AUTO COMPONENTS INDIA April 2019

www.autocomponentsindia.com Vol 6 Issue 02

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April 2019

COMPONENTS

INDIA

VOICE OF THE AUTOMOTIVE SUPPLIERS

SHOPFLOOR: VECV MANUFACTURES TRUCKS IN A MODERN, SMART AND EFFICIENT FACILITY

ROBUST MACHINING INDUSTRY DRIVES MANUFACTURING EXCELLENCE

AFTERMARKET : TVS ASL EMBRACES TECHNOLOGY AND TALENT

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An exhibition on technologies for automotive manufacturing 4 – 6 July 2019 Hall no. 1, Chennai Trade Centre, Chennai www.aes-show.com

Display exhibits from these proďŹ les: . Automotive design and R&D . Automotive inspection and quality control . Automotive paint and ďŹ nishing . Automotive plant equipment and system For bookings, please contact: Rahul Ganjapure Tel: +91 22 6103 8424 M: +91 9820796183 rahul.ganjapure@india.messefrankfurt.com Supporting associations

CONTENT

APRIL 2019

y r o t s r e v o C

COVER STORY 18 Robust machining industry drives manufacturing excellence 20 BFW works on communicating machines for smart factories 23 Altem leads the change in 3D printing 24 Hoffman plans to replicate European model in India 26 Driven by customer demand Tyrolit brings disruptive products to market 28 Askar Microns to make machines for additive and subtractive manufacturing 30 EOS offers training on additive manufacturing technology 33 EMO in Hannover to focus on smart production technologies 34 EMAG pioneers production of planetary and sun gears, cams 36 Arrow makes future-ready machine tools 38 FAR is getting ready with Industry 4.0 solutions

06 | NEWS

New Benelli showroom in Chennai presents full range of superbikes

13| CORPORATE

Bosch two-wheeler and powersports business sees growth in India Axalta offers cutting-edge coating technologies

48 | AFTERMARKET

TVS ASL embraces technology and talent TecAlliance spreads wings in Indian aftermarket

53 | EVENT 40 | SHOPFLOOR

VECV manufactures trucks in a TVKLYU ZTHY[ HUK LMÄJPLU[ MHJPSP[`

Mercedes launches AMG C43 Coupe Ashok Leyland bags GSRTC order for 1,290 buses Ather Energy ties up with Godrej Nature’s Basket Daiki India is building aluminium project in Sri City JK opens new Truck Wheels Centre Mahindra CIE acquires AEL Valeo opens new R&D facility in Chennai

46| SPECIAL REPORT

Dassault Systèmes opens 3DExperience executive centre in Chennai

Indian forging industry to tap global opportunities SIAM meet discusses future of vehicle recycling in India

56 | INTERNATIONAL

ZF establishes Technology Center for HY[PÄJPHS PU[LSSPNLUJL J`ILY ZLJ\YP[` 4J3HYLU (\[VTV[P]L KLSP]LYZ ÄYZ[ WYV[V[`WL JHYIVU ÄIYL JOHZZPZ [V 47*

44 AUTO COMPONENTS INDIA APRIL 2019

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EDITORIAL

Operational excellence AUTO COMPONENTS INDIA

UV[ PU ^VYKZ SPRL WYVK\J[P]P[` LMÄJPLUJ` HUK standardisation. It will be in concepts like growth, innovation, and customisation. The world is more connected and fast-paced than it has ever been, and the manufacturing industry needs to keep pace.

Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E),Mumbai - 400 013 Tel +91 22 43525252, Email us at s.bhargav@nextgenpublishing.net Executive Editor Bhargav TS Editorial Advisory Board H. S. Billimoria, Aspi Bhathena Web Editor Ashish Bhatia Correspondent Sricharan R (Chennai) Gunjan D. Bidani (New Delhi) Head - Design & Production Ravi Parmar Asst Art Director Ajit Manjrekar Production Supervisor Dinesh Bhajnik Publisher Marzban Jasoomani General Manager – North & East Ellora Dasgupta General Manager – South Girish Shet Deputy General Manager – North & East Chanchal Arora (Delhi) Regional Marketing Manager Salma Jabbar (Chennai) Marketing Manager Minocher Parakh (Mumbai) Manager Circulation - North and East Kapil Kaushik (Delhi) Subscription Supervisor Sachin Kelkar Tel +91 22 43525220 Apple Newsstand & Magzter Queries: help@magzter.com Territory Sales Incharge (Circulation) Srinivas Gangula (Hyderabad) Cell +91 09000555756 Territory Sales Incharge (Circulation) Vidyasagar Gupta (Kolkata) Mob: 09804085683

W

hen we talk about manufacturing, we need to consider that technology is very important in the industry; in many cases, technology is taking over jobs that people used to perform. This trend makes managing quality even more important because we are removing the human ability to control quality.

0[»Z UV SVUNLY Z\MÄJPLU[ [V JYLH[L H quality review department at the end of the manufacturing line, ^OLYL H [LHT VM WLVWSL Ä_LZ [OL defects. As a result of automation, we need to build quality right into each step of the manufacturing process so we don’t accelerate PZZ\LZ 6YNHUPZH[PVUZ [OH[ ZHJYPÄJL quality for size and speed will be left behind.

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6WLYH[PVUHS L_JLSSLUJL PZ H mindset, not a methodology. It is [OL YLSLU[SLZZ W\YZ\P[ VM ÄUKPUN ways to improve performance and WYVÄ[HIPSP[` 0[ PZ ÄUKPUN TVUL` and performance boosts in areas that organisations don’t normally look at. The future of operational L_JLSSLUJL PU THU\MHJ[\YPUN PZ

In terms of Industry 4.0 and data analytics, the cost of sensors and sensor capabilities are changing rapidly. Today it is possible to put a low-cost sensor to monitor all critical activities in a manufacturing facility. This enables managers to track the real-time data. These data combined with suitable data analytics will enable management to take operational decisions. ;OPZ OHZ [OL WV[LU[PHS [V PTWYV]L ZPNUPÄJHU[S` [OL VWLYH[PVUHS LMÄJPLUJ` VM THU\MHJ[\YPUN industry. A key factor will be to develop people within the organisation to be able to use data/ analytics effectively to take business decisions. *VTWHUPLZ ULLK [V Z[HY[ L_WVZPUN [OLPY RL` workforce in this direction so as to reap the best of the potential of Industry 4.0. Organisations with skilled people to use and analyse big data and take business decisions fast would have a ZPNUPÄJHU[ JVTWL[P[P]L LKNL Any country aspiring to be a manufacturing powerhouse must have strong and capable equipment makers for various processes and applications. Developing technologies by various means, R&D, acquisition and collaboration, is key to producing high-end machines.

Bhargav TS ,_LJ\[P]L ,KP[VY Z IOHYNH]'UL_[NLUW\ISPZOPUN UL[

Views and opinions expressed in the magazine are not necessarily those of Next Gen Publishing Pvt. Ltd. Next Gen Publishing Pvt. Ltd. does not take responsibility for returning unsolicited manuscripts, photographs or other material. All material published in Auto Components India is copyright and no part of the magazine may be reproduced in part or full without the express prior written permission of the publisher Printed by Marzban Jasoomani Next Gen Publishing Pvt. Ltd., Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E),Mumbai - 400 013. Published by Marzban Jasoomani on behalf of Next Gen Publishing Pvt. Ltd., Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E), Mumbai - 400 013. Printed at Spring Graphics, 215 & 238, Shah & Nahar Industrial Estate, Sun Mill Compund, Lower Parel (West), Mumbai 400013, India.

Published at Next Gen Publishing Pvt. Ltd., Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E),Mumbai - 400 013

All readers are recommended to make their own independent enquiries before sending money, incurring expenses or entering into commitments in relation to any advertisement appearing in the publication. Auto Components India does not vouch for any claims made by advertisers for their products and services. The editor, publisher, printer and employees of the publication shall not be held liable for any consequence in the events of such claims not being honoured by the advertisers. All disputes are subject to the exclusive jurisdiction of competent courts and forums in Mumbai only.

Editor Bhargav TS

55

MARCH 2019 AUTO COMPONENTS INDIA

News

New Benelli showroom in Chennai presents full range of superbikes

B

enelli, a leading worldwide manufacturer of premium bikes, and Adishwar Auto Ride India – Mahavir Group, recently opened an exclusive showroom in Chennai. The showroom showcases the entire range of Benelli superbikes available in India, under the dealership of ‘Rajkamal Automotive’. These superbikes encompass the TNT 300 – In-line two-cylinder 300cc engine, 302R – In-line two-cylinder 300cc engine, the TNT 600i – In-line four-cylinder 600cc engine and the newly launched TRK 502 and TRK 502X – Inline two-cylinder 500cc engine.

The prices of these bikes (ex-showroom, India) are: Benelli TNT 300 (ABS), Rs 3.50 lakh; 302R (ABS), Rs 3.70 lakh; TNT 600i, Rs 6.20 lakh; TR 502, Rs 5.00 lakh; and TRK 502X, Rs 5.40 lakh. All the 5

sales, service, spare parts and customer service, allowing customers to enjoy bestin-class, stress free ownership experience.�

products come with 5-year unlimited km warranty as standard.

“Our key motive is to ensure that Benelli’s 3-S facilities are present across India, to generate strong brand presence. Chennai in that aspect is of great importance to us. We also believe that our dealership is not just a place to serve customers but a platform for enthusiasts to come and interact with other like-minded riders,� he said.

Vikas Jhabakh, Managing Director, Benelli India said, “It gives us great pleasure to associate with ‘Rajkamal Automotive’.Our philosophy of customer service is in tandem with the ethos of our Chennai Dealer Partner. The employees at Benelli – Chennai are trained to offer the best in terms of

Interested buyers can book the newlylaunched Benelli TRK range online also.

Apart from the bikes, the showroom will also showcase merchandise and accessories. Motorcycle customisation will also be introduced in a phased manner. ACI

Mercedes launches AMG C43 Coupe

M

ercedes-Benz India launched its second product in 2019, the carmaker has brought in something smaller, quicker and more exciting in its appearance and performance – the Mercedes-AMG C43 Coupe at a launch price of Rs 75 lakh (ex-showroom, India). Back in 2016, Mercedes-Benz had introduced the AMG C43 Sedan, which found quite a few takers. The C-class has since had a facelift, and the luxury carmaker launched the updated C-class Sedan and Cabriolet last year. Now, instead of bringing the C43 Sedan facelift, the manufacturer has chosen [V ÄYZ[ SH\UJO [OL * *V\WL As with any AMG model, the highlight of the C43 Coupe lies under the bonnet. Powering it is a more powerful version of the 3.0-litre, twin-turbocharged V6 that also does duty

in other 43-series models. In the C43, the upgraded V6 makes 390hp (up from 367hp in the pre-facelift model) and 520Nm of torque. 0-100kph takes a claimed 4.7sec, and top speed is electronically limited to 250kph.

The Mercedes-AMG C43 Coupe also gets the 4MATIC+ all-wheel-drive system, so power is channelled to all four wheels via a 9-speed

automatic gearbox, but the AWD system is tuned to direct 69% of the torque to the car’s rear wheels. Additionally, it gets AMG’s ‘Ride Control’ suspension with 3 modes (Comfort, Sport and Sport+) and 5 Dynamic Select drive modes (Comfort, Sport, Sport+, Slippery and Individual).

In terms of features, the AMG C43 Coupe gets multi-beam LED headlights, 18PUJO Ă„]L ZWVRL (4. HSSV` ^OLLSZ HUK H panoramic sunroof. In its cabin, the AMG also gets sports seats with red seat belts and ambient lighting, along with a full suite of safety features and a 10.25-inch screen for the COMAND infotainment system with Android Auto and Apple CarPlay compatibility. As such, the C43 CoupĂŠ is also fairly practical, with a 2+2 seating layout and a 400-litre boot. ACI

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News

Ashok Leyland bags GSRTC order for 1,290 buses

A

shok Leyland has bagged an order from GSRTC (Gujarat State Roadways Corporation) for 1,290 buses. This order comes immediately after the 2580 bus orders received from various state transport undertakings recently.

Vinod K Dasari, Managing Director, Ashok Leyland, said, “We are very happy [V YLJLP]L [OL JVUĂ„YTH[PVU VM [OPZ VYKLY from GSRTC. Our ability to bring value, combined with our superior technology and innovation will help us maintain our

leadership position in buses in India.�

Sanjay Saraswat, Senior Vice-president, Global Buses, Ashok Leyland, said, “With this order, our order book for State Transport Undertakings is upwards of 3,000 buses. This is a testament to the reliability, durability and robustness of our buses. The cost of ownership and the product experience

which we can deliver is the best in the industry.�

Ashok Leyland is currently the fourth largest manufacturer of buses in the world and the largest in India. ACI

Ather Energy ties up with Godrej Nature’s Basket

A

ther Energy has entered into a strategic association with Godrej Nature’s Basket to expand AtherGrid, the company’s EV fast-charging public network in India. The 35 locations that Godrej Nature’s Basket operates across the country, will host AtherGrid Points, as the automobile player expands across India.

The electric two-wheeler manufacturer signed an MoU with Godrej Nature’s Basket for a pan-India association that will see the company set up its charging points at various outlets of the grocery and fresh-food store, [OL ÄYZ[ VM ^OPJO PZ \W HUK Y\UUPUN H[ [OL Sadashivnagar outlet in Bengaluru.

The electric two-wheeler company which began delivery of Ather 450 in September 2018, has its charging infrastructure, AtherGrid, at 24 locations with 31 charging points operational in Bengaluru. The fast charging network is accessible, free of cost, for all electric vehicles in the city until September 2019.

The company’s charging network is so accessible that on an average, most AtherGrid Points are no more than 4 km driving distance from the next. The Bengaluru-based automotive OEM has also announced its expansion plans for Chennai which will be rolled-out with the establishment of AtherGrid ahead of the commercial launch of the vehicles. Ather will also be setting up 10-15 charging points before the commercial launch of the Ather 450 scooters in the city and are actively seeking partnership with progressive minded institutions in Chennai. “For us, partnering with a brand like Godrej Nature’s Basket was a natural choice for AtherGrid. Their wide network and ease of accessibility allows us to offer charging H[ SVJH[PVUZ [OH[ Ă„[ ZLHTSLZZS` PU[V V\Y consumers’ lives. We are excited about bringing new locations for Bengaluru residents to charge their electric vehicles at, HUK [HRL [OL Ă„YZ[ Z[LW [V^HYKZ H WHU 0UKPH expansion,â€? Ravneet Phokela, Chief Business 6MĂ„JLY ([OLY LULYN` ZHPK

The Ather 450 is designed for city riding conditions, it comes with a top speed of 80 km/hr, a range of 75 km and one of the quickest acceleration of 3.9 seconds from 0-40 km/hr in the scooter category. Also, MVY [OL Ă„YZ[ [PTL PU [OL JH[LNVY` ([OLY comes with parking assist, which allows riders to reverse into tight parking spots.

The key differentiators of Ather 450 are its intelligent features, seamless charging and ownership experience. The Ather 450 has a 7� touchscreen dashboard that allows onboard navigation with options of alternate routes and saved locations. ACI Errata

In the March 2019 issue of ACI, Event section on page number 70, we carried a report on Minda Silca Engineering Pvt. Ltd. part of Spark Mind, Ashok Minda Group. It was wrongly mentioned as ‘Minda Silica’ part of Uno Minda. We regret the error.

The correct name of the company and the group is carried in the digital format.

88 AUTO COMPONENTS INDIA „ APRIL 2019

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NEWS

Daiki India is building aluminium project in Sri City

D

aiki Aluminium Industry India Private Limited, a 100% subsidiary of Daiki Aluminium Industry Co. Ltd., Japan, is building an aluminium alloy project in Sri City. Takaaki Yamamoto, President of Daiki Aluminium Industry, recently performed the foundation laying ceremony in the presence of Zhao Rong, Chairman, Delta Group of Industries, China, Ravindra Sannareddy, Founder Managing Director, Sri City, and a host of senior managers of the Daiki Group.

Yamamoto traced the history of Daiki Aluminium group and its major achievements. Highlighting the ‘green principles’ in production, he said that they aim to use the latest technologies in pollution control measure adhering to the strict regulation of their parent plants in Japan. He thanked the state government and Sri City management for the support being rendered.

workforce, particularly for women. We look forward to work closely with the Daiki team and assure our support,” he added.

Welcoming the Daiki group, Sannareddy said, ”As Aluminium recycling is gaining importance as an economically valuable secondary raw material, we are delighted to have Daiki in Sri City, as it would effectively meet the increasing demand for secondary aluminium, and thereby help in saving mineral resources in the country.”

“We are sure, their entry will enhance the Z`TIPV[PJ LJVZ`Z[LT PU :YP *P[` ILULÄ[PUN the auto component manufacturers. It is very heartening to note, this plant will provide ample job opportunities to the local

The project, which will be built in a plot of 20 acre in the Domestic Tariff Zone (DTZ) at an initial investment of around Rs.250 crore, is expected to be commissioned

by February 2020. The plant will produce aluminium alloy ingots at an annual capacity of 84,000 tonne. The products will be exported to ASEAN and Japan for supply to automobile companies. Daiki plans to capture the demand for aluminium alloy in the country and expand the market.

It will generate direct employment for about 600 people, and 80% of them will be women.

According to the Andhra Pradesh Economic Development Board (APEDB) sources, the State Government looks forward to a SVUN Z\Z[HPULK HUK T\[\HSS` ILULÄJPHS relationship with eco-friendly companies like Daiki Aluminium. ACI

JK opens new Truck Wheels Centre

J

K Tyre and Industries has inaugurated an all-new ‘JK Truck Wheels Centre’ and ‘JK Xpress Wheels Centre’ at Mulbagal in Karnataka. This centre is in line with the company’s plans to expand its network across the country.

Sanjeev Sharma, General Manager, Fleet Management, JK Tyre and Industries, inaugurated the Centre in the presence of several dignitaries, including key company VMÄJPHSZ HUK KLHSLYZ ;OL UL^ JLU[YL JVTLZ up within three months of inaugurating a similar truck wheel centre in Karnataka.

Spread over an area of 6,000 sq. ft., the JK

Truck Wheels Centre is strategically located on the National Highway-75, connecting Bangalore to Kolkata. The Centre will also serve as a key transit point for vehicles headed towards other prominent cities like Tirupathi, Vijayawada, Visakhapatnam, and Bhubaneswar.

The JK Truck Wheels Centre offers various solutions for truck and bus tyre care. The Centre is equipped with machineries such HZ ^OLLS HSPNULY UP[YVNLU PUÅH[VY HUK pneumatic tools set.

The JK Xpress Wheels Centre is spread over an area of 800 sq. ft. and claims to provide

a superior buying experience and quality services for car customers.

Sanjeev Sharma, said, “Our new JK Truck Wheels Centre in Karnataka reinforces our commitment towards providing bestin-class services to our customers across the country. With the new centre, we are JVUÄKLU[ VM M\Y[OLY Z[YLUN[OLUPUN V\Y service and maintenance network in this region, making the process hassle-free for our customers. Also our Xpress Wheels Centre will cater to car customers. This is a unique facility where we have solutions for both Truck and Car customers under one roof.” ACI 99

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APRIL 2019 AUTO COMPONENTS INDIA

News

Mahindra CIE acquires AEL

M

ahindra & Mahindra’s component manufacturing arm, Mahindra CIE’s (MCIE) Board of Directors has approved 100% equity acquisition of Aurangabad Electricals (AEL) for an enterprise value of Rs 857 crore, which includes a future deferred payment estimated up to Rs 62.2 crore.

Founded in 1985, AEL is a leading manufacturer of automotive aluminium die casting products based in Aurangabad, India. The company, which has 5 manufacturing facilities including those at Aurangabad, Pune and Pantnagar, is promoted by the Bagla Group and led by Rishi Bagla. It has over 3,300 employees, sales of Rs 850 crore and an EBITDA margin near 12%.

AEL is a key supplier to a number of domestic and global two-wheeler and passenger car OEMs and Tier 1 companies.

It manufactures a variety of body, brake

and engine parts through high-pressure die casting as well as gravity die casting processes. The company also has capabilities for machining, heat treatment, powder coating, assembly and leak testing, along with a modern tool room.

Jesus Maria Herrera, CEO, CIE Automotive said, “We are very impressed by the business they have built and its sustainable HUK WYVĂ„[HISL NYV^[O >L ILSPL]L [OH[ [OLPY integration in MCIE will provide important opportunities for both MCIE and AEL.â€?

Ander Arenaza, CEO, MCIE said, “This acquisition allows MCIE to enter the aluminium die-casting technology. Its complementary product and customer TP_ SLHKZ [V M\Y[OLY KP]LYZPĂ„JH[PVU VM the business portfolio of MCIE India, strengthening especially our presence in the two-wheeler space. It has very good manufacturing processes and internal controls and is run by a capable team.â€?

Rishi Bagla, Chairman and MD, AEL said, “AEL has built up a formidable reputation as a high-quality supplier of automotive aluminium die-castings in the Indian and international market over the last 3 decades. We are convinced that the partnership with MCIE and CIE will give the company a great boost and allow AEL to benefit from global best practices in aluminium die casting.

We share a wonderful relationship with CIE based on mutual respect and trust and this has given us great confidence to enter into this strategic transaction.

With the proceeds of the transaction, the Bagla group will further develop its industrial activities and businesses.� For MCIE, this transaction marks its foray into automotive aluminium die casting, which will help it increase revenues and profits in India. This strengthens MCIE’s presence in the two-wheeler segment, and diversifies its customer base. ACI

Valeo opens new R&D facility in Chennai

V

aleo, a global automotive technology supplier, has setup a state-of-the-art R&D Test Lab facility with an investment of Rs 250 Million. The 15,000-sqft facility at Navalur, Chennai, will further strengthen the technical competence of Valeo’s R&D function and house the test labs of Valeo’s Hardware, Mechanical and India Business R&D divisions.

The R&D facility in Chennai has emerged as a global software development hub for the Valeo Group that offers complete products conception capabilities WYV]PKLZ LMÄJPLU[ Z\WWVY[ PU [OL HYLHZ of mechanical design, simulation, embedded software development, computer vision, machine learning and hardware & functional safety design to Valeo’s global customers.

makes India a key market for Valeo’s future growth. Started in 2010, the Chennai facility has now become a key contributor and our investment towards the Test Lab is a strategic step for strengthening our capabilities to enhance the value that we provide to our customers.�

This Test Lab facility will provide testing and prototype services to Valeo sites across the globe, supporting Valeo’s Business and Product Groups. It will also enable the group to locally design and develop solutions for Valeo’s Indian customers.

Ashok Belani, Group President and Managing Director, Valeo India said, “The growth potential of the Indian auto sector and the availability of engineering talent pool,

Globally, Valeo is in the epicenter of 3 H\[VTV[P]L YL]VS\[PVUZ LSLJ[YPĂ„JH[PVU digital mobility and autonomous cars) and developing a wide range of innovative products that are positioning the company as a technological leader in the global marketplace.

Started in 2010 with 50 engineers in Chennai, today the R&D hub employs 1000plus talented Indian engineers. The division plans to increase its headcount to 5000 engineers by 2023. ACI

12 12 AUTO COMPONENTS INDIA „ APRIL 2019

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CORPORATE

Bosch two-wheeler and powersports business sees growth in India ACI Bureau

T

he two-wheeler and powersports business unit of Bosch is continuing the ride towards the global sales target of Euro 1 billion in 2020, being generated by HZZPZ[HUJL WV^LY[YHPU LSLJ[YPÄJH[PVU and connectivity systems. Bosch’s vision is to make the mobility of the future accident-free, stress-free, and nearly emissions-free. This goes for the continuously growing motorcycle market also. Based on Freedonia, the global demand for two-wheelers is forecasted to grow annually by more than 4% from 2017 to 2022, reaching 122 million bikes by 2022.

Bosch 10th generation motorcycle ABS

Major growth of the two-wheeler & powersports business is forecasted in India where Bosch supplies marketZWLJPÄJ TV[VYJ`JSL ZHML[` HUK powertrain solutions to comply with regulations as well as local market trends. “The two wheeler landscape today is undergoing many changes as industry players look to innovate their service offerings. As a key player in the two- wheeler space, Bosch has always endeavored to provide services

that integrate cutting-edge technology with the company’s inherent focus on M\UJ[PVUHSP[` HUK LMÄJPLUJ` ¹ .LVMM Liersch, Head of Two-Wheeler & Powersports Business Unit, said.

system, engine management, and human machine interface. This system will go to market with Ducati and KTM in 2020.

Safety solutions

From April 1, 2020, India will introduce Bharat Stage-VI (BS-VI) which is similar to Euro-6 in Europe.

Bosch is offering scalable powertrain solutions with electronic engine management systems for internal combustion bikes as well as integrated LSLJ[YPÄJH[PVU Z`Z[LTZ [V Z\WWVY[ vehicle manufacturers in India to comply with BS-VI emission standards and meet India’s unique driving pattern.

Safety is one of the most pressing trends in the motorcycle market.

According to a report by the Ministry of Road Transport and Highways up to 34% of road fatalities in India are riders of two-wheelers. Bosch is tackling this challenge with a comprehensive three-step safety concept towards accident-free mobility. Firstly, by keeping the bike stable in braking situations and acceleration with systems like ABS or motorcycle stability control (MSC); secondly, by realising predictive safety and comfort functions with innovative surround-sensing such as advanced rider assistance systems; and thirdly, by connecting the bike with its environment through motorcycle-tovehicle communication.

After the successful introduction of ABS and MSC technologies, Bosch OHZ PU[YVK\JLK P[Z ÄYZ[ HK]HUJLK YPKLY assistance systems for motorcycles, comprising adaptive cruise control, forward collision warning, and blind-spot detection. These electronic assistants are always vigilant and, in emergencies, they respond faster than people can. According to Bosch accident research estimates, these radar-based assistance systems could prevent one in seven motorcycle accidents. The technology underpinning these systems is a combination of radar sensor, brake

Compliance with BS-VI

Electronic engine management Z`Z[LTZ HYL [OL JVYL VM LMÄJPLU[ HUK economical technology for internal combustion vehicles. In combination with highly developed sensor technology, engine management systems have shown considerable PUJYLHZLZ PU LMÄJPLUJ` JVTWHYLK [V conventional carburetor systems and can reduce CO2 emissions by up to 16% (depending on the situation).

Another approach to reduce emissions HUK [V I\PSK \W HU HSS LSLJ[YPJ ÅLL[ by 2030 in India is the launch of a Faster Adoption and Manufacturing of (Hybrid &) Electric Vehicles (FAME) programme by the central government which goes to phase-2 in April 2019.

To be able to contribute in achieving this target Bosch provides solutions Z\JO HZ HU PU[LNYH[LK LSLJ[YPÄJH[PVU system including motor, control unit, battery, charger, display and app that can power light two, three and 13 13

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APRIL 2019 AUTO COMPONENTS INDIA

CORPORATE INTERVIEW

Q: India, being a cost sensitive market and when it comes to 125cc, price is the key. How you are product is going to be cost-competitive. Will it be highly localised?

Prabhu: Cost is something that is important for the two-wheeler market and it is a cost-sensitive one. We have already done localisation and we have HSZV KVUL ZWLJPÄJ PUUV]H[PVU PU IYPUNPUN this technology to the two-wheeler markets. We have made it smaller and also less in weight to meet the requirement.

Q: What about the scooter segment?

“Bosch has technology to develop WYVK\J[Z [V TLL[ HSS YLN\SH[PVUZ ¹ Prabhu Panduranga, Regional President Two-Wheeler & Powersports Business Unit, Bosch India, told Bhargav TS of Auto Components India.

Q: The new regulation for two-wheeler ABS is kicked in from April, 2019. How Bosch is geared up?

Prabhu: On the ABS front, we have long experience in four-wheelers and we are bringing this technology to the two-wheelers also. So, we started with ABS 9 and now we have 10th generation ABS, especially for two-wheelers. This is almost 35% smaller in size and 25% SV^LY PU ^LPNO[ :V P[ PZ [OL LMÄJPLU[ solution for two-wheelers. That also goes with our thinking: emission-free, accident-free and stress-free twowheelers.

Q: Will the 10th gen ABS be manufactured in India?

Prabhu: The 10th generation is already in the market. It is being manufactured in the Pune plant. We service to almost all customers in India, since our product meet most of our customer demand.

Prabhu: Legislation-wise it says when P[ PZ TVYL [OHU JJ P[ ZOV\SK IL Ä[[LK with ABS. And, if there is a requirement we can do that too.

Q: Looking at the demand for ABS, is UKQN I=JQB=?PQNEJC ?=L=?EPU OQBł?EAJP Any expansion plans?

Prabhu: We have certain volume forecast and we are prepared for it. Should there be a requirement it is only a question of enhancing.

Q: Electronic contents are increasing in the market. What is the latest technology that is available from Bosch?

Prabhu: It is not just two-wheelers. The whole automotive industry’s electronic content is going up. Compared to 10 years ago, electronics is a substantial part of the automotives since the industry is becoming safety-critical, has stringent emission requirements and comfort functions. More than the electronic content, the software content is more in the vehicle. Earlier we did not have ABS, EFI etc and it was much less. Everything is connected today and it has become part of the industry. So going forward, the electronics contents in the vehicle will substantially grow.

Q: What kind of synergies you have

in the passenger car, CV and those synergies that you plan to bring to the two-wheelers?

Prabhu: 0U L]LY` ÄLSK [OLYL PZ H Z`ULYN` For example, our EFI system was started with four-wheelers and we adopted it for two-wheelers. However, we have to consider the environment. It is a cost sensitive market and for that, we have to make a small matchbox-like ECU for the two-wheeler and that is where our manufacturing technology comes into picture. Today, I am proud to say we are developing all these ECUs in India. The R&D centre in India is the second biggest PU [OL ^VYSK UL_[ [V .LYTHU` >L OH]L a manufacturing set-up also for the ECU in India. Overall the company is well placed to cater to the market here.

Q: What is the learning from the Polar Odyssey?

Prabhu: We always believed in emissionfree, accident-free and stress-free. That is something we wanted to put to use under extreme conditions. So, it has gone through a harsh environment condition that you can imagine. Even under these conditions, the two-wheeler is safe and performs well. And, people should have the reliability of new systems and new technology. So if it is working in those conditions, it will work in other conditions. There is a lot of learning from it. This is something we have to see with respect to our reliability, data from the bikes and evaluate. At the moment we are happy and proud that the intended purpose of the system has been served very well. It is almost zero breakdown.

Q: You worked on 3 areas, stability, product safety and connectivity. So when it comes to stability and safety, suspension plays a major role though you have not contributed. So were you able to get zero eventually?

Prabhu: Along with ABS today we also have motorcycle stability control (MSC).

14 14 AUTO COMPONENTS INDIA APRIL 2019

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CORPORATE This works exactly like ESP in fourwheeler. That will understand the vehicle and evaluate how the vehicle. That is how we could get the data in real time and offer that safety feature to them. We were working with gas thrusters and it is still in development stage.

is similar to SOS service. It is already in Europe.

What are the areas you are working on for future products?

Q: You have ECU 44 for small bikes, which has a lot of things together. Is it developed in India considering the demand?

Q: What about predictive safety with surround sensing?

Prabhu: The complete system is developed by us. But the electronic components, we have to import. It happens in India actually. We have the competence for single cylinder EFI system development, globally. So we have a lot of parts that are localised like the sensors, ECU etc.

Prabhu: It is a continuous development.

Right now it is BS-VI and it will go beyond that. We are preparing for it.

-\[\YL JV\SK HSZV IL LSLJ[YPÄJH[PVU so it is not only EFI, going forward the KPYLJ[PVU ZLLTZ [V IL LSLJ[YPÄJH[PVU >L are working on how to electrify the twowheeler.

Prabhu: This consists of collision warning, blind spot detection and also adaptive cruise control. For example, if a two-wheeler is behind a car, it can get locked on to the car in the front and it will exactly behave the way the front rider is going. These are some of the features that anticipate danger in advance. These are the general technological development we have.

Q: How does connectivity play a role in two-wheelers?

Prabhu: When the vehicles communicate with each other, they can see much more than what eyes can see.

So with peer to peer communication, you can already detect the vehicle etc.

Then it can forewarn about the vehicle coming. It helps the rider to anticipate things in advance. Otherwise, it is impossible to see what is there. We also have (e-corp). In cases like accidents, it immediately detects and gets help which

Q: Apart from emission reduction, what are the other criteria that you look at?

Prabhu: Compared to BS-IV in BS-VI the emission is reduced by around 85%, that is the kind of emission targets we are talking for BS-VI. But we are not stopping at that. Our engineering requirements are much more and our Z`Z[LT JVUÄYTH[PVU PZ Z\JO [OH[ ^L HSZV take durability into consideration, may not be now but 5 years down the line.

That is our consideration and that is the technology we have to make it to work. ,MÄJPLUJ` KLWLUKZ VU [OL \ZLYZ SPRL driver behaviour.

Q: Size of the Indian two-wheeler market is the key to all these things.

four-wheel electric vehicles with up to 20kw - the powertrain of the future will be a mix of electro-mobility and combustion engines.

Lamda sensor helps the engine Y\U HZ LMÄJPLU[S` as possible while producing fewer emissions

“We at Bosch are working towards ensuring a smooth transition to the new emission norms with a tailored product portfolio for the Indian market supporting vehicle manufacturers with local engineering competence - aiming towards realising the ]PZPVU VM ULHYS` LTPZZPVUZ MYLL TVIPSP[` ¹ Prabhu Panduranga, Regional President Two-Wheeler & Powersports Business Unit, Bosch India, said.

Q: EVs will gradually come in and at the same time, you need to have IC too.

Where will you draw the line?

Prabhu: It all depends on the market.

We are a technology provider and we want to make the right kind of emissionfree to riders and we are continuously working on that. It depends on what the market is demanding from us. For four-wheelers we are working on the next level of emission. In case, a similar requirement is coming for two-wheelers we can do that too. There we do not have a concern. On the safety side also lots of innovations are happening and we are looking at which of that innovation can be used for two-wheelers. So it is a continuous improvement programme.

We believe that there will be a market for all the technologies. Depending on the usage, there should be a difference.

Some parts of the total market will go into LSLJ[YPÄJH[PVU

Spirit of the ride With its ‘Spirit of the Ride’ campaign, Bosch showcases the innovations and technology solutions for the market challenges in India. The realisation of those technology solutions is proven by the story of a Polar Odyssey. An enthralling motorcycle journey crossing some of the world’s most dangerous roads starting from the Arctic Circle and all the way to the Antarctic Circle. The set milestone PZ H JVUÄYTH[PVU VM )VZJO»Z L_WLY[PZL PU developing powertrain and assistance technologies for two-wheelers. ACI 15 15

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APRIL 2019 AUTO COMPONENTS INDIA

CORPORATE

Axalta offers cutting-edge coating technologies Story by: Gunjan D. Bidani

I

n an industrialising country like India, which will be producing about 6 million cars I` [OL ÄYZ[ SVVR HUK MLLS of a car is still being decided by the automotive coatings industry.

Axalta, a leading player in the H\[VTV[P]L YLÄUPZO JVH[PUNZ HUK a supplier of liquid and powder coatings, aims to provide top-notch customer service and stay up-todate with cutting-edge coating technologies. Contributing to the 0UKPHU YLÄUPZO THYRL[ MVY `LHYZ Axalta provides the solution for [YHUZWVY[H[PVU JVH[PUNZ YLÄUPZO coatings, auto plastic coatings and general industrial coatings.

(_HS[H»Z UL^S` VWLULK YLÄUPZO training centre in Haryana

In Haryana, quite recently, Axalta opened a new training facility, [OL MV\Y[O SHYNLZ[ 9LÄUPZO ;YHPUPUN Centre in India. Demonstrating the latest spraying application systems that use less energy, reduce waste, OH]PUN MHZ[ KY`PUN ÄUPZOLZ HUK using superior colour matching technologies, Axalta aims to train around 1000

technicians to help the customers with the most advanced painting techniques to help them be TVYL LMÄJPLU[ WYVK\J[P]L HUK WYVÄ[HISL :VILYZ :L[OP 7YLZPKLU[ Emerging Markets, Axalta, who inaugurated the facility said, “ In India, the coatings industry, especially the waterborne coatings, has been growing at a rapid pace.

The new training facility will provide our customers with the most advanced painting techniques [V OLSW [OLT IL TVYL LMÄJPLU[ WYVK\J[P]L HUK WYVÄ[HISL >L are helping our customers drive these improvements while being mindful of the environment with sustainable techniques and WYVK\J[Z 6\Y J\Z[VTLYZ» Z\JJLZZ is our success and we are proud to IL [OL YLÄUPZO SLHKLY PU 0UKPH HUK around the world.”

Equipped with an advanced Virtual Reality (VR) Training Room, digital colour

matching tool, and an online training facility for customers, this training centre is spread over 20,000 sqft. Without actually using the paint material, the VR Training duplicates the paint spraying activity and teaches about the intricate technicalities like the distance between the car and the painter, the angle placement of the painting tool, on reducing the waste and application quantities.

Vinay Rajadhyaksha, Managing Director, Axalta India, said, “We are excited about our new training capabilities in the region. This UL^ MHJPSP[` JYLH[LZ H ZPNUPÄJHU[ opportunity for us to be closer to our customers and support their success in a way that is unique in our industry. The training opportunities offered at the centre combined with our leading products and technologies, such as our waterborne coatings including Cromax Pro and Standoblue, position Axalta well to grow in India and serve our customers at the highest levels.”

Rigorous temperatures in India pose another challenge to the YLÄUPZOPUN WSH`LYZ 6U [OPZ :PUNO said, “All the products for the auto industry are exposed to the Florida exposure test and it is an expensive test. It is said that Florida is the most critical test for extreme temperatures.” Sethi added, “For this, we might have to add a different activator or an additional clear coat, but we are aware of these differences and hence we

16 16 AUTO COMPONENTS INDIA APRIL 2019

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CORPORATE introduce products which at times differ for various segments in the country, only to adhere to the environmental requirements.” ;OL JHYZ VM [VKH`»Z HNL HYL UV longer available in just 4 or 5 colours, but quite a few variants are seen in about hundred different colours, which complicates further MVY YLÄUPZOPUN JVTWHUPLZ SPRL Axalta. To ease this complexity, Sethi said, “We have brought the best tools from around the world to colour and match better and to do it faster with more productivity ILJH\ZL WLVWSL KVU»[ OH]L LUV\NO patience anymore.”

Talking about the demands of the new-age Indian customer, Lokender Pal Singh, Business +PYLJ[VY 9LÄUPZO :V\[O (ZPH Axalta, said, “First is durability, the vehicle should look brandnew until 5 to 7 years of its use. :LJVUK [OL KLTHUK PZ VM H ÄUL appearance with rich colours and mica.” He further said that an Indian customer would want the development and delivery of a colour in 3 months, while an international client would plan the same 3 to 4 years in advance.

The automotive industry is undergoing transformation and aims at lightweighting of vehicles, which is a new trend. To cater to [OL JOHSSLUNL :L[OP ZHPK ¸(_HS[H»Z extensive R&D helps in the development of such products.

Another challenge is to formulate products which can be applied VU KPMMLYLU[ Z\IZ[YH[LZ 6\Y 9 + and innovative technology comes into play here and helps us to stand apart from the other players. :V 0 [OPUR ^L»YL ^LSS LX\PWWLK [V support the industry as it evolves to lightweighting.”

In the phase of advancing technology, Rajadhyaksha said

that 20% of the Indian market has almost moved on to a waterborne technology, which is a new generation product. “The country has moved from Nitro solvent to acrylic to polyurethane to low emission and now to waterborne.

Still, most of the country uses the polyurethane variant.” Sethi added, “Polyurethane or water-based technologies are very durable and will have very good outdoor exposure. Properties of colour will remain intact for a long time, say around 4 to 5 years, which is well protected by the clear coat over it.”

The commercial vehicle industry has also started to make the shift to the new types of coatings. The

breakthrough in the coatings for CV PZ Z[PSS H^HP[LK 6U UL^ [YPHSZ ILPUN conducted for the same, Singh said, “Yes, some trials are going on for trucks where customers want to OH]L H IL[[LY ÄUPZO ^OPJO PZ ZPTPSHY to a car. Although, bigger trucks are not really transforming, light-weight CVs are on the lookout.”

With more than 150 years of experience in the coatings industry, Axalta employs approximately 14,000 people, serves more than 100,000 customers in 130 countries. In addition to this new training facility, Axalta has 3 other training centres in India, 1 manufacturing plant, a state-of-theHY[ JVSV\Y SHI HUK VMÄJLZ ACI

L-R: Lokender Pal Singh, Business +PYLJ[VY 9LÄUPZO South Asia, Axalta; Sobers Sethi, President, Emerging Markets, Axalta; Vinay Rajadhyaksha, Managing Director, Axalta India 17 17

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APRIL 2019 AUTO COMPONENTS INDIA

COVER STORY

Robust machining industry drives manufacturing excellence ACI Bureau

I

n 2014, the Indian Government began a nationwide initiative – the ‘Make in India’ to boost the manufacturing industry. The Prime Minister of India, invited many companies from across the globe to ‘Make in India’ by granting them with certain concessions.

We cannot attain manufacturing excellence unless we have a robust machine tools segment. With the Government’s thrust on ‘Make in India’, we are in the global spotlight and our future capabilities and success as a leading manufacturing hub relies very much on the growth of our machine tools industry.

The Indian machine tool industry has slowly but steadily positioned itself in the global market. The

market size of machine tools in India MVY ¶ ^HZ HYV\UK billion dollars of which the domestic production accounted for about 47% of the total consumption. The industry registered an impressive NYV^[O YH[L VM K\YPUN ¶ 2017, states the Indian Machine Tool Manufacturers’ Association (IMTMA). In terms of global rank, India was 12th in production and [O PU JVUZ\TW[PVU HZ WLY [OL Gardner Research Survey 2017.

India is considered as the preferred destination for outsourcing by numerous global manufacturing companies, due to cost competitiveness, favourable investment conditions, ease of doing business, and better engineering and designing capabilities. /V^L]LY HJJVYKPUN [V [OL World Machine Tool Survey by

the Gardner Business Media, India ranks 13th in the production of machine tools globally, but it is the 10th largest consumer. This offers us the opportunity to increase the production share in an expanding consumer market.

For instance, the global security and aerospace company, Lockheed Martin signed a landmark agreement with the Tata Advanced Systems Ltd (TASL) to produce the singleLUNPUL ÄNO[LY QL[ - )SVJR 70 in India. The move will lead to the development of India’s private aerospace and defense manufacturing industry.

In terms of Industry 4.0 and data analytics, the cost of sensors & sensor capabilities are changing rapidly. Today, it is possible to put a low-cost sensor to monitor all critical activities in a manufacturing facility. This enables managers to track the real-time data. These data combined with suitable data analytics will enable management to take operational decisions backed by data. This OHZ [OL WV[LU[PHS [V ZPNUPÄJHU[S` PTWYV]L VWLYH[PVUHS LMÄJPLUJ` of manufacturing industry. A key factor will be to develop people within the organisation to be able to use data/analytics effectively to take business decisions.

Organisations need to start exposing their key workforce in this direction so as to reap the best of the potential of Industry 4.0.

Organisations with people skilled to use and analyse Big Data and take business decisions fast would OH]L H ZPNUPÄJHU[ JVTWL[P[P]L LKNL

18 18 AUTO COMPONENTS INDIA APRIL 2019

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COVER STORY According to IMTMA, machine tools production has reached Rs 7293 crore in FY 2017-18 from Rs 5803 crore in FY 2016-17 at a YoY growth of 25.7%. Machine wise production values are collected from all the members for each quarter and consolidated to annual production values for further analysis. IMTMA segregates the production of machines into CNC machines, non CNC machines, metal cutting machines and metal forming machines. Production of metal cutting machines reached Rs 6562 crore during 2017-18 compared to Rs 5194 during 201617 registering YoY annual growth of 25.7%. Production of metal forming machines reached Rs 731 crore during 2017-18 compared to Rs 609 crore during 2016-17 registering a YoY growth of 20%.

Indian machines are offered at competitive prices within their segment and can therefore be successfully exported. Some Indian machine tool manufacturers also export to Germany, Turkey, China, the Middle East, Russia and South Korea. Machine tools exports from India reached Rs 355 crore during 2017-18 compared to Rs 360 crore during 2016-17 registering an annual YoY growth decline rate of -1.4%. Machine-wise export values are collected from all the members from each quarter and consolidated to annual export values for further analysis. All types of machines CNC, non CNC, metal cutting and metal forming were exported from India to various countries. Meanwhile the machine tools imports to India reached Rs 7752 crore during 2017-18 compared to Rs 6173 crore during 2016-17 registering YoY growth of 25.6%.

Due to the demand supply gap, we rely majorly on imports. Also, majority of high-end machine tools manufacturers in India cater

to the automotive industry due to which other segments route out their demands through imports. We need to enhance our manufacturing capabilities to deliver high-accuracy, niche machine tools for a wide range of industries. Technology upgradation, vigorous R&D efforts, increased investments and presence of large-size players in the industry are some of the key areas we need to act upon.

Any country aspiring to be a manufacturing powerhouse must have strong and capable equipment makers for various processes and applications. Bridging the gap between production and consumption is a great opportunity for the Indian machine tool makers.

Developing technologies by various means, R&D, acquisition and collaboration, is key to producing high-end machines. Building this capability will also enable Indian companies to succeed in the international market and grow exports. This is especially required for building quality solutions for the upcoming manufacturing sectors in aerospace and defence.

The machining industry does not see any serious risks for the industry in India in the near future. Electric cars are expected to replace those with combustion engines. But electric motors also need parts that are manufactured by machine tools. In this respect, the type of machine tools will change in the future, but demand will not change ZPNUPÄJHU[S` 0U HKKP[PVU [OL machine tool industry serves many other industries, such as defence, road construction, infrastructure, tool and mold making, and aerospace. Therefore the industry does not see any major threat to the machine tool industry in the near future.

In terms of hybrid technology, the

automotive industry is probably on the cusp of transformative change – from traditional IC engine-driven automobiles to hybrid/EV/fuel cell. These changes are driven by environmental concerns across the globe. On productivity, although manufacturing activities in emerging economies were triggered by labour cost arbitrage, today it’s no longer so – more and more of it is being driven by overall productivity and cost of manufacturing. Digitisation trends demonstrate that the development of advanced CAD/CAM, machineries controlled by CNC systems, etc has transformed the way typical manufacturing happens around the world. Development of cloud-based data management and computing has made physical locations irrelevant. Some of the highly advanced manufacturing companies around the world are leveraging this virtual convergence to drive lower JVZ[Z HUK OPNOLY LMÄJPLUJ` 0[ PZ Q\Z[ not an option anymore, rather an imperative in these times.

Auto and auto component industry and capital goods industry form the major market for machine tools in India. Consumer durables and aviation industry are the other industry segments where the machine tools are used. Out of these, auto and auto component industry form about 40% of the machine tools market. All these industries are currently growing at a healthy rate and the trend is expected to continue in the coming years. ACI 19 19

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APRIL 2019 AUTO COMPONENTS INDIA

COVER STORY

BFW works on communicating machines for smart factories Story by: :YPJOHYHU 9

W Manufacturing facility of BFW

hat happens if a machine communicates to the JVUJLYULK WLVWSL HIV\[ its requirement? This is exactly what the machine tool manufacturer Bharat Fritz Werner is looking at. Popularly known as BFW, the company in its R&D centre is working on a machine that communicates directly to the

respective department and gets its work done quickly. ¸>OH[ ^L HYL [HSRPUN HIV\[ PZ [OL UL_[ generation of manufacturing, the smart MHJ[VY` 0[ JHU UV SVUNLY IL KLWLUKLU[ on people having knowledge. If a THJOPUL ILJVTLZ KLWLUKLU[ VU [OL people, it can only work if skilled

people are with it. Going forward, the factories themselves should take decisions. The equipment in the factory should take decisions, and the ZOVW ÅVVY HUK [VW ÅVVY ZOV\SK IL seamlessly linked. At the same time, ULP[OLY [OL THJOPUL UVY [OL ZOVW ÅVVY ZOV\SK IL PZVSH[LK :V ^L ^PSS OH]L a factory communicating to another

20 20 AUTO COMPONENTS INDIA APRIL 2019

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COVER STORY factory, machine talking to another machine and so on. That is how it ZOV\SK IL >P[O [OPZ PU TPUK ^L OH]L a machine in R&D. This machine can communicate. For example, if a motor gets heated up, it informs the concerned person. The message will reach the concerned department and NL[Z YLJ[PÄLK ¹ 9H]P 9HNOH]HU *,6 and MD, BFW, said.

Headquartered in Bengaluru, BFW designs and manufactures precision machine tools, mostly computer U\TLYPJHSS` JVU[YVSSLK *5* ]LY[PJHS machining centres and horizontal machining centres, horizontal turning centres, vertical turning centres and special purpose machines. Founded PU [OL JVTWHU` PZ H ÅHNZOPW of the Kothari Group. It was started PU JVSSHIVYH[PVU ^P[O -YP[a >LYULY >LYRaL\NTHZJOPULU .TI/ VM >LZ[ Germany. Most of its manufacturing HUK HZZLTIS` WYVJLZZLZ VJJ\Y H[ [OL company’s main facility in Bengaluru.

BFW is scaling up its research and development centre to cater to the increasing needs. The company spends up to 0.6% of its revenue in R&D. Last year, the company L_WHUKLK [V /VZ\Y HUK KV\ISLK P[Z JHWHJP[` ;OPZ MHJPSP[` ^PSS IL SPRL H ZTHY[ MHJ[VY` HUK )-> PZ I\PSKPUN P[ with all the new technologies it has. It PZ ZJOLK\SLK [V IL JVTWSL[LK [OPZ `LHY

Ravi Raghavan, *,6 HUK Managjng Director, BFW

example is that when the machine’s oil level comes down, the sensor in it detects and sends a text automatically [V [OL Z\WWSPLY HUK OL Z\WWSPLZ P[ 6U the whole, the machine takes care of P[ZLSM ¹ The company recently entered into a partnership with Universal 9VIV[Z [V WLUL[YH[L V[OLY ZLJ[VYZ ^P[O HMMVYKHISL HUK UL^ H\[VTH[PVU ZVS\[PVUZ 9H]P ZHPK JVIV[ PZ H UL^ trend and BFW is working on it HSZV ;OLYL ^PSS IL KH[H HUHS`ZPZ sensor technology, IoT and many other parts of technology that helps the company to move forward and improve productivity. “Things like JVIV[Z HYL PU[LSSPNLU[ ZTHY[ HUK [OL` HKK T\JO TVYL ]HS\L (IV]L all these, they are easy to use. What we are trying to do is to add value in L]LY`[OPUN ¹ OL ZHPK

BFW does whatever it takes to LUHISL WYVNYLZZ I` HJX\PYPUN UL^ technology to serve its customers IL[[LY 0[ PZ ^VYRPUN VU T\S[PWSL WYVJLZZPUN THJOPULZ HUK PZ I\PSKPUN THJOPULZ [V IYPUN V\[ SPNO[^LPNO[ WYVK\J[Z ¸6U T\S[PWSL WYVJLZZPUN machines two things are happening.

(IV\[ [OL UL^ THJOPUL [OH[ communicates, Ravi said, “The WYV[V[`WL VM [OL THJOPUL PZ ILPUN THKL PU [OL MHJ[VY` HUK P[ ^PSS IL V\[ in a couple of months. An example of how it communicates is: if the THJOPUL PZ ULLKLK [V IL ZOPM[LK MYVT the factory to a customer in Delhi, it sends out messages to the customer VU [OL JVVYKPUH[LZ [OYV\NO [OL .7: seamlessly. The owners of the heavy machines are small shop owners and he cannot rent a crane for a whole day. As the machine communicates he can do the needful whenever required. We have programmed and have given it certain fences. Another 21 21

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APRIL 2019 „ AUTO COMPONENTS INDIA

COVER STORY ,HYSPLY [OL SV[ ZPaLZ ^LYL IPN HUK we could take one model, make a O\NL U\TILY HUK JOHUNL P[ 5V^ WLVWSL HYL NVPUN MVY ZTHSSLY IH[JOLZ and for this, the machines need [V IL ÅL_PISL :LJVUKS` ^OLU [OL IH[JO ZPaL PZ ZTHSS [OLYL ^PSS IL one component in 10 machines. :OPM[PUN MYVT [OVZL THJOPULZ ^V\SK UV[ `PLSK IL[[LY YLZ\S[Z :V WLVWSL ^HU[ [V ÄUPZO L]LY`[OPUN PU H single machine. This is where we are ZWLUKPUN H SV[ >L OH]L W\[ H Ä]L axle machine and similar to that we have a couple of other multi-purpose machines. We have tied up with a JVTWHU` PU :WHPU [V THU\MHJ[\YL these. In the same way, we are also developing a multi-purpose machine ^OPJO JV\SK L]LU OVSK H YVIV[ I\PS[ inside the machine. These are very JVTWSL_ HUK P[ ^PSS IL V\Y HUZ^LY MVY JVTWSL_ SV^ ]VS\TL MHJ[VYPLZ ¹ Ravi said.

‰ Light-weighting

)->»Z 69065 H6600 series machine

6U [OL SPNO[ ^LPNO[PUN JVTWVULU[Z he said people are not thinking much HIV\[ SPNO[ ^LPNO[PUN I\[ [OPZ PZ where BFW focuses on. In his view, light-weighting can only happen with the use of different alloys having different properties. With this in mind,

[OL JVTWHU` PZ I\PSKPUN THJOPULZ [OH[ ^PSS IL Z\P[HISL MVY THU` SPNO[ weighting alloy components. This TH` UV[ NP]L NYLH[ ILULÄ[Z PU SV^ LUK Z[LLS I\[ [HRPUN [OVZL TH[LYPHSZ ^PSS ZOV^ HU LUVYTV\Z LMMLJ[ PU [OL ÄUPZO productivity etc. ¸;OL ]PIYH[PVU VM [OLZL ^PSS IL 1/10th of what we witness in normal THJOPULZ ;OL UL^ THJOPUL PZ ILPUN I\PS[ ^P[O HSS [OL ILULÄ[Z PU P[ HUK [OPZ PZ NVPUN [V IL [OL UL_[ IPN [OPUN ILJH\ZL ^P[O [OL LU[Y` VM ,=Z SPNO[ weighting will play a major role in WV^LY JVUZ\TW[PVU HUK IH[[LY` SPML ¹ he said.

‰ Disruptive technologies (IV\[ KPZY\W[P]L [LJOUVSVNPLZ SPRL + WYPU[PUN HUK ,=Z 9H]P ZHPK ¸,=Z ^PSS HMMLJ[ [OL THYRL[ I\[ VUS` H SP[[SL IP[ HZ [OL U\TILY VM JVTWVULU[Z ^PSS IL YLK\JLK )\[ HJJVYKPUN [V [OL studies that the various industries have KVUL I` L]LU ^OLU VM the auto industry is getting converted [V ,= [OL THJOPUL [VVS PUK\Z[Y` ^PSS JVU[PU\L [V NYV^ ;OL PTWHJ[ ^PSS IL VM KLWLUKPUN VU [OL [`WL VM THJOPUL 5VIVK` OHZ KVUL H Z[\K` VU HM[LY HUK ^L OH]L UV PKLH HIV\[ [OH[ ,=Z ^PSS OH]L HU PTWHJ[ But many other needs are also coming up. That is why some of the simpler machines will face the challenge and people will have to go for a new and different HWWSPJH[PVU ¹ 6U HKKP[P]L technology, [OL *,6 ZHPK it will not remove the Z\I[YHJ[P]L manufacturing as it is not an alternative to it. ¸>L ILSPL]L VM THU\MHJ[\YPUN

^PSS YLX\PYL Z\I[YHJ[P]L HUK HKKP[P]L JHUUV[ YLWSHJL P[ 6M [OL YLTHPUPUN

HIV\[ HKKP[P]L JHU IL directly used. In the remaining

[OLYL ULLKZ [V IL H SV[ VM engineering done, even in the design of the component. This will make the additive effective. For example, if I take a component that we are making Z\I[YHJ[P]L HUK THRL P[ PU HKKP[P]L P[ PZ UV[ NVPUN IL HU HK]HU[HNL 0 HT UV[ NVPUN [V IL ILULÄ[[LK MYVT P[ )\[ PM 0 engineer it, design the component in H ^H` Z\P[HISL MVY HKKP[P]L [OLU [OL ILULÄ[ ^PSS IL [OLYL :V [OL HKKP[P]L ^PSS OH]L HU PTWHJ[ I\[ VUS` VU JLY[HPU JVTWVULU[Z *VZ[ HSZV WSH`Z H THQVY YVSL OLYL ¹ OL HKKLK 9H]P ZHPK [OL` OH]L WSHUZ [V IL WHY[ VM the additive technology. But, they are waiting to learn new things as it is an evolving industry. BFW is looking at HSS WVZZPIPSP[PLZ HUK PZ SLHYUPUN VU ^OH[ PZ [OL ILZ[ ^H` [V NV MVY^HYK (Z [OL` are in the metal industry, they will not NL[ [V WVS`TLY HUK NSHZZLZ :OHYPUN his views on the growth potential of the Indian market, he said, they are SVVRPUN H[ NYV^[O PU ZTHSS QVIZ [OH[ KVLZ H SV[ VM ZTHSS IH[JO JVTWVULU[Z 6[OLY HYLHZ VM ZTHSS QVIZ PUJS\KL WV^LY PUMYHZ[Y\J[\YL L[J *VUZ[Y\J[PVU equipment and dying moulds are also the areas where they witness growth. :WLHRPUN HIV\[ [OL THYRL[ MYVT India’s perspective Ravi said, “By [OL NV]LYUTLU[ WSHUZ [OL THU\MHJ[\YPUN .+7 ZOV\SK IL 1 trillion dollars. Today, it is less [OHU IPSSPVU KVSSHYZ >L HYL [HSRPUN HIV\[ [PTLZ NYV^[O PU years and manufacturing cannot grow if machines are not here. The machine tool industry has a huge opportunity to grow. The second WHY[ PZ *OPUH \ZLK HIV\[ IPSSPVU dollars worth of machine tools and ^L \ZL HIV\[ IPSSPVU KVSSHYZ :V the growth will happen in the next 6 years. Then it will slightly slow KV^U ILJH\ZL VM ,=Z HUK V[OLY things coming in. ACI

22 22 AUTO COMPONENTS INDIA „ APRIL 2019

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COVER STORY

Altem leads the change in 3D printing Story by: Sricharan R

B

angalore-based Altem Technologies (P) Ltd, a leader in the 3D printing market, partners with Dassault Systemes for PLM solutions, Stratasys for 3D Printing, Artec 3D for 3D Scanners, MSC Software for CAE solutions and ESTECO for Optimization solutions to present the most advanced products and complete solutions PU [OL ÄLSK VM *(+ *(4 *(, 734 and Rapid Prototyping Machines to enhance in-house R&D design capabilities. 3D Printing, also known as rapid prototyping or additive manufacturing, is bringing about the next industrial revolution and Altem is leading the change by bringing in new ideas to enable manufacturers and designers in India to realise their products faster and more economically.

“With the 3D printing, there is a saying that we cannot use this PU THZZ WYVK\J[PVU -VY ZWLJPÄJ machines, we can use this for producing in huge numbers.

3D printing will be very useful in aerospace components etc.

Mass production is possible for T\S[P ILUJO Z`Z[LT VY ÅL_PISL manufacturing system. This takes time, and scaling up a multi-bench system is possible,” Krishnakanth, Application Engineer, Altem Technologies, told Auto Components India.

Altem operates through the sales VMÄJLZ PU /`KLYHIHK *OLUUHP Pune, Kolkata, Ahmedabad and New Delhi. The company gives end-to-end solutions from design, simulation, 3D scanning and also end product technology for 3D printing, for the rapid prototyping.

With the advancements made towards the new technology, there is quite a lot of development happening in this area. Through Dassault Systemes’ 3D EXPERIENCE Platform, Altem Technologies provides the users with innovative PLM solutions viz. CATIA, DELMIA, 3DVIA, ENOVIA etc. Recently it has signed up with ARTEC3D and MSC software, to sell 3D Scanners and CAE Solution from these companies in India, respectively.

ARTEC Eva and ARTEC Spider are the most innovative and advanced handheld 3D Scanners offered from ARTEC3D. And MSC software offers a complete range of solution in the CAE environment viz. Acoustics, Composites, Design Optimization, Multibody Dynamics, Noise & Vibration, Structural and Thermal analysis.

Stratasys Additive Manufacturing + 7YPU[PUN ZVS\[PVUZ WYV]PKL versatility to produce FDM (Fused Deposition Modelling) thermoplastic parts, WDM (Wax Deposition Modelling) parts &Polyjet Photopolymer resin parts with strength, durability, accuracy and function of traditionally manufactured parts without machining or tooling. 3D Printing Z`Z[LTZ [YHUZMVYT + *(+ ÄSLZ from Concept models, functional prototypes, Direct Digital Manufacturing (DDM) tools viz.

Injection moulding and end-use parts. Stratasys 3D Printers consist of FDM systems (uPrint SE, Dimension series & Fortus series) for ABS & other thermoplastic parts and Objet Polyjet systems (Desktop series, Dental series, Eden series & Connex

series) with photopolymer resin parts. Stratasys has also introduced [OL ^VYSK»Z ÄYZ[ T\S[P JVSV\Y multi-material 3D printer called as Objet500 Connex 3.

“Though it is considered to be a disruptive technology, 3D printing is one of the best technologies and it attracts customers. In R&D this plays a major role. When a product is in the mode of construction, it needs JSHZZPÄJH[PVU VU OV^ P[ ^PSS IL ^VYR on various conditions. So, a model will be made and it will be tested and this one of the best solution we provide in terms of simulation, design etc.,” Krishnakanth, said.

“When the customers go for complex dimensions, they need something they need to try on. This cannot be done in casting, forging, forming, and 3D printing will help,” he added.

About the market, Krishnakanth said, cost is an issue now, but when the new approach of material modelling comes in, it will be great. The powder cost is on the higher side now.

When the new technology comes PU [YHJR [OLZL ^PSS IL YLJ[PÄLK ;OLU it gets recognised, optimised and becomes cheaper and popular. It is at the stage of development and THU` JVTWHUPLZ \ZL MVY VUS` ZWLJPÄJ purposes.”

“With 3D printing, we may also take out the dead weight which will reduce the components density.

So, if the density of the component reduces it will eventually reduce the weight of the part. It will be lighter, stronger and can be made as per requirements,” Krishnakanth said on light weighting of products. ACI 23 23

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APRIL 2019 AUTO COMPONENTS INDIA

COVER STORY

Hoffman plans to replicate European model in India Story by: Sricharan R

T

he Hoffmann Group, Europe’s leading system partner for quality tools, is seeing a promising future in the Indian market. With this in mind, the company is building its team and developing the infrastructure here. Known for its reliable and quality tools for machining, clamping, measuring, grinding and cutting tools, the group is present in India through its own subsidiary, Hoffmann Group India.

cities like Bangalore, Chennai and Delhi while simultaneously expanding the second phase of being present in tier-II cities like Coimbatore and Ahmedabad,” Hoffmann India, Director, Ulrich Magnus Öfele, said. “We have a sustainable growth over here and we want our tool catalogue to be accessed by customer at every shop in India just like in the European market. We also have a huge support from our head office,” he added.

“It has grown to 50 employees in 2 years and that is a sign we are investing greatly in the country. Headquartered in Pune, we are currently in the first phase of our growth in tier-I

Just at the start-up phase in India, the company is a €1.2bn company, globally. In India, they also supply hand tools and workstations and storage along with machining consulting

expertise for the manufacturers.

For the price-sensitive Indian market, the Hoffmann Group offers premium quality tools in an outstanding price-performance ratio and consulting services to enable the customers to use the tools longer and more efficiently. The group entered the Indian market in 2016 and had quite a successful journey, so far. As Europe’s leading system partner for quality tools, the Hoffmann Group combines commercial expertise with both manufacturing and service competence. To more than 135,000 customers, this combination guarantees reliability in supply, quality and productivity in the tooling sector, the workstations and storage sector and also in the personal protective equipment sector.

Alongside tools for machining, clamping, measuring, grinding and cutting, the portfolio also comprises hand tools, protective work-wear, workstations, and storage and workshop accessories. Customers include major listed companies as well as medium-sized and small companies in more than 50 countries. Including GARANT, its own premium brand, the Hoffmann Group offers 80,000 quality tools from the world’s leading manufacturers.

New trends About the new trends they witness in the market, Ulrich said,” There is a lot of niche 24 24 AUTO COMPONENTS INDIA APRIL 2019

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COVER STORY development in our home market in Germany. Some of them are digitalisation, Industry 4.0 etc.

Digitalisation is there in the market and it is also changing the structure in the procurement of tools in the tooling market.

Industry 4.0, is also led by digitalisation. These are the mega trends in the market. The other major changes we see is at the pattern how customers, think about production, layout production and how they layout generic tools supply. In India, we are planning to serve the customers the same way as we do in our co-markets. We are playing to our strengths, where we offer a comprehensive selection of our own products combined with a distribution model. Because, Hoffmann believes in giving the customer a choice, they can build around them. The service model and dimension we provide will be an example of that. In our co-markets, our customers sit with the experts in cutting tools, e-business process etc., to bring in the product that they require.”

Industry 4.0 in terms of connectivity.

Recently, using Parabolic Performance Cutting (PPC) from the Hoffmann Group, Koller Formenbau reduced its finishing operation time by 85%.

With PPC, Koller has not only reduced the finishing operation time for tool moulds and mould plates by 85%, but it has also improved the surface quality. In the tranquil Altmühltal, between Ingolstadt and Nuremberg, Koller Formenbau GmbH develops and manufactures tools, injection tools and lightweight components. Speaking about this, the director said, “This is actually how we literally reduce time by cutting tool strategy, PPC. This helps them to have a perfect finish and the moulds can be used longer. This is a special application where it can increase the process of the machining.“ About the competitions they face in the market, he said, “We have competitions across

Ulrich Magnus Ofele, Director, India, Hoffmann

the globe. It is not something we have only in India. We have been successful for 100 years now and our approach is unique.

This is because, we do not think of ourselves as a distributor or a manufacturer, or a service provider. We combine them uniquely and give customers as one strong system. The customer relies on us, as we deliver quality products. This makes us unique over here in the Indian market too.” ACI

Latest technologies With new technologies like the 3D printing coming into the market, the director said that they are aware of this and have seen those trends. He feels 3D printing is connected to another megatrend, EVs. According to him, electric vehicles will not come overnight and it may take some time. The possibility here is to combine 3D printing and machining. Though this might involve less machining, this could prove to be more optimistic. The company spoke to its customer on how they can offer tools in each new technologies and in a reliable way to them. Electric motors require components and there is more space to participate in them through digitalisation, 25 25

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APRIL 2019 AUTO COMPONENTS INDIA

COVER STORY

Driven by customer demand Tyrolit brings disruptive products to market Story by: Sricharan R

T TYROLIT POLARIS Plus LW grinding wheel with lightweight core for external cylindrical grinding

yrolit, one of the world’s leading manufacturers of grinding, cutting, drilling and dressing tools, and machines for the construction industry, is ready with solutions for Industry 4.0. A member of the Swarovski Group, the Austrian-based cutting tool manufacturing company has over 4,300 employees at 26 production locations in 11 countries in 5 continents.

“We displayed our industry 4.0 solutions at this year’s Imtex. It is all about digital manufacturing, reducing human

intervention, enhancing capacity, optimising the available setup and making machines interact with each other through a digital environment. We have brought in a new solution called ToolScope.

With this, customers can analyse and optimise the process and enhance the life of the machine by Ä_PUN SPTP[Z MVY [OL WYVJLZZ 0[ JHU also help in avoiding the collision inside the machine. This will save a lot of maintenance of the machine. It also helps in checking [OL ]PIYH[PVU Z\YMHJL ÄUPZO X\HSP[` requirement of the parts. With this, we can ensure that only the right quality of the product comes out and increases the life of the machine,” Subrahmanya Kumar, Country Sales Head, Tyrolit, said.

Started in 1919, the group is present in Metal and Precision, Industrial Trade, Construction and Stone, Ceramics and Glass.

In all these divisions it manufactures over 80,000 different products and sell to customers in 65 countries through 35 sales companies and additional distributors.

In India, Tyrolit’s division of metal precision started 10 years ago. Grinding is at the last stage of any operation of any component.

It is important that a customer is able to get right dimension, quality and surface condition of the product. Tyrolit plays a

major role here. In India, the company provides high-quality products which help customers bring down manufacturing cost by optimisation.

“We still are a young organisation in India. We have been witnessing very positive support from the market. As a brand, we also have been accepted by the customers here. India is a growing market and when it is growing, all companies would like to optimise their existing set-ups and they will invest in new machines. So, we always try to involve ourselves in ensuring that our customers make good utilisation of the machines. We also work closely with them when they go for new investments. It has been a very interesting journey so far and we see very good opportunity to grow along with customers,” Subrahmanya said.

Tyrolit strives to impress its internal and external target groups, and to cultivate fair, lasting cooperation with them based on partnership.

“We also optimise the quality of our products and services, and we constantly adapt our business processes to the changing demands of the market. Investment in research and development, in training our employees and in technological improvements is an integral component of our company management. The introduction of global supply chain management ensures punctual delivery to customers around the globe,” he said.

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COVER STORY Disruptions ahead Globally industry 4.0 and additive manufacturing are gaining momentum. These are growing very fast in India also. Technologywise India is in line with any other developed country. “I do not see these as a threat because this gives us opportunity. We are looking at this as a development in technology. When we talk about 3D printing, it needs certain types of material and different kinds of tools. Maybe, a few parts can go through the 3D printing, but there are many other new opportunities that are coming in from industries like medical, electronics etc,” Subrahmanya said.

With the EVs, the number rotating parts will be reduced. This means that the quality of the required parts needs to good, he said. The materials they use will not be the same because the required result for EVs is different from that for IC engines. Other criteria like light-weighting, NVH also play major role. “So, with EVs it could

be noise level, the life of the part etc. The quality is important and it should be a more advanced solution than ICE,” he said.

Tyrolit in India is concentrating more on its customers to meet their requirements. It plans to make all its products available to them. For this it plans to revamp the organization in India . Already around 100 people are working on its R & D to bringing new solutions to the market. The innovations are across various areas including new system, grain, product line and even a total change of process.

“We understand the need of the customer and give him the solution he is looking for. We are known for innovation and we bring new solutions to market.

This is how we differ from our competitors. The solution we give comes with an advantage to the customer even over the existing products. For example, we have the electroplating grinding wheel,

Subrahmanya Kumar, Country Sales Head, Tyrolit

called Polaris. Recently, we introduced a light-weight version of the same which weighs less by around 50%. This makes it easy for the customers and reduces the load on the spindle. Such things we do benefit the customers. We also try to learn from them on what they need tomorrow and start working on it today. So, when they require it in the future we will be ready,” Subrahmanya said. ACI

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APRIL 2019 AUTO COMPONENTS INDIA

COVER STORY

Askar Microns to make machines for additive and subtractive manufacturing Story by: Sricharan R The Mysore-based machine manufacturer Askar Microns is looking at the possibility of bringing in a mixture of additive and subtractive manufacturing. With the world moving towards 3D printing or additive manufacturing, the machine manufacturer feels the metal cutting industry will survive disruptions and there will always be need for a hybrid of additive and subtractive manufacturing.

K S Raju, Managing Director, Askar Microns, told Auto Components India, “Whatever be the disruption, metal cutting will be there and it cannot be avoided. With the arrival of the electric vehicles, there will be

reduction in the number of parts. But, there will be machining requirements like a composite material or special material machining. There are also a few areas where 3D printing might not work. In some areas, based on the infrastructure requirement, the machining tools might be used continuously. So, there is a possibility of bringing in hybrids which can do both additive as well as subtractive manufacturing works. We are thinking to move to such concepts. As far as 3D printing is concerned, we are getting prepared for the future and we are also looking at it. It is at a primitive stage,” Raju said.

Established in 1995, Akar Microns

manufactures CNC machines and automation products for all kinds of applications. Askar’s machining family has 23 models in the product range including Slant Saddle Series, Slant Bed Series, Flat Bed Series, Twin Spin Series, Turn-Mill Centre, Vertical Machining Centre, Trainer Series and a few more. The company has produced over 2500 machines of different sizes and models. They are also exported to Germany, France, Italy, Russia, Iran and other countries.

About the new trends in the market, Raju said, “Two decades ago, ^L \ZLK [V NV MVY H YL[YVÄ[ 5V^ with the evolution of technology, people are looking at multi-axles and multi-tasking machines. Lean manufacturing is the buzz word now.

It is mainly because of the increase in labour cost, space cost, and power cost. People can no longer afford each machine for every single process.

They try to integrate the process and machining operations. With this, the multi-tasking and multi-operational machines are becoming more popular.”

With this in mind, the company is working on various machines. “Earlier, we used to make simple turning machines. Now, we are making a turn-mill centre, where, in a single machine we integrate turning and milling. Integrating various operations together is the need of the hour. In turning machines, we have come up with turn-mill and mill-turn centres.

Another major trend is the multiple axle machines. Earlier, we used to have only 2 axles per spindle. Now, we go for X, Y, Z in the spindle, where we have multiple axles. We

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COVER STORY also have double spindle machines.

For example, in the same machine, it could hold double spindle and six axes. This makes the operation more versatile and easy,” he said.

With the industry moving towards the future, Askar Microns is also trying to work with machines for connected manufacturing and Industry 4.0. Its focus will be on machine downtime and small shop jobs. The company provides connectivity as a part of the machine, which helps the customers understand the machine uptime, downtime, maintenance, preventive maintenance and a lot more. “The IoT solution we have is connected to our machines. A small shop owner has to run the business, meet the customer and has to do a lot of other things too.

So, this helps him determine how each machine works, making it easy for him,” Raju said.

Being customer centric and by understanding the needs of the market, the company’s focus is on improving the productivity of the machine. They are also concentrating more on the reliability of the machine.

Other focuses also include downtime, machine rigidity and accuracy.

Achieving the product capability is how Askar design the machine and that is how we manufacture it, he mentioned.

irrespective of the cost. For example, the kind of precision parts we use like the liner guides, bearing, coupling etc., we do not compromise on these and we constantly upgrade to the [LJOUVSVN` JOHUNLZ ;OPZ ILULÄ[Z [OL customer and that is most important for us.”

Motivated by specialists, Askar builds the machines with a team of specialised engineers at its R&D. This ensures the ergonomic and proven design impart value to the customer. Though they do not do much of research, they do work on

the development of the product. The range of products they have is built with team efforts and technology.

Going forward, the company has a strong urge to develop its R&D centre in India. As of now, Askar Microns has invested and it is expanding at its existing space. “We are looking to expand at every area possible.

Earlier, we used to have 15000 sq. ft. of capacity, and now we have made it to 1 lakh sq. ft. We are increasing the number of cranes, bays and a lot more. With this, there will be a rise in machines, capacity and space,” he stated. ACI

About how unique and different are they from their competitors, Raju stated, “We are different because we produce a machine as craftsman do.

We build one with a lot of passion.

Even today, the machines we have sold in earlier years work perfectly and customers feel its good. Even though there isn’t much marketing, the customers come back. This gives \Z TVYL JVUÄKLUJL PU ^OH[L]LY focus we had on our craftsmanship in building the machine. We are also different from them in terms of building the machine with no compromise in technology, 29 29

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APRIL 2019 AUTO COMPONENTS INDIA

COVER STORY

EOS offers training on additive manufacturing technology Story by: Sricharan R

E

OS, the global technology leader for industrial 3D printing of metals and polymers, is working with various OEMs to set up consultancies and training programmes in India. This is to raise people’s knowledge to a higher platform and to have experience in additive technology.

there is need for learning in additive manufacturing. Though people know that additive will do something to the market, they do not know what it is. We are focusing on how to bring up the knowledge level in the market,” EOS India, Country Manager, Anand Prakasam, told Auto Components India.

“It is very important to bring the knowledge level of the people to a higher platform. So, we are working with OEMs, institutes like IGTR, CTDC, SIPET and many more, to see if we can create a curriculum that can be transferred to the engineers and even to the corporates. We feel

Founded in 1989, the 3D printing company is a pioneer and innovator for holistic solutions in additive manufacturing.

Everything EOS does is founded on the cornerstones of corporate responsibility and sustainability, both inward and outward-facing.

They are also mastering the interaction of laser and powder material and providing all essential elements for industrial 3D printing.

Though there is a potential for growth of the new technology in the market, many consider this as a major disadvantage because of the cost. Anand contradicts this saying it is the perception that is in the problem.

“You have to start the idea right MYVT [OL KLZPNU WOHZL ;OL ÄYZ[ Z[LW is with 3D printing. If you are taking a part of CNC design manufacturing and trying to manufacture it in 3D printing, it is not going to bring

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COVER STORY

HU` ILULĂ„[ )LJH\ZL HKKP[P]L manufacturing can give you a whole lot of other advantages like weight reduction, less volume per part, keeping the same functionality. So, if you can design a part and start, you will have cost ILULĂ„[ :LJVUK ^L ULLK [V PKLU[PM` the right parts. Not all parts are for metal 3D printing. This is where our consultancy department comes into play. It offers training to industry on 2 things. One, what are all the parts that are suitable for the new technology. There is a template and we explain them on how to identify them. It is the wrong approach if you think that we can print every part. Second, after you have selected the part we need to take advantage of 3D printing in terms of cost, technicality etc., For this, you need to redesign the part. We offer this as a training programme called DFAM. When these two issues are taken care of, 90% of your cost issues are sorted out. There will be a 10% issue, which is common in all the component industry.

The additive manufacturing brings in a lot of value for the aerospace industry. When you go to automotive industry, though there might be a design change in components, it may not hold economic viability,� Anand said.

About the capex margin, he said, as the number of machines increases it could come down. “In the Indian market from a metal perspective we may have 20 machines a year. Once this increases to 200 machines, the cost will also come down. Also, we OH]L H ZWLJPHS TVKLS JHSSLK )66; )\PSK 6^U 6WLYH[L HUK ;YHUZMLY If a customer has good requirement and utilisation but does not want to invest in the capex, he can sign a 2-3 years contract with us. Through which, we locate the machine and run it for him. He has to pay as per his use. He should meet a certain threshold of utilisation in them to avail this. With this, the user addresses the entry barrier of cost and we are the only one to offer this.�

More customers and companies are realizing that additive manufacturing is here to stay and they have witnessed a lot of developments in this. People have shown interest to adapt and the learning phase is still going on.

Anand feels that many stating this technology as a disruptive is not true. The technology is disruptive for people who can take this from prototyping to spare parts. People who hold a small volume and a large mix of components as in the aerospace domain can use this and bring in a change. This is because the number of pieces they require would be a few thousands. It will also be disruptive in the special

‰ Old, but new From a global perspective, additive manufacturing is not a new trend. It is already in the preproduction phase. The technology has been there for more than 20-25 years and used a lot for prototyping. Now, it is getting into layer manufacturing because of the industries like aerospace, medical etc. In India, there is a lot of discussion in the maturity of the product and technology to meet the manufacturing demands.

Anand Prakasam, Country Manager, EOS India 31 31

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APRIL 2019 „ AUTO COMPONENTS INDIA

COVER STORY W\YWVZL THJOPULZ )\[ [OPZ TPNO[ not be the solution for mass manufacturers of 1-2 lakh pieces.

3D printing can play a huge part in prototyping as far as mass production is concerned. Apart from this, the big benefit that the OEMs hold is that they would require no tooling. They can print parts as per demand.

“We are talking to a company that wants to print a certain component for a motorcycle.

The yearly requirement is only 5000 pieces and they are not sure about the market for this variant. The market for this may be less than 5000 or they might change the design or even stop the variant. For them, additive manufacturing makes sense as they do not need to spend a lot of money on tooling of different parts. The concept of agile manufacturing and ability to adapt becomes very easy with this process,” Anand said.

What’s new?

EOS has a deep commitment to customers and their needs.

System, material and process parameters are intelligently harmonised to ensure a reliable high quality of parts and thus facilitating a decisive competitive edge. Furthermore, customers benefit from deep technical expertise in global service, applications engineering and consultancy. At their R&D centre in Germany and Finland, EOS is working on machines to increase its throw-put, as it is the need of the hour. The company is working on many things including, multi-lasers, new materials, larger bed size and machines that can process high-temperature materials.

The high-temperature machines will help to process a certain grade of nickel alloys for the aerospace industry. The additive manufacturing company spends about 14% of its turnover on

R&D which will be close to 5055 million Euro.

“To set up an R&D centre in India, we need to understand the market needs. If the market here grows exponentially, the company would invest in R&D here. This applies to the manufacturing facility too. At present, it is being imported from Germany. We will have a good price benefit if we Z[HY[ H MHJPSP[` OLYL )\[ [OPZ PZ niche technology and finding a supplier locally to build only 20 components in a year is going to be a challenge. There needs to be a supplier base around you and he should have enough business to be motivated to deliver the highest quality. For a supplier who supplies small components, 20 components a year might not be a huge thing.

So, to have a full-fledged set-up, we need to have more input from the market,” he said. ACI

Component made out of additive manufacturing 32 32 AUTO COMPONENTS INDIA APRIL 2019

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COVER STORY

EMO in Hannover to focus on smart production technologies ACI Bureau

E

MO, world’s leading trade fair for metalworking, will be held between September 16 and 21, 2019 in Hannover, Germany. The 22nd edition of the event is being organised by the German Machine Tool Builders’ Association (VDW), on behalf of the European Machine Tool Association, Brussels, Belgium, in cooperation with Deutsche Messe AG. “More than 1,780 exhibitors from 41 countries had applied

by December 1, 2018. The companies include DMG Mori, FFG, Mazak, Siemens, Grob, Doosan, Fanuc, Okuma, Makino, Index, GF Machining Solutions, Chiron, Trumpf, SLM, Stratasys, Paul Horn, Iscar, Sandvik, Kuka will participate in the event. Around 31 companies have registered from India, including Bharat Fritz Werner, Forbes & company, Jyoti CNC Automation,” Dr Wilfried Schafer, Executive Director, VDW, said.

VDW has around 300 members. They represent about 90% of the total industry turnover in Germany and representsthe interests of its members both nationally and internationally. As the organizer VDW, in cooperation with Deutsche Messe AG, offers visitors and exhibitors a comprehensive range of services like online registration, contacts via the foreign representatives of Deutsche Messe AG in the national language, visa support and a lot more.

India is one of the important markets for production and metal tool consumption, and EMO always had good participation from the Indian exhibitors. In 2017, 10% of the exhibitors were from India. EMO is expecting more participation from India again. “All major manufacturers of production technology will be presenting their products and services at the largest and comprehensive exhibition of industrial

production. Nobody can afford to miss it.

EMO attracts trade visitors from all over the world. In 2017, just under half of the 130,000 visitors travelled to Hannover from outside Germany, with around 160 countries represented. The proportion rose to 64% for the exhibitors,” he added.

The Theme for this year is “Smart technologies drive tomorrow’s production.” Major trends in the industry will be discussed, especially Industry 4.0 and IOT that are growing in all sectors of production. EMO now has a dedicated exhibition area for IoT in production. A section is reserved for individual exhibitors PU [OL ÄLSK VM JVU[YVS [LJOUVSVN` ZVM[^HYL and automation technology. This area also offers an attractive environment for IT providers if they want to boost their business with manufacturers of production technology. ACI

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COVER STORY

EMAG pioneers production of planetary and sun gears, cams By: Bjorn Svatek, Sales & Marketing Director for Modular Solutions, EMAG

T

he challenges in the automotive industry are growing very fast. Take transmissions for instance, the existing systems such as automatic torque converters and dual-clutch transmissions are constantly being enhanced. These are being supplemented by unique hybrid drives and assistance systems, which increase the complexity of the overall system. In this context, the main goal of quality managers is “zero fault tolerance,” now more than ever. Each component must IL ÅH^SLZZ ^OLU [OL` SLH]L [OL production area - and at the lowest possible unit cost.

Two VL 1 TWINs can be linked with TrackMotion to form the VL 1 TWIN Line.

Machining is then performed from 2 sides

With its new VL 1 TWIN, EMAG shows how a highly specialised machinery manufacturer is able to master the challenge. The twinspindle pick-up turning center for components up to 75 millimeters (3 inches) in

diameter simultaneously machines 2 identical components in a single machining area. At the same time, equipment such as the innovative linear motor and the direct distance measuring system in the X-axis provides precision and longterm accuracy. This makes the production of essential transmission components, such as planetary HUK Z\U NLHYZ ZPNUPÄJHU[S` TVYL LMÄJPLU[ 0[ HSZV PTWYV]LZ the manufacturing of cam parts, ÅHUNLZ ZSLL]LZ HUK YVSSLY ILHYPUN rings at every level.

“Quantity and quality” are shaping transmission manufacturing more than ever. Considering the increasing number of gears in transmissions, the quantity of gears and other toothed components produced is undeniably on the rise.

At the same time, the quality of the components must also increase in order to achieve the

power density required in modern transmissions. The performance features expected of transmissions, such as a long service life with optimal dynamic response, also still apply. Is it at all possible to reconcile growing quality and productivity requirements with generally increasing pressure on costs? “That was precisely our goal,” says Björn Svatek, Sales & Marketing Director, Modular Solutions, at EMAG. “We have developed a low-cost machine, that enables high output volumes with short lead times due to its 2 pick-up spindles and also ensures dynamics as well as repeatability and longterm accuracy with its direct distance measuring systems in the X-axis, size 45 recirculating roller guide rails, and innovative linear motor. It is the perfect solution for turned parts with diameters of up to 75 millimeters (3 inches).”

Minimising cycle times The possibilities made possible by this approach become clear from a simple description of the production sequence: A

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COVER STORY simultaneous process (OP10/ OP10) is performed on 2 identical workpieces, quickly, within the machine. Both components are picked up from the conveyor belt by the 2 pick-up spindles (9.9 kW/136 Nm at 40% duty cycle), transported to the machining area, and machined in a single clamping operation—the diameter and length (X/Z directions) of the 2 components can be adjusted independently, since the movement of the spindles is entirely autonomous. The linear motor in the X-axis combined with the direct distance measuring system also increase the speed in the simultaneous sequence. What cycle times are possible with these features? “It obviously depends on the component and process,” says Svatek. “Generally, the average chip-to-chip time is just under 5 seconds.

VL 1 TWIN Line EMAG uses the productive twin approach for advanced manufacturing solutions. For example with the VL 1 TWIN Line: 2 VL 1 TWIN machines are linked together using the TrackMotion automation system. Machining is then performed simultaneously on 2 sides of 2 components in OP10 and OP20. This allows for cycle times of less than 20 seconds to be achieved for the entire OP10/OP10 and OP20/OP20 sequence—an PUJYLKPIS` SV^ ÄN\YL LUZ\YPUN ZPNUPÄJHU[S` SV^LY \UP[ JVZ[Z MVY the soft machining of planetary gears. The system is also equipped with an extensive parts storage HYLH MVY YH^ HUK ÄUPZOLK WHY[Z The use of space optimisedstacker pallets allows for a large number of components to be accommodated in a very small space. Doing so, by stacking the parts as the name already implies. With the TrackMotion automation system linking machines, EMAG is able to

Bjorn Svatek, Sales & Marketing Director for Modular Solutions at EMAG

deliver multi-technology production lines. Let’s take gearwheels as an example: After machining 2 sides of the blank using 2 VL 1 TWINs, an EMAG hobbing machine cuts the gear teeth on the component.

Finally, deburring is performed with EMAG technology in OP40. The TrackMotion automation system allows for a fast pace between operations with a maximum travel speed of 150m/min (5905 in/min).

High quality, low cost A goal during the development of the VL 1 TWIN was to achieve consistent, high quality workpieces – as evident by various JVUÄN\YH[PVU KL[HPSZ -VY PUZ[HUJL there is a direct and extremely precise distance measuring system in the X-axis, the recirculating roller guides ensure high rigidity as well as guidance precision, and the MINERALIT polymer concrete machine base reduces vibrations during the turning process.

An optional measuring system between the machining area and the pick-up stations continue to increase the process reliability.

“Extreme precision and long-term accuracy are always an integral part of this machine,” says Svatek.

However, the fact that these high requirements are achieved with low investment costs for the user may be the most surprising highlight of this technology.

all the decisive factors together,” concludes Svatek. “The VL 1 TWIN ensures extremely low cycle times, guarantees high component quality, and minimises investment costs. Additionally, we are able to JVUÄN\YL OPNOS` ÅL_PISL Z`Z[LT solutions for both sub-processes and complete processes. At the end of [OL KH` V\Y J\Z[VTLYZ ILULÄ[ MYVT ZPNUPÄJHU[S` SV^LY \UP[ JVZ[Z ¹ ACI

A simultaneous process is performed within the machine on identical workpieces

EMAG is committed to rigorous cost control during the entire development process and also uses standardised high-performance components. This is how the WYPJL WLY ZWPUKSL ^HZ ZPNUPÄJHU[S` reduced. The basic machine (without chip conveyor and automation system) has a footprint of only 4.59 square meters (50 square feet) — and this will naturally cuts costs even further when establishing a new production process. “With this turning center, we really bring 35 35

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COVER STORY

Arrow makes future-ready machine tools Story & photos: Sricharan R

do turning and drilling. We have got an additional polygon turning H[[HJOTLU[ [OH[ PZ Ä[[LK KPYLJ[S` [V the system. With this, 4-6 sides of milling can be done. Combining 2-3 operations together is another thing we are concentrating on,” Sajith Kumar, CEO, Arrow Machine Tools, said.

T

he Chennai-based machine manufacturing company, Arrow Machine Tools, has come up with a variety of futureready machines. Since its inception in 1995, the company has established a name in the machine tool industry as a manufacturer and exporter of a range of lathe machines. “Our approach is mainly to look at the possibility to reduce manpower. For example, our gantry loading system can now work without an operator. Human force is required only for job loading. We can load up to 30-40 pieces and it works automatically. Second, we are introducing small parts with

Sajith Kumar, CEO, Arrow Machine Tools

auto-bar loader. In the CNC turning centre, operations of drilling and milling can be combined to one.

The Polygon Turning machine, which is a standard lathe, can

The company with its diverse industry experience and rich expertise has become a noted manufacturer, exporter, supplier and service provider in this domain. Leveraging on its indepth knowledge of the industry coupled with its technologically high-end production facilities it has earned the distinction of serving the engineering industry in crucial capacities. The company’s fully equipped facility produces automatic lathe, CNC lathe, cutting and chamfering machine, second operation lathe and special purpose machines.

“We also have another new product that is exclusively for the cut blanks or forgings. Here, you do not need a person for the second operation. A person has to Q\Z[ SVHK K\YPUN [OL ÄYZ[ VWLYH[PVU 6UJL [OL ÄYZ[ ZPKL VM [OL operation is completed, a second spindle will automatically catch it and rear side operation takes place. It can be threading, milling, turning etc. It is a standard machine with 2 spindles. The job JHU IL [YHUZMLYYLK MYVT ÄYZ[ [V the second spindle automatically, without any gantry or a robot. We have supplied a few machines of this kind,” Sajith said.

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COVER STORY About the other new trends in the market like connectivity, Industry 4.0 and IoT, Sajith said they are into a small segment of customers and give out solutions on multiple operations. They are clear on their stand to not being a competition with big players. But where they differ is by giving out solutions to the customer, when the other players give only standard machines. They also offer machines in the economic range which help the customer who has an economical budget. With the EVs and additive manufacturing coming in, the CEO said, even when the 3D printing comes in it might not affect the turn components. “There is not much of an option for the turn components other than this.

We work based on the design given to us by the customer. Most

NOW ON STANDS

of the tier-II and tier-III suppliers of automobiles are our customers.

We are also exporting but, our concentration is more on the Indian market,” he said.

Being a small scale unit, Arrow holds a small R&D department.

Here they work to meet the requirements of the customer.

The company gets the basic machine from Taiwan, China and depending on the product and requirement of the customer, they do value addition like system orientation, hydraulics, electrical works etc., here. The design, requirements will all be made based on the requirements of the end user. Going forward the company plans to expand its dealership network in India to cater to more customers. ACI

IND IA’ S NO . 1 TW O WH EE LE R MA GA ZIN E,

BY FA R!

VOLUME 14

ISSUE 09

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` 100

APRIL 2019

IVE! Kaw

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MEAN &asaki Ninja ZX-6R GREEN

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KTM 790 Adventure

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C

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COVER STORY

FAR is getting ready with Industry 4.0 solutions Story and photos: Sricharan R

F

enwick and Ravi (FAR), a Bangalore-based machine tool company, is working on to bring in Industry 4.0 and IoT to their machines. Established in 1990, the company specialises in the manufacture of Bar feeders and Self Centering for CNC turning canter, special purpose machine like crankshaft web milling, crankshaft oil hole drilling, crankshaft pin milling, cylindrical drilling, crankshaft grinding and camshaft grinding. ¸([ ÄYZ[ ^L OH]L [V SLHYU HIV\[ the Industry 4.0 and we are doing it with our own design. We have a machine shop with various machines where we are trying to see whether

we can implement Industry 4.0.

This is done to get a feel about it.

In India, Industry 4.0 is still at a nascent stage and people are trying to understand it. It is not really a question of making the machine but, building an entire system around it.

We are trying to see whether some of it can be implemented in our company, to learn about the health of the machine etc. It is not exactly the real Industry 4.0 because we are not in the auto components segment and we are not into mass production. So, we are trying to implement a few at the initial stage.

It may be in place by April-May. For the IoT, we are working on a product to learn things with the help of data.

We are also in the learning phase of this. So far, all these have been from the user point of view. Within 2 years, many will move towards the Industry 4.0 from the manufacturers’ point of view,” Ravi Radhakrishnan, Director, Fenwick and Ravi, told Auto Components India.

Situated on a 1-acre facility with about 22,000 sq ft of built-up area, the company products go through a stringent quality control process right MYVT KLZPNU [V [OL ÄUPZOPUN 0[ JHU even provide customised solution as per the clients’ requirements.

FAR products have application in different kind of industries like the automotives, defence, railways, aerospace, machine tool. The machining company develops inhouse and it has been constantly investing every year.

About the new trends in the market, Ravi said, “CNC machines have been here in India for the past 20 years. But, during the last 5 years machines are more focused to run continuously, being more reliable with higher productivity.

Though, these were there for a long time, people now mean them.

They want their machines to be more reliable with less downtime.

If there is a breakdown they want their machine to be back at work in a few minutes. And today, machines are more towards TPM, Industry 4.0 etc. A big change in the machining industry will be witnessed with Industry 4.0, connectivity coming in and it will be quite phenomenal.”

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COVER STORY Disruptive technology Ravi feels that with the EVs coming in, there will be a disruption in the market. But, it will be effective only after 2035 in India, and in the western world it may take around 5-6 years. There may even be more disruption in the 2-wheeler market than in the 3-wheelers. As the EV market is more towards the twowheeler segment, around 25-30% of them will get affected by it. Even though the technology is available, there are other requirements like the mindset of the people, battery, charging stations and a lot more.

“People who use EVs in rural areas have reported that they have felt its pulling capacity is not similar to the IC engines. So, mindsets like these need to change. In cars, it would take a maximum of 10 `LHYZ [V ^P[ULZZ H ZPNUPÄJHU[ change. Our industry also needs to change because the number of parts will come down. At the moment, the Indian machining industry is doing really well. It will also do very well in the next 3-4 years, as the world consumption and Indian consumption is going up. Auto components exports from India has really gone up and this is the reason why the industry is doing well. With EVs a small time change might happen but, not a big one,” he said.

Ravi Radhakrishnan, Director, Fenwick and Ravi

Since 2004, FAR has been exporting its products to countries like Italy, France, USA, Canada, Brazil, Middle East, Australia, China, Taiwan, Thailand, Turkey etc. The company believes in high-quality products and price advantage are the key to success in a keenly competitive market. FAR has the vision to be among the top manufacturers of the machine tool accessories in the world and works resolutely towards achieving the goals. Around 25% of its revenue comes from export.

“We produce specialised accessories and we do not work on entire machines. Most of the accessories we produce are not available in the country. This has its own pros and cons. The advantage is that you do not have much of competitions. We have been importing to Germany from day 1. So, we are in direct competition with German products in India. Though acceptability is an issue, all our products hold precision manufacturing, close engineering and good design. More importantly,

we need to work continuously on these products for customisation and product development. Our focus is on developing complete solution to the customer and we have been doing that for a long time and 9095% of our customers are still with us. The companies invested around 5-7% of its turnover on the R&D recently, and around 12people are working over there,” he said. ACI

Adding more on additive manufacturing, he said it still has a long way to go. When people talk about additive it will be mostly on plastics. On metal, it will take time and there needs to be production methodology for this to implement.

So far, prototyping is being done and P[ ^PSS KLÄUP[LS` TV]L [V WYVK\J[PVU from here. “Chances are high and it is going to play a big role. But, this to affect the metal cutting industry might take time. So, we do not see any serious changes with EVs and additive manufacturing coming in,” Ravi said.

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VECV manufactures trucks in a IK@ANJ OI=NP =J@ ABÅ‚?EAJP B=?EHEPU "E?DAN *KPKNO PDA Å‚NOP ARAN ,"* PK NKHH KQP EJ@ECAJKQOHU I=JQB=?PQNA@ PN=?PKNO EJ PDA ?KQJPNU ODKP QL PK B=IA EJ PDA O SEPD EPO IK@ANJ =J@ =@R=J?A@ ) 3 PNQ?GO =J@ >QOAO )=PAN PDA ?KIL=JU RAJPQNA@ EJPK PDA IA@EQI @QPU PNQ?GO OACIAJP EJ?HQ@EJC PDA DECD LKPAJPE=H IE@ DA=RU @QPU ĺ'QI>K† Ä PKJJA D=QHAN =J@ ĺ3" 0ANEAO† Ä DA=RU @QPU N=JCA QL PK PKJJA $34 &J "E?DAN *KPKNO AOP=>HEODA@ = Ä¡ FKEJP RAJPQNA SEPD 3KHRK KB 0SA@AJ >U PDA J=IA KB 3KHRK "E?DAN KIIAN?E=H 3ADE?HAO Ä 3" 3 &P S=O = OECJEÅ‚?=JP IKRA OEJ?A PDA 3 EJ@QOPNU S=O KLAJEJC EPOAHB BKN IK@ANJEO=PEKJ =J@ ?KJOKHE@=PEKJ 0PKNU =J@ -DKPKOÄ¡ Bhushan Mhapralkar

I

n VECV, Volvo Group brought global technology to the table and Eicher focused on frugal engineering and local marketing.

Now the joint venture company PZ H M\SS Ã…LKNLK *= THRLY ^P[O H portfolio ranging from 4 tonne to 55 tonne GVW categories, and has a market share of over 30% in light and medium trucks, 5% in heavy-duty and 17.1% in buses.

VECV adopted several world-class systems and processes from Volvo for new product development, X\HSP[` HUK Z[HUKHYKPZH[PVU LMÄJPLU[ manufacturing, sales and aftersales, and R&D. This has helped the company to deliver excellent products and experience to its customers, which is evident in the market share gains in the last 10 years. The JV has 5 business verticals:

Eicher Trucks and Buses (ETB), Volvo Trucks India (Eicher being the brand’s exclusive marketer in the domestic market), Eicher Engineering Components (EEC), and VE Powertrain (VEPT).

In our recent visit to the VE Commercial Vehicles production facility at Pithampur, it is understood that it is a fully-

40 40 AUTO COMPONENTS INDIA „ APRIL 2019

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SHOPFLOOR integrated facility spreading across 84 acres encompassing manufacturing, product development, purchase, test track and support functions of the Eicher ‘Pro’ Series trucks. The ultra-modern facility has an annual capacity of 84,000 trucks, scalable to 100,000, making it one of the leanest and productive shops in India.

Riding on VE Commercial Vehicle’s traditional strength of making VUL VM [OL ÄULZ[ [Y\JRZ PU [OL tonne to 16-tonne segments, the recently introduced Eicher Pro YLÅLJ[Z H TVKLYU I\PSK 0[ makes a strong basis for smart and LMÄJPLU[ [Y\JRPUN ^P[O P[Z H[[YHJ[P]L looks. The fully-built sleeper cabin of the truck with a certain ability to cheat the wind is CED coated and robotically painted. Flaunting smart looking clear lens head lamps, as part of the new Pegasus-based front styling, the Pro 3015 scores well on aesthetics. As a value truck offering from VE Commercial Vehicles with a 16-tonnes GVW, the truck appeals with its modern looks. Part of the strategy to make CVs that are truly professional in their approach towards higher productivity, WYVÄ[HIPSP[` HUK WYVZWLYP[` [OL 7YV YLÅLJ[Z VU [OL YPZPUN differentiation between value trucks and basic trucks.

Noticeably upmarket, the Pro 3015, according to Shyam Maller, Executive Vice President, Sales, Marketing & Aftermarket, LMD, VE Commercial Vehicles Limited, raises the bar. Engineered to

address the changing transportation dynamics to the requirements of consignors, operators and the many stakeholders involved, the truck looks engineered to help mitigate the many challenges that the transport industry has come to face in the recent times.

‰ *=GEJC 3O At the Pithambur plant CVs with H .=> VM [V [VUUL HYL made. These include trucks and bus chassis. Supported by 40 dedicated ancillaries, 408 tierone suppliers, and an integrated sourcing arrangement across the organisation, the plant has 3 key facilities: cab welding plant, WHPU[ ZOVW HUK ÄUHS HZZLTIS` plant. Fully integrated and comprising manufacturing, product development, purchase, supply chain and other support functions,

the plant at Pithampur is highly Ă…L_PISL SLHU HUK HNPSL Using Domex steel for the chassis construction, the Pro 3015 truck WYVĂ„[Z MYVT [OL HIPSP[` [V WYV]PKL higher payload without losing strength and to cater to diverse applications. The cab welding shop at Pithampur is equipped with 22 Kuka robots for consistency and uniformity. This welding shop is one of the 3 weld shops that VE Commercial Vehicles operates at Pithampur and is termed as the condour-range weld-line. The other 2 weld shops include the legacy range and the heavier range.

VECV has wide range of modern trucks, buses and engines for the customers to choose

At the condour weld shop, which also makes the Pro 3015 cabin, [OL YVIV[Z ^LSK [OL Ă…VVY WHU ^P[O engine cover), sides, front, back, and the roof to ensure a high level

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2. Much of the cab-line operations are automated.

3. Four Kuka robots jointly build a modern cabin on the condour line.

4. The robots do the job quickly and precisely.

5. The advanced paint shop includes CED process for superior corrosion protection.

6. The cab line.

42 42 AUTO COMPONENTS INDIA APRIL 2019

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SPECIAL REPORT

Dassault Systèmes opens 3DExperience executive centre in Chennai ACI Bureau

E

uropean software company Dassault Systèmes has inaugurated its new 3DEXPERIENCE Executive Center in Chennai to present its 3D platform and associated applications to customers and prospects in India. The centre will showcase how Dassault Systèmes, as H ZJPLU[PÄJ JVTWHU` PZ JSVZPUN [OL gap between the virtual and real to harmonize product, nature and life for a sustainable society. Samson Khaou, Managing Director, India, +HZZH\S[ :`Z[uTLZ ZHPK ¸*OLUUHP PZ P[Z ÄM[O SVJH[PVU [V OVZ[ HU L_WLYPLUJL centre after France, Munich, Boston and Shanghai. With an increase in consumer expectations, national and international laws are pushing OEMs to innovate and design new products at a faster pace. The real-time simulation of a vehicle and its components will help them in it. The centre will help up showcase the latest happenings in the simulation.”

The experience centre in Chennai will offer a combination of Dassault Systèmes expertise and solutions to help customers digitally re-invent their enterprise’s approach not only to advance product development and manufacturing but also to re-invent how the business is run as a whole. The 3DEXPERIENCE platform provides decision-makers real-time visibility throughout the development cycle and across the value chain from social ideation and industrial design, through model-based system engineering, detailed engineering, manufacturing planning and prototyping. And once into production, the platform continues to provide digital continuity and real-time visibility into manufacturing operations, in and across production sites located anywhere, for pro-active decisionmaking and alignment with business performance targets.

The centre will showcase immersive experiences using virtual reality (VR) that make it easier to understand complexity, save time and reduce LYYVYZ MVY NYLH[LY JVUÄKLUJL ^OLU making a decision. Sylvain Laurent, Executive Vice President, Global Field Operations (Asia-Oceania) Worldwide Business Transformation, Dassault Systemes, said, the simulation powers innovation and the new centre in Chennai will offer the company’s expertise and solution to help consumers digitally re-invent their approach in many aspects.

Dassault Systemes has been partnering ^P[O 9V`HS ,UÄLSK MVY X\P[L ZVTL [PTL now and the bike manufacturing company has performed the complete WPZ[VU K\YHIPSP[` HUK OPNO ÄKLSP[` simulation of critical parts like powertrain and chassis using Dassault Systèmes SIMULIA applications on the 3DEXPERIENCE platform for realistic simulation, before any prototyping.

Rod Giles, Lead CAE and CAD, 9V`HS ,UÄLSK ZHPK ¸>L OH]L been using SIMULIA applications to perform realistic simulation, before any prototyping in our product innovation, development and manufacturing processes.

We have successfully launched 0UKPH»Z ÄYZ[ [^PU LUNPUL TV[VYJ`JSL Interceptor and Continental 650 performing the complete piston durability using this. We have deployed solutions such as (IHX\Z 0ZPNO[ ;VZJH ML ZHML HUK :PTWHJR [V WLYMVYT OPNO ÄKLSP[` simulation of critical parts like powertrain and chassis, at the KLZPNU Z[HNL YLK\JPUN ZPNUPÄJHU[ costs and time in prototyping and in manufacturing.” ACI

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SPECIAL REPORT INTERVIEW

need to make sure that there is no interference with others. This becomes a key aspect.

Samson Khaou, Managing Director, India, Dassault Systèmes, and Bhavesh Kumar, Brand Leader, SIMULIA India, Dassault Systèmes.

Q: The lifecycle of a vehicle has come down and this puts pressure on OEMs and designers. How are you helping?

Q: How does Dassault Systemes Indian operation perform and what is the way forward?

Khaou: The mission and ambition is on how we will tap the growth in the Indian market.

The way we do this is based on our technology and our platform is a market of over 1 billion.

This is growing on double-digit year-on-year. For us, this is a market where we do not want to lose any market share and we have to be on the double-digit growth continuously. We have achieved that in the past 2 years and we hope to be at the same pace of growth. The market is looking more towards software for a solution and it is no longer a market that focuses on pure application. When they buy software, they look at how they can get solution suites to address industry process. This is also well connected to SIMULIA which is used as an application for simulation.

Kumar: The simulation industry is evolving. As it grows, in terms of evolution with an increase in customer demands challenges, companies look at a multidisciplinary approach to solve problems. In the past, a product design would be bucketed into disciples like thermal analysis, front analysis etc., Now it has changed and it is about the product which is out in the market and how can I be sure about that product to provide the right experience

to the end user. Over the last ML^ `LHYZ ^L OH]L HJX\PYLK [LJOUVSVNPLZ HJX\PYLK ÄYTZ HUK with the 3D experience platform, we bring all these together. So, one can look at the problem from a larger picture and solve it from a multi-point of view.

The simulation market globally, as well as in India is witnessing growth. It is moving away from application and tools, towards a solution and industry processes.

Q: How are you working for future technologies like autonomous vehicles and EVs? Khaou: One of the changes which we are leveraging is electric vehicles. Today, the simulation is part of their YLX\PYLTLU[ 0[ PZ PTWVY[HU[ PU mastering battery technology.

Second, how we leverage the data collected by EV, in order to create a new experience for consumers. In the Indian market, the way we want to use EV is lean. Our platform is really a big data platform that can aggregate those data and help to extract the pattern and usage of this EV. Kumar: When you come with EVs, the fundamental and major challenge is the battery. It is not just an engineering challenge.

As a consumer, it is also a need for them to run the vehicle on the road for the desired time.

Second, it is on integrating the different pieces together.

Because the traction knowledge that the company have learnt over the years is not going to completely help them on approaching EV. Using a traditional approach will not work. Because they use different types of material and there is a need to know how they will ILULÄ[ [OL ]LOPJSL :V ^P[O [OL simulation, we can look all the way to micro-structural levels.

Right from inside the battery to the performance and even to a level of validation of vehicle, simulation plays a major role.

In EVs simulation plays an important role and a lot of them are enabled by it. Without this, they would not be entering the THYRL[ HZ X\PJR HZ [OPZ In automated vehicles, the challenges are different. A lot of smart technologies have to be incorporated inside the vehicle like the sensors etc. What we do with the 3D platform is, we are able to combine the inputs that we get based on different technologies. We can use the smart algorithms to predict how it will behave and also look at aspects like what it would do with electromagnetic interference and a lot more.

(Z [OL ]LOPJSL PZ LU[PYLS` ÄSSLK with sensors and antennas, we

Khaou: Simulation loop is becoming seamless. When you look at an industry process perspective before, you have those iterations which are ZLX\LU[PHSS` KVUL PU H KPMMLYLU[ loop. We want the simulation to be integrated into the design and we want it to be a designer’s tool. They can cope with the ÄYZ[ SL]LS VM ZPT\SH[PVU MVY [OL product at the design stage itself.

So we need not go for multiple loops of validation.

Kumar: Simulation was Z[HY[LK HZ H ^H` [V ÄN\YL V\[ what went wrong. Over the years, this has changed and the companies have started using it in the design cycle.

Once they create a design, they want to know whether it is valid or not. What we have done with 3D experience is to leverage the power of the cloud for a design. With this, they were able to validate it at [OL ÄYZ[ SL]LS )HZLK VU [OPZ the designer can make changes to the design and it becomes a more interactive process. It goes to the next level where one can do more detailed, test and validation. This has a lead simulation to be used more upfront than before. A lot of companies have an objective of zero prototyping, which means simulation is what they use. Prototypes are used just for JLY[PÄJH[PVU Sricharan R 47 47

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AFTERMARKET

TVS ASL embraces technology and talent Story by: Bhargav TS

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ftermarket is part of the automotive industry sector comprising the automotive services and parts businesses. It is estimated that there are about 1.2 billion vehicles on the road now.

The numbers are growing. In the saturated developed country markets new vehicle purchase is primarily to replace the old ones and therefore, their sales growth is very marginal.

In the major emerging markets like China and India the number of vehicles has been growing in double digits since a few years, barring some blips.

TVS ASL is implementing a new digital and centralised method of managing auto inspections

With every new model and variant, technical sophistication has been on the rise and the industry has been growing exponentially in the last two decades. The sophistication

has been mainly in electronics and software, connected technologies and telematics. Improved quality and durability of the parts, which enhance both the life of the vehicle and parts, affect the aftermarket. New additions create new markets.

However, the automotive aftermarket industry is impacted by several major disruptions like digitisation, shifting competitive dynamics, and changing consumer preferences.

The borderlines are constantly moving. The survival and success of the aftermarket industry is in getting the big data for vehicle service. It is not yet unequivocally KLÄULK ^OV [OL THU\MHJ[\YLYZ VY the owners, own the data generated by the new vehicles. The vehicles, however, upload the data directly to

their respective manufacturers. The aftermarket players are kept out of the game and lose the vehicle service business.

TVS Automobile Solutions Private Limited (TVS ASL), India’s leading player in the automotive aftermarket business, recently entered the twowheeler servicing business also.

The company aims at providing innovative, technology-based global delivery model to connect directly with customers, garages and retailers.

“For vehicles that are going out of warranty, the customer would either be part of the service network, where they are already in during the warranty period, or they would choose to go to an unorganised player. It can be anything. Be it a roadside garage or an organised dealership or a multi brand service centre. The key here is, on how you identify the need and how you position yourselves to attract customers. From our point of view, the one-stop shop solution is going to be a big attraction and value for money,” Natarajan Srinivasan, Chief +PNP[HS HUK 0UMVYTH[PVU 6MÄJLY ;=: ASL, told Auto Components India.

Multi brand service Though mature, the US and the European markets are vastly different.

The European market is very similar to Indian and it is mostly dependent on vehicle service providers. The US is a `do it yourself market’. People there buy components, assemble and do on their own.

“That is the way I see the distinction 48 48 AUTO COMPONENTS INDIA APRIL 2019

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AFTERMARKET in mature markets. In the emerging markets, I see it is dominated by the service players. The dealerships, the extended part of the OEM dealerships and their service network constitute the organised players. The other extreme of this is the unorganised players, roadside garages etc. There is a sweet spot for people to be organised in this sector also. Very similar to what is happening in the retail chain like the FMCG there is an opportunity for all these players to co-exist in the market. Our belief is everybody can operate in this space.

Unless the volume of business is as good as for the big players, it will be KPMÄJ\S[ MVY WLVWSL [V Z\Z[HPU ;OH[ PZ why there is a need for multi brand service,” Natarajan, said.

There are 3 things that really matter in coming up with a multi brand service centre: the competent technicians, the required tooling and technology to assess the vehicle and diagnose the problem and offer the solution, and the parts supply chain, he said. Training of technicians across a range of cars along with latest tools and equipment are essential for the success of multi brand service.

Parts supply is very important and it is the biggest strength of TVS ASL. A major advantage of TVS ASL is the knowledge from its leadership.

The people there understand the differences of different brands like Renault, and Mahindra, and in the CVs Ashok Leyland and Tata Motors.

circuit simulation for an OEM VU OV^ [OL JPYJ\P[ ÅV^ OHWWLUZ right from the start of the engine.

Troubleshooting of this can be done here and learning happens with hands-on experience. This is how we have our resources fungible across multiple bodies and not just on one particular model. We have digitised the repair procedure with augmented reality (AR) and virtual reality (VR). We are exploring the area and investing in it. How we digitise the whole repair procedure for people to learn, and where we can have practical exposure step by step will be a part of the repair structure.”

Natarajan Srinivasan, Chief Digital and Information 6MÄJLY ;=: (:3

Going digital

element and once it is diagnosed the issue will be assessed.

Going forward, TVS ASL will be leveraging technology for the critical HYLHZ VM ZLY]PJPUN ;OL ÄYZ[ HUK foremost aspect is to understand the condition of the vehicle and the needed number of critical parts like clutch assembly, brake assembly, gearbox, engine etc. Understanding it, is similar to knowing a patient’s health and the required care and treatment like invasive procedure.

Here too, there is a diagnostic

Technology can play a big role here.

It is reading the data of an OBD port from ECU and assessing the overall situation and analysing the data. With this, they also recommend preventive actions. Natarajan said, “This is what the OEs are also trying to bundle and the whole scanning solution is Ä_LK [V [OH[ ;OL RL` OLYL PZ OV^ [V stitch everything together and have the end-to-end view of the vehicle

About how they use the knowledge, Natarajan said, “The proof of our ability to leverage the learning is our ‘Knowledge Centre’ in :YPWLY\TI\K\Y 0[ PZ [OL ÄYZ[ of its kind. No independent aftermarket has done that and we have established the centre to address our need to learn all the technology innovations from the digitisation to vehicle diagnostics etc. and on tooling. For example, we have created a whole electronic 49 49

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AFTERMARKET and accordingly, reach out to the customer at the right time.”

“This is where the CRM components come in to play. Once I understand the health, I reach out to the customers at the right time for the right reason with a personalised contextual communication based on the vehicle condition. At the industry level many disruptions and big investments are happening in this area. All these are combined together, with IoT, a bit of analytics, AI and machine learning. It is in a state of evolution,” he said.

OEMs in the aftermarket

TVS ASL’s ‘Knowledge Centre’ in Sriperumbudur

With the cost of ownership becoming the key determinant for the purchase of new vehicles, most of the vehicle manufacturers are focussing on after-sales to attract and retain clients. They are keen to open modern service stations to offer a comfortable experience to the customers. With adequate support, even the unorganised sector JHU L]VS]L PU[V M\SS ÅLKNLK ZLY]PJL centres. However, there are several factors that impact the evolution of the aftermarket. The ever-improving life of the components poses a threat to the aftermarket business. For instance, earlier an engine used to be overhauled after it has run for 1-1.5 lakh km. Now it is done after 2.5 lakh km. Improving road conditions in

India also enhance the life of vehicles along with their parts. A decade ago, the clutch assembly of a truck had to be replaced after running for about 45,000 km. Now it is being done after 60,000 km.

“The focus of the OEMs will be on the sale, and service will be an integral part of it. But the question is will they focus on innovation and on meeting all the continual regulatory changes that are going on in the industry? When we look at the list of priorities, the focus for them is going to be on making the vehicle meet all the required standards to have an edge over the others and in sales. Attempts are made by many OEMs to extend their presence in the aftermarket as the customers need that. They get to the aftermarket with an extended warranty. This happens both in the CV and passenger vehicle segments. I think this will always be a challenge. There is an opportunity for the aftermarket players to consolidate and see how they can have the balance between the OEMs and the organised players like us,” Natarajan said.

Errors and customer needs As the complexity increases the sophistication of a vehicle and the number of ECUs also go up.

A price conscious market moves

to have a sensor in every possible area. The question lies in how a trade between what is needed to be sensed and what is to be managed by having an intervention.

The company addresses this by having a combination of diagnostic technology and manual intervention to capture the health of the vehicle. What the customer is looking for is transparency. Once, you have a level of transparency, you establish trust with the customer. All these technology investments and the processes are re-engineered to be oriented towards meeting the customer needs.

“You do not need to over-engineer anything. I see a vast shift from the way the customers are talking.

When you go back to him with a structured analysis of what is the status of the vehicle and with a YLJVTTLUKH[PVU VM H ZJPLU[PÄJ HUK rational approach, the customer will be convinced. It is a long journey and it cannot be achieved in a day. “It is a journey and you will never be able to crack it open over a day. All these, I believe, are developing into a trend,” he said.

What’s next “All of us know the disruption OHWWLUPUN PU [OL PUK\Z[Y` PZ KLÄUP[LS` of a very high magnitude. EVs are going to play a big role. There is going to be increasing pressure on regulatory requirements which are constantly changing. But, the independent aftermarket for the next 5-6 years will go through changes and the key is how the players adapt to them. We will stay ahead of the game by making the right investments. Other important factors include leveraging technologies and organising our capabilities around people, tools and technologies and attracting new customers. These are going to be the key differentiators,” Natarajan said. ACI

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AFTERMARKET

TecAlliance spreads wings in Indian aftermarket ACI Bureau

T

ecAlliance GmbH, the leading European service provider for automotive information systems and software in the international spare parts market, has started its operation in Chennai. It is also a data specialist for networked collaboration in the digital automotive aftermarket.

The company develops and distributes electronic vehicle parts information worldwide on the basis of a comprehensive sector solution for the support of

parts manufacturers, wholesalers and workshops.

The company that operates in Western and Eastern Europe, China, Australia, the US and Brazil, is actively looking at Indian Sub-Continent due to the sheer size and potential growth of the automotive market in general and aftermarket in particular. Under the umbrella of TecAlliance, TecDoc, TecCom and TecRMI form a global e-catalogues publisher for

automotive aftermarket parts.

Commenced from 1994 with 20 suppliers, the company has now over 500 suppliers globally.

TecCom is the leading B2B communications platform for the independent automotive aftermarket. It brings parts manufacturers and parts dealers together and creates effective business communications between them. TecDoc is an electronic information system for the precise identification

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AFTERMARKET

of parts for the independent automotive aftermarket. It links parts manufacturers with dealers and workshops around the world by gathering product data and distributing it across the market in a standardised form. The primary objective of this is to strengthen the competitiveness of the aftermarket and to enable business relationships to be run at a higher quality level.

TecRMI is a Europe-wide provider of information services that gathers and professionally edits OE-compliant technical information directly from vehicle manufacturers and distributes it across the automotive market.

One of TecAlliance’s first services for the Indian Independent Automotive Aftermarket will be the publication of the TecDoc Catalogue, which for the first time, will also contain the data of Indian parts suppliers. This gives dealers and workshops in India better overview of the market as to which spare parts are suitable for which vehicles.

The portfolio of products and services includes current data for fast identification and ordering of passenger, motor cycle and commercial vehicle parts from the databases of participating

parts makers in a standardised catalogue format. The electronic parts catalogue groups together more than 4 million to 5 million items in 28 languages.

The digitisation and automation of supply chain processes – among parts manufacturers, the parts trade and workshops – are in focus when it comes to efficiency, speed and service quality. The higher the degree of digital networking, the greater the benefit for all those involved – in terms of optimised order processing and digital sales with professional e-commerce.

After inaugurating the new office, Gopalan, Director of Indo German Chamber of Commerce said, “We are very pleased that we are also an active part of the Automotive Corridor. Customer proximity is an essential asset for TecAlliance.”

“With our local presence in India, we can support manufacturers, dealers and workshops in the independent aftermarket better and take full advantage of the current growth opportunities,” David J Winter, Executive Vice President Sales and Marketing, TecAlliance, said.

With its subsidiary TA Autotec Information System India, TecAlliance has closed one of the last gaps in the ranks of its Asian locations. The Automotive Corridor is a region where a number of major automotive companies like BMW, Ford, Hyundai, Renault-Nissan, Mitsubishi, Caparo Group, Komatsu, Caterpillar, Ashok Leyland, TVS and others are present. More than 40% of Indian automobile production, and almost 60% of India’s automotive supply industry are located here.

“We stand out as a global leader and in Europe, TechDoc is the standard. We are the pioneer in process of developing standardisation of generic articles etc. Other players produce catalogue in a way of enhancing their e-commerce activity. We are providing it as information and we do not involve in any transactions,” Vats R Srivatchan, Director of TA Autotec Information System India Private Limited, said.

“There are a few competitions here.

We need to get the data available from the suppliers. Once it is done, ^L OH]L H KLÄUP[P]L THYRL[PUN programme. There are around 300-400 data subscribers to the catalogues,” he said. ACI

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EVENT

Indian forging industry to tap global opportunities ACI Bureau

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ssociation of Indian Forging Industry (AIFI) recently hosted the 7th ASIAFORGE 2019 in Chennai. The 2019 edition marked India hosting the industry meet after a gap of 10 years as AIFI had earlier hosted the second Asia Forge meeting in 2008 in Delhi. The event focused on global opportunities and challenges faced by the forging industry.

The two-day event was inaugurated

by Sajjan Jindal, Chairman and MD, JSW Group. Dr Ashok Jhunjhunwala, Prof. IIT Madras, delivered the keynote address. S Muralishankar, President, AIFI, R Sivaparasad Reddy, Vice President, AIFI, Abhay Raj Kapoor, Convenor of Asia Forge 2019, and Vikas Bajaj, Co-convenor, along with the Managing Committee Members, were also present at the event.

S Muralishankar said, “Hosting of the 7th ASIAFORGE in India, after over 10 years, is a momentous occasion for the Indian forging industry. Our decision to host the event was to acquaint ourselves with the latest trends and technologies in the global forging industry, to benchmark some of the best practices and to display India’s technological prowess and engineering capabilities to the global experts. The Indian forging industry has to face challenging years ahead and the ASIAFORGE platform will help us to be prepared for future opportunities.”

best practices in the forging industry across the globe. It also provided an ideal platform for the Indian forging industry to showcase its technological prowess, network and interact with global experts and to strengthen bonds with international forging associations.

As per a survey, conducted by the forging association in September 2017, the estimated turnover of the 378 functional forging units across India in FY2016-17 was Rs 31,189 crore providing employment to over 200,000 people in the country.

According to the report, the installed capacity also increased from 37.6 lakh tonne in FY2014-15 to 38.5 lakh tonne. The overall production of forgings increased from 22.5 lakh tonne to 23.9 lakh tonne. Backed by the surge in overall vehicle sales last year and renewed thrust on infrastructure development, AIFI predicts impressive growth for the Forging Industry and anticipates around 10% demand growth in 2019.

The event witnessed a range of in-depth technical and business programmes, covering topics ranging from tooling to automation, including overviews of the forging industry in

different countries in Asia. Participation from over 14 countries, including China, Japan, Taiwan, Korea, Germany, Italy, France and Belgium among others, was represented at the event According to AIFI, the Indian forging industry was looking at Asia Forge 2019 and the experience of global experts therein, for answers on evolution, modernisation, technologies and cost rationalisation, to meet the growing demands in the years ahead. Sharing his thoughts R Sivaparasad Reddy, said, “We believe that the ASIAFORGE 2019 has played a critical role in strengthening the bonds among Global Forging Associations. These meetings have always played an important role in the evolution of the forging industry across the world and shall continue to do so by providing collaborative platforms to address the challenges faced by the industry. This was also a recognition of the Indian forging industry’s strong management, engineering and technical capabilities, that have helped us to become established suppliers to the global automotive and other key industries.

We now could build on this strong foundation and further consolidate our position.” ACI

According to AIFI, the event designed to showcase the latest trends in the global forging industry, gave the participants an opportunity to keep abreast of the new developments and 53 53

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APRIL 2019 AUTO COMPONENTS INDIA

EVENT

SIAM meet discusses future of vehicle recycling in India ACI Bureau

W (L-R) Rashmi Urdhwareshe, Director, ARAI, Vishnu Mathur, Director General SIAM, Chief Guest– Hon’ble Justice Swatanter Kumar, Former Chairman, NGT & Former Judge of Supreme Court, Special Guest of Honor, Bhure Lal, Chairman, EPCA, Vinnie Mehta, Director General, ACMA

ith a focus on sustainable material management and environmentally safe disposals, Society of Indian Automobile Manufacturers (SIAM) in association with Ministry of Environment, Forest and Climate Change (MoEF & CC), Government of India, and Automotive Component Manufacturers Association of India (ACMA), organised a day-long conference titled, “International Material Data System (IMDS) and End of Life Vehicle (ELV) Regulations” in New Delhi on March 18, 2019. ;OL JVUMLYLUJL H ÄYZ[ VM P[Z RPUK initiative, focussed on sustainable management of materials, tracking of hazardous chemicals, heavy metals, Persistent Organic Pollutants (POPs) etc. to minimise their negative

impact on the environment and human health. The data generated at the conference would facilitate the automotive sector, regulatory agencies, R&D institutions and ministries to engage in further discussions, negotiations and actions under the Rotterdam and Stockholm Conventions, for which MoEF & CC is the nodal agency.

In his welcome address, Vishnu Mathur, Director General, SIAM said, “There is a need to institutionalise automobile recycling in India and ÄN\YL V\[ TL[OVKZ [V KPZWVZL VM ,3=Z in an environmentally sound manner.

The purpose of this conference is to increase our knowledge, create awareness, capacity building and gain insights about IMDS and its regulations.”

Rashmi Urdhwareshe, Director,

ARAI said, “We need an integrated approach towards clean air. Fleet modernisation can improve air X\HSP[` 7YP]H[L JHY LSLJ[YPÄJH[PVU and the banning of old vehicles are some of the solutions we can look at. Road and public infrastructure pose a serious concern that must be addressed appropriately. There should also be a control on the number of unused vehicles. There are 35 million vehicles plying on roads that have already exceeded the age of 15 years and manufacturers must start using materials that are reusable, the government should announce an ELV policy at the earliest and the ministry must notify AIS 129 standards immediately.”

Stressing on the alarming rates by which vehicles are increasing on the roads and the serious pollution levels caused by them, Dr Bhure Lal, Chairman, EPCA said, “While talking about ELV Regulations, we must consider the sustainability of ecology and environment. We need a policy in place to discard old vehicles as P[ JV\SK WVZL KPMÄJ\S[` PU M\[\YL MVY humans.”

Justice Swatanter Kumar, Former Chairman, NGT, and former Judge, Supreme Court of India, said, “There are enough laws in regard to utilisation of dismantling material and control of vehicular pollution. We need policies to regulate the unorganised sector.

These conferences go a long way in providing workable solutions for issues like vehicular emissions and their negative impacts on the environment. We, as a country, are popular for doing wonders and we

54 54 AUTO COMPONENTS INDIA APRIL 2019

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EVENT can also do wonders when it comes to controlling air pollution.” ;OL ÄYZ[ [LJOUPJHS ZLZZPVU ZH^ THU` eminent speakers from the industry who included Rashmi Urdhwareshe, Director, ARAI, Frank Nottebom, Account Business Executive, DXC Technology, Dr Bharat Kumar Sharma, AdditionalDirector,CPCB,Government of India.

Throwing light on CPCB guidelines for environmentally sound management of end-of-life vehicles, Dr Bharat said, “With rapidly increasing number of vehicles on roads, the proper management, treatment and disposal of vehicles at their end-oflife becomes a pressing problem. The components present in these ELVs pose hazard to the environment as well as human health. Thus, at present we require a proper approach for an ‘Environmentally Sound Management’ of ELVs in India. At the moment, the ELV recycling sector is lacking an enabling framework.”

The second technical session focused on implementation of relevant provisions of national and international regulations. The speakers for this session were: Dr Sharath Pallerla, Director, Ministry of Environment, Forest and Climate Change, and Dr A N Vaidya from NEERI, Government of India.

the implementation and challenges of international obligations in the recovery and recycling of hazardous chemicals in the automotive sector.

He said, “Automotive industry deals with many regulations. We need to recognise the adverse impact of chemicals on the environment and human health, and take feasible actions to combat it. The aim is to have international integrations in the recovery and recycling of chemicals in the automotive sector.” He further spoke on how international regulations function under different annexures.

The third technical session on ‘Material Data Collection systems and ELV regulations globally,’ included many speakers like Dr Rachna Arora, Deputy Team Leader and Coordinator, Internationale Zusammenarbeit (GIZ) GmbH, Paurnima Barve, Solution Leader RnDP-PAMDOC, Volvo group, Nisha Ganesan, IMDS Coordinator, Fiat Chrysler Automobiles N.V., Dr Ishizuka Satoshi, Senior. Advisor, Maruti Suzuki India Limited, Sumit Issar, MD, Mahindra Intertrade, and S Shanmugham, Global Leader, Materials Technology, WABCO India.

In the panel discussion on ‘IMDS Reporting and Challenges for Industry

in India,’ witnessed the presence of Frank Nottebom, Account Business Executive, DXC Technology, Shridhar Rajappanavar, Technical Head, PCCS, Rahul Lalwani, Senior Manager, Mahindra & Mahindra, Mrs Asmita Sathaye, DGM, Tata Motors Ltd., Ajith Kumar, Consultant R&D, TVS Motors and Sriniwas Raghavan, Material Science Expert, Brakes India.

Prashant K Banerjee, Executive Director (Tech), SIAM said, “With substantial increase in the number of vehicles in India, our objective is to improve the air quality by focussing on IMDS regulations and vehicle recycling. Although it is being followed in many countries, there is a need to institutionalise the same in India. Through this conference, we have set the stage to have thoughful discussions on the solutions related to vehicle recycling and how it can improve the air quality to a great extent.”

In his vote of thanks, Vinnie Mehta, Director General, ACMA said, “The automotive industry has been advocating vehicle scrappage since the past few years and we need to be more conscious of the environmental issues. We’ll do our best to shield the future generations.” ACI

Explaining the salient features and implementation issues of MSIHC rules, 1989, HOW (M&TM) rules, 2016 in the automotive sector, Dr Pallerla said, “These rules apply to an industrial activity in which a hazardous chemical may be involved. It is important to deal with the safety and environmental aspects associated with hazardous chemicals in the automotive sector so that the authorities can be well-prepared in case of an emergency.”

Dr Vaidya talked in detail about 55 55

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APRIL 2019 AUTO COMPONENTS INDIA

INTERNATIONAL

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56 56 AUTO COMPONENTS INDIA Â&#x201E; APRIL 2019

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*?)=NAJ QPKIKPERA @AHERANO łNOP LNKPKPULA ?=N>KJ ł>NA ?D=OOEO PK *-

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he first prototype carbon fibre Monocell, the tub that forms the main structure of McLaren’s car produced by McLaren Automotive, has been shipped from the company’s new £50m innovation and production centre in Yorkshire to the McLaren Production Centre (MPC) in Woking, Surrey.

Codenamed ‘PLT-MCTC - 01’ – which stands for ‘Prototype Lightweight Tub, McLaren Composites Technology Centre - 01’ – the tub completed its 280-kilometre journey to the British sportscars and supercar maker’s global headquarters from the McLaren Composites Technology Centre (MCTC). There it will be involved with stringent crash testing duties.

The MCTC was opened in Yorkshire last year by the Duke and Duchess of Cambridge alongside Prince Salman bin

Hamad Al Khalifa, the Crown Prince of Bahrain, as part of McLaren’s ambitious plans to increase the rate of innovation of its famous lightweight carbon fibre chassis that are at the heart of all its cars.

This will help the firm’s designers and engineers to find further weight savings as the company develops its next generation of vehicles as part of its ambitious Track25 business plan.

McLaren aims to win the automotive race to lightweight which will become ever more important as cars move towards hybrid powertrains which are generally heavier than their traditional petrol counterparts.

All McLaren’s sportscars and supercars will be hybrid by 2024.

The MCTC currently employs around 60 people which will rise to over 200 when full production

commences in 2020.

Carbon fibre has long been part of McLaren’s DNA, the company having first introduced the material into Formula 1 in the early 1980s. Given the material’s lightweight and strength characteristics, it hasn’t produced a road car without it since.

“The delivery of the first prototype carbon fibre tub by the new MCTC to McLaren HQ is not only an exciting day for everyone who has directly worked on the project but also a significant milestone for McLaren Automotive’s ambition to be world-beaters in lightweight and composites technology which goes hand-in-hand with our move to hybrid powertrains as part of our Track25 business plan.

“We never innovate for the sake of it – we innovate to continually fulfil our promise to create iconic sportscars. It’s increasingly clear that with future heavier powertrain requirements, exploiting innovative lightweighting techniques and technologies is going to be a significant key to unlocking all the handling and agility characteristics that our customers demand,” said Wes Jacklin, Plant Director, MCTC, McLaren Automotive. &

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RNI No. MAHENG/2014/55824