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MAHENG/2009/33944 Vol 11 Issue 9 • Pages 52 • Mumbai • ISSN: 2456-7418 February 1, 2020 • Rs. 200 • www.oemupdate.com

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MAHENG/2009/33944 MAHENG/2009/33944 Vol 9 Issue 10 • Pages 60 • Mumbai • ISSN: 2456-7418 Vol 9 Issue 4 • Pages 52 • Mumbai • ISSN: 2456-7418 March 1, 2018 • Rs. 100 • www.oemupdate.com September 1, 2017 • `100 • www.oemupdate.com

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QUICK UPDATE

Maximising efficiency in operations through TRANSDAQ

thenta Technologies, one of the leading intelligent platform providers specialising in Integrated Infrastructure Management business, has released its Next-Generation TRANSDAQ monitoring and control system that can do deep dive integration into the urban transport systems and subsystems from a unified console. TRANSDAQ is a Manager of Managers (MOM), a system that can integrate with the transport and metro rail systems, and one can save the cost of all EMSs and NMSs for all the subsystems for any rail project. This helps in building a unified and security envelope over all the physically accessible locations in a rail project. TRANSDAQ maximises the efficiency in operations and maintenance to optimise costs and deliver high uptime for metro systems and customer service. The system is highly robust and scalable with the capability of working in a distributed environment where a cluster of Athenta appliances will work in a multilayered architecture, assuring availability, reliability, sustainability and efficiency for metro rail infrastructure management. Athenta’s management appliance enables metro administration to integrate its complete infrastructure to deliver tangible business outcomes. This system facilitates effective communication between the disparate subsystems and devices for proactively alerting the operations staff on any performance degradations or changes in operational status. This, in turn, helps in instantly making aware of the cause of the deterioration, so that the equipment or systems

could be changed or repaired or put in maintenance. Gopal Joshi, Director Sales, Athenta Technologies said, “Athenta TRANSDAQ solution is designed to meet the changing demands of the metro rails, and enable the collection, processing, analysis, and reporting of critical data in an actionable format with life-cycle information on assets and resources. TRANSDAQ is an application-based product that performs the infrastructure management for the metro rail and it has now become the preferred telecom-SCADA platform for metro rails in India.” Features • Single management console to manage the entire infrastructure and making sure it is coupled with top-of-the-class security • Inventory management for all electrical and mechanical equipment • Impact analysis of one equipment on another • Quick identification of the faulty equipment and bottleneck to reduce mean time to recovery (MTTR) • Integrated helpdesk and trouble ticketing system with the problem and resolution management • Efficient technology management to ensure optimum productivity of resources — cutting-edge man and machine interface • Intuitive dashboard and visual details on metro rail infrastructure health Athenta TRANSDAQ manages the facility equipment such as radio system, network backbone, PIDS, PAS, HVAC, surveillance, access control, fire safety and security equipment, pumps, etc.

HARTING interface supplies power, data and signals for “metroSNAP“ securely connected. With considerations to the special requirements for mechanical plugging, the power, signals and data begin to flow.

ARTING is taking the next step in the direction of the mobility concepts of tomorrow with the Rinspeed “metroSNAP”. Whether passenger transport or freight logistics, the metroSNAP can be used in a highly versatile manner. The HARTING module helps the driver use the vehicle for a wide range of tasks in a fast, flexible manner. Like its predecessors — the “SNAP” and “microSNAP” — the vehicle is divided into two elements. On one hand, there is the Skateboard that serves as an optimised electric vehicle, and on the other there is the “Pod”, which can be switched out in flexible manner to accommodate different tasks. Communication, signal transmission and the power supply must all work smoothly between these two elements. Connectivity between them is automatically established as soon as the Pod and Skateboard are

HARTING Automotive posts strong growth Rinspeed has relied on HARTING’s reliable solutions in recent years. Both of the past two years have seen Rinspeed go with a Fast-Charging solution from subsidiary HARTING Automotive. HARTING Automotive has long been at home in the automotive supplier industry and recently saw a sharp increase in demand for e-mobility solutions. The company leverages its decades of experience in the field of connection and transmission technology to develop and produce charging equipment for electric and plug-in hybrid vehicles. Successful collaboration between HARTING and Rinspeed Rinspeed and HARTING have been working together successfully since 2016. The MICA®, which garnered HARTING the prestigious HERMES AWARD at the HANNOVER MESSE in April 2016, was integrated into the “Etos” vehicle for autonomous emission and condition monitoring. In 2017, HARTING used its miniMICA — another component from the evolutionary MICA® ecosystem — to support Rinspeed’s “Oasis” car. In 2018, HARTING provided the fast-charging technology for the “SNAP”. Last year, the “microSNAP” was charged using the fast-charging push, with HARTING thereby living up to its ambition to be an innovative driver of technological development. February 2020 n OEM Update

COVER STORY

Leveraging technologies for machine tools manufacturing The Indian machine tools market is growing steadily, and companies are getting ready to boost growth further to make India a centre of manufacturing excellence. Read on about the trends and technologies that will impact the industry this year.

he machine tool market in India has grown in significance over the last few years. With surge in demand from other industries such as automotive, capital goods, aerospace and defence, railways, and others, the sector has become a full-fledged market that is adopting the latest technologies for increased production and productivity and reduced cycle time. Customers want high-quality products quickly that meet their specifications, so companies are now adapting their operations to ensure lower turnaround time and better quality, precision, and safety. As per Gardner’s “World Machine Tool Output Survey 2018”, India stands 8th in consumption and 10th in production of machine tools in a global list of world machine tool consuming and producing countries. Moreover, a recent report by Fortune Business Insights™ estimates the global metal forming machine tools market size to reach $48.67 billion by 2026. With such optimistic figures, it is imperative for machine tool companies in India to seize the opportunities in the market to boost their growth and thereby develop India as a leading supplier and exporter of machine tools that meet international standards. Vikas Ghai, Managing Director, GVK Metalforms Pvt. Ltd. says, “We are looking forward to an increase in localised manufacturing, with better products and raw materials to work with. When there are high-quality resources, people need to put less effort in manufacturing and we can supply better quality products to customers. This will also allow us to use our manpower in developing in R&D rather than reworking and correcting our mistakes. Thus, 8

we manufacturers can produce good-quality products that meet customer specifications in a single attempt.” Technological disruption Technologies like artificial intelligence (AI), industrial automation, IoT, smart factories, and robotics are being increasingly adopted by domestic machine and CNC tool manufacturers to meet competition from both the Indian players as well as global giants. Machine tool companies, being heavily dependent on technologies, need to harness the benefits of the new and modern technologies that are designed to make manufacturing easier and quicker. Vineet Seth, Managing Director – South Asia & Middle East, Mastercam APAC, says, “AI, industrial automation, IoT, smart factories, and robotics are relatively newer technologies and largely depend on the benefits that companies will derive after building a robust and wide (time-related) database of their processes. A large number of industries have already put industrial automation and robotics into practice in the past decade or so, and continue to benefit from the consistency, reliability, and flexibility of these systems. Smart factories are an integration of all the above technologies and integrating them into operations, which help the invested company deliver meaningful results to internal as well as external stakeholders, in a seamless manner. The Indian CNC industry is very progressive in its approach and is known to adopt best practices as well as relevant new technologies quickly. I’m sure that they will continue to grow from strength to strength.” Nilesh Chanchad, Director, Chanchad Machine Tools Company says, “We are now embracing the demands February 2020 n OEM Update

COVER STORY and needs of the new generation by joining hands with technology to make our processes faster. The new generation wants automation and faster production because nowadays procurement of skilled labour and other resources has become very difficult. So, in the Indian market, the scenario is changing. People are moving from old technologies which operated manually to NC machine control units, CNC machine control units, and automation. So there is definitely a good future for automation in the Indian market.” Niraj Seth, President, Amada (India) Private Limited, shares, “IoT is something which people are talking about now. But when one looks at Amada’s development, we were IoT-enabled around eight years ago. Back then, we were already into the concept of virtual prototype simulation system (VPSS). So, all our machines communicate with each other.” According to Vasant B Vibhute, Managing Director, Givi Misure Pvt. Ltd., automation and IoT are in the stage of infancy in India. He explains, “Every company is now wishing to adopt them. They have many advantages, but the technology is very new, so people are afraid to invest heavily. Nonetheless, there are plenty of opportunities that are arising in the Indian industry because of these technologies. They have been developed for the manufacturing sector, and machine tool is an important manufacturing sector. Automation and IoT will help machine tool companies meet customers’ obligations and manufacture products as per their specifications.” Amar Kulkarni, Vice President – Sales, Polyworks India, adds, “Everyone is moving towards Industry 4.0 and IoT because they understand that data has the power and ability through which the management or people can take decisions using that data. Earlier, decisions were taken through one’s expertise that came from experience or judgment, which was more similar to estimation. But now we have data. We have machines that can collect data, and we have software that can take this data, compile it and present it in an easy and convenient format. This is helping manufacturing companies to take faster and more accurate decisions.”

We are dealing with different kinds of materials which are high-tech and demand better technology through better machines as well as better tooling. Niranjan Manjrekar, General Manager – Indian Operations, LVD-Strippit India Pvt. Ltd.

IoT is something which people are talking about now. But when one looks at Amada’s development, we were IoT-enabled around eight years ago. Niraj Seth, President, Amada (India) Private Limited

A large number of industries have already put industrial automation and robotics into practice in the past decade or so, and continue to benefit from the consistency, reliability, and flexibility of these systems. Vineet Seth, Managing Director – South Asia & Middle East, Mastercam APAC

People are moving from old technologies which operated manually to NC machine control units, CNC machine control units, and automation. Nilesh Chanchad, Director, Chanchad Machine Tools Company

Impact of trends in automotive industry on machine tools One of the major industries that contribute to machine tools is the automotive industry. But the recent slowdown in automotive is a cause for concern for certain machine tool manufacturers. Seth says, “Mastercam has customers across diverse domains, including the automotive sector. While we haven’t seen a significant impact in the other domains, sales to automotive OEMs and their supply chain has certainly had a mentionable impact. Having said so, we grew in double digits in 2019 — largely due to projects from 2018 and before, with a lot of machine tools being delivered in 2019 to the automotive sector. With the upcoming BSVI norms and electrification discussions, I find that we are not shy of opportunities in 2020 as well.” AV Srinivasan, CEO, Meiban Engineering Technologies Pvt Ltd, explains, “The present trends in the automotive industry are affecting our business to the extent that

February 2020 n OEM Update

COVER STORY When there are high-quality resources, people need to put less effort in manufacturing and we can supply better quality products to customers. Vikas Ghai, Managing Director, GVK Metalforms Pvt. Ltd.

Everyone is moving towards Industry 4.0 and IoT because they understand that data has the power and ability through which the management or people can take decisions using that data. Amar Kulkarni, Vice President – Sales, Polyworks India

Automation and IoT will help machine tool companies meet customers’ obligations and manufacture products as per their specifications. Vasant B Vibhute, Managing Director, Givi Misure Pvt. Ltd.

The present trends in the automotive industry are affecting our business to the extent that the domestic automotive component manufacturers are still reluctant to invest in machine tools. AV Srinivasan, CEO, Meiban Engineering Technologies Pvt Ltd

the domestic automotive component manufacturers are still reluctant to invest in machine tools. However, we are able to concentrate on companies that are into export business and are manufacturing certain hightechnology products. But nevertheless, the market is certainly subdued right now.” Recent innovations in the CNC and machine tools market New product developments are instrumental in pushing the machine tool industry forward even as certain industries are in a slump. Vasant B Vibhute, Managing Director, Givi Misure Pvt. Ltd. explains, “The Indian market is valued at about Rs 20,000 crore, out of which 60 percent of the market segment is contributed to by imports from Italy, Germany, France, the UK, America, Taiwan, China, Japan, etc. Now, if we want the export market to grow from 40 percent to 60 percent, Indian machine tool manufacturers have to

focus on high-precision machines, high-productivity machines, and high-quality machines. Only if we produce such machines can we cover the gap and boost domestic manufacturing.” Seth tells us, “We have been seeing an increasing trend in investments in multitasking machines. Typically, Turn-Mills, Mill-Turns and Multi-Axis machines with turning capability are what customers are currently procuring. Machine makers are now focusing on the per sq ft utilisation of a machine tool, given escalating real estate rates in certain cities as well as the ability to machine a components on a single station, to the best permissible extent, technically.” Seth elaborates that hybrid-additive and subtractive machines are also what the industry considers “hot” currently. Low-torque high speed milling machines are also finding their place in the market; these are typically focused towards the small part, highprecision die and mould markets. In addition to the above, machine tool controllers are ever advancing. With real-time tool path simulation to advanced geometry control, new age controllers are taking the next step. A new era of growth Niranjan Manjrekar, General Manager – Indian Operations, LVD-Strippit India Pvt. Ltd., says, “The way I see the industry segment-wise, I have seen good growth in aerospace, medical equipment, defence, and infrastructure. The aerospace sector is relatively new and challenging in the present market scenario. We are dealing with different kinds of materials which are high-tech and demand better technology through better machines as well as better tooling. Also, nowadays, people don’t just want machines or tools; they want a solution for a particular part or project. People now are talking more about the functionality or features of a product which were never spoken of before. People know which kind of products is available with what functionality, features, and flexibility. From an end user perspective, there has been a big change. So, machine tooling and automation comes as a complete package now to cater to the changing market needs. Moreover, the demand for good quality machines is going up. So, I am very optimistic for the coming two years.” Srinivasan adds, “In the next three to five years, we want India to grow. We are positive about the next three years at least with regard to the country’s growth.” Seth concludes, “We continue to hold a positive outlook for 2020. We have finished 2019 on a high and would like to carry the same into the new year. Our core strengths are our software and people; we remain committed to make investments in both, to help our customers win.”

February 2020 n OEM Update

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INDUSTRY ANALYSIS

Transforming Indian welding industry with digitalisation The third CII Conference on Welding Technology 2019 discussed upcoming technologies and trends in the welding industry, with a focus on digital transformation as the key solution to the industry’s challenges. need to also adapt to the changing times and improve their welding manufacturing processes to enhance product quality and cost competitiveness. This can be achieved through emerging technological innovations such as digitalisation, IoT, automation and artificial intelligence (AI). However, to save on costs in the short term, they do not invest in manufacturing excellence, leading to losses and stagnation in the long run. Satish Bhat, Conference Chairman and Managing Director, Ador Welding Limited, said, “A recent survey by the National Association of Manufacturers, wherein about 500 manufacturers participated, revealed that 65 percent of the leaders of these organisations plan to increase capital injection in digitalisation of their plants in the next few years. According to experts, most manufacturers will be looking to revamp their production facilities in order to cater to the demands of today’s advanced and demanding digital world.”

he 3rd edition of the Confederation of Indian Industry’s Conference on Welding Technology 2019 was recently organised by CII Naoroji Godrej Centre of Manufacturing Excellence in Mumbai, where manufacturers, users, researchers, and educators in the welding industry shed light on the latest trends, technological innovations, challenges, and solutions in the industry. Several sessions were organised such as “Digital Transformation and Advanced Manufacturing/ Welding Process Technology”, “Strategies and Plans for making ‘Make in India’ Successful: The Welding Perspectives”, “Latest Advancements in Welding Technology: New Challenges and Opportunities”, “How Safe is your Welding?”, and “Future of Additive Manufacturing and Welding”. Need for MSMEs to adopt digitalisation Eminent industry leaders shared their views and experiences on how companies can think, adopt and improve welding manufacturing processes and that too in the Indian context, which has become increasingly crucial. One of the subjects discussed was how MSMEs

If the industry does not adopt digitalisation and industrial automation, it will soon find itself stagnant and lagging behind. Anil Parab, Executive Vice President – Heavy Engineering and Nuclear, Larsen & Toubro Limited

He added that Industry 4.0 or smart manufacturing is the key to help manufacturers transform from mass production to customised production via a digital supply network to adopt the ever changing needs of customers. Digital transformation helps accelerate manufacturing while addressing inadequacies in the current situation by amalgamating traditional manufacturing processes with new advanced technologies. This industrial revolution will transform manufacturing and reshape businesses, creating greater efficiency and better relationships between the producer, supplier, and customer. By adopting smart and advanced technologies, companies can increase productivity, attack inefficiencies, and promote sustainability. Simply put, advanced manufacturing can increase production throughput, performance and uptime, while simultaneously reducing operating capital and overhead costs. Smart manufacturing is not limited to production only. It is a mixture of digital transformation in product development, the entire supply chain and customer experiences, powered by enabling real-time data-based decision making across all business operations. With

We need to start our digital transformation journey now in order to cope with the challenges that Industry 4.0 will throw at us. Alakesh Roy, Vice Chairman, CII Pune Zonal Council and Managing Director, Zamil Steel India

February 2020 n OEM Update

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INDUSTRY ANALYSIS Digitalisation, automation and networking are now the dominant trends in industrial production and development, which is usually referred to as Industry 4.0. Satish Bhat, Conference Chairman and Managing Director, Ador Welding Limited

If the manufacturing sector has to grow beyond 15 per cent share (in GDP), then the role of welding technology, which is the backbone of manufacturing process, is very important. GK Pillai, Managing Director and CEO, Walchandnagar Industries Ltd.

technologies and functional upgradation, it is equally important to provide the highest quality products when the customer is ready to pay for them. Digitalisation in manufacturing facilities introduces rigorous quality management and control, thereby helping manufacturers to build their products. Bhat stated further, “The future is at our doorstep. Digital transformation is our need and it gives MSMEs the opportunity to develop their own smart manufacturing facilities to ensure better customer service, employee engagement and a collaborative approach with suppliers. Digitalisation, automation and networking are now the dominant trends in industrial production and development, which is usually referred to as Industry 4.0.”

are ready for this transformation, as part of assessing their preparedness for global competition,” Pillai said. Adding that India should have been an automatic choice for those US and European companies leaving China of late, Pillai explained, “India could not attract those global manufacturers due to low productivity. We have to bridge this skill gap on a war footing.” To achieve this, he proposed expanding the reach of the Welding Research Institute either through branches or new institutions. He also stated that if Indian has to grow, rebrand and attract investors, focusing on welding technologies and processes is vital. Anil Parab, Executive Vice President – Heavy Engineering and Nuclear, Larsen & Toubro Limited, stated that today, the manufacturing and delivery models are changing and competition is coming from unknown waters. So if the industry does not adopt digitalisation and industrial automation, it will soon find itself stagnant and lagging behind. Predictive maintenance, too, is very important, and digitalisation helps provide data for it. He added that India, which was at the 10th position in 2010 in manufacturing technology advancement, has been progressing steadily to reach the fifth position by this year. Expressing hope that India would reach the fifth position globally in advancement of manufacturing processes, he said, “I have no doubt about that. We are competing with the best of best in the world on merits. But your mindset has to be completely different. You have to be world-class; only then you will be able to achieve this.” He further explained that countries like the US and Germany, despite their highcost structures, are in the top five globally in terms of manufacturing excellence due to intelligent manufacturing, digitalisation, Industry 4.0, and advanced robotics.

Increased role of welding in manufacturing GK Pillai, Managing Director and CEO, Walchandnagar Industries Ltd. said, “India requires almost about 10 lakh welders by 2022. At a time when dearth of jobs is being debated in the economy, it provides immense opportunity for creating jobs. We need skill enhancement for those working on welding technology, by sourcing workers from lower rung towns and cities, so we can create a lot of employment opportunities. India has to be rebranded as the centre of manufacturing excellence. And if the manufacturing sector has to grow beyond 15 per cent share (in GDP), then the role of welding technology, which is the backbone of manufacturing process, is very important. It should play a greater role in improving industry’s march towards $5-trillion economy, along with digital technologies.”

Alakesh Roy, Vice Chairman, CII Pune Zonal Council and Managing Director, Zamil Steel India, warned the manufacturing sector players to guard against the rapid technological changes that the industry is likely to face in the years to come, and that they should try to be relevant. With industry requirements changing constantly, welding processes and even the industry outlook towards welding must change. Welding technology, too, will see a huge challenge in terms of alternate materials. He explained, “The welding industry has to keep an eye on the new, disruptive technologies that are coming up and that will actually hit us in the near future. We need to start our digital transformation journey now in order to cope with the challenges that Industry 4.0 will throw at us.” Some of the new technologies he cited were 3D printing technologies, self-healing textiles, new delivery models, threat for metals from plastics and polycarbonate and atomic welding.

The government is planning to take the share of manufacturing sector from the present level of about 14-15 per cent to 25 per cent in a few years in order to take the economy to the $5-trillion level by 2024. “Only one percent of the industries in India have embraced Industry 4.0, which calls for adoption of advanced technologies like automation, robotics, IoT, and data analytics. MSMEs should check if they

With so many welding technologies and innovations disrupting the way manufacturing businesses function, it is evident that companies need to quickly adapt and transform their processes and thinking to meet the ever evolving needs of customers and face global competition effectively. By doing this, they will well be on their way to growth and sustainability and position themselves for long-term success. February 2020 n OEM Update

SPEAK OUT

Prioritising health, safety, and environmental management across industries We run NEBOSH training courses as one of their few “Gold Learning Partners”, as well as our own Level 3 and Level 6 qualifications in Health and Safety. Mike Robinson, Chief Executive, British Safety Council

ike Robinson, Chief Executive, British Safety Council, explains that British Safety Council is a charity and membership organisation providing advice on health, safety, and environmental management. He also elaborates on levels of safety and how industries need to implement them for better workability. Can you talk about British Safety Council and your work around the globe? The British Safety Council is a charity and membership organisation providing expert advice on health, safety, and environmental management. Our vision is that no one should be injured or made ill through their work and our mission is to keep people as safe as practicably possible in their work, through education and guidance. We have over 5,000 corporate members based in over 60 countries. Because we work with organisations around the world and across all sectors to help them create healthier and safer workplaces, we understand local cultures, practices, and regulations. The geographic and cultural experience of our expert staff means that we can share the latest international best practice with our members and clients in India. The British Safety Council has been working with members in India for over 30 years, providing consultancy, training, and audits. In November 2017, we opened an office in Mumbai to increase our capacity to support our members in India, with products tailored to the local market, and to expand our campaigns and charitable activities there. A key focus of our work in India is raising awareness of the importance of managing health and safety risks in the workplace, where large sections of the workforce are not covered by health and safety regulations. In November 2018, the British Safety Council launched the India Safety Leadership Group, a forum for its members in India to share best practice and expertise. We run workshops and webinars and provide training. 16

How do you see the acceptance of health and safety at work in construction and manufacturing in India? Construction and manufacturing are labour-intensive the world over and the same principles apply in India as everywhere else. We are seeing more organisations in India wanting to improve their health and safety standards. Last month, the British Safety Council hosted the Sword of Honour and Globe of Honour awards in London — the most prestigious health and safety awards for those that have reached the pinnacle of health, safety, and environmental management. Forty-one companies from India won the Sword of Honour and the recipient of the highest numbers of Swords of Honour in 2018 and 2019 was the Indian real estate developer DLF (winning 11 awards in 2018 and 13 this year). We recognise that there are challenges — the number of deaths in the construction industry in India remains far too high — but we are focused on working with a growing number of organisations in India. Although there is much more to be done, workplace health and safety in India is improving. How can occupational safety be improved in factories in India? I would encourage any organisation in India to undertake an audit of their health and safety — specifically the British Safety Council Five Star Audit. And for those starting on this journey of improving standards to achieve a five-star rating, we offer a pre-audit or “gap audit”. This provides a gap analysis for identifying the steps to be taken before an organisation is likely to achieve a five-star outcome. Education and training are also essential to improving health and safety standards. We run NEBOSH training courses as one of their few “Gold Learning Partners”, as well as our own Level 3 and Level 6 qualifications in Health and Safety. How does the British Safety Council implement OHSAS 18001: 2007 Occupational Health and Safety Management Certification? OHSAS 18001: 2007 will be withdrawn in March 2021 and organisations are now moving to the new standard ISO 45001: 2018. Most of our members have already started making this change and are migrating to the new standard. The British Safety Council Five Star audit closely matches, but goes significantly beyond, the requirements of ISO 45001. We promote the adoption of health and safety standards, including the new international standard ISO 45001 through our networks, such as the India Safety Leadership Group, providing speakers at conferences, workshops and training and encouraging participation in our campaigns. Through our consultancy and audits, we support organisations to meet the very highest standards. February 2020 n OEM Update

orks:

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That’s how it works:

Placing The operator freely positions the tacked workpiece on the robot working station.

Scanning

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The scanner mounted at a linear track scans the working surface of the robot system and saves the result.

Efficient welding with minimum programming effort with CLOOS

Scanning The scanner mounted at a linear track scans the working surface of the robot system and saves the result.

IRPS Instant Robot Programming System Visualising Do you wish to weld the smallest batch The IRPS converts the saved scanner data into sizes efficiently andFrom through automation? a 3D model. the comparison of the 3D with the geometry saved Particularlymodel in steel andcomponent metal construction, in the IRPS the welding program is generated the programming automated automatically.effort Then the for IRPS sends the all welding ofcompletely small generated batch program sizes including is often welding data to the robot controller. disproportionally high. Use the IRPS Instant Robot Programming System to create programmesWelding for automated welding in a short time.TheSooperator the starts automated welding viawelding a button atof the screen. size 1 pays off now. workpieces IRPS in batch

3. 4.

Overview of the IRPS benefits: Minimum programming effort • Enormous time saving • Increase of the system efficiency • CAD workplace not necessary Weld your way. Recognising position and tolerances of the workpiece • Excellent weld quality

Visualising The IRPS converts the saved scanner data into a 3D model. From the comparison of the 3D model with the component geometry saved in the IRPS the welding program is generated automatically. Then the IRPS sends the completely generated program including all welding data to the robot controller.

That’s how it works:

1. 4.

•

Placing

The operator freely positions the tacked

Time workpiece saving onasthere-teaching is not robot working station. Welding necessary The operator starts welding via a button at the Reduction/absence IRPS screen. of the clamping device • Reducing the investment costs • Minimising of non-productive times Shortening of planning times • Just-in-time production Scanning • Reduced personnel material The scanner mounted at and a linear track scans the working surface of the robot system and binding saves the result. • Quick delivery periods Weld your way. Intuitive operation • Flexible use of personnel and minimum training expenditure • Knowledge of robot programming and Visualising welding not necessary IRPS converts the saved scanner data into Check and The change a 3D model. From the comparison of the 3D • With model the with IRPS functions, you can the component geometry saved in the IRPS the welding is generated >3 process the generated program 3D data of the automatically. Then the IRPS sends the workpiece on the screen simply and completely generated program including all welding data to the robot controller. intuitively:

• • • • •

Weld length Weld direction Welding order Angle and distance of the torch to the weld Changes of the welding parameters

2. 3.

• • •

Set tack points Insert tactile 2D search runs Create paths for multi-layer welding

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February 2020 n OEM Update

Speak Out

Redefine welding with Industry 4.0 We want to drive the word welding by changing it to a term called “joining technologies”, which will further strike the millennial generation and open gateways for new developments. Vishwanath V Kamath, Managing Director, Fronius India Private Limited

ishwanath V Kamath, Managing Director, Fronius India Private Limited, in an interaction with Megha Iyer of OEM Update, talks about how trending technologies and Industry 4.0 is transforming the welding sector by creating a substantial benchmark for finished outputs. What is your focus area currently? Our focus now is neither on products nor technology; we are in fact more focused on enhancing and improvising our customer’s experience. And for the same, we are taking measures to minimise the welding cost for our customers so that they become more competitive in terms of cost and become quality-conscious and also they can have value-for-money products. What kind of products have you added in your basket for IMTEX 2020? This edition of IMTEX has been quite good for us. We have been able to attract more customers this time and have been busy throughout the event. We have launched industry 4.0 in action, welding simulator - version 2.0 with the virtual glass which is easy to operate and easy in application, especially for training welders. Further, we have launched the “twin wire system”, which is basically a high-end and high-deposition welding process. We also launched our professional welding tool machine that can perform all the three process of SMAW welding, Mig welding, and Tig Welding by a single machine. We have introduced a new process called ‘ArcTig Welding’ where customers can weld and join two metals without using any filler wire of up to 8-10 mm thickness.

can be a game changer for the Indian industry. It’s a known fact that the industries and the welding sector are interdependent on each other and they complement each other to a great extent. So, I think it’s mutually inclusive and we should see a very good growth when this investment is realised for at least the next few years. What are the major hurdles faced by the sector? There are quite a lot of challenges in this sector. It’s evident that welding is one of the most non-glamorous sectors to gain the customer’s attention. But the point remains that an industry will remain incomplete without welding, as it is one of the most critical and crucial processes in any industry. The sector remains untold only because people are unwilling to enter it and understand it as they’re not projecting welding as a well-paid career for engineers. Fronius is not only talking about welding, but we are attempting to convert this into joining technologies. So, we want to drive the word welding to the word “joining technologies” to make it more attractive to the millennial generation. The second problem which we are facing is lack of skilled manpower and this is definitely point number two. If point number one is addressed, then point number two can be addressed much faster. What are your views on increasing localised manufacturing in India? There is nothing called local manufacturing in today’s world; we are living in a global village. Today you get food or material from any part of the world online, and just to remain in competition, nobody can start their own food joint in their locality believing that they can beat the market. Looking at the evolving trends across the industry, it won’t be right to pretend or perceive that

The government has announced an investment of ₹100 lakh crore for infrastructural development. How can welding reap its benefits? The government’s call for these investments is basically in the infrastructural segment, which is very good news for welding industry. To be more precise, you cannot move the planet without having people or technology to do it, and for that you require welding as the whole process will be accomplished only by welding. So, this is an exciting announcement for us and I feel that this 18

February 2020 n OEM Update

Speak Out being physically available will help gain the momentum. Those were the days when we required complementing productive environment, so there is no question of local. It’s a global village as far as my point of view is concerned. And that’s exactly why industry 4.0 comes into picture. Industry 4.0 is basically the data of production and manufacturing right on your fingertips, so that you can track the activities and realise what’s appropriate and what is not, and take corrective measures for the same, which can let you do predictive maintenance. Today at Fronius, we can see industry 4.0 in action. All our machines which we have are connected and I know exactly how much it costs me to run my machines in a day, in terms of energy, gas and water consumption; everything is recorded. I know how much it costs on day one, day two and so on. So that is the kind of precise control I’m having. We displayed Industry 4.0 in action, with what my Austrian factory is fabricating being shown live in the interactive session at IMTEX 2020. So this is what we call as industry 4.0 in action. We don’t just talk; we are walking too! In what ways can laser hybrid technology enhance the efficiency of the welding process? As we know, laser is a more focused art and laser welding and laser hybrid welding are two different processes. Laser hybrid calls for a separate filler metal, which is fed into the laser molten booth. We have a system which works together and we work with all the laser operators in the world. With this, you can increase the speed and productivity and reduce the heat-affected zone. You can weld a difficult material with a faster turnout. So I think this can be a good process, but the Indian industry is definitely not ready for this. It will take time. We have few systems already installed in the automotive industry; Volkswagen has our system. One more customer recently bought a system from us to make tailored blanks with laser hybrid system. There are a few systems already in the research process in the IITs. But to get into the production, I don’t see that happening in the next two to three years. It will take some more time. With growing application of technologies like AI and robotics, what kind of growth opportunities do you perceive in the near future? We are already one of the world’s largest robot consumers. We are already among the top 10 nations, and I think the sector has achieved this growth in the recent three years. Following the unavailability of skilled manpower, most of the robotics OEMs are fully equipped with orders. So, the sector will definitely be driven by automation also. But let’s understand the fact that automation is not the only solution that you can get. Being aware, attaining precise and brief knowledge, and most significantly understanding the requirement and adapting the same are also important. So, we will definitely have very good growth in automation. We are growing quite well in robotics process and automation. We hope that the sector will be encouraged a lot more with initiatives like Make in India and other huge investment opportunities and investments paved by the government. What are your projections or business plans for next three years? Last IMTEX, we only had a 36-square-metre stall; this year we had a stall of 140 square metres, and maybe in IMTEX 2022, we will have a stall of 200 square metres or more. I’m very confident that welding will grow if you give value for money to customers. I don’t think growth should be a problem. Even though the market has certain challenges today, we are quite bullish. February 2020 n OEM Update

IMTEX 2020

IMTEX 2020 showcases technological innovations and advancements IMTEX 2020, organised and managed by the Indian Machine Tool Manufacturerâ&#x20AC;&#x2122;s Association, saw a huge participation from exhibitors and visitors. Participants appraise the aggregated response throughout the event.

Anil Kumar, Director, Angel India Cad Cam Pvt. Ltd.

IMTEX 2020 has been a great show for us as we launched professional tube-cutting machines, one of our unique products for the industry. Moreover, this creates opportunities for customer engagements to enhance their experience, and with technologies like laser cutting, automation and robotics taking over technology, we can transform the entire industrial outlook. Though the industry is huge for both 2D cutting and tube cutting, the trends are inclined towards tube cutting. With people moving towards automation, I think India can become one of the tech-oriented industries.

Vikas Ghai, Managing Director, GVK Metalforms Pvt. Ltd

We aim at creating awareness among the customers on the available and upcoming trends and technologies in the industry and our latest product launches for sheet metal industry. We are willing to develop or provide solutions and technologies to ease the sheet metal manufacturing process through AI and robotics. With evolution of technologies for the manufacturing industry, we perceive a huge market in the coming years. However, the root will remain the raw material quality with intense R&D for precision manufacturing. I believe if technology and manpower join hands, we would be able to generate quality production in future. Moreover, I desire to train people as much as I can, and create more entrepreneurs in the near

Swapnil Sansare, CEO, Divide By Zero Technologies

Being involved into 3D polymer printing, we are more focused on sheet metal forming in this IMTEX and we have developed various forming tools using 3D polymer printing. The development came as an attempt to reduce the delivery time from 15-20 days to overnight. We had booked 4,000 business cards which we exhausted before the event concluded. We are looking for newer technologies as laser is already trending in the industry. Moreover, we are working closely with SMEs to understand their requirement and cater suitable applications by visiting their shop floors and ease their process.

Niranjan Manjrekar, General Manager, Indian Operations, LVD-Strippet India Pvt. Ltd

The event has been good for us so far. Being a sheet metal solution provider, I think the industry is experiencing good growth in segments like aerospace, medical equipment, defence, and infrastructure, among others. The industry has become automated in providing integrated solutions like laser cutting and punching solutions, among others, and with the same trends, we see the demand for good machines going up. So, I am very optimistic for these coming years as today people are talking more about the functionality and features which was never spoke about before. So, we are expecting to gain more momentum in the coming three years.

February 2020 n OEM Update

IMTEX 2020

Kishlay Dubey, National Sales Manager, Vaccum Automation Solutions, Schmalz India

We have showcased products for our two verticals at IMTEX. We have a component vertical called vacuum automation. We are involved more in vacuum automation and have a range of suction cups, manufactured mostly in India; most of them we are manufacturing here in India. All our products are designed with double safety. There are many products which we have already introduced into the market, but the whole idea was to bring new products along with the existing ones under one umbrella and showcase our progress to our consumers as well. So we are prepared to welcome the latest market trends and meet customer requirements.

Nilesh Chanchad, Director, Chanchad Machine Tools Company

IMTEX 2020 was great for us. Compared to the last edition, this year’s expo gave us a very good response for our business. We enjoyed good success at the event as we got a lot of customer footfall and visibility. We are very happy with the event. At IMTEX 2020, we showcased our Server Hybrid machines which come with 11 axes in total. Apart from that, we had presented four more machines including our plate rolling machines, iron worker machines, profile bending machines and mechanical sharing machines. For the first time we have introduced small machines at IMTEX, as we understand that the market size is huge in India. Durma as a brand in India definitely has a good future for the next five years. So we feel that there is a big possibility in the domestic market even for small machines. Apart from automation and high-technology products, we have a good opportunity for these kinds of machines as well. We feel that there is a good opportunity for the next five years in the Indian market for sheet metal fabrication.

February 2020 n OEM Update

Niraj Seth, President, Amada (India) Pvt. Ltd.

The event was overall good for us. This IMTEX have launched a fibre laser machine, “Ensis 3015 AJ” 9kW, which can control the beam diameter and beam collimation. It’s a fibre laser cutting machine and the first of its kind in the world to have these two functions. Talking about trends, India is just starting to develop in terms of sheet metal. So, we still have a long way to go and almost everything is now being converted into sheet metal, and then sheet metal from bio-suit end to stainless steel. So, this kind of technology really helps to boost manufacturers over here and will help these manufacturers to operate in international markets. So, they will be able to export their products in a much more competitive manner as compared to before and the running costs will reduce greatly.

Rakesh Agarwal, Managing Director, Laser Technologies Pvt. Ltd.

The exhibition was well-organised and managed as always. We received 20 percent more business than last year. The response was also excellent. We even got a good stall location, so we enjoyed a good presence at the exhibition. We mainly work in the machine tool industry, in which we are more into metal forming and metal cutting. Other than metal scale and metal cutting, we also have non-machine tool obligations. We have launched machines with the HSE x controller, which is a fourth-generation machine with the latest features, along with a diamond repair laser welding machine specifically for the Indian market. Talking about future market trends, I think automation and IoT are in the stage of infancy in India. Every company is now wishing to adopt them. Nonetheless, there are plenty of opportunities that are arising in the Indian industry because of these technologies.

automotive

Airplane part manufacturing gets compact with carbon nanotube Aerospace-grade composites can now be produced with carbon nanotube film, eliminating the need for huge ovens or autoclaves. weakness in a composite,” Wardle says. “An autoclave can push those voids to the edges and get rid of them.” Straw pressure Part of Wardle’s work focuses on developing nanoporous networks — ultrathin films made from aligned, microscopic material such as carbon nanotubes, that can be engineered with exceptional properties, including colour, strength, and electrical capacity. The researchers wondered whether these nanoporous films could be used in place of giant autoclaves to squeeze out voids between two material layers, as unlikely as that may seem.

modern airplane’s fuselage is made from multiple sheets of different composite materials, like the many layers in a phyllo-dough pastry. Once these layers are stacked and moulded into the shape of a fuselage, the structures are wheeled into warehousesized ovens and autoclaves, where the layers fuse together to form a resilient, aerodynamic shell. Now, MIT engineers have developed a method to produce aerospace-grade composites without the enormous ovens and pressure vessels. The technique may help to speed up the manufacturing of airplanes and other large, high-performance composite structures, such as blades for wind turbines. Out of the oven, into a blanket In 2015, Lee led the team, along with another member of Wardle’s lab, in creating a method to make aerospace-grade composites without requiring an oven to fuse the materials together. Instead of placing layers of material inside an oven to cure, the researchers essentially wrapped them in an ultrathin film of carbon nanotubes (CNTs). When they applied an electric current to the film, the CNTs, like a nanoscale electric blanket, quickly generated heat, causing the materials within to cure and fuse together. With this out-of-oven or OoO technique, the team was able to produce composites as strong as the materials made in conventional airplane manufacturing ovens, using only 1 percent of the energy. The researchers next looked for ways to make highperformance composites without the use of large, high-pressure autoclaves. “There’s microscopic surface roughness on each ply of a material, and when you put two plies together, air gets trapped between the rough areas, which is the primary source of voids and

A thin film of carbon nanotubes is somewhat like a dense forest of trees, and the spaces between the trees can function like thin nanoscale tubes, or capillaries. A capillary such as a straw can generate pressure based on its geometry and its surface energy, or the material’s ability to attract liquids or other materials. The researchers proposed that if a thin film of carbon nanotubes were sandwiched between two materials, then, as the materials were heated and softened, the capillaries between the carbon nanotubes should have a surface energy and geometry such that they would draw the materials in toward each other, rather than leaving a void between them. Lee calculated that the capillary pressure should be larger than the pressure applied by the autoclaves. The researchers tested their idea in the lab by growing films of vertically aligned carbon nanotubes using a technique they previously developed, and then laying the films between layers of materials that are typically used in the autoclave-based manufacturing of primary aircraft structures. They wrapped the layers in a second film of carbon nanotubes, which they applied an electric current to heat it up. They observed that as the materials heated and softened in response, they were pulled into the capillaries of the intermediate CNT film. The resulting composite lacked voids, similar to aerospacegrade composites that are produced in an autoclave. The researchers subjected the composites to strength tests. “In these tests, we found that our out-of-autoclave composite was just as strong as the gold-standard autoclave process composite used for primary aerospace structures,” Wardle says. The team will next look for ways to scale up the pressure-generating CNT film. For more detail, contact: Jennifer Chu, MIT News Office http://news.mit.edu/ February 2020 n OEM Update

BRAND REPORT

Energy supply system now easily configured online Automatic interior separation and service life calculation An interior separation configurator is used in the online expert. It uses artificial intelligence or neural networks to determine the appropriate interior separation for the defined cable pool within seconds. Thanks to an integrated service life calculation, both for the energy chain and the individual cables, the customer can quickly and easily choose the most cost-effective system which safely meets their requirements. Another advantage: the intelligent tool constantly checks the configuration for plausibility, so the user can be sure the elements are coordinated.

ew igus online tool enables a quick configuration of harnessed energy chain system. Quick and easy configuration of complete energy supply systems are now ensured by the igus e-chain expert. With the newly developed online tool, users can design their own guaranteed ready-to-connect energy chain system, in just a few steps. The quick way to a ready-to-connect energy chain is made even easier with the igus e-chain expert. With the aid of the new free-ofcharge and freely accessible online tool, users can design their energy chain system using a smartphone, tablet or a desktop computer. Be it an unsupported, gliding or hanging application, the configurator determines the energy chain that is optimally suited. To do this, the user

simply has to open the e-chain expert, select the unharnessed or harnessed cables, enter the application and environmental parameters, decide on the appropriate energy chain from a pre-selection and configure it. In the energy chain configurator, the user can choose from over 1,300 highly flexible chainflex cables tested by igus as well as over 4,200 harnessed readycable drive cables. These are tested and, like all igus cables, come with a 36-month guarantee. On the basis of the specified cables and the application data such as installation space, movement and environment of the energy chain, the customer can choose from a selection of 1,50,000 e-chain parts for the most cost-effective solution. All igus products are tested in its own 3,800-square-metre laboratory.

Configure together as a team and order directly The user has the opportunity to share the current processing state in the online tool with other people at any time via e-mail or hyperlink. Several team members from different departments can jointly design energy chain systems online at any time and anywhere, and process the CAD data. With one click, you can download the configuration or put it in the shopping basket on the igus web shop. The ready-to-connect energy chain system can be ordered online as the online tool determines prices and delivery times for every application configuration. Alternatively, the customer can also request an individual offer for their configuration. For more information, visit: www.igus.in

Fluid filtration for industrial fluids provided by BAPL level as per the requirement of the end user. Instead of just selling a standard product, we work with the end users to identify the pain areas and then we provide a suitable solution to overcome the problem. The products that you source from us works in a sustainable way at zero maintenance cost by supplying consumable-free product. The typical applications in manufacturing industry are: • Water-based coolants • Polymer quenching • Neat cutting oils

W 24

e at BAPL cater the fluid filtration requirements for industrial fluids at a very micro

Common problems observed with these fluids are: • Dirty fluid carry the micron size burr particles which creates scratch marks on the finish job

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Contaminated fluid decreases the life of a tool To clean the tank, machine has to face breakdown which affects the production output Disposing these fluids is a major concern to the environment

Having an experience of 25 years in this industry, BAPL has developed a basket of products as a solution to the above problems, which will help you to save 50 percent cost on the expenditure on your process fluids. The products include: • Paper filtration system • Pressure driven centrifuge • Oil skimmer • Motor driven centrifuge For more information, visit: www.centrifugallubeoilcleaner.com February 2020 n OEM Update

SPECIAL REPORT

Making CNC grinding machines smart factory ready benefits of a smart factory, each CNC grinding machine will need to be connected to a communication network.

hifting towards smart factories does not mean scrapping the existing CNC grinding machines and having to invest in a whole new set of machinery. Here we take a look at what it means for CNC grinding machines to become smart factory ready. Smart factories are becoming the norm of the day in manufacturing, and companies are moving towards this space to improve their operational productivity and performance and stay ahead of the competition. But being smart factory ready does not involve completely revamping the existing technology in favour of modern, advanced equipment. It simply means upgrading some of the technology and changing the way the company thinks about how it operates.

Exploit your niche, finesse your offering and charge accordingly As a small company, you’re able to offer a personalised service bigger business can’t. You understand your customers’ needs. You sell the precise product they need to keep their operation running. They need you as much as you need them. So, being small can be your greatest selling point. You can adapt to the market as it changes and respond to demand. Where potential customers may be frustrated by businesses with long lead times, you have the ability to turn things around quickly and with more flexibility. Customers wanting something you don’t manufacture yet can even be an advantage. With the tools and flexibility to make it happen, you can easily expand your offerings and show them how well you understand your niche.

Lucas Hale, Global Marketing Manager at ANCA CNC Machines, which is a company that provides practical, working solutions to extend unattended production, improve quality and ultimately deliver improved returns for increased bottom line profit, talks about how to go about this process.

This kind of specialisation is hugely valuable to a business. You’re not only providing labour and materials but access to years of knowledge and refinement. It’s been shown that customers will pay more for specialised products that offer this level of added value.

Change the way you think about tool manufacturing In the factory of the future, running a factory won’t require a company to be as hands-on with what it produces anymore. Instead of a manual production line, it will have an integrated network of machines that is more efficient in manufacturing processes, intellectual property generation, tool design, customer responsiveness, cycle time, profitability… and the list goes on. Across the company’s business, automated machines will take care of the more laborious tasks before work begins.

Embrace automation Most CNC machines, including those that ANCA produces, already come equipped with comprehensive, advanced software that allows flexibility in everything, from configuring set-up to adaptive processes like product gauging and automatic compensations, thereby freeing your team to work on more valuable tasks. By creating automated systems and processes, you’ll immediately have access to more information than ever before, and this is a huge benefit for you and your customers. Your machines will be able to alert you when you’re running low on materials. They will predict maintenance that’s required to keep them operating, so you avoid lengthy and expensive disruptions.

With a bit of investment to upgrade your existing technology and facilities, you can reap the benefits of automation easily. Your team will be able to programme machines ahead of time, so that they are able to do what needs to be done throughout the day. And not only will your CNC machines manage the production, but they will also collect and analyse data and make automatic adjustments to production in real time to improve the way you’re running. CNC grinding machines only need to be connected While the company will be able to make use of existing CNC machines, it will also have to embrace new technology. To work effectively with other machines and maximise the 26

Having a machine connected to a network may seem daunting, but the benefits are unparalleled. The CNC machine becomes part of a smart, connected set of tools working together to make work easier. Depending on the age of the machine, the company can connect machines using either Wi-Fi (the best option to avoid messy cabling) or a cabled LAN connection. While newer machines are Wi-Fi-enabled, older machines can be retrofitted with a Wi-Fi adaptor and software drivers. Check with your vendor first to make sure the driver software is supported.

Better still, they can become part of a wider network of machines. Integrating with other factories will reinvent your supply chain process. Suddenly, your factory can integrate with your customers and your machines can speak to one another. Is your customer running out of a product you manufacture? The machine at your end can find out and start the production process without any intervention from you. Move forward one step at a time Don’t worry; you don’t need to do all of this at once and February 2020 n OEM Update

SPECIAL REPORT

there are easy ways to add automation functionality: • Add after-market software or hardware accessories, such as lasers to measure tools in production and make sure they’re meeting required design and tolerances. • Retrofit with automation; robotic loaders mean lower costs and greater volumes. You can have a new robotic loader at a reasonable price installed into your machine to achieve the benefits of lights out or unattended machine production. • Enable machine connectivity on older machines through a Wi-Fi adaptor and software drivers to connect machines to each other and the wider factory. • Store tool files centrally with tools and wheel servers. Maintaining a database of each tool file that a machine can use for set-up is a great place to start with software. Your factory can store a whole range of files centrally, so each machine can access what it needs to get the process going.

to learn. For example, did you know that if you’re moving jobs between machines, you will need to have the same version of software on each? And again this is an investment, but the efficiencies will weigh out the costs in a few months; it is about knowing what will be required to make your factory smart.

Planning ahead for future success This might be brand new for your factory, and there are tricks you will need

For more information, visit: www.machines.anca.com

If scaled manufacturing is not your background, you might need more information before you scope out your strategy. ANCA can help you understand your specific requirements and also help you understand how to incorporate them into your supply chain. Whatever approach you take, you will need to invest in some degree of technology to keep your machines up-to-date and your operation functioning effectively. Without this, other companies will move ahead of you as they can produce more complex tools more efficiently. There are many ways to bring your CNC grinding machines up to speed for your smart factory. The most important thing is that you start.

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February 2020 n OEM Update

SPEAK OUT

Automatic transmissions are the dominant trend in power transmission systems The quality of clutches and gearboxes highly influences the efficiency of a power transmission system.

Ninad Deshpande, Head â&#x20AC;&#x201C; Marketing & Corporate Communication, B&R Industrial Automation Pvt. Ltd.

inad Deshpande, Head â&#x20AC;&#x201C; Marketing & Corporate Communication, B&R Industrial Automation Pvt. Ltd. discusses the factors that have led to the rise of automatic power transmission systems and the efforts by Indian OEMs to improve performance and efficiencies in the sector. What are the challenges faced in automating the power transmission systems market? What is the progress you noticed in automobile transmission in the last few years? Manual transmissions have ruled the Indian market for years now. This was solely owing to the cost factor of automatic transmission and the lower fuel efficiencies. In India, primarily in the past, having a fuel-efficient vehicle had more weightage over having a vehicle with more comfort. However, with rising income, better lifestyles, focus on comfort over costs, increasing traffic, advancing transmission technologies, and more affordable costs, consumers have moved from manual transmission to automatic transmissions. Thus, the manufacturers too have understood this changing trend, and power transmission systems have moved from manual to automation such as the most commonly available AMT, CVT, and DSG, amongst others.

Hybrid vehicles have also been launched by many OEMs. However, the demands have not seen a considerable rise from consumers. Today, OEMs are gearing up for enabling them to move in the direction of electric vehicles and electric transmission. However, due to high initial costs, consumers are still not pursuing the electric dream. Similar to the previously experienced sudden movement from manual to automatic, in my opinion, the day is not far when consumers would move from fuel-propelled cars to electric ones. How do you assess power transmission system readiness for electrical and hybrid cars among Indian manufacturers? No doubt, Indian OEMs already have a solution in place for power transmission systems for hybrid and electric vehicles. However, automotive being a competitive and innovative yet cost-sensitive market, there are consistent efforts to improve performance and efficiencies as desired by Indian consumers. In my opinion, Indian manufacturers are already geared up for various power transmission systems based on the type of vehicle. There is always place for improvements and all manufacturers are continuously exploring and heavily investing on ways to reduce costs, improve performance and efficiencies and provide a better user experience. How does the quality of clutches and gearboxes impact the efficiency of power transmission systems? The quality of clutches and gearboxes highly influences the efficiency of a power transmission system. This is true for manual, automatic, hybrid as well as electric transmission systems. If we take an example of automatic transmission, it is the basic method of power transmission from the engine to the drive wheel. Here, the driver can experience the gearshifts prominently. However, the cost of such assemblies is lower and might have higher efficiencies and comfort than manual transmission vehicles. Moreover, continuous variable transmission has higher fuel economy and better user experience at gearshifts but is relatively expensive. A direct shift gearbox combines the advantages of manual shifts and automatic transmission with different clutches for odd and even gears, providing a greater user experience, with the cost driven higher up. In electric vehicles, usually the gear ratio is set for certain specific conditions such as highway or city driving. There could be points which provide an illusion of a CVT. Thus, when you consider any vehicle, the quality of gearboxes and clutches will provide a greater user experience but at the same time will have a rising effect on the costs. It is important to note that user experience and comfort come at a price. February 2020 n OEM Update

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Opportunities abound in the Indian lubricant market The Indian lubricant market is the third largest market in the world behind the US and China, which makes the lubricant sector in the country ripe with opportunities. Deepankar Banerjee, CEO, ExxonMobil Lubricants Pvt Ltd

eepankar Banerjee, CEO, ExxonMobil Lubricants Pvt Ltd talks about how the Indian coolant and lubricant market has evolved over the years, and how the company has maintained its stronghold in the market with cutting-edge solutions and products.

an organisational goal to make an impact on the industry’s overall operations. One of the ways to do so is by adopting energy-efficient lubricants. Mobil SHC Elite Series of lubricants are exceptional performance circulating gear and bearing oils designed to deliver improved oil drain interval, equipment protection, and smooth operations. What are the challenges the coolant and lubricant industry is facing today? How can they be overcome? The industry is facing a dual challenge — to provide affordable and reliable energy while reducing its impact on the environment. However, regulatory policies and evolving technologies are helping to address these challenges better. We at ExxonMobil believe that consumer preferences backed by

How do you see the coolant and lubricant industry evolving over the years? Can you highlight the key trends? ExxonMobil TM has been at the centre stage of the evolution of lubricants as an industrial solution. From founding the Vacuum Oil Company in 1866 — a business built on new petroleum-based lubricants and its patented vacuum distillation process — to providing lubrication solution for the first electric generating station, ExxonMobil has stood firm to its belief in quality. An ideology of applying the right oil in the right place and time has helped Mobil introduce cuttingedge solutions which are industry milestones. Be it the introduction of DTE oil in 1901 or synthetic lubricants in 1949, ExxonMobil has always developed lubricants that make high-performance engines and machinery reliable. Our heritage lies in developing state-of-the-art products, which has helped make breakthrough discoveries that redefine the power of lubrication. What is one of the key ways that the coolant and lubricant industry can bring about sustainable manufacturing in the long term? How can it be ensured that industry leaders have a commitment towards sustainability? With increasing population leading to a rise in the demand for energy, it is imperative to make industrial processes environmentfriendly and sustainable. Industry leaders should adopt sustainability and energy efficiency as a functioning part of the business model and not just 30

February 2020 n OEM Update

SPEAK OUT the right lubricant technology hold great potential in making industrial operations sustainable. We are well-positioned to provide safe, reliable and effective energy solutions to meet the future energy demands while reducing environmental costs. At what rate is the Indian coolant and lubricant market growing? What are the key drivers in the industry? The commercial lubricant industry is expected to register a CAGR of 5.0 per cent by 2023. Some of the major factors that will boost the sector are infrastructural developments, growth of medium- and small-scale industries, and government’s push for cleaner energy solutions. Given this market scenario, the country will see an increased demand for energy-efficient industrial lubricants, gear and compressor oil lubes to make industrial processes efficient, productive and sustainable. How important is the Indian market for ExxonMobil Lubricants globally? Can you share the company’s plans for India for the coming years? The Indian lubricant market is the third largest market in the world behind the US and China, which makes the lubricant sector in the country ripe with opportunities. This makes India a High

Growth Region for ExxonMobil, given the growing infrastructural development and the rise of MSMEs in the country. And as a company, we also lay enormous emphasis on Research & Development (R&D) to develop the most effective products and maintenance solutions for our customers, basis their specific demands and requirements. Our scientists and engineers are presently working to develop technologies designed to produce energy in an increasingly safe, economical and environmentally responsible manner. For instance, to meet the energy demands of our consumers, Mobil offers a wide range of synthetic lubricants. These lubricants can help companies amass energy savings by directly reducing electrical energy consumption or lowering friction and operating temperatures. Mobil SHC™ line of synthetic lubricants is designed to protect equipment operating under severe conditions, including loads and pressures, frequent starts and stops, wide operating temperature ranges, and contamination. We are also future-ready to meet the upcoming BS VI demands of our customers. We are making the transition to BS VI easier with our excellence in innovating state-of-the-art lubricants.

Mission PURVODAYA will script rise of Eastern India: Dharmendra Pradhan Prime Minister Narendra Modi has given unprecedented focus to the development of Eastern India. About half of aspiration districts are in this region which is becoming a hotspot of socioeconomic development. Our government has come up with a 102 lakh crore worth of national infrastructure pipeline. Whether it is pipelines, inland waterways, shipping, air or road, our government is building infrastructure at an unprecedented pace. Eastern India holds special focus in our infrastructure development efforts.” About technology, Pradhan said, “21st century is going to be the age of knowledge and technology. New technologies are reshaping the economy and society. Industry 4.0 driven by digitisation holds immense promise. Embrace of Industry 4.0 by manufacturing in steel sector will ensure Eastern India benefits from the wave of Industrial Revolution 4.0.”

on’ble Minister of Petroleum, Natural Gas and Steel Dharmendra Pradhan launched PURVODAYA: Accelerated development of Eastern India through integrated steel hub in Kolkata, West Bengal. Speaking on the occasion, Pradhan said, “Whether it is our freedom movement or social reform, Eastern India has provided leadership to the nation. Eastern India is a land of infinite opportunities. Despite being endowed with natural resources, this region has lagged behind in socio-economic development as compared to some other parts of the country. Today, we start PURVODAYA in steel sector, a new chapter which will script the rise of Eastern India by accelerated development of steel sector through an integrated steel hub.” Speaking about the government’s efforts to develop Eastern India, he said, “Our government under the leadership of Hon’ble February 2020 n OEM Update

PURVODAYA in steel sector is aimed at driving accelerated development of Eastern India through establishment of an integrated steel hub. Eastern states of India (Odisha, Jharkhand, Chhattisgarh, and West Bengal) and Northern part of Andhra Pradesh collectively hold ~80 percent of the country’s iron ore, ~100 percent of coking coal and significant portion of chromate, bauxite and dolomite reserves. There is presence of major ports such as Paradip, Haldia, Vizag, Kolkata etc., with >30 percent of India’s major port capacity. In India’s march towards a $5-trillion economy, the 5 Eastern states can play a major role where steel sector can become the catalyst. This eastern belt has the potential to add more than 75 percent of the country’s incremental steel capacity envisioned by the National Steel Policy. It is expected that out of the 300 MT capacity by 2030-31, over 200 MT can come from this region alone, driven by Industry 4.0. 31

FACILITY

HVAC: Rising in market with smart technologies New India’s initiative towards smart cities is giving an added impetus to the current Indian HVAC industry to develop solutions that are not only smart and energy-efficient but also affordable. However, there are many other aspects to energy efficiency and power saving such as the usage of software for controls like ACT mode, Sleep mode, Eco Mode and a lot more. But since there are no set parameters and standards for testing, it is confusing for brand comparison. Johnson Controls – Hitachi Air Conditioning India Ltd is continuously working on developing products and technologies that are innovative, energy-efficient, eco-friendly and fulfil the needs of its consumers.

he growing population of the world is moving towards urbanisation, demanding for more efficient, smart and sustainable development and infrastructure. By 2050, it is projected that India will have added 416 million urban dwellers, China 255 million and Nigeria 189 million. Smart technology is a huge driving factor in the industry, pushing comfort and efficiency to new heights. Mobile solutions are also going to be a key driver of innovation in the HVAC industry. With Internet of Things (IoT) and various smart sensors, customers will have intelligent and better control of their devices. Artificial intelligence and machine learning related advancements will ensure additional diagnostics and reduce service costs and operating costs. Since the HVAC industry is maintenancedriven, new and green technologies will streamline maintenance process in an efficient and environmentally friendly manner. Measures being taken to address efficiency in the HVAC segment The best efficiency measures can be taken right from the initial phase which is the design and planning phase. Global warming and climate change has become a reality now. Governments across the world are tightening regulations pertaining to safety of environment and energy efficiency for all kinds of equipment and appliances to check emissions. Most countries continue to raise the Energy Efficiency Ratio (EER) standards. Gurmeet Singh, CMD, Johnson Controls – Hitachi Air Conditioning India Limited said “By 1st January 2021, India will also witness a higher Energy Efficiency Ratio (EER) table. The most common technological improvements required to achieve efficiency are advanced heat exchangers, efficient compressors, motors, etc. “ 32

Gaurav Kumar, Head – Projects and Operations, MG Cooling Solutions said, “Every factor contributes to the energy efficiency part. For example, the material for construction like glass, bricks, etc. plays a huge role. One should use the material which has a lower U value. U value means heat gain coefficient, and it varies from material to material. Every aspect of building construction material has a different U value and adds to the heat gain inside the building.“ Insulation is one of the best ways to reduce heat gain as it does not allow much heat to transmit inside the building which scores high in energy efficiency. Technological advancements in the sector to look out for this year As per Tech Sci research report, India’s HVAC market is expected to cross $7 billion by 2022. The growth in the market can be attributed to increasing number of high-rise buildings, shopping complexes and malls, and hypermarkets in tier II cities. The HVAC industry is moving towards smart and environment friendly technologies. The year 2020 is going to witness new technological advancements which will shape the future of the industry as well as consumer expectations. With a focus on complete comfort and convenience, the year will also witness new technologies that are aimed at reducing noise, providing fresh air, and directing air flow based on customer need and choice. The government’s push for smart cities goes hand in hand with Hitachi Cooling and Heating’s push for connected products. For the commercial building segment, one of Johnson Controls – Hitachi Air Conditioning India Ltd.’s latest offerings is its new SET-FREE Sigma (∑) Series and its new IoT-based VRF management app called airCloud Pro. Singh added, “Designed keeping in mind the needs of architects and HVAC consultants, Hitachi Cooling and Heating has introduced its new SET-FREE Sigma (∑) Series. Named after the mathematical symbol “∑” which stands for the combined strengths of Johnson Controls’ and Hitachi’s VRF Technologies, this series has February 2020 n OEM Update

FACILITY been designed with global expertise especially for the Indian climate and consumers. It offers higher energy efficiency, engineered aesthetics, enhanced strengths, compact design, compact cooling and heating.” Technological advancements are basically in terms of automation and IoT-based sensors. An automated system not only saves energy but also helps in safety measures for all the occupants. IoT is a buzzword in the HVAC industry now which tracks the activity of the system quite minutely for all the devices of the system. Kumar elaborated, “It also helps in recording the daily pattern of the HVAC system in a given space which helps in predicting the premature breakdown of any of the components of the system. This leads to cost optimisation from the maintenance front which is again a huge cost saver.” He added, “airCloud Pro is one of our latest ground breaking innovations which we have introduced recently in India for our customers. It offer 24/7 control and remote access of your VRF systems to ensure energy savings, centralised control, flexible user management, preemptive alerts, and troubleshooting. Backed with the latest updates and security features, it also offers individual controller lock to prevent inappropriate usage from the occupants and is easy to install, thus making it ideal for any application like offices, hospitals, schools/universities, restaurants, hotels, retail, etc. Thus, with least energy wastage and maximal capacity in minimalistic floor space, SET-FREE Sigma Series gives energy-efficient performance combined with premium looks.” Short-cycling and poor indoor air quality (IAQ) in terms of developing new products. Both indoor and outdoor air quality in most of the cities worldwide is deteriorating due to the rising pollution level. This is pushing the HVAC industry to focus on delivering better IAQ through disruptive products. While “energy efficiency”, “environment conservation” and “healthy indoor air experience” have already become the new buzzwords in the global scenario since a long time, the Indian HVAC industry has also started working on incorporating these into their designs and products while ensuring proper ventilation and thermal comfort. Singh stated, “Hitachi Cooling and Heating, being a technology leader and one of the most premium brands in the Indian air conditioner industry, is constantly working on new cutting-edge technology in its product categories which comprises room AC, VRF, chillers and other commercial air conditioners.” Since the buildings are airtight, the CO2 level starts building up inside the building, which can lead to sick building syndrome (SBS) and has also proven to reduce the productivity in the case of office buildings. An HVAC system makes sure that there is a provision of fresh filtered air for improved air quality. February 2020 n OEM Update

IoT is a buzzword in the HVAC industry now which tracks the activity of the system quite minutely for all the devices of the system. Gurmeet Singh, CMD, Johnson Controls Hitachi Air Conditioning India Limited

An HVAC system is responsible to improve the air quality by incorporating pre fine filters and HEPA filters, which restricts the movement of particulate matter inside the buildings. Gaurav Kumar, Head - Projects and Operations, MG Cooling Solutions

Kumar explained, “An HVAC system is responsible to improve the air quality by incorporating pre fine filters and HEPA filters, which restrict the movement of particulate matter inside the buildings. Also, the HVAC system has the provision of introducing fresh air inside the premises which helps in exhausting the CO2 level inside the building.” Poor indoor quality is the most discussed topic right now as this has a direct impact on health. Advantage of government initiatives and emerging concepts like smart cities The government initiatives for HVAC has helped the sector to gain a boost in the market. The government’s plan to make every city smart in India by 2050 is giving companies the needed impetus to innovate in their products. Singh states, “By working constantly on the philosophy of producing best technology products with the three pillars of innovation, energy saving, and comfort, Hitachi Cooling and Heating aims to achieve high customer satisfaction and become the country’s expert in air conditioning solutions.” “MG Cooling Solutions has always been working in the direction of highly energy-efficient HVAC systems. Since we need to import to produce electricity as of now, we need to make sure that we achieve energy efficiency through HVAC. This becomes more crucial as HVAC consumes 40-60 percent of total energy in the building,” explains Kumar. He adds, “We continue to leverage this momentum to supply a pipeline of products with built-in intelligence and more importantly, our customers continue to expect such products from us.” Transforming Indian cities into smart cities starts with energy- and cost-efficient smart buildings. Advanced and energy-efficient HVAC systems with low operating costs have a vital role to play in shaping these smart buildings for the country’s future cities. 33

BRAND REPORT

Belimo achieves milestone of producing hundredmillionth actuator customers the continuous reassurance that they have chosen the very best. Belimo has earned the place of the market leader by valuing ingenuity and craftsmanship and never resting on its accomplishments. Very simply, we strive to build damper actuators, control valves and sensors that solve comfort and energy challenges, perform flawlessly and earn your trust through a long and productive life.

continues its growth course by reaching this milestone as well as the demand for innovative products that sustainably increase comfort, energy efficiency, and safety in buildings.

The Swiss-based world market leader in field devices for controlling and regulating heating, ventilation and air-conditioning systems

Belimo delivers more than just products. We support our customers with innovative, efficient and energy-optimising solutions. We are close to our customers throughout the world, we speak their language and we understand them. Everything we do gives

ecently, Belimo produced its hundredmillionth actuator and in doing so, it reached another milestone in the company’s history. Today, hundreds of thousands of buildings around the world incorporate Belimo actuators into their HVAC systems.

CESIM is a company-wide methodology approach to improving and developing products and solutions to meet and exceed customer expectations. CESIM ensures Comfort, Energy-savings, Safety and security for people and their property, and provides easy Installation and commission with reduced Maintenance offering optimum system performance. For more information, contact: info.india@belimo.ch

B&R launches vendor-agnostic communication solution can also be incorporated in the network via the switch. Implementing modular machine concepts is now faster and easier than ever. Automatic configuration The switch is completely integrated in B&R’s Automation Studio engineering environment. Configuration occurs automatically. The device fully supports a centralised approach to hardware and software management. Application development and machine-specific configurations can be performed either offline or online. The TSN switch can also be used as a conventional unmanaged switch for non-real-time networks. No special configuration is required.

&R has added a real-time Ethernet switch to its portfolio. The new machine switch can be used to set up networks using the vendoragnostic communication solution OPC UA over TSN. Its design and form factor fits perfectly into the B&R portfolio for space-saving mounting in the control cabinet. 34

The TSN machine switch allows cycle times under 50 µs. It offers four real-time capable TSN ports and one standard Ethernet port – to connect a display, for example. The switch also opens up the possibility of star, tree or ring topologies in addition to daisy-chaining. Multiple switches can be cascaded in order to reach remote cabinets or implement large, complex real-time networks. Non-TSN nodes

Compact design Since the TSN machine switch is designed in the X20 form factor, it takes up minimal space in the control cabinet, mounted right alongside the X20 control and I/O system. The switch can be mounted in two different positions, depending on the cable outlet. This allows it to be installed in tight spaces. For more information, visit: www.br-automation.com February 2020 n OEM Update

BRAND REPORT

Oil-lubricated rotary vane vacuum pumps with oil re-circulation system

oshniwal supplies oil-lubricated vacuum pumps. This oil-lubricated vacuum pumps of the TMS Series are single-stage, oil-lubricated rotary vane vacuum pumps with oil recirculation system. The lubricant system is rated for continuous operation of high intake pressures so that the pump may be used in a versatile manner in most rough vacuum applications. The pumps are used for suction of air also in presence of water vapour and for continuous industrial use. TMS Series pumps are made from high-quality materials and have economical features which match together to achieve: high pumping speed over the range of absolute pressure 1,000

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mbar-0.5 mbar; high water vapour tolerance and low noise level; no pollution; air cooled: built-in anti suck-back system. The pumping capacities available are 17 m3/hr, 35 m3/hr, 65 m3/hr, 100 m3/hr, and 150 m3/hr. For details, contact: Toshniwal Instruments (Madras) Pvt. Ltd. 267 Kilpauk Garden Road, Chennai - 600 010. Tel: +91(0)44 26448983 / 8558 Email: sales@toshniwal.net

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February 2020 n OEM Update

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SPEAK OUT

Indian sheet metal industry is attracting global players quality of the finished product, resulting in zero waste and reduced downstream corrections.

A lot of sheet metal importers from Europe and the US are shifting from China to India, which is again key for the Indian sheet metal industry to gear up with adaptive technologies. Puneet Sharma, Country Head India, Salvagnini Machinery India Pvt. Ltd.

uneet Sharma, Country Head India, Salvagnini Machinery India Pvt. Ltd. talks about the new products the company launched at IMTEX 2020 and how the domestic sheet metal industry is growing due to government initiatives in several sectors. Can you brief about the products that you have launched and showcased at IMTEX 2020? Salvagnini panel bender is an automatic machine in every aspect, and as such is ideal for a modern smart factory. We are happy to introduce our new Panel Bender PX at IMTEX this year at IMTEX. Key features of the PX include auto tool setup, kit production, every job can be of different thickness, MAC2.0 which provides material adaptability and lower power consumption. This new machine, which runs on electric actuators, has reliability and repeatability. The PX is of course an adaptive machine, able to react and set itself up according to changes in bending conditions, for example according to the temperature or the ultimate tensile strength of the material being bent. This guarantees the precision, repeatability and

What, according to you, is driving the sector at this moment? India’s sheet metal market is growing at 2025 percent which is majorly due to the present government’s initiatives for the development and investment in infrastructure, railways, green energy, telecom, and textile machinery. A lot of sheet metal importers from Europe and the US are shifting from China to India, which is again key for the Indian sheet metal industry to gear up with adaptive technologies. How is Industry 4.0, AI, robotics helping the industry to increase the efficiency whilst maintaining cost competitiveness? Salvagnini is the leader in automation, smart factory, Industry 4.0, and the production of flexible machinery and systems for sheet metal machining. We already are successfully running in 18 automated lines in India. In India, we want to tap SMEs by helping them to adapt bending automation using the new PX panel bender, which can be integrated to a thirdparty robot for loading and unloading. What kind of challenges and opportunities do you see in this sector? What measures are you taking in this regard? The success of businesses is proportional to the ability to adapt quickly to new scenarios which are no longer foreseeable. We must therefore be flexible and resilient, and able to adapt to situations which we don’t know today. To do so, I think it is fundamental to choose the right way of manufacturing, where Salvagnini come in to play in giving solutions like Flex cell, FMS and newgeneration bending technology to the Indian sheet metal industry. What are your plans and projections for the next two years? With my 25 years of experience in the Indian sheet metal industry, we wish to bring concepts of Industry 4.0 in India as it involves many aspects and concepts which, if not correctly applied, can thwart all the effort and investments made. Entrepreneurs will have to transform companies and manage changes more effectively and efficiently. We want to bring more automation in bending technology so that we can move from conventional bending to automated panel benders.

February 2020 n OEM Update

You see Effluents... We see Profits for You

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Zero Liquid Discharge Systems

Pollution and increased demand have made good quality water scarce and expensive, both in terms of direct cost and effect of unsuitable water on plant economics and product quality. Meanwhile, disposal norms are getting tighter and their enforcement stricter. Ion Exchange can help you to effectively and economically solve your water scarcity problems by conserving vast volumes of water and protecting the environment by reducing discharge, while generating substantial savings for you. Backed by over 50 years of proven expertise, we incorporate advanced effluent treatment processes, innovative membrane technologies and state-of-the-art evaporation processes to maximise recovery of water and achieve zero liquid discharge. All backed by 24x7 services.

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ION EXCHANGE (INDIA) LTD. E-mail: ieil@ionexchange.co.in | Website: www.ionindia.com Ion House, Dr. E. Moses Road, Mahalaxmi, Mumbai - 400 011 Mumbai: 022 6231 2000 | Delhi: 011 6121 3200 | Kolkata: 033 6813 3400 Chennai: 044 6648 2900

INDUSTRY ANALYSIS

Eliminating the wastewater Depleting water reserves combined with the surge in demand for water has led to increased focus on wastewater management, particularly in industrial manufacturing plants. We look at the current state of industrial wastewater management and what can be done to improve it.

s India’s need for water is increasing with the growth of its population and economy, the requirement for sustainable water and wastewater management has come to the forefront. Also, with depleting freshwater resources and the widening gap between the current water demand-supply gap, there is an urgent need for improving water use efficiency and encouraging wastewater recycling and reuse. India’s manufacturing sector has seen a rapid growth, and this has resulted in increased industrial wastewater which has become one of the major sources of pollution. Industrial wastewater contains harsh effluents that negatively impact the environment and needs to be treated and reused. Since most of the manufacturing plants are in tier II and III cities, it is necessary to encourage them to opt for wastewater effluent treatment plant solutions that can treat and reuse wastewater. Measures to recycle wastewater generated in manufacturing plants The world is witnessing a gradual shift toward responsible manufacturing, encouraging methods to treat the wastewater generated as a by-product of their processes. They are setting up smaller wastewater treatment plants or processes within the facility to treat and reuse this water for other purposes. Ajit Jainath Singh, Sr. Vice President – Sales (CBS & IND), Grundfos India says, “The recycled water can be used to cool down machines and lubricate parts and other processes. Besides this, wastewater from industrial areas can also be treated to be reused in nearby agricultural lands and vice versa. Companies have also been moving towards achieving “Zero Liquid Discharge”status by reusing all the water they consume.” 38

He adds, “Grundfos India’s headquarters in Chennai is India’s first goldrated green building (LEED certification by USGBC in 2005). Since water efficiency is an integral part of our sustainability initiatives, special efforts have been taken to minimise water use by installing waterefficient fixtures, effective rainwater harvesting and sewage treatment plant to treat 100 percent of onsite wastewater for reuse. The nonprocess wastewater is treated onsite and is reused for landscaping, thereby minimising the use of potable water for these applications.” Meenu Singhal, Vice President – Industry Business, Schneider Electric India says, “It is estimated that the world population is going to double in the next 35 years. As per a World Bank report, India is among the world’s most water-stressed countries. With further increase in population, we will witness rise in water consumption levels, water scarcity, and the need for sustainable infrastructure. Since a large portion of water runs back into the ecosystem as wastewater, it can pose great environmental and health hazard if not treated. Among the multiple means for addressing water problems, one top-of-the-line option is the IoT-enabled EcoStruxure for Water and Wastewater from Schneider Electric. Based on an open, interoperable platform, it offers enhanced value revolving around safety, efficiency, reliability, connectivity, and sustainability.” Manufacturing plants today are taking several measures to remove impurities and recycle wastewater that is generated during manufacturing processes such as dissolved air flotation, biological treatment using natural bacteria to break down carbon-based impurities, filtration February 2020 n OEM Update

INDUSTRY ANALYSIS through filters, carbon filters and micro filters, softening, disinfection, and deionisation. Current scenario of wastewater management in smart factories Singh says, “Smart factories are leveraging new technologies to boost the efficiency of their manufacturing facilities. Like manufacturing processes, wastewater treatment has also been positively impacted by these technologies. Wastewater treatment in smart factories is integrated with IoT, decentralised, and modular in nature. Grundfos, a global leader in pump solutions, uses future-forward technologies to improve wastewater management. Grundfos’ ISOLUTIONS can optimise treatment processes by using sensors to monitor flow, analyse data, and predict possible downtime. It also provides real-time monitoring at remote locations, thereby reducing the need for direct human intervention.” Singhal comments, “The fourth industrial revolution has ushered in the era of smart factories through digitisation of processes and systems, including wastewater treatment systems. Alternatively, the stringent water quality standards, an ever-aging infrastructure, and rising operating cost have led to a greater investment in new treatment technologies and processes. There is a need for predictive analysis and decision support systems in order to operate and maintain the water and wastewater management infrastructure in smart factories.” Digitisation brings the capability to gather operational information from all corners of water networks. Digitising the water network technology through smart water management system offers the possibility to run them more reliably and efficiently. However, it is imperative that the smart water technologies are also energy-efficient. Singhal adds, “Water has been a strategic segment of Schneider Electric. In the Smart Water area, Schneider Electric’s technology helps to manage and optimise the operation of wastewater treatment plants. The solutions cover the entire energy cycle, from purchase, management and savings to its most efficient use, in water treatment plants, wastewater treatment plants or desalination plants along with the supply and sanitation networks.” Technologies for wastewater management at manufacturing plant level According to Singh, besides technologies such as IoT and automation to improve processes, next-generation pumps are available to augment wastewater treatment. He says, “Innovative technologies from Grundfos bring together intelligence, motors, hydraulics, and functionality to meet the challenges of modern wastewater, maximising the hydraulic, electrical and mechanical efficiency of pumps. These solutions can be used for end-to-end processes, from water procurement to the final stage of the water treatment.” He further explains, “Grundfos Dedicated Controls system is delivered either as complete control cabinets or as control components for local panel assembly. Designed for the transfer of wastewater away from a wastewater pit, they can be used with standard functionality for normal needs, and also support February 2020 n OEM Update

Syncaxis

Engineering & Integration

Syncaxis engineering and integration offers belt conveyor, top-chain conveyor, roller conveyor, plate-chain conveyor, wire mesh conveyor, curve conveyor, lift, Drum roller conveyor from Bosch Rexoth conveyor portfolio. It is widely used in the production & assembly of food, beverage and medical industries. Bosch Rexroth Aluminium Strut Profiles and Accessories. Industrial Workstations. Industrial Structures build in Aluminium Strut profiles. Syncaxis gives complete customized solutions in all type of structural requirements.

Ergonomic Work cell Automation. Modular Design Conveyors of Rexroth Make and Competitive Partner in Partner make, Flexible chain conveyors. Metrology Automation, Industrial Training Kit. Special Purpose Machines.

Office and Billing Address: Ashirwad, Plot No. 12/A, Shiv Shakti Hsg Soc, Bulk Land No. 15, Sector No. 4, PCNTDA, Sant Nagar, Moshi, Pune - 412105 Works and Delivery Address: 64/9, D II Block, MIDC, Chinchwad, Pune - 411019 Email: ddbisure@gmail.com / ddbisure@syncaxis.co.in / sales@syncaxis.co.in Contact: +91 9850007337, Website: www.syncaxis.co.in

INDUSTRY ANALYSIS Companies have been moving towards achieving “Zero Liquid Discharge” status by reusing all the water they consume. Ajit Jainath Singh, Sr. Vice President – Sales (CBS & IND), Grundfos India

Sustainable and costeffective, a decentralised wastewater treatment system is apt for India as it works well in rural, suburban and urban settings. Meenu Singhal, Vice President – Industry Business, Schneider Electric India

more advanced functions for wastewater transport. It is a perfect partner in any storm water installation or flood control installation. When used with frequency converters for the pumps, it can optimise energy consumption. It can also be used for commercial buildings, as well as municipal systems.” Besides these solutions, Singh says that Grundfos also offers iSOLUTIONS CLOUD for Wastewater Networks, which is a cloud-based solution to optimise operation and ease expansion or repair of the wastewater network. Need for decentralised industrial wastewater treatment The depleting water reserves and increasing water costs have encouraged the reuse of wastewater, which also includes industrial wastewater. This has further compelled the industries to re-evaluate their wastewater management techniques. A decentralised wastewater treatment involves a variety of approaches for collection, treatment, and reuse of wastewater. Singhal details, “As part of permanent infrastructure, the decentralised system provides a range of treatment options from simple to complex approaches. Sustainable and cost-effective, a decentralised wastewater treatment system is apt for India as it works well in rural, suburban and urban settings. This also offers long-term solution for water management if properly planned, operated and maintained.” Singh adds, “For a country like India with landlocked areas, a decentralised system of wastewater provides the most

logical and efficient way to treat water. Industries will be able to set up the infrastructure with minimum capital if it is properly designed, maintained and operated optimally. These are typically installed near the wastewater generation site and can be used to treat the water efficiently. They are a popular alternative as they are quite flexible and can be changed according to requirements of customers. In the long run, they are expected to cut costs and improve the bottom line on sustainability for industrial organisations.” Current sewage treatment system used by industries Though awareness about sewage treatment is rising, only onethird of India’s wastewater is currently treated, leading to the high burden of water-borne diseases and acute water shortage. States generating large amount of wastewater should consider treating 65-100 percent of their urban wastewater. Singhal comments, “Treatment methods are often specific to the material being treated. Methods include advanced oxidation processing, distillation, adsorption, vitrification, incineration, chemical immobilisation or landfill disposal. Thousands of small-scale and bigger industrial units simply dump their waste, more often toxic and hazardous, in open spaces and nearby water sources. Over the last three decades, many cases of serious and permanent damage to environment by these industries have come to the fore.” Singh says, “It is essential to create comprehensive sewage systems spread across the city to collect, convey and intercept waste of all to control pollution of water bodies. The conventional wastewater treatment processes are quite expensive and involve complex operations and maintenance. Due to improper design, poor maintenance, frequent electricity breakdowns and lack of technical manpower, the wastewater treatment facilities do not function regularly and properly. Apart from domestic sewage, only 60 percent of the wastewater generated by industries is treated. Considering current scenarios, effective sewage treatment has become a necessity in industries.” Friendly government policies and Sustainable Development Goals (SDGs) oriented strategies will further help empower Indian industries to strengthen their sewage treatment processes. In the last couple of years, the government has launched various schemes to develop the sewage treatment and collection infrastructure in the country. Industries also have witnessed fresh investments and new players in the form of start-ups that are entering this space. This should provide the right impetus for industries to be more responsible for the waste generated and setup necessary steps and processes to tackle the same.

February 2020 n OEM Update

Treating industrial water efficiently

hura Aqua Treat specialises in water treatment systems for treating water from ground, surface, effluent systems, etc. The company specialises in various systems like RO plants, DM plants, zero liquid discharge systems, softeners, UF (ultra-filters), UV systems, ozonators, many types of filters, etc. Ahura also offers sewage treatment plants, small effluent treatment plants, etc. It designs and manufactures high-grade sea water RO plants which are used for end-treatment of effluent plants. Understanding the typical needs of pharmaceutical, textile, plastic moulding, cosmetics, beverages, paper, bulk drugs, and chemical industries, Ahura offers systems with assured results. Besides improving feed quality for trouble-free operations, the company also provides benefits of reuse of water; hence, reduces the demand for in-feed water. Effluent treatment plants Ahura Aqua Treat offers engineering consultancy services and supply of post-ETP systems. The services provided by experienced industry professionals allow enhancement in operational conditions of various industries. The company also adopts latest treatment technologies, conceptual designing, as well as process engineering techniques for designing of plants that allow it to match the process requirements at client’s end. The company provides services for different industrial sectors include pharma, cosmetics, beverages, textiles, plastics, paper, bulk drugs and chemicals, etc. Zero discharge RO plants Ahura Aqua Treat is also engaged in manufacturing water treatment systems that include RO systems, zero liquid discharge plants, de-ioniser or de-mineralising systems, sewage treatment plants, effluent treatment plants, evaporators, water softeners, pure water systems, etc. It designs and manufactures high grade RO (reverse osmosis) plants that are used for end treatment of effluent plants. These RO plants remove TDS from feed water, which are present in the conventional industrial effluents. It is the best method to achieve ‘Zero Discharge’. Since the output is reused, it reduces the demand for in-feed water. The company has accomplished projects for the ‘high-purity’ pharma industry and ‘bulk quantity’ heavy textile Industry (capacity of 7,000 m3/day, at upto 200 m3/hr). It also has expertise in storage and distribution loop for pharma and food industries, SS tanks and pipelines, chemicals for cooling towers, chillers, boilers, etc. For more details, contact: Ahura Aqua Treat 411, Lotus Business Park , Off S.V Road Chincholi Fatak, Before Quantum Towers, Malad (West) February 2020 n OEM Update

AUTOMATION

Rockwell building the Idustry 4.0 Ecosystem shift towards progressive technologies in the Indian industries is undeniable. Thus, industrial automation and Artificial Intelligence have been the irrefutable forerunners in discussions as India endeavours to triple its combined factory output in gross value added (GVA) terms to $1 trillion by 2025. Having realised this, Rockwell Automation recently held Rockwell Automation on the Move 2019 (RAOTM) annual conference, which emphasised the acute need and explicated what the oncoming Industry 4.0 signifies across the manufacturing sector.

Blake Moret, Rockwell Automation CEO, inaugurating the Digital Transformation Experience Centre in Gurugram

s the world’s largest company dedicated to industrial automation and information, Rockwell Automation has laid its paramount focus on developing smart solutions through digital transformation and Industry 4.0. To this end, Rockwell Automation announced the launch of its first Digital Transformation Experience Centre in India — a state-of-theart, collaborative hub designed to inform and inspire Indian businesses about creative ways to spark productivity gains using automation. The Gurugram-based Centre is the first of its kind in India to fully demonstrate the integration of key technology platforms for IT-OT convergence, enabling customers to understand the benefits of the Connected Enterprise and the positive impact that it can have on their business. The Centre also illustrates how solutions and services offered are entirely scalable and can be tailored to businesses.

The Economic Times presented the Digital Transformation Dialogue in association with Rockwell Automation to bring forth the best minds on one platform and enable a healthy debate on how to share their knowledge and expertise and help India work towards becoming a $5-trillion economy. Almost 18 companies CXOs had participated, including Maruti Suzuki Ind Ltd, SRF, Ambuja Cement, Hindalco Industries, etc. Partnerships in solution development With an analogous need for Smart Manufacturing solutions in the Indian industries, the company had previously affirmed partnerships with global developers of vital solutions, such as L&T, Cisco, Microsoft, Endress+Hauser, and Wipro Infrastructure Engineering.

Rockwell Automation CEO Blake Moret said, “This is a hugely exciting time for a whole range of industries in India who stand to unlock trillions of dollars in value over the next decade as a result of rapid advancements in automation technology. It’s also a complex moment, when leaders have an exceptional number of decisions to make about how and where to invest their resources to achieve best results. With this Centre, we’re inviting businesses across the country to come and get informed and inspired about what the future could look like and how to get there.”

In his engaging address at RAOTM 2019, Dilip Sawhney, Managing Director, Rockwell Automation India, spoke on venturing in partnerships towards the emergent era of Industry 4.0. Dilip Sawhney wants to take the lead in building India’s first industry 4.0 ecosystem of partner companies that will create solutions for the Connected Enterprise, which can analyse machine conditions in advance in order to avoid breakdowns and enhance productivity, but also improve on quality and compliance parameters. Consequently, John Watts, Regional Marketing Director – Asia Pacific, Rockwell Automation, expounded on the need for assimilation of Industry 4.0 in the manufacturing segment. However, if people do not have the right mindset to change while adapting to it, then the transformation only tends to magnify existing blemishes in organisational practices. The significance of digital transformation for a business that wants to remain pertinent in its forte cannot be overlooked.

The Centre will let visitors experience first-hand the synergy of key technology platforms such as Network, Cybersecurity, Industrial Data Centre, Machine Learning as well as AR and VR. They can also experience scenarios showcasing how a business could fix problems faster and with less disruption to production by combining data on machinery faults, production commitments, and availability of parts along with insights into how long it would take a technician to fix the problem with the support of augmented reality.

Smart and connected Madan Kumar, End User Business Leader – South, Rockwell Automation, took over to speak about “How one can accelerate high performance operations through the connected enterprise”. This was followed by a session on “smart devices for smart manufacturing” by Rajendran Menon, Product Manager – Smart Devices, Rockwell Automation. He spoke about the various business drivers and challenges, smart devices in connected enterprises, and various aspects of what makes devices smart.

The Centre will also demonstrate how Rockwell Automation integrates solutions seamlessly from the plant floor up through the enterprise in collaboration with Strategic Alliance Partners like PTC, Cisco, Microsoft, and Endress+Hauserto accelerate innovation and convergence for operational and information technologies through digital transformation. With the onset of Industry 4.0 in the global market, the call for a profound

Moving on, Shibasis Patro, Manager – Equipments, Signode India, hosted a session on “Enabling digital transformation through smart machines and equipment”, discussing various aspects of technology like smart technology machines and equipment, integrated safety solutions, OEE solutions, and real-time diagnostics. Next, T D Dhanu, Technical Consultant – South, Rockwell Automation, presented a session on “How one

February 2020 n OEM Update

AUTOMATION can improve their operational efficiency through advanced analytics”. This session majorly discussed industry trends, an overview of analytics offered, and the walkthrough and story behind the development of Rockwell Automation Global Energy Drink (RAGE). IT and OT convergence The event commenced with the welcome address delivered by Abanibushan Bera, Regional End User Manager – Western Region, Rockwell Automation. Shortly after, the first session began with a remarkable presentation on “Why Businesses need to digitally transform – Your Future is Here” presented by RN Mohanty, President – Technology, Pidilite Industries. This was followed by another attention-grabbing address given by Abhay Dubey, Industry Manager – Rockwell Automation India and Asia Pacific, who explicated the topic of the Connected Process Plant and shared with the audience its trends and a few success stories. The session then turned its attention towards IT and OT convergence. Under topics like CEO’s role in redefining workplace culture, accelerating innovation for business process execution and capital efficiency, the impact and importance of new technologies in business, increasing collaboration and enhancing employee efficiency and productivity, building partnerships for tailored solutions, Make in India – Is this the best time ever to be in India and how customer experience is increasing the value of your business?, AK Agarwal, CEO, BDMA and S M Thakor, Additional General Manager, GNFC, and Chairman, IT Forum, BDMA, acquainted the audience with IIoT convergence in their presentation, “Two Worlds converging in Industrial IoT”. Digital transformation driving business outcome The event further delved into the panel discussion, which was on the topic “Digital transformation driving business outcome”. Moderated by Shekhar Jitkar, Chief Editor, A&D India, the discussion was aimed at the business outcome and future trends of digitalisation, and how other advanced technologies like AI, AM or cloud computing can be utilised in a successful digital transformation journey. The panellists were Sandeep Redkar, Business Manager, Process Solution, Rockwell Automation; Subba Rao, Director, Aztec Consulting; Ramprasad Nori, Associate Vice President, Greenco Energy; Ravi Maknikar, National Head, Zenith Technologies; and Avinash Tote, Executive Director, Logicon Techno solutions. Throwing light on the pharma aspect, Maknikar asserted that today, the buzzword is data integrity. Companies cannot achieve data integrity without the necessary digital transformation, so to achieve data integrity, various pharma companies are implementing MES, which is proving to be an effective solution. There is willingness, but there is also a certain lag in the supporting infrastructure, which needs to be addressed first. Rao added that the meaning of data integrity is very different for a small- and mid-scale pharma company, compared to a largescale pharma company. For a small- and mid-scale company, digitalisation is majorly about improvement in quality, while for large-scale companies, it is majorly about data integrity and ROI. According to Nori, firstly, it is important to have commitment from the management. Secondly, people who are going to implement digitalisation need to have the required mindset and February 2020 n OEM Update

should adapt to the change of technology. The discussion then turned to data security, which has been of importance even in top global companies. The criteria and parameters while approaching a solution provider and the expectations from solution providers and systems integrators were also discussed. Nori believes eighty percent of failures are predominantly because requirements have not been specified properly. Even major companies are not able to articulate, understand and convert what a customer is expecting into a solution, making the result zero. Everybody has to be equally updated as solutions are not readily available because they are all customised. Going further on digitalisation Post the panel discussion, Redkar gave a presentation on “What to Expect from a Modern DCS in Digital era”, which focused on the benefits of enabling IoT for better connected enterprises and customer outcomes, how digital technologies enabled by Rockwell Automation can help manufacturing organisations, life of an IIoT project, and DCS of today and tomorrow benefitting the industry. It is important for an industrialist to understand the security trends and its implementation in the industry to attain complete data protection. The event came to an end with the final presentation of the day by T Venugopal, Power Control Manager – South, Rockwell Automation India on “Rethinking Motor Control in A Digital Age”. The session highlighted various motor control technologies, like across-the-line starters, soft starters, servo drivers and more. Venugopal also divulged into evolution of communication and the two layers of digital communication. He went on to speak about the intelligent motor controls from single network and its benefits, the value delivered, implementations and benefits of premier integration and Allen Bradley PowerFlex portfolio. Global perspective The global perspective on the adoption of Industry 4.0 or digitisation was put forward by Abhay Dubey. While many multinational companies have a high degree of adoption — having a specific digitalisation department that will only focus on the digitalisation aspect — it is unclear as to what kind of investments and what kind of returns they are going to get back. Additionally, he spoke on skill upgradation and highlighted that it is a continuous process. 43

AUTOMATION manufacturers who are keen to implement change across their organisation. The conference culminated to be a journey that would create long-term benefits, guiding dynamic manufacturing professionals for the staged approach with a clear roadmap. The final session for the conference focused on the technologies and transformations that come with implementing digitalisation. The vision of Industry 4.0 in the chemical and process industry was expounded on by Ramesh Dham, AGM – Industry 4.0, UPL. Taking up the topic of infrastructure required with the onset of digitalisation, Ankur Pancholi, Product Manager – Large Control, IO and Network Security, Rockwell Automation India, spoke on Secure Network Architecture for the Digital Plant.

As digitisation requires a substantial amount of investment, Dubey also quoted the factors which according to him would achieve the ROI required, “I would sum it up in three factors — one would be the people, second would be the processes around it, and third would be the technology.” On the implementation roadmap of digitisation, he stressed that it can attain success if the blueprint is undertaken in small baby steps. He suggested, “Have a proof of concept done, have a pilot on a small project before you jump on to the entire blueprint or put the whole investments together.” Cyber security Next, Sandeep Redkar spoke briefly about cyber security and explained the importance of drawing a base document on how to tackle threats and understand specifically the cyber security threats to counter in the solutions that you implement, which can thus be cost-effective. He spoke about the stages of ensuring data security and shared, “Security has to be prevalent across the system; it is not a point solution.” He further addressed the importance of automation systems as it takes away the uncertainty of how the production was done and gives a genealogy for every product. On the topic of investment for IIoT, Redkar elucidated the three aspects which stand out: the first one is productivity yield and quality improvement; the second is maintainability and predictive maintenance; and the third is the use of AR and VR. The session reached its conclusion with an indispensible addition from Suchi Adhikari on the objectives of operational productivity, global competency, and sustainable operations. She added, “Gain an understanding of what is important to you and start taking baby steps towards a greater objective of achieving a digital enterprise.” Digital transformation must be considered as a possible solution, which will help access big data, analyse data, provide insights on hidden inefficiencies and streamline ventures towards maximum growth and potential. Creating a clear roadmap Rockwell Automation has created a platform for technology enablers to gain insights about the best practices for 44

The latter half of the session saw the presentation on “What to Expect from a Modern DCS in Digital Era” delivered by Sandeep Redkar. This was followed by the presentation on “Rethinking Motor Control in a Digital Age” by Jayesh Joisher, Power Control, Area Manager, Rockwell Automation, who imparted invaluable knowledge to the audience, as the conference drew close to its end. The final session concluded with the conclusive remarks for the event given by Komal Shah, Channel Sales Manager – Western Region, Rockwell Automation India. Thus, the conference proved to be a greatly insightful one with its exchange of perspectives, from the end users to the solution providers, and highlighted the benefits for industries with the inculcation of digital machinery in its plants. The thematic triad The exhibits and sessions at the conference also displayed new products and showcased the solutions support by Rockwell Automation and its partner companies. Subsequently, Rockwell Automation also announced that it will host the thoughtprovoking conferences of RAOTM in the cities of Bangkok, Thailand; Tianjin, China; and Jakarta, Indonesia. Throughout the event, the discussions were centred on themes of prominence, which were Connected Enterprise, Data Analytics and Augmented Reality, and Innovation. Connected Enterprise focused on the new analytics and digital solutions, that can help transform data into understandable information. This, in turn, would empower users to confidently make more informed decisions in the entirety of the industry — from the plant floor to the enterprise. Data Analytics and Augmented Reality emphasised Rockwell Automation’s expansion of its portfolio by tapping into its partnership with PTC. This will translate into help delivered to customers in order to increase productivity and plant efficiency, reduce operational risk, and provide better system interoperability. Further, the innovation segment paid attention to the availability of pristine technologies to the customers. This would help better comprehend how new technologies will change manufacturing and production, including Artificial Intelligence, Augmented Reality, wearables and other disruptive technologies. Thus, the dialogue expounded on the remarkable scope for Industry 4.0 in the Indian manufacturing sector, while highlighting the urgency to adapt to newer technology and smart solutions. With its offerings of industrial automation and Artificial Intelligence, the conference also discussed the role of globally driven competition and the requirement for partnering with solution developers to build the Indian Industry 4.0 ecosystem. February 2020 n OEM Update

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BRAND REPORT

In-line punch drive for M-3048TG

uratec M-3048TG, the new 30-tonne machine comes with a two-piece design wherein the press frame is isolated from the table base, resulting in higher quality parts and longer life of ball screws. Also this machine comes with in-line punch drive, where the servo motor is parallel to press frame resulting in greater rigidity, less stress, and long tool life. A wide table base which has twin ball screws on Y-axis is controlled by synchronised servo motors, resulting in accuracy and stability during high-speed movements such as scheduling

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Corvina cloud 1.0 completes IoT security

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Corvina cloud 1.0 can be offered as an onpremise cloud infrastructure that delivers the uptime and performance needed for

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orvina cloud 1.0 is the EXOR international system for remote control and tele-assistance, based on secure VPN and web access. The user interface is incredibly clean and easy to use. Being web-based, it allows all your remote devices, networks and users to communicate seamlessly and securely.

Besides security, one of the most common challenges industrial networks face is the problem of multiple locations having the same subnet, making it impossible to implement a central VPN management tool without significant intervention. Yet, Corvina cloud 1.0 is the only solution on the market that can seamlessly resolve this routing nightmare, allowing your deployment to go smoothly. For more details, visit: www.exorint.com/en/cloud/corvina-cloud February 2020 n OEM Update

OEM

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OEM UPDATE - FEBRUARY 2020

Articles inside

Indian sheet metal industry is attracting global players

Airplane part manufacturing gets compact with carbon nanotube

Opportunities abound in the Indian lubricant market

Automatic transmissions are the dominant trend in power transmission systems

Redefine welding with Industry 4.0

Transforming Indian welding industry with digitalisation

Prioritising health, safety, and environmental management across industries