OEM Update May 2015 by I-Tech Media Pvt Ltd

MAHENG/2009/33944

Vol 6 Issue 12 • Pages 44 • Mumbai

May 1, 2015 • `100 • www.oemupdate.com

OEM UPDATE Redefining Manufacturing Engineering How CAD/CAM solutions are changing the way a product should be designed

Machine alignment with laser trackers Applications of laser tracking technology for use with various types of machines that manufacturers use

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OEM UPDATE

Redefining Manufacturing Engineering How CAD/CAM solutions are changing the way a product should be designed

CONTENTS FEATURES Machine alignment with laser trackers

20 Hannover Messe: it was all about “Make in India” Industry keen to join the new investor friendly India’s journey to become a global manufacturing hub

26 The consumerisation of manufacturing IT Smart devices are a consumer success story. Their portability and power are also helping to ‘smartify’ the manufacturing industry – and this is just the start

30 Power tool sector best positioned for pulsating growth: Bosch An exclusive interview with Vijay Pandey, Vice President, Bosch Power Tools

32 Tips to improve life of hose U. K. Prasad, GM-Technical, Gates India Pvt. Ltd. explains the ways to improve usage life of your hose

36 The Connected Enterprise must continually evolve “Just one in 10 plants has an IoT strategy in place or is planning to put a strategy in place” Lean & Efficient Manufacturing Advanced technologies in manufacturing that automate, optimise and streamline manufacturing processes to enhance overall production performance

38 High temperature abrasion resistance coating

May 2015 n OEM Update

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I-Tech Media Pvt Ltd, 15/2, Second Floor, Chandroday Co-Op Society, Swastik Park, CST Road, Chembur, Mumbai - 400071. (India) Tel.: +91-22-32682214 / 15 Printed and published by Ms. Radha N. Poptani on behalf of I-Tech Media Pvt Ltd and printed at Print, Process Offset Printers, B-23, Royal Industrial Estate, 5-B, Wadala, Mumbai-400031 and published from 1, Gayatri, Karumari Amman, Chheda Nagar, Chembur (West), Mumbai- 400089. Editor: Ms. Radha N. Poptani. All rights reserved. While all efforts are made to ensure that the information published is correct, OEM Update holds no responsibility for any unlikely errors that might occur. The information on products and services / technology on offer is being provided for the reference of readers. However, readers are cautioned to make inquiries and take their decisions on purchase or investment after consulting experts on the subject. OEM Update holds no responsibility for any decision taken by readers on the basis of information provided herein. Tel.: +91-22-32682214/15, +91-9821667357

Dear Readers, Welcome once again. CAD/CAM/CAE solutions have become integral part of the design process. Today any company which is into designing products must have a CAD/CAM/CAE infrastructure in its research and design wing. CAD/CAM technologies provide the ability to design, visualise and simulate a product from the earliest concept phase to avoid design errors that may otherwise not appear until the physical prototyping stage. There has been a tremendous amount of improvisation and innovation in the field of CAD/CAM over the past decades. This time we have discussed on the opportunities for Indian manufacturers where they can be benefitted by leveraging on innovative CAD/ CAM technologies for higher productivity and gaining competitive edge. Experts from Autodesk India, Delcam UK, Tata Elxsi, and CAD Macro Design and Solutions have shared their bits on this topic. Highlighting the transformation in the field of manufacturing technology, experts from DesignTech Systems talked on the advanced technologies that have revolutionised manufacturing to make it more streamlined, efficient and oniterative are digital manufacturing solutions, 3D printing and PLM. Laser tracker is a portable coordinate measuring machine (CMM) based on 3D co-ordinate technology. This time, we have also discussed the applications of laser-tracking technology that can be used with various types of machines that manufacturers use. The who’s who from the industrial world have recently gathered at Hannover Messe — world’s leading trade fair for industrial technology — and showed the world that how new ideas can be turned into market-ready products and process. The event will certainly be remembered for the omnipresent ‘Make in India’ Lion that roared throughout the days. I feel the India Inc. will be quite optimistic, as it received an overwhelming response at the mega event. This issue also featured the highlights of Hannover 2015 and outcome thereof. As you all aware, OEM Update is completing its journey of 5 years with this issue, the June issue is going to be a milestone one! We’d like to invite you to be a part of this issue. Please do send me your feedback at editor@oemupdate.com

May 2015 n OEM Update

Quick update

Danfoss unveils new options for Reverse Displacement Motor Danfoss has introduced new, valuable options for its innovative Reverse Displacement Motor (RDM). The expanded RDM option portfolio increases both functionality and customer value.

New Danfoss RDM options provide customers with more functionality through control options and increased displacement. The compact motor now features the following added options: 38 cc, 45 cc, speed sensor and 24V valve

The open circuit piston motor offers reverse circuit functionality without external valves — an unprecedented hydraulic system solution for mobile equipment applications. With wider product options, the RDM can be designed to meet individual needs of customers, increasing function and value. “The RDM enables customers to achieve up to 10 per cent power savings, a 15 per cent average reduction in total system cost, and reduced system complexity,” Danfoss claims. New RDM options provide customers with more functionality through control options and increased displacement. The compact motor now features the following added options: 38 cc, 45 cc, speed sensor and 24V valve. The new increased displacements allow the RDM system solution to be available for larger machines. A new speed sensor option provides more precise system efficiency control and the 24V valve enhances the RDM to accommodate additional machine electric architectures. The Danfoss RDM features a 12V or 24V integrated proportional shifting valve that allows smooth, on-the-go

reversing using system pressure. The simplified design of the RDM eliminates the external valves and pressure supply required in typical reversing solutions — and eliminates the cost and pressure losses associated with them. The RDM is complementary to the Danfoss Series 45 open circuit axial piston pumps, PLUS+1 microcontrollers and DP700 PLUS+1 mobile machine displays, and is ideal for fan drive systems in Tier 4 agriculture, forestry and construction equipment applications. The reverse functionality of the RDM enables the fan to purge trapped dirt and debris, restoring cooling efficiency. Danfoss fan drive packages including the RDM can be tuned to meet the unique cooling requirements of Tier 4 equipment applications. “At Danfoss, we’re dedicated to being our OEM’s strongest partner in mobile hydraulics,” said John Heller, Product Marketing Manager at Danfoss Power Solutions. “We know OEMs depend on our expertise, and we’re pleased to offer a variety of options for the RDM, so each customer’s specific needs are met.” Working in partnership with customers, Danfoss provides high-value, high-performance components for a broad range of mobile equipment applications. Danfoss designs, manufactures and sells a complete range of engineered hydraulic and electronic components including hydrostatic transmissions, mobile electronics, orbital motors, steering components and PVG proportional valves. n

Hypertherm introduces new Centricut brand quick change torch for ESAB cutting systems Hypertherm, a U.S.-based manufacturer of plasma, laser, and waterjet cutting systems, announced a new Centricut brand quick change torch for use with ESAB plasma cutting systems. The torch, which incorporates proprietary Hypertherm technology, is designed to replace ESAB PT36, PT-600 and PT-19XLS torches.

were consistently equal to the OEM while costing 20 to 30 per cent less.

It will perform like the original ESAB single piece torch design, while increasing productivity. The two-piece quick-change design allows operators to change out consumables up to three times faster or, through the use of multiple torch heads, load consumables for the next job while cutting the current job.

The performance is due in part to Hypertherm’s patented SilverLine electrode and CoolFlow nozzle technologies. SilverLine technology features a hybrid copper / silver weld joint that delivers performance equal to a solid silver electrode for a fraction of the cost. Advanced cooling features reduce the operating temperature of the electrode maximizing the hafnium pit depth and slowing its wear rate to extend electrode life. CoolFlow technology improves cooling to help maintain the size and shape of the nozzle orifice for longer life.

In addition, operators can experience a lower overall operating cost by using Centricut brand consumables with either the new quick change torch or their current ESAB single piece torch. In field-testing, cut quality and consumable life from the Centricut brand consumables

“This new torch provides owners of ESAB systems with the time-saving benefits of quick-change technology at a very affordable price,” explains Cynthia von Recklinghausen, product marketing manager for Hypertherm’s Centricut brand. n May 2015 n OEM Update

The Revolution

in CNC-Machining!

The unique, patented iMachining module of SolidCAM, the leading CAM software, integrated with SolidWorks and Autodesk Inventor, provides unbelievable savings and increased efficiency in your CNC milling operations, translating into profits and success for SolidCAM customers worldwide.

iMachining saves 70% and more in CNC machining time iMachining extends cutting tool life dramatically The unique iMachining Technology Wizard, provides optimal feeds and speeds, taking into account the toolpath, stock and tool material and machine specifications.

www.solidcam.com

Quick update

AV multimedia LSZH Ethernet cabling simplified HARTING’s recently launched Ha-VIS preLink simple, fast assembly Ethernet cable connectors that are ideal for Cat 5, Cat 6 and Cat 6EA AV multimedia public building like theatres, concert arenas, schools and universities, conference and exhibition centres, cruise ships and luxury superyachts and also outside broadcast vehicle installations or any other confined space application where the latest fire regulations demand the use of “LSZH” cables. The Ha-VIS preLink is designed to terminate solid or stranded conductors allowing optimum cost efficient use for both fixed and flexible cabling installations. They can accommodate a conductor range AWG 27 to 22 allowing maximum Ethernet cabling lengths for the complete Ethernet infrastructure. The simple, repeatable, vibrationproof IDC contact termination design can handle conductor-plus-insulation material diameters of up to 1.6 mm, which supports the typical LSZH cable specifications. In addition overall cable outer jacket sizes up to 9 mm can be handled. HARTING’s Ha-VIS preLink reliable pre-terminated IDC terminal module design concept make it ideal for use in difficult confined space installations, pre-assembled patch leads fitted with replaceable protection covers allow easy trunking drag-through. The terminal modules are then

finally clicked into the connector housings to complete the job. The rugged male and female cable connector metal housing construction ensures fully screened secure Ethernet data transfer up to 10 GBit and a long service and maintenance life. The Ha-VIS preLink design concept allows the most cost effective, fully flexible future-proof installation, when higher Ethernet performance cable system upgrades become necessary, as the connectors can be re-used by retrofitting new pre-terminated low cost terminal modules The connector range is complemented with the Ha-VIS preLink Extender allowing easy cabling extensions. The HaVIS preLink female cable connectors can be accommodated in 19-inch patch panels of either the “Keystone” module or HARTING’s own “HIFF” design format. Finally they can also be fitted individually to panels by integrating into HARTING’s wide ranging IP20 to IP68 bulkhead housing connector designs. Contact: HARTING India Pvt Ltd Abhishek Bimal Assistant Marketing Communications Manager 7th Floor (West Wing), Central Square II Unit No.B-19 Part, B 20&21, TVK Industrial Estate Guindy, Chennai - 600032 INDIA Tele: +91-44-43560415 Fax: +91- 44-4356 0417 abhishek.bimal@HARTING.com www.HARTING.in

Chamfer mill 45-degree Chamfer Mill 45-degree from Nine9, Taiwan is designed for chamfering and countersinking with an indexable insert. The insert is a specifically designed for use in high speed machining thus optimizing performance and reducing cutting time. Ultra highspeed and feed rate is the biggest advantage of Nine9 Chamfer Mills. It runs 4 times faster in cutting speed and 10 times higher in feed rate. Excellent repeatability • Claims to be the smallest insert in the world for chamfering mill, diameter 4-mm. 10

• Smallest indexable counter sink, diameter 7-mm. • Insert has dual relief angle, with special honing of edge and with optimised coating for high cutting speed application. Application • 90-degree counter sink and 45-degree chamfering. • For counter sink, circular chamfering, contour chamfering and face milling. Contact Stitch Overseas Pvt. Ltd. Corporate Office: Plot Nos. 179 & 180, Industrial Estate, Udyog Vihar Phase-VI, Sector-37, Gurgaon - 122 004. Haryana Tele: + 91-124-4755400; Helpline No. +91-9313361202 Email.: stitch@vsnl.com www.stitchtools.com May 2015 n OEM Update

Honeywell launches digital dashboard to manage cyber security risk for industrial sites

Light Dashboard and industry

Honeywell Process Solutions (HPS) launched the digital dashboard designed to monitor, measure and manage cyber security risk for control systems for refineries, power plants and other automated production sites throughout the world that are at increasing risk of cyber attacks. The Honeywell Industrial Cyber Security Risk Manager is designed to simplify the task of identifying areas of cyber security risk, providing real-time visibility, understanding and decision support required for action. It monitors and measures cyber security risk in multi-vendor industrial environments. The threat of cyber attacks on industrial targets is a major concern according to a global survey on cyber security conducted by Ipsos Public Affairs in September 2014 on behalf of Honeywell. More than 5,000 adults in 10 countries were surveyed about the threat of cyber attacks on critical industries in their countries. Three quarters of respondents said they were fearful that cyber criminals could hack into and control major sectors and elements of the economy. Two-thirds of those surveyed thought that the oil and gas, chemicals and power industries were particularly vulnerable to cyber attacks. “Industrial processors are increasingly challenged to understand their cyber security risks,” said Jeff Zindel, global business leader Cyber Security, HPS. “And many times, they don’t know what to do with the data they are provided or what to do if an incident occurs. Risk Manager changes that. It gives guidance on the potential impact of threats and vulnerabilities as well as possible resolutions, making it easier to manage cyber security risks.” Risk Manager uses advanced technologies that translate complex cyber security indicators into clear measurements and key performance indicators (KPI), and provides essential information through an easy-to-use interface. The intuitive workflow allows users to create customised risk notification alerts and perform detailed threat and vulnerability analysis so they can focus on managing risks that are most important for reliable plant operations. “Industrial facilities have clearly become targets for cyber attacks. Safety and operational continuity demand a clear understanding of these serious, dynamic risks and a program to ensure that they remain within acceptable levels. While most organisations recognise this need, operational people often lack the expertise to properly assess and manage cyber risks,” said Sid Snitkin, vice president, ARC Advisory Group. “So, we applaud Honeywell’s development of the Industrial Cyber Security Risk Manager. From what we’ve seen, it is a comprehensive, yet understandable, solution that should meet the needs of operational, automation, and manufacturing IT personnel.” n May 2015 n OEM Update

Cover Story

Redefining Manufacturing Engineering

How CAD/CAM solutions are changing the way a product should be designed

Manufacturing industry is going through a metamorphosis due to changing economic environment and several global factors which are shaping the way products are being manufactured. With increased focus on higher productivity, efficiency and durability along with demand for greater looks, the manufacturing process for any product entails precision designing. Here computer-aided design, manufacturing and engineering analysis (CAD/CAM/CAE) solutions come in to the play. Today CAD/CAM solutions are increasingly being used in the manufacturing industry and have transformed the manufacturing process in terms of designing efficiency, productivity with speed and accuracy. CAD/CAM software are used by CNC Machine shops across the world for its advantages in CNC metalworking. In this article, experts from Autodesk India, Delcam UK, Tata Elxsi and CAD Macro Design and Solutions have outlined the benefits of using CAD/CAM in industrial manufacturing.

There has been a tremendous amount of improvisation and innovation in the CAD/CAM domain over the past three decades.

Vineeth Seth, Managing Director, South Asia and Middle East, Delcam UK

CAD/CAM in industrial manufacturing CAD/CAM is a process that involves usage of computer software to both design and manufacture products across various industry sectors. CAD/CAM applications are used to both design a product and program manufacturing processes. CAD is the use of computer technology for design and documentation. CAM software uses the models and assemblies created in CAD software to generate tool paths that drive the machines which transform the designs into physical parts. This software is most often used for machining of prototypes and finished parts. Talking about the advantages of using CAD/CAM solutions in manufacturing industry, Harsh Pareek, Head, Technical solutions, Autodesk India says, “Effective use of CAD/ CAM technologies help establish a product development methodology that effectively utilises a product platform to create a multitude of configurations to adapt to the customer’s needs. CAD/CAM technologies provide the ability to design, visualise and simulate a product from the earliest concept phase to avoid design errors that may otherwise not appear until the physical prototyping stage.” In addition, CAD/CAM also facilitates multiple stakeholders to communicate and collaborate throughout the development process, without recreating data to meet their needs. “The Indian manufacturers have immense opportunities where they can benefit by leveraging on innovative CAD/CAM technologies for higher productivity and quality to gain a competitive edge,” Mr Pareek adds. Mann Mohan Prasad, VP and Head, Systems Integration, Tata Elxsi, throws light on the role of CAD/CAM in manufacturing. He says, “CAD/CAM/CAE is an integral part of the design process and any company which is May 2015 n OEM Update

Cover Story

The overall integration of CAM systems and PLM tools has become the trend of the hour.

K. Manickam, CEO, CAD Macro Design & Solutions Pvt Ltd. into designing products must have a CAD/CAM/CAE infrastructure in its research and design wing. To be competitive and stay competitive, companies must have a strong design team which ensures the cutting edge for the products and solutions they take to market and stay ahead of their competition” K. Manickam, Managing Director, CAD Macro Design and Solutions speaks on the role of CAM in the industry. Speaking of CAM solutions, he says, “It is a universally accepted fact that CAM systems could maximise the utilisation of the production equipment available in the shop floor which includes improved speed, 5-axis, multi-function and operator friendly entry, editing platforms with machines related to turning, wire EDM and milling functions. They have also contributed to better manufacturing automation in NC data creation, verification, optimisation and finally to consolidate the overall documentation. The overall integration of CAM systems and PLM tools has become the trend of the hour as a part of improving the manufacturing automation and take it to the next level.” Vineeth Seth, Managing Director, South Asia and Middle East, Delcam UK shares interesting points on the current status of the CAD/CAM industry. He opines, “There has been a tremendous amount of improvisation and innovation in the CAD/CAM domain over the past three decades, with most of the major changes coming in the past decade. CAD models are now the basis of every component and assembly design – however small or big they may be. When we look at the various manufacturing processes such as drilling, turning, turn mill, milling, grinding, trimming, laser cutting, amongst others in subtractive manufacturing, and in processes like 3D printing, CAD/CAM plays a vital role in planning and executing machining sequences for such products.” CAD/CAM software and solutions Software solutions play a major role in the entire process, as several industries are heavily dependent on CADCAM solutions in order to design their products. With only a handful of software manufacturers, several OEMs are dependent on these software programs. It becomes imperative that solutions are provided keeping in mind, the end product. There are several solution providers in the market who use software tools to provide the endMay 2015 n OEM Update

user with the solutions that they need. This is true for every industry or end product where design comes into the picture. Therefore solution providers play a very important role when it comes to designing. Speaking of tools to enhance user experience, Mr Pareek says, “Autodesk delivers advanced Computer-Aided Manufacturing (CAM) solutions to a broad range of users, from designers and engineers to expert CNC programmers, regardless of their CAD tool of choice. HSM Works and Inventor HSM software are integrated CAM solutions offerings from Autodesk. Whether it is about producing prototypes or finished parts, these products put the designers in control by delivering seamless integration with leading product design software applications offers an intuitive user experience. The HSM software works on a native multi core, 64-bit CAM engine makes easier work of the most demanding tool path calculations and post-processing jobs.” Speaking on the cloud integrated CAM systems, Mr. Pareek continues, “Autodesk has also made CAM in the cloud a reality with the help of Fusion 360 enabling the next generation design-to-manufacturing workflow. Autodesk Fusion 360 allows the user to take advantage of collaboration tools and shared data storage with unparalleled ease of use and flexibility. The Autodesk approach to digital prototyping is unique in that it is scalable, attainable, and cost-effective, which allows a broader group of manufacturers to realise the benefits with minimal disruption to existing workflow and deliver a better manufacturing experience. Autodesk Fusion 360 is one of the latest examples of Autodesk leveraging the cloud to democratise design and innovation.” Speaking of Delcam’s range of software products, Mr. Seth says, “Delcam is the number one supplier of specialist CAD/ CAM software and services to a spectrum of industries including aerospace, automotive, white goods, tool making, packaging, jewellery and woodworking, footwear, healthcare and others. We also test all our software in this advanced manufacturing facility, in order to deliver realistic and meaningful results to our 40,000 plus customers across the globe.” Tata Elxsi works with the Siemens PLM and offers their entire suite of products covering CAD/CAM/CAE and PLM. “We also work with Autodesk and are the exclusive partner for their industrial design software tools used extensively in concept design and styling in automotive and other industries,” Mr. Prasad says. Explaining on some of the solutions offered by CAD Macro Mr. K. Manickam says, “During the launch of our CAM tool for Wire EDM machines in 2003, we wanted to become a one-stop-shop for the entire tool room management. With the realisation of this goal, we are today serving more than 350 clients. As a pioneer in the Tools Management CAD/ CAM solutions for turning, wire EDM, press tool, milling and overall ERP for die and mould industries, we deem it responsible to provide a wide range of solutions and contribute to better PLM models and improvise on resource planning.” n 13

Technology

Lean & Efficient Manufacturing Advanced technologies in manufacturing that automate, optimise and streamline manufacturing processes to enhance overall production performance in the inventory is also a muda as it is not being sold and it neither contributes in generating the revenue for the producer i.e. the company nor does it add consumer value. 3 Motion: It refers to the damage done to the machine while using it. Over the time due to wear and tear the machine does not operate as efficiently as it used to. working on such machines do not add to the consumer value but in fact reduces the quality of production and requires additional work to be done to rectify the damage done. It also involves the human fatigue that arises due to high stress and very high workloads. Such mudas should be addressed as they bear an adverse impact on consumer value that either result in reduced or inferior production and/or excess investment of time and costs to rectify.

Source: DesignTech Systems Ltd.

Manufacturing technology has evolved substantially and can now facilitate companies to not just design, optimise, and streamline their manufacturing plant layouts, processes and resources but also integrate manufacturing with the product design functions seamlessly to better plan production processes. Latest technologies in Manufacturing and Product design and development can help companies augment product design and manufacturing efficiency by eliminating the ‘wastes’ to enhance the quality and quantity of productivity thus bettering the overall manufacturing performance. An original Japanese methodology, known as Toyota Productions systems designed by Sakichi Toyoda, devised a way for the companies to streamline their production processes to enhance overall production efficiency. It aimed at eliminating the wastes or as it is known the ‘muda’ to enhance consumer value while increasing the overall efficiency of production processes. Toyota’s Chief Engineer, Taiichi Ohno as part of the Toyota Production System has classified 7 types of mudas or wastes which companies need to address to attain lean manufacturing: 1 Transportation: Products, raw materials or inventory should be transported as less as possible to avoid any damage, delay or risk of losing. And transportation in any way does not add to the consumer value. 2 Inventory: The stock of inventory in the form of raw materials should be in proportion required enough to achieve desired production. Over stocking or under stocking is a muda that leads to excess time and/or money consumption. the stock of finished goods lying 14

4 Waiting: The goods should never lie idle. They should either be worked upon or should be in transit or transportation, otherwise goods lying idle are a muda. 5 Over processing: This involves working on the product too many times or for a very long time than it actually matters to the consumers. Over processing involves over analysing of the product, using more complex or expensive machinery or tooling than necessary etc. 6 Over production: The supply or production should be in proportion with the demand for the product. Over production leads to over stocking of inventory not just of raw material but also finished goods. Not to mention over production leads to over utilisation of other resources such as money and space to store the inventory and over produced goods, human efforts in producing larger quantities of products, and excess use of other resources such as machine, material, etc. Over production is one of the biggest muda that companies need to do away with as it is not just a burden on the company’s’ resources but in fact also reduces consumer value. 7 Defect: Any defect in the product or process results in incurring additional time, costs and resources to rectify and reproduce. Efforts should be made to identify and correct the defects earlier in the production cycle to eliminate the chances of rectification and reproduction. The latest technologies in CAD/CAM/CAE, PLM and 3D printing can help companies address all these challenges and help them set-up processes that result in eliminating ‘muda” and maximising production efficiency. Some of the advanced technologies that have revolutionised manufacturing to make it more streamlined, efficient and on-iterative are digital manufacturing solutions, 3D May 2015 n OEM Update

Technology printing, and PLM. From manual manufacturing processes of yesterday, the industry today has made a shift towards digital manufacturing. Digital manufacturing solutions help create 3D simulations of plant design and functioning including men and machine interaction to help define the most efficient, safe, non-iterative, and non-interfering or hindrance free manufacturing processes. Right from assembly lines, human ergonomic simulation, to robotic simulation, plant layout, etc. could be defined and analysed virtually in the 3D environment. Digital manufacturing solutions and technologies through their offerings like “design for manufacturing” and “design for servicing” help the companies configure optimum work flows during the plant layout stage which enables the companies in enhancing the productivity and overall output of the company. Issues concerning to constraints in manufacturing or feasibility of manufacturing, popularly referred to as “manufacturability concerns” or “ergonomic constraints” are very difficult and highly expensive to rectify once the plant, work flows and processes are established. A prior validation would help companies identify such concerns at the earlier stage of planning and would hence save the time and cost of rectification. Even the existing plant could be rendered virtually and modified to see how manufacturing efficiency can be enhanced which then can be implemented by the companies in their physical plant space. 3D printing technologies are used not just for building models and parts for physical product design validation such as visualisation, fit, form and ergonomics, but infact can also be used to build parts for end-use applications. For example, Fortus series machines from the Stratasys can help build parts which can be used as the final product. Examples of some of these parts are jigs, fixtures, mould inserts and many more. Fortus series or production series machines from Stratasys use ABS+ Thermo plastics or production grade plastic as the material to build parts that are strong and can withstand high temperature, making them perfect to be used as final product. This is ideal for small batch productions. Some of the metal 3D printers can also build parts for enduse applications. A German company named SLM offer metal 3D printers that can build accurate and precise parts, making it an ideal choice for the companies to consider for manufacturing limited number of products. Today, more and more companies are investing in 3D printers as an option for manufacturing. The biggest advantage is lesser cost of error, easier to make design changes and faster productivity. A typical steel mould takes a few weeks to be developed, as against a mould insert can be developed using 3D printer in a day’s time. Also if a design error is identified in the steel mould, then correcting it and developing the mould takes ghastly long time. whereas if a company is using a 3D printer to build a mould, then the necessary design changes can be made in the CAD file, and the mould can be printed again in a day’s time. PLM basically helps companies integrate, configure and manage their design data, processes, and workflows right from the initial stages of product development cycle, i.e. concept stage to design, simulation and validation, right through to manufacturing and releasing the product to market. It helps May 2015 n OEM Update

companies with the setting up of effective data management systems, efficient workflow and process configurations, and overall system validation. PLM also automates the work flows that helps exert a strong grip on the product development process, and thereby bring more control and discipline, and streamline the overall development cycle. PLM typically works within and addresses these five primary functional areas namely: l Requirements management l Project management l Engineering process management l Manufacturing process management l Supplier relationship management. Benefits of PLM l End to end management of data, information, process, resources l Collaborative product development l Synchronised development process, zero idle time l Early time to market l Increased market success. It is said that, on an average, a company spends 40 per cent of its revenues and 60 per cent of its time in research and development. Latest technologies like these can help companies optimise their design and development cycle, boost product design innovation, optimise use of resources and save immeasurably precious time and costs of product development that would help them attain a leading position and higher market share. Shrinking product life cycles, growing imperative to develop innovative products faster and better than the competition, higher bargaining power of the consumers has necessitated the companies into product design and development to adopt latest technologies in product design and manufacturing that would help them compress their design and development cycle, and hit the market early with smarter products that perform offering them to the consumers at competitive rates. n Authored by__

Vivek Mahajan, National Technical Support Manager-PLM, DesignTech Systems Ltd.

Innovation

Machine alignment with laser trackers The article discusses the applications of laser tracking technology for use with various types of machines that manufacturers use use of laser trackers for industrial measurement became widespread. Compared to traditional methods, the laser tracker is a powerful, user-friendly device that can perform multiple measurement tasks in a much shorter time. This device combines the capabilities of several traditional tools in one, including the ability to: check for plumb, level, squareness, and parallelism; verify and conduct positional checks of rotary axes and multi-axis heads; reposition a part on a table without a rotational bed; perform realtime adjustments of machine beds, rails, and ways; as well as measure bore alignment, coupling, and shaft alignment. More importantly, the laser tracker captures data points in a three-dimensional (3D) space, which provides users with higher precision and versatility in data usage.

Calibration of robots with the laser tracker

The popular adage –“If it ain’t broke, don’t fix it” – might be a piece of advice that is dished out often, but perhaps less appropriate if applied in the context of a manufacturing facility. In the world of mass production, machines are put to repetitive tasks each day to churn out large outputs of identical items. At the production volume is key, it is vital to ensure that machines are often checked, so that the manufacturing process never gets disrupted. When the manufacturing process is halted due to machine misalignment, companies risk losing a significant amount of investment in the form of time delay, reduced productivity, and scraps. However, these costs can be avoided if companies take careful ownership of preventative maintenance, minimising the likelihood of equipment failure or downtime. In fact, by adopting the preventative maintenance approach, quality management departments can also better ensure that products leaving the facility meet quality benchmarks, as wellmaintained machines are the foundation of manufacturing processes. Besides, machine alignment significantly increases the lifespan of tools, which can be expensive to replace. For these reasons, companies have found it necessary to perform machine alignment regularly and efficiently. Single-use tools Vs. multi-function device In the past, companies used to rely on traditional alignment methods that involved tools such as machinist levels, piano or tight wires, optics (e.g. borescopes, theodolites, etc.), and laser. While these tools worked well in most cases, they often served only single, dedicated function. Using these methods, calibration and alignment would typically take days or even weeks to complete. It was also common to involve multiple instruments, which translated to higher costs and more time spent on setting up in each step. Naturally, companies sought out better and faster ways for machine alignment to be done. In the early nineties, the

Basic mechanics of a laser tracker The laser tracker is a portable coordinate measuring machine (CMM) that is based on 3D coordinate technology. Fundamentally, these devices provide the benefits of CMMs with the added versatility of being portable, which allows the user to deploy wherever there is a need, without having to move their machine. In addition to being less costprohibitive than fixed CMMs, portable CMMs do not require a controlled environment, making it more cost effective to operate and maintain them. Designed to handle larger working volumes, laser trackers offer extremely accurate measurements over long ranges. Put simply, a laser tracker establishes the precise location of a target in spherical space by measuring two angles and a distance, each time it takes a measurement. It does so by sending a laser beam to a retro-reflective target, which has to be held against the object being measured. The return beam re-enters the laser tracker where the distance to the target can be determined using interferometry or phase shift analysis. The horizontal and vertical angles to the target probe are determined using precision angular encoders attached to the mechanical axis of a gimbaled beam steering mechanism. Using the two angle measurements and distance determined by the laser, the laser tracker can report the coordinate location of the target probe to extremely high accuracy levels. In addition, the laser tracker can follow or track the target probe as it moves in real time. This unique feature, coupled with the laser tracker’s ability to internally sampling rate of up to 16,000 times per second, enables the user to digitise data on complex surfaces or measure the location of moving objects. In fact, laser trackers today have impressive measurement ranges and accuracies that provide users with more versatility and better results. For instance, the FARO Laser Tracker Vantage’s radial distance measuring range is 80 metres, and Continued to 18

May 2015 n OEM Update

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Checking for perpendicularity and parallelism of posts in presses

at that range, it captures data at typical accuracies of up to 39 microns (0.039 mm). Weighing just under 18 kg, the Vantage offers portability and flexibility on measuring large parts, no matter where production is located within the plant. Manufacturers can achieve unprecedented speed and efficiency by capturing more with fewer device moves and shorter routines. Laser tracker in machine alignment scenarios (para) The American Society of Mechanical Engineering established a set of standards for the correct and accepted methods to check and align machine tools with a laser tracker. Here are some documented scenarios of alignment being performed on a variety of machining centres, machinery, and other equipment. Machining centres Horizontal/vertical machines, bridge, column, or gantrytype machines On these machines, the laser tracker can be used to check for surface level, straightness, flatness, and squareness. The target is placed on the machine bed to capture measurements, and users can either make adjustments in real-time, or obtain a complete set of points before adjusting the machine bed afterwards. For tool alignment, the target can be placed in the spindle, chuck, or quill of the machining centre. Measurements can also be obtained by placing the target on a pin nest that gets mounted directly into the drill of the machine. Alternatively, it can also be placed in a ‘puck’, or a drift nest, which can be glued on to a moving bed. As the target sits on its respective locations, 3Ddata points are collected while the machine travels through a range of movements to check for alignment issues. Apart from checking the machine bed, the laser tracker can also be used to check for plumb, level, or ensure parallelism in the rails. Additionally, conducting 3D volumetric accuracy checks and re-mapping the machine are possible functions. Boring mills, jig borers, gantry drills, routers, and lathes The same checks of levelling, squareness, alignment, and 3D volumetric accuracy checks can be made on these machines. For lathes, in particular, laser trackers can perform turning centre alignment by tracking a target that is affixed on to the headstock with a drift nest. Much like how machine beds are measured, data points are collected as the headstock turns, moving incrementally towards the tailstock in a circular fashion. Adjustments are then made to align the tailstock with the headstock accordingly. Machinery Presses – platen, stamping, and brake press (sub-sub-para) With presses, laser trackers are useful for checking

perpendicularity and parallelism of posts, as well as platen parallelism. The ends of each pole on each side of the planes are measured and compared to ensure it lines up square (between pole and plane) and parallel (between planes) respectively. Any deviation can be corrected based on the readings acquired. Rolls Laser trackers are also effective at conducting shaft alignment checks in roller mill machinery. Shafts need to be in proper alignment and orientation in order to function well, and the laser tracker allows such checks to be performed easily on a roll (or series of rolls). Real-time adjustments can be made as measurements are being taken. Data points at both ends of a shaft are acquired by placing the target on the cylinder. The information collected by the software allows users to identify the movement that is required to put each roll back into alignment. Other equipment Calibration of robots In this application, the target is ‘held’ by the robot while measurements are being taken. The laser tracker dynamically tracks the target as the robot moves through its programmed path. By analysing the data points, a user can tell how much the robot has deviated from its nominal path, thereby directing him on remapping, calibration, or error compensation actions that will allow the robot to move properly through its range of motions. Drivelines including gearboxes, shafts, and couplings In the assembly of power generation equipment like a driveline, the laser tracker can ensure that components are lined up correctly, according to design. The laser tracker is mounted with a magnet to hang off the side of a machine, so that it has a direct line of sight to all the features of interest. In this manner, the laser tracker can take measurements of the driveline while it remains on the machine tool. As checks are being made right on the shop floor, adjustments can be made without taking the set-up apart, which saves time and eliminates the need for rework. Evidently, the laser tracker is an effective complement for the practice of preventative maintenance, which reduces downtime, enables cost-savings, and also improves the quality of output. It is a robust tool that can be deployed anywhere on the shop floor, the laser tracker’s multiple functions can suitably replace a variety of hand tools, making it a worthwhile investment. Companies expanding their capabilities to include in-house machine alignment now have the laser tracker as an option apart from traditional methods. n Authored by

Eddy Lek, Product Marketing Manager, FARO Technologies

Anthony Lur, Product Marketing Specialist, FARO Technologies

May 2015 n OEM Update

Special Report

Hannover Messe: it was all about “Make in India” India is going all out to woo foreign investors to bet on the country’s growth story. The efforts were continued at the Hannover Messe 2015, the world’s largest industrial trade fair. Being the official partner country, India has been able to galvanise its resurgent position as an investment and manufacturing hub in front of the global industry. Living up to the hope of “opening many more doors” as envisaged by Prime Minister Narendra Modi’s in his inaugural address, the event not only saw the ‘Make in India’ movement take a global dimension but also paved the path for several new investment avenues and stronger economic engagement with India. With the ‘Make in India’ theme splashed all over, the Indian presence is pre-dominantly visible all over the ground and the city of Hannover. An environment of enthusiasm, promising exchange of ideas and investment in the new resurgent India prevailed at the India Pavilion that was crafted to portray the economic potential of the country’s most fertile sectors— biotechnology, renewable energy, space, IT and BPM, industrial corridors and smart cities, wellness, and the demographic dividend it aims to reap. A positive revivalist fervour prevailed as senior Indian government officials and 20

business leaders reached out to representatives of German and European industries and technology institutions to ink MoUs aimed at scaling up the country’s manufacturing. At a time when India and Germany are orchestrating a paradigm shift in their bilateral economic relations highlighted by increasingly diversified cooperation, a high-powered delegation from India visited Germany and participated in the Hannover Fair 2015; over 350 companies spread across 10 sectoral halls; 6 Government of India ministries/departments participating through 6 seminars; 14 state governments participating through 6 seminars; and over 120 top Indian CEOs. Well-known industry leaders and policymakers, along with apex national level industry organisations came together to forge new relationships for Indian companies to reach out to global business and technology leaders to seek technology collaborations, business tie-ups and enhance India’s capabilities in global trade. In order to facilitate progressive dialogue between India and Germany, the Indo-German Business Summit served as a discussion forum for CEOs from both nations. Both Mr Modi and Dr Merkel addressed this summit that was attended by top Indian and German industry leaders such as Cyrus Mistry, Chairman, Tata Sons, Baba Kalyani, CMD, May 2015 n OEM Update

Special Report

List of MoUs/agreements signed at Hannover Messe 2015

Industry keen to join the new investor friendly India’s journey to become a global manufacturing hub Bharat Forge Ltd and Joe Kaeser, President, Siemens. These business leaders explored the possibilities of India’s economic interactions with Germany’s industrial prowess, while posting strong reasons to invest in India. Reflecting on the India’s role this year at Hannover Messe, as the most significant international statement the Make in India program has made to date, PS Gangadhar, First Secretary, Economic and Commercial, Indian Embassy Berlin said, “India’s participation as the Partner Country in Hannover Messe 2015 has put India back on the minds of German and Global investors and business community. We have presented the strengths of Indian economy and opportunities therein at the Hannover Fair. We hope that our efforts will lead to increased business collaboration with German companies and European partners.” Addressing the media, Dr. Jochen Köckler, Member of the Managing Board, Deutsche Messe AG said, “India has set new standards for what we can expect from a partner country and what you can do with the concept of partner country in Hannover Messe. We have had a lot of great partner countries, but it’s your strategy of Make in India with real content that has set the bar very high for future partner countries.” May 2015 n OEM Update

Government to Government • Letter of Intent on Indo German Solar Partnership • Joint declaration of intent on sustainable urban development • Letter of Intent on Indo-German skill development project Business to Business • BHEL and Russian Joint Stock Company (INTMA) for upcoming projects in Rajasthan and Kazakhstan • Rajasthan Electronics & Instruments Ltd (REIL) and Milkotronics Ltd, Bulgaria for manufacturing milk analysers • Instrumentation Limited and KE Kauer Engineering, Germany for production of control valves. • Vikram Solar with o Fraunhofer Institute for Solar Energy Systems ISE o Meyer Burger and Centrotherm for setting up solar academy in India and optimisation of module production technology. • Three MoUs by Hindustan Machine Tools (HMT) with o Num Controls, Switzerland for manufacturing of CNC controls, systems and drives o FT Machine Tools, Germany for collaborating on flow forming machines and o Enit GmbH, Germany for total engineering solutions. • Essel Group with o Wind and Sun Technology Group /FeCon GmbH to develop 12,500 MW of solar and 4,000 MW of wind energy projects in India. o Passavant Energy and Environment (PE&E) for water and waste water treatment projects o Schneider Electric to develop smart city projects in India o Fichtner GmbH & Co to provide comprehensive interdisciplinary range of engineering and consultancy services in areas of energy, water, sanitation, infrastructure, IT and consultancy on the implementation o Smart Grids-Platform Baden-Wuertemberg to act as facilitator in linking the energy networks for Essel group. Others • Declaration of interest for cooperation in the field of vocational education and training between Directorate General of Employment & Training, DGET, Ministry of Labour & Employment, Govt. of India and the Indo-German Chamber of Commerce (IGCC). 21

Special Report

Essel Group inks pact with 3 German firms

HARTING connects

L-R Mr. Ashok Agarwal, Dr. Subhash Chandra and Jean-Hugues Decalf, CEO FeCon GmbH

At Hannover Messe 2015, Essel Group has entered into technology transfer pacts with three German firms for smart cities and green energy projects in India. A MoU for transfer of critical technology in wind and solar energy was signed by the company with FeCon GmbH, a subsidiary company of Wind and Sun Technology GmbH while a similar pact was also inked with Passavant Energy and Environment (PE&E) GmbH for mega-scale wastewater treatment projects in India. As per the agreement, FeCon GmbH will assist Essel in developing and manufacturing wind turbines in India along with power station and grid equipment for solar and wind energy to suit Indian conditions. On the other hand, the MoU with PE&E will provide Essel with access to groundbreaking technologies and processes in municipal wastewater, sludge, water and industrial wastewater treatment.

Volkswagen showcases ‘Made in India’ Vento

Prime Minister Modi and Chancellor Merkel talking to young Indian apprentice who is training at the Volkswagen’s Pune site

German carmaker Volkswagen has showcased its ‘Made in India’ Volkswagen Vento at the Hannover Messe 2015. Volkswagen Vento is a model specially designed car for the Indian market and built at the company’s plant in Pune. “India is and will remain an important strategic growth market for the Volkswagen Group. We are convinced that Volkswagen will take on a key role in the Indian automobile market in the long term. We are driving localisation in India forward with our new engine assembly plant in Pune,” said Prof. Dr. Martin Winterkorn, CEO of Volkswagen Aktiengesellschaft. 22

Federal Chancellor Angela Merkel (second from the left) and the Indian Prime Minister Narendra Modi (far left) received a personalised Han-Modular connector which was produced live at the HARTING stand from Philip F. W. Harting, Senior Vice President Connectivity and Networks and President/ Partner (second from right), and Dietmar Harting, President/ Partner and Chairman of the Board of the HARTING Technology Group (far right).

Federal Chancellor Angela Merkel and the Indian Prime Minister Narendra Modi have visited the HARTING exhibition stand at the Hannover Messe 2015. They were informed about the latest HARTING solutions and products in the field of integrated industry and HARTING’s activities in India. “India has enormous growth potential for the years ahead as an emerging nation. It is therefore becoming increasingly important to HARTING,” remarked Philip F. W. Harting, Senior Vice President Connectivity and Networks and President/Partner. Prof. Dr. Johanna Wanka, Federal Minister of Education and Research, and Matthias Machnig, Secretary of State at the Federal Ministry for Economic Affairs and Energy, also gained an insight on the first day of the trade fair into the innovative HARTING technologies on display at the stand of the Espelkamp-based, family-owned company.

Welspun signs 550-MW MoU with iPLON At Hannover Messe 2015, Welspun Renewables and iPLON announced the signing of a 550-MW MoU. The Independent Power Producer (IPP) has chosen iPLON GmbH, a firm based in Schwaebisch Hall Germany, for supply, installation and commissioning of Solar PV power plant automation systems for its upcoming projects in India. May 2015 n OEM Update

igus presents a new energy supply system at Hannover “guidelok slimline P for less weight and more dynamics saves up to 80 per cent of the cost,” igus claims

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To be able to always achieve faster accelerations and speeds in aisle travels, igus has developed an energy chain supply system completely made of plastic. This is characterised by low weight and moreover, easy installation. Visitors to the igus stand at the Hannover Fair have experienced this innovation and more “motion plastics”. igus has advanced its guidelok slimline system once again and now presents the new GLSL-P, which is entirely made of plastic. The guide system for hanging energy chain applications does not require an enclosed channel trough or other elaborate, expensive enclosures and holds the energy chain system as in aisle travels on the railway. Instead, lightweight plastic segments are mounted only every two metres, which saves up to 80 per cent trough costs and also weight compared to the previous metal option. Therefore, even faster speeds and accelerations can be achieved. Another advantage of the plastic novelty is that vibrations are absorbed better. “The lightweight guide rails made of fibreglass can easily be plugged into the plastic segments of GLSP-P, hence, implementing the installation completely without tools, leading to a reduction in costs yet again,” explains Christian Strauch, industry manager for materials handling at igus.

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Secure hold for energy chain system Two automatically actuated compensators in the segments of the guidelok slimline P fix the e-chain and ensure a quiet, smooth run. If the chain moves in the radius through the segment, the compensator is activated and fixes the energy chain. The innovative locking levers are complemented by open guide rails made of reinforced plastic between the segments, which allows for more dynamics. n Contact Harish Bhooshan Product Manager E-ChainSystems & ReadyChains igus (India) Private Limited 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post Bengaluru – 560048 Tele: +91-80-45127809 (Direct) Harish@igus.in www.igus.in May 2015 n OEM Update

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Special Report

What they say India is now a changed country” with a more “transparent, responsive and stable” regulatory framework. - Prime Minister Narendra Modi Make in India is not about protectionism but about excelling in a globalised world… Research and development is shifting to Bengaluru and Hyderabad in India and alluded to almost 900 MNCs building their R&D centres in India. - Amitabh Kant, Secretary, Department of Industrial Policy and Promotion (DIPP)

Prime Minister of India Narendra Modi addressing the audience at the Hannover Messe 2015

I see a government that is laying the foundation for the long term and this is exceptionally important because we want growth that is sustainable. - Cyrus Mistry, Chairman, Tata Sons With the regulatory changes being made by State governments, in the next couple of years we will see women working side by side in the manufacturing and engineering. - Baba Kalyani, Chairman and Managing Director, Bharat Forge

PM Narendra Modi and Chancellor of Germany Angela Merkel visited Siemens AG booth

Disruptive technology, social media, mobility, cloud and Internet of Things etc. will be needed to build solution at a price point which makes sense in India. - R Chandrashekhar, President, Nasscom India is moving in supersonic speed in implementation of many of the programmes and India is leap frogging when compared to Germany in areas of mobile payment, e-governance and in the scale of UID.

Closing Press Conference India at Hannover Messe 2015 17April2015

- Franz-Josef Schuermann, Country HeadGermany, Infosys India is now evolving and aiming at encouraging growth, ease of doing business, harnessing talent and rekindling the growth story. The world is looking at the new resurgent India with renewed faith and investors are keenly evaluating opportunities of economic engagement. - Erich Nesselhauf, Managing Director and CEO, Daimler India Commercial Vehicles (DICV) 24

Seminar on Skill Development

May 2015 n OEM Update

Feature

The consumerisation of manufacturing IT

Smart devices are a consumer success story. Their portability and power are also helping to ‘smartify’ the manufacturing industry – and this is just the start, explains Christoffer Malm, Head of Connectivity Room at SKF

Smart devices such as iPhones and tablets have created a consumer revolution. No household, it seems, is without one. Smartphones double up as personal stereos and satnavs, while tablets are used as games consoles and portable movie screens. In business too, tablets are increasingly preferred to laptops, particularly for enhancing engagement during the sales process. Now they are spreading to the manufacturing and engineering sector including the factory floor. Manufacturers are harnessing the connectivity, portability and computing power of smart devices to ‘smartify’ the engineering world and create a revolution of their own. SKF, being at the forefront of this, has developed an infrastructure that will allow industry users – whether white or blue collar – to embed smart devices into their working practices. Whether for portable maintenance, personal instruction or simply banishing paper, smart devices are helping manufacturing companies boost their productivity.

SKF’s own employees and many of its customers. All of these apps take knowledge and translate it into software, with powerful analytics and IT algorithms processing the data. Smart devices are the window to access this underlying knowledge. A major US-based customer of SKF that repairs large industrial equipment which often comprises many thousands of components. In such case each step of the process needs to be documented. Earlier, this used to be done with pen and paper, creating a paper trail in case of customer complaints. Now, SKF has developed a data collection system accessed via a phone- or tablet-based app. The huge paper archive can now be replaced by a database, which the customer can instantly access and make sense of.

The potential gains are enormous. SKF has observed the productivity gains of 12 per cent from engineering staff armed with tablets. It allows them to do their job more efficiently, while accessing and making sense of more information.

Using the new system, information on components is still entered manually because they are from different suppliers. Some components will have a unique ID, while many will not. But it’s early days for this kind of system. In future, for appropriate applications, parts might be barcoded or able to broadcast a unique signal – completely removing the need for manual entry. By registering a technician’s position on the shop floor, the nature of a particular maintenance procedure, and the time it is carried out, the smart device can automatically create a log history for each part.

Case studies Apple’s App Store already offers more than 30 apps developed by SKF. They have all been channelled through the company’s digital innovation catalyst team, known as Connectivity Room. Here, SKF engineers distil their knowledge and expertise into apps that can help both

SKF has also developed a number of apps that turn phones and tablets into measuring instruments. These are being trialled at one of its Gothenburg factories to help carry out maintenance as quickly as possible. With help from an internal positioning system (a kind of factory floor GPS), the app pinpoints the position of maintenance

May 2015 n OEM Update

staff on the factory floor. When a machine develops a fault, an alarm is sent preferentially to the nearest person, ensuring the fastest possible response. Other apps guide maintenance staff through monitoring procedures. Sensors are often connected to smart devices, turning them into measuring devices for vibration, temperature and other critical measurements. SKF’s engineers have taken this a step further, by adding an app that tells the operator where to place the sensor – in order to get the best reading, and better results.

In similar fashion, a system called AliSensor ShaftLaser streamlines the process of alignment. Usually, when aligning, for example an electric motor with a pump or fan, a technician would traditionally carry with them a lot of heavy equipment. Now, thanks to smart devices and the minimisation of sensor technology, the equipment weighs much less. Through the guided support, visualisation and instruction provided by the app, training is heavily reduced and the understanding of what to do and when is made much more clear. AliSensor ShaftLaser was developed by GLOi – a Swedish alignment technology specialist that SKF acquired in September last year. GLOi developed the integrated shaft alignment solution, based on the iOS operating platform used by iPads and iPhones. Mobile advantage SKF has developed a Mobile Operator Support Tool (MOST), which visualises the factory production line and connects machine data in real time. MOST will transform the way that operators interact with machinery, by supplying them with the right information, at the right time and in the right place – via a customised mobile device such as a tablet or smartphone. Delivering this wealth of information exactly when it is needed will bring multiple benefits. Operators will be empowered to improve manufacturing performance, and to diagnose and make decisions close to the problem. They will be instantly aware of real time manufacturing process data, such as energy consumption and product variability and be able to act on it. Overall, MOST will help operators overcome many of their everyday problems, leading to greater work satisfaction and greater empowerment. The ultimate aim of MOST is to make it as easy as possible to do the right thing. As well as delivering process data direct to operators, it will include various instructions – how to re-set machines and equipment, preventative maintenance procedures, and much more. These will now be at the operator’s fingertips, rather than in a manual somewhere. Even if the information is in another employee’s head, it can be accessed quickly: one feature of MOST is a communications tool that allows operators and managers to text one another in order to solve problems. This feature has proved extremely effective during factory trials in Gothenburg. From a pure business perspective, getting this connectivity through smartphones and tablets will save enormous amounts of May 2015 n OEM Update

Feature time. SKF has already rolled out more than 3,500 tablets to employees and customers – each user has saved around 12 per cent of their time every week as a direct consequence. One of the huge benefits of smart devices is their ability to simplify data by visualising it clearly. As well as giving instant comprehension of large data sets, it could be used to give simple instructions that guide operators through a particular process, and this has already been implemented in a number of SKF’s apps like AliSensor ShaftLaser for shaft alignment.

Questions such as these must be considered to facilitate the adoption of any new technology and to anticipate any potential resistance so that it can be proactively addressed. In some cases these issues will need to be addressed at a much higher level within an organisation, as its culture, values and general attitude at a corporate level to technology will also have a significant impact on how the technology is utilised and ultimately how much benefit it provides.

MOST can also identify the presence of humans in the factory. The heat treatment department of SKF’s Gothenburg factory is 8,500 sq.m. which is covered by a handful of maintenance personnel. As well as pinpointing the closest operator to a particular machine to aid productivity, the smart device can act as a safety alarm. If a ‘Where are you?’ alert receives no reply, operators can quickly be tracked down – in case they have fainted, for example.

Information overload? The key to systems like MOST is making sense of data. Generating information is one thing; managing it is another. In order to take full advantage of this enormous new data set, it needs to be filtered and presented clearly. There may be top-class hardware, smart devices, apps that gather and collect info, and dashboards, but much of the focus will be on maintaining and ensuring the quality of data and working out how to make sense of it.

Plain sailing? There are obvious advantages to using smart devices in engineering, but a note of caution should be sounded. As with any kind of new technology, there are hurdles to leap before it becomes fully accepted. Because there are issues to resolve and minds to change.

We need to information upon – by It needs to analysis.

Lots of data flows between these devices which rely on WiFi or 3G. But this extra connectivity raises huge concerns about security. Adding more cloud services outside the firewall introduces a potential weak spot, and companies are keen to ensure their in-house data is not compromised. These services will be accessed in a number of ways such as http, https or through new standards. Password protection will be vital, but to make these services usable there needs to be a balance between tight security and ready access. If you build a fortress, nobody will use it; protect it with a single password, and the data could be at risk. In the end, it will be a careful balancing act between the two extremes. Immaterial of the type of technology introduced in an enterprise or to customers, it cannot by itself bring about a change in the way of working or improvements to a certain user scenario. The new technology always needs to harmonise with people and processes to be successful. To be truly effective, add value and cause a redesign of way of working or of a specific process requires a vision of what role the smart devices play. The integration and visualisation of information on those devices then becomes the true innovation. This is something that requires a lot of thought, a lot of perseverance and a lot of drive. You also need to consider the people facilitating the process and therefore potentially using the smart device. 28

How does the smart technology affect them? How does it change their routine and general activities? What is their level of experience of using smart devices?

simplify data visualisation, so the complex can be instantly understood – and acted technicians and maintenance personnel. be a simple interface with powerful data

Dealing with this data overload will be crucial. We’ll have to look at wireless AP (access point) management as it’s called in the IT industry, by creating an interface to integrate all the different data streams. The goal is simple: to present the necessary information clearly, and in real time, allowing recipients of that data to act on it quickly. SKF has already come some way in its journey into mobility. With technology evolving at such a rapid pace, there is no doubt that in the not so distant future things will have moved even further. Smart devices will increasingly become the window through which information is communicated. Today, it is done using off the shelf models like iPhones and iPads, augmented by rugged cases to make them IP68 compliant. In future, these will be tailored devices – thinner, more robust and with new features built in. Smart devices have already proven themselves in the demanding consumer market. If the manufacturing industry were to embrace the technology with the same enthusiasm, just think where we could all be in terms of productivity. n Authored by__

Christoffer Malm, Head of Connectivity Room, SKF

May 2015 n OEM Update

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Power tool sector best positioned for pulsating growth: Bosch

We have plans to roll out a range of competitively priced products targeted at the Indian tradesman, as part of our efforts to widen the customer base. Vijay Pandey, Vice President, Bosch Power Tools

Incepted in 1993, Bosch Power Tool division has grown to one of the market leaders in the power tools segment in India. In an exclusive interview with OEM Update, Vijay Pandey gives an over of the market highlighting Boschâ&#x20AC;&#x2122;s initiatives. Could you brief us on the power tools industry in India? What is the market size and what is your market share? India has an upper hand in the power tool industry owing to the abundance of labour, availability of raw materials and entrepreneurial skills. Estimates suggest that the domestic power tool industry is growing at an annual rate of 5 - 7 per cent and there is immense potential for players in this sector to reap the benefits. Power tools have a lengthy association with construction, woodworking, metalworking, engineering, fabrication, service and related verticals. Owing to a boom in these, the Indian power tool sector is best positioned for pulsating growth. At present, Bosch commands a third of the market share in the power tools industry. Like many other industries, power tool industry is also struggling with cheap imports. How are you tackling this issue? Since Bosch has its own manufacturing centre, this problem is averted. With this, Bosch is able to tackle this issue and have user innovations and gain greater accessibility. We are trying to educate people about the importance of quality, safety, the advanced level tools and better user interface that Bosch PT offers to users. Safety and technology features like vibration control, kickback stop, lithium-ion technology and turbo power are the features available only in Bosch PT, making the tools more powerful and safer to use. Power tools industry lacks awareness in terms of ensuring good health and safety of the workers. Could you comment on this? What are your initiatives in this regard? Power tools are indispensable for professionals and if handled incorrectly, can lead to damage, injury, and accidents. Consequently, importance has been given to safety and proper usage of tools to avert such incidents. 30

Every year Bosch Power Tools launches more than 100 new tools in the professional segment. The surge in popularity and demand for cordless tools in particular has encouraged Bosch to drive the growth of the segment within the power tools business. It has been conceptualised to simplify the process of drilling and can be deployed anywhere, anytime, without having to worry about electric supply and limited reach among other things. Bosch Power Tools is playing a significant role in providing training on safety and correct usage of power tools. Over the years, we have been able to establish a reputation for our quality, innovation, safety and initiation. All Bosch tools are accompanied by safety features and detailed manuals to ensure users are carefully instructed about proper usage so safety is not compromised and health hazards and other disasters may be avoided. In addition to providing a comprehensive range of products, we drive end-to-end post-sales services to ensure customers return to our stores and make more purchases, are satisfied with their experiences and receive adroit training and knowledge about our products, safe utilisation of the same and know-how of proper storage techniques. Power tools industry is also going through tremendous technological transformation. What are some of the latest innovation from Bosch India? As a company committed to innovation in technology and superior quality, we work tirelessly to ensure our products are in sync with the latest technological trends. Our lithiumpowered cordless tool range and the laser technology powered measuring tools are examples of our innovative prowess. The laser technology powered tools are automated, highly accurate and display results much more rapidly than manual measuring tools. The surge in demand for cordless tools in particular has encouraged Bosch to drive the growth of the segment within the power tool business. These tools do not require electrical power supply, are ergonomically designed and light-weight. Some of the new products that have been launched in the past few months include GLL 2 self-levelling cross-line laser and GLM 15 GLM 15 50-ft. laser measure. We are utilising EC technology which is maintenance free and highly efficient. In addition, we have a range of measuring tools, cleaning systems (high-pressure washers) and dust collection solutions (wet/dry vacuum cleaners.) We have plans to roll out a range of competitively priced products targeted at the Indian tradesman, as part of our efforts to widen the customer base. n May 2015 n OEM Update

Expert Column

Tips to improve life of hose U. K. Prasad, GM-Technical, Gates India Pvt. Ltd. explains the ways to improve usage life of your hose

Often you purchase a hose assembly for your hydraulic equipment or system just to experience a premature failure. In this article we will discuss some very important points to follow which will help you select the optimum hose assembly for your application, thus obtaining the maximum life for your application. Optimum life of a hose in a particular application is achieved by: l Safe hose selection l Safe coupling selection l Safe hose assembly l Safe installation of that assembly. All of the abovementioned points are critical for getting maximum hose life. We will discuss these points here in detail. Safe hose selection Proper hose selection is critical to a safe hydraulic system. A simple rule of thumb for proper hose selection is the Hose coupling blow-off

word “STAMPED” where: S = Size T = Temperature A = Application M = Material P = Pressure E = Ends D = Delivery. The first step in achieving a safe hydraulic system is selecting correct components that meet your needs. Compromises in components selection, either hose or couplings, may put you in danger, as well as affect the performance and life of your system. S (Size): The inside diameter of the hose must be adequate to keep pressure loss to minimum and avoid damage to the hose due to heat generation created by excessive turbulence. T (Temperature): The hose selected must be capable of withstanding the minimum and maximum temperature of the system. Do not expose hose to internal or external temperatures exceeding the recommended limits. An increase of 10°C above the maximum recommended temperature may reduce the hose life by half. Also, hose will crack if flexed at temperatures below the minimum recommended. A (Application): Select the proper hose for the application. Determine where, or how, the assembly is to be used.

Twist

M (Material): Hose selection must assure compatibility of the hose tube, cover, reinforcement, couplings, o-rings, etc., with the fluid used. Many hoses are compatible with one type of fluid or another, but often times not all fluids. P (Pressure): It is essential in the hose selection process to know the system pressure, including pressure spikes. Published working pressure must be equal to or, greater than the system pressure. Pressure spikes greater than the published working pressure will shorten hose life or lead to hose ruptures

Hose crack

E (Ends): Connecting ends of coupling must be correctly identified. D (Delivery): How much fluid must go through the hose? This will determine the size of hose that must be used. Under sizing a hose leads to increased pressure loss, while over sizing the hose adds unnecessary cost, weight and bulk. Safe coupling selection It is critical that the hose and coupling manufacturer are the same. Don’t mix and match hose and couplings from various manufacturers. Always use couplings that are recommended Continued to 34

May 2015 n OEM Update

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Expert Column Continued from 34

f Hose assembly routing tips

by the hose manufacturer for that particular hose. Thread ends must also be compatible in order to prevent leaking or assembly blow off from equipment. Safe hose assembly Once the hose and couplings are selected, it is important that the assembly is made properly. If not, the ends could blow off or, the hose may fail at coupling. It is important that the hose and couplings are from the same manufacturer and they are assembled using the manufacturers recommended equipment and procedures. It is critical to follow the hose manufacturerâ&#x20AC;&#x2122;s recommendations on hose, couplings and assembly technique. Following these recommendations will assure maximum assembly life. If recommended practices are not followed, or hose and couplings from different manufactures are used, there is a significant risk of catastrophic or premature assembly failure. Safe installation The art of making leak proof connections with hydraulic couplings is to tighten the couplings properly at the time of installation. An over tightened (over torque) coupling may be just as apt to leak as an under-tightened coupling. Over tightening can create a coupling that is overstressed which in turn can lead to cracking and leaks or possibly complete coupling failures. In addition, it is important to pay particular attention to the hose routing. A properly installed hose ensures hazard prevention as well as ensures long life. Avoid twisted hose installation. A twisted hose installation misaligns the reinforcement (which is the strength 34

Hose assembly routing tips

imparting component of hose) and reduces its ability to withstand pressure. Twisting a high pressure hose as little as 7 degree may reduce service life by as much as 90 per cent. Avoid positioning hose next to heat sources. Excessive heat may cause hose cover or tube to develop cracks. As explained above, an increase of 10 C above the recommended maximum temperature range may decrease hose life by half. Also excessive low temperatures beyond recommended limits will create cracks in the cover and/or tube when flexed. Avoid positioning hose next to metal edges or too close to other hose where any of them or both has movement. The hose cover and reinforcement may be damaged by abrasion leading to hose failure. This may also lead to safety problem. The selection process for proper hose and couplings can sometimes seem overwhelming and complicated. When in doubt it is best to contact your local hose manufacturing representative who can assist in the selection of the best hose and couplings for your application. But please keep in mind the best value is the hose assembly that gives you the maximum life, not the hose assembly that costs the least. n Authored by__

U. K. Prasad, GM-Technical, Gates India Pvt. Ltd.

May 2015 n OEM Update

Brand Report

The Connected Enterprise must continually evolve

“Just one in 10 plants has an IoT strategy in place or is planning to put a strategy in place” Rockwell Automation has been developing its Connected Enterprise for nearly a decade. Yet even though it has integrated information technology systems with operations systems and devices many years ago, none can be found — at its corporate headquarters, in the IT department, or on the plant floor — who thinks we’re finished. The Connected Enterprise is a big driver of Rockwell’s success — today and tomorrow. Why? Because it’s not just a revolution, it’s an evolution as well. According to Beth Parkinson, Market Development Director, Connected Enterprise, Rockwell Automation, “Companies that follow The Rockwell Automation fivestage Connected Enterprise Execution Model —with its assistance and the help of partners such as Cisco Systems — recognise that The Connected Enterprise is a foundation upon which to build great things.” Ms Parkinson observed that the Connected Enterprise evolves because the business world mutates at digital speed: Technologies The capability and affordability of plant-floor Ethernet and smart devices, powerful computing solutions, and networking technologies are constantly improving. Each information technology/operational technology (IT/ OT) enhancement will improve enterprise visibility and decision-making. Business activities The evolution of any organisation — mergers, acquisitions, new plants and offices, new customers and suppliers — requires adaptive systems and devices to mesh with The Connected Enterprise backbone. Similarly, new investments 36

in equipment and employees means new points of access to the IT/OT infrastructure. Any company wouldn’t make a new hire and then deprive him or her of collaboration tools or real-time dashboards that boost productivity and profitability, would you? Market changes The only thing certain about markets is that they will change — and change again. This presents both opportunities and challenges. For example, evolving information capabilities at utilities will help plant managers to optimise energy consumption, while metadata from commodities markets will drive cost-effective procurement. The challenges will continue to be rescuing insights from an ocean of data that threatens to drown executives. Unfortunately, many companies have yet to start their Connected Enterprise evolutions. New research finds that only about half of manufacturing plant executives are aware of the Internet of Things. Even worse, just one in 10 plants has an IoT strategy — i.e. The Connected Enterprise — in place or is planning to put a strategy in place. “The Rockwell Automation Connected Enterprise Execution Model leads to intelligent networks that boost productivity, optimise asset utilisation, deliver insights for informed decision-making — and bring operations and information security into the 21st century,” Ms Parkinson avers. n For more information: Visit www.rockwellautomation.com Or email at indiamarketing@ra.rockwell.com Customer Care (Toll Free): 18002000121

May 2015 n OEM Update

9th June 2015 The Westin Garden City, Mumbai

Balance Quality vs Cost Fourth Edition Join us at the 4th Edition of Cold Chain Strategy Summit - India’s Largest Gathering of Cool Chain and Temperature Controlled Logistics Professionals. Delivering the Right Quality vs. Cost Balance for your Cold and Ambient Supply Chains.

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Saravana Gughan S D, Reliance Retail Ltd. Sandeep Anand, Bharti Retail Ltd. Rajiv Sharma, Panacea Biotec Ltd. Prasad Deshpande, Biocon Ltd. Rashida Najmi, Piramal Healthcare Ltd. Ritesh Manchanda, Yum Restaurant Ltd. Seshadri N, McCain Foods India Pvt. Ltd. Sudha Shankarnarayan, Papa John’s International Arun Manjeshwar, Roche Scientiﬁc Company (I) Pvt. Ltd. Shoubhik Dasgupta, Godrej Hershey Foods & Beverages Ltd. Rouble Kataria, Haldiram Snacks Pvt. Ltd. Rohit Sood, Snapdeal.com Ajay Deshpande, Rich Graviss Products Pvt. Ltd. Maneesh Dumbre, HyperCITY Retail (India) Ltd. Satish SV, Max Hypermarket (I) Pvt. Ltd. Rajiv Malik, Jubilant Foodworks Ltd.* Shampayan Ghosh, Mother Dairy Fruit & Vegetable Pvt. Ltd.*

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Brand report Brand Report

FIBRO Gas Springs: safe and reliable

FIBRO Gas Springs: safe and reliable T The

he extensive range of FIBRO

gas springs an ideal extensive range constitutes of FIBRO supplement to and expansion of the gas springs constitutes an ideal traditionally used spring elements supplement tosuch andasexpansion ofdisc thesprings helical springs, and elastomer traditionally used springunits. elements such as helical springs, discminimal springs space With their and elastomerrequirement, units. gas springs close a

FIBRO Gas Springs

gap wherever the accent is on accommodation of the utmost With theirforce component minimal within space a minimum requirement, gas large springs a springs the the highest standards well as the of space or where exceedingly travel close is demanded. Whenfulfil analysing risks ofsafety what could happen as when FIBRO Gas Springs using a gasof spring, three requirement failure possibilities have been gap wherever the accent is on requirements the BAK specification. FIBRO gas springs take care of both demands, even in identified; over-stroke (S > Max), over-load (V>Max) accommodation of the utmost force combination. Their self-contained nitrogen charge makes and over-pressure (P>Max). These features have been within autonomous a minimum ofFeederWhen analysinginthe risks whatto could when using FIBROcomponent gas springs completely devices. implemented FIBRO gas of springs increasehappen the safety pipes or storage areisnot required. space or where exceedingly largevessel travel demanded. a gaslevel. spring, three failure possibilities have beenn identified;

over-stroke FIBRO gas pressure springs: safety comes first Contact: (S > Max), over-load (V>Max) and over-pressure safety and reliability as its even topmostinpriority. FIBRO gas springs FIBRO takeconsiders care of both demands, (P>Max). These features have been implemented in FIBRO gas particularly applies to its gascharge pressure makes springs which FIBRO Precision Pvt. Ltd. combination. Their This self-contained nitrogen springs toIndia increase the Products safety level. n are subject to the pressure equipment directive. Equipped (Formerly FIBRO India Standard Parts Pvt. Ltd.) FIBRO gas springs with completely autonomous devices. Feeder unique and innovative safety features such as over Plot No: A-55, Phase II, Chakan MIDC, Taluka Khed, stroke, and overpressure protection, FIBRO gas Pune - 410 501, Maharashtra pipes or storage vessel arereturn not stroke required. Contact: pressure springs fulfil the highest safety standards as well as the requirements of the BAK requirement specification.

Tele: +91-2135-338800 E-mail: info@fibro-india.com

FIBRO gas pressure springs: safety comes first FIBRO India Precision Products Pvt. Ltd. FIBRO considers safety and reliability as its topmost priority. (Formerly FIBRO India Standard Parts Pvt. Ltd.) This particularly applies to its gas pressure springs which are Plot No: A-55, Phase II, Chakan MIDC, Taluka Khed, subject to the pressure equipment directive. Equipped with PuneThe- 410 501, Maharashtra water-based binder Acrodur Power 2750 X is a healthBASF plans to launch a new alternative to conventional formaldehyde2750 X, unique and innovative safety featuresbinder, such Acrodur as overPower stroke, Tele:compatible +91-2135-338800 based reactive resins: Neither during processing nor as part designed for the production return stroke and overpressure protection, FIBRO gas pressure E-mail: info@fibro-india.com

BASF binder for automotive lightweight composites of natural fibre composites for automotive lightweight applications such as interior car door panels or shelves.

of the final product does it release any organic substances. This offers greater safety at work for the user, who no longer needs to invest in exhaust air treatment systems. In addition to this, the binder helps to improve the ambient air quality inside cars.

High temperature abrasion resistance coating Henkel

HTARC Product Image

As a low-emission alternative

Making easier and cost-effective formaldehyde-based burner tip. itThis results in sustained boiler efficiency and lesser offers toLoctite PC 7000 reactive Natural fibres bonded with Acrodur Power 2750 X can be resins, Acrodur Power 2750 X downtime as well as associated production losses, making it a High Temperature Abrasion Resistant processed using traditional thermoplastic cold-forming gives natural fibre composites cost effective solution. It is easy applyprocess on most Coating (HTARC)high that is designed to methods and be combined in onetosingle step substrates mechanical stability. At the complex plasticskilled elements such as reinforcing ribs same time, the product offersand with does not require labour. protect industrial processing equipment BASF will present a or supports. The product helps to save both system and thermoplastic processability and, unlike traditional functionalised natural like coal binders tip burners and fibre lightweight process costs. Acrodur Power 2750 X combines these thermoplastic based inon boilers polypropylene, it composite based on furnaces, against harsh temperature benefits with great mechanical component stability. allows the use of up to 75 per cent natural fibres inFeatures Acrodur Power 2750 X the pre-impregnated natural boast silica-based a lightweight components. at the JEC Composites • Furthermore, Unique three-component rapid fibres setting and abrasion environment. Show, scheduled to long shelf-life. be held in Paris from composite coating Environmentally-friendly, health-compatible March 10 to 12 low-emission Acrodur binders are based used tosystem reinforce(resins and “Due to the usecoal of Acrodur Power Environmentally friendly water Traditional tip burners are2750 proneX,tonatural• The natural fibre composites before these can be processed fibre components are up to 40 per cent lighter filler mixture) wear due to exposure to high heat from into moulded components. They are also used for the than conventional plastic products. This results High abrasion resistance up to 1,100applications C furnace andless erosion by fewer• production of high quality lightweight in in cars that flame consume fuel caused and have furniture automotive industry. like Due to their 3D refractory emissions,” Clausof Dallner, Bonds well and to porous substrates concrete, coal particles in highcarbon velocity air stream.explains High levels erosion Head• the plasticity, the binders help create attractive design options for Dispersions for Fibre Bonding bricks etc (metal substrates need metallic mesh lead to deformationofof Marketing the coal burner tips that instantly and with a natural fibre look and feel. n at BASF. reinforcement). negatively impact the boiler efficiency. 50

To overcome these shortcomings and provide a reliable, cost efficient solution to burner tip wear, Henkel has introduced Loctite PC 7000 High Temperature Abrasion Resistant Coating (HTARC). This is a unique three-component rapid setting silica-based composite coating system. It is designed to protect industrial processing equipment like coal tip burners in boilers and furnaces, against harsh temperature and abrasion environment. Loctite PC 7000 HTARC is an innovative environmentally friendly water based system that offers high abrasion resistance even at 1,000 C and above. Loctite PC 7000 HTARC offers twice the protection compared to conventional methods, leading to almost double life for the 38

April 2015 n OEM Update

Benefits • Up to 2 X protection from wear • Lesser production loss • Cost effective – almost 29 per cent cost saving over conventional methods • Laminar flow of coal-air mixture for optimum efficiency. This product has already been tried and tested in operating conditions by a leading natural resources mining & extraction company in India. They have verified that Loctite PC 7000 HTARC was intact on the burner tip even after more than 12 months of continuous operation. n For more information, contact at marketing.ag@henkel.com or visit www.henkel.in/enquiry May 2015 n OEM Update

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Mayl 2015 n OEM Update

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