Modern Machine Tools - December 2012 by Infomedia18

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Editorial

Of Control & Freedom

MT is all about solutions to all your business problems—be it related to trade or technology! But sometimes it is good to ‘switch’ roles. So, while this edition is still about answering your critical questions to help you take better business decisions, here are some ponderous questions to set the tone of things to unfold in this edition:

What good is an airplane if you are a pilot and you can’t make it go where you want it to go? What good is a chemical products production line if you can’t control temperature, pressure and pH in the process and you end up making tonne of garbage? What good is an oven if you can’t control the temperature? (And, does it matter if it’s an oven in a kitchen or an oven in a heat-treating department that is used to harden metal parts?) What good is a pump if you can’t control the flow rate it produces? (And, there are many times when the flow rate must be controlled.) Being an involved reader, you must have guessed the direction of these deliberations! The answer to these questions land you to control systems and the questions are posed to the tribe, which still questions the need to deploy advancements in control systems in the production processes. Staying with the flavour of this edition, which happens to be questioning and seeking answers, we, at MMT, did a quick survey and asked the metalworking industry whether Indian companies are ready to adopt this technology, called remote controllability and monitoring? Before getting into the industry verdict, here’s an attempt to explain remote machining in the simplest possible way. (Do read the special section in this edition). Since CNC machines can be connected to the Internet, the next obvious step is—remote connectivity and controllability. Remote machining allows you both control and freedom. Regardless of the technicians’ proximity to the actual machine, the hardware interface grants real-time access to all CNC functions via the Internet, enabling them to monitor, tweak and get notified about the progress of the job. The inputs from the industry are interesting as well as intriguing— ranging from experts believing that most manufacturing companies do not see the need to adopt the latest trends, the main cause being the mentality. Once the attitude changes, all the latest trends can be adopted, which will improve efficiency in the processes and give India a further cutting edge. Then, it was felt that though it is an interesting ‘concept’ (mind you it’s a concept and not a reality). Some industry veterans who are already using this technology and have deployed internationally branded CNC controllers, which are windows-based and can be easily connected to the WiFi are of the firm belief that the Indian market lags behind hands-on action instead of a smart approach. The final verdict ‘India is very well equipped to handle new trends, but the mentality needs to change’. Guess it’s time to gain control & freedom as well!

MMT Mentor Shailesh Sheth Corporate Strategy Advisor

Archana Tiwari-Nayudu archana.nayudu@network18publishing.com

July 2012 - MODERN MACHINE TOOLS

Contents Facility Visit Maxsee Industry Co Ltd ..................................................... 52

Strategy Machine Tools Business ....................................................... 88

Energy Management Maximising Profits Skillfully............................................... 90

Event Preview Special Focus Control Systems

Insights & Outlook Defence Equipment Machining

Engineering Expo Ludhiana 2012....................................... Engineering Expo Pune 2012 .............................................. Engineering Expo Chennai 2012 ........................................ DMG / MORI SEIKI @ JIMTOF 2012 ........................... TMTS 2012..........................................................................

101 118 121 124 128

Special Focus Sector Snapshot .................................................................. 41

Productivity: A Critical Pillar Of Industrial Achieve Success the Harada Way ....................................... 92

Remote Connectivity .......................................................... 42

Aiming for Success and Beyond?................................................ 94

One Q Many Views .......................................................... 44

Improving Metalworking Productivity...................................... 98 People Centric Productivity .......................................................... 100

Business Trends .................................................................. 46 Latest Improvement ............................................................ 50

Luigi Galdabini President, UCIMU ..........................................

Insights & Outlook Snap Shot ............................................................................ 72 Machining Saga .................................................................. 76

Regular Sections

Turn to Page 132 for Launch Updates

Web Services Collaboration ............................................... 78 Defence Component Provider .................................. 80

Editorial ...................................................................... 23

Machine Tool Probe.................................................. 84

News, Views & Analysis .............................................. 30

Sarathi Sutras............................................................... 29 Technology & Innovation ............................................ 36 Event List .................................................................. 129 Products .................................................................... 134 List of Products ........................................................ 164

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List of Advertisers .....................................................170

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December 2012 - MMT

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December 2012 - MMT

Shailesh Sheth, an eminent authority, shrewd analyser of trends, brilliant strategist and considered by the industry as a “Guru”, to us, he manifests as ‘Sarathi’, accomplishing his timely purpose in the ever-evolving world.

ByMerchant Shailesh Sheth of Dreams

Emerging Geopolitics: Agenda for machine tool industry ... Think Big, Think Global!

Lastly, the US, Germany, Japan, China and Italy are the five eopolitics exists in all industries—the machine main countries that account for over 70% of the machine tools tools industry is no exception! Let’s take a look consumption worldwide. Other than investing in the African at what’s happening around the world. and South-East Asian market, my strong advice to Indian Firstly, cross border alliances—these seem companies is to ‘Invest in those five countries’ as well. to be common among global companies such as companies like DMG-Mori Seiki, MAG and StarragHeckert. The stated occurrences concern the global market. Let’s now How is this advantageous? Apart from consolidating the take a look at the scenario in India. The Indian machine tools vast product range, R&D becomes industry is witnessing immense growth, Will the Indian industry’s production share but this growth is getting saturated. more viable and also helps in skill development. Alliances also help in consumption fall from the current 32% to Besides, Indian companies have neither set a stronger foothold in the global 20%? Will inefficient or marginal players be added to their geographical coverage, market and can sometimes capture the gobbled up by larger companies, Indian or nor has the country’s product range segment. Financially, companies are Foreign? Will machine tools technocrats be widened to a great extent. Additionally, less susceptible to risk. the Indian machine tools ecosystem replaced by financial aristocrats? is underdeveloped and the country The second important does not have proper infrastructure and branding for export. phenomenon in the industry is ‘Captive Consumption The solution: Massive improvements are required—in quality, Becoming Commercial Production’. Captive machine tools technology, aesthetics and attitude—in the Indian machine plants are now opening up to the market. Besides, companies tools industry. Indian companies need to invest substantially in such as Samsung, Hyundai and Bosch are now looking to OEMs and supply chain management. Moreover, this industry expand by becoming suppliers of machine tools and are will find abundant scope with the Indian defence, aerospace and aggressively trying to commercialise their products. At the railways, among others. recently concluded IMTS 2012, Samsung and Hyundai had one of the biggest stalls—a clear indicator of Coming back to geopolitics… What is its impact their intention to expand their presence in the on the Indian market? Increasing competition may market. induce a fall in the market shares of Indian machine Thirdly, Japan, the world’s second largest tools. As more global players enter the Indian producer of machine tools, is now looking to market, it may enhance productivity. However, set up its manufacturing footprint overseas the main questions that arise are: ‘Will the Indian as it faces natural calamities. Companies like industry’s production share in consumption fall Mazak and Mori-Seiki are heading in this from the current 32% to 20%? Will inefficient or direction. Zooming in on the Indian context, marginal players be gobbled up by larger companies, the move to set up manufacturing bases in India might work Indian or Foreign? Will machine tools technocrats be replaced as a double-edged sword for the country—as even though it by financial aristocrats?’ From among these challenges arises is an investment asset, it can prove to be a threat in terms of a thought—What is the industry doing to overcome these providing fierce competition to domestic manufacturers. challenges? In my view the industry is comfortably nestled in its own cocoon. Contrarily, they need to constantly expand its Fourthly, China is the largest machine tools manufacturer, product range in various geographies. It needs to create more but its production may decline sharply in the coming years. If alliances and shift the focus to enhance its R&D capabilities the production does goes down, it will create more demand while creating a robust supply chain infrastructure. We still opportunities for Indian machine tools players. However, this have 1–2 years to get our act together. The capabilities are may cause China might become very aggressive and go on there, we now need to Think Big and Think Global! to try to dominate the Indian market (à la energy sector).

News, Views & Analysis

HWACHEON celebrates 60th anniversary factory for the open house was dedicated to exhibiting 14 new machines from tap and drill centres to a large 5-axis doublecolumn die centre. During the event, Klaus Ludwig, International Business Unit Leader & Vice President, Hwacheon Machine Tools Co. Ltd., said, “The company is making a greater commitment to its markets outside Korea with new facilities and machine development backed by increased stocking of its machines in markets globally.” Established in 1952, Hwacheon operates eight plants, annually delivering more than 3,000 CNC machine tools

HWACHEON, on November 1, marked its 60th anniversary with the grand opening of its technology centre and an open house at Gwangju, Korea. More than 2,000 people attended the 3-day event where the company had on display its range of CNC machine tools from vertical turning centres, drill & tap machines and horizontal lathes to mould and die machining centres. The centre includes a ground-floor demonstration space filled with the latest machines from the company, two higher floors for training & meeting rooms and an auditorium. A portion of its adjacent

worldwide, half of which are installed in Korea at automotive, die & mould and machining job shops.

Stable export orders underpin demand for machine tools significantly better n the third quarter of 2012, German Machine Tool Industry Fall in demand over the course of the year has so far so far than in other order bookings for the proceeded in line with expectations European nations. German machine tool industry [Index, nominal (seasonally adjusted and smoothed values)] Machine tool fell by 4%, as compared to the production output, third quarter of 2011. Domestic 240 according to the orders were down by 12%, while Orders 200 official figures export orders remained stable at provisionally the preceding year’s level. Since 160 announced, rose by the beginning of this year, order 120 another 12% during bookings have fallen by 11%, Shipments the year’s first domestic orders by 8% and export 80 nine months. The orders by 12%, as compared to the 40 German machine first nine months of 2011. Orders Jan-Sep 2012/11: Total: -11%, Domestic -8%, Foreign: -12% tool industry “The fall in demand over 0 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 is accordingly the course of the year has so confident of far proceeded in line with exceeding previous expectations,” is how Dr Wilfried expectations. been ailing due to the now-familiar risks. Schäfer, Executive Director of Only Eastern Europe, principally Russia, the sectoral organisation VDW (German “Against the background of the order is still offering some hope. Machine Tool Builders’ Association) in trends, a continuingly high order Domestic orders were, until the Frankfurt am Main, comments on the backlog of more than eight months middle of the year, performing better than figures. Inside the triad, America reports with practically complete capacity their export counterparts, fuelled primarily rising order levels, as there is substantial utilisation, the VDW is upping its by project business involving press ongoing investment ongoing here. production output forecast for 2012 technology. “In the last two months, our Asia, in contrast, is returning to normal from its previous 6–8%,” says Schäfer. biggest customer grouping, the automotive business following its high growth rates This would correspond to sales of industry, had put its foot firmly on the in recent years. In China, the largest of almost €14 billion, approaching the brake pedal, and is postponing capital the markets, demand has cooled down record figure of 2008. The largely stable investment projects with its component temporarily, because financial policies situation has also showed up beneficially suppliers,” reports Wilfried Schäfer. This, have been tightened and small- or midin the employment figures. In August he continued, is also showing up in the tier customers, in particular, are finding of this year, they showed around 68,640 orders for machine tools. Nonetheless, it more difficult to get financing for their employees, 4.5% up on the preceding demand in Germany has held up investments. Western Europe, finally, has year’s level.

Note: Index basis shipments 2010=100, data until September 2012 Sources: VDW, VDMA

12.11.2012

MMT - December 2012

VDW

News, Views & Analysis

Schaeffler India appoints new President & CEO; opens green field plants at Savli and Hosur

he Schaeffler Group has appointed Dharmesh Arora, a highly experienced professional in the automotive field, as its new President & CEO for its operations in India. Arora has an experience of over 25 years in the automotive industry. He started his career at Maruti Suzuki and, thereafter, held several management positions at General Motors in India, Mexico, Thailand and USA. “We are pleased to have Mr Arora on board as the new head of our Indian operations. I am sure that with his global expertise and management experience, he will lead Schaeffler India with our three brands—INA, LuK and FAG—to the next level of growth and customer proximity,” said Dr Juergen M Geissinger, CEO, Schaeffler AG. Earlier this year, Schaeffler announced planned investments of €150 million (`1050 crores) in India over the next three to four years for expanding existing plants at Pune, Hosur and Vadodara—besides building a green field plant at Savli near Vadodara. More than half of the investments are now realised with the inauguration of the green field Savli plant and the new line at Hosur this week. The Savli plant manufactures Schaeffler’s most advanced low-friction deep groove ball bearings and large-sized bearings for diverse sectors such as wind energy, heavy industries and railways. The new line in Hosur produces state-of-the-art hydraulic clutch release systems that offer benefits of lower noise, vibration and harshness (NVH) levels and improved drivability while improving fuel economy. 32

MMT - December 2012

The first Italian Technology Center (ITC) to be launched in Pune

une is set to have the first Italian Technology Center (ITC), which will start functioning from December 2012. The official launch is scheduled in January 2013. As a first step, the ITC will host 11 Italian companies from the machine tools and plastic machinery sectors. The following companies are slated to have a presence within this office: BLM SPA, Colgar SPA, Giuseppe Giana SPA, Istech Segatrici SPA, Losma SPA, Millutensil SRL, Omera SRL, Productech SRL, Rosa Ermando SPA, Streparava Holdings SPA and Tria SPA. The Indian companies will now have an opportunity to consider this centre as their first point of reference and can get an immediate answer/feedback to their queries for the above companies. The centre will be presided by Dr Giancarlo Losma, Immediate Past President of UCIMU - Italian Machine Tool Manufacturers Association, through its Indian SPV Sandeep Chadha, Director, Rare Tech Projects Pvt Ltd.

KUKA Robotics organises a product launch event

he German robot manufacturer organised a product launch event at Marriott Hotel Pune on November 5, 2012. The company demonstrated robots such as the industrial robotics A B C and KR QUANTEC robot series. With its broad range of products, KUKA Robotics offers automation solutions for a vast array of customer requirements. New products, expansion of the service-proven robot family and innovative control technologies enable the Augsburg-based robotics specialist to demonstrate its areas of expertise in the

general industry. The industrial robotics A B C, where A stands for ‘AGILUS’; B, for ‘Broad range of products and services’ and C, for ‘Common control system KR C4,’ makes automation very easy and feasible. The new KR QUANTEC robot series is the successor to the bestselling comp and 2000 series. With its extensive range of models, comprising 15 basic robot types with various mounting options, the KR QUANTEC series ensures that there is a perfectly suited robot for every customer-specific application.

Taiwanese machine tool exports to remain flat

he Taiwan Association of Machinery Industry has projected that Taiwan’s machine tool exports may remain flat next year on slumping demand. Overall, there are still many political and economic uncertainties in the global market,” said Wang Chengching, Secretary-General, TAMI. Based on the association’s estimate, shipments of machine tools are likely to grow by 8 to 9% to $4.4 billion this year from last year.

According to Taiwan External Trade Development Council, Taiwan’s machine tool exports totaled $3.59 billion in the first 10 months of the year, a 9.2% increase compared to the same period last year. By destination, China imported the most machine tools from Taiwan, with total shipments hitting $1.23 billion in the first 10 months of the year, followed by $442.81 million in shipments to the US and $226.09 million in shipments to Thailand, according to TAITRA.

News, Views & Analysis

Freudenberg strengthens R&D wing in India

dentifying the Oil & Gas segment as one of the most important strategic future markets, EagleBurgmann underlines India’s importance in developing new technologies and solutions for the industrial sealing market. The company has added a new R&D centre to its Punebased production plant constructed in 2009. The R&D building is scheduled for completion in the first quarter of 2013. The Freudenberg group will use the new facility for testing various seals, addressing mainly Oil & Gas applications. The investment in research facilities in India highlights the importance of the Indian market for the Freudenberg Group’s global growth strategy. In this R&D centre, EagleBurgmann will test high-end products like dry gas seals for compressors as well as highpressure and high-speed engineered seals for pumps and agitators. It will also include running tests as well as endurance testing for various mechanical seals and seal supply systems. “The major benefit for our customers is reduced product lead time, especially for products that were fully designed, manufactured and tested abroad due to lack of such facilities in India,” says Pramod Mehata, Site Execute Officer for EagleBurgmann’s Pune site.

Makino introduces two new technologies

akino launched two new products at the Open House event named ‘Makino Die & Mold Open House 2012’ at Bangalore Technology Center on November 8 and 9. The two new products were the F8— Large High Speed Vertical Machining center and the U3—Compact High Precision Wire EDM. V L Panneer Selvan, Divisional Manager, Titan Industries Ltd, was the Chief Guest who unveiled the F8 machine. Ranjit Bhide, President, Makino India, inaugurated the U3 machine. Around 100 customers from Bangalore, Chennai, Coimbatore, Pune and Mumbai attended this event. Makino’s latest technologies for the Die & Mould industry was showcased in these two days. The company also invited its technology partners such as Hitachi Tools, Walter, GW Precision Tools, BLUM and Prime Industries who participated in this event and displayed their latest products. The F8 machine offers a competitive solution for high-precision 3- and 4-axis milling and drilling of large-size die & mould and precision parts. A brand-new wire EDM machine, U3, is the latest addition to Makino’s successful wire EDM portfolio. U3 sets a new benchmark in competitive EDM technology. The U3 is marketed as a reliable, cost-effective wire EDM solution with a unique 0.4μm/3pass capability that enables the U3 to cut

faster. And that is particularly beneficial in the time-critical stamping industry. Since another eye-catching feature is the U3’s compact size, it is also the ideal wire EDM solution for small job shops where space is always an issue. By investing in a machine of this quality, shops specialising in precision metal tooling or die stamping can look forward to a better payback than from similar machines on the market. In the stamping industry, time can be critical. Makino’s U3, with 3μmRz/3pass capability, cuts faster than other technologies. The mechanical structure of the machines also assures that movements between details will be accurate anywhere within the work envelope. This combination of speed, finish and repeatability will help increase productivity.

CGTech and OPEN MIND renew partnership agreement

GTech, developer of VERICUT® software for simulating CNC machine tools, and OPEN MIND, developer of hyperMILL® software for programming CNC machine tools, announced renewed their partnership agreement. As part of this relationship, the two companies work closely to provide seamless integration between their products and customer support. The interface, which continues to be enhanced, is designed to help their mutual customers create a better machining process by providing an easy way to verify hyperMILL’s post-processed 34

MMT - December 2012

machining paths in VERICUT. Alan Levine, Managing Director of OPEN MIND Technologies USA, Inc., stated that hyperMILL provides innovative techniques for 2.5-axis through 5-axis milling and drilling, mill-turn and specialised niche applications. He mentioned that many of hyperMILL customers’ work processes mandate part programme simulation and they are most often done using VERICUT. The hyperMILL to VERICUT data interface provides high assurance for the transfer of information between these software products. Possible programming errors

are identified sooner without putting the actual machine tool at risk. Bill Hasenjaeger, CGTech’s Product Marketing Manager, acknowledged the company’s product (VERICUT) as the industry leader in CNC programme simulation. He also stated that hyperMILL’s strength at machining very complex geometries, combined with VERICUT’s strength at simulating sophisticated machining strategies on complex machine configurations, produces a very capable solution for highend manufacturers’ most challenging machining problems.

TECHNOLOGY & INNOVATION

Innovations in Styling Steel

n the world of concrete and glass structural marvels, one common thing is the stylish stainless steel items. Be it wall claddings, hand rails, glass supports or retail store fixtures and artifacts, stainless steel is the solution, the shape and appearance of which is left to the artistâ&#x20AC;&#x2122;s imagination. The main feature of stainless steel is its trendy,

lively and different finishes. This trend is fast replacing the earlier bright

USPs

Produces a good finish Lasts longer and faster than conventional abrasive Improves efficiency

finished stainless steel products, which were preferred by the Indian consumer. 3M, through its abrasive products, is actively involved in upgrading metal fabricators to generate these new world-class finishes. Through their interactive methodology, many users are now equipped with the knowledge of styling steel or, as it is called, â&#x20AC;&#x2DC;the 3M art of styling steel.â&#x20AC;&#x2122; These solutions address all the process steps right from grinding to final finish. 3M, apart from driving new finishes, has been innovating products

Multi-Axis Machining

USPs

he technology and equipment for performing multi-axis machining has been around for a long time. The methods used to achieve simultaneous 5-axis in industries such as aerospace, energy production, oil and gas, medical, woodworking and mouldmaking are similar, yet each industry has specific applications and needs that determine how a given manufacturer

Reduces machining time Gives better surface finish Eliminates multiple setups Eliminates costly tooling and fixtures Eliminates manual millwork and handwork Machines complex parts Has fewer competitors

like CubitronTM, Scotch-BriteTM and TrizactTM. These products are designed for giving distinct advantages to the users in many ways. With CubitronTM-aided products, the users can get benefits like faster cutting and better finishes. CubitronTM abrasive mineral grains grind cooler, faster and last longer than conventional abrasive in many metalworking solutions. One major reason for this improved efficiency is the small crystal structure that makes up the abrasive grain. 3M is able to make CubitronTM abrasive grain for different grinding applications. The 3M Green CorpsTM flexible grinding discs contain 3M-patented CubitronTM abrasive grain, an advanced ceramic aluminum oxide mineral. These wheels enable to improve production standard for grinding and blending on a wide selection of metals.

gets the job done. In both vertical and horizontal milling, two additional axes are added to the existing X, Y and Z axes. These two axes are (1) a rotary axis that rotates around the Z axis and (2) a tilting axis that rotates around the Y or Z axis. The advantages of 5-axis machining are significant, and include saving time and money, among other things.

3D Printing

D printing is a form of manufacturing technology that can be used to create entirely unique products, just like the products in the machining world. However, 3D printing has a few strengths to it that machining does not. Aside from CNC cutting, 3D printing works much quicker than traditional machining methods. There is a wide variety of materials available in 3D printing, just like in machining, but there is one critical difference between the two. Machining essentially involves 36

MMT - December 2012

USPs

Reduces development costs Speeds up time to market Increases innovation Improves communications

the drilling of a block of material. The only type of product through machining involves a drill bit coming down upon a block. Sure, a table holding the block can twist and turn, but there are so many

features sacrificed through machining. 3D printers are less costly variations of Rapid Prototyping (RP) technology, which are positioned as a design tool to create inexpensive models early in the design process. Physical models produced on a dimension 3D printer allow everyone on the design team to review the concepts. In turn, the company gets better feedback, resulting in a better product. 3D printing allows companies to achieve real time collaboration on a global scale.

TECHNOLOGY & INNOVATION

Electric Discharge Machining (EDM)

lectric Discharge Machining (EDM) is a high-precision metal removal process, which uses thermal energy to erode the work material by means of controlled sparking. The EDM process is primarily used in the tool and die making industry. However, due to the capability of this process to machine ‘difficult to cut’ materials like hardened steel, tungsten carbide, high speed steel and titanium with ease, it is also used to manufacture intricate shaped dies, which are free from burrs. The process is useful to produce ‘difficult to generate’ shapes like D holes, splines, narrow slots, groves and blended features. The process finds its usefulness in automotive, aerospace, medical instruments manufacturing, oil & gas and chemical industries. According to Ramesh Kumar Singh, Assistant Professor – Mechanical Engineering Department, IIT Bombay, “The EDM process requires less post processing operations like grinding and

polishing. In this process, tool wear is minimum as compared to conventional methods. So, tooling cost can be minimised.” The EDM process can machine any hard material with ease, like titanium, Inconel, high-speed steel, etc. It gives very high dimensional accuracy (+1 μm) and surface finish (0.2 μm ‘Ra’) and requires very low cost tooling like tools, fixtures and clamps. “There are some issues in using EDM such as it requires the material to be electrically conductive, and the process is slow if good surface finish and

USPs

Can machine any hard material Has high dimensional accuracy Requires very low cost tooling like tools, fixtures and clamps Can produce sharp internal corners and holes in single pass

high accuracy is required. To overcome such limitations, one can use hybrid processing like electro-chemical discharge machining (ECDM) and ultrasonicassisted EDM to improve the surface finish and minimise the extent of thermal damage layer. The EDM process can be used to machine some non-conducting or semi-conducting materials by applying a thin conductive layer on the work piece. The extent of thermal damage can also be controlled using the dry-EDM process,” added Singh. Singh says, “The energy consumption in the EDM process is similar to other conventional manufacturing processes. It does not require very high energy as localised sparking occurs during the process. Although electrical energy consumption is slightly higher than that in other processes, it can be compensated by less tooling requirement, lower finishing operations and requirement of less man power.”

December 2012 - MMT

IN CONVERSATION WITH Luigi Galdabini Dealing with the Eurozone crisis The Eurozone crisis is certainly a cause for concern, particularly because Europe is the second largest machine tools consumer market after Asia, and the first outlet market for Italian exports, absorbing approximately 50% of the production of the sector. However, despite the crisis, Italian companies must continue to function the way they do and strive for excellence and innovation (when manufacturing machine tools, and during the globalisation of their company). According to the information processed by the Studies Department of UCIMU-SISTEMI PER PRODURRE, the global manufacturing industry is still investing in capital goods and the positive trend in consumption of machine tools will continue strongly until 2015, also involving the Eurozone. Besides, the increase in the demand for production systems will be consistent in the Asian region, where consumption will increase by 53%, to €61 billion. On the other side, although mature, the European market demand will increase to €16 billion—28% more than in 2011.

Future of the Italian machine tool industry In such a complex situation like the current one, it is really difficult to make any forecast for the next two years. All I can say is that based on the data processed by the Studies Department of UCIMUSISTEMI PER PRODURRE, between 2011 and 2015, the world consumption of machine tools will increase by 45%, reaching a record value of €88.6 billion.

India is not technologically behind “For the Italian machine tools sector, India is certainly one of the most important outlet markets. The seventh export country for Italy, in 2011, India purchased machine tools for an overall value of €135 million,” asserts Luigi Galdabini, President, UCIMU, during an interaction with Nishant Kashyap. Excerpts… 38

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Luigi Galdabini In Italy, it is forecasted that demand will grow by 20%, reaching a value of €2.4 billion.

Challenges faced For the Italian machine tools manufacturers, it is of paramount importance to continue the development of technologically advanced solutions. Doing this is even more important now that the market is becoming more and more competitive. Italian players face challenges at several levels, and quality & customisation make sure that the ‘Made in Italy’ is recognised the world over. While the export scenario is hopeful, the domestic market is still a cause for concern.

Italian superiority It is a position that really makes us proud, as it demonstrates the value of ‘Made in Italy’ and is indicative of how much such value is universally recognised by machine tools buyers. However, this ‘position’ should not be looked at as the final objective; rather, it should be looked at as a starting point that should push Italian manufacturers to continue with their R&D investment programmes, to ensure that they keep coming up with innovative products and thus, acquire new market shares.

R&D in the Italian industry This is a very wide subject, as it includes many fields, each worthy of notice for some special innovations. Therefore, only mentioning some of them would be limiting. However, a determining innovation, which cannot be overlooked, has been the inclusion of the assessment of working conditions in milling and turning processes, which gives the possibility of analysing the machine tools used, and identifying both the limit conditions to ensure stability, and optimum working parameters. Another important new introduction is the processing of ‘exotic’ materials, the so-called ‘light alloys’. These are mainly important in nanotechnology, particularly in the biomedical, dental and space segments. The list could go on and on, but I would rather stop here.

Targeting overseas markets One should certainly not overlook any opportunities, as it is of fundamental importance to pay attention to what is happening everywhere in the world, particularly in emerging markets. Southeast Asia, for example, is a market that shows great potential. In 2011, Vietnam alone bought machine tools for a total value of over €3billion. This included all kinds of machines. In 2011, Italy was the country that increased its exports to Vietnam the most—+256% compared with the previous year. Japan, the second in line, recorded a +56% increase, while countries like Germany and South Korea suffered a decrease of over 20%. These figures demonstrate the quality of work carried out by our companies, with the support of the category association, ICE, and the market operators…work that we must carry out consistently, because Southeast Asia is a market that offers great opportunities. However, it is certainly not the only one—Russia is a strongly expanding market, as is Brazil, and so on.

The Italian technology centre in Pune, India The Italian Technology Center (ITC) represents a network agreement involving 11 Italian manufacturers of capital goods that will collaborate towards facilitating a common policy for the penetration of the Indian market, with the support of a new centre established in Pune to promote the products ‘Made in Italy’. Its duty will be to promote the ITC trademark, the brands of the 11 companies taking part in the project and the development of new contacts with the institutions and the Indian cultural sectors—a mandate for the support of the international penetration of Italian companies in the area. It is important to note here that the creation of ITC is another initiative in the long list of projects promoted by UCIMUSISTEMI PER PRODURRE that include PIATTAFORMA INDIA (PLATFORM INDIA), for example, which is aimed at supporting the penetration of member companies in an

extremely lively and promising market like India.

India in terms of technology In my opinion, while India is not technologically behind, it is behind as far as infrastructure is concerned. There is a need to focus attention on specific sectors, workplace safety regulations, and machine tools safety systems, while also ensuring that there is respect for the environment. Also, one must consider that as far as India is concerned, it is not possible to generalise on technology. For instance, large Indian companies such as Tata, Mahindra, Nexteer and Delphi acquire the same advanced technology as the rest of the world, and therefore, are certainly extremely advanced.

Market size The Italian production of machine tools, robots and automation systems in 2011 reached a value of €4,762 million, employing approximately 30,000 people. Even if 70% of this production has been exported, this sector remains nevertheless one of the great excellences of our country, and significantly contributes to the total Italian GDP. For the Italian machine tools sector, India is certainly one of the most important outlet markets. The seventh export country for Italy, in 2011 India purchased machine tools for an overall value of €135 million.

Relations between India and Italy We can view them as commercial relations between a country—Italy, with extensive know-how and a large production output of machine tools, but, at the same time, with a weak domestic market. In India, the opposite is true. There is a lack of machine tools manufacturing experience, but a strong demand due to the important production expansion that the country is facing, with important industrial volumes. Therefore, I believe that a capillary and advantageous network of commercial agreements between the two countries could bring advantages to both. nishant.kashyap@network18publishing.com

December 2012 - MMT

SPECIAL FOCUS CONTROL SYSTEMS 41

Sector Snapshot Look Who is in Control?

Business Trends CNC Machines: High-end Controlling

Remote Connectivity Machining Through the Internet!

Latest Improvement Controlling New Generation Manufacturing

42 40

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SPECIAL FOCUS Sector Snapshot

Look Who is in Control? Control Systems in the machining sector has undergone a plethora of changes in the past. We see four of the latest trends that have recently entered the market.

Launch of SIMATIC PCS 7 Version 8.0 by Siemens

Live presentation of TNC 640 milling/turning control at AMB 2012

The SIMATIC PCS 7 Version 8.0 launched at the Siemens Process Automation Conference (SPACe), 2012, Hyderabad, enables project planning, configuration, commissioning, diagnostics and maintenance along with a host of advantages such as improved data exchange, simplified engineering workflow, scalable long term archiving system, ease in creating and modifying reports, redundancy-related and fault-tolerant functions to new controllers and extended functionalities for the software tools. New features such as extended plant documentation, integrated statistics, simpler operation and more convenient replacement of devices by functionalities such as export/import functions in SIMATIC PDM (Process Device Manager) would benefit users. Furthermore, users can easily archive process data and reports and can utilise them to optimise production.

Heidenhain presented the active demonstration of the TNC 640 milling/ turning control at AMB 2012. The new software includes important and proven functions that the machinist is already familiar with (from the iTNC 530 or MANUALplus 620). The TNCâ&#x20AC;&#x2122;s Dynamic Collision Monitoring (DCM), interrupts machining whenever a collision is imminent and so increases safety for the machine and the operator. This helps to prevent machine damage, which can result in costly downtimes. Unattended shifts become safer and more reliable. New functions have also been integrated for turning operations such as new cycles for recess turning and blank form updating when using the contour turning cycles. New accessories for rapid setup of tools and workpieces have also been introduced. The new touch probes-TS 460 (workpiece touch probe) and TT 460 (tool touch probe)-feature two transmission methods: infrared and radio. Combining the advantages of infrared (very high accuracy) with those of radio (high range), these touch probes can be used in several different types of situations.

FANUC introduces improved Compact Robot Controller Omron announces a new HMI series The new HMI series brings increased functionality and usability ideal for small- and medium-sised machines. The wide range of models in screen sises from 3.5 in to 10 in suit many different application requirements, and provide TFT colour touch screens with long-life LED backlighting, a wide viewing angle, and the ability to display over 65,000 colours. The NB series HMIs incorporate Ethernet, serial and USB interfaces for connection to Omron PLCs and devices, particularly the Omron CP1 compact PLC, as well as automation components from other vendors. The NB HMI also supports the use of a USB memory stick to upload new versions of your programme or for backing up stored data. Designed with simplicity in mind, the NB series HMIs provide all the features and functions needed to create intuitive operator screens quickly, with programming software that can be downloaded freely from the Omron website. The software provides flexible window handling, support for 32 languages, the ability to quickly create animations and a host of powerful macros. To save design time, projects can be tested in an offline simulation mode. Using the new cost-effective Omron NB HM1 with enhanced functionality provides operators and maintenance staff greater functionality and greater ability to interact with their machine.

The latest robot controller to be introduced by FANUC is packed with smart features to take control and productivity to the next level. Four key focus areas allow the new FANUC R-30iB robot controller to save up to 77% floor area, programme faster and easier, save power and maximise productivity. The overall volume of the compact new R-30iB design is reduced by 68%, measuring just 500mm x 600mm x 470mm. Using the same platform as the new FANUC 30i CNC controller, the completely revised robot controller packs the same power, and more, as its larger predecessor with more than 4,096 I/O supported, 40 axes control capability and 8 motion groups, up to 4 line tracking encoders and support for most common industrial communication/ bus systems and a 4D graphic function. The new pendant provides real time visualisation of process on its touch screen monitor making programming and editing faster. The new R-30iB controller comes with improved energy efficiencies helping to contribute towards important profit margins. December 2012 - MMT

SPECIAL FOCUS Remote Connectivity

Machining through the Internet! As the industry reaches new levels, technological advancements are a norm. Remote access of devices, remote controlling and monitoring are the latest trends. However, this is not present in the Indian market. Will this liberty of freedom and control via the Internet for control systems and CNC machines be the reason the Indian market lags behind? What are the repercussions of not staying with the trend? Nedra Pereira finds out...

ignificant advancements have been made in machine tools technology to cater to various sectors such as defence and aerospace, electronics, automobile, steel and so on. The on-set on multi-axis along with multi-spindles has increased the use of CAD/CAM in automating machining operations. In addition to these, the industry is now looking at remotely controlling machining operations. This could be a big boon as it can help enhance productivity and efficiency. At present, CNC machines are programmed in multiple stages. First, using CAD, a template is made for the work piece, thus enabling viewing and changing dimensions as per requirement. Next, the approved design is completed, 42

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and a programmer translates the template into CAM. The programme is then loaded from a PC directly into the memory of the CNC machine via a RS-232 link. Further, connecting the RS-232 link to a File Transfer Protocol (FTP) server and client, information can be transferred via Ethernet directly from a computer to a machine. This results in faster file transfer—files as large as ten megabytes can be transferred within 40 seconds—which, in turn, offers flexibility to operators and programmers. In addition, CNC machines can also be connected in series via a switch box that is connected to a PC that is connected to the internet. This kind of information transfer could be especially useful for companies who manage CAD/CAM operations in a different geographical

location than where their machines are located. Connecting CNC machines to the internet and tweaking the program on the control system has been around for a couple of years in the Western markets.

Remote Machining Now that CNC machines can be connected to the Internet, the next step is the obvious one—remote connectivity and controllability. Remote machining allows you both control and freedom. Regardless of the technicians’ proximity to the actual machine, the hardware interface grants real-time access to all CNC functions via the Internet, enabling them to monitor, tweak and get notified about the progress of the job. According to FANUC FA in an official statement, the company has introduced a new

Remote Connectivity option that allows its Series 30i/31i/32iMODEL B CNCs to be monitored remotely using tablet-type devices. This latest advancement in remote monitoring greatly enhances the maintainability and production capabilities of the CNC.

of the machining processes. Running continuous cycles are necessary to enhance productivity. Lights-out manufacturing has already been implemented by some of the global players; this offers both productivity and cost saving.

Possible Drawbacks

Why the Lag in the Indian Market?

Theoretically, connecting CNC machines to the Internet should make the manufacturing process more efficient while offering technicians and manufacturers with a speedy path to communicate with each other and directly with the machine. However, several considerations need to be accounted for when implementing this. There are only a few CNC machines that come with Ethernet options built in and they are used to simply download and store programmes on the machine.

Upgrading Equipment Many manufacturers and SMEs still work with older R2-232 connected machines; however, through small modifications, these machines can also be connected to the Internet. For instance, by connecting a RS-232 cable through a computer that is already connected to the Internet to the PC RS-232 port. By connecting the machines to the Internet, the manufacturers can view the machines on the Internet and optimize their process irrespective of them being in the same vicinity.

Positives Having the CNC machines connected to the Internet can offer easy installation as foreign manufacturers can help new users set up their machines through remote controllability without having lengthy discussions. Furthermore, operators optimise the use of their time elsewhere while the machine is running and can remotely check for process updates or breakdown. Timely support can be ensured via remote CNC machine diagnosis as service engineers can diagnose a problem before they arrive on the shop floor with the necessary replacement parts. Today, when productivity and profitability are in the forefront, more is expected out

consistency. On the other hand, they lag behind in terms of design and engineering capability or customisation options and, therefore, are unable to undertake very high-precision CNC (Computer Numerically Controlled) machines. Arun Nene, Mentor, Jyothi CNC and Automation Pvt Ltd, advises, “Most manufacturing companies do not see the need to adopt latest trends. This can be seen in the type of investment that is made in CNC machines. There is a need to prove that they are superior but they lack the professionalism that is observed in the international manufacturing sector.”

actually contact our manufacturers in Australia and they connect to our systems via the Internet. This helps in sorting our issues in a fast and efficient manner. Having said this, I feel that the Indian market lags behind in their approach. They would rather have a hands-on approach of getting someone to come out and check their machines instead of a smart approach that lets them reduce machine down time,” avers Kamlesh Thakur, Director, Pro Arc Welding & Cutting Systems Pvt Ltd. This implies that India’s manufacturing sector is quite capable of implementing remote monitoring and controllability. And all that is required is a change in the mindset. Inculcating the latest trends, the manufacturing sector in India might also see ‘lights-out manufacturing’ come into play, thereby increasing productivity, precision and growth and reducing costs and rejections. On the other hand, some companies in the industry feel that trends should be followed according to the requirement of the company. Small businesses may not require to be connected to the Internet and may see it as an expense rather than a way to increase productivity. “The Indian manufacturing sector will not lag behind in any way for not adopting remote connectivity. More productivity can be achieved using smaller automations of robotics,” says Mohini Kelkar, Managing Director, Grind Master Machine Pvt Ltd.

Why not connect to the Internet

Future Outlook

India ranks 114 globally for average connection speeds according to a press release from Akamai, an Internet content delivery network. Does this play a role in why the manufacturing industry is not willing to adopt the trend of remote controllability and monitoring? Should the government play a bigger role in increasing bandwidth capabilities to enhance an already expanding market? “We use internationally branded CNC controllers that are windows based and can be easily connected to the Wi-Fi. In fact, when setting up machines, we

Remote connectivity increases userfriendliness in the machining process. It allows for faster optimisation and increased productivity of not only the machine but also the workshop technicians. All the machines can be monitored from one location without the need to be right where the machine is. This is only the beginning; whether the Indian manufacturing industry implements this technology now or in the future, this trend is here to stay.

With all these advancements seen in the global manufacturing industry, one wonders whyIndia—which is to become a manufacturing hub—is lagging behind. Indian manufacturers produce generic purpose products with international standards in terms of quality, accuracy and

Remote machining allows you both control and freedom.

nedra.pereira@network18publishing.com

December 2012 - MMT

SPECIAL FOCUS One Q Many Views

Wireless Connectivity Technology:

Is India Ready to Adopt? Intelligent CNC machines equipped with technologies like remote sensitivity and wireless connectivity enhance efficiency for both manpower and the machines. Using this technology, detection, diagnosis and correction of all sorts of errors, and optimisation of processes is possible. Since these machines are being adopted worldwide, Nishant Kashyap & Nedra Pereira ask industry experts, “Are Indian companies ready to adopt this technology?” Arun Nene, Mentor, Jyothi CNC and Automation Pvt Ltd Most manufacturing companies do not see the need to adopt latest trends. This can be seen in the type of investment that is made in CNC machines. There is a need to prove that they are superior but they lack the professionalism observed in the international manufacturing sector. India is capable of incorporating remote controllability and monitoring into the processes; internet speeds or server issues are not a cause for non-adoption. The main cause is the mentality. Once the attitude changes, all the latest trends can be adopted, which will improve efficiency in the processes and give India a further cutting edge.

Suprith Kashyup, Business Development Manager, Data M Software India Pvt Ltd This is an interesting concept for manufacturing industries. I think we do need to look at this trend in the long run. At present, we do have manpower, but remote controllability and monitoring may help in bringing about further efficiency.

Somnath Majumdar, Customer Segment Manager – Energy & Aerospace, Walter Tools India Pvt Ltd We are in an era of globalisation and need to remember that to be able to compete with global players, we need to be at par with the latest trends. CNC machining itself has come a long way over the last 10–15 years. Latest developments such as remote controllability and monitoring should be implemented in India to improve efficiency. Technological improvements or trends in any form should be applied to upgrade the manufacturing ecosystem of India to global standards. We do lag behind other markets to a certain extent as India still relies on outsourced components. The R&D sector is not as impressive as the ones seen in global markets of other Asian countries. Indian machine tools are not exported to foreign countries. More sub contract work is done in India, which clearly shows that we are, to an extent, lagging on the tech front.

Jeffrey Archard, Area Sales Manager, GW Precision Tools India Pvt Ltd Yes, with today’s globalisation, adapting technology and sharing machining processes and technologies is a reality. Also, remote log in and diagnosis of machine is today a cheap and efficient method for the problem diagnoses of high-end CNC machines. With the present difficulties in getting permission to use such technologies, I do not think wireless connectivity in control systems is an appropriate technology for Indian CNC machine users. Indian industries are looking for high-end control systems, but these controllers are restricted and available only to a few countries and machine builders.

Sambit Pradhan, Manager - Business Development, Geometric Ltd India has already adopted this wireless technology in DNC (Data Numeric Control), which you can see in the large and mid cap manufacturing companies, but SMEs are yet to experience it. I think that wireless connectivity in control systems is an appropriate technology for large manufacturing shops. Apart from this, I do feel that in order to increase production, industries need high-end control systems. 44

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One Q Many Views Mohini Kelkar, Managing Director, Grind Master Machine Pvt Ltd Remote controllability is applicable only if there is a critical issue with the machine and it needs to be rectified quickly via the internet by foreign manufacturers. Only in extremely critical applications, will it be economically feasible to use this technology. Also, this trend may serve certain sectors better, for instance, the high-tech pharmaceuticals for which formulations are important and a constant eye needs to be kept on them. I do not think that Indian manufacturing

sector lags behind in any way for not adopting this particular technology. There are far more productive automations that can be implemented. Some smaller automation trends are far more productive than remote controllability. Automation trends such as robotics, now, are gaining acceptance in the industry. Remote controllability may take another decade to be accepted in the Indian manufacturing industry.

Kamlesh Thakur, Director, Pro Arc Welding & Cutting System Pvt Ltd We use internationally branded CNC controllers, which are windows based and can be easily connected to the Wi-Fi. When setting up machines, we actually contact our manufacturers in Australia. The Indian market lags behind hands-on action instead of a smart approach. It is an advantage to have light-off operation, loading programmes for a long period such as seven days. This reduces the cost of manufacturing. India is very well equipped to handle new trends but the mentality needs to change.

Verdict

The Indian industry is very aware of the latest technologies and the potential they hold. However, adoption of remote controllablility and monitoring is still on the periphery. Small players in the country may not accept this technology right away, but many are aware of how adopting it will enhance the manufacturing technology, in terms of speed, precision and quality.

December 2012 - MMT

SPECIAL FOCUS Business Trends

CNC machines: High-end Controlling The Computer Numerical Control (CNC) system has evolved as a key technology in the machine tools industry. The machines are employed in almost all manufacturing sectors, as they provide accuracy, speed and productivity. The sophisticated technology has transformed the manufacturing domain, resulting in unmatched precision and execution. The need for speed and accuracy has given a push to control system manufacturers. Nishant Kashyap finds out the business trend of control systems.

NC machines were mainly developed for metal cutting applications like turning, milling and grinding. With expanding market dimensions, automobile and aerospace sectors became the main drivers for the development of CNC machines. Over the years, the CNC system has undergone a dramatic change, keeping pace with the developments in the personal computing segment. While previously, the CNC control system occupied considerable space, the new-age system remains just inside the screen. As a result, the machine tools industry is equipped with fast controls, which have helped users gain speed and productivity 46

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Indian Manufacturers The emerging Indian economy has generated demand for quality goods and services that meet global standards. To meet such demands, the manufacturing industry in the country has to incorporate technologies like control systems in its manufacturing process, which produces high-quality goods with precision, thereby improving efficiency and reducing manufacturing time. At present, there are no major domestic manufacturers of control systems in India and the functionalities of the few that exist are localised, that is, they are meant for specific applications only. As a result, Indian companies are dependent on foreign suppliers like Siemens from

Germany, Fanuc and Mitsubishi from Japan and, in very small numbers, some Chinese players like GSK. The opportunities for control manufacturers are bright since the Indian machine builders are investing heavily in expanding their capacities. This means that the number of machines will increase which, in turn, will increase the number of CNC control systems required in India. Standard CNC control manufacturers have a range of products from low-end to high-end controls. They also have the standard control with bare minimum features and extra options as per the requirement of the user, although this comes with an additional cost. Some of the CNC machines are customised

Business Trends and manufactured keeping in mind the requirements of Small & Medium Enterprise (SMEs). These are costeffective basic solutions that have the capability to add more features at a later stage. Some of the SMEs also use CNC machines to save their manpower costs.

SMEs: Controlling the Productivity The implementation of CNC machines offers an added advantage to the industry. This has led to improved productivity, easy working and quicker processes. Realising the benefits, and to bring in efficiency, even SMEs are increasingly adopting CNC machines. Nowadays, companies do not need to just deliver high productivity; they also need to make sure that the product is being manufactured on time. To achieve this, companies need to adopt automation in their process. Realising the demand trend, Indian SMEs are geared up for the latest CNC control systems. Although CNC control systems require high initial investment, they offer immense benefits over a period of time even for an SME. In some cases, manufacturers of CNC machines provide basic control and add extra hardware and software requirements for a price. Also, numerous machines have been built keeping in mind the specific requirements of SMEs. The machine tool industry comprises more than 70% of the SMEs dominating the industry. These SMEs have now realized that to tap into global opportunities, they will have to upgrade their technology and improve the production systems. Constant innovation and adoption of modern business strategies by SMEs for their development will be beneficial for the industry as well. To address these concerns, many SMEs are now adopting CNC machines for their units

Adoption of High End Control System In todays demanding world just having a automation process in not enough, many large and mid size companies are 48

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Advantages of control system

Consistent quality Reliable operation Reduction in manual error Shorter cycle time High accuracy Reduced lead time Just In Time (JIT) manufacturing

demanding for continuous up gradation in control system. To cater to this demand control system manufacturers have also come up with many cutting edge innovations such as remote sensing technology, wireless connectivity and wifi enabled control systems. In Indian the latest technology has been adopted by large companies but SMEs are yet to experience it. Industry expert believes that the technology is been adopted only by big manufacturers but the volume is still very low. Indian companies are ready to adopt latest control system for high end operations.

Current Business Demand At present, productivity is the manufacturing industry’s mantra. The need of the hour is to enable a fast and accurate turnout from the machine after getting a job. In short, we need a control system that is user-friendly, fast, accurate, reliable and with easy programming steps

Nowadays, companies do not need to just deliver high productivity; they also need to make sure that the product is being manufactured on time. To achieve this, companies need to adopt automation in their process.

and a lot of tips inside. Additionally, it must have infinite storage capacity and the best communication possibilities. Sambit Pradhan, Manager – Business Development, Geometric Ltd, “India has already adopted CNC control system in their shop floor, which you can see in the large and mid cap manufacturing companies, SME`s are yet to experience the high end control system. For large manufacturing shops there are lot of demand for control system as to meet the requirement the companies are adopting automation in their system. Lately to increase production industries need high end control systems. This will surely generate huge demand for control system manufacturer in the country.”

Promising Future Currently, companies require high precision for accurate and error-free components. As these requirements are gaining precedence, manufacturers are ensuring that the need is taken care of in the machine design itself. Customers are constantly on the lookout to cut the cost per piece while achieving superior results. Similarly, the usage of Special Purpose Machines (SPMs), dedicated for specific operations, is being avoided, and CNCs are taking over these operations, as they are able to perform multiple jobs. Besides, manufacturers look to provide customers with high value for money in the form of faster operations, greater productivity, abolition of rejections, freedom from human supervision, self-maintenance or any other value addition. India is moving towards becoming the second largest producer of steel in the next five years and has become the second largest manufacturer of small cars. As a result, CNC machines are expected to witness a surge in demand in the near future in the Asian market. India has many greenfield steel projects and capacity expansion projects, which provides great opportunities for CNC manufacturers to grow in the field of metalworking. nishant.kashyap@network18publishing.com

SPECIAL FOCUS Latest Improvement A control system is the central component that determines productivity and flexibility of your production plant. Over the years, the control system has gone through a rapid change, and the new developments in the segment have allowed users to monitor the process remotely and design the product in the control system itself, thus dramatically enhancing speed and efficiency. Nishant Kashyap takes a look at some of the latest developments in control system.

NC has touched almost every facet of manufacturing. Many machining processes have been improved and enhanced through the use of CNC. CNC is being increasingly used as manufacturers look to reduce the cycle time and increase the speed of production. This has pressurized CNC control system manufacturers to constantly upgrade the technology by adding new features.

Wireless Connectivity Today, with the availability of nextgeneration technologies, CNC machines are rapidly incorporating wireless capabilities. The latest trends in this area focus more on harnessing the recent developments in IT systems as well. CNC machines are increasingly becoming wireless, i.e., these machines need not be accessed using a computer sitting next to the machine connected with a cable, but by simply using the Wi-Fi feature available on almost all laptops to connect and access these machines. Most direct numerical control or Distributed Numerical Control (DNC) & CNC machines are now wireless, and the usage of cables has been minimized. Such features have given freedom to the 50

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top management as well as to shop floor managers. There is more visibility and accessibility in the system, which is the need of the hour for faster decisionmaking capability.

Remote Monitoring and Diagnosis Feature such as process monitoring and remote diagnosis by the user are fast becoming the norm in the industry. Machine builders are increasingly incorporating these abilities into the machines due to the growing demand from the users. Major players now employ these technologies for machine maintenance and even foresee crucial issues before any major breakdown takes place. The health of the machine is constantly checked, ensuring that the process runs smoothly. Currently, for the manufacturing industry, the shop floor is attaining more visibility. Managers can monitor the work as well as the machines sitting away at a remote site. Apart from the real-time shop floor data, the access is also an added advantage. With the technological innovations, one can ascertain the condition of the machine in the shop floor, sitting at the office desk. Using a mobile phone, one can determine the health, productivity and status of the machine. CNC machines are becoming intelligent systems. Nowadays, one can programme the

technologies to switch the power off after the work is completed. The entire machine backup as well as the health of the machine is remotely monitored by a server, which can be accessed by the machine builder. Other than this, the team can carry out appropriate activities to address the issues, much in advance before the actual breakdown takes place.

Enhancing Speed of Operations One of the major benefits of CNC control systems is the speed of operations. The IT systems using graphic user interface make programming and operating userfriendly and easy to understand. A major feature of CNC controllers is to increase the processing speed of the control as much as possible. If we compare the controllers of the late 80s and early 90s, where a single processor of 8 or 16 bits was controlling CNC, PLC, display, graphics, servo position loop control, etc., the present-day controllers have a 64-bit Reduced Instruction Set Computer (RISC) processor exclusively for CNC and PLC control. These also have a separate digital signal processor for servo drives that take care of the position loop control and separate human-machine interface with Windows & compact PC cards, having optical communication between CNC & drives. This reduces the burden on the CNC processor and increases the part programming processing speed, thereby delivering high performance. nishant.kashyap@network18publishing.com

FACILITY VISIT Maxsee Industry Co Ltd

Growing from Strength to Strength Maxsee Industry Co. Ltd. was formed in 1985 with an aim to offer quality machine tool solutions, which ensured efficiency and productivity for its customers. With a standing of 27 years, the company has emerged as one of the leading companies in offering quality machine tool solutions in Taiwan. Arindam Ghosh finds out the factors contributing to the growth and success of the company…

ince the establishment of Maxsee Industry Co. Ltd., the company has always followed the philosophy of progressive elaboration and advancement. It has also kept pace with the changing needs of customers and has evolved into a ‘customer-centric’ company. Moving in this direction has allowed the company to establish itself as one of the most successful players in the machine tool industry in Taiwan. In the company’s journey of 27 years, it has gained a considerable wealth of experience in hardware and cutting tools production. The company has always followed the philosophy of progressive elaboration and advancement. Further, as part of the initiatives taken to move in this direction as well as achieve maximum customer satisfaction, the company is continuously investing in its plant and equipping its factory with 52

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the latest machinery. Talking about the company, Carol Lai, Sales Supervisor, Maxsee Industry Co. Ltd., says, “We have been serving customers from a variety of industrial sectors such as aviation, electronics, device suppliers, mould makers, auto manufacturers and other various industries. Based on customer’s working demand, we are able to work with customisation and provide total solution and service.” Adding further, she says, “Our goal is provide machines that fulfil the requirements of the customers and allows them to grow their business smoothly.”

About the Plant The plant of the company is located in an industrial park of the Taichung City in Taiwan and it is set up on an area of 800 sq ft. The factory is divided into various sections where different

operations are performed. The plant has state-of-the-art machines, which are primarily manufactured in Taiwan. In addition to this, the raw materials are procured locally. Such a scenario has allowed the company to offer its products at highly competitive prices, especially in the international market. The factory is certified with ISO 2002 and it also has a CE certification so that the solutions developed from the market are accepted in the European market. “Given that quality and high performance of machines are always our top priorities, it has made our machines globally acceptable. From the factory, our machines are sent to various markets in the globe like the US, Russia, Brazil, Thailand, Malaysia, Korea, Japan, Germany and Netherlands,” says Lai. In terms of going green, the company collects all the scrap from the manufacturing

Maxsee Industry Co. Ltd. MAJOR HIGHLIGHTS

process, which is then given to various specialised recycling agencies.

Year

Milestone

Workers’ Training The basic operations in the factory include assembly, casting, painting, testing, etc. Given that the company is not involved in mass production and does have a production line, the usage of automation is not high. “The orders for our products mainly come in the range of about 10-20 sets maximum and not like a 100 sets,” Lai says. But the company has hugely invested in its workers to ensure accuracy in the production process. The company has also taken active steps towards organising regular workshops and training programmes for their workers in the factory. As part of the initiatives taken in this direction, the company sends its engineers and workers to various specialised management and training institutions every six months. Lai said that these courses are highly specialised and developed according to the industry and market dynamics. This has allowed the engineers to constantly improve their skills as well as remain updated with the latest trends in production and the industry as a whole. “We believe that if we invest in activities related to the skill development of our workers, it will lead to the development of superior quality solutions,” Lai points out. Presently, there are about 30 engineers in the factory. Such a procedure has taken care of the industrial safety of the workers and engineers. They are highly aware of the procedure and know how to operate a machine. Further, the company conducts special sessions at the factory in order to educate workers on the injuries that can be caused if the machines are not handled properly; this makes them more aware about the workings of the machines. Such a module has allowed the company to bring in more safety in the factory. In addition, the company has asked the workers at the factory to wear special garments that ensure more protection.

1985

Year of Establishment

1989

Introduction of the 1st CNC EDM

1995

Introduction of the 1st Wire EDM Introduction of the 1st Drill EDM

2003

Establishment of a new facility in China, Center Technology Shanghai Co. Ltd.

2011

Maxsee’s Auto Wire Treading system filed under US patent no. US7,923,656 B2

The Product Range The major products of Maxsee Industry Co. Ltd. are EDM, Wire EDM, High Speed Machining Center and Drill EDM. The products ensure high speed, accuracy and precision along with efficiency. For the CNC series, the machines offer comprehensive machining functions and various shape patterns with instant graphic display. In addition to these features, the company has newly developed a Window CNC system, which provides a user-friendly interface with a 150-inch colour touch screen as well as eliminates vibration during machining. In case of High Speed Bridge-Type Machining Centre, it provides speed, power and accuracy machining in graphite and hardened steels. The laser inspection in the equipment ensures high accuracy and repeatability. The machine is also fitted with a ball bar tester for inspecting backlash and geometric errors such as squareness and straightness. By using the high-precision ball bar testing, a machine will exhibit extremely high accuracy. The equipment is very critical for the machining of aerospace spare parts, and it is also highly suitable for the production process of Ceramic, Quartz, Titanium, etc.

raw materials, the company follows a strict parameter in terms of the quality of solutions offered by the concerned vendor, the reputation of the supplier in the market, the price, etc. In addition to this, Lai also says that when the company gets an order from European customers, there are special guidelines, which the vendors have to follow when it comes to supplying of raw materials, i.e., they need to specialise in this area as well. “Such a procedure allows us to be competitive in the market and offer solutions and technologies of high quality,” she says.

Expansion Plans Speaking on the total production capacity, Lai says, “The total production capability of the factory is to manufacture 300 machines per year.” Adding further, she said, “We are building another factory in Taichung to improve our production. It is expected to be completed by the end of this year or by early next year around January.” Currently, the company has its other production factory in China, which looks after the markets there. Referring to the company’s interest in the Indian market, Lai said that they have not yet finalised any specific plans to enter the Indian market.

Selection of Supplier In terms of choosing a new supplier of

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INSIGHTS & OUTLOOK DEFENCE EQUIPMENT MACHINING 72 76 78 80 84

Snap Shot

Waging Towards a New Generation of Manufacturing anufacturing

Machining Saga

Strengthening India’s Defence Needs

Web Services Collaboration

The Future of Midsize Manufacturers

Defence Component Provider

Shifting Gears to Seize India’s Defence Potential tential

Machine Tool Probe

Minimising Error Using Probes...

December 2012 - MMT

INSIGHTS & OUTLOOK Snap Shot

Waging towards a new generation of manufacturing The Indian defence industry is at its glorious best. As the government-dominated industry is opening up to private sectors, the industry is going through a gigantic change. With so many new things happening in this field, here is a look at some of the latest happenings of this industry. HMT manoeuver towards defence manufacturing Public Sector Hindustan Machine Tools Ltd (HMT) is gearing up to undertake the manufacture of weapons and ammunition like rifles, missiles components and shells as part of its diversification plans. The company is in its advanced stage of discussions with institutions like Defence Research and Development Organisation (DRDO) to manufacture defence items. MD Sreekumar, Managing Director, said that DRDO passes on technologies to industries through an open tendering process. “So far, we did not have the qualifications to participate in the tender. After the discussions, DRDO will permit us to participate in the tender. And we are confident that we have the expertise to absorb the technologies,’’ he said. The weapon manufacturing assignments would be mainly carried out in the Kochi, Bengaluru and Hyderabad units. HMT was also planning to enter the manufacture of critical components in the nuclear industry like centrifuges and manipulators. The company is in talks with some leading global players in the machine tool industry to form joint ventures for technology transfer and manufacture of high-tech machine tools in the country. “We are confident of inking at least three MoUs with firms from Japan, Korea and France before the end of the current year,’’ Sreekumar said.

US-India defence ties strengthen, more arms trade US Defense Secretary Leon Panetta recently promised to let India buy America’s best weapons technology and jointly produce and develop equipment in a bid to increase trade with the world’s top arms importer. “The United States is firmly committed to providing the best defence technology possible to India. We are both leaders in technology development and we can do incredible work together,” he said, during his visit to India. Both the countries are close partners on defence issues with some $8 billion of arms sales under their belts. The friendship between the world’s two largest democracies is viewed with caution by Beijing, where some in government fear that India is part of a US strategy to limit China’s rise on the world stage. India is spending about $100 billion over 10 years on modernising the military, in large part, with an eye on China.

US offers 245 Stinger missiles to India The US offered 245 Stinger missiles to India as part of a weapons package for the Apache attack choppers being acquired by the Air Force. India has selected the American Apache helicopter for its requirement of 22 attack helicopters,which will have both air-to-ground and air-to-air roles in the service. The American helicopter edged out the Russian Mi-28 in the race for the IAF contract. The surface-to-air version of the Stinger missile is widely credited for the collapse of Russian helicopter fleet in the Afghan war in the 1980s and was also used by Pakistani troops to bring down an IAF Mi-17 helicopter during the Kargil war in 1999. Under the Modernisation of Air Field Infrastructure (MAFI) programme, India plans to upgrade 30 military air fields to enable them to carry out night operations and operate largebodied planes such as the C-17 Heavy-lift transport aircraft.

ITI Ltd seeks `6,000 crore to produce defence equipment Ailing telecom equipment maker ITI Ltd has sought `6,000 crore from the government to diversify into manufacturing products for defence services and pay salary arrears to its employees. ITI Ltd submitted a plan to the Department of Public Enterprises (DPE) asking for `6,000 crore to manufacture and supply technology equipment required by the defence services and also to pay arrears to the staff. The loss-making PSU was mainly providing telecom equipment to MTNL and BSNL. But now, due to less number of orders from these firms, ITI wants to undertake projects related to defence sector, they added. In the last five years, the government had infused about `4,000 crore in the company for its revival. However, there has been no improvement in the health of the company.

MMT - December 2012

Snap Shot New defence procurement procedure in early 2013 A top defence ministry (MoD) official revealed the Defence Procurement Procedure of 2011 (DPP-2011), which governs the buying of military weapons and equipment, would be modified in early 2013. “The Defence Procurement Policy is undergoing changes, and the 2013 edition of the DPP will come out early next year,” said Air Marshal M Matheswaran, Deputy Chief of the Integrated Defence Staff (IDS), addressing a KPMGorganised defence industry gathering. The new DPP would liberalise defence procurement further. This conformed to industry expectations, as it has been the trend in successive modifications to the DPP in 2005, 2006, 2008 and the currently valid DPP-2011. Matheswaran urged the private industry to focus less on the high value, high technology weapons platforms (eg., aircraft and tanks) on which considerable defence money is spent. Instead, he suggested that the private industry should emulate the automobile parts industry by setting up manufacturing units that were part of a global supply chain. These small units would form the backbone of a countrywide defence industrial base. In the MoD’s planning, such a defence industrial backbone is crucial for maintaining, repairing, overhauling and upgrading the complex defence platforms that are currently being bought from abroad and manufactured under licence in India. “Rather than focusing on large weapons systems integration and manufacture as the only way, I think we need to break down the supply chain into many component parts, so that we become part of the global supply chain. If you look at the Indian military as the only source of your order book, then you’re not going to have continuous orders for any length of time,” said Matheswaran.

Boeing wins IAF heavy-lift chopper deal Boeing’s CH-47F Chinook helicopter has beaten out Russia’s Mi-26 in India’s $1.4-billion heavy-lift helicopter competition. The Chinook and advanced version of the Mi-26 helicopter were put to flight trials last year in desert and high-altitude terrains. The Indian Air Force will use the 15 heavy-lift helicopters, with delivery to be completed within 54 months of the contract signing, which is expected to occur by March. The Chinooks will replace India’s existing Mi-26 fleet, more than two dozen helicopters purchased in the 1980s and the majority of which have been grounded for lack of spares. Capable of carrying more than 45 fully equipped troops, the Chinooks will be able to cruise at 230 km per hour, an Indian Air Force official said. The selection is one of several recent wins for US firms in India. In October, the MoD finalized the selection of 22 Boeing AH-64D Apache helicopters over Russia’s Mi-28s in its $1.3-billion heavy duty attack helicopter programme. The US has contracted weapons and equipment sales of more than $8 billion in the past four years, including a $4.1-billion contract to sell 10 C-17 transport aircraft to the Indian Air Force.

Sweden’s SAAB invests in Pipavav Defence SAAB has invested `202 crore in Pipavav Defence and Offshore. Pipavav issued `2.45 crore shares to SAAB at `82 per share, which is at a premium of 7.75% to the average six month’s weekly closing price of Pipavav’s stock price. With this share issue, SAAB will get 3.5% shareholding in the Indian company with an option to increase it further at a later stage. SAAB is a global leader in military hardware and will bring in advanced proprietary technology in India through the company, which will immensely benefit India’s armed forces. The two will also look at exporting military hardware. According to Pipavav officials, this is the first strategic investment made by a global defence major into an Indian company focusing on defence production. Pipavav already has a joint venture with Mazagon Dock in Mumbai to execute their Naval warships production orders worth `60,000 crore.

HAL signs design phase contract with Russian firm Indian aerospace major Hindustan Aeronautics Ltd entered a preliminary design phase contract with its Russian partner United Aircraft Corporation for development of a multi-role transport aircraft. With this, HAL and UAC-TA will start the preliminary design work immediately at Moscow. The HAL design team consisting of 30 designers will be positioned at UAC-TA. The primary objective of the project is to achieve self-reliance in design, development and production of aircraft of this size and also to manage the programme with international collaboration and large number of global suppliers. India and Russia had signed an inter-governmental agreement in November 2007 to design, develop and produce the multi-role transport aircraft (MTA) in the 15-20 tonne class. India’s HAL and Russia’s UAC-TA were to produce 205 such aircraft to meet the requirements of 100 aircraft for the Russian Air Force, 45 for the IAF and 60 for other countries. After completion of the agreed work share of the PDP contract in 10 months, the Detail Design Phase (DDP) contract would be signed to complete the design and development of MTA. December 2012 - MMT

INSIGHTS & OUTLOOK Machining Saga

Strengthening India’s Defence Needs The Indian manufacturing industry has been one of the largest contributors to India’s economic growth. The industry has significantly grown over the last decade. While this sector contributes 16% to GDP, the industry aims to grow in stature by culminating its share to over 25% over the next decade. To achieve this aim, the industry has constantly diversified its operations. Among all, the growing defence manufacturing sector has today become one of the most significant areas for the industry. Debarati Basu takes a look at how the industry has grown and what it promises to the Indian economy.

he Indian aerospace industry lately has been giving unremitting attention to defence manufacturing. The sudden outburst of interest among global OEMs towards testing the potential of Indian manufacturing has given the country enough reasons to take the opportunities into account. Given the strategic geographical positioning, India has been one of the highest spenders of defence. Over the last five years, equipment spending by the Ministry of Defence has increased at 15–20%, and is expected to grow further. With continuous modernisation programmes in the pipeline, there is a projection of an investment of USD 76

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80–100 billion in the next five years. Apart from manufacturing, the country is also among the largest arms importer in the world. As per the projections, it is expected that India would become the third largest defence spender after the US and China by 2014. Right from satellites, aircraft and other requirements for the armed forces, this gives a huge opportunity for the Indian market to grow. The enormous global competition has given the Indian manufacturers a significant piece of the pie. The country, overall, has nine Defence Public Sector Undertakings (DPSUs) and 39 Ordnance Factories. However, with the demand continuously

growing, large government setups have been beating the odds to match the production output with the demand. The government has finally realised the need for private participation. The Defence Production Policy 2011 reiterates the strategic and economic importance of self-reliance in the area of defence. However, the government is yet to garner confidence on Indian manufacturers to entrust highly complex manufacturing on them without supervision. In this race, the foreign OEMs have been making the most in the bargain.

Meeting the Need of the Hour Defence equipment manufacturing is still

Machining Saga in its nascent phase. While the industry is still trying to understand and adopt the nuances of the industry dynamics, the sudden interest of the global market has left the Indian industry questioning its role in the manufacturing set. The game has just begun and the Indian industry is yet to know the rules. There are a lot many things that the Indian industry still needs to change in its entire set-up to encourage the business inflow and the overall growth of the industry. Some of the areas that require immediate attention are: Making DPP policy industry friendly: While the Defence Procurement Policy has been compiled keeping the growth of the industry in mind, the policy is yet to garner clarity among the players of domestic and foreign industries. The domestic players still find themselves at the periphery of the global cauldron of opportunities. On the other hand, the foreign players are still seeking transparency and clarity in the DPP policies. Single window operations: This extensively guarded sector has just opened up to the private industries. The various layers of processes have made the entire chain of project approval a tedious task. There is need to streamline the process at the level of offset implementation to hasten the project. Strengthen Indian manufacturers: As per the DPP scheme, any foreign company getting a project needs to offload 30% of the work to domestic companies. However, is our domestic market ready to take up a task of such complexity? Every government organisation involved in defence manufacturing needs to come up with programmes that would strengthen the manufacturing capabilities of the domestic players. This will also give assurance to foreign players to tie up and offload their work to domestic players with full confidence.

Increasing the FDI Limit for

Foreign Participation The FDI limit has always been an issue with the industry. The current upper cap of 26% on FDI in defence production needs to be relaxed to 49% to ensure adequate participation of interested parties on case to case basis. Bring in technology: There is a daunting need to significantly upgrade our technology. Measures need to be taken to transfer critical global technologies to India and help build our capability in this field. Create infrastructure: None of the measures will be successful if the industry does not have the adequate infrastructure. While there are tasks taken up by the government to boost business in this sector, there needs to be proper infrastructural development in the country.

The SMEs form the major link in this entire manufacturing chain Hand-holding Indian players: Despite foreign participation, the Indian companies need maximum support from their own government. While the country has its defence demands soaring high, the private Indian companies are still not able to garner the government’s confidence in them. Most government work is being outsourced to foreign OEMs but the same is not coming to domestic players directly. “Most of the work which comes to private Indian players is offloaded from HAL or foreign OEMs. Even though we have the capability to take up manufacturing, Indian companies are not the first choice. But since we anyway undertake manufacturing indirectly, the government needs to have more confidence in us and give us a portion of work directly. This will ultimately help the industry to grow,” says SM Kapoor, CEO - Aircraft Manufacturing Complex, TAAL. Giving an instance he adds, “We have manufactured the first four

prototypes of Nishant UAV from the scratch. But as per the protocol, the production order will be given through tender system. So, even though we have built our capability and technology in the manufacturing of this project, we may not get the order. Instead, the order might as well go to a foreign OEM, which has to start the project from square one. If the government does not show confidence in Indian players, how can we have confidence in our government?” Strengthening SMEs: The SMEs form the major link in this entire manufacturing chain. With a huge proportion of work coming to the SMEs of the country, the industry segment needs to be prepared technologically and financially beforehand to confidently undertake major projects. This will also be a strategic way to encourage job creation. According to a report, if India can achieve its objective of meeting 70–80% domestic supply in defence, the indigenous production would need to expand by an average of 30% a year. This will result in the creation of approximately 1.2 lakh new jobs. NASSCOM estimates that this would result in 3.5 lakh indirect jobs. Hence, a total of 0.5 million jobs could be created in the next five years alone.

Future Prospects The need for modernising its defensive capabilities, India’s armed forces are expected to increase their purchases of new equipment and technology in the coming years. As per details with the Ministry of Defence, since the introduction of offsets, contracts worth `14,146.22 crore have been concluded so far. And this is certainly just the beginning. A tremendous amount of opportunities is about to spur into the growth of the country’s defence industry. It is only by supporting the country’s own capabilities can the defence sector create a strong platform to support the growth opportunities waiting at our threshold. debarati.basu@network18publishing.com

December 2012 - MMT

INSIGHTS & OUTLOOK Web Services Collaboration

The Future of Midsize Manufacturers Why are Web services so important to manufacturers, particularly in the Aerospace & Defence (A&D) sector? For midsize manufacturers who supply to A&D manufacturers, there are big incentives for driving electronic collaboration more firmly into their supply chain. Web services collaboration is fast becoming a necessity in the business world.

he A&D industry is an emerging market in India, with the Indian military expected to spend roughly $80 billion over the next four to five years. India competes internationally with worldclass manufacturing facilities that meet international standards for quality, productivity and cost. This means that India is rapidly developing into a manufacturing hub for corporations worldwide who want to leverage Indiaâ&#x20AC;&#x2122;s proven skills in product design, reconfiguration and customisation with creativity, assured quality and added value.

A&D Manufacturing in India Driven by factors such as human resources, a distinct cost advantage, IT competitiveness and progressive policy changes like liberal laws in Special Economic Zones (SEZs), India provides attractive fiscal benefits to developers and manufacturers. India has emerged as one of the most promising markets for global A&D companies. Indiaâ&#x20AC;&#x2122;s fundamental strength lies in the large number of small- and medium-sized enterprises

supplying A&D manufacturers at subcomponent and component levels. These companies are gradually transforming themselves into major players in this sector through the use of cuttingedge technologies to become suppliers for global A&D companies vying to outsource products and components to India.

Critical Problems Faced The Indian A&D manufacturing sector continues to face challenges, which include increasing cost of energy and raw materials, the ripple effect of the decreasing value of the US dollar, access to technology and funding and the certification processes essential to their success. As the A&D sector is a precisiondriven industry, mid-market manufacturers providing components to large manufacturers have to be precise with planning and delivery. The sector needs flexible manufacturing systems that deliver high-quality and quick output while keeping costs u n d e r

control. Manufacturers also have to keep pace with varying production schedules as they participate in a complex global supply 78

MMT- December 2012

chain. Due to the high cost of the final product, the quality of individual parts becomes critical. Therefore, being able to track parts is essential, and it requires the use of proven technology solutions. At the same time, mid-market manufacturers need to leverage the advantages arising from the globalisation of the A&D supply chain. They need to adapt to these challenges by incorporating more and more elements of advanced technology.

Web Services: Robust Technology Framework In manufacturing technology, organisations and systems are connected through Web servicesâ&#x20AC;&#x201C;a specific function that is delivered over the Web to provide information or services to

u s e r s . Web services is the most important technology for optimizing manufacturing value chains. They allow the sharing and communication of data without hampering the privacy and security of the information and participants. This facilitates the integration of systems and helps to orchestrate the flow of information across the manufacturing value chain at

Web Services Collaboration an affordable cost. Leading technology providers are uniquely positioned with a complete suite of applications based on 100% Web services technology, thus protecting their customers’ investment in software and services well into the future. With the rapid development of communication technologies, the Internet has become ubiquitous and instantaneously accessible. Together with the rapid growth of online information sources, the Web services model is a desirable approach to connect remote software applications and information sources and t o

utilize w e l l established I n t e r n e t protocols and commonly used machine-readable representations. The potential of next-generation software applications is increasingly being realized by software vendors with Web 2.0. Advanced technology helps to leverage Web resources beyond information services and uses the Internet as an integrated system that brings multiple sites and services to a single platform. This collaborative approach provides a secure platform for the interaction and exchange of information seamlessly. Web services also make information more readily available to wireless and other mobile devices. By streamlining processes and creating a single platform for information sharing, workforce productivity improves, resulting in enhanced value chain performance.

Web services allow for dynamic integration between applications without costly and time-consuming programming. By reducing implementation times with simpler installations, Web services can accelerate the return on software investment for mid-market companies. With Web services, integration is not limited to within the four walls of the enterprise; rather, businesses can integrate processes with customers and suppliers up and down the entire value chain, beyond the firewall, improving inter-enterprise collaborative capabilities. This integration can be achieved without having to understand the specifics of how suppliers, partners and customers built their own IT systems. For example, a distributor could streamline its supply chain management by outsourcing inventory fulfilment simply by authorizing the partner’s system to use the distributor’s Web services over the Internet. In this accuracy-based industry, technology can be a key advantage and differentiator. Significant time savings can be achieved by implementing available technology suites. It also makes it possible to access vital data like costing information within the system, which helps free up valuable resources so that emphasis can be placed on growing revenue. Manufacturers are able to streamline business operations and interactions with customers, suppliers, partners and employees through easyto-deploy Web applications that give businesses new levels of flexibility, control and inter-enterprise integration. A key concept of the Web services model is its use of the Service-Oriented Architecture (SOA) model in which information sources and software functionality are delivered as distinct service units distributed over a network and combined to create business

applications for solving complex problems. SOA facilitates interoperability among information sources and systems, which are converted into modular and flexible service components that can be requested through a standard protocol. The components can be reused by multiple applications or other services within a network. They can be

“

With the rapid development of communication technologies, the Internet has become ubiquitous and instantaneously accessible.

“

updated or replaced without changing the functionality or integrity of other independent services. Reusability enables modular system and application development, and is essential for building a flexible system for dynamic supply chains. Web services and SOA also mean that the integration process is easier and less costly. Integration and openness are two key factors in the total cost of ownership equation for enterprise software solutions. With the introduction of Web services, applications not only communicate among themselves more seamlessly but also share information with external systems in a faster, easier and more cost-effective manner. Since organisations look to use Web services for deployment, speed, stability, reusability and more, Web services collaboration is fast becoming a necessity in the business world.

Vineet Fogat joined Epicor Software Corporation as a result of the company’s acquisition of Scala Business Solutions in 2004. During his long tenure with Epicor, Vineet has worked in different roles for Epicor in the Middle East, including customer account management and new business acquisition.

December 2012 - MMT

e India’s z i e S De o t s

Poten t i nce a fe

ng Gea i t f i Sh r

INSIGHTS & OUTLOOK Defence Component Manufacturer

Indian is among the top ten countries in defence expenditure, and ever since the government opened the defence sector to private and foreign investors and set a challenging target of achieving 70% indigenisation, the industry has given birth to many SMEs catering to the defence sector. Nishant Kashyap provides an insight into the opportunities created by the industry for machine tool builders.

ndian defence market presents a huge opportunity for Indian and foreign manufacturers. India spends 2.14% of its GDP on the defence budget. According to a PWC report in 2012-13, the budget for defence has increased by almost 17% to reach $38 billion. India is one of the largest importers of conventional defence equipment and spends about 40% of its total defence budget on capital acquisition. Around 70% of its defence requirements are met through imports.

Benefitting Component Manufacturers The Defence Procurement Procedure (DPP), 2011, issued by the Ministry of Defence (MoD), which deals with requirements of all capital acquisitions, has adopted an offset policy, which 80

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applies to all capital acquisitions by the MoD, categorised as Buy (Global) or Buy and Make with Transfer of Technology, where the estimated cost of the acquisition proposal is `3 billion or more. While in the case of ‘Buy Global’, a uniform offset of 30% of the estimated cost of the acquisition is the minimum required value of the offset, in ‘Buy and Make’ category acquisitions, 30% of the foreign exchange component will be the minimum value of the offset. In terms of DPP, the offset obligations can be, inter alia, discharged through combinations of (a) direct purchase of or executing export orders for eligible products and components manufactured by Indian industries or (b) direct foreign investment in Indian industries for industrial infrastructure for services, co-development, joint ventures and

co-production of eligible products and components. Further, for the discharge of future obligations, OEMs can create offset credits, which can be banked and will remain valid for two financial years. According to Shivpriya Nanda, Partner, J Sagar Associates, “With the offsets policy, the sheer volume of planned expenditure will create new opportunities for Indian firms, enabling them to have broader market access and platforms that can be met by foreign firms. The DPP has further liberalised the policy as it entitles an OEM to choose its Indian offset partner, change the partner in exceptional cases and choose any combinations for discharge of offset obligations.” “Although the offset policy appears to be quite liberal in its approach, it is still viewed with an element of conservatism. In contrast to acceptable global practices,

Defence Component Manufacturer the offset policy does not permit indirect offsets and technology transfer through offsets. This implies that discharge of offsets will be primarily through the export of defence goods and services. Since the present Indian defence exports expenditure amounts to $50 million annually, it will be difficult to convince OEMs that the Indian defence industry can absorb offsets worth billions of dollars. One cannot ignore that it is primarily in defence technology that India needs to achieve its objective of 70% indigenous production. However, the government has neglected this significant aspect and does not accept technology transfer under its offset policy,” Nanda further adds. As part of its efforts, the MoD proposes to permit transfer of technology as a valid offset; extend by two years the period within which vendors must discharge their offset obligations and extend the validity of banked offset credits to seven years (as compared to the existing two years).

Need Gap The Indian manufacturing sector today is globally competitive with international quality standards, efficiency and manufacturing facilities. The country is fast developing into a manufacturing hub for world corporations wanting to leverage on the sector’s proven skills in product design, reconfiguration and customisation, thereby assuring quality with value. The defence expenditure and changes in policies have created huge demand in the country, which is the reason why many companies are entering the manufacturing of aerospace and defence components. The aerospace industry, which calls for high-precision machining, requires equally high-end machines and technology to strike the equilibrium between the demand for quality and technology. Although Indian components have been accepted in the global market, they still need to graduate from lowcost secondhand machines to high-end technology. “At present, even HAL is not in a position to support the 30% offset 82

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The Indian manufacturing sector today is globally competitive with international quality standards, efficiency and manufacturing facilities. business. There are countries like China, Brazil who have an offset clause of 100% and above and meet the requirements. Indian component providers, though ready to grab the opportunity, have not geared up fully in terms of technology. May be a better FDI option shall enthuse foreign partners to invest more in JV operations in India. A consortium approach by the Indian manufacturers can get them good business, rather than individual aspirations. Something similar to the EADS model could definitely help the Indian aerospace component manufactures in the future,” says Sudhindra Haldodderi, a former DGM (Design), HAL and a former Scientist/Joint Director DRDO, who currently teaches Aerospace Engineering at Alliance University. To capture the defence market, component providers have to initiate and carry out more R&D activities to pump in additional investments to recruit technical and highly skilled manpower dedicated to this segment, constantly interact with the aerospace machining industry, give additional and adequate training to their workforce, generate innovative ideas from within the organisation, create awareness among the workforce about the aerospace requirements and the quality issues, to sustain the market competition.

Instant Prospects To mitigate the constraints of capital, capacity and capability, the government has already opened the sector to private participation. Tata, Mahindra and Hinduja are groups with strong financial credentials that have entered into various alliances for manufacturing parts and assembling machines under offset agreements.

Defence equipment and aerospace component manufacturing have created high demand for the machine tool building industry. This spells good news for OEMs. The machine tool building industry earlier focused on the general engineering, automotive, tool, die, mould, capital goods, consumer durables and intermediate goods sectors. Much of the growth in the machine tool industry came from these sectors. All these sectors need high-production, low-cost machine tools. These machine tools are produced and sold in significantly higher volumes with decent profitability. However, the needs of the defence and precision machining market are a little different; they need high precision machine tools, which are produced in low volumes, but fetch higher profits. This again calls for high volume of machine tools as well as good business opportunities for machine tool builders. According to Haldodderi, “If someone is looking for a challenging business environment, there is a huge space available for him/her. Two to three decades from now, India could be a major hub (other than China) for all the aerospace components. But this business is highly capital incentive, and the volumes are low. At the same time, margin or returns are high compared to the automotive business. Those who plan to expand their business from the existing ones can always take a call on aerospace business. I feel there is a greater recognition when you are associated with aerospace business.” With the support of the state in areas such as technology development, tax incentives, establishment subsidies and access to state-owned resources (both infrastructure & intergovernmental alliances for design and manufacturing) and a focused & clearly articulated policy commitment to the sector, Indian component manufacturers should be able to establish a strong presence in the global aerospace market over the next 10 years from what, on the surface, appears to be a small beginning. nishant.kashyap@network18publishing.com

INSIGHTS & OUTLOOK Machine Tool Probe

Minimising Error Using Probes...

The OMP60 and OTS optical tool setting probe on a machine tool at Associated Tooling.

Associated Tools, a Kolkata-based Indian manufacturing company, uses BFW, LMW and Hurco machine tools, each one fitted with Renishaw touch trigger inspection probes and tool setting systems, for supplying products to the defence industry. Ever since it adopted the machine tool probes, Associated Tools has benefited from an elimination of component rejections and a 66% reduction in tooling set up times.

he demand for the production of defence components is growing by the day in India, and by their very nature, precision manufacture of these components is critical. HJ Bishnu, Director, Associated Tools, took on the responsibility for the manufacturing unit in 2005 and filled the company’s workshop with the very latest manufacturing technology, including LMW, BFW and Hurco CNC machine tools—all equipped with a variety of Renishaw touch trigger probes and tool setters.

Investing Only in Machines Not Enough When he first took charge, there were 84

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various issues surrounding the production techniques. Bishnu recalls, “After investing so much in CNC machines, we were still facing problems with slow machining cycle times, setup idle times and inconsistencies in quality and operator errors.” Initially, the process of loading

Challenges

Manual indexing and a manual dialling system with nine indexing positions consumed a lot of time Set up was slow and inefficient Manual indexing and operator errors resulted in inconsistencies in quality and rejection rate

components required manual indexing and a manual dialling system with nine indexing positions. Each manual indexing process took around 45 minutes. This, followed by a further 30 minutes while the machine checked the position, made the set up slow and inefficient. In addition, the result of manual indexing and operator errors meant that the inconsistency in quality was 5% and the rejection rate, 1.5%. The tool setting process was also manual, which again contributed to time delays each time a new tool was set. Before long, Bishnu, realised that investment in CNC machine technology alone was not enough. He had visited SECO, Pune, and had seen first hand the benefits of Renishaw’s touch trigger and tool setting probes, and decided they

Machine Tool Probe

Solutions

Introduction of a CNC 4th axis and OMP60 made indexing automatic Component setting time reduced substantially Rate of scrap almost nil Increased accuracy Optimised tool life

would have a great impact on his own machining process.

Dramatic Results With the introduction of Renishaw’s OMP60 touch trigger probe and OTS contact tool setting probe, Associated Tools began to see dramatic results. Introduction of a CNC 4th axis and OMP60 made indexing automatic. For every indexing position, the reference point is set automatically, meaning that the component setting time is reduced to 20 minutes and the rate of scrap is reduced to almost zero percent. The cable-free OTS optical tool setting and broken tool detection probe also brought about successful process improvements; the tool setting time was dramatically reduced and also benefited from increased accuracy. Even the tool life was optimised.

The cable-free OTS optical tool setting and broken tool detection probe brought about successful process improvements. Associated Tools: Well Placed to Compete for High Accuracy Work With two decades of experience in manufacturing valves, a special unit for manufacturing products for the defence industry and increased accuracy and decreased set up times resulting from Renishaw probing techniques, Associated Tools is now on track for growth. With the focus on manufacturing and supplying components to factories in Kolkata, Ishapur and Thirchi, Associated Tools aims to double or triple its defence unit turnover. Associated Tools is well placed to compete for high accuracy work. Bishnu adds, “Since we started using Renishaw probes and software, we have been able to consistently manufacture critical components for the defence industry. There has been a reduction of 66% in set up time and we have stopped talking about component rejections and manual errors, as these have been eliminated completely.”

Outstanding Efficiency Associated Tools has proven how the correct integration of Renishaw’s touch trigger probes and broken tool detection systems, in combination with the innovative software required, can result in a highly efficient system for the manufacture of precision components for the defence industry. Courtesy: Renishaw Metrology Systems Pvt Ltd December 2012 - MMT

STRATEGY Machine Tools Business

Attracting New Age Technocrats Is it your goal to enter the machine tools business? Are you passionate enough to join the success story of this business? It takes time, skill, effort and, most importantly, passion, but it can end up being a highly profitable business. Nishant Kashyap provides insight into what it takes to become a machine tool entrepreneur.

he famous business tycoon Ratan Tata once said, “I do not believe in taking the right decisions. I take decisions and then make them right.” Entering the machine tool business can be the right decision as the industry is growing at rapid pace and customer demand is increasing. The only things you need are passion, enthusiasm and the skill set of entrepreneurs from the 70s and 80s. The machine tool industry is known for its entrepreneurs. Most of the companies in the machine tool industry were started by individuals who were technically advanced, and 88

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this is why machine tool entrepreneurs have always been considered as ‘Techno Entrepreneurs’.

Why Machine Tool? The machine tool industry has always been considered as the ‘Mother Industry’ or the ‘Back Bone Industry’ since everything around you has been touched by machine tool in its manufacturing process. The machine tool industry is a customer-driven industry and has found customers in almost all the sectors or, at least, is associated with the overall manufacturing ecosystem. The automobile industry consumes

about 60% of machine tool, while other industries like infrastructure, energy, consumer durables, electrical & electronics, aerospace and engineering components are gradually catching up in the country, thus creating huge demand for machine tool. According to Kumar Ramachandra, Founder & Director, Wintegral Engineering Pvt Ltd, “Machine tool is the mother of manufacturing and is strategically very important for the economy of a nation. Machine tools are indispensable and the ‘least common denominator’ to most industries such as automotive, aerospace, medical, mining, military,

Machine Tools Business railways, capital goods, electronics and white goods. As we are aware, without a strong manufacturing base, it is almost impossible to achieve inclusive growth. So, India will have to commit itself to increasing its manufacturing-to-GDP levels from 14% to around 20–25% soon.” According to projections—the Indian machine tool industry ranks 13th in production and 7th in consumption— the industry believes that by 2020, India will be the among the top five markets for machine tool. These figures clearly highlight the opportunities available in India. This industry is growing with time; yet, it has a lot of ground to cover before achieving a significant position in the global market. The availability of skilled manpower provides the required thrust to propel India forward. The Indian machine tool industry has always been an import-driven sector owing to the technological advancement of global giants. However, in recent times, some of the Indian companies with technological collaboration and tie-ups with MNCs are gradually becoming the major players in the nation’s machine tool sector.

Getting Things Right When you think of starting a business, the first thing that comes in mind is ‘where’? You should always consider a place where your product will have demand. In the case of machine tool, the best location is where there is a requirement for automobile and related industries. Apart from this, there are other sectors that also demand for machine tool in heavy engineering, engineering goods, aerospace component and energy-related equipment. In India, the biggest machine tool hubs are Bengaluru, Pune, Rajkot and Ludhiana, while other regions such as Aurangabad, Hyderabad and Chennai are catching up. Apart from the customers, there are many other important aspects to consider, such as availability of land, water, skilled manpower, enough electricity and, the most factor, raw material providers and related

component vendors. While starting a manufacturing base, one can also look at government subsidies and support for SMEs and new entrepreneurs.

1 billion people. India is losing out on opportunities in manufacturing owing to this,” says Ramachandra.

Government Support Beginner Challenges There are many challenges when starting a machine tool business. The machine tool industry is a technologydriven industry; almost all companies formed in this sector were set up by techno entrepreneurs. Apart from mechanical engineering, machine tool technocrats also need inputs from electrical, electronics, metallurgy and tribology engineering. If you want to enter this business, you have to possess good technical skills. As far as India is concerned, we still lag behind in terms of technology; this is also one of the biggest reasons that foreign companies hold approximately 70% of the market share in India. According to Ramachandra, “There is a big technology gap that exists between India and machine tool superpowers such as Germany, USA and Japan. One needs a careful understanding of this technology gap. Today, India is full of opportunities for the keen-eyed entrepreneur; this technology gap is one such opportunity. It may not exist 10 years from now, but it exists today. Gaining a correct perspective of this is the main job of an entrepreneur.” The main challenge in the Indian machine tool industry is skilled manpower. There can be two reasons for the lack of the same: a poor education system and the fact that young engineers do not consider it to be a lucrative career option. The industry needs more qualified manpower on the shop floor. “The machine tool industry is special because it requires relatively more qualified manpower, especially shop floor manpower, as compared to many other sectors of manufacturing. However, there is a great lack of machine-tool-literate labour in India. This dearth for manpower is posing a very stiff challenge for growth, especially for SMEs. There is an urgent need to address this ironical manpower deficiency in a country with more than

The Government of India understands and appreciates the significant contribution made by the various SMEs in terms of employment generation, technology development and fostering a spirit of competitiveness among Indian entrepreneurs. Apart from the many initiatives taken by the Indian government to encourage entrepreneurs in the sector in terms of subsidies and tax liabilities, financial support has also been. But there are still many loopholes in the policies and support that the industry is seeking. “It is important for the government to understand the need for a large number of world-class training centres. I would expect deeper government funding for developing world-class training institutes with the latest equipment and infrastructure in Tier I and II cities, which would create skilled jobs. The government can also take proactive measures such as partnering with private companies in this sector and encouraging them with sops to set up training institutes with world-class apprenticeship programmes. So, if the government came forward to upgrade and create competent manpower that is freely available, it would be very encouraging,” says Ramachandra.

Get Ready! India has established itself to capitalise on the new opportunities in the global metal working industry, owing to the advantages it holds in low-cost manufacturing certification. Now, it is time that existing entrepreneurs get their act together and those who want to make it big in the industry, to take the plunge. Going by the statistics and the opportunities that the industry holds, the Indian machine tool industry’s future looks very promising. As for New Age entrepreneurs, this is the ‘Time to Capitalise on the Moment’. nishant.kashyap@network18publishing.com

December 2012 - MMT

INSIGHTS & OUTLOOK Energy Management

Maximising Proﬁts Skillfully In today’s day and age, we need to be practical with our resources. It is easy to say that using alternate sources of energy may be good enough. However, utilising energy efficiently, especially in an industrial environment, requires a proactive approach. There is constant talk about reducing the carbon footprint. But in actuality, how can this be achieved? Nedra Pereira looks at the latest trends the tooling industry is currently following or trying to implement...

he manufacturing industry accounts for a large portion of energy consumption. Energy conservation or management is very important in order to increase manufacturing efficiency, flexibility and responsiveness. Some may 90

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think that replacing old machinery with new ones may be the ideal solution or perhaps using a heavy-duty motor with the machine will bring optimum output, but this is not always true. Managing and planning power consumption can not only save money but also improve sustainability. However, limited material, human resources and capital can make it challenging for industries to adopt energy management. Moreover, because energy accounts for over 20% of production cost, effective energy management offers the potential for significant savings. In addition to technological improvements like motors and spindles in machines, companies need to look at improving their overall energy management by looking at the whole picture— manpower, process or machine design, productivity improvements and costcutting measures on essential additional energy consumption.

Skilled Manpower Having knowledgeable and skilled staff definitely boosts productivity. Knowing the system well allows you to make optimum use of your machine and also increases tool life. Nikul A Malvi, Director, Wonder Writing Wicks (India) Pvt Ltd, whose company relies on semi-automated machines, avers, “One needs to gauge well what is required from a machine, running it with a heavy-duty motor may not be necessary and should be done in accordance with the need of production. Use of heavy-duty motors for applications that may not require them may cause more harm than good.” He adds, “Skilled technicians are important for the well-being of the machine. Without skilled technicians, the machines would not run at their optimal capacity and productivity would be affected. Uninterrupted running times for machines increase output.”

Role of Automation Energy consumption, productivity, labour costs, design control, quality of

the end product and safety in working conditions can all be brought about through automation. Automated systems enable a detailed systematic recording of all the operations and in-process controls, thereby avoiding quality issues. It also allows for highquality and high-accuracy output. Less labour is required and human error is also minimised, leading to reduction in costs, savings in power utilisation and increase in production rates.

Government Initiatives and Renewable Energy The Indian Government made significant advances in the conservation of energy. Government policies, campaigns by associations of the industry and strategic decisions by firms all contribute to sizeable ongoing improvements in the intensity of energy use. Additionally, the government has been very active in promoting the use of renewable energy by setting up solar power parks in Gujarat, Maharashtra and Rajasthan; the country already has a sizeable number of wind power generation plants. Renewable power generation can also be used to solve the power crisis in places where there are massive power cuts. Manufacturing sites, depending on their infrastructure and amenities, can have solar panels or wind turbines to self generate renewable power to help in energy management. It can be seen that energy management is possible and beneficial. The first step is to monitor and analyse where you can see potential for improving processes, be it through labour, automation or energy. Bigger or faster machines may not be the answer or solution to a problem. The next is to plan and strategise effectively— everything from skilled labour to uninterrupted cycle times. The last is to make use of government policies and initiatives to go green. This will not only save the environment but also reduce cost and increase productivity. nedra.pereira@network18publishing.com

Systems Approach: Improving Metalworking Productivity India has an emerging economy and is a developing country. With the GDP improving and liberal policies being formulated, the Indian industry is poised for growth. But the situation is changing the market scenario from a ‘driving market scenario’ to ‘market-driven scenario’. It is important for the growth of the economy that changes in business practices occur in the different aspects of manufacturing.

t is imperative that the manufacturing sector be a growth engine for the Indian economy to move forward. The machine tool industry and all its areas need to keep advancing to meet the international requirements. Even though the Indian manufacturing system has been evolving over the past 50 years, we still carry the legacy of the past production system— most of it is outdated. To change this legacy, we are making efforts to adopt Japanese manufacturing practices over the past 20 years. The Toyota Production System (TPS), Total Productive Maintenance (TPM) and some lean manufacturing techniques have been adopted with some success. We focus on machine tools—higher speeds, improved ball screws, chilled coolants, feedback mechanism and a closed loop system. But what is the extent of value-added time to the total time needed to produce a product or part? There are a number of non-valueadded activities that need to be analysed for streamlining to get business results. Benefits for a company can be categorised into two: industrial engineering benefit and business benefit. Reduction of the cycle times, i.e., reduction of non-cutting times and improved feed rates, will improve the industrial benefit. A number of cutting tools have been developed—CBN, Diamond and so on—to increase the cutting speed. If the inventory is kept 92

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between machines or if parts are stored and not made into finished goods and sold, then the benefit of increased speed, etc., will not be a benefit for the company. Hence, we need to look at the entire system—handling and reduction of inventory, faster conversion to finished goods and reaching the customer. Thus, a systems approach is needed to obtain the business benefit. Currently, resources, in terms of space, energy and manpower, are critical. Hence, we need to evolve the manufacturing systems focusing on efficient use of these scarce resources. Space productivity needs special focus to maximize asset utilisation or building space utilisation. Advances in machine tools like multi-tasking, next-generation cutting tools and near net shape processes can go a long way in enabling business achieve breakthrough improvements in space productivity. A leaner manufacturing system, in turn, helps in improving the manpower productivity as well. The machine tool industry should move in the direction of customisation options as they may become the need of the hour. The changing customer demands are another focus area for manufacturing. The end product user has a choice from a variety of products in the market. Consequently, as a product provider, the need to have a competitive edge in terms of quality and durability is imperative. How does this translate

to changes in manufacturing systems? It is through the demand for improved process capabilities, built-in inspections systems and closed loop controls. Thus, the development focus for machine tools should be on the aspects of engineering a machine tool capable of delivering customer requirements with quality and consistency. Many of the operations like washing of components and deburring are done separately, leading to additional machines and handling. We need to combine these operations in the same machine. Additionally, we need to debate the fundamental question of ‘why create a burr and then deburr it?’ Value stream mapping (V mapping) is one of the most fundamental systems approaches that help in achieving the business benefit. It can be applied at each cell or from end-to-end in a company. We find that the value-added ratio, which is the ratio of the value-added time to the total time (including the time element of the inventory), will enable a company to achieve the business benefit. Another approach is automation. It can be used to move a single piece or a small lot between machines and between cells. Automation needs to be approached with full focus as it requires component design modification. It is not a simple process to automate a running manual line as automation demands consistency of the parts. Investment needs to be minimal and

benefits gained from existing machines need to be maximised. Environment and energy also help in achieving business benefits. The demand for clean processes that are environment-friendly is being met through TPM and Total Quality Management practices. While lubricants of sufficient quality such as mist lubrication enable environment-friendly practices, we should also use coolant recycling systems. Stores, transportation and logistics will also reduce the valueadded ratio if we extend the calculation to the entire manufacturing chain. Therefore, we need to extend the ‘Small m’, i.e., machine tool, cutting tool, cycle time improvement to the entire manufacturing supply chain, i.e., the ‘Big M’. This will bring about sustainability and economic, environmental and social benefits for the company. To be sustainable, total employee involvement is a basic necessity. For total economic impact, teamwork brings out the best in employees.

Both these experts will be speaking at the Productivity Buzz held on December 8. To hear both these experts talk, attend the Productivity Buzz at the Bangalore International Exhibition Centre, Bengaluru, December 7-8, 2012.

So, the application of systems approach and moving from the Small m to the Big M will help achieve both— industrial engineering benefit and business benefit. As India is poised to be a manufacturing hub in the future, it is essential to look into new manufacturing systems approach of the Big M, which is a challenge for all industries. The curriculum of Engineering also needs to change by drawing in the current experience so that it brings about innovative and consistent practical engineers to take India forward. s.devarajan@tvsmotor.co.in

Dr S Devarajan, Head of Production Engineering, TVS Motors He has been working with the TVS group from the past 29 years and has set up facilities for press shop, welding shop, painting plants, heat treatment plant, machining of steel and aluminium engine parts and assembly lines. Dr Devarajan has also led many projects in TVS Motors and TVS Electronics. Presently, he is concentrating on lean manufacturing systems, TPM and JIT implementation in TVS Motors. He has done his BE (Mechanical engineering), MBA, MS and Engineering Doctorate (Manufacturing systems engineering from University of Warwick, UK) and has been awarded the prestigious ‘Rolls Royce’ award for excellence in manufacturing concepts and implementation in UK.

People Centric Productivity People centric productivity is the ratio of valuable outputs from a person in relation to the inputs and resources that he/she uses. Enhancing it will enable an unhindered flow of human energy towards worthwhile goals.

uman beings are meant to be highly productive. They are meant to be joyfully creative and productive and also give their very best. However, this often gets blocked because of unresolved issues and erroneous thinking and assumptions. There are two kinds of blocks to people centric productivity: inner blocks within the person and outer blocks in the organisation. When people understand the larger context of the work done by their organization and link it to their own personal vision and inner calling, energy and a passion for excellence are released.

In today’s fast paced life, a few spaces of

generative conversation are needed. Regularly stepping back, taking time to listen to each other and having free and relaxed conversations are necessary for creative energies to flow. Regularly connecting with the space of silence, peace and unboundedness within, through regular quiet time/ meditation brings us to awareness. This awareness transcends all our roles, concerns, issues, expectations and demands. Even the best of us sometimes forget what we have to do. Regular reminders and checklists area greatly improve people centric productivity.

Arun Wakhlu, Executive Coach and Master Facilitator, Pragati Leadership Arun’s career began with Nelco (1976-78) and he continued his stint with the Tata post 1980 as part of the Tata Administrative Service (TAS). He worked for Tata Motors, Jamshedpur & MAP Consultants, Pune, before eventually starting Pragati Leadership in 1986. Arun is a globally recognized trainer, coach and facilitator in Leadership and Organizational Transformation with over 25,000 hours of experience in facilitation and coaching. December 2012 - MMT

Achieve Success the Harada Way In order to survive the stagnant demand, globalization dynamics, increasing customer expectations, we need to perform to higher standards through constant innovation and excellence. This requires that people development be taken seriously by companies as they are the only true capital that will make you a Great organisation. Harada method is the Game Changer for building Great organisations.

hy is that only 3-5% people in the world are truly great and successful? What stops people from realizing their dreams and unlocking their unique creative potential? Why is there so much disenchantment with jobs and saturation of employee engagement levels? Low cost competitive advantage primarily based on blue/white collar labour in all sectors will not last long. Great Organisations Famous Irish philosopher Charles Handy stated: “The companies that

survive longest are the one’s that work out what they uniquely can give to the world not just growth or money but their excellence, their respect for others, or their ability to make people happy. Some call those things a soul.” Organisations such as Toyota, Pixar, Apple, SAS, Google, etc. truly live by these virtues. They generate a portfolio of unique successes and innovative magnetic products and services over long period based upon culture of respect, growth of their people and extremely loyal customer base. Ask yourself how many organisations would

How it all began... Takashi Harada was a track and field coach for high school kids in Osaka city, 2nd largest city in Japan. The school was the worst out of 380 schools in Osaka city. Located in very bad neighbourhood, children were least interested in even going to school. Parents were not good influence either. It seemed like a lost cause. He made a deal with the parents and principal that he will turnaround the school’s academic and athletic performance in three years, otherwise they can fire him. Harada was never able to coach his students to win the top championship title in Japan in his 15 years as coach. But he asked of himself that if other coaches can do it, why cannot he? A successful team comes not from great athletes but from having a great method and coaching process that helps develop students into great athletes. He created a systematic method for developing people to excellence called the “Harada method”. In next 5 years, from 1998 to 2002, his students won 13 Gold Medals and several silver and bronze medals at National level. Even after he left that school, the winning trend continued by following his method. He was able to predict accurately 12 times that his students would win even before the actual competition began. This incredible magnitude of achievement of winning so many medals and more importantly the personal transformations of students from no dreams, skills to national excellence was noticed by Japanese Organisations. They approached Harada and wanted the same kind of people development for all their employees. Since 2002, Harada has consulted more than 280 companies and 55,000 people in Japan.

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meet these holistic set of ideals and can call themselves Great. Open-mind Cup It is important for organisations to have open-minded culture in which continuous experimentation and learning with new ideas, methods etc. is routinely practiced and encouraged. Outside-the-box thinking tends to get shot down quickly by people pointing their weakness and why it would not work! Ask yourself how many times you hear “Yes, but...” or “No, because...” or simply “No!” People cannot grow and progress if their mind cup is facing down due to personal ego, conditioned beliefs, misuse of power and control and overconfidence of being an expert. More likely, there is no challenge to status quo and people/organisations operate within their comfort zone. Unlimited human potential cannot be realized in companies with their mind cup facing down. Mediocrity This can be seen at various levels of customer service even from so called premier organisations. For example, the relationship management service of banks, after sales services of capital goods companies, call monitoring or growing mobile services industry. They have the guts to ask for customer satisfaction codes or lock people in contracts since they find themselves in growing markets. Unfortunately, this does not help them to excel and differentiate from the competition and instead engage in marketing treadmill with their competitors and eroding profit margins. Operational excellence initiatives such as Lean, Six Sigma focus on process and tools and techniques, not on people. The

Coating Technology efforts hence hit a wall, and there does not seem to be a competitive advantage for the organisations as the ‘human link’ is missing. Employee Engagement Gallup’s 2010 State of the global workplace study shows that more than 55% people are ‘not engaged’ while level of actively disengaged people in the US is 18% and in India is 37%. The same study showed that personal well-being (suffering and struggling) is 38% in the US, while in India, it is 78% even for engaged employees. The quest for productivity and growth of a business is achieved at the expense of overall unhappiness with the quality of life. Isn’t the ultimate goal of humanity to be happy beings while pursuing great things? Leadership IQ, a leadership training and research company study showed that only 13-15% people believe that their goals help them achieve great things or maximize their full potential. Leadership and Coaching It is said that best leaders inspire others, build trust, and develop people. Research shows that less than 40% of senior management is able to drive influential leadership. Tennis coach Robert Lansdorp, who has trained greats like Pete Sampras and Maria Sharapova, said that the best coaches make their trainees independent thinkers and get them to figure things for themselves. The effectiveness of leadership development programs and related training tends to wane within few months without realizing the real leadership and coaching intents. It is time that leaders, HR and employees self reflect on these disturbing statistics and take affirmative

action. We read lots of self-help books, inspirational talks, web articles, etc. (but when rubber meets the road, there is not a defined and proven system to follow and excel at achieving our goals. Have you seen success stories with any of these approaches that people have followed and become successful? Common sense or knowledge is not common action nor does it lead to great performance. That is why 44% of U.S. Doctors are overweight, 80% of New Year resolutions are broken. The Harada method It is recognized as the best human resource development and day-to-day management method by the Japanese Management Association. The transformational power behind the method is available to people similar to the way in which Harada took bottom performers and transformed them into national heroes in sports. The same success has been achieved in organisations. Harada method is the SYSTEM for Success for Everyone! It allows thoughts, behaviour, and habits of the individual to be examined and constructive improvements made for the development of the individual. The method starts with making ‘given’ goals (thru policy deployment) as self concordant goals for the person, followed by understanding the purpose, self analysis of the individual, building a creative action plan for the goals set, developing good habits, integrating action plan into daily life, making yourself accountable for progress and using mentor/mentee approach. It is supported by proprietary integrated set of tools. With the Harada method, organisations can significantly improve

The Harada method is a roadmap for people excellence (Winners) by making them Self Reliant

Performance skill and knowledge in which a person has a strong selfdirected will and has passion to work hard and produce meaningful results Sustainability skill and knowledge in which a person has the desire and will to share and spread ideas, knowledge and experience and achievements with others

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To know more on how you can use the Harada method to your advantage, be a part of the Productivity Buzz this December 7 and 8, 2012. Mr Girish V Datar, Harada Expert, will share his expertise on the subject on December 7, 2012, at the Bangalore International Exhibition Centre.

employee engagements especially for middle and bottom performers, which in turn will improve customer satisfaction and business performance. People take their goals seriously and are inspired to achieve great things for themselves and their organisations. Flawless execution by people (since they become self coaches), allows leaders to focus on more strategic issues. Organisations build a powerful culture that is hard to copy. You will develop real leaders and coaches. info@alignstream.com

Girish V Datar, PMP Proprietor, AlignStream The Pune-based training and consulting company is the first and only certified company in India to educate and effectively implement the “Harada method” through combination of workshops, mentoring and consulting. AlignStream also has vast domain experience in operational excellence, engineering, manufacturing & project management in the international and Indian market. Datar is B.E., M.S. (USA), Six Sigma Belt and CPIM certified and has more than 18 years experience working for Fortune 500 companies such as ABB, Alliedsignal (now Honeywell), Flextronics and Arvin Meritor in the US, Canada and India.

Aiming for Success and Beyond? All businesses aspire to increase productivity; while some succeed, many fail. What are the factors that could help you raise your productivity quotient? The answer to this question would be a thorough analysis of existing practices with an aim to improve them. Here’s taking a look at 10 such ‘productive instances’…

INNOVATIVE BURR REMOVAL GREEN TECHNOLOGY Company Name: SHRIRAM PISTONS & RINGS LTD A burr problem was faced when nodular cast iron (ductile) oil ring was developed for prestigious American customers for the first time. There were complaints of a similar nature by TCL, Jameshedpur, who were using the conventional cast iron (brittle) oil ring— the complaint involved the spring/ring assembly in the automatic engine assembly line. The previous process of burring was to cut a slot from the OD and then groove the ID in the oil ring. The burrs generated during machining were then removed manually through multiple iterations. The manual removal of burrs created a number of problems. The evolution of the innovative burr removing process and the design/development of suitable equipment for blasting crushed walnut shells (organic & biodegradable material) required extensive optimisation of various parameters to make it a success. With the successful implementation of the innovative process, equipment productivity has improved and all other problems have also been resolved. There has been substantial saving in the operational cost as well.

CHIPS ELIMINATION INSIDE CYLINDER HEAD Company Name: MARUTI SUZUKI INDIA LTD Our machine shop team took up the challenge of eliminating chips inside components by following four basic steps: Investigation Reason analysis Cause Analysis Kaizens (movement) The countermeasures adopted are summarised as follows: Chips size reduction to enable easy removal of chips during machining or in the washing process Use of through-coolant tool for extraction of chips during machining Use of water jacket masking during cutting to prevent chips from entering intricate parts Improving washing effectiveness in machining centres and washing machines Use of air blow automation Inspection movement—use of fibre optic lights Burr removal by introduction of chamfer before machining

SINGLE PIECE FLOW/MOVING LINE FOR INJECTION MOLDING MACHINES Company Name: L&T PLASTICS MACHINERY LTD The machine line is designed for Lower Tonnage (LT) IMMs, which accounts for approximately 80% of the total machines built by LTPML, i.e., 540 out of 683 machines in 2010–11. The existing machine building process was studied and the final assembly and testing procedure for building LT IMM was split into 10 stages—integration, wiring, cladding I stage, start-up, strain gauging, plasticizing, cladding II stage, optional checks, quality checks and dispatch—each with a TAKT time of 2.5 hours. The moving line was operated in the first shift and material loading was done in the second shift. New assembling and testing methods using power tools and quick changeovers have been introduced in the moving line. A visual production tracking system with online recording of machine history file has also been introduced for better traceability. The area required (600 sq m) for Single Piece Flow (SPF)/ Moving line has been obtained by converting the existing storage space to vertical storage.

December 2012 - MMT

CAPACITY ENHANCEMENT OF WEGO CRANK CASE LH Company Name: TVS MOTORS CO LTD This project was implemented as part of the New Product Introduction (NPI) requirement in existing WEGO manufacturing cells to enhance capacity with minimal investment as per the planned lead time. This strategy promoted the idea of â&#x20AC;&#x2DC;Constraints to Solutionâ&#x20AC;&#x2122; through an unconventional approach, concurrent engineering, risk vs. mitigation plan, design for manufacturing, flexibility in fixtures to reduce changeover time, poka yoke, real time data acquisition (DAQ) and monitoring, faster ramp-up of production and online metrology. The action adopted was to form an exclusive and efficient manufacturing cell with flexibility and horizontal deployment of learning to existing cells to cater to 1200 units per day of two different models responsive to the market requirement.

INKJET PRINTING OF GRAPHICS ON FUEL TANKS OF MOTORCYCLES Company Name: BAJAJ AUTO LTD Graphics are applied to motorcycle accessories such as fuel tanks as an essential element of a brand strategy. The conventional method uses pre-printed graphics sticker known as Decal. In paint shops, decals are applied on fuel tanks after top coat baking and this is followed by applying a lacquer coat over the decals. This process needs expensive decals skilled manpower, hazardous waste disposal and has a low output/man/shift (150 tanks) with a considerable rejection rate (3% on average). With Inkjet printing, we have developed a new process in which decals are eliminated and we print the graphics directly on the metallic fuel tank after top coat baking. Inkjet as a process is capable of delivering high-quality prints as compared to screen printing used on decals. UV curing inks qualifying to automotive standards were also developed for this process. The fuel tank, a complex 3D surface, is manipulated by a robot under stationary Inkjet heads, which dispenses inks as per the image in the printing software and the print is simultaneously cured under UV rays by a UV light source installed close to the print-head to prevent ink spread. Change of graphics is through software.

INTRODUCTION OF LOW SPEED CBN GRINDING WHEEL Company Name: TATA MOTORS In transaxle shop, we produce all transmission gears and shafts required for Indica and Indigo cars, from soft machining to finish grinding stage (ready for assembly). Speed gears are ground in the hard grinding shop. During analysis, it was revealed that quality parameters like cone diameter, angle and surface finish of the cone have a heavy impact on the smooth shifting of gears in transaxle while driving a car. Hence, our cross-functional team decided to take on the project of improving the process capability of the machine and the improvement of surface finish. Third gear cone grinding operation is done on a CNC Parishudh grinding machine by using an aluminium oxide wheel. Aluminium oxide wheels have poor form retention as compared to CBN, which results in variation of above gear quality parameters. The use of CBN wheel for cone grinding will result in better form retention while grinding, hence better gear quality and fewer set up changes. Adding to the above list, it also eliminates the oil chiller unit required for hydrostatic spindles eliminating chiller unit breakdowns, oil leakages and frequent changing of coolant owing to oil leakages.

PRODUCTIVITY IMPROVEMENT IN FORGING CELL Company Name: WHEELS INDIA LTD Forging & flow forming is the key process that will decide the entire line output for the Forged Aluminium Wheel line. We have classified our products as super single wheel and dually wheel. Super single wheels are produced from disc type forging, which takes more processing time in forging, while dually wheels are produced from skirt type forging, which takes more processing time in forging. The bottleneck operation is altered based on the type of product. Hence, we found scope to improve productivity in both the operations by eliminating manual intervention with simple automations and upgrading the existing system. The loading-unloading time was reduced by changing the operation sequence, the cycle time was reduced by developing an offline process and manual dependency was eliminated by developing autonomous solutions.

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ELIMINATING HAZARDOUS WASTE GENERATED IN FUEL TANK PAINTING PROCESS Company: BAJAJ AUTO LTD Background: Conventional technology of zinc (tri-cation) phosphating leads to generation of phosphate sludge as a by-product and as it contains heavy metals, the sludge is treated and disposed as hazardous waste. The process of treatment works at 50°C. Current Condition: For the processing of fuel tanks at a volume of 4.5 million per annum, the sludge generation is 16.2 tons per annum. Root Cause: By-product (sludge) generation as a part of the chemical reaction with metal 2Fe2 + 4H2PO4 + [O] + H2O 2FePO4.2H2O + H3PO4 (Generation of Iron phosphate - Sludge) Countermeasure: No by-product generation using Nanotechnology based on Zr metal. Zirconium Tec-Talis process reaction. H2ZrF6 + M + 2H2O ZrO2 + M2 + 4H+ + 6F- + H2 M - Fe, Zn, Al, Mg (Treated substrate)

APPLYING THE DBR (TOC-PRODUCTION PLANNING TECHNIQUE) Company: LAXMI OIL PUMPS & SYSTEMS PVT LTD One of our quality objectives is to achieve a delivery performance (per customer per product) of more than 90%. Past data shows that it was 70% for one of the customers, Kirloskar Oil Engines Ltd (KOEL). KOEL contributes to 50% of our total business share. We supply 12 different types of lub oil pumps to KOEL. Raw material planning and production planning are conventionally done on a weekly basis. As a result, the capacity on the constraint machine (CCR) was utilized for other components due to a shortage of required raw material. We applied the TOC production planning solution (Drum-Buffer-Rope) to overcome this problem. Hence, weekly production and raw material planning were eliminated and buffer management was implemented. Because of buffer management, the constraint machine (CCR) produces the required components at the right time. This resulted in an improved delivery performance of up to 90%.

PRODUCTIVITY IMPROVEMENT IN PLASTIC PAINT SHOPSPROCESS Company: BADVE ENGINEERING LTD Badve Engineering Ltd is a leading manufacturer of auto components, with 13 plants across India. We manufacture and supply silencers, chassis, press parts and plastic molded parts with painting as well as auto manufacture two-, three-, four-wheelers and white goods. We present here one such success story. Challenge: At the paint shop, which supplied aesthetic ‘A’ class motorcycle plastic painted parts, the challenges were (1) to improve capacity from 2900 to 5000 sets/day within a short span of nine months, (2) to execute the project within the given space and (3) to improve quality based on customer demand, as 60% supply is for export. The solution was achieved through the Total Productive Maintenance route. First, we formed a dedicated team to develop a knowledge bank with current trends and then made the following changes: 1) Reduced OEE losses by breakthrough ideas in colour change loss and achieved a capacity of 3250 sets/day 2) Increased pre-treatment line spray riser’s height and optimized the painting jig cube size to achieve 4442 sets/day 3) Increased conveyor speed from 2.1 to 2.4 m/min using the concept of partial distribution of paint coat in booths, to achieve 5080 sets/day, i.e., up by 75%. The passion for productivity is still persistent and the next target is set for 6000 sets/day.

The above mentioned case studies will be presented in detail at the Productivity Buzz to be held on December 7 and 8, 2012, at the Bangalore International Exhibition Centre. 100 MMT - December 2012

Engineering Expo Ludhiana 2012

LUDHIANA December 21-24, 2012 GLADA Ground

Making manufacturing-friendly North accessible Led by manufacturing biggies, Ludhiana is fast emerging as a leading investment destination in the northern belt of India. In this backdrop, the upcoming Ludhiana edition of Engineering Expo, organised by Network 18 Publishing during December 21–24, 2012, will bring into the limelight the potential that northern region offers manufacturers by showing investors how to gain easy access into this manufacturing-friendly zone.

Northern Prospects Elaborating on the changing scenario in the manufacturing arena in Punjab, Robin Basant, Managing Partner, Basant Mechanical Works, says, “The industry in Punjab is now embracing global manufacturing technologies on the shop floor; the mindset of people is changing as well. Everybody is now concentrating on quality and quantity. Punjab is known globally for woollen clothes, hosiery, machine tools, auto/car parts, cycle manufacturing, etc. People

are travelling places to learn the new technical skills being used by bigger units in the international market.” Commenting on the growth potential of Punjab as an industrial area, Didarjit Singh, Proprietor, Karam Chucks, informs, “Manufacturing in Punjab has undergone various phases of development over the last 10 years. It has grown at a robust rate during this period and has been one of the best performing manufacturing economy. The manufacturing sector contributes about 15% to Punjab’s GDP and 50% to the country’s exports. It employed 58 million people (about 12% of the workforce) in 2008. By 2012, it is estimated, based on the current economic projections, that this sector will employ a further 12–13 million out of the nearly 89 million additional people who will enter the workforce.” The key markets in Punjab include

Highlights of this edition 250+ expected exhibitors 20,000+ business visitors expected Business transactions worth `150 crore expected 20,000+ products on display Spread over an area of more than 1,50,000 sq ft Showcasing more than 30 diverse industry categories

Ludhiana, Hoshiarpur, Jalandhar and Amritsar.

Samana,

Ludhiana: Potential Waiting to be Tapped The growth potential of the city has brought it on the radar of large manufacturing houses. Singh elaborates, “People of Ludhiana are skilled and high spirited. In addition to theoretical knowledge, they have technical skills imbibed through their family lineage. Besides, they are regularly upgrading themselves as per the needs of the time. So, many international machines/technologies are being used by manufacturers to stay abreast with competition. All the big industries are eyeing Ludhiana for sourcing materials and selling products to end-users.” Sharing similar sentiments, Manjit Singh Matharoo, GM, Consortium of Ludhiana Machine Tools Manufacturers (CLMTM), observes, “Ludhiana has a large base of manufacturing companies, with a wide network of possibilities. It is capable of delivering quality, and since the last six years, the area has seen rapid development of internal support units. It has the perfect model for costeffective business.” Ludhiana is also emerging as a major automotive hub in northern India. “Ludhiana is the most appropriate destination for investment. The latest study by World Bank has adjudged Ludhiana as the best place for doing business in India. Though not a major December 2012 - MMT 101

CURTAIN RAISER Engineering Expo Ludhiana 2012 tourist destination, the city has come up as a major medical tourism destination and also a budding commercial centre. The city is not far from the National Capital and hence, is easily accessible,” adds Basant. Sajni Khanna, Consultant, AMC Pvt Ltd, states, “The area has been emerging due to its proximity to the National Capital and provides immense opportunities to domestic and international investors.”

Exhilarating Engineering Expo There is general consensus that Engineering Expo is getting better with each passing year, and coming up with novel initiatives keeping in mind SMEs in the region. Its association with leading organisations such as National Small Industries Corporation (NSIC); United Nations Industrial Development Organization – International Centre for Advancement of Manufacturing Technology (UNIDO – ICAMT) and CLMTM will take Engineering Expo Ludhiana to new heights. Commenting on the Expo, Sandeep Khosla, CEO, Network 18 Publishing, says, “After 10 successful years of service to the industry, Engineering Expo today has established itself as India’s largest multi-location trade show on manufacturing. The Expo is a preferred destination for small and medium enterprises as well as manufacturing & engineering organisations to further their growth and that of the industry at large. For the 2012–13 season, we have eight editions spread across an equal number of locations of a rising India. Keeping our esteemed exhibitors and valued customers in mind, we have made elaborate provisions to offer a never before experience. These, we reckon, will add substantial traction to the industrial growth of the nation.” Expressing his views on the event, Basant opines, “Today, Engineering Expo attracts more business visitors than some of the other large events organised to facilitate business. More than 1,00,000 industrial buyers benefit 102 MMT - December 2012

from Engineering Expo every year. Over the years, it has become one of the most lucrative platforms for business growth. In fact, they help us interact with national as well as international visitors including manufacturers, investors, diplomats, government officials and industry stalwarts. And as a multilocation tradeshow, Engineering Expo reaches out to prospective clients, in their respective cities.” With over more than a decade experience of organising exhibitions, Network 18 has been successful in understanding and meeting the expectations of exhibitors, which in turn has resulted in unconditional trust in the Expo. Singh observes, “In today’s world, displaying your strength, product range, skills, etc., on a common platform is important. People who do not know you directly can gain full knowledge about your product range at such type of platforms. This Expo provides a one-to-one meeting opportunity and a platform to share vital prospects to grow one’s business. Besides, having an organiser like Network 18 is again a value addition.” Echoing similar sentiments, Ashok Kumar Gupta, MD, Crane Bel International Pvt Ltd, says, “We have been associated with Engineering Expo for a long time, and since Network 18 is the organiser, we are keen to extend our relationship further. We keep introducing innovative concepts every year at the Expo, and this year will be no different.”

Business Opportunities Galore The Expo plays a crucial role not only in business development, but also in increasing profitability. Over the years, it has evolved as an ideal launchpad for exhibitors. Basant asserts, “Engineering Expo is considered to be an ideal platform for companies to foster growth through reach and awareness to their right target audience. It proves to be a perfect combination of a vast range of exhibitors, spacious venue, stateof-the-art amenities and humungous visitor turnout, which constitute the

New Attractions in This Edition

Panel discussion aims at providing a roadmap to infuse growth in the region Institutional Buyer Involvement Plan to attract delegations from large corporate and major institutions Improvised visitor profiling – profile, scan, filter and bring in visitors as per exhibitors’ requirements Providing business networking support to exhibitors by leveraging Network 18 Publishing’s industry connect Credit rating facilities for the benefit of exhibitors Providing complete travel solutions for exhibitors Offering logistics services to ensure smooth cargo handling, custom clearing, transport compliance, etc

most crucial factors for any exhibitor.” Talking about his expectations from the Expo, Singh says, “Personally, my expectations from Engineering Expo Ludhiana are high. Looking at the potential, knowledge and management of the organiser, we expect a huge turnout of quality-oriented customers at the show.” Engineering Expo is considered an ideal platform to showcase the industrial talent residing in smaller towns and cities of India. Matharoo feels, “A place like Ludhiana has the skills to attract international manufacturers to India, and such events do a commendable job in materialising this goal.” With enthusiasm and optimism regarding the event riding high among participants, the Engineering Expo Ludhiana is poised to provide an important ground for nurturing business opportunities in the State of Punjab and explore untapped markets, which can emerge as lucrative business sites.” anwesh.koley@network18publishing.com

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REPORT Engineering Expo Pune 2012

PUNE November 2-5, 2012 Auto Cluster Exhibition Centre, Chinchwad

Generating high volume of opportunities Housing varied manufacturing industries as well as services sector, etc., Pune has witnessed immense development in the past few years. Engineering Expo Pune has proven to be a catalyst by accelerating business transactions, especially for SMEs in the manufacturing industry. The four-day event, held between November 2 and 5, 2012, saw some serious business opportunities and leads transforming into profits. Many exhibitors confirmed participation, and most visitors plan to exhibit in the next edition!

he emerging markets in the North have become an attractive investment haven, and Ludhiana is one such prospective destination where the manufacturing sector is growing at a rapid pace. In a bid to provide ample growth opportunities to the manufacturing fraternity, Engineering Expo Ludhiana, slated to be held during December 21–24, 2012, is expected to generate high levels of enthusiasm among the manufacturers in Punjab. Over the past few decades, the concentration of industrial units has transformed the city of Pune into one of the major manufacturing hubs in the country. While proximity to the commercial capital Mumbai has certainly played a role in it achieving this grand status, other important factors contributing to its prominence include availability of skilled manpower, conducive climate and intellectual richness. Also, the industrial infrastructure in the area has kept pace with real estate development. Providing a boost to the attractive investment destination, Engineering Expo Pune saw impressive activity. Organised by Network 18 Publishing, it was held at Auto Cluster Exhibition Centre, Chinchwad, in the month of November, an extremely strategic time for business generation. Engineering Expo Pune has turned into a favourite destination for generation of high118 MMT - December 2012

Dignitaries unveil the exhibitor directory at the 7th edition of Engineering Expo Pune

volume business leads. Bringing together high-profile visitors, decision makers and a multitude of exhibitors all across the country, Engineering Expo Pune truly emerged as the largest SME gathering.

Highlights of this edition 200 exhibitors pan India Spread over more than

3,500 sq m 16,000 business visitors Business transacted worth

`68.03 crore 7,860 business leads generated 15,000+ products displayed More than 1, 10,000 kg machinery moved in for display

The 7th successful edition of Engineering Expo Pune was inaugurated in the presence of eminent dignitaries Anant Sardeshmukh, Director General – Mahratta Chamber of Commerce, Industries & Agriculture; Nitin Chalke, General Manager – India & South East Asia, Eaton Fluid Power Ltd; Sanjay Marathe, Head – Strategic Services Unit and CTO, Zensar Technologies; Sandeep Khosla, CEO, Network 18 Publishing; Sudhanva Jategaonkar, Associate Vice President, Network 18 Publishing; and Manas Bastia, Senior Editor, Network 18 Publishing. The traditional lamp lighting ceremony was followed by the unveiling of the official exhibitor directory, which comprised all important details in a consolidated manner.

Engineering Expo Pune 2012 Pune as an Ideal Investment Destination Experts have been noting the rise in technology adoption of SMEs. Expositions such as Engineering Expo have been promoting an atmosphere of high-end technology. According to Marathe, “SMEs have been showing an encouraging response to the adoption of advanced technologies such as cloud computing.” Pune, being an industrial hub, has benefitted greatly from the Expo because of the variety and wide range of technologies and solutions on display. Commenting on the same, Chalke observed, “The area chosen for the Expo, Auto Cluster, is strategic and ensures quality turnout of visitors. Pune, being a hub for auto industry and ancillary units, has seen real-time advantages due to Engineering Expo.”

Promoting Collaboration In recent times, the SME sector is witnessing extensive growth in Pune. New projects and capacity expansions are visible results. In this backdrop, Engineering Expo brings in its expertise of uniting the SME sector with prospective clients, thus providing a holistic business generation experience. One of the biggest takeaways from trade shows has been the creation of a collaborative atmosphere among the companies. SMEs benefit hugely from this experience, which helps them develop products and technologies of a higher quality, thus making them globally competitive. Elaborating further, Marathe opined, “Innovation is a differentiator when it comes to SMEs. Trade shows such as Engineering Expo nurture the collaboration in a competitive environment, something which is difficult to achieve otherwise. Both exhibitors and visitors utilise this opportunity to make the most out of this experience and improve the quality of their products and services.” Being the largest SME gathering for the manufacturing industry, this platform has helped them immensely.

“Manufacturing is one of the most important revenue-generating sectors for Pune. A tradeshow of this scale has added greatly to the growth of the manufacturing segment as it majorly focusses on SMEs in the segment. The event is an excellent platform for promoting businesses, branding and networking. It is an extremely relevant concept, which benefits the nearby SME clusters year on year. They get to learn and update themselves on the new technologies,” said Sardeshmukh.

Wide Array of Technology on Display The exhibition halls were buzzing with activity on all the days. Most exhibitors were buoyant about the sales and leads generated in huge numbers. Emphasising on his association with Engineering Expo, Snehal Mehta, Director – Marketing, Energy Mission Machineries (India) Pvt Ltd, said, “We have been participating in Engineering Expo since a long time. The event has helped us build our brand name and enhance the image of our organisation. It has provided a good platform to gain exposure to industry, and enabled us to generate business leads. The show has provided us an ideal platform to display and demonstrate our products and meet potential buyers.” “We are machinery manufacturers and so, we aim at building long-term associations with the industry. In such a case, the Expo helps us introduce our products to new buyers and gradually get the enquiries converted into business leads,” Mehta added. The exhibitors were able to interact with a large number of serious business visitors. To this, Sridhar Nalluri, Country Manager, CST Sensors India Pvt Ltd, added, “We are expecting to increase our brand value and reach more customers in the Maharashtra industrial sector through this trade show. We are looking to tap the machine tools, SPM & automation segments through Engineering Expo.”

With a large range of technologies on display, visitors benefitted greatly from the exhibition. “This is an effective platform for generating business opportunities. I came to scout for suppliers for my venture. There is wide range of products and services for hydraulics & pneumatics, material handling, etc.,” said Chintan Shah, Proprietor, Mech Tech Engineers, a visitor. “This is a one-stop solution for all my business needs as I found relevant products on display. There are exhibitors from various parts of the country, which makes this a holistic exhibition,” Shah added. “It is an all-in-one Expo on a large scale, with technologies ranging from automation, cooling solutions, IT, etc. It includes a mix of big names as well as SMEs. Branding is more visible. I could generate many leads relevant to my business,” commented Nitin Penpatil, Director, FS Engineers, another visitor.

Gearing up for the Next Edition of Engineering Expo! With a splendid response received in this edition, most exhibitors have already booked slots for Season 2013 of Engineering Expo. Some have even confirmed participation at more than one edition. An interesting observation was that most visitors are planning to turn exhibitors too in the next season. “It was a great experience for us. The new technologies on display served as an eye-opener. We look forward to leverage our experience at Engineering Expo to better our products and solutions. We were actually looking for MNCs and have got many leads. We plan to be an exhibitor in the next edition,” said Sherman Britto, Executive – Business Development, Vinsys IT Services India Pvt Ltd, a visitor at the event. The next edition of Engineering Expo will be held in Ludhiana from December 21-24, 2012. mahua.roy@network18publishing.com

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EVENT REPORT Engineering Expo Chennai 2012

CHENNAI November 22-25, 2012 Chennai Trade Centre, Nandambakkam

Showcasing Southern Manufacturing Strengths Home to 34,500 companies and 35,000 expats, Chennai—the 34th largest city in the world and 4th largest city in India—has become home to several IT companies and auto majors, among other industry verticals. Offering industries a favourable industrial climate, Chennai has, over the years, bagged several envious deals. With an aim to help manufacturers across the country encash on the Chennai advantage, Network 18 Publishing inaugurated the 5th edition of Engineering Expo Chennai 2012, at Chennai Trade Centre, Nandambakkam, Chennai, on November 22, 2012. A report…

n the recent years, along with IT investments of repute, Chennai has bagged huge deals in the auto, OEM and ancillary industries. The city has, over the years, transformed itself into a bustling investment destination with major auto companies like Daimler, Ford, Ashok Leyland, Mahindra, NISSAN, Renault, BMW and TAFE Tractors offering a boost to the ancillary units in the industrial clusters of Ambattur, Sriperumbudur and Padi. According to P Shanmugasundaram, Chief GM – Projects, TIDCO (OD) & MD, TICEL Bio Park Ltd, “Unlike China, Chennai’s development is not an

Highlights of this edition 200+ exhibitors Pan India Spread over more than

4,500 sq m 12,072 business visitors visited across India Business transacted worth

`62.47 crore* 8893 business leads generated* 8,000+ products displayed from different industries More than 80,000 kg machinery moved in for display * Feedback received from exhibitors

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(L-R): Nitin Kunjir, Deputy Manager – Sales, Network 18 Publishing; Manas R Bastia, Senior Editor, Network 18 Publishing; Ramesh PS, President AIEMA & MD Airflow Engineering; P Shanmugasundaram, Chief GM – Projects, TIDCO (OD) & MD TICEL Bio Park Ltd; Sandeep Khosla, CEO, Network 18 Publishing; Ameer Munaff, CEO, Fein Power Tools and Hari Hara Subramaniam, Manager – Sales, Network 18 Publishing at the recently held Engineering Expo Chennai

integrated one but has its own reasons for housing 34,500 companies, 35,000 expats. The Tamil Nadu Government also facilitates the process of clearances to set up companies.” Leveraging on the Chennai advantage is Engineering Expo Chennai, which brings in its expertise of uniting the buyers and sellers of the engineering and manufacturing sectors, thereby providing a holistic business ecosystem. Launched in Ahmedabad in 2002, Engineering Expo has come a long way today by becoming one of India’s largest multi-location SME meeting points. Elaborating on the legacy of

Engineering Expo, Sandeep Khosla, CEO, Network 18 Publishing, said, “After 10 successful years of service to the industry, Engineering Expo today has established itself as India’s largest multi-location trade show on manufacturing. The Expo is a preferred destination for small and medium enterprises as well as manufacturing & engineering organisations to further their growth and that of the industry at large. For the 2012–13 season, we have eight editions spread across an equal number of locations of a rising India (including Ahmedabad, Pune, Chennai, Ludhiana, Indore, Aurangabad,

Engineering Expo Chennai 2012 Rudrapur and Hyderabad). Keeping our esteemed exhibitors and valued customers in mind, we have made elaborate provisions to offer a never before experience. These, we reckon, will add substantial traction to the industrial growth of the nation.”

The Inauguration… The 5th edition of Engineering Expo Chennai 2012, one of the largest trade fairs in the city, was inaugurated in the gracious presence of Ramesh PS, President, AIEMA & MD, Airflow Engineering; Ameer Munaff, CEO, Fein Power Tools; Shanmugasundaram; Sandeep Khosla, CEO, Network 18 Publishing and Manas Bastia, Senior Editor, Network 18 Publishing. “Engineering Expo provides a single window shopping solution for SMEs as they usually sell their products to a variety of clients such as automobile, machine tools, material handling and so on. Additionally, a visitor can meet all his demands in one day,” highlighted Ramesh while commenting at the occasion. Elaborating further, Munaff averred, “Engineering Expo is one of the best platforms for us to reach the end customer. This is also an opportunity for us to let our customers have a feel of our product operations and train them about the right working procedures. This is one of the major reasons why we are launching our new handheld codling machine—the first of its kind in terms of technology, quality and cost in the whole world.”

Cutting-edge technologies Over the years, Engineering Expo Chennai has been providing opportunities for SMEs, which are critical for the growth of emerging markets like India, to display their products as well as witness some of the latest technologies that could help develop their business. The 2012 edition offered similar growth avenues. The Expo served as a platform for Indian & overseas companies to exhibit their products & services, interact with

potential buyers & sellers, generate new incremental business and forge new partnerships. Showcasing cuttingedge technologies, this year’s edition also unveiled the latest in products, machinery and equipment from manufacturing & related industries. This edition of Engineering Expo Chennai, which spanned over a period of four days, i.e., from November 22–25, 2012, generated revenue in excess of `62.47 crore.

Exhibitors Speak The Expo showcased over 30 diverse segments of industries and gave visitors an opportunity to witness the latest technologies and products. Some of the leading companies who participated in this edition included National Instruments, Durga Bearings, Dirak India, Fein Power Tools India Pvt Ltd, Gandhi Automation Pvt Ltd, Hitachi Koki India Ltd, Larsen & Turbo Ltd, Macht Exim Llp, Malwa Machine Tools, MGM-Varvel Power Transmission Pvt Ltd, Shuter Enterprises India Pvt Ltd, Testo India Pvt Ltd and Tussor Machine Tools India Pvt Ltd among others. Among the exhibitors, Sonal Sulania, Director, Durga Bearings Pvt Ltd, averred, “Earlier, we used to participate only in ELECRAMA and IMTEX. We decided to participate in this event due to the direct involvement of Network 18. While events such as ELECRAMA are focussed on switchgears and IMTEX on the metalworking industry, i.e., they have a specific sector or source in mind, the focus of Engineering Expo is diversified and you can avail the benefit of a single platform to reach all the sectors.” “The Expo provided a brilliant platform for all sectors to interact. To make it attain more prominence, perhaps, more well established companies could also showcase their products along with other SMEs,” she added. Vishak Mani, Director, Clasys, another visitor, stated, “This is the fourth time that we are participating in Engineering Expo and second time

that we are participating in Chennai; the previous three editions were quite successful for us. Exhibitions like these help us get new customers as well as enhance the know-how of the market.”

Visitors’ Voice A variety of visitors groups were seen at the Expo, which included engineering students, Universities’ R&D professors, SME proprietors and tier I companies representatives. Dr P Meganathan, Consultant, Sinto India Ltd, who visited the event the very first day, exclaimed, “We are in the process of setting up a new manufacturing plant here and I was looking for prospective suppliers at the Expo. It was my first visit to such a diversified exhibition, and I have interacted with a couple of fabrication, rubber and tool making companies. So far, I have had a very positive response in this regard.” Another visitor, Karthik Chandra Shetty, Director, Lumens Group Of Company, said, “I have been regularly visiting Engineering Expo since the last 2–3 years in Pune and Ahmedabad and it is good to see that it has prospered over the years. Engineering Expo covers almost all the segment of engineering goods. I always get to learn new things at the Expo.”

Expanding Business Meets While the Expo is tending towards generating `1,000 crore business all over India, it appeared to be an apt platform for exhibitors to directly interact with end customers. Besides, it served as a launchpad for SMEs and facilitated interaction between end customers and suppliers. The 2011 edition of Chennai Engineering Expo recorded business transactions worth `41.98 crore, with more than 12,692 business leads being generated; this year exceeded to... as per the feedback received from exhibitors. Around 8,000 products from various industries were on display in an area spanning 4,200 sq m. The next edition of Engineering Expo will be held in Ludhiana during December 21–24, 2012. December 2012 - MMT 121

EVENT REPORT Panel Discussion: Chennai

Can Chennai surpass the China factor? With 34,260 companies in Chennai, the city—despite being known for its low labour cost— today stands for the highest quality of life ahead of the three metros and Bengaluru (as per the survey conducted by ECA international). Viewing the big investments made and being planned in the coming years in the milieu of Engineering Expo Chennai 2012, Network 18 Publishing, along with event partner Religare, organised an electrifying panel discussion on the theme ‘Can Chennai better the China MFG model?’ in Chennai on September 19, 2012.

ith the presence of all auto majors, IT and electronic hardware companies of the world, Chennai has made itself a benchmark in the country. Encashing on the recent improvements made at the governance, entrepreneurship and corporate levels, Engineering Expo, the flagship multilocation engineering & manufacturing exhibition organised by Network 18, held its intriguing panel discussion on November 19, 2012. The session was moderated by Archana Tiwari-Nayudu, Executive Editor – SEARCH, Network 18 Publishing. The panelists constituted a mix representing experts, entrepreneurs & industrialists including Ramesh PS, President – AIEMA & MD, Airflow Engineering; Ranganath NK, MD, Grundfos Pumps India Pvt Ltd; Narayan Kumar, GM, Hurco India; Kumar Kandeswamy, Sr Director and Country Leader Manufacturing, Deloitte; Sharmila Kumbhat, Director – International 122 MMT - December 2012

(L-R): J Chandrasekaran, National Consultant – Plastics, UNIDO; Kumar Kandaswami, Senior Director and Country Leader – Manufacturing, Deloitte; Ranganath NK, MD, Grundfos Pumps India Pvt Ltd; Archana Tiwari-Nayudu, Executive Editor – SEARCH, Network 18 Publishing; Sharmila Kumbhat, Director – International Marketing, K-Lite Industries; Ramesh PS, President, AIEMA & MD, Airflow Engineering; Narayan Kumar, General Manager, Hurco India at the panel discussion

Marketing, K-Lite Industries and J Chandrasekaran, National Consultant – Plastics, UNIDO.

The Chennai edge The session addressed the ecosystems of Chennai and China and the possibilities that might propel Chennai as a manufacturing hub ahead of China. “According to statistics, the labour cost in Chennai may be lesser than that of China. However, on a gross scale, it is still 20% costlier. Additionally, the city will have to deal with more of public sharing rather than solely relying on private sector investments,” Rangnath added. On the other hand, Kumar emphasised on India’s distinctive practices versus China’s method of replicating. “Indians actually excel in terms of technical expertise, innovative skill and value-added service. This is why we stand ahead of China; the two are simply incomparable,” Kumar averred. Taking the discussion forward, Kandaswami commented, “China is no longer known as the cheap product producer; they offer much more variety of products than we do. We produce only those kinds of products which we feel are in demand and do not focus on the kinds of products that might create demand. Thus, we are only limiting our market capabilities.” Meanwhile, Kumbhat pointed

out, “Micro level situations are more proficiently handled here rather than macro level situations which we cannot change on our own. Further, we follow the mantra of survival of the fittest, but China follows the mantra of the fittest is the survival.” Reacting on the recent State Government policy to encourage the use of solar power with an aim to generate close to 3,000 MW by 2015, which makes it mandatory for heavy consumers of electricity, like industrial units, to draw 3% of their power requirements from solar energy by December 2013 and 6% from Jan 2014, Ramesh pinpointed the hurdles in its implementation. “About 1 MW of solar power generation needs at least 3–4 acre of land. This implies that to generate 3,000 MW of solar power, there is a need to acquire 9,000–11,000 acre of land. Keeping the current shortage of land, it seems very difficult to achieve the same,” opined Ramesh. The electrifying panel discussion was followed by an interactive question & answer session with the highly enthusiastic audience. The discussion ended on a positive note, wherein all the eminent panelists agreed that Chennai is the most preferred place for future investments in the country. suprita.anupam@network18publishing.com

EVENT REPORT DMG / MORI SEIKI @ JIMTOF 2012

Adding Precision to Productivity The nouns were driving the adjectives at JIMTOF 2012 for DMG / MORI SEIKI! High precision and continuous accuracy on one hand and speed and dynamics in operations on the other, were showcased during this mega event. Adding to this edge, reliability of the name and quality that DMG / MORI SEIKI stands for befitted the ‘statement’ rather than the ‘presence’ of this multinational during the 26th Japan International Machine Tool Fair by way of a stellar showcase of manufacturing might. A report…

t JIMTOF 2012, held for six days from November 1–6, 2012, at Tokyo Big Sight, DMG (GILDEMEISTER AG) and Mori Seiki exhibited altogether 32 innovative machines, i.e., 30 machine tools and two presetters, including eight new models, at the largest booth of 2,340 sq m among the participating companies. Talking about the Group’s combined strength, officials at DMG / MORI SEIKI said, “We combined the technologies of both Mori Seiki and DMG under the theme of ‘Thinking Beyond Technology’.”

NLX Series on Display A complete line-up of the NLX series, which has been highly praised by customers since the release of the NLX2500 in 2010, was displayed for the first time in the world at JIMTOF 2012. Three classes of the NLX1500 with a 6-inch chuck, the NLX2000 with an 8-inch chuck, the NLX3000 with a 12-inch chuck as well as the NLX4000, covering small as well as large parts in the Oil and Gas industry were also displayed. DMG also released five new models including the DMC 60 H linear, a high-precision horizontal machining centre, which is most suitable for machining power train components of 124 MMT - December 2012

DMG (GILDEMEISTER AG) and Mori Seiki exhibited 30 machine tools including eight new models at the largest booth of 2,340 sqm at JIMTOF 2012 5-Axis Machining of Engine Block

automobiles. A variety of new 5-axis machining centres improved in the European market, such as the DMC 65 monoBLOCK, with which a 20-station pallet pool is integrated, were exhibited, proposing process integration and manpower saving to improve

productivity. Elaborating further, the officials added, “We also exhibited a wide variation of models with the latest solutions to respond to diversifying needs. At the DMG / MORI SEIKI Theater of our booth, automation systems such as Linear Pallet Pool (LPP), the robot system and loader were introduced, and seminars regarding advanced machining technologies were conducted.”

DMG / MORI SEIKI @ JIMTOF 2012 All this more than proves that the ‘nouns’ were indeed driving the ‘adjectives’ at JIMTOF 2012 for DMG / MORI SEIKI during JIMTOF 2012 with impressive offerings for the metalworking and cutting industry. Talking about the ‘adjectives’, the DMC 60 H linear—the new horizontal machining centre from DMG / MORI SEIKI—impresses with a unique tool magazine and modular system kit and promises 25% more productivity because of linear drives. Again, the LASERTEC 65—a compact 5-axis milling combined with laser texturing of synthetic injection moulds on a single machine—delivers unlimited possibilities in surface design.

Advantages Galore! The advantages do not end here! The DMU 80 eVo linear with 5-axis milling performance and fast rapid traverse speeds of 80 m/min adds productivity to precision, not to forget the next-generation compact machining centre MILLTAP 700 with outstanding milling performance. The fusion of the machine tools and measuring system was ascertained with S-Quad (high-speed in-machine coordinate measuring system) and ECOLINE, the completely redesigned machine programme, promised high-tech at an attractive price!

NHX4000 Series Production The NHX4000 horizontal machining centre is ideal for the machining of work pieces of up to 24.8 in x 35.4 in, with a loading capacity of up to 880 lbs. Through an in-depth analysis of current market needs, Mori Seiki has improved the already high level of performance of the NH Series. The NHX4000 offers cutting capacity equivalent to the previous NH model, with improved features for greater productivity and efficiency.

126 MMT - December 2012

Grand Opening of North American Factory Dr Masahiko Mori, President, Mori Seiki Co. Ltd., and a member of the Supervisory Board of Gildemeister AG, addressed key members of the local government, manufacturing community and press at the ribbon cutting of the newly built Mori Seiki manufacturing facility on November 7, 2012. His message for the audience was one of projected continuing prosperity and support for the US manufacturing sector. Dr Mori referenced the new factory, a first for the company in America, not only as a resource for manufacturers seeking horizontal machining centres but also as a collaborative partner for general manufacturing concerns such as factory automation.

Digital Technology Laboratory The audience at the ribbon-cutting ceremony included the staff of both Mori Seiki Manufacturing and the adjacent Digital Technology Laboratory (DTL). Over 80 staff members are employed at DTL—an R&D centre that collaborates with Mori Seiki Japan on a 24-hour work cycle to support global manufacturing solutions. The factory and R&D centre comprise a combined area of 291,000 sq ft spread over 19.2 acre in Davis, CA, with eight additional acres reserved for future expansion. In addition to the ceremonial ribbon cutting, behind-the-scenes tours of the factory gave a glimpse inside the state-of-the-art facility. Mori Seiki NHX4000 is currently being built at the Davis, CA plant, with column and medium part machining on three NHX10000 machines installed with a Linear Pallet Pool (LPP) system with 60 pallets. The highly automated factory also boasts of two NH6300 machines with 40 pallets that include machines pallets and small castings. The large machining area is equipped with two Toshiba MPC-B Series 5-face, high-performance machines. With capacity of up to 180 tools and 44,092 lbs, this Toshiba cell controlled by DTL’s own LPS III software is able to efficiently produce large NHX Series castings, which are then cleaned by air blow robots. The castings used in NHX production at the Davis campus come from the same foundry as the NHX machines produced at factories in Japan. Over 40% of the machine components are produced domestically, with spindles and ball screws being imported from Mori Seiki Japan. Domestic content will continue to be increased in the future, as additional suppliers are secured. To maintain economic and environmental standards, the factory performs dry and Minimum Quantity Lubricant (MQL) machining only, with chip evacuation by vacuum, in a temperature-controlled facility. Production started in July, 2012, and currently 20 machines are produced per month, while the total capacity is up to 80 units per month.

EVENT REPORT TMTS 2012

Expanding the reach of ‘Made in taiwan’ tools ways. Carl, C.C. Hung, Secretary General, Taiwan Machine Tool & Accessory Builders’ Association (TMBA), said, “At TMTS 2012, we have organized a series of factory visits. This will give the buyers the scope to not only view the demonstrations of various products and technologies at the exhibition but also visit the manufacturing plant.”

Global Presence at TMTS

With an objective to strongly promote the implementation of ‘Made in Taiwan’ machine tool solutions in various manufacturing applications globally, Taiwan Machine Tool & Accessory Builders’ Association organised the Taiwan International Machine Tool Show from November 7-11, 2012. A report by Arindam Ghosh.

ith the ever rising competition today, companies are looking out for quality and affordable machine tool solutions that will make their manufacturing process highly competitive. Such a demand scenario has generated a huge interest in the global manufacturing community to opt for Taiwanese machine tools and equipment. To further promote the usage of ‘Made in Taiwan’ solutions, Taiwan Machine Tool & Accessory Builders’ Association (TMBA) organised the Taiwan International Machine Tools Show (TMTS, 2012) in Taichung. Honourable Ma Ying-Jeou, President of Taiwan ROC (Republic of China), inaugurated the 2012 edition of TMTS along with Eric Chuo, Chairman, Taiwan Machine Tool & Accessory Builders’ Association (TMBA) and other eminent industry representatives. Speaking on the occasion, Chuo said, “I believe that TMTS 2012 is an ideal platform that provides an opportunity to both the global and local visitors to have to look at the latest machine tool technologies available in 128 MMT - December 2012

the country and the exhibitors get an opportunity to find new customers and expand their business. Further, TMTS is happening just after the conclusion of Japan International Machine Tool Fair (JIMTOF), which will give international customers ample opportunity to look at the latest available solutions in both these markets.

USPs TMTS 2012 was unique in various

TMTS @ a Glance

Total no. of Exhibitors: 475 (Local: 406, Overseas: 21, International Associations and Trade Media: 48) No. of Countries Participating: 11 Exhibit Space: 36,200 m2 No. of Visitors: 65,227 (Local: 63,243, Overseas: 1984) Location: Greater Taichung International Expo Center (GTIEC) Organizer: Taiwan Machine Tool & Accessory Builders’ Association (TMBA)

Given that TMTS 2012 was the largest international machine tool exhibition in Taiwan this year, the event saw a huge influx of several overseas business delegations as well as visitors from 45 countries. Giving a perspective from the delegations side, C. Renganathan, Director, Chennai Metco Pvt Ltd, said, “We have six members in our delegation. We have come to this event to look for machine tool solutions that will help us to further improve our manufacturing processes and be more competitive in the market.”

TMTS: A Unique Platform The five-day premiere event gave equal opportunities to visitors both from the local and overseas regions to know about the capabilities of the Taiwan machine tool industry and further keep themselves updated with the current scenario of the industry. The event turned out to be a perfect platform to showcase the latest technologies. According to Fanny Chang, Sales representative - 2nd Business Department, Hiwin Technologies Corp., said, “The response from the visitors to our products has been highly encouraging. It gave us a chance to interact with potential customers from abroad.” Although Taiwan is an increasingly favoured destination to opt for highquality and affordable machine tools, a major contributor to this growth story has been TMTS 2012. The next edition of this event is expected to take this growth even further.

Event List - National

CHENNAI LUDHIANA INDORE

AURANGABAD

RUDRAPUR

Tamil Nadu Punjab Madhya Pradesh Nov 22-25, 2012 Dec 21-24, 2012 Jan 11-14, 2013

Maharastra Feb 1-4, 2013

Uttarakhand Feb 23-26, 2013

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment. For details Infomedia18 Ltd, Ruby House, 1st Floor, JK Sawant Marg, Dadar (W), Mumbai 400 028. Mob: 09819552270 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

Industry Automation & Control Industry Automation & Control is the event where Industrial and Process Automation, Instrumentation and Industrial Electronics come together. It will highlight will highlight factory automation, process automation, instrumentation & controls, Robotics; January 15-18, 2013; Bombay Convention & Exhibition Centre, Mumbai For details, contact: Chemtech Secretariat 26, Maker Chambers VI, Nariman Point, Mumbai - 400 021, India. Tel: +91-22-40373737 Fax: +91-22-22870502 Email: sales@jasubhai.com Web: www.chemtech-online.com

IMTEX 2013 The 16th Indian Metal-cutting Machine Tool Exhibition, with international participation, will showcase an exhaustive range of innovations and technological refinements in the complete product segment of metal-cutting machine tools and manufacturing solutions. The concurrent event—Tooltech 2011— the international exhibition of cutting tools, tooling systems, machine tool accessories, metrology and CAD/CAM will feature the latest trends in cutting tools and tooling systems from across the globe; January 24-30, 2013; Bangalore International Exhibition Centre (BIEC), Bengaluru

For details, contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road Madavara Post, Bengaluru Tel: 080 6624 6600 Fax: 080 6624 6661 Email: info@imtex.in Web: www.imtex.in

Automach The show is focussed on latest technologies and equipments used for developing auto components and vehicle assembly; February 15-17, 2013; Pragati Maidan, New Delhi, India

Plot No 859, Phase-V, Udyog Vihar, Gurgaon-122 016 Haryana, India Tel: 124 452 4207 Fax: 124 452 4234 Email: blech.india@interads.in Web: www.blechindia.com

International Industrial Trade Fair INTEC 2013 The 14th edition of the event will showcase latest in Machine Tools and Accessories, Hydraulics and Pneumatics, Material Handling Equip & Machinery Foundry Equipment’s, Precision Tools, Cutting Tools and Instrumentation and Automation; June 06-10, 2013; Codissia Trade fair Complex, Coimbatore, India For details, contact: CODISSIA GD Nadiu Towers, Post Bag No-3827, Huzur Road, Coimbatore - 641 018. Tel: 0422 2222396 Fax: 0422 2222397 Email: intec@codissia.com Web: www.intec.codissia.com

Productivity Buzz 2012 For details contact: Confederation of Indian Industry Trade Fairs Division, 249F, Sector 18, Udyog Vihar, Phase IV, Gurgaon - 122 015, Haryana, India. Tel: +91-124-4013871 (D) / 4014060, Fax: +91-124-4234170 / 4014080 / 83 Email: rachna.jindal@cii.in Web: www.automach.in

The two-day event is a first-of-its-kind event to display productivity solutions and innovations. The event promises to be a complete platform to share, learn and network with productivity gurus, practitioners, productivity solution providers (exhibitors) and productivity solution seekers (visitors); December 07-08, 2013; Bangalore International Exhibition Centre (BIEC), Bangalore

BLECH India 2013 The event is focussed on sheet metal forming related sheet metal, tube, sections, finished products, components, assemblies handling; April 17-20, 2013; Bombay Exhibition Centre, Mumbai For details, contact: Brooks Exhibitions (India) Pvt Ltd

For details, contact: Bangalore International Exhibition Centre (BIEC) 10th Mile, Tumkur Road, Madavara post Bangalore - 562 123 Tel: 80 6624 6600 Fax: 80 6624 6661 Email: imtma@imtma.in

December 2012 - MMT 129

Event List - International Machine Tool Indonesia 2012 The international event will focus on Machine Tool, Metalworking and Allied Industries; December 05-08, 2012; Jakarta International Expo (JIExpo), Jakarta For details, contact: PT Pamerindo Buana Abadi Deutsche Bank Building 13th Floor Jl Imam Bonjol No 80 Jakarta 10310, Indonesia Tel: +62 (021) 316 2001 Fax: +62 (021) 316 1981 Email: info@pamerindo.com Web: www.pamerindo.com

Email: taitra@taitra.org.tw

Web: www.sheetmetal-asia.com

MTA 2013

China International Industry Fair

The event will focus on the technology and quality required to machine parts and components in metals and composites; April 09-12, 2013; Singapore Expo, Singapore For details, contact: Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore Tel: +65 6233 6638 Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mta-asia.com

Pacific Design & Manufacturing The 13th annual trade show will showcase custom moulding, custom CNC metals processing CAD/CAM, precision machining and rapid prototyping; February 12-14, 2013; Anaheim COnvention Center, Anaheim, CA, USA For details, contact: For general inquiries, please contact: UBM Canon 2901 28th Street, Suite 100 Santa Monica, CA 90405 United States Tel: 310-445-4200 Email: TSsalesadmin@ubm.com Web: www.canontradeshows.com

For details, contact: Taiwan External Trade Development Council (TAITRA) 5-7 Fl., 333 Keelung Rd Section 1, Taipei 11012, Taiwan ROC Tel: 886 (2) 2725-5200 Fax: 886 (2) 2757-6245

130

MMT - December 2012

For details, contact: Shanghai Eastbest International (Group) Co,Ltd CIIF Breach, Add No - 837 Yanâ&#x20AC;&#x2122;an Road (C) Shanghai, China, 200040 Tel: 86-21-62892666 Fax: 86-21-62895703, 62790302

Machine Tool Indonesia CIMT 2013 CIMT is a truly global machine tool sourcing and trading platform for the global advanced manufacturing industry at the worldâ&#x20AC;&#x2122;s largest machine tool market; April, 22-27, 2013; New China International Exhibition Center, Beijing For details, contact: China Machine Tool & Tool Builders Association (CMTBA) No 88 Yuxiang Road, Tianzhu Airport Industrial Zone Shunyi District, Beijing Tel: +86-10-6334 5694 Fax: +86-10-6334 5699 Email: cmtba@cmtba.org.cn

TIMTOS 2013 The 16th international exhibition will showcase the latest in metal working machinery, metal cutting machinery, machine parts & accessories, industrial automatic equipment/machinery, tools, cutting tools, molds and other related equipment; March 5-10, 2013; Nangang Exhibition Hall, Taipei

The event will focus on the latest in manufacturing technology; November 05-09, 2013; Shanghai New International Expo, Shanghai, China

Sheetmetal Asia 2013 The 17th international exhibition will showcase the latest developments in sheetmetal fabrication technology and machinery; May 16-19, 2011; at Bangkok International Trade Exhibition and Convention Centre (BITEC), Thailand For details, contact: UBM Asia (Thailand) Co Ltd 503/23 KSl Tower, Sri Ayuthaya Road Thanon Phayathai, Rajathewee Bangkok, Thailand Tel: +6600 2642 06911 Fax: +660 2642 6919-20 Email: info@sheetmetal-asia.com

The international exhibition on metal cutting machine tools, metal forming machine tools, presses (mechanical, hydraulic, pneumatic), sheet and plate metalworking tools, machinery and accessories, surface treatment, wire and tube forming equipment, precision measurement and testing technology; December 4-7, 2013; Jakarta, Indonesia For details, contact: PT Pamerindo Buana Abadi Deutsche Bank Building 13th Floor Jl Imam Bonjol No 80 Jakarta 10310, Indonesia Tel: +62 (021) 316 2001 Fax: +62 (021) 316 1981 Email: info@pamerindo.com Web: www.pamerindo.com

The information published in this section is as per the details furnished by the respective organisers. In any case, it does not represent the views of

Launch Pad

EMUGE Softsynchro® Modular launches new generation collet holders

he German company association E M U G E FRANKEN, a leading manufacturer of precision tools for thread cutting, gauging, clamping and milling technology has come up with its new series of Softsynchro® Modular. It combines the patented and proven technology of Softsynchro® Minimum length compensation with the requirement

of flexible operations in modern manufacturing facilities. With the modular construction, adaptations such as tool shanks with male or female centre, length adjustments of the tool as well as different coolant-lubricant systems are possible. The HSK-transfer element is available for 1-channel Minimum Quantity Lubrication (MQL) system, 2-channel MQL system and standard internal coolant-lubricant system. These components enable and ensure a reliable, loss-free transport of coolant-lubricant from machine spindle onto the tool tip. Together with the effectiveness of Softsynchro® Minimum length compensation technology, this unique collet holder highly improves the thread manufacturing process.

FARO launches new FARO CAM2 Gage 2.2 software

ARO Technologies Inc., a globally trusted source for 3D measurement technology, released the FARO CAM2 Gage 2.2 software. It is the latest software update for the company’s leading lines of portable measurement solutions, the FaroArm and FARO Gage. New features like enhanced QuickTools, barcode functionality and temperature compensation dramatically expedite and

improve the accuracy of measurement routines. These and over 30 more new features make CAM2 Gage 2.2 one of FARO’s most complete solutions for fast, high-accuracy contact measurement. As part of the newest update to CAM2 Gage, FARO’s temperature probe provides feedback on part temperature during measurement routines. By closely monitoring and automatically

compensating for these changes, CAM2 Gage helps ensure that users receive consistent and accurate results despite changing measurement conditions. “CAM2 Gage 2.2 software presents new features that accelerate and simplify measurement activities,” said Markus Grau, Product & Business Development Manager for the FARO Gage.

Inserts Provide Specialised Solution

ARGUS has its expanded 14D line of high productivity VTXPgrade inserts and toolholder range, designed to meet the unique challenges of tough and unstable applications in the oil and gas industry. The new VTXP grade complements VARDEX’s existing

14D line of industrial solutions for the oil and gas sector, which offer a wide variety of both standard and tailor-made

tools. Designed for internal and external applications, the new VTXP-grade inserts offer increased strength and protection as a result of the unique edge preparation, serving to decrease insert cutting forces and significantly increase the tool life.

COMSOL Multiphysics 4.3a released

ontinuing its tradition of innovation that users have come to expect, COMSOL introduced Version 4.3a of COMSOL Multiphysics®, its flagship software for modeling and simulating physics-based systems. With version 4.3a and in response to user requests, COMSOL introduced LiveLink™ for Excel® to connect multiphysics results with spreadsheets. Version 4.3a also further extends the ability of engineers, scientists 132 MMT - December 2012

LiveLink™ for Excel® adds a dedicated COMSOL® tab to the Excel 2010 for Windows® ribbon bar, providing easy access to COMSOL’s parameters, variables, functions, geometry, mesh, solvers and results.

and researchers to leverage multiphysics to design and optimize breakthrough products and technologies from the desktop to the cloud with new support for cluster computing on the Amazon Elastic Compute Cloud™ (Amazon EC2™). New modules for analyzing fatigue and for importing ECAD files make their debut in Version 4.3a as does the new LiveLink for Solid Edge®, a CAD software from Siemens PLM Software.

Launch Pad

Easier multi-tool use in Radan 2013

ew developments in the 2013 release of the world’s most powerful sheet metal CAD/CAM software, Radan, provide considerably improved support for multitools. Chris Asto, General Manager, Radan, says that the traditional way of setting up multi-tools in the machine system data file is cumbersome and

time-consuming. However, a major concept change in Radan 2013 provides

considerable support for multi-tools. The combination of all enhancements in Radan 2013 provides greater automation while still giving the user manual options. It contains key enhancements to the navigational tools, increasing accessibility to functions; along with improved integration of Radbend; and the addition of colour making it easier to identify parts.

The new KenFeed 2X milling solution from Kennametal

he new KenFeed™ 2X milling solution from Kennametal is the latest development in high-feed for light to heavy end milling operations. Developed from the original KenFeed™ platform, this new generation promises larger depths of cut using larger inserts. These new inserts are engineered to provide superior material removal rates and productivity at high feeds for

roughing operations. Each double-sided trigon insert offers six cutting edges for better cost per edge position with full usage. The thick design of the inserts provides outstanding strength and reliability, making them withstand highfeed operations. KenFeed™ 2X is also the ideal solution for deep cavities or milling operations from 3 x D. The HD insert geometry is the first

choice for steels, highstrength steels, and cast iron, while the GD geometry provides lower cutting forces for softer materials.

Insert geometries and customised tool holders

andvik Coromant has introduce a range of new insert geometries and customised tool holders, featuring fixed nozzles that guarantee a precise coolant jet flow to get right to the centre of the cutting zone. The coolant flows from the pump to the tool through nozzles directed exactly at the cutting zone. This produces a wedge of coolant that efficiently removes the heat from the cutting zone and forms

the chip. Improved chip control and longer tool life are just two of the benefits which contribute to secure and predictable machining, preventing unplanned machine stoppages. The Sandvik Coromant advanced cooling technology has until now been a solution primarily for customers using quick change with Coromant Capto®, SL- and QS holding system. Now, the same premium technology can be applied

with general shank tools, making it possible for everyone working with wet machining to utilise this highly productive coolant solution, even in small lathes.

TI introduces new SafeTI™ design packages

exas Instruments Incorporated (TI) introduced new SafeTI™ design packages for safetycritical medical, industrial and energy motor control applications. They include 15 new Hercules RM4x ARM Cortex-R4 safety microcontrollers and TI’s complementary TPS65381-Q1 multi-rail power supply (PMIC). The Hercules RM4x

microcontroller and PMIC safety chipset maximise failure detection and mitigation while minimising software overhead. The microcontrollers and PMIC adhere to the SafeTI-61508 design package, helping customers to easily achieve IEC 61508 certification and accelerate time to market with safety-critical products. The addition of these Hercules

RM4x safety microcontrollers expands the Hercules microcontroller product line to 35 configurations. The new Hercules RM46x floating-point safety microcontrollers provide additional memory and performance configurations with expanded motor control capabilities and pin-compatibility with Hercules RM48x safety microcontrollers. December 2012 - MMT 133

General Products This section gives information about the national and international products available in the market

Hydraulic system Electrically operated power pack hydraulic systems are compact, portable and light weight. They are equipped with 3way/4way/ double acting cylinders. The power pack includes direct on-line starter/electrical control whenever required. The oil reservoir capacity depends on the stroke volume of the cylinders to be operated. The hydraulic systems can be designed to meet specific customer requirements. Features are flow up to 450 lpm and pressure up to 300 bar. Application areas include hydraulic power units for power plants, steel industry, presses marine applications, hydraulic test benches for hydraulic valves and pumps, lubrication systems, valve stations for steel industry, hydraulic flushing systems with hydraulic oil and water glycol for defence industry.

Automation project design software Software for design of automation project lets you enter project data from the preliminary research stages. A huge part of project planning can be achieved without having to invest time on scheme drawings. It consists of processing tools such as the line diagram and components management. It has been developed as an electrical CAD system for use by design engineering professionals. Scheme diagrams employ intelligent wiring and internationally recognized symbols standards that provide seamless continuity of project data. The modules are available in a variety of bundles e.g. SolidWorks, 3D Routing and cabling module, PDM link, Harness, etc. Ezar Engineering Pvt Ltd Pune, Maharashtra Tel: 020-27111704, 09552593842 Email: hk@ezar.in, solidworks@ezar.in Website: www.ezarengg.com

Achieve Hydraulics & Pneumatics Pune, Maharashtra Tel: 020-66139004/5, 09922449243 Fax: 020-66139003 Email: sales@achievehydraulics.com Website: www.achievehydraulics.com

Motorised lubrication unit Motorised lubrication unit are electric driven pumps along with reservoir, oil filter and breather, suction strainer, pressure relief valve, bleed valve, etc. These units are suitable for single shot automatic oil lubrication. These units are made to run intermittently. During motorâ&#x20AC;&#x2122;s ON time, all the metering cartridges eject out predetermined amount of oil at various points of machine. During the OFF period, the same metering cartridges get recharged for the next lubrication cycle. If desired, these units can be supplied without float and pressure switch as per customers requirement. Units for liquid grease are also manufactured.

Portable circular saw Portable circular saw can effortlessly saw at high speed through all kinds of material such as steel, stainless steel, aluminum and copper. It faces no problems sawing wood and plastic. Showers of sparks belong almost to the collector and therefore the surroundings remain clean. The Blade Runners are lightweight and ergonomically designed. Besides, they are easily manageable, extremely precise and accurate in working. All Blade Runners are equipped with a variable angle setting. They are useful for fast and burr-free working and no greasing or cooling is required. Consortech Tools (India) Ltd Pune, Maharashtra Tel: 020-24445576, 65002414. Email: constech@pn2.vsnl.net.in

Lubrite Industries

3D CAD software

Phagwara, Punjab Tel: 1824- 228438, 329988, 09814121288 Email: info@lubriteindustries.com, lubrite75@hotmail.com Website: www.lubriteindustries.com

SolidWorks 3D CAD software offers three package building in functionality and is tiered to best suit the needs of any organisation. All package utilise the intuitive SolidWorks user interface to speed the design process and make it instantly productive. Machining intelligence is the most advanced CAM programming software available for getting products to market faster, more efficiently and within budget. It is a next generation best-of-class CNC programming solution for producing moulded parts from solid models. It is a Certified Gold Product for manufacturing/CAM

Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MMT (space) Product Name and send it to 51818

eg. MMT EDM and send it to 51818

134 MMT- December 2012

General Products software that provides state-of-the-art machining capabilities seamlessly integrated into SolidWorks design software. It leads the way in advancements in Automatic Feature Recognition (AFR) and Interactive Feature Recognition (IFR). Its modules are available in a variety of bundles and combinations such as 2.5 axis, 3 axis, 4 and 5 axis prepositioning, 4 and 5 axis, simultaneous milling, 2 and 4 axis turning, rotary milling, 2 and 4 axis wire EDM. Ezar Engineering Pvt Ltd Pune, Maharashtra Tel: 020-27111704, 09552593842 Email: hk@ezar.in, solidworks@ezar.in Website: www.ezarengg.com

Fiber laser Optical fiber is used to generate the beam inside the electronic source and transport the beam from the source to the cutting head. It offers a large number of advantage such as elimination of optical path and laser gas as well as the creation of a more simple and compact layout. The single cutting head uses only one lens for high-quality cutting across the entire range of thicknesses. The wavelength typical of fiber means that highly reflective materials, such as high-purity aluminium alloys, brass, copper and galvanised steel can be cut successfully. The airplane structure carriage design is extremely rigid and allows fast and accurate positioning together with easy access to the work piece. Salvagnini Machinery India Pvt Ltd Bengaluru, Karnataka Tel: 09913815775 Email: riddhish.jalnapurkar@salvagninigroup.com Website: www.salvagninigroup.com

Gear head Planetary gear-boxes for servo motors offer high precision, low backlash unit. They are available as both inline units and in right angle configuration. These units are available in 3 levels of backlash â&#x20AC;&#x201C; precision which has less than 3 arc minutes, low back lash which has less than 5 arc minutes and standard which has less than 15 arc minutes. These gear heads come in various frame size which range from A to E with allowable torques upto 92 Nm and peak torques of upto 274 Nm. The motor mounting side is made-to-order in order to match the servo motor. Gear ratios are available from 1:3 to 1:100. The gear heads have a lifetime lubrication and need no periodic maintenance. They are silent operation gear heads in its class. Applications abound in packaging, pharma, machine tools, etc. Strategi Automation Solutions Pvt Ltd Bengaluru, Karnataka

December 2012 - MMT 135

General Products Tel: 080-32329798, 32467879 Fax: 080-41163047 Email:sales@strategiautomation.com Website: www.strategiautomation.com

Hydraulic press brake machine Hydraulic press brakes are highly productive, accurate, and economical. They provide simplified and easily accessible controls for optimum operator efficiency and output. The press brakes are manufactured to high standards of lifetime durability and precision accuracy. Pair of hydraulic cylinders is synchronised mechanically by a heavy-duty torque tube construction. This facility ensures absolute parallelism between ram and table working surface. NC hydraulic press brakes are economical and very reliable solution for industry demand. NC hydraulic press brakes are designed to give more accuracy and better productivity. The controller has a facility to program the various jobs with complex bending sequence on screen. The numeric control is used for two axis control: ram axis Y, back gauge axis X. The program gives facility to bend different bending degrees; different back gauge positions and different open positions. Range is 20 ton to 700 ton and length is 1250 mm to 7000 mm. Energy Mission Machineries (India) Pvt Ltd

136 MMT- December 2012

General Products Ahmedabad, Gujarat Tel: 079-65436237, 09824481470 Email: info@energymission.com , energymission@gmail.com Website: www.energymission.com

punch, shear and bend sheet metal without any interruption in the process that leads from blank to finished part without any need for intermediate handling of the semi-finished parts. Automatic set-up in masked time ensures extremely high levels of productivity and makes “batch one” production possible.

Lathe Machine

Salvagnini Machinery India Pvt Ltd

Heavy-duty, medium-duty and light-duty lathe machines are available. They offer heavy-duty lathes sizes 5’6’’, 7’, 9’, 10’ and 12’, light-duty lathes size in 4’6’’ and 5’3’’ and medium-duty lathes in 4’6’’ and 6’. Heavy-duty lathes are split type, hand scrapped precisely graded bush bearing for running main spindle with flate belt driven cone pulley and tapered r o l l e r bearing at both ends of main spindle w i t h double V-belts driven conepully. Options are open for customers. They offer heavyduty lathes having std 10’’ height of centre and 2’’ spindle hole as well as 12’’ HOC and 3’’ spindle hole charging extra. In light-duty and medium-duty tapered roller bearing is used for running main spindle with V-belt driven conepulley. Graded cast iron for all sliding or running parts are used. In light-duty lathe height of centre is 7’’ and hole through of 11/2’’, cross slide of 6’’ wide, in mediumduty height of centre is of 9’’, hole through spindle of 2’’, and tailstock of 2’’. Customer specifications are also serviced.

Bengaluru, Karnataka Tel: 09913815775 Email: riddhish.jalnapurkar@salvagninigroup.com Website: www.salvagninigroup.com

M/s Sunil Enterprise Rajkot, Gujarat Tel: 0281- 2926239, 09825636244 Email: microlathes@rediffmail.com

Flexible manufacturing systems

Flexible manufacturing systems help in smoothening of automated production, eliminating the costs associated with intermediate material handling, optimising production times and improving factory logistics. The proprietary software provides perfect management and makes unmanned lights-outproduction a reality. The automatic panel production line can December 2012 - MMT 137

General Products

cal The purchase manager should consider the techni rt suppo sales after and ct produ the speciďŹ cations of ct. extended by the company before buying the produ must Considering it as an investment, the consumer pay attention to ďŹ ner details so as to secure ROI.

Snehal Mehta (Director - Marketing) Energy Mission Machineries (India) Pvt Ltd

that the bearing remains permanent and secure in its place. The motor therefore runs more quietly and the bearing is subject to considerably less wear. The sheet metal working tools range comprises of the following tools; nibblers, slitting shears and sheet metal shears for cutting and separating single rolled sheets, corrugated sheet metals, trapezoid sheet metals, pipes and profiles. The range of power tools has the right tool for various metal working materials, applications and trades. Fein Power Tools India Pvt Ltd Chennai, Tamil Nadu Tel: 044-43578680, 11 Email: info@fein.in Website: www.fein.in

Core cutters Sheet metal working tool Sheet metal working tools are developed for continuous use in metal construction and have a robust and ergonomic design. A high-power motor and an optimally coordinated transmission ensures rapid and constant work progress. The power tools are also particularly durable because of a metal transmission head. Unlike the shell design, the barrel-type motor housing design ensures

138 MMT- December 2012

Core cutters having the finest tool design and superior quality raw materials, are used in CNC machines for manufacturing. The core cutters features a perfect and stable start without slipping, have a conical inside surface for easy slug pushing, precise and easy center pilot fitting that saves handling time, ground clamp surfaces, tooth design that facilitates uniform load on each tooth and quick drilling, seizure is virtually impossible, accurate, greater drill depth, strong and tough, less breakage if handled properly and guaranteed slug ejection. From 12 mm to 100 mm in diameter in one mm

General Products increments and above 100 mm to 130 mm in five mm increments are available in depth of cut (DOC) 30 mm/50mm/75mm/100 mm. All flutes are fully ground resulting in superfast feed rates, better chip clearance and higher cutting performance. It is ideal for use where superior red hardness is needed to cut special metals. The TCT cutters are ideal to drill, difficult materials by conventional metal working tools, such as hardox steel, railway tracks, etc. Consortech Tools (India) Ltd Pune, Maharashtra Tel: 020-24445576, 09422323948 Email: constech@pn2.vsnl.net.in Website: www.constechtoolsindia.com

Filter press The polypropylene executor ser ies filter press is ideal for p ro v i d i n g filtration capacities in the range of 5 to 50 KLD of sludge per day. It is

used

for

separating

suspended

December 2012 - MMT 139

General Products solids from the liquids. In the plate and frame type, the plates,the frames and the plate accessories of the filter press are placed on two horizontal parallel bars and are pressed together in between two end plates (i.e. fixed and moving ends) by a closing device. The material to be filtered is then pumped into the press which goes to all the frames where the filter media stops the suspended solids and allows only the clear liquid to go through the discharge ports leaving the solids in the frame. In the recessed type, the slurry is fed through the central inlet and the solids are retained in the recess between the plates, while the filtrate is collected through the corners. Fluid Control Equipments Chennai, Tamil Nadu Tel: 044-24349179 Email: fluidcon@md3.vsnl.net.in Website: www.flu-con.com

Cordless driver drill The cordless driver drill has application areas in the field of construction,wood working,metal working and other engineering segments. It has a soft wood capacity of 18 mm, wood screw capacity of 6 mm diameter x 38 mm and machine screw capacity of 6 mm. It has a compact design at 147 mm long and weighs 0.8 kg. It has a drive of 6.35 mm hex bit shank with a maximum torque in lock of 10 Nm. The battery capacity of 1.5 Ah provides longer run time. The load speed of 0-400 RPM covers a wide range of drilling applications. Standard accessories such as the battery (BCL1015), charger (UC10SFL), driver bit and a carrying case are also available. Hitachi Koki India Ltd Bengaluru, Karnataka Tel: 080 - 28396198 Email: ho@hitachi-koki.in Website: www.hitachi-koki.in

Bench grinder Bench grinder with built in dust collector is specially designed for collecting dust generated during the grinding process. It is mounted on a rigid steel frame and has high filtering efficiency, enabling it to grasp even the finest dust particles. It has features like low power consumption and low noise level. Cotton filtering sleeves provide total security against inflammation. It has a 1.0 HP, 3 phase 2800 RPM grinding motor, 3 phase dust collector motor and is fitted with a manual shaker. The machine has dimensions of 775 x 800 x 1050 mm.. Prem Brothers New Delhi Tel: 011-28117456, 28117464, 45595068 Email: powermaster59@gmail.com Website: www.powermaster-india.com 140 MMT- December 2012

General Products Cathodic lectrocoating Cathodic electro deposited coating is used extensively in the automotive industry. In this process, the component after phosphate pre-treatment is dipped in the bath of ecoat chemicals and is given an electric charge. The coating gets deposited on the component. The component is removed from the bath, washed and then baked. This process requires the following auxiliary equipment: hot water generator, RO water system, DI water system, laboratory and effluent treatment plant. Coatec India Mohali, Punjab Tel: 0172 - 5090231 Fax: 0172 - 50963469 Website: www.coatecindia.com

Flap disc Flap disc can be used for quick grinding due to consistent high abrasive quality right up to the last abrasive grain. Maximum economic efficiency due to increased performance per time unit and less wear on discs is attained. Grinding work with high stock removal performance is achieved. It features largest possible stock removal. The innovative design of the ceramic grit abrasive reduces sparks to a minimum. This means that damage to stainless steel work pieces caused by glowing sparks flying around is almost excluded. The surface temperature is reduced by 30 % during the grinding process which makes sure that there is no heat accumulation, no deformation, no thermal damage to the joints in the work piece. Tool life and aggressiveness for surface grinding and for the leveling of welds are 50 % higher than those of conventional flap discs. Besides, there is no glazing and constant use right down to the last grit. SWIT India Bangalore, Karnataka Tel: 080 â&#x20AC;&#x201C; 42187117, 09741481117 Email: sales@pferd.co.in Website: www.pferd.com, www.swit.in

Drilling cum milling machines The drilling cum milling machines are used for drilling, milling, tapping, lapping and counter boring. The drilling capacity of these machines is 40 mm, with face mill capacity of 25 mm, tapping capacity of 22 mm in cast iron and drilling capacity of 35 mm in mild steel. Quill spacers are made from steel while main spindle are made EN Steel with 6 slots. Spindle nose is MT-4, spindle travel is 170 mm, spindle speed of 8 gears 142 MMT- December 2012

General Products made from best quality material and helical teethed for smooth and noiseless running. These can be applied for better and accurate square and parallel cutting. Siddhapura Industires Bhavnagar, Gujarat Tel: 0278-2445148, 09824246655 Email: bipin@siddhapuradrills.com Website: www.siddhapuradrills.com

Thermal camera Thermal camera picturises the difference in temperature of desired objects under load/ running condition without touching or taking a shut down. This technique is being used for predictive maintenance and many other applications. Apart from electrical and mechanical uses, this technique is being used for different industrial applications like automation, medical, building, research and development, gas detection and security. The infrared image resolution ranges from 160x120 pixels to 320x240 pixels depending on camera model. Every additional pixel means more valuable temperature information to isolate problem areas. The camera is compact, lightweight and extremely rugged and can withstand a 2 meter drop. Visible light camera makes observing and inspecting faster and easier. High accuracy of Âą 2% or Âą 2 Â°C of reading is achieved. A conveniently located button activates the

December 2012 - MMT 143

General Products laser pointer that will help you associate the hot or cold spot in the thermal image with the real physical target in the field. Flir Systems India Pvt Ltd New Delhi Tel: 011-45603555, 47212006 Email: flirindia@flir.com.hk Website: www.flir.com

Drill bit grinder machine Drill bit grinder machine is used for 2 mm to 13 mm twist drill re-sharpening, at an angle 118째135째. It gives precise grinding results and has a precision assurance within 0.02 mm. Special design high accuracy alloy steel collets are used. Accurate grinding consumption of 0.2 mm is acquired. It has a high efficiency DC motor, stable quality GE diamond dust grinding wheel, invisible tool box, delicate and user-friendly portable design weighing 7 kg. J K Machines Corp New Delhi Tel: 011-26361242 Email: info@jkmachinescorp.com Website: www.jkmachinescorp.com

December 2012 - MMT 145

General Products Angle lock vise The angle vise comes in two operating methods mechanical and hydraulic. Vise body is made of ductile iron FCD-60.Vise bed is hardened to HRC45 and maintains accuracy for long. Vise bed height-size and the guide block side are all made with full control. The machine has 4 ways of clamping. It also has a down thrust with ‘semi-sphere’ to prevent work piece lift. JIN YEAR PRECISION CO LTD Tel: 886-4-25232817 Email: liu0930@ms58.hinet.net, jinyear.vise@msa.hinet.net Website: www.jinyear.com.tw

Vertical machining center The 3-axis machining center represents an economically attractive version for small and medium size production shops. Parts with diameters up to 800 mm can be processed on a set-up area of only 6 m². The benefits of this product are high quality parts at low per-part costs, excellent accessibility to the parts and tools, quick programming and short conversion times. Large door openings and a short control distance allow work pieces and tools to be changed quickly. Pittler T & S GmbH Gutenberg Tel.: +49 (0) 6074 4873 0 Email: vertrieb@pittler.de Website: www.pittler.de

Tapping chuck The QCSL non-reversible tapping chuck is specially developed for builders of heavy machinery, turbines, motors, nuclear reactors and other types of heavy equipment. Capacity of the tapping chuck ranges from M30 to M200. This chuck is available in morse taper, ISO taper or in special shanks. The tapping chuck is suitable for heavy jobs and for tapping on higher diameter. It is provided with length compensation features that allow the tap to act as its own lead screw. IMI Machine Tools Pvt Ltd Ahmedabad, Gujarat Tel: 02764-233983 Email: imi@imitoolsindia.com Website: www.imitoolsindia.com

Base circle discs Base circle discs are made of high alloy tool steel and hardened to 60 HRC. The discs are sub-zero treated for dimensional stability and calibrated at 20°C under standard room conditions. Design is as per customers’ requirements. The manufacturing range is from 40 mm to 300 mm. Cyclo Instruments Pvt Ltd 146 MMT- December 2012

General Products / 300 x 6oo mm) is hydraulic. The machine features the wheel head spindle hardened & ground, runs on precision angular contact bearings with imported grease and is driven by flange mounted motor through flexible couplings. Dimensions with wheel head micro feed is 0.002 mm. cts One must make a comparison of different produ ct. He produ any buying before d offere es servic and and must also possess industry speciďŹ c knowledge avoid know-how of the product before purchasing to unnecessary expense.

Arun Nene Mentor Jyoti CNC Automation Pvt Ltd

Satara, Maharashtra Tel: 02162-240406, 09922424224 Email: cycloinstruments@sify.com

Surface grinding machine manual Hand scraped to fine tolerance, the manual surface grinding machine (working surface with manual oil dip of 225 x 450 mm

148 MMT- December 2012

Atul Machine Tools Rajkot Tel: 09227602034, 0281-2360227, 02827- 287607 Email: info@atulmachine.com Website: www.atulmachine.com

Micro grain carbides Micro grain carbide is used for aluminum alloy processing end mills. These are suitable for copper, aluminum, aluminum alloy, copper alloy, nickel alloy, titanium alloy and plastic processing. Micro grain carbides are high-performance tools manufactured with 5-axis CNC grinding machines from Germany. Zen Wu Zheng Sun Tool Co Ltd Kaohsiung City, Taiwan Tel: +886-7-3525743 Fax: +886-7-3544111 Email: first@jsk-tools.com.tw Website: www.jsk-tools.com.tw

MMT December-12 Ad Name: Samkrish Pg No.153

MMT December -12

Ad Name: Emuge Pg No. 154

MMT December -12 Ad Name: Quaker Pg No. 155

MMT December -12 Ad Name: Brila Pg No. 156

List of Products Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MMT (space) Product Name and send it to 51818

eg. MMT EDM and send it to 51818 Product

Pg No

3 axes high speed machining center...................13 3 axes machining center.....................................12 3D CAD software ...........................................134 5 axes high speed machining center....................13 5 axes machining center...................... 12, 131, 165 5 faces double coulmn milling machine............182 AC gear motor ..................................................18 AC servo motor ................................................18 Advance cutting material...................................31 Aerosol multispray ............................................83 Aerospace machine .........................................179 Airline fluid ......................................................83 All geared auto feed pillar drilling machine ......168 Analog timer.....................................................14 Angel head .......................................................66 Angle encoder ................................................BIC Angle lock vise................................................146 API gauge.........................................................26 Assembly and high temperature grease...............83 Assembly technology and transfer system ...........66 Auto feed radial drilling machine.....................168 Automation .............................................. 99, 106 Automation product........................................127 Automation project design software .................134 Automotive lubricant ......................................152 Balancing machine ..........................................105 Ball screw .........................................................37 Ball screw support shaft ....................................37 Ball screw support unit......................................37 Bar feeder ................................................. 67, 111 Base circle disc ................................................146 Bearing .............................................................70 Bed type/travelling column milling machines/boring .............................................159 Bench grinder .................................................140 Bending ..........................................................141 Bonded abrasive ..............................................181 Bone screw .......................................................26 Boring machine ................................................66 Boring mill .....................................................136 Broaching machine .........................................108 Building automation .......................................106 Burnisher .......................................................175 Business park and community center .................81 Cabinet ..........................................................160 Cable and hose carrier .....................................143 Cable carrier .....................................................70 Cable conduit ...................................................33 Cable connector ................................................70 Cam follower ..................................................136 Camworks ......................................................135 Carbide end mill ...............................................16 Carbide endmill tool ....................................... BC Carbide rod ......................................................59 Carpet extractor ..............................................175 Cathodic electrocoating ..................................141 Chain ...............................................................70 Chain oil ..........................................................83

164 MMT - December 2012

Product

Pg No

Chuck jaw.........................................................99 Clamping tool................................................. BC Cleaner...........................................................155 Clomping and accessories for automat ...............64 Closed PLC CNC system................................117 CNC ......................................................5,13, 104 CNC automatic line .................................... 28, 74 CNC cutting machine .....................................106 CNC double column machining center ..............10 CNC equipment ...............................................35 CNC grinding machine ............................... 28, 74 CNC horizontal borer ..............................131, 165 CNC horizontal boring and milling machine .....10 CNC horizontal boring machining .............. 28, 74 CNC horizontal machining center..........10, 28, 74 CNC horizontal turning center .........................10 CNC laser cutting machine .............................106 CNC lathe ......................................28, 74,131,165 CNC lathes/turn mill ........................................12 CNC machine..........................................7,13,115 CNC machine tool ..................................28,65, 74 CNC machining .............................................109 CNC machining center ............................... 13, 24 CNC milling machine .....................................138 CNC multi-tasking center.................................10 CNC oxy fuel cutting machine ........................106 CNC plasma cutting machine ..................106, 138 CNC robodrill ............................................ 28, 74 CNC sliding headstock machine........................55 CNC small machining center ............................24 CNC tap chuck and tap adaptor ......................177 CNC tap holder and pull stud .........................177 CNC toolholder..............................................145 CNC tools holders and pull stud .....................177 CNC turning ..................................................109 CNC turning center ..........................................13 CNC turning machine ................................ 28, 74 CNC turn-mill center .......................................10 CNC vertical chucker.................................. 28, 74 CNC vertical machining center ......... 10,13, 28, 74 CNC vertical turning lathe ................................10 Co2 laser marker series......................................85 Coated abrasive and super abrasive ..................181 Coating machine.............................................106 Coating plant..................................................106 Coating system ...............................................106 Coating thickness gauge....................................45 Collet and tool holder ......................................64 Collet chuck ...................................................145 Combination machine.....................................175 Commercial vacuum cleaner............................175 Compressor oil .................................................83 Connector .................................................. 51, 70 Control cabinet .................................................51 Control panel ...................................................51 Control system..................................................51 Controlling machine tool ...............................BIC Conventional phase failure relay ........................14

Product

Pg No

Coolant ..........................................................149 Coolant thru turning solution ...........................64 Cordless driver drill ........................................140 Core cutter .....................................................138 Coromill .......................................................FGF Corothread ...................................................FGF Corrosion preventive.......................................155 Counters ..........................................................14 Counters and power supplies .............................57 Countersink............................................... FIC, 9 Crush blade ......................................................61 Cutting fluid...................................................155 Cutting machine .............................................106 Cutting tool ................................... 16,19,59,61,63 Cyclone scrubber ............................................175 Cylindrical and internal grinding .......................69 Deep hole drilling .............................................66 DFMPro ........................................................135 Diamond tool ............................................ FIC, 9 Didactic equipment for training ........................51 Die coater .........................................................61 Die/mould machine ........................................182 Dies and gauge .................................................64 Diode end pumped laser marker ........................85 Diode side pumped laser marker ........................85 Drawing and forming compound .....................155 Drill ......................................................... 16, 168 Drill bit grinder machine.................................145 Drill tool ........................................................ BC Drilling cum milling machine .........................142 Drilling machine................................. 66, 167,168 Drilling tool ..........................................FIC,9, 19 Drilling unit ...................................................157 Drive technology ...........................................BIC Drives.............................................................104 Edrawings publisher........................................135 Element shrink disc ........................................136 Encoder ............................................................57 Exhibition : Blech India 2013 ............................54 Exhibition- Engineering Expo .........................173 Expandable mono block-reamer ......................113 Exposed linear encoder ..................................BIC Extrusion screw.................................................26 Factory automation .........................................106 Fiber laser.......................................................135 Fiber laser cutting machine ...............................49 Fiber laser marker .............................................85 Filter press......................................................139 Financial solution .............................................15 Flap disc .........................................................142 Flexible manufacturing system ........................137 Floating holder ...............................................177 Floor automation ............................................150 Fork head .........................................................66 Form measurement .........................................107 Freewheel-oneway-clutch ................................136 Gantry automation..........................................150 Gantry machining center.................................136

List of Products Product

Pg No

Gantry type machining center ...........................55 Gap frame press ..............................................143 Gas spring ................................................ 86, 116 Gear box ..................................................... 37, 56 Gear cutting .....................................................12 Gear cutting machine......................................182 Gear grinding ...................................................12 Gear head .......................................................135 Gear inspection center ......................................12 Gear milling solution for CNC milling and turn-mill machine ............................................................22 Geomcaliper ...................................................135 Glass ................................................................58 Grease ..............................................................83 Greases and specialities ...................................152 Grinding ........................................................157 Grinding machine .................................58, 66,158 Grinding tool for hard material .........................58 Grooving and parting tool .................................59 Gun drill ................................................... FIC, 9 Handling-system module ..................................51 Hard cut end mill..............................................16 Heat exchanger machine .................................167 Helical gear box ................................................56 High performance tooling .................................64 High precision tap ............................................64 High speed drill tap center .......................131, 165 HMC .............................................................167 Hold back .......................................................136 Holemaking......................................................31 Holemaking tool ...............................................61 Honing machine ...............................................66 Horizontal boring mill ....................................182 Horizontal machining center .. 5,12,13,55, 131, 165 Horizontal milling machine ............................182 Hot and cold forming........................................12 Hydraulic and gear oil .......................................83 Hydraulic cylinder ..........................................108 Hydraulic equipment ......................................108 Hydraulic forging hammer ..............................148 Hydraulic machine .................................... 67, 111 Hydraulic power pack......................................108 Hydraulic press .................................. 108,143,148 Hydraulic press brake machine ........................136 Hydraulic press brake ........................................49 Hydraulic shearing machine ............................143 Hydraulic system ............................................134 Imaging and vision system ..............................106 Indexable tool ...................................................16 Inductive proximity switch ................................33 Industrial cleaning ..........................................163 Industrial control and sensing device .................57 Industrial lubricant .........................................152 Industrial robot...............................................169 Industrial vaccum cleaner ................................175 Internal turning solution ...................................64 Iron and steel part .............................................61 ISO and milling inserts .....................................16 ISO turning inserts ...........................................16 Jig boring class ..................................................12 Jig grinding.......................................................12 Keyless transmisson element ...........................136 Knife grinding machine.....................................95 Knurling and marking tech................................64 Lamp pumped laser marker ...............................85

166 MMT - December 2012

Product

Pg No

Large part drilling machine .............................167 Large part milling machine .............................167 Large size machining center ............................182 Laser cutting............................................141, 157 Laser cutting machine .......................................85 Laser engraving machine ...................................85 Laser marking machine .....................................85 Laser shaping....................................................58 Laser welding machine ......................................85 Lathe ................................................................. 5 Lathe chuck ......................................................99 Lathe machine ................................................137 LED .................................................................33 Length gauge .................................................BIC Lens mold.........................................................61 Level controller.................................................57 Linear bearings and shaft ..................................37 Linear guide way ...............................................37 Linear motion system ........................................37 Load break switch .............................................33 Machine measurement ...................................BIC Machine tool accessories .................................177 Machine tools and spares ................................139 Machinery loan .................................................15 Machining and grinding fluid..........................155 Machining center ........................................ 66, 91 Magnescale technology ...................................153 Magnetic modular encoder .............................BIC Material handling ...........................................162 Material testing ..............................................107 Measured value acqusition and DIS ...............BIC Measurement equipment.................................107 Measuring and monitoring relay for 1ph/3ph .....57 Measuring instrument ............................... 66, 105 Measuring technology .......................................95 Metal cutting tool ...........................................161 Metal injection moulding ................................139 Metrology equipment......................................107 Micro grain carbide .........................................148 Micrometer screw and DTI plunger rack ...........26 Micron drill ......................................................61 Milling ...............................................19, 31, BIC Milling / drilling machine .................................12 Milling center .....................................FIC,5, 9,59 Milling grade ................................................FGF Milling head .....................................................66 Milling machine ....................................... 66, 167 Milling tool ................................................61,BC Modular tooling system.............................. FIC, 9 Mold component ..............................................61 Motion control ...............................................104 Motor ........................................................ 56,104 Motor protection circuit breaker........................33 Motor spindle .................................................151 Motorised lubrication unit ..............................134 Motors and control .........................................108 Multi function turret................................. 67, 111 Multi functional tool ........................................59 Multimedia union ..................................... 86, 116 Multipurpose machining center.........................55 Multispindle automatic lathe.............................55 NC lathe...........................................................91 Open PLC CNC system..................................117 Optical measurement ......................................107 Other automation accessories ..........................117

Product

Pg No

P4-1612 panel bender......................................141 P4-2220 panel bender and material handling ...141 Panel bending machine .....................................49 Panel meter ......................................................14 PCB drill ..........................................................61 PCD and carbide reamer .................................113 Penta IQ grip for grooving and parting..........BGF Phase failure relay .............................................14 Photo electric sensor .........................................57 Pillar drilling machine ....................................168 Pilot light .........................................................33 Plasma 3D ......................................................157 Plasma cutting machine ....................................49 PLC ...............................................................127 Plug and socket.................................................33 Port .................................................................81 Portable circular saw .......................................134 Power press.....................................................143 Power source ..................................................114 Precision gear cutting tool...............................182 Precision locknut ..............................................37 Precision steel ...................................................58 Precision switch single and multiple ..................33 Press brake machine ........................................143 Pressure sensor for wet packaging application ..112 Process automation and control equipment........51 Process oil ......................................................152 Productivity Buzz ...........................................144 Programmable logic controller ........................127 Proximity sensor ...............................................57 Pump .............................................................108 Punching .................................................141, 157 Punching laser cutting ......................................49 Punching shering machine ................................49 Push button ......................................................33 Quick change tapping chucks and tap adaptor ............................................177 Rack ...............................................................160 Rack and pinion................................................37 Radial drilling machine ...................................168 Reamer ...................................................... FIC, 9 Reaming and tapping ......................................177 Rear cylinder hydraulic press brake ..................143 Relay ................................................................14 Robotic automation ........................................150 Roll forming machine .......................................49 Rolling oil ......................................................155 Rotary damper .......................................... 86, 116 Rotary encoder...............................................BIC Rotary feed back .............................................104 Rotary joint and union .............................. 86, 116 Rotary pump ...................................................... 5 Rotary switch ....................................................33 Rotating union ......................................... 86, 116 Rust preventing ..............................................155 S4 punching-shearing system ..........................141 Safety lig...........................................................57 Safety protection device ....................................33 Sawblade grinding machine ...............................95 Screw press .....................................................148 Scrubber dryer ................................................175 Sealed linear encoder .....................................BIC Servo drive......................................................127 Servo motor and drive .....................................117 Shearing machine ...........................................143

List of Products Product

Pg No

Sheet metal working machinery .........................62 Sheet metal working tool.................................138 Shock absorber ......................................... 86, 116 Shrinking technology ......................................105 Single disc ......................................................175 Single limit switch ............................................33 Siphon system........................................... 86, 116 Slant / flat bed .........................................131, 165 Slotting machine.............................................139 Solid carbide drill.....................................113, 161 Solid carbide drill with IC ...............................161 Solid carbide mill ............................................161 Solid carbide reamer........................................161 Solid carbide reamer with IC ...........................161 Solid carbide special drill.................................161 Solid carbide special mill .................................161 Solid carbide special reamer ............................161 Solid mono block reamer.................................113 Solid state laser cutter .......................................85 Special boring bar ...........................................113 Special fine boring tool ...................................113 Special hydraulic expansion technology .............99 Special induction hardening machine ..............114 Special line boring tool ...................................113 Special reaming tool........................................113 Spindle ...........................................................151 Spindle nose tooling .........................................59 Stacking system ................................................49 Standard fine boring tool ................................113 Standard induction hardening machine ...........114 Stationary work holding ....................................99 Steam cleaner .................................................175

168 MMT - December 2012

Product

Pg No

Steering shafts and nut ......................................26 Stepper motor and drive ..................................117 Surface and profile grinding ..............................69 Surface grinder ........................................131, 165 Surface grinding machine manual ....................148 Sweeper ..........................................................175 Swiss type auto lathe .........................................64 Switching relay .................................................57 Synthetic and semi synthetic metal working fluid149 Tap .................................................................. 9 Tap FIC, .......................................................154 Tapping chuck ................................................146 Tapping holder ......................................... 17, 156 Tapping system...............................................145 Temperature controller ............................... 14, 57 Temperature indicator ......................................14 Tensioner nut .................................................136 Thermal camera ..............................................143 Thread grinding................................................26 Thread mill.......................................................22 Thread milling cutter and tap holder ...............154 Thread plug and ring gauge...............................26 Thread roll .......................................................26 Threading tool .........................................113, BC Timer ...............................................................57 Tool grinding ...................................................69 Tool grinding machine......................................95 Tool holder ....................................................105 Tool holding system..........................................99 Tool logistic system ........................................105 Toolholding collect.........................................145 Tooling system ..........................................31, BC

Product

Pg No

Toolings for edm / wedm / vmc-s / hmc-s ..........49 Touch probe ..................................................BIC Track roller ....................................................136 Transformer oil...............................................152 Transparent gel.................................................83 Tubing accessory ..............................................51 Turning ..............................................19, 31, BIC Turning holder .................................................59 Turning mill .....................................................66 Turning tool ..............................................61, BC Turnmill center .......................................... 28, 74 Turret punching machine..................................49 Ultra high pressure apparatus ............................61 Ultra precision micro milling .............................64 Universal quick change chuck and adaptor for drilling ......................................177 Vaccum chuck........................................... 67, 111 Valve ................................................................51 Valve terminal ..................................................51 Velocity and feed controller ....................... 86, 116 Vertical machining center........ 5,11,12, 55,103,146 Vertical machining centers-single / double coloumn .......................................131, 165 Vertical turning lathe ......................................136 Vertical turret lathe ...........................................20 Vision sensor ....................................................57 Warehousing / logistics .....................................81 Wear parts ........................................................59 Wear resistant tool............................................61 Wire cut EDM ...............................................103 Workforce accommodation ...............................81 Worm shaft ......................................................26

List of Advertisers Advertiser’s Name & Contact Details

Accut Machinery Co. Ltd.

Pg No

136

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Drass Mechatronics & Machinery Pvt

103

Castrol

T: +86-411-84804589

T: +91-44-42198885

T: +91-80-23478764

E: info@accutmachinetools.com

E: TN.Suresh@castrol.com

E: info@drassautomech.com

W: www.accutmachinetools.com

W: www.castrol.com

ACE Micromatic Group

W: www.drassautomech.com

Ceratizit India Pvt Ltd

Durr Ecoclean-A Division Of Schenck

163

T: +91-80-41492285

T: +91-33-24947146

T: +91-20-30585001

E: customercare@acemicromatic.com

E: info@ceratizitindia.co.in

E: info.india@ecoclean.durr.com

W: www.acemicromatic.net

W: www.ceratizit.com

Ann Way Machine Tools Co., Ltd. 142

Chrystec Machine Tools Pvt. Ltd.

W: www.durr-ecoclean.com 12

EFD Induction Limited

114

T: +886-4-2563-1259

T: +91-80-40927021

T: +91-80-7820404

E: annway.tools@msa.hinet.net

E: pmascarenhas@chrystec.com

E: sales@efdgroup.net.

W: www.annwaytools.com.tw

W: www.chrystec.com

W: www.efd-induction.com

Autotech Machine Tools Sales & Services

Coatec India

106

Electromech Material Handling Sys P

T: +91-20-25690044

T: +91-172-5063436

T: +91-20-66542222

E: autocnc@vsnl.com

E: info@coatecindia.com

E: getcranes@emech.in

W: www.autotechcnc.com

W: www.coatecindia.com

Axiconn

138

Crane-Bel International Pvt Ltd

162

W: www.emech.in 108

Emuge India Pvt Ltd

154

T: +91 9746262618

T: +91-120-3263281

T: +91-20-39310000

E: info@axiconn.com

E: office@crane-bel.com

E: marketing@emugeindia.com

W: www.axiconn.com

W: www.crane-bel.com

Big Daishowa Seiki Co. Ltd

T: +81-729-828277 W: www.big-daishowa.com Birla Precision Technologies Ltd B

156

T: +81-729-828277 W: www.indiantool.com Blech India 2013

T: +91 124 4524207 E: bleoh.india@interads.in W: www.blechindia.com 45

T: +91-22-2342 6495 E: info@bombaytools.com W: www.bombaytools.com T: +91-124-4283106 E: info@brisloy.com W: www.brisloy.com

170 MMT - December 2012

W: www.emugeindia.com 64

179

Engineering Expo

173

T: +91-22-24943540

T: +91-09819552270

E: anevatia@daggermaster.com

E: engexpo@infomedia18.in

W: www.daggermaster.com Danobat Group

157

W: www.engg-expo.com Ermaksan Machinery

T: +91-20-66094531

T: +90-224-2947500

E: nmehta@danobatgroup.com

E: emre.ozkaya@ermaksan.com.tr

W: www.danobat.com

W: www.ermaksan.com.tr

Dijet Industrial Co Ltd

Erwin Junker

T: +91-22-40121231

T: +91-20-26053896

E: ravisane@dijet.co.jp

E: info@junker.in

W: www.dijet.co.jp

Bombay Tools Supplying Agency

Brisloy Tools India Private Limited

Dagger Master Tool Industries

158

W: www.junker.in

Dongguan Minglee Steel Mould Products Co.,Ltd 68

Everising Machine Co.

140

T: +86-769-8311-8946

T: +886-4-2359-3178

E: patrickho@wim.hk

E: jacqueline@everising.com.tw

W: www.minglee.com Doosan Infracore India Pvt Ltd

W: www.everising.com 10

Fagor Control Systems Pvt Ltd

104

T: +91-80-42660122

T: +91-80-42682828

E: sandesh.kumar@doosan.com

E: info@fagorcontrolsystems.es

W: www.doosaninfracore.com

W: www.fagorautomation.com

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Farmax Machines Private Limited

Advertiser’s Name & Contact Details

Pg No

Haas Automation India Pvt Ltd

Advertiser’s Name & Contact Details

Isgec Heavy Engineering Ltd

T: +91-80-28435034

T: +91-22-61392800

T: +91-120-4085001

E: skr@farmax.in

E: indiasales@haascnc.com

E: trading@isgec.com

W: www.farmax.in

W: www.haascnc.com

W: www.isgec.com

Festo Controls Ltd

Haimer India Pvt Ltd

105

T: +91-20-66 75-0551

T: +91-1732-307211

E: info_in@festo.com

E: haimer@haimer.in

E: presses@isgec.com

W: www.festo.com

W: www.haimer.in 20

Heidenhain Optics & Electronics (I)

Jyoti CNC Automation Pvt. Ltd.

T: +91-44-30234000

T: +91-2827-287081

E: fullton@fulltontech.com

E: info@heidenhain.in

E: info@jyoti.co.in

W: www.fulltontech.com

W: www.heidenhain.in

W: www.jyoti.co.in

161

Hong Ji Precision Machinery Ltd.

T: +886-4-2335-0356

T: +91-80-41158997

E: info@gwindia.in

E: hongji_jasonlin@hotmail.com

E: gm@kabelschlepp.in

W: www.gwindia.in

W: www.hong-ji.com.tw 14

Hwacheon Asia Pacific Pte Ltd

Kabel Schlepp India Pvt. Ltd.,

T: +91-80-40431252

Gelco Electronics Pvt Ltd

165

W: www.isgec.com BIC

T: +86-411-82767678

G W Precision Tools India Pvt Ltd

131

Isgec Heavy Engineering Ltd

T: +91-80-22894100

Fullton Machinery Co Ltd

Pg No

143

W: www.kabelschlepp.com 115

Komet Precision Tool India Pvt Ltd

113

T: +91-79-22200902

T: +91-20-30429140

T: +91-80-280780000

E: info@gelco-world.com

E: sales@hwacheonindia.com

E: info.in@kometgroup.com

W: www.gelco-world.com

W: www.hwacheon.com

W: www.kometindia.com

Geometric Ltd

135

Hyundai Wia India Pvt. Ltd

Korber Schleifring Gmbh

T: +91-22-67056880

T: +91-9940653703

T: +91-80-41554601

E: inquires@camworks.com

E: mvhari@gmail.com

E: sales@schleifring.in

W: www.camworks.com

W: www.hyundai-wia.com

Greenleaf Corp

123

IFM Electronics India Pvt Ltd

W: www.schleifring.in

112

Korloy India Tooling Pvt. Ltd.

T: +91-2312672770

T: +91-124-4930080

E: info@wexper.com

E: info@ifm-electronic.in

E: sales.kip@korloy.com

W: http://www.wexper.com

W: www.ifm-electronic.in

W: www.korloy.com

Gsk CNC Equipment Co. Ltd

Igus India Pvt Ltd

T: +91-80-39127800

T: +91-9650892692

E: gskwang@hotmail.com

E: info@igus.in

E: r_ota@kyocera.net.in

W: www.gsk.com.cn

W: www.igus.in 150

IMI Impex Pvt Ltd

Kyocera Asia Pacific India Pvt Ltd

T: +91-9886835186

Gudel India Pvt Ltd

W: www.kyocera.com.sg 177

Larsen & Toubro Limited

BGF

T: +91-20-25459531

T: +91-079-65499019

T: +91-22-67051093

E: info@in.gudel.com

E: imi@imitoolsindia.com

E: sm.haridas@larsentoubro.com

W: www.gudel.com

W: www.imitoolsindia.com

W: www.larsentoubro.com

Guhring India Private Limited

FIC

Intec Capital Ltd

Larsen & Toubro Ltd

127

T: +91-80-40322500

T: +91-8860612707

T: +1800-2335858

E: info@guhring.in

E: marketing@inteccapital.com

E: cic@lntebg.com

W: www.guhring.in

W: www.inteccapital.com

W: www.larsentoubro.com

176 MMT - December 2012

List of Advertisers Advertiser’s Name & Contact Details

Pg No

Lexis Tooling Systems

145

Advertiser’s Name & Contact Details

Mitutoyo South Asia Pvt Ltd

Pg No

107

Advertiser’s Name & Contact Details

P R Sales Corporation Pvt Ltd 67,111

T: +91-422-3052110

T: +91-11-26372090

T: +91-20-25437591

E: sales@lexisindia.com

E: delhi@mitutoyoindia.com

E: info@prsales.in

W: www.mitutoyoindia.com

W: www.prsales.in

W: www.lexisindia.com Lico Machinery Co., Ltd.

147

T: +886-4-2563-0950 E: sales@licomachinery.com W: www.licomachinery.com Maco Corporation India Pvt Ltd

86, 116

E: rdutta@macocorporation.com W: www.macocorporation.com 168

E: makwana_eng@yahoo.com W: www.makwanaeng.com Marox Tools Industrial Co. Ltd.

146

E: service@marox.com.tw W: www.marox.com.tw Matrix Machine Tool (Coventry) Ltd.

T: +91-44 (0) 2476 71 8886 E: sales@matrix-machine.com W: www.matrix-machine.com Mehta Cad Cam Systems Pvt Ltd

T: +91-79-26840551 E: sales@mehtaindia.com

E: para.mill@msa.hinet.net

W: www.moonlightindustrie.com

W: www.paramill.com

117

T: +91-80-42105031 E: sales@metrolindia.com W: www.toolsensor.com Mitsubishi Heavy Industries India P ld

182

T: +91-11-41021234 E: mtdsales@mhiindia.com W: www.mhiindia.com

178 MMT - December 2012

Phd Abu Dhabi

T: +91-80-28374885

T: +971 (0)4 4574570

E: sales@nerigroup.in

E: Mohammed.Halawi@phdnetwork.com

W: www.nerigroup.in

W: www.kizad.com 159

Precihole Machine Tools Pvt Ltd

T: +91-20-25654891

T: +886-3-329-9968

E: u.medha@correaanayak.es

E: pshtech@gmail.com

W: www.correanayak.es

W: www.peei.com.tw 175

Precimac Solutions

151

T: +91-22-61188188

T: +91 -9325277701

E: balajnee.soundararajen@nilfisk.com

E: aketkar@precimac.com

W: www.nilfisk.com

W: www.precimac.com

Nmtg Mechtrans Techniques Pvt Ltd.

136

Productivity Buzz

T: +91-79-22821527

T: +91-80-66246600

E: nmtg@nmtgindia.com

E: augustin@imtma.in

W: www.nmtgindia.com

W: www.imtma.in

Octahedron Superbrasive Pvt Ltd 139

Quaker Chemical India Ltd

144

155

T: +91-141 -2570495

T: +91-33-22822181

E: jb.roytalukdar@gmail.com

E: sales@quakerchemindia.com

W: www.mehtaindia.com Metrol Corporation India Branch Off

145

E: info@moonlightindustrie.com

Nilfisk Advance India Ltd

T: +886-4-2278-0167

Para Mill Precision Machinery Co., Ltd T: +886-4-2680-0678

Nicolas Correa S.A.

T: +91-278-2446437

139

T: +91-281-2364836

Neri Engineering

T: +91-33-24758371

Makson Machines Pvt Ltd

Moonlight Industries

Pg No

W: www.quakerchem.com Omron Automation Pvt. Ltd.

Quickmill Inc.

T: +91-22-42288400

T: +705-745-2961

E: in_enquiry@ap.omron.com

E: info@quickmill.com

W: www.omron-ap.com

W: www.quickmill.com

Optical Gaging (S) Pte Ltd.

137

Raj Petro Specialities Private Limi

T: +65-6741-8880

T: +91-44-42288900

E: kelly@smartscope.com.sg

E: francis@rajgrp.com

W: www.smartscope.com.sg

W: www.rajgrp.com

167

List of Advertisers

Rightvision (India) Pvt. Ltd.

148

Advertiser’s Name & Contact Details

Pg No

SAP Technical & Marketing Consultant 28, 74

Advertiser’s Name & Contact Details

Tajmac - Zps A.S

T: +91-120-4261026

T: +91-80-26662386

T: +420-577-533593

E: lasco@rightvision.biz

E: saptech@eth.net

E: info@tajmac-zps.cz

W: www.rightvision.biz

W: www.saptechnical.co.in

W: www.tajmac-zps.cz

Rotomotive Powerdrives India Ltd. 56

Schunk Intec India Pvt Ltd

Taurlube Petrochemicals Pvt Ltd

T: +91-2692-230430

T: +91-80-41277361

T: +91-20-25893580

E: info@rotomotive.com

E: info@in.schunk.com

E: info@taurlube.com

W: www.rotomotive.com

W: www.schunk.com

W: www.taurlube.com

Sah Petroleums Ltd

152

Seco Tools India Pvt Ltd

T: +91-22-26592392

E: ipol@sahpetroleums.com

E: seco.india@secotools.com

E: teknic@vsnl.com

W: www.sahpetroleums.com

W: www.secotools.com/in

W: www.tecknic.co.in

Shailesh Sales Corporation

143

149

T: +91-2137- 667300

181

Teknic

T: +91-22-66301911

Sak Abrasives Ltd

Pg No

Tungaloy India Pvt Ltd

T: +91-44-24543500

T: +91-281-2461102

T: +91-22-61248888

E: super@sakabrasives.com

E: info@shaileshmachines.com

E: info@tungaloyindia.com

W: www.sakabrasives.com

W: www.shaileshmachines.com

W: www.tungaloy.co.jp.in

Salvagnini Machinery India Pvt Ltd

141

Shuter Enterprises India Pvt. Ltd. 160

Vargus Limited

T: +91-80-32214123

T: +91-44-32407116

T: +91-9730028248

E: riddhish.jalnapurkar@salvagninigroup.com

E: 32407116@shuter.in

E: vishal@vargusindia.com

W: www.salvangninigroup.com

W: www.shuter.in

W: www.vargus.com

Samchully Machinery Co Ltd

SHW Machine Tools (India) Pvt. Ltd.66

Vollmer India

T: +82-32-822-4811

T: +91-22-32222491

T: +91-9008844977

E: makeitdream@samchully.com

E: adeshmukh@shw-wm.de

E: ravindra@vollmer-group.com

W: www.samchully.com

W: www.shw-wm.de

W: www.vollmer-group.com

Samkrish

153

Superslides & Bushes Corporation 37

Wendt India Ltd

T: +91-44-23612310

T: +91-22-61567567

T: +91-4344-405500

E: info@samkrish.com

E: sales@superslides.in

E: vijayvernekar@wendtindia.com

W: www.samkrish.com

W: www.superslides.in

W: www.wendtgroup.com

Samkrish Machine Tools

109

Taegutec India Ltd

Yaskawa Robotics India Ltd

T: +91-44-23612310

T: +91-80-27839111

T: +91-124-4758534

E: info@samkrishmachinetools.com

E: sales@taegutec-india.com

E: sales@motoman.co.in

W: www.samkrishmachinetools.com

W: www.taegutec-india.com

W: www.motoman.com

Sandvik Coromant India

FGF

Taiwan External Trade Development Council

125

YG Cutting Tools Corporation Pvt Ltd

T: +91-20-27104800

T: +886-2-2725-5200

T: +91-80-43543636

E: rupali.kavi@sandvik.com

E: taitra@taitra.org.tw

E: admin@yg1india.com

W: www.sandvik.coromant.com/in

W: www.taitra.org.tw

W: www.yg1.co.kr

FGF - Front Gate Fold FIC - Front Inside Cover BIC - Back Inside Cover 180 MMT - December 2012

169

BGF - Back Gate Fold BC - Back Cover

Not Available

Pg No

Our consistent advertisers

Advertiser’s Name & Contact Details

December 2012

Reg No: MH / MR / WEST / 235 / 2012 â&#x20AC;&#x201C; 2014 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 5th & 6th Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

186