSTR IAL AUTOM AT I ON

Automating at every step

Today, the Indian manufacturing industry is facing competition from global giants. When system engineering and automation technologies synergize to change the face of manufacturing, companies can reach unprecedented levels of performance and flexibility. This is what domestic companies should look at to compete globally.

muscular requirements of work, automation greatly reduces the need for human sensory and mental requirements. Processes and systems can also be automated. Automation makes manufacturing less dependent on manpower. Automation imparts that intelligence through its three main constituents - sensors, analyzers and actuators.

‘Industrial Automation’ (referred to as the wider term that encompasses machine automation, process automation, energy automation) is the glue that binds plant people and processes for better productivity and profitability. As production lines work faster and with minimal stops during

changeovers, safety and sustainability also acquire prominence. The developed economies have mastered the art and science of deploying industrial automation technologies in process, factory, electrical, robotics, machine vision, material handling systems, sensors and many more fields. It is time to re-invent the relationship with emerging technologies, and fuel the passion for continuous innovation.

Adding value

Indian engineering and manufacturing needs to add value in many areas, in particular boost productivity per person employed, so that we make the concept of frugal engineering and lean manufacturing count in the market place.

There are several benchmarks we must cross to enhance global acceptance for our manufactured products, but one essential change needed is ‘real-time’ management of assets. The ‘real-time’ way of thinking, engineering and managing production is an art known well to automation engineers, so a meeting ground of machine designers, users and automation suppliers is quite in order. As the debate of automation costs vis-à-vis cost of labor, transforms to value creation based on increased levels of quality, safety, reliability, repeatability, etc. the role of operators, technicians, engineers and managers will also undergo a change.

Automation in India

The role of industrial automation has evolved significantly beyond the control function. It is morphing from measurement and control to include asset management.

The Changing Face of Automation

Automation is understood as “the creation and application of technology to monitor and control the production

and delivery of products and services.” In the context of industrial production, automation is a step beyond mechanization. Where mechanization provided human operators with machinery to assist them with the

Anup WadhwaDirectorAutomation Industry [email protected]

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IN DUST R IAL AUTOMAT ION

Robots working in an automotive plant

The purpose of asset management is to focus on improving operational efficiency of the production lines, down time reduction and increasing returns from the assets. Plant assets need to be managed in three phases - creation, operation and disposal. During creation phase, care is taken to ensure that just adequate assets are created for immediate requirements. In this environment, industries must have the capability and tools to get things right the first time in order to respond to each and every market change. It is known that costs of development are continuously increasing. It is also a fact that all future demands cannot be predicted today, and therefore the design has to be of a nature to support modifications and improvements. At the same time, servicing of earlier versions is also important. Therefore, the tools and development processes must support this with revision control systems, simulation, online testing etc. The tool also helps to perform parallel development and subsequent integration. Modern simulation tools allow evaluation of market scenarios to aid in optimizing control system and machinery specs, layout and investment.

Meeting customer demandsThe key to cost optimization of the overall project is to be in a position to work with the local suppliers, as it helps in terms of strengthening the eco-system over the entire project lifecycle. Local line builders, in turn, have their task cut out. Their customers are becoming more demanding in terms of price, performance, reliability and support. This obviously calls for processes, which are high speed, high accuracy and responsive to different scenarios. Traditionally, mechanical, electrical and software elements of manufacturing machines have been strictly

separated and developed in a rigid sequence. Today, these disciplines are merging into a more integrated mechatronic approach. This not only paves the way for more efficient parallel development, but also simplifies coordination between mechanical, electrical and software engineers.

Plant operations phase is relatively easier to monitor and manage as measurement metrics can be put in place for direct assessment of efficiency. But, there are lessons being learnt by machine makers, line builders and owners of large plants. Enhanced real time visibility of manufacturing operations with key parameters and ability to drill down to shop floor is vital for operational assessment. Apart from the routine operations, it is essential that the management has an overview of the entire factory. The methods of shift reports and daily reports are no longer sufficient in days of smart phones and satellite connectivity. The common thought that most people carry is – “We have enough reports maintained, so what’s new in information?” But a few introspective questions by the executives will provide the missing link:

▶ Is the information coming as an alert or analysis in real time and available

before the problem grows? Or is it a postmortem of issues being discussed in a review meeting?

▶ In terms of operator or supervisor empowerment, is the authenticity and periodicity good enough for the executive to take a timely decision?

▶ Is it mapped scientifically to the designed parameters and its basis, so that one can make a meaningful operations decision?

Uma Balakrishnan, CEO and Founder, Axcend Automation feels that today, when enterprises envision having an adaptive manufacturing environment, the machinery, automation, IT assets and strategy must be kept contemporary. On the other hand P V Sivaram, MD, B&R Automation suggests that the role of analytic thinking and communication can be delegated to every machine sensor, PLC, HMI. The demand is growing significantly for high speed computing and high ruggedisation.

The SME scenario

One of the big aggregates of India’s employed and self-employment sector is the SME sector; Indian SMEs are expected to be major contributors in forging, plastics and precision engineering. The challenge is to adopt a global vision. This will help the SME sector to upgrade talent, employ skilled resources and invest for quality, sustainability and continuity of supplies. Short term success in price and delivery agreements may no longer be adequate to earn a place in the global supply chain. In addition, automation investments have to be made as part of capability building, else the virtuous cycle will not manifest!

A good understanding of manufacturing strategy and production line features are critical foundation. Automation is a way to convert strategies into flawless execution. In early adoption, customers and suppliers blame each other in case of any fault. Mature companies, however, think through their processes at a much deeper level. They work concurrently on several areas, minimizing the risk of breakdowns and non-conformances. That ensures proper attention towards an automation system strategy and selection of hardware and software components. This decade is being called as the manufacturing intelligence decade, because machine design, computing power and human-machine interface will unleash a whole lot more competitiveness and innovation. The challenge is that the industry has to attract more talent and find ways to nurture and grow that talent. MMI

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The India Automation Technology Fair (IATF-2013) will be held in Mumbai, from 1 - 3 February. The event will provide state-of-the-art demonstration and focused workshops for engineers, managers and operating heads to experience world-class automation solutions.

According to K Nandakumar, President, AIA, the prime engagement of the fair will be on enabling technologies for the manufacturing sector. Hence, AIA invites cross-functional teams to visit IATF and be a catalyst for further exploration, problem and knowledge sharing and relevant innovation.

Providing a platform

1 - 3 February 2013, Bombay Exhibition Centre, Mumbai/India

www.iatf.in

FAC I L I TY V IS I T


Blue Thinking is the only concept that brings in some spark into industries especially in today’s economical climate. It’s this Blue Thinking strategy that when applied from the grass root levels has helped Volkswagen India Pvt Ltd to drive change from within the organization and constantly feel the pulse of its consumers while envisaging a better, greener future.

Volkswagen India Pvt Ltd makes that wish come true. Contradicting what most automotive plants do, Volkswagen opens its plant to the general public. Occupying a total area of 2.3 million sq mt (575 acres), with the building covering about 1115 thousand sq mt, the Volkswagen plant in Chakan, Pune organizes tours for educational institutes, corporate houses and private groups and the tours are conducted

in English, Hindi and Marathi. They also organize plant tours for Volkswagen employees and their families. This initiative of organizing plant tours for the layman started in 2012 and this month the company will see its 10,000th visitor. “I am really proud of the kind of response we have received and the relationship that we have established with our customers,” exclaims Andreas Lauenroth, Executive Director- Technical &


How do you like the concept of actually witnessing the making of your car before you purchase it? And I’m not

talking about just looking at the external body frame; I’m talking about seeing every part that goes into the car to make it run.

The Volkswagen plant in Chakan, Pune where 100,000 cars are manufactured annually




Member of the Board, Volkswagen India Pvt Ltd. “This exercise is all about building relationships. When one sees for themselves how a car is built, immediately the trust factor goes up. In fact, in Germany, people after seeing how their car is made can directly pick their car up from the plant.”

Redefining technology

At the moment the company manufactures 100,000 cars a year. The Pune plant is one of the most modern in the Volkswagen Group with a high level of vertical integration and a large share of local suppliers. “High local content is one of the key pillars for the long term success of the Volkswagen Group in India. As of now, we have around 70 per cent local content from over 100 suppliers at the Pune plant. Over 60 Indian suppliers are new for the Volkswagen Group. We developed them together to the high Volkswagen standards in terms of quality and processes. Some of them are also now supplying parts to other Volkswagen Group production plants worldwide,” affirms Lauenroth. The facility is the only production plant operated by a German automaker in India that covers the entire production process from press shop through

body shop and paint shop to final assembly. Though the automation level in Germany is around 90 per cent, in India it’s a combination of manual and automation, where the latter is up by 30 per cent. There are about 100 robots in the factory all over. While in the rest of the factory there are robots from KUKA, in the paint shops they use robots from Fanuc. This is a standardization for them the world over. “A balanced vendor-manufacturer relationship and co-operation is certainly most important for reaching our targets. There are key technologies which we are developing in-house, for others we partner with our vendors in terms of outsourcing. We use various risk management tools globally to be flexible and avoid impact to our production caused by local financial crises or natural hazards, for example. Volkswagen intends to deploy intelligent innovations and technologies to become a world leader in customer satisfaction and quality,” asserts Dr John Chacko, Group Chief Representative India, President and Managing Director, Volkswagen India Pvt Ltd. A couple of their unique technologies are as below:

Laser brazing

The body shop uses the Diode Laser Brazing (DLB) technology, where the roof and side framer laser technology is used for welding the roof to the body of the car. This technology is unique to India “because we are the only company to use the technology for the roof of the car. Companies like Audi and Mercedes do this too but they do it in their plants in Germany and not in India. When the roof is done with laser brazing there is no possibility of potential water leakages as the gap is permanently sealed by metal,” elucidates Lauenroth. Also,

The plant has futuristically designed state-of-the-art equipment at its Pune plant

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”The ecological footprint of a car does not begin when the customer buys the car, but in fact, it starts from its development and manufacturing and goes on till the end of the recycling process.“

Dr. John Chacko, Group Chief Representative India, President and Managing Director, Volkswagen India Pvt Ltd

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primarily there is higher torsional rigidity of the car during roll over thus enhancing the safety feature and for getting a good laser weld the body should be maintained within very tight tolerance which automatically drives the upstream process to be always in control.

Inline measurement

Another one of their advanced technologies is the inline measurement. Here highly advanced camera mounted on robots captures the critical holes and surfaces and sends the data to measurement software where the measured data is compared with



nominal data and the measurement trend will be under observation for 100 per cent cars. This method guarantees 100 per cent inspection of cars and if the measurement trend is varying abruptly or when it is going towards the maximum tolerance level, then the measurement system alerts all concerned agencies to act. Also, if the data exceeds tolerance, provision is made to stop line until corrections are done. Using this method also helps in making perfect cars as per international standards of Volkswagen.

Think Blue Along with using futuristically designed state-of-the-art equipment, the facility is also one of the few environment friendly manufacturing plants around the area. Their ‘Think Blue’ campaign was created to build a platform for those who want to make a difference to the environment. On an interesting note though all their measures to go green in their concept are called ‘blue’. “This is because earlier we had a campaign called ‘Think Small’. Think small was related to making auto mobility available for all - For example, everyone could use a car like the Beetle. Building on the same concept we came up with “Think Blue” and it’s also called blue because it’s the Volkswagen color,” explains Lauenrot.

At Volkswagen, they have set their sights on developing vehicles that are smarter, more fuel efficient and pave the way for a sustainable future. Think Blue is a philosophy that embodies their goal of creating environment friendly products and solutions. They also take the onus of educating people along the way. Agreeing Chacko says, “The ecological footprint of a car does not begin when the customer buys the car, but in fact it starts from its development and manufacturing and goes on till the end of the recycling process. The holistic approach gives high importance to the car’s lifecycle that includes the development and manufacturing of the car and it is necessary for us as a manufacturer to adopt ecologically friendly systems of manufacturing cars in order to reduce the carbon footprint of the car right from its development stages all the way to its recycling.” The company was awarded a trophy in Germany recently for reducing their energy consumption by around 40 per cent.

Investing in the Indian market

The plant was built in 2009 with an investment commitment of `3800 crore (580 million Euros). This is the largest investment by a German company to date in the Indian growth market. “India is a huge market for us with 1.2 billion people to cater to. We see all the BRIC countries as huge markets with immense potential. We always aim to build a long term relationship with the country we go to,” says Lauenroth. There can be no better testimony to this statement than the company investing heavily in training and retaining its talent.

Training academy in India

Volkswagen’s training academy in Pune provides training for apprentices, employees and dealers from all Group brands and production plants in India. The academy which has 1,500 sq mts of space is equipped with seminar rooms and provides practical training in advanced vehicle and production technologies. The group in 2011 launched the ‘Mechatronics Apprenticeship Program’, which is a three year program based on the German dual system of vocational education and training. The program was designed keeping in mind the increasing complexity of production processes which demands a workforce that has expertise in mechanical, electronic and informatics skills as well as in other modern automation technologies. Apart from these skills, the workforce also develops their interpersonal skills through the program. “It’s our philosophy to educate people. In India, we find educating people is very important; especially imparting education on quality. Just teaching on how to build a car is not essential it’s essential to teach how to build a good quality car. These apprentices are highly skilled people after three years and we are very proud to say that we have six women in our program,” enthuses Lauenroth. “At the end of the day, it’s all about building relationships and we try and retain our people by developing them constantly.”

Moving forward

The company has always been involved with people. With greater emphases on building relationships with existing and future customers, the company is sure to go a long way. Going further, in India Volkswagen plans to focus on further increasing their localization while simultaneously working on possible new projects. MMI

“High local content is one of the key pillars for the long term success of the Volkswagen Group in India. As of now, we have around 70 per cent local content from over 100 suppliers at the Pune plant.”

Andreas Lauenroth, Executive Director- Technical & Member of the Board, Volkswagen India Pvt Ltd

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The training academy provides practical training in advanced vehicle and production technologies

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Tool change time

0.9 sec

MILLTAP 700

Highly productive compact machining

centre with a fast tool changer

Rapid traverse in all axes

60 m/min

Siemens 840D

solutionline OperateFast, easy, effective

Highlights MILLTAP 700

_ Control: Siemens 840D solutionline Operate, optionally

available with JobShop and SINUMERIK MDynamics

_ Safety Integrated – Safe loading and pocket relaying of the tool

magazine through the open cabin door

_ 60 m/min rapid traverse in all axes; 1.6 g acceleration

_ 0.9 second tool change time

_ 15 magazine pockets (25 optional)

_ Spindle with 45 Nm, 10,000 rpm (24,000 rpm optional)

_ Higher precision through the optimised machine design

_ Direct measuring system (optional)

_ Largest work area with travels of 700 × 420 × 380 mm

_ Optimal free chip fall with a chip pan

_ Compact with small footprint, setup width of 1,650 mm

_ Highest machine rigidity for maximum cutting performance

_ 400 kg max. table loads

_ PROGRESSline – Clear display of remaining machining

time and number of pieces in a complete machining

process (optional)

_ 30 % energy savings compared to competitors through

the advanced electrical package

If your phone is equipped with QR-code recognition software, you will be directed to our homepage.

All of the latest news available at: www.dmgmoriseiki.comDMG MORI SEIKI India:No. 3/1, 3rd Main Road, K I A D B Peenya 1st StageBangalore 560 058, India, Tel.: +91-80-40896500, Fax: [email protected], www.dmgmoriseiki.com

For Service & Spareparts support

call our new Toll Free No. 1800 103 6467

/ / simply more success

24 – 30 January 2013

Hall 3A, Booth B113

IN_MMI (Jan)_MILLTAP700_210x297_15th Jan_Layout 1 13-1-15 11:30 Page 1

CUTT ING TOOLS


Whether or not it‘s a small world remains open to debate. However, the fact is that the products around us continue to shrink, as does the equipment required to make them. In this scenario, micro-machining plays an important role.

Sandvik Coromant. It points out, for example, that in 1950s radios had five transistors and computers were vacuum-tube-filled rooms. Nowadays, most people have inexpensive, 100-million-transistor computer chips at home.

Consumers continue to demand small products, particularly when it comes to electronic gadgets. Regardless of the devices – mobile phones, laptop computers, MP3 players and gaming consoles – the focus is on ‘compact’. This on-going reduction in the size of electronic devices has a knock-on

effect for associated mechanical components, Sandvik noted. In such gadgets, one can find a wide range of tiny metal parts, or components with micro-features. These devices also contain high numbers of plastic parts, each of which requires a metal mold for its production. Manufacturing such parts and molds was once best accomplished by the slower electric discharge machining (EDM) process, according to Sandvik. It pointed out that the market is seeing a notable shift to milling as cutting tool technology meets demands.

Along with consumer electronics, other sectors have been driving the trend for micro-machined parts, Sandvik said. Other parts might include medical equipment (micro-surgery tools, implants, pacemaker features, fluidic mixing chambers, bone screws, capillary units), automotive components (fuel injectors, gears, pumps), aerospace parts (cooling holes in engine components, pressure transducer parts, gyroscope parts), as well as a host of parts for dental implants and wristwatch components. Ultimately, this all means there are genuine opportunities in the current micro-machining arena for machine shops armed with the appropriate manufacturing technology.

Cutting Tools Tailored for Micro-machining Requirements

Small-parts machining or micro-machining as it is sometimes known, has grown in stature in recent years as

the trend toward miniaturization has picked up pace. In fact, the need for ‘small’ has been nothing short of astonishing over recent decades, according to cutting tool supplier,

Eric Culp Editor-in-ChiefETMM-ONLINE [email protected]

High-performance tooling is vital for shops processing micro-components or parts with micro-features

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VOGEL BUSINESS MEDIA, GERMANY

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Meeting demandsWith this in mind, the milling of profiles for micro-components places huge demand on cutting tools, and this is intensified further if hard materials are used. To help overcome this challenge, the company has introduced a new series of small ball-nose end mills to its CoroMill Plura range. Suitable for profiling applications in medium-hard to hard steels (35-72 HRc), these small diameter cutters (down to 0.1 mm) are said to suit almost all micro-machining applications where high precision is vital, i.e., moldings, forging and casting dies, electronic components and medical tooth implants, to name a few.

Dimensional tolerances of +0.001/-0.005 mm are achievable.

Along with offering high levels of precision across the entire ISO H application area, the special design means users are able to keep the profile shape intact for longer times in cut. Furthermore, a long neck allows extended reach for difficult-to-produce features, such as when pocket milling.

The small ball-nose end mills are made of GC1700, a fine-grained solid carbide grade that the supplier said is able to reconcile rigidity and chip clearance – the principal design challenge for this type of tool because it is essential to minimize heat

CoroMill Plura cutting tools from Sandvik seek to make milling an alternative to EDM processing for micro parts

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ik transfer from the chips back to the cutting tool. In addition, the tools also feature a multi-layered PVD coating, which offers high levels of hardness and wear resistance. The edge is specially prepared to offer improved wear behavior through the generation of a consistent chip load, while the geometric design prevents the radius from deteriorating uneven wear. Additionally, a 30° helix angle helps reduce cutting forces and vibration.

The shape of things to come

The company said in tests, a 1 mm diameter cutter maintained its profile shape after 120 m cut length, unlike a comparable competitor cutter, which showed considerable deviation. The cutting data included a cutting speed of 38 m/min, feed of 0.032 mm/rev, 0.05 mm radial depth of cut and axial depth of cut of 0.14 mm. According to Sandvik, for many manufacturers performing micro-machining operations, cycle time is not top priority – rather a process that reliably and precisely machines the feature without error or failure.

High-performance tooling is vital for shops processing micro-components or parts with micro-features. At a scale of around 0.1 mm (the thickness of a human hair), the slightest variation in the manufacturing process caused by material or cutting tool characteristics, thermal variations in the machine, vibration or any number of minute changes will have a direct impact on the ability to generate features of this type on a production basis. Sandvik said its application engineers can help customers select the appropriate cutting tools and apply the correct parameters to suit individual requirements and machining conditions. MMI

World Trade Fair for Used Technology

22 – 24 April 2013 Cologne, Germany

Organisers: Koelnmesse GmbH and Hess GmbH · Technical Sponsor: FDM e.V.Registration and information: Tel. +49 7244 7075-0 · www.usetec.com

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CUT T IN G TOOL S


CUTT ING TOOLS | INDUSTRY MAVENS

Sanjay Baljekar, Director, EMUGE India Pvt Ltd, discusses how tools are being modified constantly to satiate the ever increasing demands of the new generation machine tools and suggests how the industry – academia partnership should be fostered.

“Cutting tools has not been given its deserved status by the academia”

“There has to be constant interaction between the cutting tool manufacturers, machine builders and the user industry to ensure that the user industry’s needs are taken care of.” Sanjay Baljekar, Director, EMUGE India Pvt Ltd

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The interview was conducted by: Indira Rao E-mail: [email protected]

How prevalent are quick-change tooling and fixturing to reduce machine downtime and increase productivity? Are tooling providers in India providing the ‘quick tool’ packages?

Sanjay Baljekar: As the pressures on costs increase, downtime controls are necessary and that’s when the “tool / component changeover” time comes into focus. In a mass production scenario, even a second saved per operation per machine in tool changeover or work piece clamping can go a long way in improving productivity. More and more Indian manufacturers have realized this and are looking for flexible / faster clamping systems with quick change tooling as a possible solution for controlling the down time. While there are many options provided by cutting tool manufacturers to reduce

downtime, there are only a couple of players who can provide end to end solutions, i.e. from right tool holding, the right tool and right clamping solution with high accuracy and ensured repeatability. This area is bound to see an upsurge in the Indian manufacturing scenario in the years to come.

It is often said that the end-user of cutting tools does not always utilize the technology to their best advantage and hence productivity gains are left untapped by global cutting tool users. How true is this statement according to you?

Baljekar: This is debatable. In India, today, all the major global cutting tool manufacturers are here. Hence, the most currently used technology, world over, is available at ones door step. However, there has to be a constant

interaction between the cutting tool manufacturers, machine builders and the user industry to take advantage and ensure that the user industry’s needs are taken care of. It is difficult for the end user to keep every aspect affecting performance of the tool under control and hence there is always a possibility of them not using the technology offered to its best advantage. Constant communication and interaction through various forums will ensure optimal understanding of the tools and technology that is on offer. It has been observed that the user industry will not hesitate to procure the latest machinery but will cut corners, when it comes to tooling; work holding and other auxiliary add-ons.

How according to you is the industry – academia partnership as far as this industry is concerned? What should be done to foster this relationship?

Baljekar: Cutting tools as a subject has never been given the status it highly deserves by the academia. There has to be a paradigm shift conceptually. I believe the cutting tool fraternity is willing to extend its services and share its experience and knowledge with the academia, provided it is not given a step treatment. The machine tools related trade bodies and industry associations need to interact with policy makers and course content developers to explore ways of giving cutting tools a better place in their syllabus. Besides, there has to be more practical exposure to this industry by the academia, by way of more in plant training and greater industry visits.

MACHIN IN G CENTERS


Volvo Aero, the leading developer and manufacturer of aircraft engines and their components uses the technlology from DMG / MORI SEIKI made by Deckel Maho Pfronten, for its milling and turning operations. Get to know how by combining all the right ingredients, the Company scaled new heights.

Combining all the Right Elements

The process chain at Volvo Aero encompasses among other things its own complete in-house manufacture of

turbine assemblies and many different types of casing. The combustion chamber and compressor fuselage casing in particular, demand the special expertise of the Swedish manufacturer. The unmachined parts are made of high-alloy material and cost alone between 30,000 and 70,000 Euros. There are only two manufacturers in the world that can produce these casings using the special investment casting in the quality required. Subsequent milling and turning is carried out in Volvo Aero’s main plant in Trollhättan. Precision, efficiency and profitability take top priority here.

Growing pressure from the market means that the demands on efficiency and profitability have increased over the years. This is why Volvo Aero started its search for suitable solutions at a very early stage. This search led to an enquiry to Deckel Maho for a “factory within the factory”. Not just one, but several state-of-the-art mill/turn machines were to be integrated into one complete material and information flow of unmachined and finished part logistics as well as tool supply chain. At the end of the year 2004 Volvo Aero ordered the largest flexible manufacturing system (FMS) to date from Deckel Maho.

Project details

This project set new technical standards both as far as manufacturing and automation was

Central Tool Storage (CTS) as a closed cabin unit offers space for 1,250 tools

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Director-Aerospace Excellence Center DMG / MORI [email protected]

MACHIN ING CENTER S


concerned. As early as the first half of 2006 saw the part of the system put into operation step-by-step. The system solution included five of the latest DMC 160 FD duoBLOCK milling-turning centers from Deckel Maho, over 100 different pallets in the shelf magazine, and almost 1,300 tools in the central tool magazine. Tomas Lindsta, the permanent project leader at Volvo Aero, looks back on the order: “First of all we had to plan and carry out some structural modifications in Trollhättan. While this was going on we made an early start with intensive training of all project partners.” It was the close cooperation with the partners that finally led to the whole system being successfully accepted. One of these partners was the Finnish company Fastems Oy AB, a specialist for FMS. Even if the name of this company is not actually mentioned in the contracts, it has nevertheless been a reliable partner to Deckel Maho for many years when it comes to orders of this kind.

As a Deckel Maho “sub-supplier” Fastems supplies the complete interlink of the system components: this includes: the multi-level storage system MLS-XMD with up to five levels for the management of the 54 DMC 160 FD pallet places, including their three corresponding setup stations, as well as the 50 material pallets with their four corresponding material setup stations. Fastems also supplied the central tool storage (CTS) as a separate unit for 1,250 tools including transport system to the five DMC 160 FD duoBLOCK machines and an area of tool regeneration with a pre-setting function. This is in addition to the integrated deburring cell and its tool management as another integrated system station.

Central tool storage

The integration of the individual components was wholly justified as the example of the CTS unit shows. Advanced machining

technologies involve increased tool wear. That is why the CTS encompasses complete tool regeneration including measuring and maintenance so that the required tool is always available for every process phase at every DMC 160 FD duoBLOCK when needed. The corresponding robot serves as a buffer for the individual machine magazines. All processes running in the system are controlled and meticulously recorded by a master computer and three client computers. The so-called auto pilot function is an aid to the operator at the unmachined part loading or the setup stations. It also is an aid for the loading and unloading stations for all tools. Tools can also be loaded onto carts ready for transport to other departments from the robots or the CTS area as required.

More sophisticated equipment is found in the workpiece loading areas, of which the FMS has three. Each of these has a loading station for the raw material and a separate workpiece setup station. The same pallet tables are used here as those used in the FD machines, hence, rotational symmetrical workpieces can be pre-set precisely in the center of the pallet. An ingenious material control guides and tracks all workpieces through the seamless manufacturing process. The supply of unmachined parts and the removal of finished parts from this FMS as an internal factory is the interface to the external factory via the transport and setup stations.

Efficient operations

Automatic deburring of the finished machined workpieces is carried out by a de-burring cell with a rotating pallet station

The flexible manufacturing system from Fastems installed at Volvo Aero supplies in total five DMC 160 FD milling-turning centers with raw parts and tools and also includes a robotic deburring cell

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The flexible manufacturing system from Fastems installed at Volvo Aero supplies in total five DMC 160 FD milling-turning centers with raw parts and tools and also includes a robotic deburring cell

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from Fastems. This is integrated in the pallet storage and transport system. The CTS can supply 50 tools with an ISO 30-holder for the Fanuc 710iW de-burring robot. Internal sequence control, inspections and maintenance are also taken care of. The special extraction and filter system ensures the de-burring process runs smoothly with no particle contamination to other areas. The system computer controls all the necessary tools and programs. There is also a station for manual de-burring integrated in the overall system that is used for carrying out any finishing work detected during the workpiece inspections.

Fastems guarantees the integration of all other system stations with its management solution. The MMS control system allows exact scheduling and therefore highly efficient total output according to production schedules more or less round the clock. The system never has to wait for unmachined parts, nor for milling, turning or de-burring tools. In addition the self-optimizing system is connected to the higher-level systems of Volvo Aero via the respective interfaces. This also applies to the off-line programming environment. So appropriately controlled intervention is possible at all times should there be an emergency or accident.

This full system concept integrates the four main technologies of milling, turning, measuring and de-burring, as well as its auxiliary technology, including management and supply of all unmachined and finished parts, as well as tools. This concept probably makes it second to none in the world where systems to this degree of complexity and automation are combined. MMI


INDUSTRY MAVENS | MACHIN IN G CENTERS

S N Mishra, Vice Chairman, Bharat Fritz Werner Ltd, taking an optimistic look at the future, talks on how machining centers have come of age and how it can go green and contribute to sustainability.

”Tough periods make one stronger, wiser and better”

“India ranks as the 16th highest producer of machine tools in the world, but only 27th as the highest exporter. Even in India we use more imported tools than the ones locally produced.” S N Mishra, Vice Chairman, Bharat Fritz Werner Ltd

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The interview was conducted by: Indira Rao E-mail: [email protected]

Today’s CNC machines allow machining of different types of material, which was not the case earlier. Please give your views on how these machines have come of age and take us through the technological trends being witnessed today.

S N Mishra: The CNC metal cutting machines have undoubtedly covered a long distance! You can machine material which, till few years ago, was considered too malleable, fragile, soft, hard, etc. Whether metal or a polymer, ceramic material, wood, composite and special material – all are being machined to perfection today. Apart from CNC machining, other technologies are also becoming acceptable such as ultrasonic machining, laser machining,

water jet cutting, electrical discharge machining, and so on.

As far as machining centers are concerned, is it possible to go green in the operations? If yes, how?

Mishra: Machining centers go green in two major areas – power consumption and pollution. There are several ways of going green on both. For example, the number of power consuming units such as pumps can be reduced, units can be made more efficient, auto-shutdown in case of non-usage beyond a certain period can be used, and even the controller screen display can be made environment-friendly! It’s the same on the pollution front – the usage of coolant

can be reduced, usage of non-petroleum lubricants can be reduced, mixing of lubricant with coolant can be avoided and fumes can be arrested.

Are machine tool manufacturers in India using green designs and coming up with solutions that enable a sustainable future?

Mishra: BFW adopted green design some years ago. For example, the Agni+ introduced at the IMTEX 2011 incorporated several improvements including green design, resulting in 100 per cent saving on lubricating oil, 100 per cent freedom from oil separation hassles, 24 per cent saving on electric power, etc. The machine later had to be modified to suit the market. I am sure that the other manufacturers also observe some green designs.

How do you think will the industry fare in the coming year?

Mishra: If winter is there, can spring be far behind! I am aware that the industry did not have 2011-12 as a particularly memorable year, but then troughs and peaks are part of the business cycle. How can one enjoy the boom without weathering the slowdown? I eagerly look forward to the future, which appears to be bright. The worst should be behind us. In any case, tough periods make one stronger, wiser and better equipped to tackle difficulties. So, chin up!

MANUFACTUR IN G SOFTWA R E


In the manufacturing process, choice of the right software makes a lot of difference. Get to know how by using SolidWorks Premium design software, the Martin Jetpack, a Jetpack for the masses, was made.

means of propulsion strapped on one’s back. The concept of the jetpack reaches back to the early days of science fiction, yet previous models were unwieldy, unsafe, or unrealistic. To solve this problem, Martin Aircraft has developed the world’s first practical jetpack.

Creating a jetpack for the mass market has long been Glenn Martin’s dream. Initially, development progressed slowly, with the company primarily using AutoCAD 2D tools and outside design contractors.

However, Martin decided to move all development onto a 3D design platform in 2008 to accelerate the process. The move resulted in the selection of the Martin Jetpack as one of Time magazine’s 50 Best Inventions of 2010.

“Upgrading to 3D was more a matter of necessity than a luxury,” Martin recalls. “R&D had progressed to the point at which we needed to streamline processes and refine the design. In addition to needing better

Developing the World‘s First Practical Jetpack

Mankind has dreamed of flying freely, like a bird, since the beginning of time; not just soaring within the

confines of an airplane, helicopter, or rocket—or suspended from a hang glider or balloon—but as a single entity, with the only

Martin Aircraft used SolidWorks design and simulation tools to develop the Martin Jetpack, the first jetpack created for the mass market

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Manoj Mehta Country Manager - India & SAARC Dassault Systèmes SolidWorks Corp. [email protected]

MAN UFACT UR IN G SOFTWARE


design, simulation, and visualization tools, the engineers that we hired had experience using one 3D system in particular. That was SolidWorks,” he added.

Martin Aircraft selected SolidWorks solutions to finalize development of the Martin Jetpack, implementing SolidWorks Professional and SolidWorks Premium design software, and SolidWorks Simulation and SolidWorks Flow Simulation analysis tools, in 2008. “Our engineers knew how to use SolidWorks. Our composites partner used SolidWorks. The choice was obvious,” Martin says.

Accelerating R&D

Since the company moved to the new software, development of the jetpack has

accelerated at a rapid pace. The Martin Jetpack is unique in its use of vector controls and a custom-designed gasoline engine, which drives twin-ducted fans that produce sufficient thrust to lift and stabilize the jetpack during vertical takeoff and landing, enabling sustained flight. It’s also less expensive than previous jetpacks and will sell at a price comparable to a high-end motorcycle or car.

As the design nears completion, software’s surfacing and mold development tools have become increasingly important, according to Bill Clemence, Design Engineer. “Designing the engine and main structural frame was fairly straightforward, involving generic shapes. Creating the fan blades and housings was another matter. On some parts, everything is a curve, and many are made using composite materials. SolidWorks gave us the surfacing, simulation, and flow simulation tools that we needed to quickly optimize key components,” Clemence stresses. Elaborating the same, Martin added, “It’s fantastic to have access to a modern tool like SolidWorks, which gives us as a small company the same skills and capabilities as a multinational corporation.”

Streamlining prototyping cycles

One of the key productivity benefits that Martin Aircraft has realized since moving to

In a nutshellChallenge:Accelerate development of the world’s first practical jetpack to enable safe, controllable, single-person flight.

Solution:Implement SolidWorks Professional and SolidWorks Premium design software, and the SolidWorks Simulation and SolidWorks Flow Simulation analysis applications, to optimize design, improve prototyping and shorten development time.

Results:▶ Cut mold development from three weeks

to a day▶ Eliminated need for prototype molds▶ Accelerated jetpack development▶ Named one of Time magazine’s 50 Best

Inventions of 2010

Martin Aircraft engineers relied on SolidWorks surfacing and mold development tools to bring the company’s unique jetpack design through the final stages of development

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SolidWorks software is a substantial reduction in the time required to produce composite molds and parts, which has dramatically streamlined the company’s prototyping operations. Producing composite parts from a mold used to require a minimum of three weeks. The company can now create molds and parts within 24 hours, and has eliminated the need to produce prototype molds.

“The combination of SolidWorks and our CNC machine allows us to make molds and parts more quickly and accurately,” Clemence explains. “Testing multiple variations is an integral part of our design process, and with SolidWorks we can make parts with a very short turnaround,” he mentioned.

Making it look good

Since, the Martin Jetpack will be sold in leisure and recreational markets—in addition to military, search and rescue, and first responder markets—the design must be aesthetically pleasing. The company also needs to show and demonstrate the design’s attractiveness. Using PhotoView 360 rendering and SolidWorks eDrawings communications tools, Martin Aircraft is able to show cool-looking renderings of the jetpack, as well as detailed engineering views of how it operates.

“We’re using the renderings that we created in SolidWorks in our brochures and pamphlets,” Martin points out. “When I’m traveling overseas, I use these renderings and eDrawings files to show how the jetpack works in as much detail as necessary. SolidWorks solutions are integral to every facet of the jetpack’s development.” MMI

“There’s no doubt that SolidWorks has helped us to accelerate development and save time and money.”Glenn Martin, Founding Director & Inventor, Martin Aircrafts

INDUSTR IAL ROBOTS


Kuka CNC has made direct processing of G-code possible with an integrated CNC kernel on the robot controller. Get to know how through direct integration of an CNC kernel on the robot controller turns the industrial robot into a machine tool.

guidance, injection molded parts are trimmed and cut to size by robots, and castings are finished, fettled or deburred.

While many CAD/CAM-based systems already exist for the offline programming of robots, there has never yet been an integrated approach to process data all the way to the robot controller. The prerequisite for processing programs until now was the compilation of the CNC programs into the corresponding robot language with the aid of an adapted post-processor. This automatically resulted in a loss of

information, as functions from the CNC program were not always supported in the widely differing robot languages.

The direct integration of a CNC kernel on the robot controller gives the robotic machining system an inherent range of additional functions.

The complete standard code can be interpreted and implemented by the robot. (G functions, M/H/T functions, local and global subprograms, control command structures, loops, etc.) These options broaden the range of applications for an industrial robot, particularly in the following fields:▶ Milling of shaped parts made of soft/semi-

hard materials, such as wood, plastic, aluminum, composite materials, etc.

▶ Polishing and grinding of shaped parts▶ Coating and surface treatment of complex

workpiece surfaces▶ Trimming and cutting of complex

workpieces and workpiece contours▶ Laser, plasma, waterjet cutting of

complex workpieces

Robotic machining

In addition to the general possibility of executing programs using the CNC kernel integrated into the robot controller, Kuka also offers the full range of functions of a robot controller. In this way, it is possible to switch between CNC operation and conventional robot operation for different applications. This allows selection of the ideal controller, programming and operator control environment for the process in question.

Advantages for CP processes

CNC mode is particularly advantageous for continuous-path processes. Machining programs with a large number of points on the path can be executed more precisely and

A Direct Approach

Machining with industrial robots is a widespread application. The flexibility of industrial robots opens

up a large range of applications that until now has involved primarily the finishing of series products. Taps and fittings are ground and polished under robotic

The direct integration of a CNC kernel on the robot controller gives the robotic machining system an inherent range of additional functions

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Alexander Bay Product ManagerKUKA Roboter GmbH [email protected]

IN DUST R IAL ROBOTS


with shorter cycle times using the CNC kernel and its sub-functions. These improvements in accuracy and cycle times are due to the advanced path planning functions in the CNC kernel. Path planning with point anticipation for more than 500 points makes it possible for the robot above all to maintain constant velocities during the machining process and to plan optimal acceleration/deceleration ramps. The path accuracy is also improved by means of various spline interpolations in the CNC kernel. Akima and B-Spline calculations ensure that the robot executes its set path as accurately as possible. These typical CNC functions are combined with the conventional functions of a robot controller, thus achieving optimal machining results.

Simplified robot integration

The use of robots in the domain of conventional CNC machine tools redefines the possibilities of G-code processing. In automated machining systems, it will in the future be possible to program and operate not just the machine tool but also the robot by means of DIN 66025-compliant code. This facilitates robot integration and offers a crucial advantage especially for the machine operator. In the future, the operator will no longer need robot-specific programming knowledge, but will be able to operate the robot using his existing CNC expertise.

Merging automation and machine toolA special case in the field of automated machining is the processing of workpieces handled by the robot. The combination of

machining and handling makes this process variant particularly efficient since the robot picks up the workpieces, guides them to a machining station for processing and then transfers them to a storage facility, no further transfer or handling kinematic system is required for automation of the process. In this example, the machine tool and automation system are combined to form a single unit, with a great influence on the aspect of cost-effectiveness.

CNC programming opens up a whole new range of programming systems for robotics. The CAD/CAM system market offers specially adapted solutions for a wide range of different machining applications. Robot programming and application possibilities will thus also multiply in the future. CAD/CAM systems are increasingly recognizing this development and providing their software with corresponding modules for robot programming and simulation.

The great advantage of this solution lies precisely in the combination and integration of the entire process chain from the CAD system via a connected CAM module to the robot-specific path and process planning. The process chain is closed and kept to a compact size by the directly connected robot system including the CNC kernel. Detours into post-processor tools are not necessary and optimization is possible at every process level on account of the direct integration with the CAD/CAM system. MMI

Typical CNC functions are combined with conventional functions of a robot controller, thus achieving optimal machining results

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In addition to general possibility of executing programs using the CNC kernel integrated into the robot controller, Kuka also offers the full range of functions of a robot controller

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MEASUR ING SYSTEM S

Using the FaroArm to align a fixture and ensure accurate positioning

Outdated technology is dangerous for any business. Hence, to keep abreast with the changing business environment, Chinese company, C-Weld Technology automated its factory. The article states successful application of the new technology.

assembly lines, with particular focus in non-standard products that offer in-line solutions for customers. Some of C-Weld’s products include automotive fixtures, check fixtures, car rigs, welding frames, exhaust pipes, and automation equipment.

In keeping up with the times, the company procured new technology to stay ahead of competition. By mid-2010, C-Weld was ready to roll with industrial automation trends that were current then. Amongst its capital investment plans was Faro’s high precision metrology equipment, which

helped C-Weld gain further business expansion in subsequent years.

In a manufacturing environment like C-Weld’s, several stages of the production process call for accurate measurements in different applications, such as pre-production checks, product sampling and final inspections.

Prior to using Faro, C-Weld relied on traditional hand tools for inspection and measurement needs. With manual methods, the company was unable to optimize productivity as technicians had to perform measurements painstakingly, and repeat them to verify the accuracy of readings.

“Inevitably, our efficiency was not at its best,” shared Xiao Xiong Hua, Project Manager, C-Weld.

“We put a lot of effort into inspection. Even then, there was neither guarantee nor objective evidence to prove that the measurements were precise,” Hua elaborated.

In addition, the C-Weld team struggled with moving large, bulky objects that needed to be measured. The team had access to a desktop Coordinate Measuring Machine (CMM), but it was not ideal for the inspection of large objects. “The components we work with vary in sizes, ranging from 0.5m to 6m,” said Hua. “Among them, large welding parts pose the greatest challenge. Its weight and bulk

Practical Metrology Solutions

Chengdu C-Weld Technology (C-Weld) is a one-stop shop that provides design, manufacture, research and

development, installation, commissioning and integration engineering services. The company specializes in fabricating automotive welding production lines and

Amrita Gokhale Marketing Specialist Faro Business Technologies India [email protected]

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MEASUR IN G SYSTEMS

makes it very difficult to shift. Even after placing them onto the machine, we still had the challenge of locating reference points with each rotation in the measurement process. It was simply not effective!”

For these reasons, as well as the company’s desire to stay ahead of competition, C-Weld purchased three sets of FaroArm over a few successive years. A portable CMM that takes the form of an articulating arm, the FaroArm has multiple rotating axes (exact number is model-dependent), and provides maximum versatility suitable for measuring odd-shaped objects.

A solution with a perfect fit

Since switching to Faro, C-Weld has greatly improved on the quality of its products, as well as enjoyed much higher levels of productivity. The FaroArm offered tight tolerances of 0.07mm, well within C-Weld’s specifications of 0.1mm. With this investment, C-Weld eliminated the human error that came with the arena of traditional hand tools, greatly boosting accuracy levels.

Utilized daily in a variety of settings, the FaroArm is now an indispensable part of C-Weld’s operations. When asked about the

favorite feature of the device, Hua replied, “It is hardy in nature. One of our biggest raves is that the FaroArm functions well even in harsh environments like our shop floor.”

Furthermore, measurements are performed in a much shorter time than before, even if measurements were repeated for verification. Large objects are also no longer a problem, as the FaroArm has a larger working volume and can be brought to the object. “We saw significant time-savings over different projects, and

inspection times were slashed by up to 50 per cent,” revealed Hua.

Customer satisfaction

Aside from savings in time and manpower, Faro has also enabled C-Weld to serve its customers better. With the FaroArm, C-Weld was able to provide on-site sampling of its products at point of delivery. The software made it possible to generate objective reports of inspection checks as proper documentation. MMI

Chengdu C-Weld Technology is a one-stop engineering services company that serves the automotive sector

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The Faro CAM2 software allows easy report generation

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Innovations

D-96145-Seßlach ▪ Tel.: (+49) 9569 9221 0 ▪ Fax: (+49) 9569 9221 20 ▪ www.geiss-ttt.com

CNC – Laser Cutting Machine For Processing OfComposite Materials And Thermoplastics

The latest generation of CNC machines ECOPlus equipped with a TruCoax laser by Trumpf as laser cuttingmachine is particularly suitable for processing of composite materials like GRP or CFRP and thermoplastics.Due to contact-free handling of the parts simplerand less expensive jigs can be used. Anextensive post-processing of the edges iscompletely eliminated in most cases.

Sample part by BroseGmbH trimmed on a lasersystem by Geiss AG

LASER TECHNOLOGY


3D scanner optics add the Z motion of a focusing lens to the X-Y motion of the mirror. This allows the focus spot to move freely and smoothly over the part. The next generation of scanner optics will release the focus spot from the working plane. Here’s how users will benefit from this three-dimensional dance.

Volkswagen has already integrated the process into its production lines. Thorge Hammer, who is responsible for technology planning and development, body shop planning, and tool and die operations at Volkswagen, explains that the mirrors in this process manipulate the beam in a circular motion as they guide it along the gap said, “We call this the ‘wobble effect’, and it causes the laser to stir the melt pool, which increases the volume of molten material. As a result, we can now bridge larger gaps than we could before.” It also means that the laser

is even capable of processing components designed for MIG and MAG welding, without the need for modifications. “We weld mounting blocks with gaps of up to 0.5 millimeters,” avers Hammer.

There is no doubt that scanner welding using robot-guided optics has become firmly established in car body manufacturing and is increasingly pushing production engineers towards ever more exciting innovations, but there has always been one major limitation — the Z axis. The scanner mirrors could make the focus spot dance and jump across the workpiece along the X and Y axes. To bring the Z axis into the equation, the only option was to move either the entire scan head or the lens inside the scanner optics.

Now, however, new 3D scanner optics have given the focus spot a whole new freedom of movement. Equipped with a highly dynamic drive unit, the movable lens quickly positions the spot in a precise location on the Z axis without moving the optics. This allows the laser to move around in a third dimension, eliminating the problem of working in different planes and enabling the beam to quickly reach small weld spots in previously inaccessible locations.

Returning to the example at Volkswagen, the company has incorporated this technology in the laser stir welding process it uses to join sub-assemblies for the Golf VII, which are subsequently integrated in a platform. The front seats are held in place on the four seat supports, while the two mounting blocks referred to by Hammer are used to secure the engine and power train. Seat supports are made from deep-drawn, medium-strength sheet steel, 0.7 mm thick. To fix the mounting blocks, Volkswagen welds a 3 mm flow formed sheet into a shell 3 mm thick. “The ability to move in a third

The Dancing Photons

Conventional wisdom states that a gap width of 0.2 millimeters is the upper limit for remote laser welding.

However, Volkswagen has now developed a solution that makes this rule of thumb a thing of the past. Remote welding works by using two mirrors inside the scan head to rapidly focus the laser beam on the workpiece with a high degree of precision. The automaker has taken this method one step further by making the laser beam oscillate, or ‘dance’, along the gap. This new technique is called laser stir welding, and

3D scanner optics add the Z motion of a focusing lens to the X-Y motion of the mirror. This allows the focus spot to move freely and smoothly over the part

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dimension allows us to laser weld components with undercuts,” says Hammer.

Volkswagen uses six remote welding systems equipped with 4,000-watt disk lasers to process the Golf VII sub-assemblies, including the laser welding system for welding on the fly. This is the minimum setup to achieve the cycle time required to turn out 4,500 pieces a day. “The laser has 7.5 seconds to carry out a total of 19 weld seams per part. But at a laser power of 4,000 watts, the robot should not take more than 1.2 seconds to move between two welding spots, professes Hammer.” A newly developed robot-based control system re-calculates the position of the scanner every millisecond and corrects the position as necessary to create the welding structures specified. This new-found freedom of movement means the laser system can also be employed in the passenger compartment. OEM supplier Faurecia uses this process to manufacture its seating products. Remote welding already plays a key role in the company’s production operations — the technique is used to weld the frames for seat backs of the front and rear seats, recliners and seat tracks. The laser beam is used to process the materials in packages 0.7 to 6 mm thick comprising multiple layers. For materials up to four millimeters thick, the laser uses remote welding technology.

Each year, Faurecia uses this technique to manufacture 18 million frames for front and rear seats and 115 million seat recliners and tracks. Geert Verhaeghe, Senior Expert for welding, adds, “There is a clear trend toward lightweight construction — materials that are thin yet stable — and consequently toward high-strength steels.” This material can only be welded using a laser. Faurecia now has more than 20 systems in operation worldwide, equipped with robot-guided and fixed scanner optics, and the third dimension gives them more freedom of movement. “The PFO 3D from Trumpf enlarges the working area without requiring us to move the optics over the workpiece,” says Uwe Viehmann, Joining Technology Manager, Trumpf.

Viehmann added, “The seat backs come in different heights. The PFO 3D programmable focusing optics do a better job with them because we can now position the laser beam in the Z axis using the same dynamic system we use for the X and Y directions.” Verhaeghe already has one eye on the next technological innovation — he wants to use the PFO 3D for welding on the fly. “Some of the components we process are very large, and the

Example of laser-welded joint, smaller and thinner than MAG welding

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LASER TECHNOLOGY


combination of robots and 3D optics would give us an even bigger working area,” he says.

By gradually making a transition from CO₂ to solid-state lasers, the company is gaining important benefits. “Disk lasers are far more efficient — which has helped us significantly reduce our costs,” says Verhaeghe. Optimizing the design of the joints and connections improved the situation for the laser and led to a positive side-effect: laser-welded joints are up to30 times smaller and thinner than their MAG-welded counterparts. That saves resources and cuts down weight: the laser-welded spots take up just 0.6 millimeters of space compared to the 10 millimeters required in resistance spot welding.

Lasers are making their mark deep inside the cars of today and tomorrow, with the vast flexibility of the third dimension finally making it possible to weld housings for high-voltage batteries. Each battery module consists of individual cells in rectangular aluminum enclosures. By the time it reaches the laser processing stage, the battery is already inside the housing and fully charged. That means a laser can only be used if heat input is kept to a minimum and if welding depth is precisely controlled. Penetration would damage the battery, which could have fatal consequences with a battery that is already charged. Spatter is unacceptable and the seam must be fully sealed. Welding performed using TruDisk disk lasers with an output power of between one and five

kilowatts, on battery housings ranging in thickness from 0.8 to 1.5 millimeters, has confirmed that the laser lives up to its promises - the weld seams were fully sealed and the battery sustained no damage.

In addition to welding housings, lasers are finding other novel applications in batteries, including welding thin battery contacts and joining individual battery cells into complete modules. At the moment for battery cells to be changed, the current practice is to screw the modules together but once these teething problems have been ironed out, the laser could become the preferred solution for holding the modules

firmly together. At the moment, these new applications are at an early stage, and manufacturers are only just starting to consider what form of automation would work best in each case. Nowadays, lasers supported by modern scanner optics play a crucial role in the production of car body parts and seating components. The laser is already playing a key part in the development of electro-mobility, and it will continue to help light the way towards ever more cost-effective vehicle production.MMI

“The laser has 7.5 seconds to carry out a total of 19 weld seams per part. But at a laser power of 4,000 watts, the robot should not take more then 1.2 seconds to move between two welding spots.“

Thorge Hammer, Volkswagen

“There is a clear trend toward lightweight construction — materials that are thin yet stable — and consequently toward high-strength steels.“

Geert Verhaeghe, Faurecia

“The PFO 3D from TRUMPF enlarges the working area without requiring us to move the optics over the workpiece.“

Uwe Viehmann, Faurecia

The single-lens reflex principle he camera constantly “looks through” the scanner mirrors to the exact point at which the laser is aimed

X-Y Axis The PFO unit scans the area around the tiny central hole in the sensor. The photodiode detects the maximum power level when the light is beamed precisely into the hole

Z Axis The PFO 3D focuses on the hole and displaces the focus spot along the Z axis. The Z coordinate is determined by measuring the change in laser power

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Courtesy: TRUMPF (India) Pvt Ltd

Makino India Pvt. Ltd www.makinoindia.co.in, [email protected]

Axis Travel (X, Y, Z)

Machine Specification

500 x 400 x 400 mm

Slim3

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Slim3 PC

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Table Size

Pallet Size

Spindle Taper

Spindle Speed Range

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Tool Storage Capacity

Machine Size (H x W x D)

50 - 15,000rpm / 50 - 8000 rpm

11/15kW & 22/28Nm / 7.5/11kW & 31/52Nm

13 tools (Std) / 20 tools (Opt)

3100 x 1280 x 3150 mm 3100 x 1280 x 3575 mm

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A Lean & Compact Machine, ideal forAccurate High Volume Part Production

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Though cloud computing has not remained a novel concept now, it faces a set of problems when it comes to applications. Engineering is one field where cloud computing has a long way to go. Get to know how the solution can take engineering to new heights.

Analysts are united in their assessment that hurdles still exist on the way to widespread use of the cloud in CAD/CAM/CAE/PLM related work. Apart from technology reasons like dependable connectivity, response time, etc., there exist apprehensions related to data and IP security. The analysts are also united on the view that it is only a matter of time before these hurdles are overcome.

Much information is available about the different avatars in which cloud computing can be used. Infrastructure as a Service

(IaaS), Platform as a Service (PaaS) and Software as a Service (SaaS) are the most visible ones. Benefits of cloud computing include the almost limitless capability it offers, its ability to expand and contract computing resources as required, its ubiquitous access and, most importantly, its ‘pay per use’ business model.

Bringing it all together

On the face of it, it seems difficult to bring together cloud computing and CAD/CAM/CAE/PLM applications (referred to as engineering applications subsequently). Following are some of the reasons why this problem exists:

▶ Engineering applications are UI intensive and need to provide real-time graphics response. If applications are run in the cloud, network bandwidth limitations and latency might adversely impact this resulting in sluggish and unacceptable response to the users.

▶ Engineering data is voluminous. Huge data is routinely moved and processed by applications. If applications are moved to the cloud, the time required for moving such data will drastically increase execution time.

▶ In most cloud based applications data needs to cross the enterprise’s boundaries. This is not acceptable to most large enterprises and their contractors.

Taking to cloud based software

Solution providers are innovating in the way they are re-looking engineering applications. As single monolithic installed solutions these may seem unsuitable for

Will the Cloud Ever Cast its Shadow on Engineering?

There is never a day when we don’t get to read or hear about the impact of cloud computing on our daily lives. Frequency

of launching such new kind of technology is also high. However, there is one question that remains to be answered - when will cloud computing really touch ‘engineering’?

Re-looking engineering applications via cloud computing

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Dr. Vinay Kulkarni VP - Innovation & Incubation Cell Geometric Ltd [email protected]

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cloud based implementation, but when they are broken down into their constituent parts, cloud based possibilities bubble up! Some of such examples include:

▶ CAD applications: These are usually bundled with many sub-applications - the editor, analysis, simulation, etc. The editor, which is used to create, visualize and communicate engineering models – including 2D and 3D CAD models - is the most demanding in terms of data movement and UI response times; hence, the most difficult to migrate to the cloud. Analysis and simulation applications, on the other hand, are more amenable to cloud based implementation as explained in subsequent points.

▶ CAE applications: The main part of a CAE application is the solver. It is in the solver that the CAE model is passed through a large number of computations. This is where the cloud can definitely exercise its muscles and speed up the whole process significantly. Processes hitherto ran sequentially due to lack of resources. They can now run in parallel and that too on better and faster cloud based computing infrastructure. Analysis time can potentially reduce from days to hours to minutes, with multiple design parameters being tested in parallel. Unlike the editors, analysis tasks can be launched by transferring only the required data to the cloud; thus, taking care of IP concerns.

▶ Simulation: Like analysis, simulation too is a number crunching activity that can be positively impacted by cloud based implementation. It is no longer difficult to imagine simulation models being run in the cloud, with only the final video streamed back to the user – YouTube style – on whichever device the user prefers to use for watching it!

▶ CAM applications: In terms of workflow these are no different from the CAD/CAE and simulation applications already described. A CAM solution bundles together its own editor, analyzer, CNC code generator, simulation engine and post processor. Barring the editor, all other parts are mainly computational in nature and can be spawned off to the cloud in order to take advantage of all the associated benefits.

▶ PLM applications: These are largely non-graphical applications and we already have many commercial cloud based products announced and available for use. Data and IP protection is the only hurdle in the case of cloud based PLM applications.

Defining suitabilityIt is evident from the above description

that parts of engineering applications are very suitable for running in the cloud. In fact, we will stand to gain immensely in terms of engineering productivity resulting from our ability to: get tasks to execute faster, evaluate multiple engineering decisions in parallel, and enhance our ability to collaborate effectively using cloud based resources. This will shrink overall engineering time and cost.

There are other advantages to using cloud based engineering solutions – both for the users as well as creators of software.▶ Pay-per-use extended to pay-per-module:

When engineering software gets modularized and implemented in the cloud, innovations in business models will follow. The ‘pay-per-use’ model will, in addition, get extended to ‘pay-per-module’. Users will have to pay only for the modules they use, and only for the period they use it. This is unlike the huge license and support fees users currently pay for a software suite – whether or not they use

Witnessing 3D in the browser

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all parts of it. For the software creators, such business models will open up new markets, such as SMBs, thereby increasing overall revenue.

▶ Cloud-based software: By adopting cloud-based software users can save themselves the trouble of installing, and updating software to the latest versions. They are also saved from the trouble of procuring, maintaining and upgrading the expensive hardware usually required to run high-end engineering applications. For the software creators the savings will be in terms of much lower support calls –most of which get generated during software installations –and efforts required to maintain multiple software versions.In my opinion, and considering the trend,

a slew of very compelling and innovative cloud-based engineering solutions are likely to be announced in 2013 and beyond. It will be prudent to embrace these solutions not only because they make business and technical sense, but also to get accustomed early to the rapidly changing nature of software solutions, driven by the cloud. MMI

TURNING CENTER S


Implementing a done-in-one approach to production has to be managed carefully. Reata Engineering and Machine Works seemed to have made all the right moves in what turned out to be a truly transformative experience by adopting Mazak‘s five-axis multitasking machine.

customer looking for contract services that start with a “napkin idea” and take it all the way to aftermarket support.

Grady Cope, President & Founder of Reata Engineering and Machine Works in Colorado, USA, had an opportunity most shop owners don’t enjoy. He recently visited numerous other job shops and contract manufacturing companies. Making these visits was part of his duties as Chairman of the Executive Committee at the National Tooling and Machining Association (NTMA).

“I had a chance to see many very advanced manufacturing operations, and one of the things I noticed was the prevalence of multitasking machine tools at these sites. The

more I saw of these machines, the clearer it became to me that this technology would benefit my own company,” Cope explains. At the time, Reata was largely processing parts by moving them across multiple machines—horizontal and vertical machining centers for milling, turning centers for lathe work, and sometimes a third or fourth type of machine for drilling and tapping or grinding.

These CNC machines were relatively recent models—not a “slouchy” collection of equipment at all. What Cope realized was that Reata was locked into a conventional machining mindset. “We did turning on turning centers and milling on machining centers, pretty much with one milling guy on

Moving to Multitasking

Reata Engineering and Machine Works is a contract manufacturer that distinctly balances its engineering capabilities with

its machining resources. It provides prototypes, tooling, production machining and assembly to industries including aerospace, medical, semiconductor capital equipment, retail, automotive and material handling. The company seeks almost any

Recognizing that square parts could be efficiently produced from round stock was one way the shop changed its thinking about part production after a multitasking machine was in place. For example, this part for the medical industry requires drilling a 5/8-inch hole at an odd angle on each of the four sides. Precise intersection of these holes is easily achieved on the Integrex. Features on the front and back of the part make this an example of true six-sided machining.

Mark AlbertEditor-in-ChiefModern Machine [email protected]

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TURNING CENTER S


This array of parts is representative of some of the earliest workpieces Reata produced on its Integrex. Looking at these parts in a clock-wise direction, the part at “nine o’clock” is the first piece the shop completed on the new machine. With several milling operations, a saw-cut slot and surfacing on the backside, this aluminum medical pump component validated the done-in-one concept that is the essence of multitas-king. It was produced from barstock.

The taller part at “12 o’clock” is also an alu-minum component for a medical pump. Produ-ced from a round aluminum slug, this part has critical features with tolerances of ±0.0003 inch, proving to the shop that precision machi-ning is enhanced by avoiding multiple setups on several machine tools. The ability to produ-ce parts of this size from barstock is Reata’s prime motivation for ordering a second, larger Integrex machine.

The part at “three o’clock,” also a pump component, formerly required substantial four-axis milling on a VMC. Parts such as this de-monstrated that B-axis milling capability is one of the most important strengths of a multitas-king machine. This part is also machined from aluminum.

Sometimes relatively simple parts are candida-tes for multitasking because of their setup effici-ency and processing flexibility. Reata tested this concept with the part at “six o’clock” and verified that including such parts in the mix, made good use of the productivity of the multitasking machi-ne. Since the shop got a taste for multitasking, it has been moving as many jobs to the Integrex as possible. With automation such as the bar feeder and parts receiver, Reata can regularly run this machine unattended at least one shift a day.

Reata‘s earliest workpieces on Integrex

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Result of Multitasking Machine

A machine that makes the shop run “Around the Clock”

one machining center and one turning guy on one turning center. No matter how efficient these operations were or how competent we were at running these machines, though, we inevitably had scheduling issues, too much setup time and repeatability problems with multiple fixturings,” Cope says.

The move to multitaskIt became clear that Reata had to move to multitasking. It was also clear to Cope that making this move would require some fundamental changes throughout his company. “I remember thinking it would change our world, and it did,” he reminiscence’s.

In 2011, the shop installed its first multitasking machine, a five-axis Integrex i-200S from Mazak (Florence, Kentucky). Although introducing multitasking technology involved a steep but manageable learning curve, this approach to part production soon became a boon for the business. Cope reports that parts that once took weeks to move through the shop in

batches of 25 to 50 pieces are now being produced completely in only a couple of hours on the Integrex. The shop can run larger or smaller batch sizes equally well to suit the different needs of customers, whether for a rush job or a standing JIT order.

In addition, completing parts in one setup has eliminated the repeatability issues that delayed production and raised scrap rates. Another key benefit has been the ability to both quote competitively and make a profit on certain complex jobs if it did get the order.

Making the move to multitasking was challenging and strenuous, but the transition went smoothly overall because Reata’s workforce learned some important lessons early on. “We changed our thinking and our habits. It wasn’t always easy, but it made a difference in almost everything we do,” says Rob Volkert, Vice President - Operations, Reata Engineering and Machine Works. Volkert believes other shops considering multitasking can learn from his shop’s experiences. “Buying a more capable machine is a significant capital

decision, but one that has a very rapid return on investment,” he says.

The learning‘s

As capable engineers, Cope and Volkert can analyze their shop’s transition to multitasking and identify the important principles or learning points that contributed to successful adoption of this technology. Here are some of those points and principles, with comments on their meaning and importance from these two top managers.

Buying a multitasking machine is unlike buying any other machine▶ Don’t be put off by the price of the

machine. They consider the Integrex two machines in one and expect it to run at least one shift a day unattended.

▶ Be sure tooling needs and a good postprocessor are addressed early

▶ Get operators and programmers involved in the machine acquisition process so they are comfortable with and confident in the technology. Be sure there’s no fear.

Training is not optional▶ Training is an investment and a

commitment. For Reata size shop, sending two of their best operators for a week of training was a big deal, but it paid off quickly for them.

Finding the right operators ▶ Intelligence, flexibility in thinking and

adaptability are traits to look for in operators assigned to a multitasking machine. Find a quick learner who is not too wedded to either milling or turning.

▶ The skill of the operator makes a multitasking machine more productive. A shop manager has to be confident in both the machine and the operator.

Auxiliary equipment is an essential part▶ The Integrex is equipped with a bar feeder

and a part receiver. The quick load server 80 S2 from LNS (Ohio) is part of the automation that makes unattended operation possible and reliable. Although load part blanks or castings can be manually loaded, they actively look for ways to use the bar feeder by seeing how their squarish parts can fit inside a length of bar stock.

Unattended operations▶ It wasn’t long before the Company were

running the Integrex close to 24/7. Unattended operation is a key part of the profit potential in multitasking.

Little or no turning is required▶ Parts that might normally require

operations on a mill and a lathe are not the only likely candidates for multitasking. Prismatic parts with multiple holes at

T URN IN G CENTERS


lines to the part program. What may have involved an extra setup or a special cutting tool is now just additional seconds of cycle time on a multitasking machine.

A new metric

Cope admits that moving to multitasking changed not only his shop’s mindset about machining parts, but also his outlook on manufacturing in general. For example, he says he was accustomed to sizing up a shop by the number of shopfloor personnel and the number of machine spindles. Now he sees that these numbers do not adequately reflect the productivity or the competitiveness of a manufacturing company. “What really counts is the throughput—how much work can move through the shop,” he says.

He can point to his own shop’s experience with adding its first multitasking machine. After one year, that single machine now accounts for 18 to 20 per cent of annual sales. Most of the shop’s growth in the last year can be attributed to this machine alone. “We’d like to move even more work to that machine, but it’s already fully booked,” Volkert reports.

Reata now has such faith in multitasking that it ordered a second, larger Integrex from Mazak. This machine features a 4-inch spindle bore, so the shop can expect to use barstock for about 90 per cent of the parts that will be produced on this machine, Cope says. “This level of automation and productivity ensures a solid growth path for years to come,” he concludes. MMI

different angles or bores that are off-center can be ideal for the Integrex.

▶ Learning to re-imagine how parts formerly made from square blocks of raw material can be machined from round stock is a key part of the transition to multitasking.

▶ One reason they chose the Integrex was the wide distance between centers. This enabled them to process long parts with flat surfaces milled on multiple sides. Its Y-axis travel is also important for flexibility in parts that largely involve milling. They have 9.8 inches of Y-axis travel and 24 inches of vertical, X-axis travel, including almost five inches below centerline. With these features they can think of the Integrex as a very capable machining center in its own right.

Think six-sided machining for flexibility▶ The shop uses the second turning spindle

primarily for backworking operations. Most of the machining is done at the first spindle using the machine’s B-axis milling head, and then the part is transferred to the second spindle by synchronizing C-axis rotation. This gives them a true six-sided machining capability.

▶ C-axis contouring enables them to machine complex features on both ends of the part. Flipping a part and refixturing it would be the only way to accomplish the same results on a standard machining center.

Get customers involved▶ Designers are becoming more creative in

part designs because they have CAD systems with solid modeling that enable them to conceive and construct complex

part geometry. This complexity becomes a serious challenge manufacturability. The company was able to take on complex jobs that would almost be impossible to produce conventionally because they lend themselves to production on a multitasking machine.One example is adding a radius to a part

feature. With five-axis contouring on the Integrex, machining a well-placed radius is now usually a simple matter of adding a few

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One of the most unusual workpieces Reata produces on its Integrex is this aerospace part made of 7075 aluminum. The shop starts with a section of round stock that is 30 inches long and 7 inches in diameter. This picture shows the extensive milling required to produce the part...

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V. ANBUCEO, Indian Machine Tools Manufactuerers‘ Association (IMTMA)

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Print • Digital • Events • Services No. 1 · January 2013 · Volume 1 · www.modernmanufacturing.in

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BLO CK YO UR D IARY


EVENT CALENDAR

Event Name Contact Date & Venue

India CNC & Tooling Expo

Harish Arora Tel. +91-9814211848www.cnctoolingexpo.com

8 – 10 Feb 2013Gandhi Maidan, Rudrapur, Uttrakhand

MACHINEX Arabia

Tel. + 966 (02) 654 6384 [email protected] www.machinex-arabia.com

18 – 21 Feb 2013 Jeddah Centre, Saudi Arabia

INTER TOOL KIEV Tel. +38 044 496 86 [email protected]/

20 – 22 Feb 2013IEC Kiev, Ukraine

TIMTOS 2013 Tel. +886-2-2725-5200www.timtos.com

5 – 10 March 2013Taipei World Trade Centre, Taiwan

EMAT International

Tel. 91 - 9974 0096 [email protected]

7 – 10 March 2013Autocluster Center, Pune

BLECH India Tel. +91 124 452 [email protected]

17 – 20 April 2013BEC Mumbai, India

CIMT 2013 Tel. [email protected]

22 – 27 April 2013China Int. Exhibition Centre, Beijing

Sheet Metal Asia 2013

Sukanya [email protected]

16 – 19 May 2013BITEC, Bangkok, Thailand

MTT EXPO 2013 Tel. (62) 21 - 7818 [email protected]

22 – 25 May 2013JIExpo Kemayoran

IMTOS 2013 Tel. +91 - 79 - 26469725,[email protected]

4 -7 July 2013Pragati Maidan, New Delhi

ACMEE 2014 Subram Raghavan, Tel. +91-44-26258619, www.tradeindia.com

19 -24 June 2014, Chennai Trade and Convention Center

To suggest an event, please send details to [email protected]

October 9-11, 2013

BLOCK YOUR DATES

EVENT REPORT


India is steadily making its presence felt on the global manufacturing front. Addressing how India can take advantage of the window of opportunity that has opened up as a result of declining cost competitiveness of China, was CII’s 11th edition of its flagship event, the Manufacturing Summit 2012.

Over the past two decades, China‘s manufacturing sector has proven to be a great growth story relying primarily on its strength in the manufacturing sector. Output across sectors like auto, steel, energy have witnessed jumps of 2-5X over the past decade alone in China. Indian manufacturing has grown by a slower amount at around nine per cent over the last decade. Over the last year, the growth has slowed down even more - to less than five per cent. The recent events surrounding China‘s decreasing cost competitiveness due to Yuan appreciation, wage inflation and fall in investments as a percentage of GDP has further opened up a plethora of opportunities for Indian manufacturing firms to capture. However, for India to fully capitalize on this golden

opportunity and propel the economy on a manufacturing led growth, all stakeholders including government and the private sector need to work in conjunction.

India vis-à-vis China

Over the last two decades, labor rate arbitrage was the main driver for off shoring of production to China and provided substantial costs savings of 20–40 per cent, in spite of lower productivity levels. However, since 2009, production worker wages have inflated at almost four times the rate of Indian wages. Add to this the relatively low productivity as compared to the US standards, and China’s competitiveness in low cost labor is clearly eroding. In this regard, Jamshyd N Godrej, Chairman of the Summit and Chairman & Managing Director, Godrej & Boyce Mfg Co Ltd said, “Although the recent performance of the Indian manufacturing sector has been below par, excluding October’s performance from a trajectory of 8–9 per cent, manufacturing GDP growth has slowed down to a y-o-y growth of 2.5 per cent over FY 2010–12 and has almost flattened (0.5 per cent) during the first six months of FY 2012–13.” He emphasized that the challenge now lies in our readiness in developing and enhancing the Indian manufacturing

Throwing Open the Window of Opportunities

The 11th edition of Confederation of Indian Industry’s (CII) flagship event, for the Indian manufacturing sector, the

Manufacturing Summit 2012, was held from 17 - 18 December 2012 in Mumbai. With the theme of the event as ‘Re-igniting India‘s quest for manufacturing leadership’, the Summit explored opportunities that India can now attain thanks to China’s decreasing cost competitiveness due to Yuan appreciation, wage inflation and fall in investments as a percentage of GDP.

Jamshyd N Godrej, Chairman of the Summit and Chairman & MD, Godrej & Boyce Mfg Co Ltd, addressing the summit while Pradeep Bhargava, Chairman, CII WR and Director, Cummins Generator Technologies India Ltd and K Venkataramanan, Chairman, CII National Council on Manufacturing and CEO & MD, Larsen & Toubro Ltd, look on

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EVENT REPORT


ecosystem. “A low cost focus alone will not be able to drive the differentiation, India needs to also focus on developing other sustainable competitive advantages in order to create a footprint on the global manufacturing landscape. The aspiration for India should be to not become Factory to the West, but Germany of the East,” stressed he.

Taking the lead

Addressing the 11th edition of the Summit, Arun Maira, Member, Planning Commission asserted that the manufacturing sector in the country must play a much bigger role in growth and employment than what has been undertaken so far. He mentioned that in order to reach the target of 100 million jobs by 2025 in the manufacturing sector, there must be an increase in depth in manufacturing and also institutional and stakeholder collaboration, coordination, and consultation should be encouraged which would lead to implementation. He further averred, “A single point plan that the country now needs is implementation. We recognize clearly that action is required at the state

level and must therefore work towards fine tuning administration and regulation in the states.” Maira also mentioned that in order to improve the quality of coordination and implementation of the 12th Five Year Plan, they have constituted the Indian Backbone Implementation Network (IBIN). He concluded by emphasizing that the role of the state is only as a ‘facilitator’ to industrial eco-system growth and not the ‘doer’; this is where industry needs to take the lead.

Understanding the BCG report

CII along with their knowledge partner The Boston Consulting Group (BCG), released a report titled “Re-igniting India‘s Quest for Manufacturing Leadership,” against the backdrop of the Summit. The report talks about the rapidly changing global manufacturing landscape, and the emerging window of opportunity for India. The report stresses that to capture this opportunity; India will have to fix the basic enablers of the manufacturing sector, and look beyond low cost advantage. It also states that the country has the right

(L-R) Dr Naushad Forbes and Arun Maira, Member, Planning Commission

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An attentive audience at the summit

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“We at the CII Western Region are undertaking a pilot project to create a good model of industrial relations along with some of the leading manufacturing companies, to improve the current industry-labour relations.“

Pradeep Bhargava, Chairman, CII WR and Director, Cummins Generator Technologies India Ltd

ingredients – a strong talent pool in science and technology, strengthening quality systems—as evidenced by a string of Deming awards (Indian companies have won over 50 per cent of Deming awards since 2003), and a strong intent to invest in technology, R&D and innovation. However, this starting point has to be backed by the right policy support and investment by companies into strengthening their R&D, innovation and quality infrastructure, including aggressively re-branding Indian manufacturing.

The points raised in the report also served as relevant discussion points by the CEOs of manufacturing companies during the Summit. R Gopalakrishan, Director, Tata Sons stated that product innovation is key if we want to become the Germany of the East. He added that frugal innovation is somewhat synonymous with India, especially in the context of product innovation and the ‘jugaad’ culture is uniquely ours. Dr Pawan Goenka, President - Auto and Farm Equipment Segment, Mahindra & Mahindra Ltd mentioned that in order to become the Germany of the East, we would need to focus on premium, quality and precision. “There is space for a country to become the Germany of the East, and there is opportunity for India to occupy this position,” he added.

Regaining the growth trajectory

Having covered topics such as: Indian manufacturing’s competitive advantage, creating the right ecosystem for manufacturing, R&D and innovation, skill development, etc., the Summit hopefully showcased how companies can drive advantage through people development and how by applying the right strategies, India can think of becoming the next manufacturing superpower. MMI

th

Hall: 2B Stall: E107

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EVENT PREV IEW


Indian Machine Tool Manufacturers’ Association hosts its proud twin show – the 16th edition of IMTEX 2013 and 15th edition of Tooltech 2013 from January 24 – 30 at its eco-friendly exhibition center, Bangalore International Exhibition Centre (BIEC). The entire machine tool, cutting tool and accessory fraternity is coming to make it bigger and better.

largest machine tool show ever held in the country. Sharing his views on the machine tool industry, Vikram Sirur, President – Indian Machine Tool Manufacturers’ Association (IMTMA), said, “The current market size of the machine tool industry stands at `1,17,644 million of which the domestic production makes for around 33 per cent of the total consumption. The Indian players have grown rapidly over the last ten years and now have their presence across all the product categories.”

Already recognized as one of the premier events in the world of machine tools, IMTEX has proved to be the largest exhibition of metal-cutting machine tools and manufacturing solutions in South and South-East Asia.

Impressive display

This year’s IMTEX theme of ‘Making India a manufacturing powerhouse’ is creating a huge business opportunity for the stake holders connected with the metal factory. It

A Mega Factory in Operation

Organized in the midst of a very challenging economic environment, IMTEX 2013 is slated to drive new

sectors of machine tool demands to newer heights; expand market opportunities and reach new customers. With every passing year the event has grown from strength to strength. This show is expected to be the

(LtoR) L Krishnan, Vice-President, IMTMA & Managing Director, TaeguTec India, Shailesh Sheth, Chairman –Media, IMTMA, Vikram Sirur, President,IMTMA, V Anbu, CEO & Executive Director, IMTMA, on the dias.

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Swati DeshpandeAssistant [email protected]

EVENT PREV IEW


has tremendous significance at all levels of manufacturing in the organization from CEOs, entrepreneurs, shop floor engineers, supervisors, technicians, senior executives, corporate planners & strategists, manufacturing managers & executives, shop-floor engineers & technicians, agents & dealers and spanning industries.

Spread in a huge exhibition area of 48,000 sq mt in five different halls there are around 1200 exhibits valued at ̀ 1500 crore weighing 6,000 tonne consuming 11 MW power. No doubt it looks like a mega factory in operation! The exhibition is an ultimate facilitator of B2B cooperation between manufacturers and users showcasing exhaustive range of innovations and technological refinements in the complete product segment of metal-cutting machine tools from India as well as all over the world. It also has displays of LIVE technologies in working condition.

Concurrently run with IMTEX 2013, at the same venue Tooltech 2013 features the latest trends in cutting tools, tooling systems, machine tool accessories, metrology & CAD/CAM, etc, from all across globe.

International participation

With the number of exhibitors growing year after year, this edition of IMTEX witnesses the participation of 947exhibitors in IMTEX and Tooltech. The exhibition also has group

participation from nine countries - China, Germany, Italy, Korea, Spain, Taiwan, Czech Republic, Singapore and USA. There are also exhibitors from Australia, Canada, France, Korea, Holland, Turkey, Belgium, Russia, Japan, Thailand, UK at the event.

“Apart from traditional sectors, there will be a galore of visitors from new industry sectors ranging from aerospace, medical engineering, in this IMTEX show.”

V Anbu, CEO & Executive Director,Indian Machine Tool Manufacturers‘ Association

Exhibitors’ profileParticipants at IMTEX cater to various sectors such as turning, drilling, boring, milling machines, gear cutting & finishing machines, screwing & threading machines and planning, shaping, slotting & broaching machines. There are also companies belong to sectors like sawing and cutting-off machines, grinding machines, tool grinding machines, special purpose grinding machine, honing, lapping, polishing & deburring machines, machining centers, etc.

Besides, exhibitors in Tooltech 2013 offer products and services in areas such as sensors and diagnostics, portable electric or pneumatic tools, CAD/CAM - hardware and software, testing and balancing machines, etc.

Special attraction

The special attraction in the upcoming show is the ‘Academia-Industry Pavilion’ where academic/research institutions are invited to present themselves and their particular field of research interest related to the Indian machine tool industry. IMTEX is also an ideal platform for visitors from academia & technical institutions, policy makers, budding engineers, technocrats and industry trade delegations.

Awards

Some of the most prestigious awards such as the fifth IMTMA BFW-Life time achievement award in memory of Late Shri H R Gupta;

“We are encouraging to invest heavily in R&D and innovation to bridge the wide gap between the technologies in the industry. We intend to close technology gaps through joint ventures, mergers and acquisitions.”

Vikram Sirur, President,Indian Machine Tool Manufacturers‘ Association, Chairman, Miven Mayfran Conveyors Pvt Ltd

“IMTEX is a witness on how the Indian machine tool industry is transforming to become more productive, efficient and competitive. It is a complete show of end-to-end solution of manufacturing problems.”

Shailesh Sheth, Chairman –Media Indian Machine Tool Manufacturers‘ Association

“Exhibitions play a vital role in our constant efforts to serve our existing customers, both end-users as well as OEM’s even better. An even more important function of exhibitions is to provide a window to get to know new clients and to learn about their short and long term needs.”

Anders Fager, Managing Director, Seco Tools India Pvt Ltd

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World_Image_210x297_IND_0113.indd 1 14.01.13 08:08

EVENT PREV IEW


the fourth IMTMA Vinod Doshi outstanding entrepreneur award and FIC – Foundation Award are going to be presented to recognize, appreciate and encourage ideas and innovations in the machine tool technology.

Exhibitors’ voices

Talking about his expectations from the show, Shashank Dangi, Manager Marketing, Festo Controls said, “We anticipate visitors, particularly from Western and Southern region, in larger numbers than usual since there is a slowdown being experienced in the industry in general and most of the people would like to utilize this time to keep themselves informed of new technology and products available in the market. The participation from companies abroad is increasing and innovative technologies and products are made available to Indian customers.”

Elaborating on his previous experience with IMTEX, Sambit Pradhan, Business Development Manager, Asia Pacific, Geometric Ltd added, “Our overall experience with IMTEX has been excellent. The visitor levels, in terms of both their quality and quantity, are very high. With its remarkable spirit and drive, IMTEX has been a complete success for us always.”

Tushar Mehendale, Managing Director, ElectroMech Material Handling Systems India is also expecting a good response at IMTEX 2013. Talking about it, he stated, “We certainly hope that there is healthy and

quality footfall at IMTEX this year. We look forward to forging long lasting ties with new clients and strengthening bonds with existing ones.” Furthermore, Anders Fager, Managing Director, Seco Tools India opines, “We have high expectations on this year’s

version of IMTEX. We know that all the important players are exhibiting. So a high attendance is to be expected. We look forward to welcoming all our existing and new clients into our both, to witness the technology being displayed.”

Presenting his expectations from IMTEX, Syed Md Samim, Marketing Manager, Quaker Chemicals, mentioned, “IMTEX is the most efficient and effective platform for a manufacturing company like us to showcase our innovative fluid solutions, cutting edge technologies like ours. It’s a platform to understand the ever changing needs of the customers within the manufacturing industry and across various locations in India. IMTEX presents a wonderful opportunity to take stock of the current capabilities of the Indian machine tool industry, and its attempt to emerge as a global player.”

Make the most of it!

With IMTEX assuming a big role in the manufacturing world, this edition of IMTEX might see a footfall of 110,000 visitors. After all, the entire machine tool fraternity wants to make the most of such unique platform to meet and share information on value-added innovation and technological refinements to optimize productivity, enhance quality, reliability and increase competitiveness to world-class standards. MMI

“We certainly hope that there is healthy and quality footfall at IMTEX this year. We look forward to forging long lasting ties with the new clients and strengthening bonds with existing ones.”

Tushar Mehendale, Managing Director, ElectroMech Material Handling Systems India Pvt Ltd

“At IMTEX, we can have an active presence of machine tool players across the globe, which surely will give us a confidence about the bright future of the machine tool industry. A great flow of potential customers will boost a sentiment in today’s so called uncertain market condition.”

P G Jadeja, Managing Director, Jyoti CNC Automation

“IMTEX attracts customers from all over India and a lot of exhibitors themselves are customers of Festo. Many of our solutions and products can be seen on some of the machines displayed in many other stalls.“

Shashank Dangi, Manager Marketing, Festo Controls Pvt Ltd

“Our overall experience with IMTEX has always been excellent. The visitor levels, in terms of both their quality and quantity, are very high. With its remarkable spirit and drive, the show will be a complete success for us.“

Sambit Pradhan, Business Development Manager, Asia Pacific, Geometric Ltd

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INNOVAT IONS & SOLU T I ONS


Turning Center

Disc Milling Cutter

Defining Performance & Versatility

Air Plasma Solution

EX Series by Jyoti CNC contributes to machine tool by performance and versatility, providing competitiveness to manufacturing companies. The machine is based on a special design concept of traveling column with all axis movements on tool tip and none on table for better dynamics and tool trajectory. It possesses versatility and capacity to carry out the maximum range of jobs within the working envelop with high precision of dynamic positioning with total geometric, mechanical and thermal stability in structural parts. EX 1680 with X/Y/Z (1600/800/800mm) has all axis movement on spindle head and a 20-Tool ATC.▶ Jyoti CNCTel: - +91-2827-287081, www.jyoti.co.inIMTEX 2013: Hall 4 / Booth A102

Powermax105 is Hypertherm’s 105-amp air plasma solution, featuring an ability to comfortably cut 32 mm-thick metals, and to sever metals up to 50 mm-thick. This product has especially been developed for most challenging metal cutting and gouging. Powermax105 is the toughest and most versatile system in its class. Furthermore, it offers flexibility for both manual and

automated cutting and gouging applications.▶ HyperthemTel: +91-44-2834 53 62, www.hypertherm.com

Haas DS-30 Series Y-axis turning centers combine dual-spindle turning with Y axis, C axis, and live tooling to create powerful “done-in-one” machining solutions for any shop. The opposed spindles support fully synchronized turning, and allow on-the-fly part pass-off to reduce cycle times. The machines provide 120 mm of Y-axis travel (±51 mm from the centerline) for off-center milling, drilling, and tapping, and come standard with high-torque live tooling and a servo-driven C axis for versatile 4-axis capability. The machines are available in standard and super speed configurations.

▶ Haas Automation India Pvt LtdTel: +91-22-66098830, www.haascnc.comIMTEX 2013: Hall 3A / Booth A102

Seco recently released its 335.25 disc milling cutter, a version adjustable in width. The cutting width can be adjusted with high precision from 21 to 26 mm with size 14 inserts. Cutters are available from diameter 125 to 315 mm with an optimized chip

space and number of teeth to get a productive and reliable machining operation. All the inserts feature four cutting edges, optimized free cutting geometries and a built-in wiper flat. Together with a complete range of grades and corner radii, this allows the disc cutter to meet all application needs with high productivity at the best cost.▶ Seco Tools IndiaTel: +91-2137-667300, www.secotools.com/inIMTEX 2013: Hall 3C / Booth B101

Tube Polishing Machine Dental CAM System

Grind Master offers automatic centerless belt grinding and finishing machines for belt grinding, bright finishing and satin finishing of round tubes and pipes. The machine has easy

settings to ensure quick change over from one job size to another. The floating belt grinding heads are specially designed to take care of bend and ovality in tubes. Up to 10 heads are offered. Machines are designed for dry grinding as well as wet finishing. A wide range of consumables like abrasive belts, flap wheels, non woven wheels, sisal and cotton buffs can be used in predetermined sequence for achieving the desired finish most economically.▶ Grind Master MachinesTel: +91-240-2374104, www.grindmaster.co.in IMTEX2013: Hall 1 A / Booth B105

DentMILL by Delcam is a 3-, 4- and 5-axis dental Computer Aided Machining (CAM) program for the manufacture of simple and anatomical copings and bridge frameworks, including full crowns, abutments, dental bars, inlays / onlays and implant bridges. It is a completely ‘open’ CAM system based on Delcam’s machining program, PowerMILL and delivers fast, accurate and time-saving performance. This makes it highly automated and reliable dental CAM system. DentMILL uses industry-standard formats to enable easy model sharing and connectivity between other open CAD/CAM systems and CNC machines.▶ Delcam Software IndiaTel: +91-20-30613900 – 39, www.delcam.inIMTEX2013: Hall 3A/ Booth J102



High-feed Milling Cutter

Economical VMCSpindle, Milling & Boring

Measuring DeviceCoroMill 419 by Sandvik Coromant is a new five-edge high-feed milling concept for roughing to semi-finishing, offering high performance in all material groups and with great possibilities for optimization. The new milling cutter is suitable for most applications and industry segments requiring high feed face and profile milling. It is well-suited to machining of components requiring long overhangs and even perfect for

lower-power machines and weak fixtures. Its benefits include high productivity, in applications requiring light cutting action and long tool life, especially in difficult-to-machine materials with an optimization for stainless steel, hardened steel and titanium.▶ Sandvik CoromantTel: +91-20-27104720, www.sandvik.coromant.com IMTEX2013: Hall 3A / Booth B119

Pittler’s latest 3-axis machining center, PV 630 ValueLine, represents an economically viable version for small and medium size production shops as well as machined parts suppliers.Parts with diameters up to 800 mm can be processed on a set-up area of only 6 m². This ensures that this multi-talented machine can be integrated economically into all multiple shift production shops. The result is high quality parts at low per-part costs. In addition to high performance machining of unhardened parts, this machining center also allows precision hard turning, milling, drilling, thread cutting and circular milling. ▶ DVS Sales & Service IndiaTel.: +91-99-60 01 93 88, www.dvs-gruppe.com IMTEX2013: Hall 2B / Booth E105

The Mikromat V Series high precision Vertical Spindle Milling and Boring machine by Mikromat meets most of the critical demands. This machine is also equipped with a 5D milling head, and the 12V-5D and 20V-5D machines are suitable for both pre-processing (prototype machining) and final processing of steel, titanium, cast or light metal. It is used for applications in many different areas, predominately within the aerospace, machine tool branches and precision machine tools and large parts production. ▶ Mikromat GmbhTel: +49 (0) 351 / 2861 0, www.mikromat.net IMTEX 2013: Hall 3A / Booth B109

The IM-6500 Series by Keyence is a new type of measurement device that uses state-of-the-art imaging technology, thus enabling the user to perform reliable measurements in minimum time and with increased accuracy. This measurement concept combines the flexibility of a vision system with the accurate execution of a double telecentric lens. This lens, with a large diameter of 100 mm, captures the complete image of the target element, thus allowing the measurement of all the control points at once. With this technology it becomes possible to capture pixels without image distortion of the component that is placed around the lens circumference. Hence, measurement is neither affected by distortion, nor by the distance. The lens size dictates that parts up to 100mm in diameter can be measured.▶ Keyence IndiaTel: +91-124-469-6669, www.keyence.co.in

CNC – Laser Cutting Machine

The latest generation of CNC machines ECOPlus by Geiss is equipped with a TruCoax laser by Trumpf. This laser cutting machine is particularly suitable for processing of composite materials like GRP or CFRP and thermoplastics. Due to contact-free handling of the parts simpler and less expensive jigs can be used. An extensive post-processing of the edges is completely eliminated in most cases.▶ Geiss AG Tel.: +49 (0) 9569 9221 0, www.geiss-ttt.com

Pre-shaped & Pre-formed Blanks

Tungsten Carbide Metal offers pre-shaped (odd-shaped) and pre-formed (fluted blanks) of step drills, step reamers, cutters & special tools. These blanks are supplied with and without, fluting and internal coolant holes, and are also supplied in raw blank – as sintered condition, semi-finished blank – rough ground

(with grinding allowance). Total finished ground blanks finishing ground to tolerance for the tool manufacturer can directly load on their CNC tool grinding machine saving a lot of time and money.▶ Tungsten Carbide MetalEmail: [email protected]

IN N OVAT IO N S & SO LUT IONS


www.dvs-gruppe.com

Hall 2B , booth E105Bangalore 24. – 30.01.2013

For more information please contact:

PV 630 ValueLine

DVS Sales & Service IndiaTel.: +91 99 60 01 93 88Email: [email protected]

Complete Machining: More than a Lathe Soft turning, hard turning, milling, drilling, grinding, threading, measuring, ....

Cold Forming MachinesThe XK series cold forming machines by MAG is designed for machining involute splines, ring grooves, knurls and threads with diameters up to 120 mm and module 3.0, for example on car and truck drive components or

electric motor components. All models provide for a robust and reliable process, from the XK 2 series, which is suited for high performance forming of smaller parts, up to the XK 8 and XK 12 models, which can be used to machine heavy equipment drive components such as mining truck shafts. The newly developed XK 651 hydraulic-free cold forming machine is characterized by high productivity and energy efficiency. Eliminating hydraulic power for the drives leads to a smaller footprint and reduced energy use as well as more user-friendly operation. Together with its milling and hobbing products, MAG covers the full range of gear manufacturing technologies.▶ MAG India Industrial Automation Systems Pvt Ltd Tel: +91-80-4067 7000, www.mag-ias.com IMTEX 2013: Hall 4 / Booth A108

CAD Integrated SolutionGeometric’s DFMPro is a CAD integrated Design for Manufacturability (DFM) and Design for Assembly (DFA) solution for design. It helps engineers that performs upfront design for manufacturing validation. It provides solution to avoid downstream issues, which impacts cost, quality and product launch time. It comes with pre-configured guidelines and global best practices in the industry for various processes like machining (milling, turning, drilling), injection molding, casting, sheet metal and assembly. By using DFMPro, organizations in automotive, consumer, industrial and high tech sectors have achieved increased productivity, cost savings and improved quality. Customers have reported more than 60 per cent savings in time and more than 15 per cent improvement in overall productivity by deploying DFMPro at early stages of design.▶ Geometric Ltd Tel: +91-22-6705 6500, www.geometricglobal.com IMTEX 2013: Hall 2B / Booth A126



Hardinge produces state-of-the-art collets for the production of capsule bodies and caps in sizes of #00, 0, 1, 2, 3, 4 and 5. Hardened and ground collets assure reliability and long life for the medical and pharmaceutical industries. A polished radius nose on the collet reduces friction and eliminates marking, while allowing to take full

advantage of production capabilities with reduced downtime. Collets are 4-split or 3-split, depending on size.▶ Hardinge IncTel: 800-843-8801, www.hardinge.com

Port Counter Bore Tools

CNC Internal Cylindrical Grinding

Integrated Valve & Actuator Control

Universal builds precision port counter bore tools for the port counter bore holes as per ISO, SAF, ROSAN & other international standards. They can also be custom made. The company offers port counter bore tools in solid carbide, carbide brazed tipped & lugged version with straight shank or taper shank also tools with internal thro coolant or without internal thro coolant as desired. Additionally, the company also offers drill cum port forming counter bore tool to perform operations in one go without any pre-drill, which helps users to save time.▶ Universal Tool Inc Tel: +91-20-46765151, www.universaltool.co.in IMTEX 2013: Hall 3C / Booth D106

This two-axes CNC, compact cylindrical internal grinding machine from Ace Micromatic is ideally suited for precision grinding application of small bores, taper bore, face, stepped bore and small CAM. Its precision antifriction work head with spindle locking arrangement makes it easy to change work holding devices. This machine can be equipped with various type of work holding devices such as hydraulic chuck, universal gear jaw chuck, diaphragm chuck, angular opening face clamping chuck, magnetic chuck, manual chuck etc. as per applications requirement.▶ Ace Micromatic Tel: +91-80-40200555, www.acemicromatic.net IMTEX 203: Hall 1A / Booth A110

Norgren has developed Integrated Valve and Actuator Control (IVAC), an integrated unit, which combines the valve, flow controls, cushioning and sensors in a single actuator package. IVAC is a weight and space optimized actuator, suitable for a range of bore

sizes from 40 to 80 mm, featuring integrated valve and magnetically operated switches for complete actuator control. Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories. Additional advantage of this is cost effectiveness. Because it is easier to install, maintain and replace a single unit, scheduled and unplanned installation, commissioning and maintenance time and costs are reduced.▶ Norgren Tel: +91 120 4089500, www.norgren.com/ivac

PORT HOLE TOOLS

Capsule Collets

Air Microwswitch

Metrol launches Air Microswitch for work-piece seating check and gap detection at IMTEX 2013. It claims to detect gaps up to two micron at one micron repeatability. With the principle of air micrometers, the accuracy of the product at fast response speed is assured. The IP67 protective structure enables the installation inside the machine tools as compared to the conventional externally mounted air sensors. The advantage of internal installation is shortened air piping, which translates into improved response speed and higher accuracy.▶ Metrol Corporation IndiaTel: +91-80-4210 5031, www.metrol.co.jp/en/ IMTEX 2013: Hall 4 / Booth B101

Linear Motor Units

Drake Manufacturing Services with its representatives, VMT Technologies India will display a high accuracy work head and linear motor demonstration unit at IMTEX 2013. The display will feature Drake’s high accuracy work head and the various components of the linear motor platform - linear motor and magnets, rails, and roller cars and 8-million count Heidenhain encoders. Linear motors help users to be away from drive train windup backlash, or lead error due to aging ball screws, couplings, or bearing blocks.▶ Drake ManufacturingTel: +1-330-847-7291 IMTEX2013: Hall 3B / Booth A118

IMPR INT ADVERT ISERS ‘ IN DEX


October 9-11, 2013

IMPRINT

India

EDITORIAL STAFFEditor: Soumi Mitra Tel. +91 (0)22 25644469, [email protected] Editor: Indira Rao Tel. +91 (0)22 25644469, [email protected] Editor: Swati Deshpande Tel. +91 (0)22 25644469, [email protected], Creative & Production: Shanmugam Pillai Tel. +91 (0)22 25644469, [email protected] Manager: Kruti Bharadva Tel. +91 (0)22 25644469, [email protected] Office India: Vogel Business Media India Pvt. Ltd, 32, New Unique Industrial Estate, Dr. R. P. Road, Opp. Jawahar Talkies, Mulund (W), Mumbai - 400080, India. Tel. +91 (0)22 25644469 www.process-india.in

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Advertising rates: At present valid price list No. 1 from 01.11.2012Publisher’s address: Vogel Business Media India Pvt LtdPublishing frequency: 6 times per yearPrinting: Oscar Offset Pvt. Ltd, Navi Mumbai, India.Manuscripts: No liability is accepted for unsolicited manuscripts. They will be returned only if accompanied by sufficient return postage.

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CO-OPERATION PARTNERS:INDIAN MACHINE TOOLS MANUFACTURERS’ ASSOCIATION (IMTMA), BENGALURU, KARNATAKA

Director General: V. AnbuSenior Director: Balasubramanian [email protected]

GARDNER BUSINESS MEDIA, CINCINNATI, USAPublisher: Claude MasChief Editor: Mark Albert [email protected]

PUBLISHERProprietorship and Personally liable partner: Vogel Business Medien Verwaltungs-GmbH, interests held: Max-Planck-Str 7/9, 97082 Wuerzburg, Germany limited partner: Vogel Medien GmbH & Co. KG, Max-Planck-Str 7/9, 97082 Wuerzburg, GermanyCEO Vogel Media Group: Stefan RühlingGroup Editorial-Director/Publisher: Ken FouhySources of supply: Orders can be placed directly with the publisher or with any book store. No claims for the supply of back copies or reimbursement of subscription fees can be entertained for nondelivery of the magazine for reasons beyond the publisher’s control. Cancellation is possible after the minimum subscription period of one year, giving two months notice to the end of a quarter Bank Germany: HypoVereinsbank, Wuerzburg, Germany (BLZ 790 200 76), Kto.-Nr. 326 212 032, IBAN:DE 65 7902 0076 0326 2120 32, SWIFT: HYVEDEMM455.Place of fulfilment and jurisdiction: Wuerzburg, Germany. The editors assume only press law responsibility for contributions bearing the name or signature of the author. Copyright: Vogel Business Media India Pvt. Ltd. subsidiary of Vogel Business Media GmbH & Co KG. All rights reserved. Reprints, digital processing of all kinds and reproduction only by written permis-sion of the publisher. Photocopies of published items are permitted for in-house purposes if each copy is authorized with a revenue stamp of the applicable tariff rate available from the Verwertungsgesellschaft Wort, Abt. Wissenschaft, in D-80336 Munich, Goethestr. 49. ***Any veiws, comments expressed are the sole responsibility of the respective authors, Modern Manufacturing India and Vogel Business Media India and/or Germany and their co-operation partners do not undertake any responsibility, implied or otherwise. Any actions, legal or otherwise, OR causing any form of harm (physical or otherwise) made by permanant, temprory and honarary staff will be their sole responsibluty! The Editor (Soumi Mitra) is responsible for this publication as per provision of the PRB Act 1867.

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ADVERTISERS’ INDEX

ACE Micromatic Group www.acemicromatic.net .......................... 73

Blum Novotest Measuring & Testing Technology www.blum-novotest.com ........................ 89

DMG Mori Seiki India www.dmgmoriselki.com .......................... 49

DVS Sales & Service India www.dvs-gruppe.com .............................. 87

EFD INDUCTION www.efd-induction.com .......................... 41

Emuge India Pvt. Ltd www.emugeindia.com ............................. 79

FESTO www.festo.in ......................................... 77

GDP GmbH www.gdpgmbh.de ................................... 15

GEISS AG www.geiss-ttt.com .................................. 61

GREEN LEAF CORP www.wexper.com .................................... 91

GROB India www.grobgroup.com ................................. 3

HAAS AUTOMATION www.haascnc.com..................................... 5

Hangsterfer’s www.hangsterfers.com ............................ 63

Indo-German Chamber of Commerce www.indo-german.com ........................... 85

JYOTI CNC Automation www.jyoti.co.in ........................................ 43

Korber Schleifring-India www.schleifring.in ................................... 75

Korloy India Tooling www.korloy.com ...................................... 23

MAKINO www.makinaindia.co.in ........................... 65

MASTERCAM www.mastercam.com .............................. 13

MAZAK INDIA www.mazakindia.in ................................. 11

METROL CORPORATION INDIA www.metrolindia.com ............................... 7

MIKROMAT GmbH www.micromat.net .................................... 2

Miven Mayfran www.mivenmayfran.com ......................... 39

MMS www.mmsinfo.in ..................................... 37

REINISHAW INDIA www.renishaw.com ................................. 31

Schunk India www.schunk.com .................................... 81

SECO TOOLS www.secotools.com ................................... 9

Siemens India www.siemens.com ................................... 21

Starrag Group www.starrag.com .................................... 83

TAEGUTEC www.taegutec-india.com ........................ 92

UNIVERSAL ENGINEERING www.universaltool.co.in .......................... 10

USETEC _ HESS Gmbh www.usetec.com ..................................... 51

Wendt India www.wendtindia.com ............................. 69

Seeing Green in Blue - IMTMA

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