MART April 2016 by MART INFOMEDIA PRIVATE LIMITED

Volume 12 Issue 10 April 2016 ` 100

“SIMPLIFY COMPLEXITY; QUICKER & FASTER IS THE GLOBAL TREND” Asim Behera Chief Operating Officer, Daifuku India

HOW TO DETECT AND CORRECT A BADLY IMPLEMENTED QUALITY MANAGEMENT SYSTEM PREDICTIVE INDUSTRIAL MAINTENANCE THROUGH INTERNET OF THINGS FUTURE VALUE MANAGEMENT

SUCCESS STORY PENNANT

April 2016

INNOVATION LEADS CREATION

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April 2016

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April 2016

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April 2016

foreword Inspire, Green Revolution! Hi, We are just in mid- April, and the whole India is already experiencing scorching heat. All major cities are recording 1-degrees increase in temperature compared to last year. As per the latest reports about 25% of India is facing complete drought. The water levels at dams are coming down alarmingly and there are reports that authorities in Central Madhya Pradesh have been forced to deploy armed guards to safeguard Barighat Dam from water stealing and ensure supplies. Latur in Maharashtra’s Marathwada region and Jaladoot Express took all media attention when a 50 Wagon train carrying 25 Lakhs litres of water bringing relief to around 5 Lakh people. One of the worst water crisis in years, it’s reported that more than 33 crore people are suffering from drought due to the scarcity of proper monsoons. The only hope is coming from the weatherman forecasting better monsoon rains in these drought hit areas. 2 The way temperature is on its rise every year, it’s not that far when the mercury reaches 50 degrees. We complain about the heat, but is this not anticipated? We are reading and listening about global warming, different measures undertaken by United Nations, NGOs, Governments and the latest, India signing Paris Agreement on Climate Change at the UN headquarters in Newyork. The day of the agreement also signed by US, China along with almost 175 nations coincides with “International Mother Earth Day”. The implementation of this agreement will see member countries taking several measures to prevent disastrous results of climate change, and the agreement was first adopted by 195 countries in Paris during December 12, 2015. Sure these measures are going to bring better results and save Earth advancing towards instability. Are these steps enough for bringing down the changes happening around us? With whatsapp and latest mobile applications we all are now part of this mission. With each one of us suffering from heat, the easiest way is to Copy, Paste and Send messages forwarded by our friends/ relatives/ associates creating awareness about planting trees, reducing pollution by using public conveyance systems. Some messages lecture us on how unscientific urbanization and infrastructure developments created concrete jungles, and how hopeless our administrators and politicians are. The worst is same message reaches our inbox several times, maybe in the same interface, meaning people don’t even read it properly. All said makes sense only if you take at least small steps planting trees, reducing pollutions and act responsible towards the environment we live in. The irony is after 69 years of Independence, we are still giving an opportunity for our PM to request us to keep our premises clean – Swaach Bharat!!! Industries should play a major role, undertaking environmental projects under its CSR activities, and lead the green revolution in our country. Headquartered at Osaka, Japan, Daifuku is one of the leading global players in the field of Material Handling. Since its inception in 1937, Daifuku has focused on material handling – the movement of finished goods and work in progress. Daifuku entered Indian market before a decade and with its Factory Automation Group initiated before 3 years under the leadership of COO Mr. Asim Behera, Daifuku was able to increase its share in the Indian market within a very short time.Mr. Asim in an exclusive talk with MART shares his views about new techniques, future plans which is featured in our On Face Section. In this edition we are including articles on Inventory Management, Industrial Maintenance, and Improving Machine Performance along with our regular columns, innovations, Success Story, Case Studies, Fair Mart and Mart Updates. From this financial year, MART is getting published by our new management Mart Infomedia Private Limited, based in Pune – team consisting of young talents guided by seasoned industrial experts, the mission to bring out better values to our readers. We look forward your valuable feedbacks and comments to make MART, SMART!

Hari Shanker hari@martinfotech.in April 2016

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24 MAIN STORY

10 INNOVATIONS

24 Future Value Management 26 “Innovation is the key to maintain Leadership”

Predictive Industrial Maintenance through Internet of Things

36 Validation Of The Arc Welding Equipment with Arc Validator L650

36 Understanding and Controlling Foam in Industry

Volume 12 Issue 10 April 2016 Annual Subscription `1200 Member INS Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre S M Dangi Sandeep Hingne

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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manne the Publisher no any of its employees accept any responsibilities for any errors or omissions. © All RightsApril Reserved 2016

CONTENTS 40

Asim Behera Chief Operating Officer, Daifuku India

ON FACE

Columns

52 How to Detect and Correct a Badly

Implemented Quality Management System

58 Managing Change 62 Bring loving Energy to whatever you do 44 SUCCEESS STORY

70 CASE STUDY

78 FAIR MART

82 97

MART UPDATE THE LAST LEAF

Managing Editor

Hari Shanker

Associate Editor Hiya Chakrabarti Executive Director Siji Nair General Manager

Priya Kundu

HR & Admin

Sonalisa Dey

Creative Assistant

Sayan Chaudhuri

Regional Office Chennai Bangalore

Subramaniam V +91 8925847523 Manvendra Sharma +91 9845108361

• Five years (60 issues) at `4800 You save `1200 • Three Years (36 issues) at `3000 You save `600 • One Year (12 issues) at `1200 Send your subscriptions to: The Circulation Manager - Mart Infomedia Private Limited , C-507, Wisteria Fortune, Bhumkar Chowk Marunji Road Near New Poona Bakery, Wakad, Pune - 411057 Email: mart@martinfotech.in Web: www.martupdate.com & www.martonline.in

IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post. m. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 er whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither April 2016

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Matrix Launches VARTA WIN200 - The UC Client for Seamless Collaboration

Today’s dynamic business environment requires real-time communication solution with anytime anywhere access. Business communication often fails to keep pace with these demands due to complex architecture and rigid interfaces.

. In the modern era of technology, organizations are finding it difficult to cope up with the conventional legacy of telecom infrastructure. Businesses are looking for vigorous growth which gives rise to the need of the next big thing also known as Unified Communications (UC). Matrix launches VARTA WIN200 - The UC Client, redefining communication experience with its variety of collaboration features and intuitive user interface. Powered by MATRIX SARVAM UCS, VARTA WIN200 empowers user to switch or extend the extension to their desktop computer. It offers real-time features such as Video Calling, Presence Sharing, Instant Messaging, Drag-and-Drop Conference and BLF Keys (up to 600).

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The VARTA WIN200 elevates communication effectiveness and business productivity to the next level. With VARTA WIN200 organizations can transform their desktop into a smart collaborative workstation. VARTA WIN200 provides flexibility by allowing users to access services at any time in any place. Services are tightly linked to the user, providing unique levels of personalization and control over the communication experience, leading to enhanced productivity. An example is the ability to access voice mail, text and instant messages from a single interface. VARTA WIN200 is also a business mobility solution which enables employees to get full access to enterprise

communication features on their desktop computers. In turn, it extends connectivity between employees so as to stay in touch with business communication and enhance customer responsiveness. Optimized for Hospitality, Corporates and Call Centres, VARTA WIN200 offers a perfect blend of real-time and non-real time communications. This in turn helps organizations reduce operational costs, enhance productivity and leverage communication infrastructure and services all at one place. VARTA WIN200 comes loaded in two set of features: ESSENTIAL and PROFESSIONAL Key features:• Corporate Directory

Integration •1000 DSS & 600 BLF keys for Monitoring • Popup Window for Incoming Message and Call • Comprehensive Call Management - Hold, Transfer, Forward, DND • Presence Sharing and Instant Messaging • Video Calling • Drag and Drop Conference • Contact Grouping VARTA WIN200 is a revolutionary step in technology as it is focused on mobility and collaboration. With Unified Communication in its arsenal Matrix can now set new benchmarks and address new markets. We look forward to greet our customers, discuss their requirements and offer prompt solution to fulfill their growth aspirations with VARTA WIN200.

April 2016

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Seco adds larger insert sizes to T4-12 square shoulder, helical milling cutters

Square T4-12 Square Shoulder And Helical Range with Product Background Assortment

By adding larger insert

operations. These inserts

The inserts also come in a

mm (2” to 4”), with corner

sizes to its popular T4-12

tangentially mount in

wide selection of grades

radii up to 3.1 mm (0.125”).

line of square shoulder

their cutter bodies for

and geometries. Normal

The inserts also come in a

and helical milling

increased performance

and close pitch versions

wide selection of grades and

cutters, Seco allows parts

stability and easier access

contribute to successful

geometries, including high

manufacturers to achieve

to their mounting screws.

slotting/contouring and

positive rakes. Normal pitch

Moreover, this type of

optimised contouring

cutters perform slotting and

mounting directs the

operations, respectively.

contouring operations, while

cutting forces to the

Internal coolant channels

close pitch versions only

thickest part of the inserts,

within the cutters

handle contouring, with a 30

which contributes to the

further maximise insert

percent radial width-of-cut

higher metal removal rates

performance. Available

capability in full axial depth-

of these products.

mounting systems for T4-

of-cut situations. Mounting

12 square shoulder cutters

systems for these cutters

consist of various shank

include Arbor, Weldon and

and arbor-style cutters.

Seco Weldon.

increased depths of cut and higher metal removal rates when roughing and semi-finishing steel, cast iron and other workpiece materials. In continuing the value and stability of

the T4-12 line, these larger-

Cutter diameters for

sized inserts all come

the larger T4-12 square

with four curved cutting

shoulder inserts range

edges that lower the

from 25 mm to 125 mm (1”

Cutter diameters for the

For further details visit

tooling cost per part and

to 5”), with corner radii

larger T4-12 helical inserts

www.secotools.com/in/

ensure smooth machining

up to 3.1 mm (0.125”).

range from 50 mm to 100

squaret4

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April 2016

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SHA wire rope hoist â&#x20AC;&#x201C;

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Fast, cost-effective, frequency-controlled

STAHL CraneSystems presents in the SHA wire rope hoist a new, flexible motor concept for light industrial cranes.

The wire rope hoists in the

power due to the lower

SHA range combine the

output, reducing stress

advantages of frequency-

on the power supply

controlled hoist and

and conserving valuable

travel motors (FU) with

resources.

an adaptive speed range (ASR): Stepless speed adjustment and smooth starting make work easier and reduce the stress on the crane system. The adaptive speed control

its own in production environments where lower loads are lifted

range of applications

times standard speed if the

and an excellent price-

load is 10 % maximum load

performance ratio make

or less.

the SHA wire rope hoist

hook. The SHA uses less

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- Adaptive speed control - Three times the hoisting

- Smooth starting reduces stress on crane system and building - Maintenance-friendly, long-lived

required for occasional

lowering process to three

to the actual load on the

- Frequency-controlled hoist and travel motors

- Lower energy consumption

higher lifting capacity is applications. A flexible

hoisting speed is adapted

- 6 S.W.L. variants between 3,200 kg and 10,000 kg

speed up to 10 % nominal load

frequently, however a

speeds up the lifting and

With higher loads the

The SHA comes into

advantages

an attractive alternative to the SH series of wire rope hoists. SHA wire rope hoist â&#x20AC;&#x201D; the

April 2016

High Precision Z-Axis Nanopositioners

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New QNP-Z stages offered in travel range from 100 μm to 600 μm

High Precision Z-Axis Nanopositioners From Aerotech Added To Piezo Nanopositioner Family

Aerotech (www.aerotech. com) has introduced a series of Z-axis piezo nanopositioning stages for extreme precision research and industrial requirements. The new QNP-Z stages join a family that includes the QNP-L linear and QNP-XY stages, providing a complete range of positioning solutions for most extreme precision applications. They provide the resolution, linearity, repeatability, and high dynamics required for the most demanding applications from microscopy to optics alignment. Nanometerlevel precision is assured by

April 2016

resolution to 0.15 nm, linearity to 0.007%, and bidirectional repeatability to 1 nm. A variety of travels (100 μm to 600 μm), feedback options, and vacuum versions add to the versatility of this stage series. They are guided by precision flexures that are optimized using finite element analysis. The resulting design offers outstanding stiffness and resonant frequency (up to 1050 Hz) enabling high process throughput and fast closedloop response. All QNP stages provide excellent geometric

performance (straightness and angular errors) while

Applications include:

minimizing overall package

• Test & Inspection

size. Available adapter plates

• Industrial and Academic

allow linear, XY, and Z-axis

Laboratories

stages to be mounted together

• Military

for simultaneous multi-axis

• Nanometrology

positioning.

• Microscopy

Aerotech is a leading global

• Semiconductors

supplier of positioning and

• Microelectronics

motion control products for

• Optics

industry, government, science

• Photonics

and research institutions. Its products provide critical performance for demanding applications requiring high precision, high-throughput motion control solutions.

• Data Storage • Precision Mechanics • Metals • Life Sciences • Medical Devices

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Detectable plastics from igus for maximum safety in foods

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Magnetic, lubricant-free motion plastics aid in preventing foreign substances from entering foodstuffs

Detectable and lubricant-free high-performance plastics from igus reduce costs and increase process reliability. (Source: igus GmbH)

In the food and packaging

derived from the production

bearings. Both the housing

in the machine,â&#x20AC;? points out

industry, the highest safety

environment. Subsequently,

and the spherical balls are

Lars Braun, Industry Manager

standards apply. To protect

the products can be sorted out

made of the detectable plastic.

for Food and Packaging

consumers, food must be

as soon as possible. But how

This characteristic is sought

Technology at igus. A major

free of contaminants of any

can plastic particles be traced?

after in other areas of bearing

contribution towards this is

kind. As part of its ball and

That was the question that

technology. For example, xiros

made by the lubrication-free

spherical bearing series, igus

developers at Cologne-based

M180 is a lightweight polymer

and maintenance-free plain

offers plastic products that

motion plastics specialist igus

ball bearing, whose material is

are lubricant-free and at the

bearing materials from igus.

asked themselves. The solution

also detectable.

same time, detectable. This

was finally the development

guarantees that no lubricants and no plastics enter the production chain during operation or in the event of a system failure. In the plants of the food and packaging industry, metal detectors are now an industry standard. They detect any metallic conductive particles

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of a special high-performance plastic, which can easily be

Freedom from lubrication ensures additional safety

Because, they precisely meet these requirements: materials like iglidur A181 or iglidur A350 need not be actively

traced with standard metal

In addition, these high-

lubricated. Moreover they are

detection methods. The

performance polymers do not

compliant with the EC Directive

material is used today in

require external lubrication.

10/2011 and also with FDA

selected products in the igubal

â&#x20AC;&#x153;A central point in the

specifications for repeated

series, which includes rod

production process of the

contact with food.

end bearings and clevis joints,

food and packaging industry

flange bearings, spherical

is the avoidance of contact

For more details visit

bearings and pillow block

of product and lubricants

www.igus.in

April 2016

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Manual changing system with extensive features

The SCHUNK SHS manually operated quick-change system fea-tures an extensive line of options. The options include integrated monitoring of the tool presence, and the locking state as well as different signal feed-through modules.

spaces. A relatively large

be equipped with an

to facilitate mounting on

change system defines a

number of air feed-

integrated tool presence

the robot arm. The repeat

new standard for manually

throughs, which can be

control and with a

accuracy is < 0.02 mm. This

operated tool changers for

connected both axially and

locking monitor. Different

series is an expansion of the

robots. It features a space-

radially, allows a great deal

standard SCHUNK

SCHUNK portfolio for fast

saving locking mechanism

of freedom in the planning

electrical feed-throughs

tool change. The modules

and offers numerous op-

of systems. In addition,

can be connected to the

for automatic quick-change

tions for the feed-through

large diameters provide

modules by means of a

systems alone comprise

of air, vacuum, and signals.

for a high air flow rate

standard flange for the

22 unit sizes for payloads

Since the locking lever for

and fast operation of the

supply of signals. The non-

from 1.4 kg to 4,080 kg

changing the tool only has

actuators. Special shaped

corrosive manual changing

and a selection of 2,000

to be pushed forward and

seals guarantee a highly

system is available in six

versions that is unequaled

not turned, the manual

sealed sys-tem that can

sizes (40 to 125) with 4

worldwide.

changing system is de-

also be used for the supply

to 12 air feed-throughs.

signed for convenient

of vacuum. Optionally,

It is equipped with hole

For further details visit

operation also in confined

the SCHUNK SHS can

pat-terns for ISO flanges

www.in.schunk.com

The SCHUNK SHS quick-

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April 2016

Organized by

April 2016

Supported by

Gold Participants

Silver Participants

Awards By

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New range of FFB “Flexible concept” brake motors on the IMfinity® induction motors platform

Many sectors, including conveying, hoisting, transfer and indexing, require safe and increasingly flexible drive solutions. The brake motor, at the heart of the system, is a key element for reliability and safety, and must meet the most demanding requirements in industry.

Emerson Industrial Automation, a company well-known in the handling business, presents its new range of Leroy-Somer FFB brake motors developed around the “Flexible concept”, a high-performance design which is the product of over 50 years’ experience in industrial applications. This robust, innovative concept offers an extensive range of options associated with safety and variable speed as standard, thus making the FFB brake motor ideal for a multitude of applications. Reliability and robustness With the latest generation IMfinity® induction motor from Emerson, the FFB brake motor is based on a tried and tested design, ensuring it can withstand the most severe stresses encountered in handling applications. Its mechanical and electrical design is based on recognised

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expertise in industry, civil engineering and lifts, making it highly reliable and extremely robust. Performance and safety Designed making full use of Emerson’s technological and industrial expertise, the FFB brake motor can be integrated in most fixed or variable speed applications quickly and easily. Its modular encoder adaptation principle makes it a versatile motor, suitable for the simplest to the most demanding variable speed applications. The total control of the noise level, for both pick-up and engagement, as well as optimum control of application and release, make the FFB brake motor one of the best of its generation. This new range, sized for dynamic braking, is based on failsafe operation. The industrial control of its performance

(running-in of all the friction parts as standard) and a wide range of braking function supervision accessories (opening, closing and wear sensor, etc.), significantly increase the safety of the transmission chain. International use and energy efficiency The multi-voltage, multifrequency construction of the FFB brake motor, covering 80% of the world’s power supplies, makes it ideal for use in many countries. Just one product reference is all that is needed, in place of the previous four or five. In order to achieve significant energy savings, FFB brake motors offer various different efficiency levels: non-IE, IE2 and IE3. Ideal for variable speed operation, they comply with requirements for improved energy efficiency in motorised industrial applications.

Express availability The flexible architecture of the FFB brake motor, together with the organization of Emerson production and distribution facilities, make it possible to meet customers’ delivery requirements precisely. A wide variety of products and options, combined with a range of gearboxes and variable speed drives, are available within one, five or ten days. The new IMfinity® induction motors platform, the latest generation 3000 range of geared motors, the high performance levels of the Unidrive M variable speed drives and the FFB brake motor range all enhance Emerson’s ability to offer solutions that are designed to work together perfectly. For more details visit www.EmersonIndustrial.com/ Automation

April 2016

Witness a true international event with state-of-the-art infrastructure

Venue: The Exhibition Center, Helipad Ground, Gandhinagar, Gujarat, INDIA.

April 2016

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Schmalz Introduces Vacuum Lifters for Ground Conveyors

The vacuum tube lifter is attached to the upper end of the lift frame.

The scissor arm with three joints ensures ample freedom of movement.

The vacuum tube lifter allows to work in a more efficient, back-friendly and ergonomic way.

Electrically operated ground conveyors play a central role in logistics centers and intralogistics. The need for lifting aids in warehousing and picking technology is also increasing in order to improve efficiency on the one hand and take the strain off employees on the other â&#x20AC;&#x201C; especially against the backdrop of shifting demographics. Schmalz is offering an integrated solution based on vacuum tube lifters and electrical stackers. The tube lifter is attached directly to the floor conveyor and allows you to move loads with ease. Electrical stackers play a key role in intra-logistics and are extremely versatile. Whether

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transporting loads in prestorage zones or operating shelving systems, todayâ&#x20AC;&#x2122;s devices have mastered warehousing and transport tasks, even in only the tightest of space. However, many vehicle loading and unloading processes are still frequently performed by hand, especially when the loads are light or mediumweight. With the aim of making work in warehousing and commissioning more efficient and ergonomic, Schmalz worked together with the intra-logistics experts Still to develop a vacuum tube lifter for use on electrical stackers. It is attached to the upper end of the lift frame and can be extended out on a scissor arm.

The vacuum tube lifter allows you to work in a more efficient, flexible, back-friendly and ergonomic way. Schmalz is planning to release two versions with up to 40 and up to 70 kilograms of lifting power. The operator has access to a range of different quickchange gripper variants for items like boxes, crates, small load carriers, sacks, pallets or other applications. The scissor arm with three joints ensures ample freedom of movement. The tube lifter can be extended lengthwise or sideways to a length of two meters, making it easy to handle goods that are harder to reach. At the same time, the small dimensions of the integrated vacuum

tube lifter solution make it very compact and ensures excellent all-round visibility. The power in the vacuum tube lifter is supplied by the 24 V standard battery installed in the electrical stacker, which makes the solution even more flexible: An external power supply and cables are not required. The developers have also placed a major emphasis on safety. The electrical stacker and vacuum tube lifter are blocked for use with each other. That is: The electrical stacker cannot be started while the vacuum tube lifter is being used, and vice versa. While the device is moving, the scissor arm is locked in a fixed position.

April 2016

Elmo Motion Control launches Gold Lion motion controllers for harsh environments: -40°C to+70°C, Vibrations up to 14GRM

Elmo’s Gold LION family consists of advanced network based, multi-axis machine motion controllers designed to withstand harsh environmental conditions Gold LION controllers can command over any multi axis scenario. From simple Point-ToPoint, to complete multi-axis coordinated / synchronized motion. The GOLD LION series comes in two forms: -Rugged, Stand Alone, Ready To Use metal package -“Ready-To-Use” module that allows for a high-level of customization by embedding the unit on a PCB. This highly advanced motion control solution, with tremendous design flexibility and functionality allows significant space savings. Elmo’s GOLD LION multi axis controller is perfect for ruggedized applications operating in extreme and harsh environments requiring maximum performance.

April 2016

Suitable for applications such as unmanned robots, azimuthelevation systems, inertial stabilization systems, gun fire/ radars turret stabilizations, gimbals, radar tracking systems, ground based vehicle leveling, etc.

before.

The wide variety of standardized and proprietary communication protocols between the GOLD LION Motion Controller and Host computer, PLC, or HMI enables fast and simple communications with 3rd party elements such as touch panels, teach pendant, Complete integration of the PLCs, Computers etc., using Gold Lion with Elmo’s advanced servo drives is extremely fast and standard “by the book” industry simple, making it one of the best protocols. Host communication capabilities such as Ethernet, TCP/ performing, highest reliability multi axis systems in the market. IP, and UDP Fast Binary Protocols Modbus and Ethernet/IP, allow The GOLD LION high speed simple and fast communication Compliant EtherCAT network with almost any high level Host in is fast, deterministic with high the system. communication reliability, and The GOLD LION enables superior telemetry capabilities rich, high-level, multi-axis that are essential in Military programming in environments solutions. The fast-real time such as Microsoft .NET, IEC deterministic operation of the 61131-3 PLCopen, Native C/ GOLD LION over the EtherCAT C++ programming using the network perfectly harmonizes PLCopen for Motion and with Elmo’s ExtrIQ servo drives Win32 C/C++. Elmo supplies an within the system. Multi axis enhanced Use of intelligent, coordinated motion and system simple to use Elmo Motion Block telemetry, on top of the highest servo control for fast and precise Libraries (EMBLs), machine templates, function, capabilities operation, all result in system and libraries to operate under performance levels never seen

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Missiles Launcher controlled by G-LION and 5X G-EAGLE 100A/ 800V servo drives

those environments. The EMBLs are complementary to the EASII (Elmo application Studio), a single tool that does it all - Configuration, Set-Up, Networking, Programming, Tuning, Load Identification, Multi-dimensional Control Optimization, Synchronization, Motion Blending and Transitions, Error mapping, ECAM, Gain Scheduling, Templates, Libraries, Scripts, Functions, Testing, Monitoring, Recording. Elmo developed numerous EMBLs to simplify machine development process. For example, Homing (all DS-402 methods and more), Output Compare (PEGS), Emulation, ECAM, PVT, Splines, Joystick etc. Elmo’s Philosophy is “Intelligence By Simplicity”, by applying ready to use motion function blocks and advanced tools to significantly simplify the development process of the application rapidly. For more details visit www.elmomc.com

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MAIN FEATURE

Future Value Management

From the early days of Craftsmanship to Mass Production and now to Customization for One and that also at a Global scale but in sync with local context, we are ushering in a Uncertain, Volatile, Complex and Ambiguous world. In this world, demand Projections and Commitment come with a many BIG IFâ&#x20AC;&#x2122;s.

Harish Pant harish.pant@hotmail.com

As customers graduate to experiences rather than product and services, value variables like what, where, when, who and how much get pushed to future where companies have to get set to operate in a predictive scenario, for want of time and opportunities lost. Now the experiences are to be delivered through a Platform meticulously designed and operated by various business partners through a flexible network. Pyramid tiered Suppliers base are likely to be subsumed in 3D Printing, IOT and Artificial Intelligence. A rapid obsolescence will collapse a legacy supply chain where an assured order book used to provide jobs to many and allowing them to be cocooned in the comfy, why change?! Product life Cycles will not get defined by

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Price and Useful life but also by many other Environmental and Social impacts. While organizations are still fighting age old issues of traditional organizational hierarchy and trying to see the new world through functional dominant prism, the Gen Next are having nothing of it! In this Innovation led world even consultants with all the well-earned medals and deep skills find themselves without work! A world full of Startups will unleash a storm of Innovations where many identities and organizations will humbly vanish. A company who has invested heavily on Leadership and Complete Cultural change will be only qualified for this innovation led world. Business Growth will come to only those who would smartly manage Business risks while organizing capacities and capabilities. Foremost in

risk management is risks and opportunities share through an engagement at platform level. Welcome to the world of Equal Collaborators in a platform where there is strong bond to create and appreciate Value for Customers in a meaningful and sustained way and also there is an appreciation of Human Values of respect, trust and growth for all. This building up of Leadership, complete Cultural Change and Creating a platform/cloud where Innovation is the driving force, calls for answering new questions and imagining, defining and subsequently designing the Future. This means we need to create our Digital and Connected World: design thinking! The stake holders need to understand and appreciate that unless they decide

new ways of measuring performance of their business, during this transition and later, they would be helping faster closure of present business. In this world of overcapacity, increasingly Intangibles are of more value than the Tangibles. Imagining a new world is the starting point where a Dynamic Supply Chain works on Predictable algorithm triggered by a Dynamic Customer requirement. Impact on Inventory and Solution Now we need a predictive way of working rather than reactive! No one is paying for waste loaded pricing where future success is being discounted in the present! The companies those leverage predictive customer

April 2016

Future Value Managment

- one gauge, many applications

requirements thrive in the B-to-B space of manufacturing. Now companies need to create flexible capabilities for this predictive business model where in the past customer used to provide it through Confirmed Purchase Orders and neat projections. Conclusion The word Inventory will be of a little significance by year 2020 as Man Machine merge, 5 Billion population get connected through internet world with 50 Billion smart devices, and we usher into Quantum-Block chain-Recursion-ArtificialIntelligence-Nano (Q-BRAIN) Singularity world! “The Future” will arrive faster now and will become aggressively transparent where there will not be any place for shortsightedness. Invite you to create a new

collaborative world where truth and humanity become integral part of professional life as well! Mr. Harish Pant, a Mechanical Engineer with multi-faceted global exposure and experience of 30 years across Steel, Automotive, Aerospace and Engineering sectors, is presently working with Hampson Industries Private Limited as Managing Director. He worked with HAL, Maruti Udyog Ltd, General Motors and Jindal Group. Mr. Pant has been honoured with “Distinguished Alumnus” Award by IEI, Member Advisory Council All India Management Association (AIMA) Bangalore, Lifetime member of Aeronautical Society of India, a Fellow of Institution of Engineers and also the recipient of Immai Operational Excellence Award and Award for Industrial Development. For more details, you can email to harish.pant@ hotmail.com

Nothing compares to Equator™, Nothing compares like Equator™ The unique new Equator™ is a versatile alternative to traditional gauging, offering inspection of an unprecedented variety of manufactured parts. It has been developed and proven on the shop-floor with industry-leading gauging users in multiple industries and applications. Benefits which can be gained by using Equator™ include: • Reduced gauging costs • Robust shop floor measurement process • Reduced production bottlenecks

To see Equator in action visit www.renishaw.com/gaugingapps

Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com

April 2016

www.renishaw.com

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MAIN STORY

“Innovation is the key to maintain Leadership” Samir Gandhi Director, Gandhi Automations

Mr. Samir Gandhi, is a Chemical Engineer from Institute of Chemical technology, Mumbai (earlier University Department of Chemical Technology). He has over 20 years of experience in Entrance Automation & Material Handling equipment Industry. Mr. Samir Gandhi is steering Gandhi Automations pan-India sales network. Further, he steered the setting up of state of the art manufacturing & warehouse facility in Mumbai. His decisiveness in strategizing and implementing has helped Company to reach newer heights. His visionary effort was crowned with success when the Company started exports in year the 2011. He has invested heavily into research and development. A well respected, renowned professional with innate technical & management skills, Mr. Samir Gandhi’s approach to business has always been ethical. Excerpts from the talks we had with him about the latest developments in the Handling industry.

Automation is the key of global manufacturing today. How far India has advanced in heralding Automation in Material Handling? With entry of international players in India, use of automation increased to great extent. Indian companies also have understood the importance of automation in material handling and are investing to great extent. Use of automation reduces time and efforts required. Most importantly increases efficiency and is also important form safety point of view. Quality enhancement is

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one of the key elements of manufacturing. What steps yourorganization initiating to ensure quality products? Gandhi Automations has become synonymous with quality and service excellence. Our core strength has been its product innovation and the latest technology. Without innovation an organization may make sustainable, stable growth, but to achieve the desired growth rate, innovation is the key to maintain one’s leadership in the market. To achieve its strategic goals, the production processes are made as efficient as possible and the products

are technically superior, hence possessing a natural advantage in the market. For Gandhi Automations research is an on-going commitment, a large share of resources is invested to continue producing winning solutions in terms of functionality, safety, energy efficiency and design Please share the latest innovations by your company which will revolutionize the way we manufacture today? We have been working on self-repairing clean room high speed door for pharma industry for quite some time and we have been able to

achieve a break through. Our research & development team has worked very hard and I must say we come up with a best product for pharma industry. We have also received good orders for the product. We are very confident that this product will be welcomed by clients and in coming years it will contribute to our top and bottom line. The benefits India achieve in the manufacturing sector through the recent Make In India campaign? First it will create employment for our young work force. We have very young and talented work

April 2016

Dock Leveler

Rolling Shutter

force. This will reduce our dependency on imports and will be self- sufficient and in long term will reduce our current account deficit. How Start-Up India can revolutionize manufacturing industry, and how we can bring young talents to innovate in the material handling industry? There’s definitely lot of room for innovation, a right product in material handling

segment for consumer can do wonders and my experience says clients welcome good product. There’s lot of scope for innovation. Comparing to global manufacturing techniques, where India stands in manufacturing techniques? We are slowly catching up with international standards, In the last ten years we have improved a lot in

manufacturing techniques. Our labour force is more skilled now. We have improved drastically on quality of products being manufactured in India. There’s is lot of awareness among entrepreneur, focus is more on producing quality products using latest technology. The future of manufacturing in Indian Manufacturing? Growth in manufacturing

sector and infrastructure will be a positive for our industry. Necessary steps and policy have been made to put country back on growth track. Growth rate of 8 % is only possible by implementation of policies on ground. Industry is hopeful about growth in infrastructure and Make in India initiative.Yes, we have to improve and work a lot but I am hopeful in coming years India will emerge as manufacturing giant.

High Speed Doors

April 2016

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MAIN STORY

“Expectation of our Overseas Customers keep us on our Toes”

Sumit Nevatia Director, Vinar Systems Pvt. Ltd.

Vinar Systems Pvt Ltd is one of India’s premier manufacturer of material handling and storage equipments. With a team of more than 500 employess, Vinar has revenues exceeding USD 30 million, and an established customer base of over 5500. Vinar is present across the country through its eight full fledged Sales and Service Offices. Kolkata based Vinar Group is a major player in each of it’s business vertical and serving Indian industry with it’s customized solutions for last four decades. Vinar’s customers include national and global giants in automotive, white goods & process industry.

Can you brief the latest material handling technologies available in India? Are we globally competitive? I can only speak of the Automotive sector. Though we have almost all the leading companies with their manufacturing facilities in India, in my opinion, we still lag behind the global standards by atleast 10~15 years in terms of material handling technologies. For a given technology, yes we are globally competitve but it is too early for the Indian vendors to export to the overseas customers in significant volumes. Automation is the key of global manufacturing today. How far India has advanced in heralding Automation in Material Handling?

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I would say that the local vendors have learned immensely from the global companies setting up manufacturing base in India and have successfully absorbed new technolgoies and have adopted to automation. Though innovative technologies emerging from India is yet to happen and if we wish to compete globally, huge investements are required in R&D. What are the new technologies that are driving significant advances in the area of Handling & Storage industry? The new technologies being adopted range from automation in high density warehousing solutions to various automation products adopted for tracking the entire

manufacturing cycle - right from raw material, to inprocess and upto the final product. Quality enhancement is one of the key elements of manufacturing. What steps your organization initiating to ensure quality products? Frankly speaking, the expectation of our overseas customers keeps us on our toes and we continually evaluate & upgrade our quality processes. The benefits India achieve in the manufacturing sector through the recent Make In India campaign? Make in India campaign has brought about a paradigm shift in the way we think and look at the manufacturing sector. The benefits at the moment

may not be visible in the short term but this campaign was never started for a short term gain. This if pursued sincerely for the next couple of decades will bring us close to the levels achieved by China. The future of manufacturing in Indian Manufacturing? The general prosperity and per capita income of our people can improve if Manufacturing starts playing an increasing role in Indian economy. We can no longer depend only on agriculture for employment. The huge shift of population from rural to urban area can be catered to if the employment opportunities increase drastically and that is only possible if the manufacturing sector grows by leaps and bounds.

April 2016

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MAIN FEATURE

Predictive Industrial Maintenance through Internet of Things Industrial maintenance usually refers to the repair and upkeep of the different types of equipment and machines used in an industrial setting. The basics can be broken down into the following five categories: general knowledge, mechanical knowledge, electrical knowledge, welding knowledge, and preventative maintenance. Industrial maintenance also involves a great degree of problem solving skill. Identifying the problem alongside the best and safest means of resolving the difficulty typically are integral parts of the maintenance process.

Rajesh Angadi rajesh_angadi@hotmail.com

The general knowledge usually required in industrial maintenance is an understanding of tools, blueprint reading, and safety. The correct tools and the comprehension of how to use them can be crucial for fixing potential machinery problems. Blueprint reading enables the technician to understand how a particular machine works. Safety is also a pivotal aspect of maintenance, as most industrial machines can be very dangerous. It is important for the technician to maintain his or her own safety, as well as those of the workers using the machinery. Industrial maintenance technicians may be on-site employees or can be privately contracted in the event of required maintenance. Many manufacturers of machinery offer maintenance plans for their respective products and will send out service technicians periodically. These technicians are experts on the machinery

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produced by these companies and are familiar with how to fix any possible problems. Types of Industrial Maintenance: Traditionally, 5 types of maintenance have been distinguished, which are differentiated by the nature of the tasks that they include: •Corrective maintenance: The set of tasks is destined to correct the defects to be found in the different equipment and that are communicated to the maintenance department by users of the same equipment. •Preventive Maintenance: Its mission is to maintain a level of certain service on equipment, programming the interventions of their vulnerabilities in the most opportune time. It is used to be a systematic character, that is, the equipment is inspected even if it has not given any symptoms of having a problem.

•Predictive Maintenance: It pursues constantly know and report the status and operational capacity of the installations by knowing the values of certain variables which represent such state and operational ability. To apply this maintenance, it is necessary to identify physical variables (temperature, vibration, power consumption, etc.). Which variation is indicative of problems that may be appearing on the equipment. This maintenance it is the most technical, since it requires advanced technical resources, and at times of strong mathematical, physical and / or technical knowledge. •Zero Hours Maintenance (Overhaul): The set of tasks whose goal is to review the equipment at scheduled intervals before appearing any failure, either when the reliability of the equipment has decreased considerably so it is risky to make forecasts of production

capacity . This review is based on leaving the equipment to zero hours of operation, that is, as if the equipment were new. These reviews will replace or repair all items subject to wear. The aim is to ensure, with high probability, a good working time fixed in advance. •Periodic maintenance (Time Based Maintenance TBM): the basic maintenance of equipment made by the users of it. It consists of a series of elementary tasks (data collections, visual inspections, cleaning, lubrication, retightening screws,) for which no extensive training is necessary, but perhaps only a brief training. This type of maintenance is the based on TPM (Total Productive Maintenance). Impact of Predictive industrial maintenance •Lower maintenance costs by matching a maintenance activity with actual symptoms of future

April 2016

Preventive Maintenance’s mission is to maintain a level of certain service on equipment, programming the interventions of their vulnerabilities in the most opportune time. It is used to be a systematic character, that is, the equipment is inspected even if it has not given any symptoms of having a problem.

asset failures •Save vital resources by reducing the need to purchase replacement parts for asset components before they fail •Reduce out-of-service time for an asset by determining when maintenance must be completed in order to minimize asset failure Predictive industrial maintenance is enabled by a three major solution enhancement over a traditional maintenance schedule. 1. Capturing Sensor Data – There are sensors on the asset being monitored. These assets provide a constant flow of data – most of which are all within standard ranges of tolerance and trigger no alert or error. However, a very small percentage of those data falls outside standard ranges and trigger alerts that might indicate a reason to undertake maintenance. 2. Facilitating data communications on the shop floor – The data flowing off these sensors are connected to a central processing facility using

April 2016

some Wireless Access Network - or Local Access Network -based connectivity platform. The choice of connectivity technology is dependent on several factors including security requirements, level of asset mobility and expected integrations with other assets. 3. Making predictions – The captured data is continuously evaluated – for example, in a business intelligence system – based on expert knowledge or data from past events. The application relies on a series of rules that are based on expected and observed data associated with the assets being monitored. If the application can make better predictions, it can suggest a maintenance schedule which better matches the progressive deterioration of the asset. An enterprise need not over-invest in maintenance labor and parts. Predictive maintenance allows an enterprise to match its cash outlay with actual prevention of asset wear-and-tear. Predictive maintenance is one such IoT or Machine to Machine solution that helps lower

operating and capital costs by facilitating proactive servicing and repair of assets, while allowing the more efficient use of repair resources – both human labor and replacement products.

automatically adjusting environment control systems to

Reduce energy consumption when it is not needed. For example, lighting and heating, ventilation and air-conditioning Every day we are hearing more systems can be switched to a and more about the Internet of lower mode when systems in things (IOT), the next generation the immediate area are powered of the Internet, but what exactly down. does that mean? Essentially, The IOT will also enhance asset the Internet of things is the management processes by interconnection of everyday devices to the Internet. The introducing more automation, concept of the IOT is so big that real-time data analysis and it has been described as the intelligent decision-making. fourth industrial revolution after steam, mass production and the Improving maintenance through Internet of Things Internet. Today, we can control our heating system via phone or Predictive industrial maintenance tablet so that our house is at the requires the collecting and right temperature when we get systematic analyzing of large home. In the future, technicians quantities of data to help predict will be able to see equipment failure codes on their application faults and errors outside the in real time as the breakdown is normal tolerance range. These anomalies could be symptoms of happening. larger problems with the asset In the coming years, the IOT will and might trigger a maintenance be fundamental in improving response. productivity and efficiency everywhere. It will lead to more Following are different ways the IOT can improve the way assets efficient power management are managed. at plants and factories by

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1. Greater Adoption of Predictive Maintenance The main reason for applying IOT to manage your assets is predictive maintenance. Rather than performing routine calendar-based inspections and component replacement, predictive techniques monitor equipment for pending failures and notify you when a part replacement is required. Sensors embedded in equipment check for abnormal conditions and trigger work orders when safe operating limits are breeched. When a predictive maintenance strategy is working effectively, maintenance is only performed on machines when it is required, thus reducing the parts and labor costs associated with replacements. With more and more systems shipping with Internet connectivity, the concept of

predictive maintenance is likely to expand exponentially in the Internet of things. 2. Real-Time Data Analysis Machine-to-machine (M2M) is defined as the technologies that allow machines to communicate with each other. The Internet of things takes M2M to the next level by including a third element: data. The availability of all machine data in one virtual network gives original equipment manufacturers (OEMs) the ability to aggregate and analyze the data to generate better predictive analytic models. Rather than waiting for a system to fail, manufacturers are able to accurately predict failure because sensors start reporting back when operating conditions trend out of specification. By accurately mapping user behavior, identifying failure patterns and

quickly recognizing recurring issues, OEMs will be able to design out failures, improve their product and guarantee uptime. This should result in increased customer satisfaction and fewer warranty claims. 3. Accurate Performance Metrics Availability, reliability and other key performance metrics such as mean time between failures (MTBF) and mean time to repair (MTTR) can be calculated automatically by the system and fed to reporting dashboards. This removes the human element in capturing all downtime, ensuring the data is as accurate as possible. In addition, reliability metrics from different customer sites can be analyzed to identify best practice for implementation around the world. 4. Automatic Software

Upgrades Software changes can improve equipment performance or eliminate technical issues. Internet-connected machines make the software upgrade process easier and more efficient. When software fixes or patches are needed, the OEM vendor can push the upgrades to all systems in the fleet at the same time without customer assistance. 5. Recommended Repair Actions When equipment goes down, failure data from various sources can be gathered, aggregated and analyzed in real time within the cloud. Repair options can be taken automatically by the system, and actions can be recommended to the technician if necessary. All possible failure data will

Predictive Industrial Maintenance

Lower Maintenance Costs

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Save Vital Resources

Reduce out-ofService Time

April 2016

be used to direct the repair, including system operating conditions at the time of failure, previous repair data from the computerized maintenance management system (CMMS), wear patterns and operating data from the equipment fleet. In effect, the technician will be presented with all the information needed for more effective decisionmaking and the fastest route to resolution. Deploying a CMMS with an application programming interface (API) that makes connection with IOT devices possible will be crucial in ensuring the actionable information can be presented to the end user in a usable way. 6. Tighter Parts and Inventory Control Effective inventory control can have a significant impact on limiting equipment

downtime and controlling maintenance budgets. Connected stockrooms that proactively monitor inventory movements and stock on hand to ensure the site is only holding what is needed will become commonplace in facilities everywhere. Through predictive maintenance and data analysis, OEMs will be able to optimize the recommended spare parts lists, freeing up much needed capital and increasing customer satisfaction. 7. Remote Assets When it comes to unplanned breakdown maintenance, the IOT will make repairing geographically dispersed assets a breeze. It will reduce unnecessary service visits to remote or geographically dispersed assets through predictive maintenance. Imagine connected assets such

as wind farms, substations and pumps generating their own work orders in the CMMS with a proposed list of action items and recommended list of spares to complete the job. This will reduce the mean time to repair, which will in turn reduce the costs associated with those emergency repairs.

ongoing monitoring and

Every business type can find bottom-line value from IOT devices and services, but this will only occur when the IOT seamlessly interacts with other applications such as CMMS software. The IOT can also be a game-changer for OEMs. It will redefine the business model as equipment vendors supplement their offerings with software and data analytics services. Hardware will ship with greater computing power, becoming more intelligent and more connected. OEMs will create added value through

completed his BE, MBA, PMP

analysis, improving reliability while reducing unnecessary maintenance costs. Organizations need to allocate their resources effectively as well as efficiently for predictive industrial maintenance. The author Rajesh Angadi and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.

Machine-to-machine (M2M) is defined as the technologies that allow machines to communicate with each other. The Internet of things takes M2M to the next level by including a third element: data. The availability of all machine data in one virtual network gives original equipment manufacturers (OEMs) the ability to aggregate and analyze the data to generate better predictive analytic models.

April 2016

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INDUSTRY FOCUS

Validation Of The Arc Welding Equipment with Arc Validator L650 Validation of the welding equipment is to ensure that the equipment function correctly and produce the desired welding parameters (Current, Voltage & Wire Feed Speed) as per its operation characteristics with adequate accuracy.

Rashmi Ranjan Mohapatra Rashmi.Mohapatra@Kemppi.com

Sritharanandh.G Sritharanandh.Govindraj@Kemppi.com

In General, the Validation Should be carried out once in a year. It may be necessary to validate at more frequent intervals, depending upon the recommendation of the manufacturer, the requirements of the user, or where there is reason to believe that the performance of the equipment may have deteriorated. Validation should always be carried out after any repair or operation liable to affect the validation.

customer requirements

Arc Validator is used for

either standard validation

for welding equipment

current, voltage and wire

(normal accuracy) or precision

accuracy.

feed speed validation of

validation (higher evel of

welding power sources and

accuracy) according to the

wire feeders. In manual

European Standard EN 50504

Today, welding companies face strict requirements from customers, regulators and inspecting bodies. If their welding equipment is not validated, they fail to meet national and international standards and

reporting and standards

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ARC VALIDATOR L650: Kemppi’s Arc Validator is the first ever automated and universal solution for welding equipment validation. It offers fast, consistent and thorough welding equipment validation, meeting the requirements of ISO 3834 and EN 50504 standards. Among the benefits it offers are up to 80% faster validations, effortless compliant documentation and certificate creation. It is compatible with all brands and models of welding machines and welding processes (TIG, MIG & MMA)

mode, Arc Validator is compatible with the vast majority of welding equipment with absolute unit meters – despite the brand or the type. In case of Kemppi’s FastMIG M,X, Pulse, KMS & Kemp arc Pulse Series welding Power sources and its suitable Wire feeders Automatic Validation option is available. In that mode, Arc Validator automatically controls and operates the validated equipment through the remote control connection during the validation process. The user / customer can choose

Manual validation is often very time consuming. The welding equipment is set up and the person coordinating the validation process has to manually adjust the parameters and write down whether they are within the certain tolerance limits. This process is slow and prone for simple human errors. With Kemppi Arc Validator we don’t need to calculate or write down anything. Just connect the validator to your welding equipment and let the system do everything. As all the tests and parameter adjustments are done automatically and we are less likely to have

April 2016

Picture Shows the Arc Validator L650 unit, the remote control(RC) device used for operating the Arc Validator, saving and transferring validation data from and to a computer and the PC Software installed on the computer used to generate report & Validation certificate creation..

Picture shows the typical validation Certificate is generated from the PC Software.

errors in the process, thus

than standard grade

Generally, Slope and pulse

high knowledge of the

the Arc Validator delivers

equipment and a 6-month-

controls are considered

power source control

consistent and accurate results.

interval, or more frequently is

to be precision grade and

circuits and special

recommended.

the validation accuracies

instrumentation is required

should conform to Âą5 % of

and is most likely to be

setting, unless specified by

carried out by equipment

the manufacturer.

manufacturers.

The validation of pulse

For more details contact a

controls are very

KEMPPI partner near you.

Generally, It is recommended that precision grade equipment

Why Validation is more

is validated more frequently

Critical in Pulse welding:

Validation accuracies for Precision grade power sources as per EN50504

important contribution to the quality of pulsed welding. It is a more difficult task than the validation of slope controls. It requires Validation accuracies for Precision grade power sources as per EN50504

equipment with a faster response than is necessary for the validation of slope controls. An instrument response of at least ten times that of the maximum pulse frequency of the power source is

Validation accuracy for Wire feed Equipment as per EN 50504

recommended to validate the Pulse controls. To Validate the Pulse Controls, normally the

April 2016

KEMPPI â&#x20AC;&#x201C; And you know .. The article is written by Rashmi Ranjan Mohapatra and Sritharanandh G of Kemppi India. Rashmi Ranjan Mohapatra, BE, MBA in Marketing, having 21 years of experience in Industrial consumables and equipment in the Indian, European and South East Asian Market, has worked for Linde, earlier known as BOC India, ADOR Welding and currently works as the Managing Director of KEMPPI INDIA based at Chennai since April 2011.

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INDUSTRY FOCUS

Understanding and Controlling Foam in Industry Exciting new technology developments in foam measurement and control are bringing important benefits to the wastewater industry, as well as a wide range of other process industries. The accurate and reliable measurement of foam brings substantial savings to companies through the improved control of anti-foaming agents, improved process control, increased yield, reduced product loss and reduction in equipment failure. In certain processes, especially in the wastewater sector, significant energy savings can be made through improved foam control.

Steve Gallagher sales@hycontrol.com

The patented measurement technique developed by Hycontrol uses level measuring technology specifically developed for measuring foam levels and foam-liquid interfaces. Suitable for both aqueous and non-aqueous liquids, this technology already has a proven track record in a wide range of applications and industries. By comparison, alternative, less effective solutions use existing level measuring technology that has been ‘adapted’ to measure foam. These tend to be inherently unreliable, inaccurate and adversely affected by process product build-up on the measuring probes. “Measurement is the first step that leads to control and eventually to improvement. If you can’t measure something,

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you can’t understand it. If you can’t understand it, you can’t control it. If you can’t control it, you can’t improve it.” H. James Harrington, 1929 Harrington’s principle is certainly true of the challenges presented by industrial foaming and its subsequent control, as we shall see. Foaming affects almost every industrial sector: from pharmaceuticals to brewing, from paint manufacture to wastewater treatment, from oil & gas to food processing, from textiles to pulp and paper. Foam may be an integral and important part of a process or it may be an unwanted side effect. Foaming has the appearance of a simple material, partly because we are all familiar with it whether, for example,

in the form of bath foam, bubbles in a milkshake or the head on a glass of beer. However in practice foam is a very complex, dynamic material with its production involving physical, chemical and biological processes. Most of the common foams are an unstable, two-phase medium of gas and liquid with a particular structure consisting of gas pockets trapped in a network of thin liquid films and plateau borders. Several conditions are needed to produce foam: there must be aeration (generated for example by mechanical agitation, mixing, stirring and sparging) and surface active components (surfactants) that reduce the surface tension. There is always a natural drainage along the thin films of liquid between the bubbles. Liquid gradually drains out from top to bottom, creating a

density gradient through the column of foam. The foam at the top of the column collapses as the films become too thin to support the bubbles. Equilibrium develops between this material collapse at the top and the build-up of new foam from the liquid surface below. This ongoing process limits the maximum height of the foam column. However, in some processes foam stabilising agents such as proteins reduce the drainage, resulting in much more stable foam. In these circumstances, the foam production rate can far exceed the dispersal rate and the foam can build up to a serious level. Proteins as long chain molecules have this effect by lying along the thin films between the bubbles, thereby preventing drainage. The stability of such foams clearly has a large impact on their lifetime.

April 2016

Proven measurement technology leads to optimised foam ontrol and reduced process costs.

Additional factors such as poor system design and leaking pumps can exacerbate foaming problems. In all instances, in order to minimise the impact of foam, it requires to be effectively monitored, measured and controlled. Controlling Foam There is an extremely diverse set of chemical formulations that can be effective either to prevent foam forming or to destroy it once it has formed. In practice most foam-dispersing chemicals can serve either role. Each anti-foam or de-foamer agent is specifically developed for individual applications and the world-wide market for these essential evils is worth billions of pounds per annum. Commonly used agents are insoluble oils, polydimethylsiloxanes and other silicones, certain alcohols, stearates and glycols. The most universal characteristic of any defoamer is the fact that it is surface active. Most are insoluble, however some are water-soluble which only adds to the complexity.

April 2016

The latter type has a property known as inverse solubility. An increase in the temperature of an aqueous system in which the defoamer is present causes a decrease in its solubility. At or above the cloud point (the initial effective temperature), the de-foamer separates from solution and acts as an extremely effective de-foamer. Reduction of the system temperature below the cloud point enables the de-foamer to become solubilised again. Insoluble de-foamers have to be formulated so that they will be dispersed as tiny droplets, i.e. as an emulsion. The surface-active nature of the material causes it to spread very rapidly onto any air-liquid interface that it encounters. This is especially the case if that interface is already covered by the types of surface-active materials that tend to stabilise foams. Anti-foamers and de-foamers operate by being absorbed into bubble surfaces in preference to the foam stabilising agent. They are then effective in increasing the drainage rate so that the bubbles drain quickly and

then collapse. An effective defoamer can disperse foam in a few seconds and the process can be dramatic to watch. Adding up the Costs Foam generation can cause a variety of expensive and time-consuming problems. These include environmental pollution, potential product contamination, loss of product through excessive foaming, downtime and clean-up costs if foams spill over from the process. Excess foam can severely limit product throughput in a process and can result in damage to equipment including pumps, filters and valves. Add into this the ongoing cost of de-foamers and it is clear how important it is to implement effective foam control. The key problem is being able to understand the characteristics of the foam and then measure its thickness and, in some applications, where the foam-liquid interface resides. The foam can be controlled through the addition of de-foamers, but without the above key information their addition is typically done on an empirical basis, often

based on historical experience. This can then result in a cyclic or sine wave solution to the problem. De-foamers are added in quantities based on maximum demand and the foam subsides. It then develops again above acceptable levels and more defoamer is added. This staccato, reactive (rather than proactive) approach is expensive and wasteful. In many cases, when the foam disappears and the problem subsides, the rate of de-foamer addition is not reduced, resulting in excess chemical usage, which can have substantial cost implications. Measuring Problems The effective and reliable measurement of foam thicknesses and foam-liquid interfaces presents a number of challenges. Results can be adversely affected by a range of factors including constantly varying foam density and gradual coating or fouling of the measurement probes with residual product from the process chemicals. Traditional measurement techniques have been based on a range of existing level probe technologies adapted for foam measurement. In most applications, these fall short of providing an adequate and

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sustainable solution. The Solution A highly versatile range of Foam Control systems have been specifically developed to fulfila variety of functions, for examplemeasuring the thickness of foam in a process; detecting foam-liquid interfaces; or measuring liquid levels whilst ignoring the presence of any foam. Hycontrol point out that the technology behind these systems originated from detailed research into foam control during pharmaceutical fermentation and that the special measuring sensors and control equipment have been designed specifically for foam control and are not modified level sensors. This is a tool that has been specifically created for this task alone. Industry Specific Foam Problems Uncontrolled foam generation can affect productivity in a wide

range of industries. It causes particular problems in the waste water, pharmaceutical, and food & beverage sectors. The foam control systems developed by Hycontrol are proving to be very effective in these industries, bringing significant cost savings and productivity improvements. By monitoring and measuring foam production, real time data can be used to ensure de-foamers are only added in controlled quantities when required. Wastewater Bulking sludge and foam are two undesirable, complicated and unpredictable challenges for many waste water treatment plants (WWTP). In many cases, the filaments causing bulking sludge tend to float and thereby produce huge amounts of foam. The foam may vary in depth considerably and extend throughout the biological circuit, as well as to anaerobic

digesters and dewatering units. The traditional approach is to dose anti-foam into the process on a continual basis. This dose rate is typically set to cope with foam during the plantâ&#x20AC;&#x2122;s peak demand. However on average this is far too high and in some systems there is little or no foam generation for most of the time. Alternatively the addition of chemicals is often done randomly, in far too large quantities and too late. This reactive approach results in very limited control and shows little understanding of the entire process. In some cases, a WWTP can suffer for years without finding a sustainable solution to the problem. The chemicals used may themselves also add to the foaming problem. In both cases, the excessive cost of chemicals and energy through unnecessary pumping can be substantial. Additional costs are also incurred through unnecessary equipment wear and damage.

Pharmaceutical Accurate foam control is essential in the Pharmaceutical industry, especially during the fermentation process, which is used in the production of antibiotics, vaccines, steroids and other drugs. These products are frequently created by biotech processes which use natural organisms such as bacteria, algae or animal cells to produce the end product. Probably the bestknown process of this kind is brewing in which yeast is used to create alcohol. Natural organisms require a healthy environment for growth and optimum yields. Products such as vaccines require very hightech fermenters for efficient production. These usually involve stirring and air or gas mixing to operate. However natural organisms also tend to create unwanted proteins as a by-product and these act as foam stabilizers, creating the perfect environment for stable

Figure 1: Foam probe in action

Figure 2: Wastewater foam

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April 2016

foam production on top of the broth. Stories of so-called â&#x20AC;&#x2DC;foamoversâ&#x20AC;&#x2122; abound in the pharmaceutical industry by which whole processes and equipment can be destroyed. A ruined batch can often represent hundreds of thousands of pounds in lost product before taking into account the costs of any equipment damage or cleanup costs. There is also the possibility that the liquid could be completely turned into foam if not controlled quickly enough. Typically antifoams are used to control the foam build up in fermenters but these are difficult to control and can have some unwanted side effects. Firstly, by reducing surface

April 2016

tension the gas bubble size increases, reducing the mass gas transfer into the broth. This can seriously limit the yield of the process. Secondly, the excess use of some antifoamers can contaminate to the end product and be very difficult to remove. Food and Beverage In the food-processing and beverage industries, foam can be generated at various points in a production process. This is caused predominantly by the presence of surface-active substances such as proteins, fatty acids and sugars. Foam is a particular problem in alcohol distillation and in the production of deep-frozen foods, deep-frying oils and gelatine, as well as in fruit conservation and vegetable

washing. Invariably, the resulting foam impairs product properties in many different ways and greatly disrupts the process flow. Foam spillages are disruptive and time-consuming to clean up and dispose of Silicone-based antifoam agents are the most common chemicals used to manage foam but product contamination is a major consideration. Conclusion Companies world-wide spend billions of pounds each year dealing with foam and the effects it has on their businesses. Consideration must also be given to the long-term detrimental effect that the disposal and dispersal of defoaming chemicals has on our health and the environment.

There is clear evidence that considerable savings can be made by actively controlling the addition of antifoaming chemicals and the technology is now available to achieve this. There is no need for companies to continue with out-dated control systems, which ultimately only serve the interests of the chemical suppliers. The author Mr. Stephen Gallagher MSc, MBA, MIET, CEng is the Technical Director of the Charis foam detection and control range at Hycontrol in Redditch, UK. Prior to developing the Charis range of technology, Stephen worked as Electronics Manager for Thermofisher Scientific and as a Senior Engineer for Shell Research. He can be reached at sales@hycontrol.com.

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ON FACE

“Simplify Complexity; Quicker & Faster is the Global Trend” Asim Behera Chief Operating Officer, Daifuku India

Asim Behera has a Bachelor of Science in Electrical & Computer Engineering at Oklahoma State University, USA. He has designed, implemented and automated numerous multi-million dollar Distribution Centers in the USA for companies including mega-retailers Wal-Mart and Target to name a few. Asim has the heart of an engineer and spirit of an entrepreneur. He is the face at the forefront of Daifuku’s new and growing presence in India. A Material handling veteran for over a decade, he is now the COO of Daifuku India. Asim’s native understanding of India’s local and business culture, coupled with his deep knowledge of Material Handling in a wide range of applications makes him particularly adept at cultivating and advancing local partnerships. He moved to India in 2011 and since, has been very active in the growing Material Handling & Robotics market in India. He shares his views and opinions about the current scenario of handling industry in our country, excerpts.

Daifuku is now one of the leading brand in the Material Handling sector in India. Can you brief your success journey?

Please share the latest innovations by your company which will revolutionize the way we manufacture today?

Believing in the market and our solution offering has been key. We are a global company and many a times global companies like us tend to discount India’s manufacturing sector and its need for automation. However we have always believed in the potential of the Indian market and have stayed focused. Daifuku’s automotive division has been in India for over a decade but the Factory Automation group started actively about 3 years back. In a very short time we have convinced many local customer of our value proposition and the orders we have received is the proof of the pudding.

Most of our new products globally are more suited to case handling. They are more focused on simplifying the complexity of Distribution Centers; quicker and faster is the global trend we are seeing. However here in India our focus is on the manufacturing sector, rather than focus on pushing our latest innovations here, we are more focusing on using our standard product portfolio but putting them together to create innovative solutions. For example we have a WMS (Warehouse Management System) called eWareNavi which gives the end client real time access

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to inventory. By utilizing this many of our customers are now thinking of reducing the amount of stock they hold, as they have better visibility to what they have in hand. So in a way our solutions are pushing our client to think of lean inventory or Just in Time inventory. This is definitely a revolution as today most companies hold a lot of stock. Is Indian manufacturing sector able to adopt the latest technology in their shop floor? Yes and No. In my experience convincing the business owner/decision maker of our technology & solution is fairly easy. But at the end, it’s the shop floor in charge, who needs to run the system, and here is where the

biggest challenge is. It’s not that our systems are overly complicated. Our solutions revolutionize the way things are done and many a times the skill set of the people running the shop floor are not at par to understand the system or there is a case of high attrition, where you train one person completely and then he/she leave and the new person needs to be retrained. Unless the end customer has an excellent training plan a lot of time is lost when there is attrition. Can you brief the latest material handling technologies available in India? Are we globally competitive? Because of companies like us present in India, locally

April 2016

Automated Storage & Retrieval Systems

one has access to our global portfolio of solutions. In our world of automated material handling, we broadly divide our solution offering into two categories- Pallet Handling & Case Handling. Pallet Handling solutions are more relevant to Manufacturing sector while Case Handling more apt to modern retail and ecommerce. ASRS(Automated Storage & Retrieval Systems), High speed Sorters, Palletizing robots, Pick Stations, WMS etc. are some of our offerings in India. Low cost innovation is what India can offer to the world, off late we

are seeing some of this crop up but more needs to happen. The automotive sector is one which has successfully proved that India can be a competitive manufacturing hub for global exports; other sectors have similar potential but as the domestic demand is huge, most companies are focusing on satisfying this demand first. Automation is the key of global manufacturing today. How far India has advanced in heralding Automation in Material Handling?

Automated Material Handling is now at a growth stage in India, of course the biggest challenge is we are a very cost sensitive country, so the right solution at the right price is key. For companies like us this is a big opportunity which we need to address in due time to remain successful here. What are the new technologies that are driving significant advances in the area of Handling & Storage industry? ASRS is starting to get popular, as people understand more of

its benefits. Many companies are now embracing some form of WMS to manage inventory. Both of them put together is more of what we are seeing people think off as they build or expand their factories. Quality enhancement is one of the key elements of manufacturing. What steps your organization initiating to ensure quality products? Quality in my mind is a touchstone that if adhered to unfailingly ensures longevity for any company. As of now

Indian Automobile manufacturer Mahindra & Mahindra introduced a unit load AS/RS as a paintedvehicle bodies buffer system at Nashik Plant

April 2016

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most of our manufacturing is done in Japan. Japan has a very stringent Quality adherence policy. We also procure some peripheral items for our solutions locally; to ensure that the out-sourced vendor complies with Daifuku standards we impose very detail technical specifications along with frequent visits for inspections to the local manufacturing facility. The multiple follow-ups definitely increase our costs but we cannot compromise on quality as long as the Daifuku name is attached to it. The benefits India achieve in the manufacturing sector through the recent Make in India campaign? Make in India along with policy betterment has definitely

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caught the attention of multinationals to think of India as a potential manufacturing hub. Some companies such as Foxconn amongst others have announced that they are seriously contemplating to set up manufacturing in India, we will have to wait to see if other follow suit. How Start-Up India can revolutionize manufacturing industry, and how we can bring young talents to innovate in the material handling industry? Startups are a new phenomenon and whilst some of them have been very successful many have vanished in a very short time. This is simply because to make a startup profitable you need the staying power (cash flow), which is a challenge as your

initial costs for establishing yourself is high. In the material handling industry many new ideas are being discussed such as IOT, drones etc. I personally know of a few people who are leaving their mainstream jobs to start something in this sector but I doubt on how successful they will be, simply because this sector is a capital intensive one. Comparing to global manufacturing techniques, where India stands in manufacturing techniques? As I had mentioned earlier most of our manufacturing with the exception of automotive, pharmaceutical are predominantly for the domestic market. As a result we have not had the need to have mega manufacturing

(less of automation). Most of our factories are small in size and scale compared to that of the West or China. Also because of the complicated tax regime, as of now mega manufacturing does not make commercial sense. However with the successful passage of GST I envision this will change; manufacturers will prefer consolidation and this will then lead to significant embracement of automation. The future of material handling in Indian Manufacturing? The need for automated material handling will only grow. As we head towards consolidation of manufacturing units, automatically the higher throughputs will push companies to opt for more and more automation.

April 2016

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4540, 2418 1649, 2775 0662 Fax : 022-2414 9659, 27751612 E-mail : sales@kusam-meco.co.in www.martupdate.com 43

SUCCESS STORY

Innovation Leads Creation Leading the way for three decades Pennant was established in 1985 with a vision of making it a leading manufacturer of steam traps. The seed that was planted then has grown and branched out to cross continents and international borders. Today, Pennant Corporation is a global entity boasting of countless clients and a diverse product portfolio.

The Beginning: 31 years ago, in 1985, a journey began in a small setup in Hadapsar, Pune. Pennant came into existence as a home-grown unit to meet the manufacturing industry’s need for steam related products. It began with thermodynamic steam traps, and very soon, the demand from the market and a desire to innovate led Pennant to develop the complete range of steam traps and specialty products.

Pennant began doing machine job work and then started manufacturing steam traps. The first lathe machine was brought in August 1985 and the second one in December same year. Today, Pennant manufacture steam traps, valves, engineered solutions. They also offer consultancy services, and energy audits to improve their customer’s process efficiency. Consistently, they have sought to add value to their clients through revolutionary products, expert consultancy and

impeccable service, earning us the trust and loyalty of our customers. Vision and Mission: Pennant’s aim is to increase their global market share through high quality manufactured products and engineered solutions for steam and thermal applications. A constant quest for quality means that theirr total solutions meet and often surpass, stringent international standards.

State-of-the-art machinery is deployed at every stage, and only the most qualified personnel look after the complete process. The strict quality compliance has earned us approvals and recognition. Besides receiving the ISO 9001:2008 certification by Det Norse Varitas (DNV) in 1999, they are also registered with almost all global OEMs and consultants worldwide. Pennant products have been approved by third party inspection agencies like Lloyds, BV, INTERTEK, TUV,

Factory

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April 2016

“Understand Growing Need of the Market” Creating Pennant Brand in India?

manufacture both types

worldwide. Taking a risk in

of steam traps. We went

business back in the 80’s

ahead and designed and

was easier as we didn’t have

Coming from a family of

manufactured both the

much to lose. But we have

businessmen I was always

types of steam traps. Our

been lucky and successful

sure I wanted to be one

diligence in design, hard

in all the risk that we have

myself. I did my mechanical

work, and determination

taken in the past and stand

engineering from IIT Bombay

helped us to get a firm

after which I did my PGDM

foothold in the domestic

from Xaviers Centre of

as well as international

Management Studies, Pune.

markets, making us one of

As soon as I finished my

the leading manufacturers

PGDM I was hired by Tata’s. I

of Steam Traps.

worked with them for a long time where I learnt lot of tricks and trades of business. This experience helped me understand minute details of a manufacturing industry. With the exposure I got in the industry I was sure that I was ready to start my own business. I had a huge liking for engineering products and hence started doing a lot of market research to be sure that I started the correct thing. I decided to manufacture steam traps and understood that there were 2 major players in the industry who manufactured steam traps. But both made different types of steam traps and marketed their

Tell us about your

where we are today. We have gained respect for our quality, design and technical knowledge and more importantly the dynamic team behind all this. Tell us about your team?

experience as an

We started with only 2

Entrepreneur in India?

workers back in 1985 and

We started exporting in 1997 when I travelled abroad for the first time for work. Indian products weren’t appreciated in the foreign markets then. But

have a huge team now, both in factories and on field. We believe that it’s the team is equally important as the products to grow any business. Hence we have a team of highly experienced,

with time the scenario has

motivated and dynamic

changed. Many overseas

people in their respective

companies have also

fields.

invested in India. The demand for Indian products in international market has increased drastically.

by the government. It’s however still at a nurturing stage. It has helped in Indian Manufacturers in a great way

entrepreneurs.

to manufacture and export

market has been an

important to understand

experience of its kind.

the growing need of the market. It is important to

their products. The positive results for the same would however be seen in the future.

take the back foot at the

What do you feel about the

correct time to let your

Government’s new scheme

team handle situations and

products respectively. There

Our journey has been

was a desperate need for

beautiful. We started with

a new player in the market

1 lathe machine in 1985

who could manufacture

and have 3 manufacturing

both types of steam traps.

units in India, 2 warehouses

The impact of “Make In

This gave me an idea to

in USA and an extensive

India” in the Indian and

open Pennant and be the

sales and dealer’s network

global manufacturing

only manufacturer to

to cater to 25 countries

scenario?

April 2016

great initiative started

message to the budding

As an entrepreneur it is

back thirty years?

The “Make in India” is a

On 30th anniversary, your

Being a part of this growing

Tell us about your journey

Christopher Fernandes Managing Director Pennant Group

act like a coach to them

“Startup India”?

always. That’s what a true

It’s again a great initiative

entrepreneur is.

started by the government to promote the startups. But however it’s at a very nascent stage and would give better results in future.

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Ball Valve

Control Valve

DNV, TATA PROJECTS, etc. Manufacturing Facility: Only the latest state-of-theart infrastructure is deployed to create the products that their customers trust and rely upon. Comprehensive testing facilities and an R&D center support the core business of manufacturing. Pennant’s extended client list goes beyond domestic borders and today they have three manufacturing units based at Pune at Wadki, Shivane & Bhosari, that

can cater to the constant demand, both, in India and the overseas market. An extensive sales and service network enables us to bring these new-age technologies to the customer, when they need it, where they need it. Major Breakthrough: From the humble beginning, Pennant started to grow with a vision of making it the leading manufacturer of steam traps. Their good quality products and strong engineering knowledge helped them to setup their

market across India. After establishing their foothold in the domestic market they started exports. Pennant USA was set up in the year 20052006, which was the biggest boost in their business.

consultancy vertical to their business which they are now focusing on strongly. The newly set-up plant at Bhosari at Pune is further expected to bring substantial growth to Pennant this year.

Growing Substantially:-

Key areas of Manufacturing:

Pennant has always been known for its quality and strong engineering knowledge. Pennant’s order booking is healthy and they are able to manage the balance of 50% domestic and 50% export throughout. Pennant successfully added a

Customization is the key at Pennant. While they have standard products, each individual unit is designed around specifications unique to the customer it is being designed for. A dedicated team spends precious time studying the customer’s

Gate Valve

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April 2016

T&D

April 2016

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“Pennant Quality Ensures Durability” Challenges faced today in the Indian and International Market? • Pennant is an established brand and people know us for the quality products we offer. There is however huge competition in the market with many global players business and exact need, and only after duly satisfying itself of all angles is the design team briefed. Pennant have expanded their product portfolios across three diverse ranges to suit the needs of their customers across the globe. 1. Flow control products Piston Valves, Gate Valves, Globe Valves, Check Valves, Control Valves, Ball Valves, Plug Valves, Angle Seat Valves, Bellow Seal Valves, Pressure Reducing Valves 2. Steam Traps & Accessories – Thermodynamic Steam trap, thermostatic steam trap, ball float steam trap, inverted bucket steam trap, strainers, separators, pipeline connector, compact module, manifold etc. 3. Engineered Solutions Pressure Reducing Stations, Condensate Recovery Systems, Compact Modules, Desuperheater, Hot Water Generation Systems, Other customized systems for energy efficiency and to improve process efficiency 4. Consultancy services 5. Energy audits New Innovations: At Pennant, its always looking for the next new technology to explore, the next new product to launch. Innovation is always on their minds and the future comes a day earlier

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for Pennant. A continual process of innovation is very important to remain a leading manufacturer in a highly competitive market. With their strong design knowledge and 30 years of expertise they leave no table unturned to offer the best products and services to the customers. Pennant offers two lines of products, one being the standard products and other being the solutions that they offer. Their engineered solutions and consultancy vertical involve a continuous R&D and innovation so as to meet the growing need of the customer and offer solutions.

as well entering the market. Indian products weren’t accepted • I believe financial control is one of the biggest challenge we are facing. Order books are full with new orders. However there is a lot of financial crunch in the market and hence it takes double the time for collection The USP of Pennant Products/

• 30 years knowledge

Rajeev Saxena Head Marketing & Sales Pennant Group

• Quality product that ensures

as well as domestic bodies and

Services?

durability • Experts in field to help improve

it gives me immense please to inform you that our traps have

customers process efficiency

been working successfully in

Projects:-

• Strong Design and technology

years.

At Pennant, no project is too small and no client too far. They have serviced clients across industries, across the globe. While every project is critical, some have posed challenges that they overcame or some are unique simply because of the scale of operations or some because of the tight deadlines worked within. Each project teaches a new lesson and serves as a stepping stone towards bettering their services.

team to help us offer consultancy

Team Pennant:The management at Pennant comprises some of the most experienced and dedicated

and engineered solutions

customers places from last 20- 23

• Major challenge was to promote our products to the

• Customer Centric Tell us about some of your projects which fetched success across industries in India?

international market. But with Pennant USA being established in 2005-2006 it has helped in a big way to promote our products in USA. Also we have a huge and

• Pennant has always been lucky

extensive reps. And distributors

to get good response from the

network all around the globe to

market.

cater to 25 countries worldwide

• We have a strong hold in

• Few of our esteemed

domestic market where we cater

customers include Reliance,

to almost all major players in

TEVA – complete project, GACL,

various industries. We supply our

Mylan, BPCL, IOCL, EIL, Petrofac,

products and solutions to private

KNPC, SABIC

April 2016

Globe Valve

individuals in the industry. Many have been part of Pennant since its inception, and continue to take the company further with their acumen and insights. Christopher Fernandes, Managing Director, Pennant Group is the Founding Director of Pennant Group. In his 30 year career, he has

worked across industries and has acquired rich and diverse skills. A strong advocate of home-grown technologies, Mr. Fernandes ensures all his products are manufactured in India and exported to 25 countries worldwide. This is immensely beneficial to the economic growth of the country. A strong focus on quality, throughout

the entire manufacturing process, has helped the Pennant Group become a renowned global player. The Pennant Team is led by Directors Ryan Fernandes, Raj Devi , J K Kakkad and supported by Michael McCauley, VP – Sales and Marketing Pennant USA, Rajeev Saxena – Sales &

Marketing Head, Pennant Group, Sunil Kulkarni – Plant Head, Pennant Engineering Pvt Ltd, Rajiv Harolikar, Technology Head, Pennant Group and Raymond Lazarus – AGM Corporate Quality, Pennant Group. CSR Initiatives: Education: Pennant

Piston Valve 40 Nb Flanged

Swing Check Valve Flanged End

April 2016

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“Believe in Quality, With No Compromise” The latest manufacturing techniques used at Pennant? We have multiple VMC and HMC machines along with the

Prs Station

CNC machines which provides a single setup to finish the a job i.e. once a job is put in this

adopted a school at Wadki (Saswad Road) and they have taken over their financial obligations and infrastructural requirements. Pennant have been paying their electricity bill for the last 20 years, giving the children uninterrupted access to electricity. They have constructed a classroom and furnished it with benches for the students to sit on and study. Uniforms have also been stitched and given to the students. The school has been equipped with 3 computers, giving the children access to technology and gradually preparing them for the future. Regular spoken English classes have been started with the same intention of preparing the students. Healthcare and Medicine: Pennant organize blood donation camps at their plants twice a year. All employees (staff as well as factory workers) contribute in a big way to this activity. This activity is being conducted in association with Rotary Club, Pune and Ruby Hall Clinic, Pune. Pennant have received recognition and awards for the same from Ruby Hall Clinic as well as Rotary Club. Contribution during natural disaster/ social unrest: Philanthropy is in the DNA at

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Pennant and it trickles down to all their employees. The complete staff of Pennant joined hands with the Sakal Relief Fund and donated a day’s salary to help the Nepal Earthquake victims. Donations: Besides specific disasters, theyregularly contribute to orphanages or NGOs. Grains and books are donated to needy orphanages / NGOs to ensure children are not deprived. Pennant regularly initiates steps for distributing old clothes to old age homes. Major Awards/ Recognitions: Pennant won twice in a row Manufacturing Today’s Entrepreneur of the year Awards in 2014 and 2015. They were also awarded Trophys and certificates by Rotary Club and Ruby Hall (Renowned hospital in Pune) recognizing their work towards the society.

machines, then its directly ready for assembly after that. The quality policy of Pennant? • Pennant is an ISO 9001 – 2008 certified company and we comply to all the norms specified at all stages • At Pennant we are very stringent about our quality process to ensure we deliver a quality product to all our customers • We conduct in process inspections at every stage • We have assemble inspections at every stage of assembly • If we find a rejection of any job at any stage we try to find the root cause of it and rectify the same so as

Future Plans:

to avoid similar problems/

Pennant have added new vertical like consultancy and engineered solutions to our scope of business. They are also strongly promoting the energy audits vertical which has huge potential too. Seeing the huge demand Pennant is expected to offer these consultancy and solutions to the international market.

rejections in future 2. What strategies you follow to deliver the best quality products? • We believe in quality and try to make sure that the same is not compromised at

Sunil Kulkarni Plant Head Pennant Engineering Pvt. Ltd. any stage • All are suppliers/ vendors are ISO approved • We conduct chemical as well as physical inspection of all raw material at the inspection area • We ensure that we do not compromise in any process or material during manufacturing • The company in run by 100% engineers for manufacturing • We have well trained workers at the shop floor

April 2016

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QUALITY

How to Detect and Correct a Badly Implemented Quality Management System Shoddily implemented QMS does more harm than good. When adopted in true spirit, using all its inbuilt principles and key requirements, QMS helps transform your company. You are able to effectively deliver high value to your customers and sustain growth.

Saravjit Singh Saravjit@pcshp.com

ISO 9001 is a Quality Management System (QMS). Hence forth we will refer to it simply as QMS. When your QMS has weaknesses, it produces defective products and services, creating waste and additional work for everyone. At the same time, it delivers low value to your customers. You lose business and stagnate. A well designed

Symptom Frequent and unexpected quality issues

process-based QMS achieve opposite results. QMS best practices are well known and adequately defined. Then why does a company land up with a badly implemented QMS? The main reason could be that the QMS is seen only as a means of getting ISO certification. Its potential value is not appreciated –

Probable Causes • Lax Internal and external audit • Weak management reviews • Weakness in planning • Disregarding employee inputs • Rewarding employees for short-term solutions

maybe not known to the top management, who only can lead a totally effective implementation of QMS. Few people, other than those in the Quality Department, are able to see the true role of QMS in producing quality products and creating an excellent organization. This situation needs to be

changed. Yes, there are ways to move from a flawed QMS to an effective QMS. We can do this by uncovering the symptoms, arriving at possible root causes and then taking corrective action. Let us look at seven common symptoms, causes and corrective actions. 1. Frequent and unexpected quality issues: Here, fire

Corrective Actions • Strengthen audit systems. Appoint strong internal audit head • Schedule frequent and thorough management reviews • Actively seek employee inputs and suggestions about problems • Focus on long-term improvement

Table 1: Correcting Frequent and Unexpected Quality Issues

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April 2016

Symptom Weak preventive action process

Probable Causes • Reactive culture dominates • Corrective action preferred and arriving at preventive solutionsis secondary • DFMEA and PFMEA are often not considered when developing preventive action programs • Failure costs not analyzed  • Continuous improvement is not a part of the culture

Corrective Actions • Have cross function teams forDFMEA and PFMEA. • Use DFMEA and PFMEA to take preventive actions at all new/revised product and process designs • Evaluate quality costs • Revise documented procedures to connect with a process for continuous improvement • Change employee reward system to emphasize continuous improvement

Table 2: Correcting a Weak Preventive Action Process

fighting is common. Fire fighters are rewarded. Focus is on correcting the immediate problem rather than identifying its root causes and implementing a permanent solution. Table 1 shows how this symptom can be addressed. 2.Weak preventive action

Symptom Numerous repetitions of problems

process: Major cause could be a reactive culture. Continuous improvement is not the norm. Table 2 shows route to corrective action.

Weak responses to repetitive

3. Numerous repetitions of problems: Some problems are considered inherent in the business, and their root causes are therefore never addressed.

recurring. Problem solving

problems are accepted. Creative problem solving is not done. Customer complaints and internal problems keep may be limited to increased inspection and retraining of operators. Possible corrective actions are shown in table 3.

Probable Causes • Missing senior management support and involvement • Management responsibilities not defined as a process • Root cause analysis not usedacross the organization • Ineffective responses such as increasing inspections and retraining for performing defective processes •Not addressing inherent business problems

4. Infrequent and ineffective top management reviews: Is your company falling into this trap? It is found that often to keep records clean, real problems are not discussed. Reviews are viewed as boring and seen as all-day punishments for participants. This can be corrected by following table 4.

Corrective Actions • Introduce guidelinesfor escalation of issues • Provide root cause analysis training for employees at all levels • Create an open culture in which real problems are discussed freely • Use cross-functional teams to solve problems seen as inherent to business. • Educate team members in mistake-proofing and use of lean principles

Table 3: Corrective Actions Related to Numerous Repetions of Problems

April 2016

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Symptom

Probable Causes

Infrequent and ineffective top management reviews

Corrective Actions • Increase the frequency of management review meeting to at least four times a year • Use an agenda that is inclusive and cross-functional • Discuss essential pressing topics • Add line workers as participants • Ensure that participants have the opportunity to speak without censure or fear • Include team presentations • Encourage free and frank discussions.

• Long and tedious meeting structure • Controversial topics avoided • Management reviews not seen as means to identify and solve problems • Agendas not interesting or challenging • Participation only bysome selected officers •Employees fear exposure and embarrassment

Table 4: Correcting Infrequent and Ineffective Top Management Reviews

5. Resistance to change: Change is not promoted as a positive way to sustain improvement. It is resisted and so change takes too long. Maintaining the status quo of a formal quality system certification that looks good on the surface is deemed at risk if it is changed. Change is initiated onlywhen it is forced by customers. How to correct this is shown in table 5.

QMS documentation: QMS

6. Voluminous and irrelevant

valid.

Symptom Resistance to change

document reviews are required before changes can be made. Changes are dreaded and avoided by employees because of the tedious approval process. Computerized document control systems are built around existing documentation, and unused documentation is not eliminated when no longer

Probable Causes • Low employee involvement in planning • Lack of communication about what is changing and why • Objectives of change not made known throughout the organization • Weak teamwork • Fear of failure and exposure

Many procedures are written to describe what is perceived as an ideal system and may not reflect actual practice. At least one employee, maybe more, has a full-time job controlling and managing the documentation systems. How to correct this is shown in table 6. 7. Lack ofunderstanding of customerrequirements: Customer’s quality

requirements may change, but changing customer requirements are often not part of the company’s strategic plan. Planning does not seem to involve customer and supplier quality representatives. Corrective action to be taken to get the customer in the loop is shown in table 7. QMS implementation is considered to be successful

Corrective Actions • Create a team-based, open and participative culture • Use employees from all levels in teams and for planning • Discuss change and responsibilities • Establish routine communications of direction and activities throughout • Change employee reward systems to emphasize participation

Table 5: Correcting Resistance to Change

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Symptom

Probable Causes

Voluminous and irrelevant QMS documentation

• QMS is developedfor thepurpose of certification only; adding many documents that are not actually used or needed • Documentation reviews are ineffective • Core understanding of requirements is missing • Lean thinking not used for document flow and management

Corrective Actions • Limit document review and approvals to no more than three employees • Train employees in document control requirements • Integrate lean thinking into document flow and management • Delete documents that are not required or no longer useful • Develop QMS documentation specific to company needs • Develop a checklist for documentation reviews

Table 6: Correcting Voluminous and Irrelevant QMS Documentation

only when it fulfills two objectives: (1) Includes clearly designed practices and processes that effectively satisfy all the needs of customers and other stakeholders. Focus is on preventing errors/waste and continuous improvement to keep ahead of customers’ changing requirements. (2) Have processes, with inbuilt

checks and balances, to ensure that the product meets all statutory and regulatory requirements.

customer focus. Objective (2) is less difficult to implement. So usual focus is on achieving this objective.

Many organizations implement QMS only with the aim of acquiring ISO certification, and not as a means of becoming a high quality supplier. They do not effectively implement objective (1) since it requires a lot of effort and adaptation of a culture of excellence and

Successful organizations, that achieve sustainable growth against the toughest competition, are those that effectively implement and then follow the use of both the above objectives. At the same time,such progressive companies move towards

Symptom

Probable Causes

Lack of understanding customer requirements

• Misunderstood customer needs and communications • Customer information kept within marketing and sales functions and not sharedwith all employees • Customer information not discussed in top management review meetings

organizational excellence by going further. They implement a business excellence model (could be EFQM, Baldrige or any other model) – not with the purpose of winning any award but to have an excellent business-wide system in place that exceeds customer satisfaction and sustains long term growth. The author Saravjit Singh is the Additional Director of Pushkarna Consultancy Services Private Limited

Corrective Actions • Create customer feedback processes and information flow to ensure that all employees understand customer needs • Establish strong customer feedback system across the organization • Establish internal processes for using customer information in all areas • Focus on customer for all planning

Table 7: Correcting Lack of Understanding of Customer Requirements

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April 2016

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TALENT MANAGEMENT

Managing Change

What Effective Leaders Do?

Managing change is the make or break for successful organizations and their leaders. A good leader can help to make change possible even in adverse situations!

Pavan Sriram pavan@ittige.com

What happens when you want to make changes in your company? We start with the best of intentions and with innovative ideas, meetings, vision statements, data collection, and strategic plans and goals. Maybe we want to increase sales, improve or introduce new products and services, streamline work processes, enhance customer

service, expand the business, and so on. We are optimistic that positive results will follow. We would never implement change with the expectation that it will fail. After all, if we expected it to fail, then why bother? Yet, organizational change efforts often do fail. Why? To survive and thrive,

every organization - from for-profit to non-profit to governmental - has to know how to navigate change. But sadly, 75% of change initiatives fail, according to a recent study by McKinsey & Co. That means organizations inevitably suffer, and the leaders of those failed initiatives get hit with major setbacks.

Change fails for a number of reasons. Sometimes the company’s culture simply doesn’t tolerate change. People aren’t ready for it yet and they resist it. Maybe the change was ill-conceived, poorly thought-out, or even unnecessary. Perhaps needed resources weren’t available, or the timing just wasn’t right. But one of the

In a world that is increasingly fast paced and ever changing, the change management process is an integral part of any organisation

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April 2016

Change management is in full-force across all industries and preparedness begins at the top and that means leadership

biggest obstacles to change is the behaviour of leaders. Not only can leaders fail to manage change effectively, but their behaviours can make things even worse, resulting in a situation where it would have been better to do nothing! It’s easy for leaders to say that they need to improve and invest in doing things better (either because the marketplace is telling them to or because they need to be proactive before circumstances force their hand). The reality is that without strategy, change is merely substitution – not evolution. Simply put, you can have an idea, but without the right strategy and execution of the idea, very little if any progress will be made. When leaders fall into this trap, they are being irresponsible and their credibility suffers, their intentions come into question, and doubt begins to loom about their capabilities and know-how Change management is in full-force across all industries

April 2016

and preparedness begins at the top and this means that leadership – across all levels – must have absolute clarity in purpose and focus; there also must be alignment in strategic philosophy and resolution goals. At ITTIGE learning, where we have facilitated several change managment workshops for leaders- the following behaviours are perceived as successful in implementing change initiatives: Communicate frequently and enthusiastically – Successful leaders provide abundant, relevant, and truthful information about the change, and communicate how the change will personally affect employees. While it’s important to be realistic and not overly optimistic, ambivalent communication will produce resistance and weaken the leader’s credibility in building a case for why change is needed. Motivate employees –

Successful leaders establish an environment that is conducive to change and persuade employees to work toward common goals. Leaders who are skilled in creating an atmosphere of motivation during a change initiative “communicate effectively, address employees’ questions, generate creative ideas, prioritize ideas, direct personnel practices, plan employees’ actions, commit employees to action, and provide follow-up to overcome motivational problems.” Build teams – Successful leaders promote synergistic teamwork. Leaders clearly define roles and expectations, but at the same time, value and welcome diversity of work styles, skills, and backgrounds. Act as coaches – Coaches build one-on-one relationships with the intent of improving employees’ ability to maximize their strengths and work cooperatively with others during and after the change

initiative. A coach is a futureoriented agent of change. Mentoring, counselling, training, and providing feedback are coaching behaviors that can help in facilitating organizational change. It should be obvious that the leadership behaviors necessary for effective change are peopleoriented. Too often, leaders simply mandate change and expect employees to fall in line and get it done, but do little or nothing to help them get there. Leaders who focus on people are likely to be the most successful in managing change in their companies I look forward to hear from you at pavan@ittige.com on how you are ensuring a positive experience during the organizational change and clearly setting the expectation that employees are expected to work collaboratively in teams. Pavan Sriram is the CEO of ITTIGE Learning, a performance-based training company that works with organisations to improve learning outcomes.www.ittige.com

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MANUFACTURING EXCELLENCE

Take care of safety in the Industry - Part 2 Managing SME in India

Companies typically track monetary direct losses in view of unsafe act or incidence. These are basically tangible ones and hidden indirect losses will be much more. Rough estimate is that indirect losses will be 6-7 times higher than direct losses.

P S Satish gotopssatish@gmail.com

Let us look at some of the ways how safety can be ensured. 5E method is predominant here. 5Es for taking care of safety are – • Engineering control • Education and Training • Employee participation • Effectiveness check • Enforcement A. Engineering control Here focus is on incorporating safety in machines and equipment. Safety to be considered in all factors that can come from 6M – Material, Method, Machine, Measurement, Mother earth. It includes further designing of proper layout, appropriate storing methods, selecting right persons with skill and experience, selecting right type & size of material, establishing correct procedure, correct way of handling chemicals, proper checking methods and factors that will come from environment like humidity, temperature, pressure etc. High emphasis on safety

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aspects is given at the time of establishing the process. It could be a part in design and process FMEA. Poke-yokes are built into system so that possibility of mistakes that can lead to unsafe condition can be reduced. B. Education and Training Everyone in the company have to be made to undergo necessarily a training program on safety. It should not be a ritual. Live examples from the company to be taken to train and they should be involved in implementation of few actions. Since Employees are likely to forget lessons learnt in training, it is necessary to retrain with a definite frequency. Education is also possible with posters related to safety and videos. Mock drills by creating an artificial panic situation with the guidance of experts in safety domain is also a good idea. Employees also have to be trained on using first aids. Even temporary workers and contract laborers have to be included in the training. Display

of boards visualizing scores of safety audits, incidents and accidents happened at prominent places will help in educating Employees. On job training in shop floor to educate operators on proper usage of tools. Few examples – o To use the right tools for the job. Example – Wrench is not used as hammer o Not to use broken blades o Electrical tools are properly grounded o Portable grinders have proper guards o To avoid using sockets without proper electrical pins C. Employee Involvement If Employees are not involved in any idea, it is very likely that they will not follow. They should be encouraged to give suggestions to improve safety aspects and they should be rewarded suitably. Safety committee can be formed to monitor safety aspects in the company and

they should be empowered. All employees to be involved while formulating procedures and guidelines as per ISO 14001 and OSHAS18001 standards. It should not be a ritual of Management Representative to maintain some papers for the sake of standards. Sensitivity to safety starts from childhood and at home. It may be a good idea, as I saw in one company, to train families of the Employee in a group to create awareness on safety in the home and society. With this family members of the Employee are also involved. D. Effectiveness check No system is sustainable unless there is a periodic review or audit. Company should make a checklist as suited to their activities and to be used to assess the gap. Audit should focus on adherence to procedures/guidelines & efforts made in improvements. It should be a fault finding mission. Good practices seen in one area have to be deployed horizontally. Management have to involve in looking at the gap and to support for closure. Focus

April 2016

Everyone should undergo Training Program on Safety

Training should not be a Ritual

Live examples from the company to be taken to train

Since Employees are likely to forget lessons learnt in training, it is necessary to retrain with a definite frequency. Display of boards visualizing scores of safety audits, incidents and accidents happened at prominent places will help in educating Employees.

should be on prevention than correction. 5S audit is also related to safety. Supervision including disciplinary action for Employees not following safety instructions (for example not wearing goggles in welding) is a must for enforcement. E. Enforcement During the contract of any equipment or machines, aspects related to safety have to be included and enforced. Any statutory requirements have to be adhered without fail. Before undertaking any work that may have concern related to safety say for example welding of a boiler, proper approval by authorized person and prechecking before start of work have to be ensured. Role of 5S in maintaining safety 5S as we all know is beyond cleanliness. In fact, some companies follow 6S wherein last S stands for safety. Even otherwise, many aspects covered in 5S are related to safety. Few examples are – o Keeping floor free from oil and dirt o Floor without any damage

April 2016

o Storing the parts properly to avoid piling up o Keeping gangways free from any obstruction o Ensuring that area around machine is clutter free o Avoiding any loose electrical wires o Regular empting of scraps o Proper storage of Jigs, Fixtures and tools o Proper guards for the machines including splash guards o Daily cleaning of machine by the operator. It is not just for keeping it dirt free, but logic is different. While cleaning operator may observe further potential problems related to maintenance and safety. E.g. loose belts, high temperature etc. In Japanese use a word for this called, ‘Warusa-Kagen’ which means that things are not yet problems, but still not quite right. By integrating safety related points in regular 5S audit checklist, many safety issues can be avoided. Use of Personal Protective Equipment(PPE) These are meant to minimize exposure to injuries and

Everyone should be involved in implementation of few actions

Employees to be trained on using first aids

illnesses. It should be made as a habit for all the employees to use proper personal protective equipment. Some discipline has to be ensured. It should be part of training and also work instruction to explain type of PPE to use, when to use, how to use, limitations of usage and its maintenance. Few examples of PPE are – o Face and eye protection – To protect against dust, flying particles, harmful rays and chemical splashes o Ear protection – Using proper enclosures and guards, usage of ear plugs or ear muffs. Acceptable level of noise is 85 dBA o Respiratory protection – To protect against harmful dusts, fogs, smokes, mists, gases, vapors and sprays. o Safety shoes – can avoid most of foot injuries. To avoid slippers/ chappals. o Head protection – Usage of helmets o Protective aprons – To guard against any likely splashes of chemicals and radiations Safety Audits

The purpose of safety audit is to identify unsafe conditions and practices. Other focus would be to educate employees, to make them participate, to measure level maintained, to compare among departments or sections and most importantly to identify preventive actions. The type of questionnaire differs from company to company. Points observed have to be brought to notice of management and involve them. In the next audit, previous actions to be reviewed. In the last two articles, we saw basics of safety, the importance, implications if not cared, steps for maintaining safety. Let us follow to inculcate good practices daily and not do it as ritual in the month of March. Have a safe day. Please send your inputs,remarks,opinionsand suggestions toP.S. Satish,Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103, MantriPara diseApartments,Bannerghat ta Road, Bangalore-560076. Email:gotopssatish@gmail. com;www.linkedin.com/pub/ satish-cp-pii/35/153/85b;Mob: 9845043202. Have a nice day

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ENTREPRENEUR SPIRITUALITY

Bring loving Energy to whatever you do Spirituality for SME’s- 3

In this third series of articles on spirituality for SME’s, let us discuss about another simple principle which gives great results. It is about bringing your loving energy into whatever you do. Don’t work for joy, instead work out of joy. Learn the many ways to be happy.

A S Shetty

If you enjoy doing any job,

have a good attitude. A

It was mentioned that he

you will be free of any

pessimist sees difficulty in an

revealed this secret in his

stress in both your body and

opportunity and an optimist

letter to his eleven year old

mind. Body and mind are

sees opportunity in a

son Hans Albert. He wrote

interconnected. A stressful

difficulty. For a lot of people

“I am pleased that you find

body affects the mind and

action is a burden. They

joy with the piano. This

vice versa. If the mind is

want to postpone action. If

and carpentry are in my

stressed, it will affect the

you enjoy anything you are

opinion for your age, the

body also. Learn to focus on

doing, you won’t postpone

best pursuits, better even

happy incidents in life and

doing it. You have to bring

than school, because these

remember less of unhappy

that quality of love into

are things which fit a young

incidents. Don’t confuse

whatever you are doing.

person such as you very well.

material things as being equal to happiness.

Whatever you are doing, start doing out of love. Our

You should not think problem

biggest problem seems

is equal to unhappiness. It

to be that we are quick to

is the way you are looking

identify ways to become

at the problem that causes

dejected and are too slow

unhappiness. Try to convert

to register the abundance of

problems into challenges and

opportunities for happiness.

challenges into opportunities.

In one of the magazines, I

A difficult task becomes

recently read about Albert

challenging when you

Einstein’s secret to learning.

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Mainly play the things on the piano which please you, even if the teacher does not assign those. The way to learn the most is that when you are doing something with such enjoyment that you don’t notice that the time passes. I am sometimes so wrapped up in my work that I forget about the noon

meal ………. Don’t work for joy, instead work out of joy. Do each task with full loving concentration, as if you have nothing else to do. As you get completely absorbed in it, you will experience a beautiful fullness within you. The most modern language in the world is also the language of love. Speak lovingly, act lovingly, and work lovingly. Throw yourself wholeheartedly, lovingly and sincerely into every activity that you take on. Wholeheartedness dispels drudgery, enriches your inner life, and enlarges your inner vision. You feel deep fulfillment and become majestic and calm.

April 2016

In life, you can’t always get

vast industrial experience

in Rollforming Technology

In this new series on

what you like. Therefore, you

of more than 28 years is

in India. Apart from steering

SME Entrepreneur

have to learn to like what

a mechanical engineering

the growth of his company

Spirituality Article series,

you get. Love what you do.

graduate from IIT BHU and

Sedvik Industries Pvt Ltd,

he is penning down his

Creativity means loving,

a Post Graduate in Welding

he is also helping companies

experiences and you can

enjoying, celebrating your

Technology from Germany. He

to promote Rollforming

reach him at sedvik@

work. Don’t hanker after

is one of the leading experts

Technology as a consultant.

vsnl.com

recognition. If you enjoy the work, it itself is a great reward. Osho says: change the frame of your mind. Always rely on just a happy frame of mind. Let it become one of the fundamental rules of your life. Even if you come across something negative, find something positive in it. Then you start turning each opportunity into a challenge for growth. Osho also says, Heaven is here- - you just have to know how to live it. It is only a question of changing your perspective, your approach towards life. Get more into your body. Make your senses more alive: see

Advance to the IIoT. Connect devices and ignite productivity.

more lovingly, smell more lovingly. Let your senses

Give your existing infrastructure a brighter future.

function more and more.

Red Lion has been connecting devices and igniting productivity for years. From plug-andplay Ethernet switches to HMIs and visual management systems with built-in protocol conversion, our industrial automation and networking solutions will enable you to connect, monitor and control virtually anything, anywhere at any time to meet today’s Industrial Internet of Things (IIoT) requirements. Visit www.redlion.net/IIoT and discover how to extend equipment lifespan, improve process visibility and push control to the edge.

Then suddenly you will see the energy that was moving too much in the head is now well dispersed in the body. Life should be a passion, a vibrating passion, a pulsating passion, a tremendous energy. Whatever you do should not be dull; otherwise don’t do it. Whatever you are doing, do it so completely, so unhurriedly, so patiently, that the mind is saturated and becomes content. The author A S Shetty, with

April 2016

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CORPORATE FEATURE

NORD Drives provide boost for in-house Paint Shop

At the NORD DRIVESYSTEMS headquarters, the power, functionality, and intelligence of NORD products are used to the companyâ&#x20AC;&#x2122;s own advantage across the factory floor, with geared motors and drive electronics handling various applications. Notably, this includes a recently established surface coating facility, where NORD systems drive overhead conveyors, fans, and hoists.

The new surface coating

NORD configures each drive

an automated high-bay

and packing stations together occupy 1,400 mÂ˛. An intelligent control system has, on average, halved the lead times for paint jobs. Any drive can be painted and shipped within two hours after assembly.

warehouse for paint cure,

Paint line with a fast lane

of urgent orders has now

facility at the NORD DRIVESYSTEMS headquarters in Bargteheide, Germany, has twice the size of the previous paint shop. New paint booths,

system to order, drawing almost exclusively on components manufactured in-house. Application-specific coatings are part of this process. Fast processing

become much easier. Previously, geared motors were routinely returned to the end of the queue once the first coat had been applied. The new conveyor system enables completely flexible routing: after curing, high-priority products

Three out of four available paint booths are now regularly used, up from two before the recent extension.

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April 2016

Technology box for easy connection of sensors and Profibus communication with the control system.

Paint jobs can be handled more efficiently and faster.

can jump the queue and

optimal solutions for each

They automatically detect

Designed to achieve a great

immediately get their next

of the various requirements.

partial load and reduce the

price/performance ratio while

paint coat. Intelligent sorting

Both highly efficient

energy consumption of the

offering a full complement of

algorithms also ensure that

helical bevel gear units

motor accordingly. Since

efficiency functions, the SK

paint jobs with equal priority

and worm gearboxes with

the inverters are installed

180E supports motor outputs

are optimally grouped by

very high gear ratios are

on the roof along with the

from 0.25 to 2.2 kW to address

coating systems and shades.

used. Depending on the

ventilation units, they are

all simple handling tasks in

This has reduced wastage

performance and function

designed for IP66 ingress

horizontal applications.

and setup times. In addition,

requirements, the motors

protection.

state-of-the-art filter systems

are controlled by different

in the paint booths limit

frequency inverter models.

pollution to a minimum. The packing stations also draw on the smart sorting capabilities

Ventilation systems

Overhead conveyor The NORD motors and gear units passing through this

Four fans with a 22,000

facility often weigh several

mÂł/h circulation capacity

hundred kilograms. Robust

ensure proper air exchange

hardware is therefore

in the paint booths. The

required. The overhead

fan drives are equipped

conveyor is operated at a

with 22 kW distributed

maximum speed of 10 m/

drives from the SK 200E

min. It is equipped with over

frequency inverter series.

100 smooth-running worm

More than 100 drives

The control solution enables

geared motors. Some parts

take over various tasks in

standby mode and ensures

of the facility are classified

the new facility â&#x20AC;&#x201C; NORD

adequate compensation of

hazardous areas (Ex zone 2).

drive technology powers

filter pollution by regulating

The 14 drives installed within

conveyors, hoists, exhaust

the motor speed based on

them are controlled by SK

ventilation and cooling fan

the measured air flow rate.

500E series cabinet-installed

systems. Drawing on its own

Like all NORD inverters,

inverters. All other drives

modular drive program,

these drives provide smart

feature a motor-mounted

NORD has configured

energy saving functionality.

SK 180E type inverter.

of the conveying systems: each packing station can be designated to handle a particular mode of shipment. The right drive for each and every task

April 2016

A technology box installed with the inverter adds a Profibus interface as well as various sensor and pneumatic interfaces for transmission of position data and controlling switches. The integrated drive configuration capability as well as the consistent use of plug connectors was instrumental in minimizing the drive installation effort in the extensive facility. The AC vector drives have a separate 24 V control voltage supply and can therefore be accessed via Profibus even when the 400 V power supply is switched off. Hoist technology The facility includes a high-bay

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storage as a drying room.

position control loops for the

An automated storage and

hoisting and driving axes. That

retrieval unit enables flexible

is, type SK 545E frequency

access to all drive components.

inverters simultaneously

Each drive unit can be

process absolute position

retrieved via its individual

data and the signal of an

designation and automatically

incremental motor encoder.

transported to a paint booth

They then autonomously

with the overhead conveyor.

adjust the position according

The automated storage and

to the set value specified by

retrieval unit is equipped

the automated storage and

with powerful helical bevel

retrieval unitâ&#x20AC;&#x2122;s PLC and report

geared motors for hoisting

back the reached position to

and driving. The telescopic jib

the PLC. The drive electronics

that picks up the payload is

control speed and gentle

extended by means of a light-

acceleration and braking (S

weight, compact aluminum

ramps). In this application,

helical inline geared motor.

Profinet interfaces were

NORD has implemented

integrated for communication

with the PLC. NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 3.200 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or explosion-protected systems. Gross sales amounted to approx. EUR 540 mn in the 2015 business year. The company founded in 1965 now has over 36 subsidiaries worldwide. The closely meshed

sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 1,000 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units. For more details visit www.nord.com

The new paint-coating facility at NORD enables extremely flexible management of paint jobs by means of automated conveyor and warehouse technology.

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April 2016

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CASE STUDY

Automation Delivers 75% Energy Savings For Extrusion Application For many manufacturing plants, the opportunities to achieve savings on energy consumption are plentiful.

Businesses consider options ranging from simply adopting best practice in terms of switching off energy sources when not required, to making significant changes to machinery. Maintenance personnel are often the individuals tasked with making the savings. However these teams often come up against the issue of obsolescence, which can make it extremely challenging to find new efficiency opportunities.

When Tech Folien Ltd, based in Liverpool, UK, was faced with this very issue, the company turned to Emerson official partner RJW, who designed and installed a solution which delivered energy savings of

over 75%. Tech Folien is a specialist producer of polycarbonate, polypropylene and other co-extruded blown films, specifically for industries such

as packaging, automotive and construction. The previous motor and drive solutions had been installed on the companyâ&#x20AC;&#x2122;s extruding line for over 15 years. The challenge

for maintenance personnel has been the sourcing of spares. Having been out of production for a number of years, parts for the incumbent solution were becoming hard to find. It was

Installed in a cabinet away from the line, the Unidrive M701 sets the speed control parameters of the motor, which itself is installed close to the line in the space vacated by the obsolete combination.

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April 2016

The new drive and motor combination from Emerson Industrial Automation ensures control over energy costs and ensures 24/7 operation for the manufacturing facility

also noted that from an energy consumption perspective, the existing solution was highly inefficient. As a result, Tech Folien decided it was time to renew and upgrade. Once the company had specified its requirements, RJW was able to advise on the best solution. It was decided that the Unidrive M701 variable speed drive from Control Techniques and an energy efficient IE4 LSRPM motor from Leroy-Somer (both Emerson Industrial Automation group companies) would provide the optimum solution. Installed in a cabinet away from the line, the Unidrive M701 sets the speed control parameters of the motor, which itself is installed close to the line in the space vacated by the obsolete combination. The control parameters can be easily programmed via a set of on-board drive macros. When it came to the installation of the motor, RJW’S

April 2016

engineering expertise and comprehensive support were vital as the solution had to fit in to the same space occupied by the old product. A custom base plate was machine engineered by RJW for the motor to drop onto. This matched the old footprint, which was critical as installation space was very limited. Tech Folien had the old solution independently verified by a firm of energy consultants, who in turn also measured the new solution once installation was completed. The difference in energy usage was significant. Measured over a year, the new solution is predicted to deliver savings of over 75% annually in energy costs. “For Tech Folien, energy efficiency plays a vital role in ensuring profitability. This, combined with machine uptime, represents critical operational factors,” stated David Churm, maintenance manager at Tech Folien.

“The new drive and motor combination from Emerson Industrial Automation ensures that we have complete confidence that we can control our energy costs and ensures 24/7 operation for our manufacturing facility.” As part of Emerson Industrial Automation, Control Techniques and Leroy-Somer have operated globally as sister companies for many years, each with their individual areas of expertise and specialist technologies. Now our combined business allows us to provide optimized drive and motor technology, develop perfect industry-specific and customized automation solutions, with strong local technical and sales support on a global scale. Emerson Industrial Automation, a business of Emerson, is a global technology provider that enables productivity, efficiency and quality gains for customers across a spectrum of industries.

Our products include alternators, electric motors and drives, electrical distribution devices and mechanical power transmission, fluid automation and ultrasonic joining solutions. Emerson brands include Appleton, ASCO, Branson Ultrasonics, Browning, Control Techniques, Kop-Flex, LeroySomer, McGill, Morse, Numatics, O-Z/Gedney, Rollway, SealMaster and System Plast. Emerson (NYSE: EMR), based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial, commercial, and consumer markets around the world. The company is comprised of five business segments: Process Management, Industrial Automation, Network Power, Climate Technologies, and Commercial & Residential Solutions. Sales in fiscal 2015 were $22.3 billion. For more details visit www.emersonindustrial.com/ automation

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CASE STUDY

Renishaw reels out new RTLA scale length options to 21 metres Renishaw, the global metrology specialist, has more than doubled the maximum length of its RTLA linear stainless steel ribbon scale. It is now available in lengths up to 21 metres and can be used with or without the FASTRACK™ scale carrier system.

Samina Khalid Samina.Khalid@renishaw.com

The longer RTLA scales, used with Renishaw’s RESOLUTE™ absolute optical encoders, are now suitable for applications with very long axes. These include large aerospace trimming and drilling systems, wing structure drilling systems,

milling machines for power turbine manufacturing and the manufacturing of outsized components. Renishaw’s RESOLUTE is the world’s most advanced singletrack true-absolute optical encoder system delivering up to 1 nanometre resolution,

superior long-term reliability, instant operation after powerup without reference return, high speed performance to 100 m/s, smooth velocity control with interpolation errors (SDE) of ±40 nm and excellent positional stability with jitter (noise) of 10 nm RMS. RESOLUTE is also

compatible with a range of ‘open’ and ‘proprietary’ serial protocols including Siemens DRIVE CLiQ, BiSS®, FANUC, Mitsubishi and Panasonic for connection to a wide range of industry-standard motor drives and controllers. Furthermore, combining RESOLUTE’s easy installation,

FASTRACK™ linear encoder scale on reel

Wind turbine application

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April 2016

RESOLUTE™ with FASTRACK™ RTLA and RTLA-S icon

RESOLUTE true-absolute optical encoder with DRIVE-CLiQ interface and FASTRACK RTLA scale

thanks to its generous set-up tolerances and integral set-up LED, with its excellent dirt immunity gives outstanding performance even on the very long axes typical of heavy industrial applications.

is limited, thus reducing

RTLA scales are mounted to the substrate using either their own selfadhesive backing or the FASTRACK scale carrier system. Comprising two miniature guide rails, FASTRACK securely retains Renishaw’s low-profile stainless steel scales and allows them to expand at their own coefficient of thermal expansion. RTLA with FASTRACK is ideal for environments requiring frequent removal and replacement of damaged scales even when access

of ownership for the end-

April 2016

machine downtime. Installation of RESOLUTE and RTLA scale on machine axes translates into increased up-time, greater reliability and reduced cost user. Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. Since its formation in 1973 it has won numerous awards, including a Queen’s Award for Enterprise 2015 for its RESOLUTE true-absolute encoder system. For Further details visit www.renishaw.com

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CASE STUDY

Todo Impresión

Manufacturing companies and OEMs sometimes get to a point in their growth and development where it makes sense to opt for independence from subcontract machinists. There are many reasons why, but the most common, perhaps, is that local suppliers simply do not give an appropriate or reliable level of service – slow deliveries, poor part quality, lack of capacity, or technical ability, for example. This is precisely the case with Todo Impresión, a specialist printing company based near Bareclona. The company uses a Haas VF-3 vertical machining centre to make a patented robot-loaded system for printing brand names and logos on stainless-steel beer barrels.

Rubén Rueda Ruiz:

company. It uses two

rotating fixture, allowing

our design, and we intend to

We’ve designed and

ABB robots – one to

the screen-printing heads

market it around the world.

developed a large-scale

load a beer barrel, the

to quickly and accurately

printing machine for a

other to unload it. Once

mark the barrels with

particular client – a well-

loaded, the barrel is

brand logos and text. The

known German brewing

held in a custom-made

machine is 100 percent

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Up until recently, we relied on local subcontract companies to machine

April 2016

almost all of the main

although I’m an engineer

We machine a wide

than 90 percent of all our

precision parts. We had

with more than thirteen

range of different parts

parts. Some of them only

a few manual mills, but

years of experience.

in different sizes, so the

just fit the VF-3; perhaps

until we bought the Haas

We also invested in

Haas Wireless Intuitive

we should have bought a

VF-3, we didn’t have in-

Mastercam®, which

Probing System (WIPS)

bigger one! We probably

house CNC capability.

works very well with the

has been very useful. We

will, but in the meantime,

can keep set-up times to

I’m working the machine

a minimum, and since I’ve

12 hours a day until, at

That wasn’t a good place to be. We needed flexibility, reliability, and good quality – which we couldn’t always count on. We were spending too much time resolving supplier problems. We ordered the Haas, and it was delivered in a week! The support from the Haas Factory Outlet in Spain has been incredible.

Haas. I’ve had to learn how to use both, and I’m happy to say, it’s been a painless experience. We’re machining ST52 steel for the structural parts of the printing machine, and 6082 aluminium for many of the other parts, such as base plates to attach the barrel grippers to the robots. We also machine some PE and nylon parts,

The Haas VF-3 is my

for the maintenance-free

very first CNC machine,

guide ways, for example.

April 2016

had to learn programming on the job, it’s been a huge help. As a business, we have three priorities: service to customers, controlling part costs, and meeting delivery dates. Since we bought the Haas and brought the machining inhouse, we feel confident we can consistently achieve all of them. We now machine more

some point, we employ an operator to take over. Haas was recommended to us by several local companies who already use their machines. We took their advice, and I’m happy to say, we made the right decision. Things are moving fast for our company, but we now feel like we have the control, confidence, and independence we need.

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TECHNICAL FEATURE

Are You Getting the Best Performance from your Machine??? Metal Finishing Machines, especially Superfinishing and Microfinishing machines are very specialized equipment. Most Manufacturing companies have Maintenance teams well equipped and trained for General equipment such as Machining Centers and Lathes or Grinders. Also most machine operators have undergone basic training in such General Equipment.

Sameer Milind Kelkar sameer.kelkar@grindmaster.co.in

It is observed that 75% of

of skill-gap. â&#x20AC;&#x153;Microfinishing

rightâ&#x20AC;?. Tool cost optimization

not have the background or

manufacturing companies are

Machines have complex Film

with upgradations in

experience.

not able to maintain Metal

Management Systems. We

Consumables and Durable

finishing equipment on their

invariably find many customers

Tooling is yet another aspect

own, due to above reason

struggling to get this aspect

where maintenance teams do

Grind Master Value Added Services steps in to bridge

Grind Master Value Added Services: Annual Maintenance Contracts Training Process Optimization Maintenance Audits

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April 2016

these gaps, providing

efficiently working on the

customers with various

machine.

services such as :

“There is gradually a

1. Annual Maintenance

trend in industry to make

Contracts

maintenance contracts

2. Training

for specialized equipment such as Metal Finishing

3. Process Optimization

Machines. In the last year

4. Maintenance Audits

than 10 Contracts with

On one of the Microfinishing Machines supplied to a major crankshaft manufacturer in 2005, there was a requirement to upgrade volume of production by 25% and retool the machine

we have completed more various manufacturers, including some OEMs. Machines maintained under such arrangements perform much better over the long term”, says Mr. Barde, Service Manager at Grind Master.

for another Crankshaft

Grind Master is known as a

Variant. Mr. Mahesh Zope,

Trustworthy Solid Partner

one of our Process Experts

to its customers. Customers

in Microfinishing, visited

trust us to do what is best

the customer for Process

in their interest. Value

Optimization. The machine

Added Services are one of

was still performing well,

our offerings which goes a

but was not being used to

long long way in securing a

its optimum, having set at

headache free working of

various points in the past 10

your machine over its life

years for varying capacities. After setting parameters

cycle.

correctly, the productivity

The author Sameer Milind

improved by 20%. The

Kelkar is the Executive

resulting Retool cost 25% of

Director of Grind Master

its original estimated cost.

Machines Pvt Ltd. Metal

In yet another case, a Dynamic Balancing Machine had been supplied. Due to “Multiskilling” initiative and “Operator Rotation” new people were working

Finishing and Deburring is as much an Art as a Science. Grind Master takes pride in being pioneers and leaders in this technology since 1984. Grind Master has a very

on the machine after

strong Application R&D team

a year or so. Being a

and a very well equipped

specialized equipment

Tech Center with various

Grind Master service team

testing equipment and tools.

gave “Training” modules

For more details visit

to the new operators for

www.grindmaster.co.in

April 2016

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TECHNICAL FEATURE

Cable reel for energy chains proves its worth on the stage The igus e-spool achieves success in noise emission tests

The e-spool from igus, a cable reel for energy chains, has passed all the noise tests in the igus test laboratory with flying colours. This means it has distinguished itself as an ideal solution for applications in noise-sensitive areas, such as in stage engineering. With the space-saving e-spool, energy, media or fibre optic data cables can be run together in a single system, as it requires no slip ring.

The Cologne-based

more than 3,000 basic

and pressures, or even

noise emissions during

motion plastics specialist

and user-specific tests

in contact with chemical

operation. e-spool is an

igus operates the largest

are performed annually

substances. Tests are, for

alternative to conventional

testing laboratory in the

for energy chain systems

example, also conducted in

cable reels for very tight

industry with a floor area

alone in 180 test facilities

the special noise chamber.

radii and installation spaces.

of 2,750 square metres,

under real conditions.

It was here that the e-spool

In the tests, the cable-

where all products have to

These include tests at

from igus was subjected

friendly energy, data and

pass various tests. There,

various temperatures

to an intensive test for its

media supply system of the

Tests conducted in the 2,750 square metre test lab demonstrated the low noise emissions of the e-spool. Thus, the cable reel without slip ring qualified for low operation noise in the stage sector. (Source: igus GmbH)

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April 2016

The igus twisterband is used in the e-spool: Thus rotations can be implemented economically and with low wear and low maintenance in a confined space, while reliably guiding energy, data and media. (Source: igus GmbH)

latest generation has been

and a maximum rotational

Suitable for noise-sensitive

proved extremely quiet. In

movement of the used igus

applications

particular the absence of slip

twisterband the e-spool

rings minimises the noise

has surpassed the required

development significantly in

24,000 double strokes by

this special reel. An e-spool

far, completely trouble-free.

equipped with â&#x20AC;&#x2DC;anti-vibration

The twisterband works as

mattingâ&#x20AC;&#x2122; was able to reach

the rotating link through

levels below 46dB (A) in

which the cables are routed

these tests.

smoothly for the chain and

The tests in the igus test lab also proved the performance of the e-spool with respect to its service life. In addition to the noise emissions, this special insulated option was tested for compliance with the service life expectancy for a customer. This result was amazing: at full extension to twelve metres, the integrated return spring held the required tension of the pull-out e-chain at all times,

April 2016

which allows the rotation of the reel. igus offers e-spools with one or two twisterbands, depending on the number of cables to be routed. The achievable life is dependent on the application and execution of up to about one million movements. For the model with spring reel, the spring must be replaced after 75,000 double strokes. In the e-spool power with motor drive, that is not necessary.

The latest test results prove that the e-spool is ideal for use in noise-sensitive applications such as stage installations. Finally, moving stage elements must be moved as smoothly and quietly as possible, at the same time the energy supply system needs to be as compact as possible in order to manage with the limited space. Similarly, factories or logistics centres, where noise emission limits are increasingly becoming a norm, are suitable areas of its application. But there are even more features such as the strain relief of the cables, the variable guiding in all directions, as well as halogen-free components

support the use of an e-spool. The latter is particularly important in order to achieve the required fire safety standards. For this purpose, igus offers the appropriate chainflex cables with TPE outer jacket for moving applications. The e-spool energy supply system is available in standard catalogue sizes of four to 14 metres. For special projects which are either particularly compact or for very long extension lengths up to 50 metres, igus also offers customised special solutions. All components together according to customer requirements with completely pre-assembled cables and optional installation. For further details visit www.igus.in

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FAIR MART

7th ALUCAST 2016@ Bengaluru:

‘The Platform’ to meet Key Industry Players Under One Single Roof

The international exhibition and conference ALUCAST has continuously evolved as ‘’The Platform for Aluminium Die Casting’’, where latest trends and technologies are showcased. It is the ideal platform for companies to reach out to major target groups - Automotive manufacturers, automotive component suppliers, machinery and plant manufacturers as well as production specialists, developers and buyers.

Leading companies from more than 15 countries with over 100 exhibitors and more than 3000 visitors marked the successful conclusion of the 6th edition of ALUCAST 2014 in Bangalore (December 2014). Continuing the success story, the next edition of ALUCAST will be held in Bangalore from the 1st – 3rd December, 2016. Business prospects The growth of the Global Aluminium Casting market has been promising in the recent years due to the growing demand for aluminium castings by the APAC (Asia-Pacific) region. The Market is

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expected to grow at a CAGR of 10% from 2014-2019. Government initiatives such as “Make InIndia “anational programme designed to facilitate investment, foster innovation, enhance skill development will provide further impetus to the industry. The exhibitor spectrum at ALUCAST would include products and services from Aluminium Die Casting, Aluminium Recycling, Automation of Casting Process, Melting Practices and Metal Treatment, Post Casting Operations, Heat Treatment Specialists Instrumentation

and Control, Software Systems Integration/Rapid Prototyping, Die Casting Machinery Manufactures, Die Manufacturers, and Machine Tools. Event Highlights The three day exhibition will be supported by knowledgeenhancing conference program and workshops. Eminent speakers from across the globe will share their expertise and knowledge suggesting how some of the latest challenges being faced by the aluminium die casting industry can be overcome.

The Theme of ALUCAST 2016 conference is: “Challenges Ahead for Aluminium Die Casters”. The effect of burning of fossil fuels, especially by the Automobile vehicles is one of the critical issues which is being faced by automobile manufacturers and die casters alike. Need for compliance to stricter norms for emission and fuel efficiency is forcing complete rethinking among designers, engineers, scientists. The papers and presentations would focus on topics such ascost effective processes to produce parts using composite materials, overcoming design challenges, complexities of joining of diverse

April 2016

“ALUCAST is The Platform where all the manufacturers and suppliers in aluminium die casting industry can network under one roof. The 2016 edition promises to unfold the latest developments in the industry, with an increased number of exhibitors and through knowledge driven conferences/ workshops.”

Ms. Sonia Prashar Managing Director, NürnbergMesse India

materials, amongst others. The Aluminium Casters’ Association of India (ALUCAST) is a registered body, with Head Office at Pune, Maharashtra. It is managed by a Board of Trustees. Its list of members includes manufacturers of aluminium castings, users of castings, manufacturers and suppliers of die casting machines

April 2016

“Government of India initiatives and healthy sequential growth over the last few years in the automobile and auto components industry, has given way to an increased demand in aluminium castings. OEM’s and their suppliers are engaged in R&D to find ways of improving fuel efficiency and reducing the weight of the automobile’s core components, thus leading to an enhanced usage of non-ferrous materials like aluminium. Effective adoption of aluminium casting enables manufacturers to develop superior-quality products.”

Prasan Firodia President, ALUCAST

and peripherals for die casting machines, foundry chemicals and consumables, design software, casting process simulation software, dies, and others connected with casting manufacture and post casting processes. NürnbergMesse is one of the 15 largest exhibition

“The overall impression on ALUCAST 2014 participation is very positive. It was professionally managed on all fronts starting from promotion of the exhibition, Registration online as well as at the venue; Quality visitors visited the Exhibition and Technical Conference. It was a great platform & opportunity to network, communicate, exchange ideas, showcase our latest products and technology in Die Casting field to our existing and potential customers.” Mallikarjuna S Head – Marketing &Business Development Buhler India Pvt Ltd

companies in the world. The portfolio covers some 120 national and international exhibitions and congresses and approx. 40 sponsored pavilions at the Nuremberg location and worldwide. Every year, around 30,000 exhibitors (international share: 41%) and up to 1.4

million visitors (international share of trade visitors: 24%) participate in the own, partner and guest events of the NürnbergMesse Group, which is present with subsidiaries in China, North America, Brazil, Italy and India. The group also has a network of about 50 representatives operating in over 100 countries.

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FAIR MART

Die & Mould competence across the board DMG MORI at Die & Mould in Bangalore (Hall 1A, position B43)

Its many years of experience and application-specific expertise enable DMG MORI to develop customised solutions for users from the die & mould segment. The machine tool manufacturer will be presenting 4high-tech machines and innovative production solutions for the die & mould industrylive in operation at its 144 m² booth in Hall 1A (position B43) at this year’s Die & Mould exhibition in Bangalore.Daily shuttle services to the DMG MORI Technology Center and dedicated seminars round off DMG MORI’s trade fair presentation.

That advanced production solutions ensure competitive ability in the manufacturing industry is an undisputed fact. DMG MORI supports its customers in this respect with its many years of experience and holistic process competence. A key feature in the range of products and services of the leader of innovation is also its specific branch orientation. Thanks to innumerable projects in the die and mould making branch, DMG MORI has been able to build up a wealth of application-specific expertise

from which its customers today benefit. Because experts from DMG MORI concentrate on developing future-orientated manufacturing solutions for branch-specific applications in dedicated competence centers. HSC Center and Mould Laboratory – die & mould competence built on years of experience Die & mould applications have ranked high at DMG MORI for many years and this has resulted in an enormous wealth of

experience in this sector on the one hand and the development and continued development of path-breaking manufacturing technologies on the other. The HSC Center in Geretsried and the Mould Laboratory in Japanese Nara impressively underscore this competence with specialised application technicians who always develop optimum manufacturing solutions for the tool and mould making sector. Trials are carried out here, customers are given technological support and training courses are offered.

The demands on precision, long-term accuracy and surface qualities are met by stable DMG MORI machining centers that are convincing with their thermosymmetric design and innovative cooling systems. While spindles with shaft, flange and sleeve cooling ensure best surfaces, dynamic linear drives enable the required precision and at the same time shorter machining times. At the Die & Mould trade fair in Bangalore, DMG MORI will be presenting its branch competence with the powerful

The most accurate, state-of-the-art technologies for tool and mould making are the center of attention in the HSC Center.

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April 2016

CELOS® enables smooth entry into the future of metal cutting production, because this takes place gradually. Customers who decide for CELOS® today receive firstly unlimited access to the existing 16 CELOS® APPs and secondly they open up the chance of benefiting from future APPs.

The ecoMill 600 V impresses with its design and revolutionary DMG MORI Multi-Touch SLIMline® control.

entry-level vertical machining centreecoMill 600 V as well as thehigh-tech vertical machining centers DMC 650 V and NVX 5080 andthe universal milling machine DMU 65 monoBLOCK®. CELOS® is on board, as it is in all high-tech machines from DMG MORI. This uniform, app-based user interface enables consistent management, documentation and visualisation of order, process and machine data. In die & mold applications in particular, users benefit here from a seamless process chain. CELOS® from DMG MORI for Industry 4.0 The topic “Industry 4.0” is dominating the discussion of the future like no other, even in the sector of machine tool construction. As the leading manufacturer of metal removing machine tools worldwide, DMG MORI supports its customers on their way to digital transformation of manufacturing process chains with the appbased CELOS® system, which the

April 2016

machine tool manufacturer first presented around three years ago and which it has consistently continued to develop in a targeted manner ever since. Using this uniform user interface for machine and office PC, employees in shop floor and job scheduling can manage, document and visualise job order, process and machine data. Thanks to its open architecture, CELOS® allows the exchange of information with higherlevel structures in addition to its effects in the shop floor area. So CELOS® offers customers complete integration of their machines in the company organisation while simultaneously creating today the interface of metal cutting production in the cyber-physical production system of the future. The benefits in day-to-day operation are convincing: a 30 percent time saving in tooling times and 50 percent lower time and effort for the calculation of technology values or the search for important information are just a few of the effects that can

be achieved with CELOS®. ecoMill V series –New revolutionary vertical machining centres in the new design with thenew DMG MORI Multi-Touch SLIMline®control With the ecoMill 600 V at the Die & Mould trade fair in Bangalore, DMG MORI is presenting the new generation of the ecoMill V series . DMG MORI has defined a new standard of performance in the sector of entry-level machines with the ECOLINE product line. Even at the very first glance, the vertical machining centre impresses with its new design that ensures further improved work ergonomics and a higher level of value retention. The ecoMillV series is based on a C-frame cast iron bed for the best stiffness and vibration characteristics ensuring highest precision. Ball screws of the highest quality and a powerful 12,000 rpm spindle were combined to meet the highest standards in production. The

performance of the ecoMill V machines even in the smallest size is outstanding already in the standard version. The highest precision (without direct scales) can be realized, due to direct coupling in X / Y, no belt drive for no backlash. An optimized machine structure also increases stability during machining, and a high degree of manufacturing flexibility is provided in the standard version by having 30 tool pockets in the tool magazine. The absolute highlight is the new 19 – inches DMG MORI multi-touch SLIMline® multi-touch control with Operate on SIEMENS (19” / Operate on SIEMENS / 400 V) with top screen resolution and touch functionrepresents the next advanced step for a modern user interface. The practical and ergonomically optimised 19” multi-touch display with its maximised resolution and 45° swivel range offers decisive user benefits.The new ecoMill V series is also available with DMG MORI SLIMline® Panel (15“ / MAPPS IV on FANUC).

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MART UPDATE

Smaller and smarter: New single fiber optic connectivity solution The FO1 connector is available

rates over long distances, while

either in pre-configured reels

reducing space and guaranteeing

or integrated into custom

performance by means of rugged

assemblies for applications

miniature solutions.

in instrumentation, sensing, defense and broadcasting â&#x20AC;&#x201C; to name only a few of the various fields for which this new product is ideally suited.

The FO1 connector integrates fully into the existing Fischer FiberOptic Series, well-known for its robust and faultless optical performances in any conditions,

Combined miniaturization

combined with easy use, cleaning

and robustness

and maintenance even in the field.

The new connector fulfills the growing market need for higher data transmission

UPC & APC polishing reduces insertion and return losses, making devices more secure, while IP68 sealing provides highly valuable

The FO1 connector can be pre-

device protection. The push-

configured with Fischer FiberOptic

pull locking system allows

Series reels of any required length,

quick and easy connections

a convenient and flexible turnkey

and disconnections, making

solution. To enable customers

these connectors ideally suited

to choose the right connectivity

for outdoor environments.

solution for their specific needs,

The removable sleeve holder

Fischer Connectors also provides

(monobloc mate adapter)

a user-friendly request form that

ensures that end faces can

guarantees the mistake-proof

be cleaned easily, keeping

configuration of cable assemblies.

electronics in top condition.

For more details visit

Selecting fiber optic solutions

www.fischerconnectors.com/

made easy

single-fiber-fo1

Shot Blasting Machine For Fasteners Surface Finishing Equipment Co. have launched intelligent Shot Blasting Machine Tumblast Type for cleaning and roughening of Fasteners. The Fasteners require uniform surface roughness suitable for anti corrosive coating.

The thread of screws posed problem of delecate handling. All these issues are taken care of in the Machine. The Machine has got high rate of production and meet Central Pollution Control Board Norms. For further details visit www.sfecindia.net Surface Tumblast Machie

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April 2016

Lapp India Receives ISO 14001: 2004 Certification Lapp India, a 100% subsidiary

“This Certification is a

core (UNIPLUS HFFR

of the Lapp Group, Germany

milestone achievement

and INFRA HFFR),

and a leading supplier of

for Lapp India and reflects

HFFR multi core

integrated solutions and

Company’s long-term

flexible cables and

branded products in the

commitment in achieving

Fire Survival Cables.

field of cable and connection

our environmental

A performance

technology in India has

responsibilities. Conformance

program is in place

received ISO 14001:2004

to International Standards

that minimizes

certification from TUV

will instill confidence in our

scrap of copper and

Rheinland.

customers, of our products’

compound during

safety, reliability and quality.

manufacturing. We

Attaining standards such

also focus on efficient

as ISO 14001 will enable

waste segregation at

us to formalize energy

source and disposal,

management within our own

including STP

operations”, said Mr. Marc

(sewage treatment

Jarrault, MD, LAPP India.

plan) Lapp India is

ISO 14001: 2004 certification is an internationally recognized standard for environmental management of businesses. The certification helps organizations minimize their impact on the environment, comply with applicable

Cables are an integral part

laws and regulations and

of our homes, offices, public

work towards continual

space and industries. To

environmental improvement.

avoid mishaps and accidents,

The certification has been awarded to Lapp India for successfully implementing and incorporating international standards of Environment Management System (EMS) initiative as its corporate way of life. As a responsible corporate citizen, Lapp India provides assurance to employees, company management and

Lapp cables are coated with a unique thermal compound and are halogen-free which

actively contributing to renewable energy by committing to install 1/3 of solar capacity and supplying extensively to wind mills.

that improves environmental health.

ensures 80% visibility during

The organization has

a fire outbreak. These cables

undergone a meticulous

About ISO 14001: 2004

generate less smoke with

procedure for implementing

certification

low generation of corrosive

a gamut of awareness drives

and toxic gasses. Its low fire

for imparting EMS related

propagation characteristics

training to its employees

ensure a safe evacuation

and vendor partners.

process during emergency

Adhering to an extensive

situations.

assessment procedure, Lapp India has raised the bar for

ISO 14001:2004 sets out the criteria for an environmental management system and can be certified to. It maps out a framework that a company or organization can follow to set up an effective environmental

other stakeholders that the

Lapp India is committed

environmental activities

towards improving its

are being measured and

environmental performance

improved. Going forward,

and strives to improve

the company will invest

energy efficiency. As

During this Certification

sector. Using ISO 14001:2004

in further measures in

part of its commitment

process, Lapp India

can provide assurance to

providing a healthy social and

towards sustainable

employees were given the

company management

occupational environment

green environment,

opportunity to understand

and employees as well as

for its employees, customers,

Lapp India manufactures

how their work affects the

external stakeholders that

vendors and the society at

environmentally-friendly

environment, and to develop

environmental impact is being

large.

products such as HFFR single

practices and technologies

measured and improved.

April 2016

health, safety, security and environment in the wire and cable industry.

management system. It can be used by any organization regardless of its activity or

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Omron unveils first-of- its-kind ‘Total Tamper Detection Solution’ to address power theft Omron, the world leader

importance such as the need

in sensing & control

to channelize and curb the

technologies, announced the

losses caused by power theft.

launch of its Total Tamper Detection Solution – world’s first of its kind - to address the national level concerns of power ‘theft’ in the electricity sector. Positioned as a revolutionary offering for Smart Energy Management, the solution has been unveiled by the company at the ongoing India Smart Grid Week -2016.

Transmission and distribution (T&D) losses remain one of the major concerns for the power sector in India. As per varied industry reports, the country ranks 5th in the world in terms of installed capacity, but still more than 300 million people do not have access to electricity. This unavailability and insufficiency of electricity has a strong linkage with the

The solution comprises of

transmission & distribution

a technologically advanced

losses which amount to

security sensor, made by

around 40 % of the total

Omron, positioned in a

production. The losses give

smart meter. Conceptualised

rise to a vicious cycle - utilities

in association with the

running into losses leading to

utility, Tata Power Delhi

increased power tariff leading

Distribution Limited (TPDDL),

to more burden on the end

the endeavour is visualised

user which ultimately results

as a milestone in enabling

into more unscrupulous ways

the Smart Grid initiative of

to tamper with the meters.

the Government of India and is also expected to play a key role in shaping the macro initiatives of national

shared, “The government

and to contribute towards

plans to install 35 million

moulding India as a Smart

smart meters in the country

Grid Nation.

by 2019 which is a promising business avenue. As we

In a bid to further utilise the

move ahead, we aim to

opportunity of connecting

widen our customer outreach

with all relevant stakeholders

by associating with more

in the smart grid world, the

utilities and contribute

company also exhibited other

towards developing a sturdy

key electronic components

Sharing an overview of

infrastructure in the power

for smart meters and

the business prospects of

sector benefitting the utilities

varied electrical equipment

this solution, Mr. Raphael

and the end consumers.”

making them safer, energy

As per the reports, the

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“Though it is difficult to reckon the proportion of power theft in the T&D losses, it is certainly one of the major concerns for the utilities. Omron’s security sensor for the smart meters is multi-functional, imparting a unique artificial intelligence to the meter by detecting all kinds of tampering”.

power distribution loss in

Vinod Raphael Country Business Head , Omron Automation

Meter Task Force’ to address

India rose to INR 70,000 crore recently*. Omron’s new solution is in synergy with the Government’s efforts towards minimizing T&D losses, considering the Government set up a ‘Smart this alarming state of affairs

efficient, compact and better in performance. Notable solutions for Smart Energy Saving and Smart Energy Supply comprising of panel builders solutions, real time automation based applications for the manufacturing sites, concepts of PV Inverter and Solar Pump were also put on display.

April 2016

th INTERNATIONAL MACHINE

AIEMA

TOOLS EXHIBITION

Initiative

INDIA’S PREMIER MACHINE TOOLS SHOW

BLOCK YOUR DATES

16th - 20th JUNE, 2016 CHENNAI TRADE CENTRE, CHENNAI TITLE SPONSOR

PLATINUM SPONSORS

GOLD SPONSORS

Precision Surfacing Solutions

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ORGANISED BY

For Show Details & Visitor Registration : www.acmee.in April 2016

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Red Lion’s RAM 9000 Industrial Cellular RTUs Receive ATEX Zone 2, Category 3 Approval Rugged 4G LTE Multi-Carrier Cellular RTUs are Safe for Use in Hazardous Environments Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, today announced its Sixnet® series RAM® 9000 industrial cellular RTUs have received ATEX zone 2, category 3 approval and are safe for use in potentially hazardous environments. This approval follows recent announcements that Red Lion’s rugged RAM industrial cellular RTUs support highspeed 4G LTE worldwide throughout the Americas, Europe and Asia Pacific. Ideal for deployment in industrial M2M networks such as oil and gas, water/ wastewater, utility and transportation applications, RAM 9000 cellular RTUs provide a seamless network extension to remote locations. With more I/O than many competitive offerings,

the RAM 9000 serves as a robust control platform that enables customers to simplify remote site equipment by combining separate functions into one feature-packed cellular RTU. The secure allin-one RAM 9000 platform combines built-in I/O, a powerful event engine and data logging capabilities to securely monitor and control remote devices via 4G LTE cellular communications. “Earning ATEX approval will allow the RAM 9000 to be deployed in even more hazardous and industrial environments,” said Denis Aull, vice president of products at Red Lion Controls. “As the Industrial Internet of Things continues to grow, approvals such as ATEX coupled with global 4G LTE communications will help connect critical data from rugged applications to nextgeneration IIoT platforms

regardless of location.” Features of the RAM 9000 include: • High-density on-board I/O: lowers total system cost with two digital inputs, two digital outputs, three analog inputs and one relay output • Powerful built-in event engine: triggers actions based on real-time operational data • Detailed data logging capabilities: record I/O registers on SD Card or internal memory • Remote connectivity: securely monitors serial devices via separate RS-232 and RS-485 ports • Secure routing: enables reliable data exchange over 4G LTE cellular communication For more information about Red Lion’s RAM 9000 industrial cellular RTUs, including a

complete list of features, please visit www.redlion.net/ RAM9000. About Red Lion Controls As the global experts in communication, monitoring and control for industrial automation and networking, Red Lion has been delivering innovative solutions for over 40 years. Our automation, Ethernet and cellular M2M technology enables companies worldwide to gain real-time data visibility that drives productivity. Product brands include Red Lion, N-Tron and Sixnet. With headquarters in York, Pennsylvania, the company has offices across the Americas, Asia-Pacific and Europe. Red Lion is part of Spectris plc, the productivityenhancing instrumentation and controls company. For more information, please visit www.redlion.net.

Indo-MIM recognized at Shimano Vendors Award in Singapore Ralph Marston had said “Don’t lower your expectations to meet your performance. Raise your level of performance to meet your expectations” and Indo-MIM

proved it again with winning a prestigious award recently, adding a feather in the cap! Indo-MIM won the “Shimano Vendors Award 2015” under

““Indo-MIM believes that creative minds and innovation are the keys to success and we have been putting all our possible efforts to prove the same! Our strength is our people and their extra-ordinary effort towards this technology has not only made us a world leader; but such kind of recognition in the global platform has always boosted our morale to do better day by day” Melagiriyappa Giriyappa Head of Engineering, Indo-MIM

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the “Excellent Management Support category” at Raffles Marina Ltd., Atrium Compass Ballroom; Singapore on 12th March 2016. Indo-MIM’s extraordinary capability to offer the best of world-class technology at competitive prices with an eye on consistent development, delivery and quality was applauded at the ceremony. Mr. Manjunath N, Team LeaderProduct Engineering; Indo-MIM received the award from Mr. Chia Chin Seng, MD of SPL/SCM & Head of S.E.A.

Shimano (Singapore) PTE. LTD.; a subsidy of Shimano Inc. is a world class leader in development, production and distribution of bicycle components, fishing tackle and rowing equipments. With an intention of appreciating the continuous support of its global suppliers in achieving excellent product quality, cost and delivery with upholding the Quality objective of Best quality and service for customer satisfaction; Shimano had organized the awards.

April 2016

Optimize your machining process and increase your profits with ESPRIT 2016 Camarillo, Calif. –- CAM industry innovator DP Technology Corp. has announced a new version of its pioneering flagship product ESPRIT®2016. ESPRIT 2016 features a new innovative high speed lathe roughing strategy, called ProfitTurning™ that implements ESPRIT’s new

When holes share the same axis, they will be treated as a single operation with ESPRIT 2016’s New Hole Feature Recognition.

(a)

(b) With the new Max Trochoidal Width parameter in ESPRIT 2016, users can now adjust the width of trochoidal movements from wide (a) to narrow passes (b) with ESPRIT’s ProfitMilling strategy in order to generate trochoidal movements for any size or shape pocket.

April 2016

Physics-Based Cutting Engine. While traditional cutting strategies only consider the geometry of the part, ProfitTurning™ creates the toolpath considering multiple cutting factors and machine characteristics that impact machining performance. “ESPRIT 2016’s ProfitTurning toolpath maintains consistent cutting forces and chip loads, allowing cutting speeds to be significantly increased. By employing trochoidal turning and controlled engagement techniques, the ProfitTurning toolpath also reduces vibration and residual stresses, which in turn makes it particularly well suited to thin walls or hard materials, especially superalloys. The net result is significantly reduced cycle times and maximized productivity.”, said Ivan Krstic, R&D Director of Product Engineering at DP Technology. Simulation speed also plays a pivotal role in CAM software and ESPRIT continues to be at the forefront of accelerating simulation without compromising accuracy or stability. ESPRIT 2016 includes increased simulation speed and higher quality surface finishing saving the user valuable time. Advanced Tool Settings in ESPRIT 2016 provide CAM programmers enhanced tool management solutions. Additional Barrel Tool Support has also been extended to cover more 5-axis and 3-axis cutting cycles. Furthermore, CloudEnabled ESPRIT supports the MachiningCloud APP, which enables users to retrieve ideal

cutting tool solutions and import them directly into ESPRIT with ease. ESPRIT 2016 also features enhanced CAD recognition functions to correct and detect any acute unseen defects in imported CAD models. In addition, users can now edit or remove fillets or even extract a spine curve from fillets as a tool drive curve in machining operations. The new Hole Feature Recognition features in ESPRIT 2016 include automatically recognizing different types of complex holes and names them accordingly. ESPRIT also measures the curvature angle of open holes, making complex drilling operations more accurate and productive. Wire EDM improvements in ESPRIT 2016 make rough cutting easier. The Optional Cut-Off Clearance in ESPRIT specifies additional clearance for cut-off moves to reduce the amount of grinding required. Another new Wire-EDM feature is the Optimize First Cut-Off, which protects the wire from rethreading where there is no pre-drilled thread hole.

New ESPRIT ProfitTurning combines traditional cutting strategies on a lathe with trochoidal movements.

(a) Before removing fillet

Fluid 5-axis features in The New Hole Recognition feature in ESPRIT ESPRIT 2016 eliminates 2016 automatically recognizes different unwanted plunge-type types of holes, including partial and coaxial moves in Swarf cycles, and holes and names them accordingly. smooths any concealed defects in Spiral Finishing with increased simulation part surfaces. The feed rate of speed and innovative cutting Spiral Roughing can now also be strategies that save users increased for non-cutting moves programming time and to save cutting time. ESPRIT optimize profits. 2016 accelerates machining

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Powermax45 Becomes Hypertherm’s Bestselling Plasma System of All Time with Production of 100,000th Unit Hypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, is marking a major milestone with the production of its 100,000th Powermax45® plasma cutting and gouging system. This milestone makes the Powermax45 the bestselling plasma system of all time. It easily beats Hypertherm’s previous record set in 2007 when the company announced it had sold 50,000 Powermax600® units. Introduced in 2008, the popularity of the Powermax45 is due in large part to its incredible versatility. It is portable — weighing in at 16 kg — yet

powerful enough to easily cut 12 mm thick metal, and sever 25 mm thick metal if needed. In addition, the system is designed for handheld or mechanized cutting and gouging. The 100,000th system came off an assembly line in New Hampshire on Thursday morning. It was then outfitted with a special commemorative cover signed by dozens of Hypertherm Associate-owners, including company founder Dick Couch, and shipped to Savannah, Georgia for the Gases and Welding Distributors Association (GAWDA) Spring Management Conference, which began on Sunday April 3. Conference attendees, which include representatives from gas and welding distributors throughout North America, were given an opportunity to bid on the system

during a silent auction that concluded late afternoon on April 4. The winning bid was made by Dave Walker, treasurer at GAWDA who offered $2,525 for the system. Proceeds from the auction will be donated to the GAWDA Gives Back,which provides funding to in-need nonprofit organizations in the city of the GAWDA Annual Convention. “As a company, we are humbled by a milestone such as this, as we realize the enormous amount of work that went into making this system (Left) Hypertherm Founder Dick Couch putting his the world’s bestselling signature on the 100,000th Powermax45 system plasma,” said Bruce (Right) Successful bidder Dave Walker Altobelli, who leads Hypertherm’s Powermax team. their customers for choosing “We are grateful to our network Hypertherm.” of authorized distributors for For more information, please their support and belief in visit www.hypertherm.com/en/. Hypertherm products and to

Kennametal Named One of the World’s Most Ethical Companies for Fifth Consecutive Year Kennametal Inc. (NYSE: KMT)

standards of ethical business

Companies distinction, which

industry standards by introducing

today announced that it has

practices.

recognizes organizations that

tomorrow’s best practices today.

been recognized as one of 2016’s World’s Most Ethical Companies by the Ethisphere

This marks the fifth consecutive year that

excel in three areas – promoting ethical business standards and practices internally, enabling

Institute, a global leader in

Kennametal has received

managers and employees to make

defining and advancing the

the World’s Most Ethical

good choices and shaping future

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Kennametal is one of only two companies in the machine tools and accessories category honored this year.

April 2016

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India’s expanding market opts for German production technology The German machine tool industry continues to arouse keen interest in India. For the fourth time in succession, the VDW (German Machine Tool Builders’ Association) has joined forces with the German-Indian Chamber of Industry and Commerce to organise one-day symposia on 15 March in Chennai and on 17 March in Pune. 17 front-ranking companies like DMG Mori, Emag, Gehring, Gleason-Pfauter, Heckert, Heller, Hermle, Kapp, Leistritz, MAG, Mauser, Open Mind, Peiseler, Profiroll, Samag, Schwäbische Werkzeugmaschinen and Waldrich Coburg showcased their products, solutions and services for modern-day industrial production operations. Around 240 customers from the automotive industry and its component suppliers, the general mechanical engineering sector, and the aviation industry accepted the invitation in Chennai; 220 customers came to Pune. India’s machine tool market offers huge potential With a market volume of almost 1.8 billion euros, India came eighth in the world rankings for machine tools in 2015. The VDW’s British forecasting partner, Oxford Economics, expects the Indian economy to pick up speed in the years ahead, with industrial production output and capital investment both rising. The machine tool market is predicted to expand by 9 to 10 per cent in both 2016 und 2017. The growth of the Indian market is directly linked to improvements in the local infrastructures. “The slogan ‘Make in India’ is aimed at central investments on the spot, and creates ideal conditions for direct investments from abroad. We want to benefit directly from this welcome trend,” emphasises Gerhard Flores, Head of Technological Development and Patents at Gehring Technologies GmbH, Ostfildern, who was

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attending the VDW’s symposium. German manufacturers see a turnaround It was in 2007 and 2008 that the German machine tool sector achieved its biggest successes in India. Exports reached a figure of just under 300 million Euros. In the two subsequent years, the worldwide financial and economic crisis caused them to shrink by a quarter. In 2014, for example, the volume of exports was a mere 150 million euros. In 2015, however, signs of a turnaround emerged, which the sector is keen to benefit from.To quote Dr. Manfred Berger, Executive Vice President Global Sales at MAG IAS GmbH in Eislingen: “It’s primarily the automotive industry and its component suppliers that are our principal focus in India. We are anticipating significant growth in these customer sectors in the future. International component suppliers, in particular, are exhibiting growth potential of exceptional dynamism.” Symposia are ideal platforms In order to enter into direct dialogues with Indian customers, and broker new business relationships, the VDW has for years now been offering its successful technology symposia in India. Firms like DMG Mori, Emag, Gehring, Heller and Profiroll are already involved for the fourth time. For Viktor Schulze, Sales Manager at Samag Saalfelder Werkzeugmaschinen GmbH in Saalfeld, the concept is a cogent one. “The symposia are a brilliant platform, not least for the smaller German vendors. The customers come to us, and are keenly interested. During the symposia we had an opportunity to conduct intensive conversations. In addition, it’s a great to get to knowmore about the Indian market. Otherwise you’d have to do that by yourself.” Dr. Berger of

MAGIAS adds: “The visitor quality in Chennai and Pune was very good, and I’m very satisfied with the entire event.” The event itself, and the product solutions being showcased by the German companies concernedare being well received by the Indian customers. K. Mohan, Managing Director at the Indian automotive component supplier Sep India PVT Ltd in Hosur, puts it succinctly: “The symposium is a unique opportunity to familiarise yourself with the diversity of German machine tools. In contrast to a trade fair, you find out all you need to know in a single day, and can enter into direct discussions with the vendors concerned.” Ashol Aseri, Vice President of the Aviation Division at Maini Precision Products Limited in Bangalore, is primarily impressed by the performance spectrum of theGerman machine tools on show, and says: “The automotive and aviation industries need maximised quality. Only German vendors can meet these expectations in terms of precision, efficiency and high availability levels. Which is why we are only prepared to consider machines from Germany.” German machine tool industry opts for can-do associates

The VDW’s symposium was organised in conjunction with the German-Indian Chamber of Industry and Commerce. In the view of Hubert Reilard, Chamber of Foreign Trade President in India, the Indian subcontinent is an important market for the German mechanical engineering sector. Under the new government, particularly, India’s industrial sector is achieving notable development, and German vendors, with their production capabilities, could assume a crucial role for the country’s upcoming industrialisation thrust, he emphasises. Klaus-Peter Kuhnmünch of the VDW confirms this, and adds: “We as the German machine tool industry are confident that India will, in the future too, continue to develop with vigorous dynamism. Chennai and Pune, in particular, are home to the centres of India’s automotive industry and its component suppliers.”So the association will also be present here in the future for the mutual benefit of Indian customers and German machine vendors.

April 2016

Couplings Provide Accurate Measuring Results Backlash-free, torsionally rigid ROBA®-DS shaft couplings for measuring flanges in dynamometers Essential components for torque measuring flanges in test benches are shaft couplings, which reliably compensate for any shaft misalignments. In this way, they ensure accurate measuring results and also protect the bearings installed into the shaft train against wear. Based on the tried and tested, backlash-free and torsionally rigid ROBA®-DS construction series, mayr® power transmission offers compensating couplings which are specially tailored to the high requirements placed on them in measuring flanges.

measuring flanges as the core of modern test benches, which themselves have to supply precise and reliable data even in maximum performance and highspeed applications. Here, however, the measuring result is always only as good as the shaft misalignment compensation coupling used, as shaft couplings are of decisive importance in order to minimise the disturbance variables affecting the measuring flange. Such disturbance variables frequently occur due to alignment errors in the drive line. Therefore, radial, angular and axial shaft misalignments Short development times, occur in almost all an improved degree of applications between the efficacy or increased input and output sides. Even energy saving potential – a high-precision alignment the requirements on test of the shaft train with state benches are consistently of the art laser alignment increasing. In this way, the devices can only assist to a performance requirements certain extent. In addition, are increasing on torque the misalignments cannot be completely eliminated due to the existing tolerances in the measurements of the components used and the external influences such as temperature. Therefore torsionally rigid shaft misalignment compensation couplings are used together with the measuring flange. mayr® power transmission offers ROBA®-DS compensating couplings, which are especially tailored to the On the ROBA®-DS disk pack coupling, the requirements placed nominal torques stated in the catalogue upon them by can be used without any restrictions. modern measuring They transfer torques up to the nominal flanges. torque completely backlash-free and with a consistently high torsional rigidity. High performance

April 2016

density and backlash-free The ROBA®-DS disk pack couplings compensate for radial, axial and angular shaft misalignments. They thus not only ensure precise measurement results, but also protect the bearings installed Backlash-free and torsionally rigid ROBA®-DS disk pack in the shaft train couplings compensate for radial, axial and angular against unnecessary shaft misalignment. They thus not only ensure precise loads and therefore measurement results, but also protect the bearings against unnecessary installed in the shaft train against wear. downtimes and costs. On the ROBA®-DS couplings, the range from 8,000 to 18,000 nominal torques stated in the rpm, and are balanced to catalogue can be used without a balance quality of G 2.5 any restrictions. A reduction (reference speed 3,000 rpm). of nominal torque due to In the case of the high-speed offsets, load complexes or constructional design, on balance requirements is not which the individual parts required. The couplings are are produced with extremely compact, and simultaneously high accuracy (quality IT5) unite high performance density and reduced axial and shaft with completely backlashrun-out tolerances, speed free function. They transfer values of up to 30,000 rpm torques up to the nominal are permitted. The balance torque completely backlash-free quality of the coupling is G 2.5 and with a consistently high at a reference speed of 5,000 torsional rigidity. The stated rpm. shaft misalignments can be utilised in total to 100% without affecting the transmittable torque. Tailored to test bench requirements The couplings are particularly robust and durable, and feature, in addition to their quiet running properties and low mass moment of inertia, a high balance quality. In this way, the standard constructional designs of the ROBA®-DS coupling cover, depending on the construction size, a speed

The connection of the ROBA®-DS couplings and the measuring flanges on the shaft train are generally conducted backlash-free via high-quality shrink disk hubs. Different coupling construction designs especially tailored to the differing requirements of the test benches and flexible combination options also permit the integration of measuring flanges into almost any test bench and drive constellation.

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First EtherNet/IP Linking Device from HMS enables communication between Rockwell Automation PLCs and serial devices HMS Industrial Networks now releases the first product in a new family of EtherNet/ IP Linking Devices. The new Serial EtherNet/IP Linking Device allows users to connect any serial device to a Rockwell ControlLogix® or CompactLogix® PLC. The main advantage of the new Linking Device is the unique integration to Rockwell’s Studio5000 Logix Designer. All configuration is

made from inside Studio 5000. The new serial EtherNet/IP Linking Device makes it possible to include any automation device with a serial RS-232/422/485 application interface in an EtherNet/IP-based network architecture. It supports all kinds of serial protocols including Modbus, DF1, produce/consume, ASCII and custom protocols. Besides being a more costeffective alternative to in-chassis communication modules, the distributed EtherNet/ IP Linking Device also brings other advantages:

All configuration is made from inside Rockwell Automation’s Studio5000 Logix Designer.

Improved system architecture

Contrary to an in-chassis module which is physically connected to the PLC, the Linking Device can be mounted close to the connected machine. This means that it is possible to establish a connection via a single Ethernet cable instead of multiple network specific cables. The Linking Devices support ODVA’s Device Level Ring (DLR) for ring topology. Easier configuration Users access serial protocol configuration through their existing Studio 5000 software. All configuration is made inside Studio 5000 where there is support for Process Variable Data Tags and manual and automatic generation of named and structured Studio 5000 Controller Tags without any

required user logic. High performance and stability Since the Linking Devices are stand-alone (distributed), they do not affect PLC backplane performance (PLC execution time), even when large amount of data is transferred. The PLC simply scans the Linking Device as if it were any other I/O device on the network

Serial EtherNet/ IP Linking Devices from HMS Industrial Networks

For further details visit www.hms.se

National Instruments Expands R&D Center and Launches NI India Business Incubator Program National Instruments (NI) India has launched the NI India Business Incubator Program and announced the expansion of their R&D Center in India. Both these initiatives aim to support the government’s Make in India program and enable Indian engineers to become global knowledge partners in driving innovation and development across industries and domains.

R&D Center ensures that NI has access to the top talent instrumental in building a platform that meets the needs of all engineers and scientists today. NI works with leading universities to hire the best and brightest talent within the region and provides world-class, formal and on-the-job training to create a long-term and sustained career progression.

The expansion of the India

Through NI India’s Business

Incubator Program, NI will provide increased access to NI technology, technical training and support to shared local communities like domestic Small and Medium-sized Enterprises (SMEs), academic incubation centers and startups. To extend its reach and maximize the impact of the Business Incubator Program, NI is partnering with missionaligned local organizations, as

“For Make in India to succeed and sustain, manufacturing in India should bring more benefits to the table than just cost of labor. Companies can differentiate themselves by adopting smart technologies to reduce defects and improve quality. NI’s technology provides a flexible and powerful platform to build these intelligent systems that power the factory of the future. Startups are an integral part of building the future and we believe that the NI India Business Incubator Program will contribute to the Make in India initiative.” Jayaram Pillai Managing Director, NI India

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well as experienced technology and business consultants, to provide world-class support and assistance to the applicants. It is also aligned with the flagship initiative of the Government of India, Start-up India, which strives to build a solid ecosystem to support innovation, promote domestic startups and generate viable economic growth by generating large-scale employment opportunities. These forward-looking actions of the Indian Government and the abundance of engineering talent will significantly contribute to Bangalore’s transformation into the home of some of the best technology companies in India and abroad. For more details http://india. ni.com/business_incubator_ program

April 2016

Hermle Open House More Popular Than Ever The number of visitors to this year’s Open House in Gosheim was overwhelming. On Friday alone, Hermle AG welcomed more than 1000 visitors to Gosheim. In total, roughly 2800 visitors from 1200 companies came to learn about the latest development trends in milling, turning and generative production.

The event also attracted an increased number of guests from overseas. Hermle AG welcomed more than 800 international visitors during the four-day Open House event. The largest delegations came from the Czech Republic, Italy, Spain, Russia, the Netherlands, Denmark and Turkey. Good interest was also shown by attendees from Japan, India, the USA and many other European countries who used the Open House to discover more information about Hermle’s latest innovations. More than 20 interesting components from various sectors illustrated quite clearly the outstanding performance of the German company’s products. For example, a ship’s propeller, motorcycle rims, engine components and various tool and mould making dies were milled. Visitors were also able to marvel at traditional show highlights such as a sink machined precisely from a 260 kg block of aluminium and weighing just 40 kg once finished, the machining of a titanium blisk from an aeroplane engine measuring 800 mm in diameter and an intricate fan impeller which was re-manufactured for a 1959 Porsche Junior tractor. “The new C 250 machine model, which has found its place in Hermle’s extensive portfolio, generated a lot of interest among visitors. Hermle will play a major role for Government’s Make in India initiative. The 3 and 5-axis machining centre offers the highest levels of precision, speed and reliability, and will definitely become a firm favourite with Indian customers.” says

April 2016

Mr. Swapnil Patil – Product Manager for Hermle in India. The largest machining centre in the Hermle portfolio, the C 62 U / C 62 U MT (mill/turn version), which can machine workpieces weighing up to 2500 kg and cuts an imposing figure in the Technology and Training Centre, was showcased as a re-engineered version. The guided factory tours gave visitors the unique opportunity to experience first-hand the state-ofthe-art production and assembly facilities, the Hermle training department and Hermle’s automation subsidiary Hermle-Leibinger Systemtechnik. Numerous lectures dealt with various issues from the world of milling and offered attendees very useful and practical information about the latest trends. A special show featuring over 60 exhibitors from the fields of tool making, CAD/CAM, measurement engineering, software and control engineering was also well received. Within the context of Industry 4.0, Hermle setups for machine tuning according to the cutting task, Hermle control functions for increasing precision and productivity through intelligent setting of the machine dynamics and Hermle control tools for operator assistance and transparency were presented live at both the machining centres and in the Hermle User College. Hermle subsidiary Hermle Maschinenbau GmbH was presented in an exhibit

featuring components generatively manufactured using MPA technology (Metal Powder Application process). Hermle service competence was demonstrated in a separate area at two machining centres. Extensive diagnostic and service tools showed users how quickly and competently Hermle Service can be on the scene to solve the problem at hand. The Hermle training department’s presentation of training concepts was also a very popular exhibit.

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Renishaw to highlight various metrology products at Diemould 2016 At the Diemould exhibition taking place at Bangalore International Exhibition Centre, Bangalore, India, from 6-9 April, Renishaw (hall 2A stand B38) will highlight a range of process control solutions that help tackle the increasing drive to lean manufacturing, from new technologies for preprocess machine calibration, to on-line and off-line post-process measurement. There will also be a significant focus on the company’s additive manufacturing (3D printing) systems with the new PlusPac™ upgrade for its AM250 additive manufacturing machine. The company will have active demonstrations of its Equator gauging system along with various machine tool software’s catering to Diemould industry. Renishaw is the UK’s only manufacturer of a machine that ‘prints’ metal parts and visitors to the Renishaw stand will be able to see applications that demonstrate the capabilities of the company’s additive manufacturing technology and Strain gauge high-accuracy machine tool touch probes - Unparalleled accuracy and repeatability make this technology the best choice for complex multiaxis work and machine calibration. RENGAGE™ technology RENGAGE™ technology delivers true three dimensional (3D) measurement performance and submicron repeatability. So for exceptional performance, reliability and durability, why choose anything less?

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Conventional probes continue to fulfil a valuable role, which is why Renishaw maintains its position as market leader in the design, manufacture and support of these products. However, for numerous applications, the significant performance benefits offered by RENGAGE technology provide users with a competitive advantage, for both now and the future. RENGAGE technology is available with radio transmission in the RMP600; with optical transmission in the ultra-compact OMP400 and compact OMP600; and in the miniature MP250, offering an unmatched combination of size and accuracy. The Primo™ system – opening up the world of precision manufacturing At Diemould Renishaw is highlighting the Primo system: an entry‑level machine tool probing system that opens up the world of precision manufacturing to all types of manufacturing operation. A genuine breakthrough business model, the Primo system makes it easy for manufacturers to take their first steps towards higher-value manufacturing by automating their operations and achieving repeatable processes. Renishaw fixtures: the new single source for metrology fixturing Following the acquisition of R&R Sales LLC in 2012, Renishaw has developed an extensive new range of modular fixturing designed specifically for co-ordinate measuring machines (CMMs), vision systems and its Equator™ gauging system. Visitors to Diemould

2016will see that the new range offers a wide choice of base plates and components available in M4, M6 and M8 thread sizes, and can be utilised for measurement applications across multiple industries, such as aerospace, automotive and medical. Automated gauging and process monitoring software for the Equator™ gauge Renishaw Equator™, a lightweight, fast and highly repeatable gauge, will be demonstrated in an automated cell. Equator’s innovative flexible gauging technology is based on the comparison of production parts to a reference master part, which can greatly increase throughput and reduce scrap rates at a fraction of the cost of an equivalent custom gauging system. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines. A new process monitoring window has also been added to the shopfloor user interface for the Equator gauging system. This instantly displays measurement results of inspected features to the operator on a bar-graph display. It also shows the history of measurement on each feature so that process trends can be seen. The system’s re-mastering process can now be managed based on temperature limits, number of parts or time since last master. Enhancements in metal 3D printing Visitors to Diemould will also see a new range of additive manufacturing technologies. Renishaw’s laser melting systems utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a highpowered fibre laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100

microns. The AM250, Renishaw’s first additive manufacturing machine is now available with PlusPac – an add-on kit which transforms the machine to meet the demand for cleaner process environments, improved surface finish and precision. PlusPac includes new Optical Control Software (OCS), a gas knife lens window protection system, and a high capacity filtration system. These updates give the user tighter control over the build process, enabling users to create even better components. For full details of Renishaw’s range of metrology products visit www.renishaw.com.

April 2016

Dürr Ecoclean Strives for Faster Expansion

After the successful refocusing under the umbrella of the Dürr Group, the Dürr Ecoclean Group has become the international market and technology leader in industrial parts cleaning over the last few years. Now, various strategic options for the future alignment and further growth of Dürr Ecoclean are reviewed. The goal is to strengthen the company’s international presence and the proximity to customers as well as to enhance the spectrum of applications and products.

growing market for industrial cleaning technology it is important to further expand our global presence. It is our goal to strengthen our competitiveness and to significantly boost the group’s market share with innovative solutions tailored to the specific needs of our versatile target groups. We will be even closer to our existing and potential customers, additionally we will be able to react in a faster and more focused manner”, states Frank Ringat confidently.

“The heterogeneous target groups of the Ecoclean business require different structures in research, development, production and sales as well as in marketing than those present at the Dürr Group. In a strategic partnership with another company or with an investor we see the opportunity to respond more flexibly to the demands of our markets and therefore to accelerate our growth”, explains Chairman of the Board Michael Förster, who runs the company together with CEO Frank Ringat.

The Dürr Ecoclean Group has ten sites with approximately 825 employees in eight countries around the world. They generated around € 200 million turnover and an EBIT margin of around 6% in 2015. Customers are, on the one hand, the automotive industry and its suppliers, on the other, the company provides industrial cleaning machines and systems for the broadly diversified industrial market, including aviation, mechanical engineering, optics, medical engineering, electronics and semiconductor industry. With individually tailored technology from Dürr Ecoclean, customers can exploit potential savings for example in unit costs, energy consumption and process time.

The further global growth of the Ecoclean Group also requires a consolidation of the strongly fragmented competitive environment. This may be realized for example by the acquisition of relevant companies. “In the globally

April 2016

For more details visit www.durr-ecoclean.com

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February 2015 November April 2016 2014

THE LAST LEAF Dear Readers, Considering the focus on skill development in India and elsewhere, the absolute need for education is, without question, the manufacturing industry’s most critical driver for remaining competitive. The workforce of tomorrow must be trained, not for the jobs in the market today, but for the jobs that will emerge as critical to the operation of that digital factory in the future. To remain competitive, every link in the supply chain will be called upon to hire better, smarter and more flexible workers at every level of their companies. the importance of mechatronics in the machine building industry must be emphasized, as it already plays a key factor in the design and construction of the machines for that digital factory. Machines will not only need to make the part, they will need the ability to see it, measure it, compare it to the design, make changes on the fly in an entirely electronic mode with no more trial-and-error and, finally, log all the production and workflow data, uploading it to a bus for non-stop statistical analysis of the factory or factories, in the case of multi-nationals. Collaboration amongst players in the market will be the next key to success, not ignoring the focus on new and emerging technologies like additive manufacturing. (Courtesy :www.industryweek.com) It seems that most product companies are racing to create “smart devices” that will simplify how we manage our homes, cars, our health and our business efficiency. Internet of Things (IoT) solutions promise to connect us to devices anywhere and anytime -- regardless of where we are in the world. More importantly, IoT should help us gather and analyze information so we can make better decisions. A company called Think 7, startup from Bangalore has designed a shop-floor management solution, for manufacturing companies, to help them rejuvenate into a SMART manufacturing unit. With water scarcity plaguing prime regions in India this summer, there is an urgent need to find an affordable solution. One possible alternative that can substitute water sources during the scorching summers in India is Gabrielle Diamanti’s solar powered saline water purifier. The simple effective device is a personal desalination still that can be designed with expenditure falling under fifty dollars. The ‘Eliodomestico’ work like an upside down coffee percolator and has a simple design that can be achieved with widely available materials. The desalination takes place in two ceramic pieces that sit one atop the other. In the top piece is a black container where the saline water is poured. The sun heats the container, converting water into steam. As the pressure of the steam builds in the top container, it is forced down a tube into the lower ceramic piece where it condenses and collects in the basin of the container. The remarkable utility of this device is defined by its capacity to collect and purify about five litres of water per day. The container is designed to be transported on the head- a common practice of water collection in many rural regions in India. This device is half the price of a normal solar still and provides two litres of more freshwater than the normal still. No fuel, no electricity. and no maintenance make it ideal for usage by people from all walks of life. The design is available as an open-source project for anyone who wants to make one and is licensed under http://creativecommons.org/licenses/by-nc-sa/2.0/. This device can be built from readily available materials anywhere. We are making an attempt to create a positive outlook around us that we feel, would stimulate and energise our industry atmosphere. Your feedback in this regard is welcome, to enable us improvise our channel of information and motivation to our readers for a better tomorrow. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board April 2016

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