VOL 06 | AUG 2015 www.efficientmanufacturing.in
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
EFFICIENT MANUFACTURING
AerospAce mAnufActuring trAnsfer systems
A framework for enhancing reliability FOCUS Laser/plasma cutting EM - Interview Kel Kearns
Site Plant Manager, Sanand Vehicle Assembly & Engine Plant, Ford Motor Company (p. 26)
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SPECIAL FEATURE Additive Manufacturing
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EEDDIITO TORRIIAALL
The need for outsourcing “Companies now understand that they will not succeed if they are not competitive with the level of quality, innovation, efficiency, safety and environmental stewardship delivered within both their home country and in the various countries where they operate�
Over the last few years, a new breed of global consumer has emerged that is more diverse, demanding and connected than ever before, thereby raising product quality and service delivery expectations to unprecedented levels. Serving these customers is perhaps the greatest opportunity for growth many global companies will have for a generation. In response to this changing trend, manufacturing has gone global. Production facilities and supply chain networks are now distributed across the world. Leading manufacturing firms are racing to standardise and harmonise their processes and systems on a global scale in an effort to ensure the right products are delivered on-time, on-quality, and on-volume. Companies now understand that they will not succeed if they are not competitive with the level of quality, innovation, efficiency, safety and environmental stewardship delivered within both their home country and in the various countries where they operate. The first step to accomplish this goal is selecting the right business partners with the track record of successful global deployments. The next step is to actually implement a system capable of delivering visibility, control and synchronisation of your business processes to attain operational collaboration for manufacturing excellence on a global scale. In case of aerospace industry too, the ability to collaborate remotely has significantly increased the globalisation of aerospace supply chains. With this, the amount of manufacturing and maintenance outsourcing is estimated to have reached to about 80% of the airplane. This crucial need for outsourcing calls for having systems in place to manage the entire complex process of manufacturing transfer. The Cover Story in this issue addresses the technicalities of this topic, not just relevant to aerospace industry but other manufacturing sectors as well. Happy reading!
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net
Sonali Kulkarni President & CEO Fanuc India Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant Vivek Sharma Managing Director Yamazaki Mazak India
EDITORIAL ADVISORY BOARD N K Dhand Raghavendra Rao CMD Vice President Micromatic Grinding Technologies Manufacturing & Process Consulting Frost & Sullivan Dr K Subramanian President, STIMS Institute, USA Dr P N Rao Training Advisor, IMTMA Professor of Manufacturing Technology S Ravishankar Department of Technology Managing Director University of Northern Iowa, USA Walter Tools India
Satish Godbole Vice President, Motion Control Div Siemens Ltd Vineet Seth Managing Director India & Middle East Delcam Plc
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Aug 2015
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I M A G E C O U RT E S Y: Willemin Macodel
A U TO M AT I O N & C O N T R O L | A P P L I C AT I O N
Quantum leap in micromachining With the 701S machining centre, Willemin-Macodel has introduced a quantum leap in the machining of small parts by fully exploiting the dynamics and rigidity of the delta kinematic for the first time. This was achieved through the reduction of moved masses and by leveraging powerful PC-based CNC technology from Beckhoff. The Delémont, Switzerland-based Willemin-Macodel company specialises in machines for small part machining. The systems are used in the watch making industry, medical technology and the aerospace industry, among others. Denis Jeannerat, Technical Director, explains, “Our core competency is in high-precision machines for full-process machining. Because fixing small workpieces has always represented a challenge, the same machine now performs all machining steps – without the traditional division of processes into turning, milling and grinding. The machine also takes care of the parts handling, i.e. the careful insertion
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Ajey Phatak Marketing Manager, Beckhoff Automation, info@beckhoff.co.in
and removal of the workpieces. A prime example of this is the 701S machining centre, which was introduced at the EMO 2013 trade fair.”
A simple idea revolutionises micromachining On the face of it, the idea behind the new machine sounds simple: The 701S micromachining centre features a delta robot that has been inverted – placed “upside down”, so to speak. This robot moves the workpiece – a task usually handled by the tool carriage. Denis Jeannerat explains the thinking behind
EM | Aug 2015