Volume 11 Issue 2 August 2014 Pages 76 `100
ITs Evolution in the Manufacturing Industry • Information Technology Role in Manufacturing • How Business Analytics help Manufacturing Operations •
“The world is looking at Indian Engineers to be Knowledge Partners”
Perfect integration: EPLAN and SAP • Leadership – The Art of Parenting • SMED in Micro Manufacruting •
Joel Shapiro Marketing Manager, National Instruments
The Data Matrix Code allows intelligent Tool holder Management
August 2014
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“From ramparts of the Red Fort, I would like to call people of the world to ‘come, make in India’. From electronics to electricals, from chemicals to pharmaceuticals, come, make in India. Paper to plastic, automobiles to agricultural products, come, make in India, from satellite to submarine, come, make in India. Come here and manufacture in India. Sell the products anywhere in the world but manufacture here, come I am inviting you.”
Foreword
Dear Readers,
- Narendra Modi, Prime Minister of India On 16th August I received a mail from Manoj Kabre, Vice President of Indo MIM as well as our EAB member about devoting 2 hours every week for our country. This group mail was inspired by the promise our Prime Minister made during his maiden speech at Red Fort during this years Independence Day – “If you work for 12 hours, I will work for 13, If you work for 14 hours, I will work for 15 hours”. Several emails were exchanged within the group and the end result was everyone was charged up to extend their hand to spare some time every week so as to realise the mission of creating a Better INDIA! During the speech PM touched upon a range of issues which was directly connecting with common man including lack of toilets, rape, efficiency of government officials etc received encouraging efforts from different corners of the country. Meaningful efforts are taken up by corporate, media and state governments to build and maintain restrooms in schools after the speech. One of the scheme PM announced was “Jan Dhan Yojana” to integrate the poorest of the poor with bank accounts. We always listened in past to so many schemes, but the effective PM was able to inaugurate Jan Dhan Yojana” on 28th of August, and 1.5 crore people got benefited with the scheme in the first day itself, which is something very new our country witnessed after independence. This gives a very promising time for the manufacturing sector in India where I started this editorial by the quote of PM.
Hari Shanker Managing Editor
implementation was always in question. To the controray, within 13 days,
I was having some difficulties in getting my newspaper on time in the morning, and several calls to the vendor gone unanswered. I was lucky enough to meet him and he told me, why cant you just “Whatsapp” me! That’s how the IT have taken over our lives and manufacturing no doubt is empowered by the innovations of information technology. In this edition of MART we are featuring the main story on IT in Manufacturing along with our regular columns on Quality, Talent Management, and Manufacturing Excellence etc. We received a lot of encouragement from our readers on our last anniversary edition, the interactive contents and the valuable experiences our industry leaders shared about the SMEs. This edition have given us a new benchmarking to be maintained and with the coming editions we will be starting new regular columns on people management, best practices, innovations as per the feedback we received. We look forward to hear from you on each of our issues, to make MART, SMART! August 2014
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Cover Story Design
ITs Evolution in the Manufacturing Industry
8
12 Information Technology
Production Planning & Scheduling
Order Managment
Role in Manufacturing
14
Role of Information Technology in Manufacturing Industries
16
How Business Analytics help Manufacturing Operations
19
Perfect integration: Eplan and SAP
Information Technology
Logistics and Distribution
20 20
On Face
Manufacturing
Procurement
On Face
Columns Journey Towards Excellence
26
P S Satish
28 Leadership – The Art of Parenting Pavan Sriram
30
SMED in Micro Manufacruting Gorur Sridhar
Volume Issue212August June 2014 Volume 10 11 Issue 2014 Annual Annual Subscription Subscription `1200 `1200 Member Member INS INS Editorial Advisory Board
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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2n Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed August 2014 Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every eff employees accept any responsibilities for any errors or omissions. © All Rights Reserved
Case Study
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Feature Article 34
Advanced Ballbar Training Enables Extend Machine Life and Accuracy Accurate, Timely Tool Knowledge from NOVO™
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Equip for the future today with RoHS-compliant iglidur plain bearings The new DMG MORI design
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The Last Leaf
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7
IT IN MANUFACTURING
ITs Evolution in the Manufacturing Industry
Rajesh Angadi
The manufacturing industry is an integral part of every national economy. Jobs, technology, and regional trading indexes follow the high and lows of this important industry. Many IT and manufacturing organizations are paying close attention to this sector, specifically, how manufacturers remain optimistic about their financial prospects, how they find ways to capitalize on opportunities, or adjust expenses to compensate for missing projected outcomes. Successes can be found everywhere across industries, sizes, and regions.
For instance, some companies lead to product innovation curve while others are prime examples of productivity, sustainability, and quality. Common to their efforts has been the use of data and information systems. From managing resources to operational process, and other business activities, manufacturers are immersed in continuous improvement closed loops that help companies adapt business capabilities to top priorities, sharpen strategy, and stay competitive. Our research indicates that leveraging information technology to improve the way they work is closely related to top performance. In fact, when we examine what makes manufacturers breakaway from their competitors, From Deming to Lean, Six Sigma, and Operational Excellence, and from Business Intelligence to Big Data, the Best-in-Class are more likely to use these technologies to update business processes and feed data back into operations as new best practices emerge. Manufacturing costs are controlled and minimized
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when there is no latency between material flow and information flow. Especially, in the practice of demandbased manufacturing, wherein the vendors that supply accessories to OEMs are based on JIT (just-in-time) or in-line sequencing methodologies, it is absolutely imperative that a good information technology infrastructure is put in place. The main goal of this IT infrastructure is to enable zero latency within and between business processes that have stakeholders that are distributed across the organization. A good IT infrastructure in the process industry is absolutely necessary for not violating regulatory or safety norms, to improve performance and quality via real-time process monitoring, and finally, improve reliability via appropriate maintenance, driven by up-to-date information on equipment status. A good IT information infrastructure in manufacturing has five levels. The lowest level is the ‘control systems layer’ which directly controls the equipment used for producing the product. At this level, the information
real time, and receiving feedback from and of a system are vital to manufacturers, especially to those involved in product innovation. This is precisely where IT contributes greatly to the sector. Additionally, the use of IT in manufacturing has resulted
Vrushal Phadnis
in reduction of wastage,
Director, Losma India Pvt. Ltd
positively affecting
www.losma.in
company’s bottom lines
“As a very large amount of
and environmental impact.
information is generated
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during the manufacturing
implementation of new
process of a product;
information technology
involving design,
based systems to meet the
prototyping, its testing
goals of a manufacturing
and final production,
organization will be
modern tools involving
essential for the growth
the use of Information
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of manufacturing
highly important. Making
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century.”
gathered is control data and the output signal achieved from the said device/equipment for a certain input and controller. The second level is the ‘supervisory
control layer,’ wherein, ‘Supervisory Controllers and Data Acquisition systems’ (SCADAs), VSAT(Very Small Aperture Terminal), VCON( August 2014
are installed for exercising supervisory control and acquisition of process data and information. The third layer is that of the manufacturing execution systems – a ‘production management functional layer’ encompassing product life cycle management (including computer-aided design), management of all production operations such as scheduling of production, dispatch of production orders, data collection on production orders, production reporting and analysis, tracking materials and genealogy, etc. The fourth layer is the ‘plant to enterprise connection layer’ wherein the business processes of the plant are connected to the business processes of the enterprise. The connection is established by a business rules engine that establishes the link between plant systems and enterprise systems for information sharing, analysis and reporting. The final layer is the ‘enterprise application layer’ which has all of the enterprise level applications such as ERP, enterprise asset management, supply chain management, customer relations management, etc. A good infrastructure will seamlessly tie in one layer with the other so that all of the layers are interconnected in real time. The technologies that are used for various applications include, but are not limited to, state-of-the-art in Web 2.0, database programming, service-oriented architecture, systems and network analysis, wireless communication, enterprise mobility, design, and application of new technologies in the domain areas of artificial intelligence, operations research, global optimization, theory of constraints, simulated August2014 2014 August
annealing, stochastic predictive modelling and so on. Real-time and non-real-time operating systems are used, based on the mission-criticality of the operations. For instance, maintenance is a function that not only concerns the maintenance organization within the company but has an impact on production (via the need for availability), inventory (for spares), purchasing (for procurement of spares, tools), finance (for budgeting, asset replenishment, replacement, etc.), logistics (for scheduling, dispatching and executing maintenance work orders), corporate executive management (business strategy for ensuring lower manufacturing cost, and/or increasing reliability in order to get better return on production assets) and so on. This concept of achieving a unified synthesis of existing business processes, knowledge, data, etc., within the company, which are buried in disparate applications, divisions and departments using a zero latency infrastructure is now called ‘enabling a real-time enterprise.’ By using the realtime enterprise infrastructure, a manufacturing organization can assist its management and labor to maximize performance efficiency, manufacturing effectiveness, quality, reliability, and thereby increase the competitive advantage leading to better market share and better return to shareholders. Recent news about job gains or lack and manufacturing sector growth remind us that there are numerous ways to achieve success. Some people focus on the potential of micro regions around the world. Others believe in continuous improvement cycles that encourage companies to thrive in tough conditions and with fewer resources. Technology is
buzzing with activity describing how mobility, cloud computing, and Big Data are shaping efficiency. Manufacturing organizations like to connect success with customer needs. They tend to focus on innovation to bring better products and services to the market. Others pay attention to strengthening Supply Chain Management – which is becoming part of manufacturing inefficiencies and risks. Labor, capital, materials, and assets represent key areas for keeping companies in business in the long run, so manufacturers continue positioning resources management at the top of their priorities. Opportunities to succeed are everywhere and the common denominator is quality. Most companies rightfully describe quality as their competitive advantage. Manufacturer executives tend to use quality to manage intangible assets such as brand and reputation. These arguments imply that quality is not fixed in time or assigned to a product, a supplier, or a single company initiative. It represents how the dynamic force of quality influences all operational tactics, enables learning new things; accelerate opportunities, or how companies bounce back from failure. Quality principles explain that growth doesn’t depend on a best practice; it is how you adapt and respond to the specific situation. Good quality as a common denominator makes company leaders aware of change including new risky situations, new customer needs, new competitors, and new priorities as well as the chances for success measured in terms of customer satisfaction. Review finds that margin growth (60%) and organic revenue growth (43%) are the top two goals for manufacturers in 2014. But with growth comes
Shaker Tekwani CEO, Spectrum Cable-Tech www.spectrumcables.com
IT in manufacturing is the most vital tool in 21st century. It enable manufacturers to virtually proto type plant layouts , optimize raw materials usage and asses relevant factors prior to investing in plant redesigns or new factories. IT help manufacturers to enable the transfer, storing and processing of data, knowledge and information while at the same time controlling the hardware machinery and also facilitates mailing services, telephone and FAX Networks. The Internet traffic is increasing day by day and manufacturing companies have got the opportunity of Globalization. IT has connected the world in its web of opportunities and has made manufacturers’ life more exciting and easier like never before. growing pains. No longer can manufacturers only be content with maintaining standards organization-wide, while being www.martupdate.com www.martupdate.com
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greater value to customers. In many cases, it is no longer safe to provide the same products to the same customers without change. Therefore, manufacturers must enable collaboration and access to greater amounts of data. It has been found that Enterprise Resource Planning should enable manufacturers to accomplish these goals.
U Rajagopalan CEO, Toshikcon ABS www.toshikcon.com
“For any industry, there is a need for IT solutions – to have better planning/ monitoring tools; to perform repeated jobs/ operation in easy way; for simple & cost-effective communication; etc. In particular, IT solutions improve the productivity in industries, in various levels. This provides instantaneous operation status update; warning signals through SMS etc. to operators. Current process trends; comparison with previous/ standard one; pre-warning signals; breakdown alerts; spares management, supervisory controls; data acquisition & backup to supervisors / mid level management; and MIS reports & web updates on sales, production, performance etc. to top management.”
more efficient in managing front and back-office processes. Today’s manufacturers are also required to be increasingly innovative and more agile in decision-making to stay ahead of competitors, and provide
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There is no argument against the power of data as fuel for organizational transformation. Manufacturing companies want operational visibility to anticipate risks and close performance gaps. They also want a greater understanding of users to direct innovation efforts, operational incentives to increase competitive capabilities, and opportunities for partnerships to grow. Data is of paramount importance to support those and other decisions that help manufacturers gain quality, improvements, and efficiencies. What a difference a decade makes. Fresh from their MBA school degrees and “measure to improve” as motto, manufacturing executives from the early 1990s used spreadsheets to manage by numbers. Later on, Business Intelligence tools were used to analyze metrics, define controls, and create performance dashboards. The internet amplified the data explosion. Social media expanded the data structures by adding pictures, text messages, likes, preferences, and behaviors to define personas for users of internet technology. Cloud computing has also expanded data storage, processing, and sharing options. More recently, advances in mobility allow for quick access to information. The difference is that manufacturing organizations understand that everyone can benefit from using data to
support decisions that help improve the way they work. Today’s game changing insight is data in the right form at the right time and in the right hands. This requires that manufacturing organizations must reach for opportunities to bring manufacturing data to the forefront. Users need help to make sense of data in order to prepare plans, execute, and measure effectiveness. Data, facts, and insight complement intellect and expertise which increases the decision-making ability at all levels of the organization. When managed effectively, manufacturing data can help companies grow and support the vision for a knowledgeable and more effective organization. When the strategy is to improve, tactics turns into data trails and information management. Primarily, we want to collect the thoughts and insights of the manufacturing community about Big Data as a driver for improvements, but also to understand opportunities that are materializing in this sector. During the study we will connect with users via a questionnaire and 1-on-1 interviews. Additionally, we look at how users adapt technology solutions to fit their needs. Another reason for participating is personal development. People want to know how to use data effectively. Conversations quickly evolve to their vision on how Big Data can help them improve. For example, some people expect Big Data to create a bigger and better picture. Others want access to more and different knowledge. There is increasing interest in behaviors, events, and actions. Culture is always factor. Solutions – Business intelligence tools, analytics
embedded in enterprise systems, or homegrown solutions can help transform data into knowledge and value. Users have plenty of options: Enterprise solutions from SAP and production software from Apriso can be architected to take control of operational data across all facilities, and all countries. Preventive, defensive, and triage activities can be supported by a combination of Microsoft and Honeywell solutions for both plant and enterprise users. Visualization and analysis from Product based companies can help manufacturers identify what they don’t know about warranty or asset reliability. Applications to manage specific quality tests from Viewpoint Systems can connect R&D and system engineers with the data that they need to characterize product degradation. Manufacturers are in the interesting position of being in control of massive amounts of data and being driven to do their job better. Perhaps you’re already familiar with how Big Data is helping companies map customers and opportunities, customize products, or increase user experience. While this is important, we want to also look into how manufacturing intelligence (MI) can be used to arm ordinary people with facts and operational knowledge, so they can take extraordinary actions that lead to productivity gains. Rajesh Angadi completed his BE, MBA, PMP 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 Technologiesresearch areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis. August 2014
August 2014 June 2014
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IT IN MANUFACTURING
Information Technology Role in Manufacturing
The future lies in the manufacturing sector were the confident statement entire nation heard on the Aug 15th morning from the PM. And that is indeed true! While China like nations has 34% of their GDP coming from manufacturing, in India GDP contribution from manufacturing is mere 16% and there is an immense potential for the sector to grow. This growth will help India revive overall industry sector, help increase jobs available to the youth of this country. Prashant Katikar
Though “Come, make in India, manufacture in India” sounds a sweet slogan, it comes with its own set of challenges but not an impossible task to accomplish. Manufacturing industry faces two types of challenges. External and Internal ones. External challenges include land acquisition rules, environmental clearances, labour laws and multi point and corrupt administrative clearances. While an entrepreneur can do little on these external challenges front as an Individual, dealing with internal challenges could be entirely in their control. Manufacturing sector has internal challenges to sustain and grow in the global competitive environment. These challenges can be categorized in three areas. Competitive positioning, Competencies and Constraints. In all three, information technology has a vital role to play. Competitive Positioning We cannot have policies and strategies which are merely designed to safe guard Indian manufacturers. Right from the Ford motor company there are several examples which show that, if you are
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unprepared for the world competition, you may perish one day. Competition globally needs following aspects to be considered:
need to be compliant with local laws and statutory needs. One cannot imagine to have all this managed effectively without use of software.
• Product Innovation • Product Life cycle shortening / optimization • Product Quality • Product Cost • Ability to market and distribute product offerings
Increased automation helps optimize production operations, saves time and money for transporting parts to the external facilities for certain operations. Automation and use of software can also help enhance product quality, reduce rejections and also to do tighter quality assurance before product is shipped out.
In all areas software and newer technology has vital role to play. Product life cycles have shortened to less than a third of what they used to be. Use of design and simulation software has become critical now. That helps you save several rounds of proof of concept, model building and trials. One can visualize product by sitting in the lab saving large amount of time and money. Also this helps you keep yourself ahead of the competition. Ability to design and engineer multiple models in quickest possible time can be accomplished only by using software tools. As industry targets to cater the world market, various countries have different localization needs and that makes things more complicated by creating need to have numerous product variants. Also all these variants
Now, you don’t need to travel extensively around the world to evangelize, market your product offerings. One can make effective use of digital avenues to market products. This can be done by building effective product and manufacturing services offerings website, build a software based catalogue access mechanism, ability for your customers to surf through your products and capabilities, enquire about products specifications and cost. Customers can also take a glance at your product availability and order online. One can also build online advertising mechanism to reach out to the desired audience for your products and manufacturing services. Your products and manufacturing services can be advertised
effectively and lead generation can be done by interfacing with social networking tools like Face book, Blogs and LinkedIn. This is all now considered as part of digital marketing. Surveys have shown that, though digital marketing is now a decade old concept, mainly used by western manufacturers, it is catching up a lot in India in last 4-5 years. Many companies have started allocating part of their sales and marketing budgets for the digital marketing. This certainly helps you reach world market seamlessly, reducing huge amount of time and money that was otherwise needed to take your products around the world. Develop Competencies Competencies must be built to support a stronger abs sustainable manufacturing base. Key areas of competencies include Product Design, Engineering, Production Methods, Sales and Marketing and customer Support. Information Technology again can play a key role in developing, and maintaining these competencies. It’s important to get connected with the external August 2014
IT help manufacturers to enable the transfer, storing and processing of data, knowledge and information while at the same time controlling the hardware machinery and also facilitates mailing services, telephone and
Sudip Sarkar Founder & CEO, Utzsho Industries
IT in manufacturing is the most vital tool in 21st century. It enable manufacturers to virtually
FAX Networks. The Internet traffic is increasing day by day and manufacturing companies have got the opportunity of Globalization.
proto type plant layouts,
IT has connected the
optimize raw materials
world in its web of
usage and asses relevant
opportunities and has
factors prior to investing
made manufacturers’ life
in plant redesigns or new
more exciting and easier
factories.
like never before.
world and continuously understand what’s happening in the surrounding to optimize production cost, reduce rejections, source materials etc. Software and communication technologies are powerful enablers of production flexibility and networked enterprises. In past two decades India missed opportunity, especially small and medium enterprises in the application of IT tools. Raw material cost contributes anything between 60-80% in SME manufacturing and its key that industry sources right type of material from the right sources and for the right cost. Keeping inventory levels highly optimized is another key challenge and without software support, once cannot imagine accomplishing this. Also large variety of production skills are required for different industries — machining , August2014 2014 August
customers, availability of trained manpower and availability of right set of tools and equipments to manufacture the components and products. While ERP software’s can help in managing finances with tight rope walk, it can also provide company’s ability to track and follow-up customer outstanding on a day today basis thus making your cash flow better. Effective scheduling of manpower and machines, maintaining best possible machine up time, following up near perfect maintenance schedule, tools calibration on a periodical basis are some of the key aspects of production operations where one has to work within several constraints. There are few software systems available to run manufacturing
operations withing given set of constraints. Deven InfoTech Pvt Ltd is a Pune based company which has developed DiSC framework based solution to manage manufacturing operations in efficient manner by saving operations cost, by increasing product quality and maintaining near perfect shop floor up time using their DiSC based software modules. This software is in operation for the past two years and has been implemented at 35+ manufacturing units across India. Author Prashant Katikar is Director and co-founder of Deven InfoTech Pvt Ltd. Prashant has overall 25 years of IT experience worldwide and continuously try to understands manufacturing industry from IT solution standpoint.
tool making, CNC machine programming, textile weaving, leather finishing, etc. Skills to manage people and production systems are critical, especially for managing high variety production. Software based training, keeping data of employee skill levels, developing multi skilling related plans and trainings and tracking those using software’s will certainly help companies understand how they are moving in this direction. Managing Constraints Indian manufacturing faces numerous constraints today and one view could be that, given the set of constraints we have today, what we have been achieving in the manufacturing sector is really praise worthy though we still need to travel miles in that direction. Some of constraints include availability of finance, accessibility to the overseas markets and www.martupdate.com www.martupdate.com
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IT IN MANUFACTURING
Role of Information Technology in Manufacturing Industries
Sathya Narayana Singh
Information technology (IT) has changed more drastically over the past twenty five years than practically any other field. Particularly in connection with the internet and mobile communication technologies, IT has progressed at rapid speed to become firmly engrained in every aspect of the modern factory. Information is the lifeblood of the enterprise and IT is central to all activities. Predominantly IT is implemented to achieve 5 objectives driven with 5R’s - Produce the Right Product, with the Right quality, in the Right quantity, at the Right price, and at the Right time.
I started my career 25 years back with Manufacturing Industry (Reputed and prestigious company) and found very interesting to work, because whatever I have studied in my engineering, to some extent I could relate to my work. My job was to prepare process sheets for heavy machinery components (A0 size drawings) in machine tool industry which was quite interesting. Within 3 years of my joining as Graduate Engineer Trainee (GET) around year 1992, our company wanted to translate the manual process sheets and feed them into computer. In those days we were using word star 3 and word star 5. As young graduates, it was thrilling to sit in AC as the computers were operated in controlled environment and we started entering the Process sheets data in computer. Later we used to print the process sheets (reusable) and use them in the machine shop which was then easy to modify at a periodic intervals. The point I was trying to highlight here is, when we prepared the process sheets manually the data was not editable and not easy to modify, while we have started using the computers the data was editable, reusable and easy to use. That was the beginning of computer era and gradually we entered into Information
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technology (IT) era. Later, I learnt Enterprise Resource Planning (ERP) – SAP after few years and since then there is no look back. Personally I felt, Information technology (IT) has changed more drastically over the past twenty five years than practically any other field. Particularly in connection with the internet and mobile communication technologies, IT has progressed at rapid speed to become firmly engrained in every aspect of the modern factory. Information is the lifeblood of the enterprise and IT is central to all activities. Predominantly IT is implemented to achieve 5 objectives driven with 5R’s - Produce the Right Product, with the Right quality, in the Right quantity, at the Right price, and at the Right time. Implementation of IT in manufacturing industry is no more a choice or option but it has become mandatory. To realize the goals and business objectives it is imperative to implement IT solutions to realize its corporate vision. The role of IT is to provide information to decision makers, in order to determine whether the capacity in manufacturing industry is being utilized in effective manner which will be give better ROI and eventually help for faster decision making
Design Production Planning & Scheduling
Order Managment Information Technology
Manufacturing
Procurement
Logistics and Distribution
Figure 1. Typical IT influence on Manufacturing Industry
thus generating profits for the company. Today, globally the technology is being developed at a faster pace with several options and software being available at the doorstep of manufacturing industries. For example, ERP – SAP, Oracle, and other customized products for various verticals such as Oil & Gas Industries, Manufacturing Industries, Pharmaceuticals, etc. For manufacturing industries, options are many, as IT solutions can be developed based on On-Demand (Cloud) solutions
or On-Premise (Physical Servers) purely based on the requirement and affordability of the various industries ranging from Micro to Small, Medium and Large Business Enterprises. By implementing IT and aligning with newer technologies the companies have largely benefited to meet the demands of the entire supply chain. Information Technology (IT) has traditionally been a provider of basic transaction systems for industries. Now IT has become a provider August 2014
of information, to enable better and smarter utilization of available capacity in all industries. It is only with the extensive application of these technologies that it has been possible to network production facilities, plants and machines across different locations, supply chains and national boundaries. This development has served to bring about a boost to productivity comparable only to the advent of automation technology. In short, IT has changed in every walk of our life. Today one can’t imagine without IT in our day to day life, be it manufacturing industry, smart phones, communications, social networking, aircraft industry, Shipbuilding industry or any other industry for that matter. For all these, timely availability of information is a key to meet the goals and information technology - database management systems, Enterprise Resource Planning (ERP) systems, Simulation and Computer Aided Design (CAD) Tools have become more vital to most manufacturing enterprises. Above diagram depicts how IT helps in a typical manufacturing industry. This starts with understanding the customer expectations, detailing in design, procurement of raw materials (Inputs for manufacturing components), production planning and scheduling, manufacturing, logistics and distribution, so on and so forth. At every level, IT plays vital role in faster decision making with utmost accuracy. To supplement the IT in manufacturing industry, Six Sigma is implemented to enhance the customer satisfaction, improve the productivity, remove wastage, thus maximizing product and service quality (close to ZERO defect) and attaining the accuracy at highest level of August 2014 August 2014 April 2014
over 99.997% of non-defective products. In addition to above, IT can also provide accurate information to the customer rather than the company’s representative doing so. This is especially useful when the company goes for real-time pricing and order placement over the Internet. This involves direct interaction of the customer with the data provided by the company. Information analysts and data architects in the IT departments will be asked to understand, help, analyze and present the information collected by the systems. This information will become increasingly critical to effective management of capacity and also helps in predictive analysis. This in turn, helps in shaping decisions, which will determine the relative success of companies. Bottom line, Information technology is playing an important role worldwide & has given competitive edge to the business, customers and provided employment to the millions of people world-wide. The IT industry is growing at the rate of over 7% - 24% per annum for on premise solutions and on-demand solutions (Cloud Computing) year-onyear.Only time will tell us how IT is going to transform the entire manufacturing industry into fully automated with minimal or negligible human intervention. Need to wait and watch. The author Sathya Narayana Singh is currently employed with IT consulting and Tier 1 Company and has overall 25 years of experience and 16 years of IT consulting experience. In the past, he has worked with reputed and top-notch world class manufacturing and consulting companies and played various leadership roles and managed large transformational deals. Do write with your feedbacks to Sathya at mssingh_s@rediffmail.com www.martupdate.com www.martupdate.com www.martonline.in
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IT IN MANUFACTURING
How Business Analytics help Manufacturing Operations There is a lot of Information in an ERP (Enterprise Resource Planning) software system that will assist in taking Manufacturing operations up a notch or two. Here we will talk about several efficiency enhancements and the use of Dashboards to attain that. Concepts like MRP (Manufacturing Requirements Planning), Manufacturing Dashboards are explored in some detail here. Kishore Tarachand
MRP and MRPII MRP is a tool used for Production Planning and Inventory control system. It is used to increase efficiency by making material available for Production so ship dates to Customers are honored. It assists in reducing Inventory and production costs. Several customers are using it successfully and others are new to it. Here we will talk about it’s role and how it is used. Usually it is a software, however many customers are using by manual systems. As Software evolved in Manufacturing companies in the 1950’s – several challenges remained open. They were a) Customers requiring products earlier than it took to produce them, b) maintaining the lowest inventory levels and c) planning production to match delivery options.
No
Yes
Every Process Batch/ Sl. No. for the Input parts and for the WIP FG - Serial No
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Prior to the evolution of MRP, industry used, reorder-point/ reorder-quantity type methods for manufacturing and inventory management. In 1964, Toyota started the move towards MRP and several companies jumped on it. In 1981, MRP, evolved into Manufacturing Resource planning (MRPII) which included scheduling of equipment/ operators and capacity planning into the mix. By 1989, many companies adopted MRPII and
this addressed the majority of Manufacturing challenges that they had faced earlier. MRPII includes Capacity or Resource planning and assists in planning/allocating the production resources to meet customer demand. Here machine and operator loading can be reviewed and allocation/scheduling done for production. Dashboards “A picture is worth a thousand words”--With the Global competitive environment we are facing, it is imperative to be highly efficient to survive and prosper. By Quantifying and visualizing a host of information in real-time, it is possible to address the challenges of Lean Manufacturing, Predictive Analytics (to assist in learning about trends as they occur and August 2014
to take appropriate action prior to them becoming problems), improve production quality (lower defects), improve agility and capacity in your plant. These can pull in a variety of current and historical data/KPIs to increase the productivity of Manufacturing operations. Information like work order requirements, Quantity, Items on Order, shipment during the last 3 months, whether production is on schedule, downtime vs plan, production vs plan, etc. Kanban or Lean Manufacturing Kanban is a system for Lean Manufacturing or “Justin-time� production. It is a scheduling system that helps in synchronizing what, when and how much to produce. The need to optimize production led Toyota to utilize Kanban to run the production system as a whole and thereby minimizing their parts inventories and relying on their suppliers to provide parts as needed by Toyota. Kanban uses the demand to drive the production and supply chain. While the supply chain can not keep up with fluctuating demand, Inventory levels are maintained to take the buffer. This is particularly deployed by Auto parts manufacturers all over. Several other industries are also starting to deploy this system. A Case Study with Granada Software Production Flow : Let us take the case of a FMCG Company that is manufacturing fruit products. The Production Flow chart of the product is as follows. It includes the key steps for MRP to enhance the planning process. Manufacturing Dashboard
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We will review the attached example of a dashboard (screen shot from the product) that extracts several KPIs (Key Performance Indicators) to present visual information to review the state of the Manufacturing operations.
Prakash Balasubramanian CEO, Sastha Scienitific Agencies
www.sasthascientific.com
“We at SSA is a growing organisation - where things have to be effectively managed with a small team and cost on communication, travel etc is a key factor in the competitive trading world - every penny saved is penny earned. whatsup - the mobile app has not only changed the way college students and friends communicate, but also changed the way business communication is done too. For our service team be it while repairing a machine at Bangalore (Made in Swiss, Japan, UK, US) we get tech support online, take a short video and instantly send it to Factory tech support team for a quick solution. For selling a new product its just a click away on you mouse to send the video and picture to the customer avoiding a physical visit. With a short corporate video which is quite economical not only create a brand image for our company, but boost the morale and inspire the entire team to give great productivity. There are so
The bar charts below show 5 days of production and downtime for the selected WO in question and shows the 5th day in red indicating that the benchmark was not met for that day. The red bar can be drilled down to indicate what the problem is on that day compared to bench mark for total production scheduled for that day In the right hand bottom corner is the output of a cctv camera that enables the shop floor view from anywhere as the product is 100% webbased. This dashboard gives a visual indication of the problem areas instantaneously to a Manufacturing Director or VP. Off course the green items indicates that the operation is well within/exceeds the Benchmarks for that day.
many other areas where
Better Resource Planning
IT have made its mark in
The key resources in Manufacturing are machines and operators – this greatly enhances the efficiency of a manufacturing operation --- the
the industry, making us dependable to produce better.”
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In the top table, The first row in red indicates a WO (Work order) that has an estimated completion date that is beyond the promised date. This work order can be drilled down to show where the problem is in detail at the shop floor process level. In addition, In row 1, if you look at the Quantity on order (demand) vs work Order Quantity (Supply), The supply (500 units) is <= demand (1200) and hence indicates a problem or delay in shipping. A case of Business Analytics flagging a problem with the Order Quantity shown in red. This creates the need to create another Work Order (1000 units) for the item to catch up with the demand (row 2).
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utilization for both is shown below: Higher efficiencies are attained due to the following: - Procuring and maintaining the right (least) inventory levels to meet customer contractual delivery requirements at the least cost-effective level
enables the mining of data and creating custom reports and graphics. Conclusion
- Improved design control
As the global competitive challenges have grown, Manufacturing software systems have risen to the occasion and we should be prepared for continued improvement in this area. The area of Business analytics and Dashboards is only just being tapped. Capacity planning is available to larger companies at this point and software systems are becoming more cost-effective for mid-market companies.
- Improved Quality
Sources:
- Improved Scheduling of equipment and Operators to maximize their utility, thereby reducing costs and increasing profits - Better planning improves relationships with customers and suppliers
- Reduced working capital due to optimum inventory control - Better cash flow due to ontime deliveries Granada Software This is a highly innovative ERP software company to enable taking your Manufacturing operations to the next step. The software is available as self-hosted or on the cloud. The starting point is an affordable Rs 3000/5 users/month for the starter version of the product. The Software includes the following modules: Lean Manufacturing or Kanban is available in this system. In addition, The BI or Business Intelligence system also
- Capacity Planning- Wikipedia - Other Internet References - Granada Software Instruction Manual The author Kishore Tarachand is a Graduate of IIT Chennai, MSME from Univ of Cincinnati and MBA from Univ of Santa Clara. He worked for over 25 years for fortune 500 companies in the US in Manufacturing, Operations, Finance and Marketing. He is the designer of the Granada ERP Product which is preferred over the leading ERP products for Manufacturing, currently selected to be marketed by IBM on the Cloud Marketplace. He can be reached at kishoret1000@gmail.com August 2014
IT IN MANUFACTURING
Perfect integration: EPLAN and SAP Synchronising data via interfaces is the core of process organisation. Eplan has expanded its mechatronic expertise: In close collaboration with Cideon Software GmbH, an affiliated company in the Friedhelm Loh Group, fully automatic data synchronisation between Eplan Platform and SAP PLM and SAP & ERP has now been realised. The integrated workflow between these leading systems supports controlled throughput from the initial design to production and through to delivery and maintenance. Ramji Singh Cideon Software GmbH, the newest member of the Friedhelm Loh Group, is a longstanding partner of SAP; it thus made sense to merge their interface expertise. The new direct EplanSAP integration enables the secure storage of projects in the SAP system, down to the exchange of parts lists and bills of materials. Additional advantages for companies include project data availability across departments, access controls through the SAP authorisation system, backup of older versions of projects, status and approval management, and accessibility of PDFs and other neutral formats for all SAP users. And all of this is made possible without the integration of an additional PDM system. For designers, template management through SAP and integrated comprehensive search tools â&#x20AC;&#x201C; that also find further projects â&#x20AC;&#x201C; are a reliable and fast pathway to required data. For each individual, this alsomeans more innovative work practices. Deep SAP integration The Eplan SAP integration will use the SAP-defined communication mechanisms. But things get really interesting when you look beyond the August2014 2014 August
Eplan Sap.jpg: EplanSAP integration allows parts lists to be transferred.
document management and examine the deep integration into the entire SAP PLM. The interface makes it possible to link to customer orders and SAP project structures in maintenance and other SAP objects simply via drag and drop. This integrates Eplan projects with subsequent SAP processes, but more importantly, it makes it easier for designers to find the SAP objects relevant to them via the pertinent Eplan project. Integration into the SAP
update service offers additional opportunities to manage historic statuses according to date or effective serial number in the Eplan Platform environment. Data continuity and access authorisation are likewise controlled via SAP mechanisms; SAP workflow sustains the controlled flow of Eplan Platform data throughout the entire company.
As part of the ordering process,
At the same time, access control management determines group and project access authorisations in order to protect project data.
action by users.
the Eplan SAP integration also supplies functions for transferring bills of materials. This holds true not only for the end of a project, but can also be accomplished for partial bills of materials that are automatically created in advance in SAP. Triggered by a mouse click, they are saved in the background requiring no
Source: Eplan Software & Service GmbH & Co. KG www.martupdate.com www.martupdate.com
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ON FACE
“The world is looking at Indian engineers to be knowledge partners” Joel Shapiro leads Marketing in the Emerging Markets for National Instruments and is responsible for directing teams focused on the go-to-market strategy and execution in India, Southeast Asia, Russia, the Middle East, Australia, and Africa. He is based in Malaysia. Additionally, Joel is responsible for product strategy and assessing market direction and customer needs in the Emerging Markets for inclusion in NI’s product portfolio and roadmaps. Joel pioneered NI’s work in clean energy technology and the smart grid, and worked with leading utility and energy companies to drive NI product strategy to address regional and industry needs. He has a proven track record of success in both marketing and business development, working with international teams and customers in the Emerging Markets and East Asia (China, Korea, and Japan). Prior to his international work in the Emerging Markets and East Asia, Joel led the industrial measurement and control product and program marketing teams at NI headquarters in Austin, Texas. Joel holds a master’s degree in Business Administration from the University of Texas and a bachelor’s degree in Computer Science from the University of Tennessee. Joel shares NI journey in India to MART.
National Instruments India brought Virtual Instrumentation Technology in India during 1998, which has enriched Indian engineers and scientists. Can you brief your success journey? National Instruments started its operations in India in 1998, and brought productivity technology tools such as LabVIEW to scientists and engineers here. The Indian market saw the benefit of using these tools and there were early adaptors such as Dr Sanjay Gupta and Dr. Vyas from IIT Kanpur who started using this platform. From then we have seen a variety of customers, including the Automotive, Aerospace, Machine Builders, MNCs, Engineering Service Providers, and last but not the least, the Academic fraternity, join us in our Virtual Instrumentation journey and continue to benefit from our evolved vision of Graphical System Design which helps them do more things with significantly less effort and a higher certainty of success. We at NI are extremely excited about these kind of things, be it Embedded systems or Automated test systems that our tools
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Our flagship product, LabVIEW, is a graphical programming language that abstracts a great deal of the complexity out of traditional programming paradigms, especially as it applies to importing physical measurements into the program, controlling and automating instruments, data analysis, etc., and provides an intuitive environment for engineers to develop and customize their wapplication to meet their exact needs.
have enabled the Indian Engineers and Scientists to achieve. To make these tools easily accessible to the growing community of innovative startups, we have rolled out the Planet NI SME program in India and have supported over 250 SMEs in India with our tools, our support, and guidance in building their businesses. What was the technology available in the market before NI entered India and what are the changes NI brought to the Instrumentation technology today? When National Instruments first entered the Indian market, the primary benefit we offered was a platform to automate and control instrumentation and
measurements through a software-based approach. Prior to this, collecting data from instrumentation was a manual effort, with engineers often times taking pictures of the analog displays on their instruments, and writing down the results on a pad of paper. In addition to simply automating measurements through software, NI offered a different, modular approach to building the hardware components of measurement and control systems, allowing customers to select the specific type and amount of measurements (analog input, analog output, timers/counters, etc.) that they needed for their application, and to combine them into a single system August 2014
that synchronized the modules together. This approach allowed the various measurements to act as a single system, greatly reducing the complexity and cost of applications requiring multiple instruments and/or measurements. Key to all of this was the software to build these measurement and automation systems. Our flagship product, LabVIEW, is a graphical programming language that abstracts a great deal of the complexity out of traditional programming paradigms, especially as it applies to importing physical measurements into the program, controlling and automating instruments, data analysis, etc., and provides an intuitive environment for engineers to develop and customize their application to meet their exact needs. Many of the capabilities mentioned above are possible with traditional programming languages, but require in-depth experience for tasks such as low-level driver development, which require large, expensive development teams. Obviously the technology and capability of our platform has evolved drastically over the past 20 years, but the same core principals hold true today. Modular hardware, programmed with software that abstracts much of the complexity that is typically required to develop these types of applications, allows engineers to solve the real problems they are tasked to work on. How mature is Indian instrument technologywhen compared to developed countries? The Indian customers are certainly demanding in they way they try to get the best of what they have already and at the same time get the best out of the latest technologies aswell. Today, Indian products compete in the world markets and strive to meet the quality needs of the outside world and to compete against the foreign brands inside the country. Indian Manufacturers have consistently been raising the bar of the Instrument Technology needs within constrained budgets in an effort to bring quality products to market faster.
Today, Indian products compete in the world markets and strive to meet the quality needs of the outside world and to compete against the foreign brands inside the country. Indian Manufacturers have consistently been raising the bar of the Instrument Technology needs within constrained budgets in an effort to bring quality products to market faster.
One of my favorite examples of how NI products have helped improve various processes in India is the project we did with the Government of Rajasthan to modernize their power grid. In Rajasthan, there are over 1800 electric substations, most of which were equipped with very old power meters with very basic communication capabilities. To measure and monitor how much electricity was being used at each of the station’s feeders, employees were deployed to the substations, often times which were hard to get to, and had to manually take down the numbers from each of these meters.
systems such as a smart appliance. This once “simple” application requires domain knowledge in a handful of RF standards, power management, physical design, heat dissipation, image capture and analysis, and potentially video quality measurements.
By the time the data was entered into the central system, it was significantly outdated and not useful to make any kind of real-time decisions on power shedding or whether or not additional power plants were needed to be brought on line. For this project, National Instruments products were deployed next to each of these power meters, communicating to them through various communication buses, some custom, and some using industry standards, and then this data was wirelessly transmitted back to the central database via the existing telecommunication structure. Not only was the open communication of our platform important in this application, but also the reliability and ruggedness of it, as it is not unusual for temperatures to exceed 50C.
The expectation in the Indian market is to be able to develop solutions that meet the exact needs of the local challenge. A lot of manpower and intelligence exists in India, capable of solving not only the biggest challenges in India, but also in the world. With IT, once the equipment and internet access was made available, innovations from India impacted the entire world.
How has instrument technology in India grown up with National Instruments? The world is looking at Indian engineers to be knowledge partners as we build complex designs that span multiple knowledge domains. Consider the testing of today’s sophisticated cyber-physical
If we want to keep students inspired throughout their engineering education and prepare them for the jobs of tomorrow that don’t exist today, we have to provide hands-on tools and applicable, real-world experiences that motivate them to continue.
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Indian engineers, with a wide range of educational experience in different streams of engineering, are well positioned to serve this demand and will drive a change in the R&D scenario. National Instruments, with its platform based approach, has helped Indian Scientists and Engineers achieve these objectives easily.
This is now the case with instrumentation and engineering tools as well.As our Graphical System Design platform is now available across the entire world, people working on solutions can develop IP in one part of the world, and have a global platform to deploy it on. This opens up a huge market for Indian firms to develop and deploy solutions not only in India, but anywhere in the world. Can you forecast the growth Indian manufacturing will achieve by 2020, and where we will be placed in the global manufacturing map? According to the Ministry of Communications and Information Technology, Government of India, the demand for electronics hardware in India is projected to increase from $45B USD in 2009 to $400B USD by 2020 (Source: Task Force Report), with an estimated domestic production of just over $100B USDby 2020. This $300B USD gap between Indian demand and production, along with many www.martupdate.com www.martupdate.com
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government programs aimed at spurring growth in domestic manufacturing, identifies an incredible opportunity for companies that design and manufacture electronic devices to either move or establish their manufacturing operations within Indian borders. As production is expanded to serve the growing domestic need, it will also increase India’s capacity as an exports hub for the same class of products. There is no doubt that India has one of the largest and most skilled technical labor forces in the world. With government initiatives paving the way to increase manufacturing capabilities in India, plans to address infrastructure through manufacturing clusters and government grants, and a fast growing domestic demand for electronic devices, there is no doubt that India is poised to become a significant force on the global manufacturing map. As the devices that Indians will use (and ultimately design and manufacture) become more and more complex, so too will the end-of-line testing procedures that insure their quality. We are excited about the opportunity to work with and partner with firms that will increasingly manufacture these types of devices in India, as this is one of our company’s core areas of expertise, and something that our automated test platform, PXI, is specifically designed for. If interested, here is a link to our automated test platform: http://www. ni.com/automatedtest/ Source: http://deity.gov.in/esdm Can you brief us about your latest offerings to the Indian market? The Internet of Things describes a world where more and more of our every day devices are connected to the web, sharing
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data with each other, and connecting us all together. As this becomes more and more of a reality, the manufacturers of these devices need not only to design these communication capabilities into their products, but also test their functionality. Today, the vast majority of this communication is done wirelessly. Many devices support multiple protocols of Wi-Fi, blue-tooth, and custom wireless communication standards. This means that wireless communication has become one of the most important aspects of design and test for modern electronic devices. Unfortunately, wireless test has traditionally been one of the most complex and expensive aspects to test on electronic devices. This is something that we are trying to change with our products and platform approach, striving to make wireless communication just another type of measurement you can make as you design and test your various devices. To this end, one of the areas that our company has heavily invested in over the past few years has been in our RF hardware and software product lines. We have released a variety of products that allow engineers to add wireless test alongside their traditional verification and production testequipment. As new wireless communication standards are constantly being released to market, supporting our RF hardware with the latest communication standards and protocols is something that we are constantly working on, and we will continue to release new products and supported protocols to the market. This, in fact, is one of the many important areas that the NI R&D team in Bangalore is focusing on. The end goal, of course, is that a test engineer will be able to test and validate the wireless communication
of the device they are developing, just as they would test all of the other aspects of the device, and would not require the expertise of a wireless engineer to do this. Is the R&D invested by National Instruments in India exclusively for the Indian market? The short answer to this question is no. Here’s why… One of National Instrument’s core beliefs is in the power of our horizontal platform. This means that we prioritize our R&D investments to make improvements or innovations that can be used across as much of the NI platform as possible, rather than making an improvement or product developmentthat is targeted towards one specific market or application. This approach allows any of the innovations or product developments to be used by a much larger set of potential customers and or application areas – many times in a ways that were not initially intended. To this end, we have not made products specifically for India or any other geographic location. This does not mean, however, that we have not developed products that have been heavily influenced, and sometimes specifically driven by the Indian market or key customers. In fact, some of our most exciting products that will be releasing this year were heavily influenced by needs identified by our Indian customers. National Instruments views the security of their products as an important part of their commitment to their customers. Your view on this? National Instruments products are deployed across the world in countless applications, ranging from simple temperature monitoring applications, to the control of some of the world’s most
August 2014
advanced machines. As such, security is absolutely a top concern and priority for National Instruments. Security can be viewed in many different ways. For our customers that develop and sell applications based on NI hardware and software, their IP is one of their most valuable assets, and often times deployed in the actual product. They need a way to insure that this valuable IP isnâ&#x20AC;&#x2122;t simply taken off of the hardware, and then reengineered or deployed on other hardware illegally. We have built a suite of tools and heavily documented best practices to insure that any application and source code developed in LabVIEW can be safely encrypted and deployed to our various hardware targets. On the other hand, National Instruments platforms are also based on industry standard networking technology and standards. This allows deployed systems to connect to servers and display information on web based user interfaces,distributed systems to communicate and share data
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At National Instruments, we are very passionate about our approach to developing systems, and we believe that the best way to empower people with these tools is to share knowledge and teach them the usage of these Graphical System Design tools. While many competitors hold their knowledge too close to them, we believe in sharing the same with our customers in the industry to ensure that they are self-reliant.
with one another, as well as a wide variety of other capabilities. Being connected to the web also means that protection from various viruses and mal intended hackers is also important. NI ranks among FORTUNE Magazineâ&#x20AC;&#x2122;s 100 top employers for last fifteen years. How has NI India attributed to this achievement? We are very proud to have been honored as one of Fortune Magazineâ&#x20AC;&#x2122;s 100 top employers for the last 15 years. An integral component of this success, which is often times overlooked, has been our strong
track record of growth during this same period. Growth is important because as our company grows, so too do the careers of our employees. This allows our employees to continually seek out new and exciting areas to focus on within our business, and keeps us engaged with new challenges to work on. NI India has been a huge contributing factor to the growth of our company, both from the success of the sales and marketing teams that have helped grow the presence and success of NI in India, to the products that are developed by our Bangalore R&D team, which serve
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growth markets for NI.
India has one of the largest and most skilled technical labor forces in the world. With government initiatives paving the way to increase manufacturing capabilities in India, plans to address infrastructure through manufacturing clusters and government grants, and a fast growing domestic demand for electronic devices, there is no doubt that India is poised to become a significant force on the global manufacturing map.
our global customer base. In addition, many innovations that have been made by the teams in India have had widespread adoption across our entire company. Of course, creating a company and atmosphere where people are happy to work is not only about growth. We also have been fortunate enough to have a CEO whose mission from day one has been to create a company where people enjoy coming to work and love what they do. This has permeated down throughout our entire company, and is something that we all feel accountable for. To this end, we try to elevate the impact to our employees as a key input for any decision; we communicate early and share the rationale for the hard decisions that we sometimes have to make, and in general, strive to have constant respect for all the employees in our company. As we do this, and focus on what each one of us can do to help keep our company growing, it creates an environment where we feel a sense of ownership for what we do, an understanding of how we are all contributing to the success of the company, and hopefully, pride in our shared success. National Instrument organizes a lot of events. How has the industry benefited from these activities? At National Instruments, we are very passionate about our approach to developing systems, and we believe that the best way to empower people with these tools is to share knowledge and teach them the usage of these Graphical System Design tools. While many competitors hold their knowledge too close to them, we believe in sharing the same with our customers in the industry to ensure that they are self-reliant. This is a part of our guiding principles; we believe in “Customer success”, and that leads to our success eventually. These events that we conduct are our humble steps in educating
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the market on the capability of these powerful tools. NI works towards the long-term success of its key stakeholders and society through CSR activities. Tell us more about these activities? There are many different ways that NI chooses to contribute back to society through various CSR activities. Our company believes that the biggest impact we can make on society is through empowering and helping our customers to do what they are already doing. For us, that means providing an engineering platform that makes them more efficient at what they do, abstracts the complexities that oftentimes bog engineers down in low-level details, and enables them to make progress on the important objectives that they are actually working on. Of course, there are also many other opportunities for NI to make an impact in CSR beyond our normal day-to-day activities. One of these activities that I am most proud of is our Planet NI Program. The mission of Planet NI, a National Instruments signature program, is to empower engineers in emerging countries to achieve sustainable prosperity by providing increased access to NI technology. The program nurtures local innovation by supporting small and medium enterprises (SMEs), startups, and organizations that collaborate on projects to bring prosperity and sustainable development in emerging nations through technology-based innovation and development. The Planet NI program is an extension of the NI company mission to equip engineers and scientists with tools that accelerate productivity, innovation, and discovery. This program extends the reach of NI tools and technology into geographies where large gaps exist in technology access, engineering skills, and entrepreneurship, and it supports the development of future
Going back to the question about how NI India is making an impact on the Fortune 100 List for companies to work for… the Planet NI program was an initiative that was started in our India branch. It has enjoyed great success in India so far, and has evolved into a larger program, serving emerging markets all over the world. The NI employees that participate in this program have consistently said it is a source of great joy, and something they are quite proud to be a part of. What are the measures NI India has undertaken to bridge the gap between the industry and academy? If we want to keep students inspired throughout their engineering education and prepare them for the jobs of tomorrow that don’t exist today, we have to provide hands-on tools and applicable, real-world experiences that motivate them to continue. This consists of NI LabVIEW Graphical System Design software combined with scalable hardware platforms for each stage of engineering education, from kindergarten to rocket science. We know that textbooks, theory, and simulation are important for science and engineering education, but they do not have to be the only experience. Students can learn fundamental concepts and build up to more complex systems, with hands-on project work that helps to solidify the textbook theory. Towards enabling researchers, we have setup Center of Excellence in leading academic institutions such as IITs, and to enable a better teaching experience, we work with colleges in settingup “Do Engineering” labs for different streams of engineering such as Signal Processing, Communication systems, Control Systems, etc. We also run NIYantra, a Graphical System Design competition to motivate the young engineering minds to solve tomorrow’s challenges. This year we had an overwhelming response and we plan to declare the results in the India Academic Graphical Systems Conference, during Educators Day in September. Stay tuned to hear about the great work that students and faculty are doing with our tools. Your future plans for NI India? We would continue to bring the latest in Graphical System Design technology to India and ensure that we package and deliver it for the Indian market based on the local needs. August 2014
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MANUFACTURING EXCELLENCE
Journey Towards Excellence Managing a SME in India - Part 20 As a continuation of last article, we will discuss on few more points to manage SME’s better in India
P S Satish 32. Importance of growth of the Company Which company does not want growth? No one wants a stagnant situation. Growing companies are valued more. We have seen in History that if the company is not growing, it cannot remain stagnant and eventually starts dwindling. There are many challenges that growth brings in and we will deliberate on importance of growth and tips on how to manage. After completing startup phase of company, next point of focus is on growth. Growth here meant can be in terms of turnover, profits, market share, number of Customers or number of employees. Focusing only on one point sacrificing others will not take the company higher. For example, too much focus on turnover without considering profit will not make the business sustainable. Combination of turnover and profit works well. Do not compromise on the long term profit for short term growth. I was a Mentor to company which had a sales volume of 8 crores/year after 24 years, though they should have been around 50 crores/year considering their capability and market opportunities. I started analyzing the reasons for the situation and found that problems were all inside the company though outside world was blamed. There are many
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reasons why a company does not grow especially SMEs. Few of them could be – • Satisfied with the existing situation • No ambition • Past success leading to complacency
no stones unturned towards growth. He grew very well for few years. Having seen the success, complacency developed and he overlooked on areas of people, his product, finance discipline, Investment viability etc. Finally he ended up company being taken over by Banker.
• Wrong motive to keep business as it is
Having said that all companies are interested to grow, it is important to ask few critical questions on readiness to grow:
• Not able to take risk & conservative approach
o Why should you grow? What is the purpose of growth?.
• Too much control by a single man
o How much to grow? By when?
• Too much focus on cost cutting and productivity
o Can you afford to grow?
• Struggling with the existing business
• Unfavorable market conditions
o Are you capable for the growth?
• No focus on Innovation
o How will you grow?
• Not generating enough profit in current business
o Do you have enough and capable people for the growth?
Even if the current performance of the company is very good, focus on growth is required. Otherwise, you would allow the competitor to take away the market share. Business is a race of growth. I quote here a saying which reflects well on challenge of growth. “You have to run faster than yesterday to be at the same place. To grow, you have to run still faster”.
o Is your growth sustainable?
I know an owner of a small scale company who was highly ambitious and was keen to grow. He was very hard worker and left
o What is your vision and mission?
o What is your financial discipline? o What is your risk appetite? Does growth match with this? o Who is there to take on the growth? Succession plan? o Do you have enough patience?
Following points will help to
think on growth and also to be prepared. All of these are internal to the company and those are the ones which matters for the growth: • Review critically your current business performance. No point in just focusing on growth if you are struggling to manage today’s business. I used to help a company where delivery performance to Customer was at 70%. The CEO was very keen to add new Customers. I said by doing that you would make situation even worst and it is likely that you would lose the existing Customers also. The first focus in such situation is on how to improve current performance. Operational excellence is one of the pre-requisite for the growth of the company. Get rid of Alligators biting your legs, hindering you to run. • Take the support of a mentor or a well-wisher to assess your strengths and weaknesses of the company and which strengths to be nurtured for the growth. In India, small and medium companies are hesitant for a critical assessment by an external mentor. The belief is that we know all. This has to change and to grow open mind approach is required. • Analyze critically what constraints and behaviors today are hindering the growth. Work on changing these. Leaving the external factors not in control, are we in August 2014
control of things where we can exercise control?
motivate them to put in their best is the key task of CEOs.
• Work on strategiesfor the growth. Growth should be one of the strategic focuses of the company which should be constantly reviewed. A set of actions, will not make the company grow. Come out of syndrome that by being busy, company is growing.
• Orient Employees towards Customer. Customer centricity is a must for the company to grow.With this, new business will flow towards the company. Normally Customer service will get affected with the growth.
• Be clear of your goal. To make more profit is not a goal. Articulate to be more specific. Business plan to include growth plan also. • Now one knows future exactly. To hit at a higher point in future, a set of definite actions will not take you there. This is due to the fact, during the journey, there are innumerable challenges that comes from market, customer, employees, economy and so on. Employees have to be taught to have mindset of problem solving so that they are capable to overcome challenges on the way towards growth. • Work on continuous improvements. By doing set of workshops on Kaizen will not help much. Focus on each process to look for daily improvements which ultimately make Customer happy. Focus on innovation. Then you are on the journey of growth. • Too much control will hamper growth. You may have to ‘Let go’ few things. Leadership style matters a lot here. • Work on high employee engagement. Without this, growth is not possible. By investing on infrastructure and technology alone is not enough. Create a culture where employees are free to express, allowed to take decisions and allowed to fail as a path towards learning. Engagement of employees is a challenge all over the world. By hiring right talent does not mean he or she would put in their heart and soul towards their work. Creation of environment to August 2014
• Have strong focus on developing people in the company. This should start with hiring process to take right people. Continuously train people to meet challenges of growth • Do not underestimate supply chain and distribution. This is has a direct link to your growth • Build the brand. This helps when you need an Investor or a venture capitalist for the growth. • Financial discipline and control is a must. Keep your balance sheet well. Helps to get credit from bank for the growth. Cash flow is seriously affected with growth and plan this well. • Make time to think. Many times, decision makers are so much immersed in current operational issues, leaving no time for future planning. • One of characteristic of growing company is their ability to learn everyday about new Technology, new methods, and new product and so on. So focus on learning of the Organization to grow the business.
to learn &experiment new things and ready to take risk. Difficult to grow with a culture of complacency
• Work on development of leadership to take the company to the next level including clear succession plan.
• Look at measures to have quality control at process than in inspection. Many times, this goes uncontrolled with the growth.
• Be clear of the risks of growth and be ready to come out of comfort zone.Take all precautions to mitigate the risk.
• Study what your competitors are doing. What is their growth strategy? What you need to counter that? With whom you can benchmark?
Every company can grow. There are enough opportunities in this global village where boundaries between countries are becoming thin. Wish you a good growth journey.
• Decide on type of growth – a) Organic – focusing on in house competencies, innovation and service b) Inorganic – Through merger, acquisition or take over Inorganic will help to grow faster, but has challenges of aligning the culture, systems etc. Decision on type also depends on type of product,market, goal of growth and alignment to existing business.
I will continue the series of article in the next issue. Please send your inputs,remarks,suggestions to P S Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q 103, MantriParadise Apartments,Bannerghatta Road, Bangalore-560076. Do visit www.satishps.com. Have a good day.
Applications Riveting Punching
Marking Staking
Embossing Assembly Riveting etc
Revolvi Riveting machine
• Work on systems and processes which becomes basis for improvements. Toyota believes more in management by means than management by results for long term success. • Generate enough profit in current business to keep a cash reserve for the growth. You need to evaluate continuously to watch not profit making products and take necessary actions. • Work on culture of company where people are encouraged
Rack and Pinion Press
Hand Operated Impact Press
Gala No 6, Punjani Industrial Estate, Khopat, Pokhrann Road No.1, Thane - 400601 Tel:- 022 32444073/ 25479447 Mob: +91 9029023231 Email: sales@hammerknock.com Web: www.hammerknock.com
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27
TALENT MANAGMENT
Leadership – The Art of Parenting My eldest daughter will turn 7 this year. It seems like only yesterday that she was a helpless and dependent ‘puppy’ (well, she is always family to us!). And this week my son will turn 3 months old. As I reflect back on my journey as a parent I am humbled by the immense learning that I have gained from it and how it has helped to shape who I am today. Pavan Sriram
We learn to be parents through the act of parenting by listening, observing, responding and experimenting with what works and what doesn’t. In fact my son has his own way of giving me feedback – be it crying (whether hunger or sleep), having a tantrum, sulking and often just telling you it as it is – the painful truth with no frills!
Parenting is much about learning to ‘be a parent’. You can read a ‘how to’ guide, learn from other peers and experienced parents but the real learning comes from being in that role and going through it yourself. A more experienced parent may share what works for them but you will not know whether it works for you and your child until you experience it. Using the same learning analogy, to me and to many
others I know ‘Leadership is all about Parenting’. Leader-led relationships are analogous to parent-children dynamics in many respects.To lead you need followers and to ‘be a leader’ you need to ‘lead’ and learn from your followers. You can learn concepts, theories, frameworks, tips and strategies from a leadership course but you still need to put them into practice – to do so,
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experience it first-hand. And ‘to do’ requires a lot of listening, communicating, engaging, building relationships, supporting, developing, adapting and to respond accordingly. Let me quote here what Jack Welch once said - “Before you are a leader, success is all about growing yourself. When you become a leader, success is all about growing others.” – This is so true to parenting as well. The relationship between a parent and a child is an ever
evolving one as he/she grows and matures. From one that is dependent to becoming independent as the child leaves home for studies or to make a career. Their upbringing and the core values instilled will have influenced who they are and lays the foundations for the way ahead. ‘True leaders who are transformational are
calm under pressure and dependable’says George Kohlrieser, author of the bestselling book Care to Dare. They accept their team-members as people first and see their potential. They listen and ask constructive questions rather than dictate. They say the right thing at the right time, delivering a powerful message that’s short and to the point. In short, both parents and leaders promote (a) trust in others; (b) self-confidence and self-esteem; (c) selfrealization; (d) achievementorientation and (e) a tendency to become similar to them.
leadership skills. Two critical skills - Relationship building and Communication apply to parenting, and being a parent allows a person to practice Consistency and Assertiveness, which can be applied to the workplace. Both spheres of the work-life balance influence and reinforce each other. I’ve found that since becoming a parent, I feel my leadership style has become more effective, and part of that performance can be attributed
Parenting and leadership often tap into the same skill sets. Many lessons learned from parenting can be applied to leadership styles in the workplace and other areas of life. Raising children forces a person to become a leader and a manager around the clock presenting more opportunities to learn, challenge and refine August 2014
Always the Truth
Deepak Kulkarni Director - HR Bristlecone India
I see two critical missing elements in today’s leaders – their tolerance level is far more different and hence owning up is becoming an issue while the business and team size is growing. The other is the curiosity factor; my son is so excited to learn new things and I always try my best to make this possible – likewise employeesdeployed into newer projects or businesses need to be hand-held while they learn the ropes and have to be taught in the most interesting and simplistic way by their leaders. to practicing more leadership skills more often at home. As I see it and heard from my corporate friends, many leaders spend their day trying to “make up” for parenting that didn’t happen for the lack of time or effort. And, if you happen to be doing both jobs – you have the perfect opportunity to cross-train and cross-learn.I consider these 4 rules, the basic foundation of a happy family and a happy working team:Sharing and Learning It just feels better in the long run because leaders create relationship. And relationships are what humans are built for to share and learn. They facilitate clarity on concepts like communication, collaboration and coordinationand what really mean in their business. August2014 2014 August
Leaders are Parents believe that teaching their wards to say the truth takes them a long way in their journey of life. Its making the commitment to accepting responsibility for what you know, acting in alignment with that knowledge to the best of your ability. What do you want? Being clear on what you want and then asking nicely is a virtue in itself that every leader should learn for themselves and teach others too – this brings more clarity of thought and helps prioritise for things at the moment of need. Play Fair and Nice In NLP, the assumption is that‘Every behaviour has a positive intent.’ Pretty simple isn’t it. Regularly reminding people and teaching them about the presence of positive intent can transform any situation. It is the leaders who ought to do this every time they are put into a conflict situation that demands their time and attention in making it fair and transparent for everyone involved. Parenting and Leadership is a journey without a final stop. You don’t reach a point where you become the ‘best’ leader or parent and stop there. It will test and challenge you and provide you with new learnings at home and with people- what a wonderful opportunity that isto inspire, shape, influence and develop others in both unequivocal roles. Do write to me on your thoughts on leadership and how you have been able to influence and develop others using your own parenting styles and skills. Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to improve learning outcomes. www.martupdate.com www.martupdate.com
2929
QUALITY
SMED in Micro Manufacruting Why do we need SMED? Within production strategies such as lean manufacturing and just in time ( JIT), we are aiming to reduce the waste within the system, waste being one of three main areas as defined in Lean/Toyota Production System (TPS): the Waste of Muda (non-value adding), Mura (unevenness) and Muri (overburden). Waste reduction is an effective way to increase profitability. Gorur Sridhar
concept of SMED let us understand its two main components viz.
Figure 1
1. Internal Activities are those activities that can only be performed safety when the equipment is stopped such as unbolting the tool in the machine etc.
What is SMED?
being one of three main areas
the most important lean
as defined in Lean / Toyota
manufacturing tools, if not the
Single Minute Exchange of
Production System (TPS). The
most important for enabling
Dies (SMED) as it is commonly
Waste of Muda (Non-Value
Just in Time production.
known is defined as “The time
adding), Mura (Unevenness)
2. External activities are those that can be performed when the equipment is in operation such as fetching the next tool etc.
elapsed between when the
and Muri (Overburden).
To better understand the
Let us understand the 7 Steps
“Last Good Piece” of product A comes off and the “First Good
2. SMED tackles all of these
Piece” of product B starts.”
waste areas but it’s greatest
This is as illustrated in the
achieve the elimination of
Figure 1 below.
Mura.
Why do we need SMED?
3. The biggest obstacle to
1. Within Lean Manufacturing and Just in Time (JIT) we are aiming to reduce the waste within the system, waste
strength is in helping us to
having smaller batches is the Change Over Time of our equipment.
Figure 2
4. SMED is probably one of of SMED as shown in Figure 2 with respect to a Micro Manufacturing setup. Step 1: Separate Internal Activities from External Study the setup and classify all the activities accordingly as illustrated in Figure 3. Figure 3
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Step 2: Standardize External Activities
August 2014
Document
Materials
Tools
Jigs & Fixtures
√
ECO / ECN
√ √
Work Instruction Updated Drawings
√
Production order etc.
√
Quantity specified
√
Specification
√
Approved Source of Material
√
Test Reports etc.
√
Respective labeled positions on the peg board
√
Torque setting of the tools being ascertained Work tables clean
√
Calibration status checked etc.
√
All dies, fixtures, gigs cleaned and ready to go
√
All in working condition etc. Figure 4
Look at the identified activities
so the driver does not have
that have been classified as
to wait for his car to get to
external, those that can be
temperature!). Other examples
done while the machine is still
can include having additional
running and standardize them.
sets of clean common tooling
Ex. A checklist is prepared as shown in Figure 4, and exhibited at the machine to ensure external activities are completed before stopping the machine. Step 3: Convert Internal Activities to External Look at the activities that have identified as being Internal and somehow convert them to being external as illustrated
that would otherwise have to be cleaned, setting cutters and other equipment off line, having “intermediate” fixtures to set and just slide in when the machine stops. Step 4: Improve Internal Setup Activities Look if the Internal activities can be eliminated or streamlined as illustrated in Figure 6.
in Figure 5, thereby further
Examples like locating points
reducing the setup time.
can be made more positive,
Some examples of this can be pre-heating dies or moulds before putting them into the machine so that you don’t have to wait for the machine to heat them (Formula One tires are heated to driving temperature before fitting August 2014
Bolts can be replaced with wing nuts, etc. to eliminate the usage of tools, Dowel pins can be used for locations, Self locking bolts can be an answer in many places, use Quick change over hardware and couplings etc.
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Step 5: Improve External Activities Review what you have done in earlier stages and improve further on what has been done to improve change over times. Step 6: Mechanization of Activities Introduce mechanization wherever possible. Example can be usage of pneumatic torque tools in place of the manual torque wrenches, Pneumatic screwdrivers can replace the Figure 5
manual ones etc. Step 7: Complete Elimination This is achieved with some
As it rightly said â&#x20AC;&#x153;SMED is one
divergent thinking and going
of the most important tools
back to the design board.
within Lean Manufacturing, it
Example of several functionalities can be combined into one tool, or some of the parts can be eliminated by using the design for mfg./assy concepts etc.
is the philosophy by which you will methodically reduce your changeover times allowing you to implement Just in Time (JIT) and reduce waste from your processes, thus reducing your costs and making you much
The author Gorur N Sridhar is
more profitableâ&#x20AC;?. Going a step further once the entitlement of SMED is achieved, One Touch Exchange of Dies (OTED) can be thought of.
a Mechanical Engineer and a qualified Six Sigma Master Black belt with more than 26 years of experience in Manufacturing, Quality and Design in Aerospace, Automotive, Engineering
Continuous Improvement is Continuous.
Services and Medical domains. He has been instrumental for substantial cost savings through Value Engineering, Process Improvements & Failure Analysis. He has got major achievements to his credit including filing of 6 Patents and authoring articles on Quality to various International Quality Portals and Journals. He has mentored more than 100 Six Sigma & Kaizen projects and is a Qualified Internal Auditor for ISO9000, QS 9000 & AS9100 Quality Systems. He is also associated with the Implementation and Sustainance of CMMI L5 activities. He is also equally contributing in EHS and Community development programmes. He is located in Bangalore, India and can be
Figure 6
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reached at gnsridhar@gmail.com August 2014
August 2014
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33
FEATURE ARTICLE
Advanced Ballbar Training Enables Extend Machine Life and Accuracy Advanced ballbar training enables shop to achieve “better than new” machine tool accuracy and extend machine life for unconventional silicon processing. Semiconductor industry supplier now understands its machine tool’s performance better than OEM service technicians. Ballbar data supports TPM and emerging SPC and OEE programs. Samina Khalid
Ballbar testing is nothing new to those who use fleets of machine tools, including people like Wayne Ross and Jacob Hebbeler of Silfex Inc based at Eaton, Ohio, USA. Both have used ballbar analysis to maintain and enhance the accuracy of the plant’s 50+ machines for more than a decade. But, it turns out that experienced ballbar users can still learn a few new tricks that can be transformational to a business. After upgrading to a QC20-W wireless ballbar and taking Renishaw Advanced Ballbar course, TPM manager Ross and machine operator Hebbeler now use captured ballbar data to evaluate machines, “super tune” them to better-than-factory accuracy and get longer life out of machine components. They have also changed the way the company proves out machines, schedules maintenance and evaluates the need for new machines. “We’ve done ballbar testing for years, but until we took the advanced ballbar
course we weren’t making full use of the results,” said Ross. “Now we’re using the ballbar to qualify metrology, time our maintenance decisions, implement TPM and SPC, and even forecast machine life. It’s helping us make operational and capital equipment decisions in ways we never thought possible.” Unconventional processing with conventional equipment Silfex’s machining application is like a military proving ground for machine tools, so machine diagnostics are a way of life. Its lathes and VMCs – primarily Haas and Mazak – use diamond tooling to grind and polish silicon and quartz for the semiconductor industry, resulting in glass-like debris and diamond particles forming an abrasive compound that wears out components in months. The 290 employee company is a rapidly growing division of Lam Research Corporation and has built a reputation
as a premier single-source supplier of electrodes and silicon fixturing for Lam plasma etching chambers. These consumable parts support the etching process in the manufacture of computer chips, and part values can be as high as $30,000. “We are one of the few companies in the world that can grow defect-free, single-crystal silicon to a diameter of 460 mm,” Ross explained. “We do start to finish manufacturing under one roof, which is important because the semi conductor industry requires 100 percent traceability on everything from the material source to the machined parts, and we have all of that under direct control,” added Ross. “For our customers’ requirements, this is a purchasing manager’s dream.” The plant is environmentally controlled and equipped with multiple clean rooms from class 10,000 to 100. “One speck of contamination can wipe out a lot of computer chips,” Ross stressed.
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Processing the silicon includes wire sawing, waterjet cutting, milling, drilling, grinding and lap polishing before inspection in metrology rooms with CMM and VCMM equipment. Parts then go to an on-site clean room for packaging. Production runs range from 5 to 100 pieces per setup and the required tolerances are typically ±0.001”, with some requiring ±0.0005”. Grinding silicon creates an extremely harsh machining environment. “We’re using conventional machines to do unconventional processing, and using ballbar diagnostics to stay on top of our machine capability in a high-wear application,” said Ross. “We use the ballbar to diagnose ballscrew wear every six months, but usually get called to test machines before that. The advanced ballbar training showed us how to determine if we can make machine adjustments or if it’s time to replace the ballscrews. This allows us to control downtime August 2014
scheduling and maintain our accuracy as machine components wear out, rather than judging machine capability from the quality of finished parts. We run these machines hard, three shifts, five days a week, with quite a few long runs, and the grinding environment is tough on the equipment. I’m amazed at how accurate we can make these machines considering how rapidly the machining environment changes. Our VMCs are hitting accuracies comparable to much higherend machines. And, while high-end machines are faster, we can only grind so fast. So, we don’t need ‘faster,’ just accurate.” Advanced ballbar training raises the bar for company’s machining capability Ross and Hebbeler came away from Renishaw advanced training with a much better understanding of their ballbar data and how to use it. Conducted at Renishaw in Hoffman Estates, Illinois, USA, the hands-on course lets participants practice setting up and running ballbar analysis on a variety of different machine tools in a learning lab. “I’ve been working with ballbars for 13 years and thought I knew my stuff,” said Hebbeler. “But after 10 minutes, I was learning new tricks. Among other things, we learned how to troubleshoot scale mismatch, which has helped us super tune our circular interpolation and extend the useful life of the mechanical parts of our machines. We also look at lateral play to gauge the condition of our linear guides.” “After the advanced class we concentrated on interpreting our numbers to see if there were more details we could control,” Ross explained. “Jacob has gotten really good at adjusting the backlash and reversal spikes, so we can get more life out of the ballscrews, which is our edge until we can get a service technician in. Sometimes we can do two or three adjustments and that August 2014
buys us a lot of productive time to schedule when to take the machine offline for repair.” Accuracy now starts at ground level Silfex uses ballbar diagnostics to determine a machine’s squareness, which is the prerequisite for analyzing backlash and reversal spikes. “Many machine shops overlook the effects of the floor, as we were, on machine level,” said Ross. “We are lucky our concrete is substantial enough to support all the weight we put on it, and we check and adjust the machine level upon installation. Once we set the level we can diagnose reversal spikes, backlash and scaling mismatch, which we didn’t know how to do before the class.” Ross and Hebbeler now handle machine levelling, largely because they can hit specs that some technicians have trouble achieving. “The two-tenths bubble servicemen can meet our requirements, but the five-tenths bubble guys can’t,” said Hebbeler. “Our levelling is so precise today that we often wish the levelling screws had a finer pitch on them.” After the training Ross and Hebbeler used their new knowledge to push the boundaries of machine accuracy. “Our goal on squareness was 0.000050”/ inch, and I decided we would try for 0.000025”/inch,” said Ross. “When I told Jacob he expressed doubt, but I showed him data that proved he had already achieved it three times prior.” Based on their success with the ballbar, Ross and Hebbeler are expanding their machine diagnostics. “The ballbar tells us about the foundation: the linear guides, the ballscrews and the truss bearings – the bottom end of the machine – that’s where mechanical tolerances are established and it also confirms our metrology,” said Ross. “We’ve also started using some vibration analysis,
and that tells us about the top-end of the machine which dictates finish. So, between the two, we are analyzing all the factors that affect our size and finish. We’d like to get into volumetric compensation testing with the ballbar. We currently test X and Y on VMCs, and X and Z on the lathes and have done full Y-Z testing in the past on a few machines but with volumetric testing we’ll also hit X-Z and I think we’ll be able to get what we need in the 220-degree sweep the ballbar is capable of performing.” No wire, no worry Upgrading to the wireless ballbar simplified data collection, and made it safer, Hebbeler explained. “With the wired ballbar, I spent a lot of time babysitting a machine under test,” said Hebbeler. “I had to feed wire in through the back of the machine, and if I walked away for a few minutes I often came back to a twisted wire. I always had a nagging thought that any little tug on a wire during a test might skew the results. We don’t have those issues with wireless operation. I can set it up and go do something else until the test is complete. It’s also safer now that we’ve eliminated opendoor testing.” Ballbar data opens doors for new programs Silfex is now using ballbar data to establish thresholds in relation to its various processes and determine process capability. “We now have diagnostics to back up what we think is happening with our machines,” said Ross.
“This data is being used for our TPM program, implementation of SPC and our future OEE (Overall Equipment Effectiveness) monitoring. Full SPC will allow us to move away from 100 percent inspection. We are also working to determine what will be the useful life of a machine based on capability, maintenance costs and consistent quality.” Even machine tool technicians are impressed with the expertise demonstrated at Silfex. “Some of them will say, ‘well, this machine is now as good as new,’ and we tell them we need it better,” said Hebbeler. “Their response is, ‘well then tell us what to do,’ and when we show them they ask how we did it. The advanced training provided us with knowledge that is techlevel and, in some cases beyond, so we have data to backup our thinking.” The data generated through ballbar analysis has even found its way to the company’s C-suite. “The executives at corporate now want to see a ballbar report every time a machine is qualified,” said Hebbeler. “This is filed with the machine documentation as part of our regular procedures between here and headquarters. Manufacturing keeps raising the bar and ballbar analysis helps us reach higher.” Ross added, “The world revolves around numbers and ballbar analysis is our magnifying glass to help make good business decisions.” More information about Renishaw’s calibration and performance monitoring products can be found at www.renishaw.com/calibration www.martupdate.com
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FEATURE ARTICLE
Accurate, Timely Tool Knowledge from NOVO™ Seamlessly interfacing with tool management, e-commerce, and other programs, NOVO™ from Kennametal powers shop systemshungry for accurate, timely tool knowledge. Expanding Capabilities, Efficiently Turning Digital Tool Knowledge into Real-World Productivity Improvement.
Since its groundbreaking launch in 2013, Kennametal’s NOVO digital tool and process planning application has continued growing by adding process capability constantly. Now, NOVO Version 1.3 is connecting via the cloud to tool management, e-commerce, and other shop systems, reducing data errors and making non-value-added datatransfer efforts things of the past “Our vision for NOVO from the beginning is to provide an open-source system that interacts seamlessly with shop systems needing to leverage cutting tool data and machining knowledge for productivity improvement,” says John Jacko, vice president and chief marketing officer at Kennametal. “This is only the beginning of delivering the promise of the digital factory. Connecting to Kennametal’s ToolBOSS™ tool-management
NOVO is an advanced digital tool selector and process planner with real-world productivity results.
system via the cloud and streamlining input into Kennametal’s e-commerce system, that vision is quickly becoming reality.”
More than a catalog, NOVO brings users into a community, delivering all of Kennametal’s ongoing expertise in a digital means, so process knowledge is quickly accessible. The results empower users by providing the right solutions specifically tailored to their operations.
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Seamless Connectivity Includes E-Commerce Customers expect continuous fast development of technology platforms to deliver more value. Since the 2013 launch of the NOVO’s original Tool Selector, Tool Configurator, Tool Advisor, and Job functions, NOVO has added connectivity to E-commerce, easy ISO 13399 exports, and seamless integration to the ToolBOSS tool management system via the Machining Cloud. Specifically, NOVO users can request a price quote from their local Kennametal Distribution Partners by transferring their shopping cart list to them via the “Request Quote” button. The distributor will receive a notification with complete detail of the items and requestor information to respond. A new
pop-up also makes it easy to add spares and other individual items to existing shopping carts. Spare parts are clearly identified as “included” or “non-included” on bills of material. ToolBOSS users on the cloud with the latest software version can now use NOVO to see if an item proposed for a process plan is already available in their ToolBOSS inventory, making both plans and budgets more efficient. Customer part numbers are automatically populated in NOVO Tool Advisor results and Tool Availability pop-ups via the ToolBOSS database. “By adding ToolBOSS credentials to their user profile, customers easily check the inventory in their local ToolBOSS units with their developing process August 2014
SIDEBAR 1 – How It Works
SIDEBAR 2 -- Addressing the Skills Gap
NOVO can be used in a number of intuitive ways, from “I need to make a ½” hole x 1 ½” deep in ANSI 4140” to “I need a ½” by 5xD solid-carbide drill in grade KC7315.” In the first case, NOVO helps users define machining features, drilling a blind hole in this case, and then immediately reduces the product set to those that can do the job, taking into account constraint requirements such as material, tolerance, and machining sequence for both single tools and multitools. NOVO then ranks the results—based on knowledge-based rules—to best meet the challenges of the application as defined by the customer’s operating environment and user preferences, providing far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time.
Manufacturing is experiencing a global renaissance in developed and emerging economies around the world as major industries such as aerospace, automotive, energy and others consistently demand new and better products. Manufacturing technology providers have responded with computer-driven machine tools, digital-based computer-aided design and manufacturing software (CAD/CAM), and significant advances in tooling. Yet behind this positive outlook lies a major barrier threatening this scenario: a significantly widening skills gap as older workers retire and new workers fail to engage in manufacturing careers.
In the second case, when a customer already has preferred tool and grade in mind, NOVO smart-attribute filters not only quickly select the products available to do the job, NOVO also gives the options on what cutting item and adaptive item fits and also works with the selected solution. NOVO smart filters take the task of selecting ALL cutting tool components from hours to minutes, while users get the assurance that the list is both comprehensive and correct. In both cases, NOVO’s Tool Configurator then provides all CAD files and graphic support for all tool components and their assembly – a major time savings for customers. “NOVO thinks like a process planner,” explains Thomas Long, head of the newly formed Virtual Machining RDE department at Kennametal. “It works from the feature back to the tooling strategy. In addition, each order number is tied to application data gleaned from hundreds of subject matter experts and decades of Kennametal experience. Request a part number and you also get pictures, assemblies, spare parts lists, as well as inserts that fit. Not only does it accomplish in minutes what formerly took hours, it yields an optimized solution, backed by Kennametal expertise, every time”
“To effectively meet the skills gap for our customers, we need a better way to distribute the collected knowledge of Kennametal,” states Francois Gau, VP of Strategic Marketing and New Business Development. “More than a catalog, NOVO brings users into a community -- all our ongoing expertise delivered in a digital means of accessing process knowledge quickly. The result empowers users by providing the right solutions specifically tailored to their operations. It solves problems instead of managing data.”
once you log in, all your jobs data transfer is over, making organizations and teams much more powerful by extending
process knowledge to those who need it.” For more information, visit www.kennametal.com.
Even further, NOVO’s Job Functionality option is a cloud-based repository linked to a user by a unique ID where tool lists can be stored for future use, editing, copying, and sharing. These can be easily downloaded into standard report formats and include tooling commercial and dimensional data and weights, speeds and feeds, and photo or CAD model images. plans,” says Chris Merlin, Marketing Manager for the Virtual Machining initiative at Kennametal. “They’re better able to visualize items already in their shop.” Mobility Users can leverage NOVO via the tablet of their choice. “Mobility is no longer a luxury. With Android and Windows Tablet versions of NOVO now available, it brings
August 2014
an element of added mobility and access to your tool list no matter which device you log onto,” Merlin adds. “This also makes it easy for people working on the shop floor with tablets to collaborate with the process planners in other departments.” Being “device agnostic,” NOVO avoids the “which app do I choose and use” or even the need to evaluate among multiple apps, he adds. “And www.martupdate.com
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CASE STUDY
“How Daifuku’s ASRS saved M&M Time & Money!” Introducing ASRS as a painted vehicle body buffer system, Mahindra & Mahindra improves productivity, including the supply of vehicle bodies to the assembly line.
Indian automobile manufacturer Mahindra & Mahindra Ltd (M&M; headquartered in Mumbai, Maharashtra) manufactures sport utility vehicles (SUV) and light commercial vehicles (LCV) and other vehicles. In June 2013, M&M introduced a unit load AS/RS as a painted vehicle body buffer system at Nashik Plant. The buffer system stores painted vehicle bodies temporarily and sequences them by retrieving in assembly order so that various types of vehicles can be assembled in one line. The buffer system enhances productivity in supplying vehicle bodies to the assembly line and
Painted vehicle bodies are conveyed from the paint line (far right) and are loaded from overhead conveyors onto pallets to store in the AS/RS. The input and output stations are located on the mezzanine.
Adjusting the shift difference between the paint line and the assembly line drastically shortens cycle time in production. In addition, assembly parts, which were previously dispersed throughout the facility, are consolidated into one location next to the assembly line in the now open space created by installing the AS/RS.
Dhanajay Joshi Senior Manager, Paint PU.
“During commissioning, the Daifuku staff was very good. The system was completed before the target date. Everyone within M&M who knows about the Nashik AS/ RS loves the system because of its reliability. We are satisfied with the system.”
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M&M, a core company of the conglomerate Mahindra Group, was founded in 1945 as Mahindra & Mohamed, a steel trading company. In 1947, Mahindra & Mohamed changed its name to the current Mahindra & Mahindra and entered the automotive manufacturing business when they started the license production of the Jeep. Now, M&M operates six plants in India. The Nashik plant, which started operations in 1980, produces five types of vehicle, including main products Scorpio and Xylo, with an annual production capacity of 200,000 vehicles.
A buffer system acted as the core function in adjusting the difference between the three shift paint line and the two shift assembly line. However, the previous buffer system consisted of conveyors that stored vehicle bodies and retrieved them according to order instructions from the assembly line. Supplying a vehicle body to the assembly line took up to 30 minutes. In addition, the previous system took too much space. To address these problems, a new buffer system using an AS/RS was introduced. The new buffer system drastically shortens retrieval time from 30 minutes to two minutes. This made manufacturing cycle times shorter and also saved floor space by utilizing vertical storage, keeping almost the same storage capacity as the previous system.
Retrieval time drastically shortened to as low as two min vs. original 30 min
The AS/RS reaches 15.5 meters high and has a 92-vehicles capacity. Each rack can accommodate a maximum vehicle of 1,800 mm wide, 5,000 mm depth and 1,900 mm.
Vehicle bodies are rotated on the rotate table and loaded onto overhead conveyors to be tranported to the assembly line.
Moreover, fixed racks to store assembly parts were placed in the vacated space next to the assembly line, having previously been dispersed throughout the facility, reducing picking time to supply parts more speedily. August 2014
FEATURE ARTICLE
Equip for the future today with RoHS-compliant iglidur plain bearings High performance plastics from igus meet EU directive and provide planning reliability The extended EU Directive 2011/65/EC (RoHS II) became valid at the beginning of the year, therefore tightened the permissible limits for hazardous substances in more and more areas. From the 22nd July, products with unacceptably high concentrations, such as lead-containing plain bearings face extinction in the Medical Technology industry. igus offers iglidur polymer bearings as a RoHS-compliant alternative that promises legal and functional reliability to the manufacturer, and safe use and disposal to the user.
Since the mid-1990s, limitations
compliant with
on the use of environmentally
RoHS.
hazardous substances were enforced for electrical and electronic devices and their components all over Europe. Steadily tightened guidelines under the abbreviation “RoHS”, (Restriction of [the use of certain] Hazardous Substances) set limit values for the use of industriallynecessary but potentially harmful substances such as, chromium, lead, mercury or bromine. With the new RoHS II standard, a maximum value of 0.1% of the total weight is determined for most. Many manufacturers changed their production accordingly in the past, and others must now respond because exemptions, such as for the medical and control technology, will expire this month. Since similar regulations are also put in place in countries such as the USA, Japan or China, these standards must be met increasingly with a global perspective. However, metallic composite bearings often have alloys that are not
August 2014
Santhosh Jacob
Reliable planning and amendments with iglidur plain bearings Customers, who consider the RoHS compliance, have an immediate alternative with iglidur bearings. This is because the substances covered by the Directive basically have no role to play in this material made of thermoplastic compounds.
whose equipment and
the natural features of iglidur
Based on the principle of dry
components today fulfil the
plain bearings. The igus plain
lubrication, the iglidur bearing
admissible limits, or are even
bearings are safe not only in
technology uses tribologically
excluded from the standards
terms of laws and regulations.
optimised base polymers,
today, must expect a further
By the option of life prediction
solid lubricants and fillers of
tightening. iglidur polymer
and configuration using online
exclusively non-metallic and
bearings provide planning
tools, all metal bearings can be
RoHS-safe ingredients.
reliability today.
replaced quickly and easily by
The provisions of the RoHS
In addition to their “traditional”
Directive are also subject to
advantages of freedom from
For further details write to
permanent review and thus
maintenance and lubrication,
Santhosh Jacob, Product
there is the possibility of
all igus products are without
Manager- iglidur,igubal,xiros at
future revisions of the legal
hazardous substances. RoHS
santhosh@igus.in,
requirements. Manufacturers,
compliance is therefore one of
visit www.igus.in
iglidur plain polymer bearings.
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FEATURE ARTICLE
The new DMG MORI design multifunctional, user-friendly and value retaining The new design illustrates DMG MORI’s uniformly high quality standard and impresses with more functionality, extra user-friendliness and high value retention. Next to all the technical equipment features, the customer can choose between two machine designs. The new DMG MORI design is optionally available in either “BLACK” or “WHITE” at no extra cost.
The design of a product instantly determines the customer’s perception and estimation of value. From this perspective alone, DMG MORI has once again set standards in the field of machine tool manufacturing with the new common design. Above all however, the new design makes its mark with a number of impressive details. Look, feel, ergonomics and materials play just an important role as ease of use and service friendliness. Large viewing windows ensure the best possible view of the work area for better monitoring of the production process. Access facilities and the interior working area are designed so that it is easy for operators to reach inside
and to ensure optimum chip disposal during the machining process. In addition, the safety glass windows can only be removed from the outside, which benefits service friendliness. Another highlight of the new DMG MORI design is the machine housing which is provided with a special finely textured coating in the premium area. These long life surfaces offer better scratch resistance and better protection against damage in general, which further increases the ability of the high-tech machines to hold their value. Eighteen machines in the new DMG MORI design are presented with CELOS. CELOS
Highlights of the new common DMG MORI design User-friendly • CELOS from DMG MORI: ERGOline® Control with 21.5” multi-touch screen and uniform interface • Continuously adjustable display and control desk for a comfortable working position • SMARTkey® for customised authorisation of the operator for individual access rights to the control and to the machine Multifunctional • Maximum view of the working area for better monitoring of the production process • Improved functionality, e.g. removal of safety glass windows from the outside Value retaining • Premium area with fine texture, for higher scratch resistance and protection against damage
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simplifies and accelerates the process from the idea to the finished product. Special CELOS APPs support the operator intuitively and comprehensively in his day-to-day work, enable complex processes to be managed, and also provide direct interfaces to superimposed systems in production engineering and design. Finally, APPs help to avoid errors, optimise sequences and processes, and increase overall productivity. Overall optimisation of the human-machine interface is achieved by the new ERGOline® Control with its 21.5” multitouch screen and continuously
adjustable display and control desk, which guarantees a comfortable working position at all times. The ERGOline® Control with MITSUBISHI also has a trendsetting multi-touch control panel, which trade visitors will be able to see in Pfronten on the new universal lathes of the NLX range. Common to all new control systems as a special extra is the “intelligent” SMARTkey® with memory function and chip for customised authorisation of the operator and his individual access rights to the control and to the machine. For further details visit www.dmgmori.com August 2014
August 2014
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MART UPDATE
Industry to safeguard vital water resources Grundfos India Partners with CDP to Promote the Business Case for Water Disclosure in the Country There will be increased pressures on industry to conserve water as India approacheswater-stress conditions and could be water-scarce by 2020, finds CDP’s report titled ‘The Business Case for Water Disclosure in India’. Nearly 50% of villages do not have any source of protected drinking water. Rapid population growth coupled with mass industrialization, expanding agriculture and urbanization has resulted in an increase in competing demands for water resources. The country faces a looming water crisis where demand is set to outstrip supply by 50% by 2030 according to the 2030 Water Resources
Group. As a result, governments are increasingly putting pressure on industries to adopt best international practices to improve water management. Grundfos Pumps India Pvt. Ltd. (Grundfos India), has partnered with CDP to launch the report prepared by CDP and KPMG which aims to promote water stewardship and reporting among the corporate community in the country.
Ranganath NK Managing Director Grundfos India
“Water is a major driver for sustenance of a civilisation, food security and economic prosperity. Its mismanagement can result in significant harm to the environment and to the people. Effective management of water resources and use is one of the most critical business and sustainability challenges of the 21st century. We hope that through this report, we are able to help fuel the acceptance of water auditing and annual water reporting within corporate India”.
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it moves on into the 21st century with the potential to stifle economic growth. • Water is a critical business issue that deserves serious attention. • An increasing number of stakeholders are calling for transparent and comparable disclosure of water related information from Indian companies for consideration in decision making.
CDP’swater report identifies that companies are increasingly aware of water related risks but actions to manage water issues at a corporate level are inadequate. An increasing number of stakeholders are calling for transparent and comparable disclosure of water related information from Indian companies for consideration in decision making. Interestingly, the report also highlights how water presents a strategic opportunity for companies to improve financial and brand performance. It stressesthat disclosure is good for business: The process of water disclosure helps businesses and institutional investors to better understand the risks and opportunities associated with water scarcity and other water-related issues whilst promoting water stewardship and delivering insight that enables companies to take intelligent action to manage this critical resource.
• Indian businesses are currently underestimating water-related risks due to a lack of effective measurement and monitoring.
This report is aimed at government, business and investor communities and states the case for why corporate water disclosure is the most effective way to stimulate a rational and coherent business response to the issues of water availability. The report finds that:
• Most of the companies are focusing only on direct operations, while serious water related risks might lie in the supply-chain: Around 60% of the companies analyzing water related risks are doing that only at facility or business unit level. Similarly, 56% of all the water-related goals and targets are focused on direct operations.
•India faces an impending water crisis as
• Companies see the water crisis as a serious and immediate threat: Two thirds of Global 500 respondents to CDP’s water questionnaire report exposure to water-related risks, of which 64% have the potential to impact business now or within the next five years. • Companies are aware of increasing water related risks but actions to manage water issues at a corporate level are inadequate: More than half of Indian companies (55%) have a water policy, strategy or management plan in place. Butonly half of these policies include concrete quantitative goals or targets for water resource management.
August 2014
Cold Store Scanner with Intelligent Heating from Pepperl+Fuchs Can be used universally from chilled to warm conditions Difficult ambient conditions sometimes exist during the processing, transportation, and identification of products, such as large below-zero temperatures. However, normal automation components such as barcode scanners are generally not suitable for operation in cold storage warehouses. Instead, special device designs are needed for this in which frequently reduced performance values must be taken into account. Systems that are not subject to restrictions are of more interest here. The compact cold store scanner VB14N-T from Pepperl+Fuchs operates at temperatures from -35 °C to +45 °C and delivers its full performance potential over this exceptionally large operating temperature range. With a scan rate of up to 1000 scans/s and resolutions of 0.2 mm, the device offers the same performance as the VB14N type counterpart available for standard temperatures. The special feature of the low-temperature version lies in the integrated heater, which is monitored
by microprocessorcontrolled temperature control. Depending on the internal and external temperatures of the barcode scanner and environment, the device constantly determines the optimal heating power. The developers have therefore The compact cold store scanner VB14N-T from Pepperl+Fuchs operates at succeeded in combining temperatures from -35 °C to +45 °C counter-acting properties such as the low power consumption of a maximum 10 W with a very short warm-up contrast, damage, or in-motion blurring. period of a maximum of 20 minutes. With identical dimensions, the standard Other highlights in this device class include master-slave operation in which up to 32 scanners work together in a network, configuration via the convenient PC software Genius, and the innovative directoperation concept with mode button. With the help of intelligent code reconstruction, the model can even decode poor-quality code readings such as those with low
scanner can easily be replaced by the new cold store version if required. Cabling effort is also low, as the device and heating are supplied via the same cable. The possibility of using the VB14N-T in the positive range in normal temperatures makes the device—which is accommodated in a robust housing to IP 65 degree of protection—a universally usable allrounder with a wide field of application.
MECO offers Multifunction Power & Energy Monitor – Model “MFM-96S” “MECO” Multifunction Power & Energy Monitor, Model : “MFM-96S” Microcontroller based with MODBUS RTU Protocol is indigenously designed, tooled and manufactured by the R & D Department of MECO and Competitively Priced. “MFM-96S” eliminate using conventional panel with 10 different meters. It save more then 50% of the cost in panel, as it reduce size of panel, with One MFM-96S having 10 parameters and very little wiring. “MFM-96S” is built with 4 rows, Super Bright Red LED Displays with 4 Digits Resolution and 8 Digit Resolution (Energy Import-Export - 4 Quadrant operations). It has Inbuilt Memory to store CTR, PTR, Inst. Address, Password & Energy Reset facility. August 2014
“MFM-96S” has Simultaneous Display of 10 Parameters, 48 Values on 16 Pages for Voltage, Current, Active Power, Reactive Power, Apparent Power, Frequency, Power Factor, Active Energy, Reactive Energy & Apparent Energy (Import / Export - 4 Quadrant operations). TRMS Measurement, 3Phase 3Wire / 3Phase 4 Wire (User Selectable) CTR, PTR, Instruments address, Password Protected, Energy Reset & Auto / Manual Scroll Display (Programmable) are key features of “MFM96S”. “MFM-96S” is Ideal to monitor & acquire Power Data from Generator, Remote Monitoring, Building Management System, PLC’s / SCADA application, Energy Audit, QC Testing, Power Management,
etc. RS485 Port with MODBUS Protocol & Power Master Software to store parameters on the PC is optional. For further details do write to sales@mecoinst.com www.martupdate.com
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Tomorrow’s technology must become simpler: KOLLMORGEN presents a new machine design from 17 to 20 September 2014 during the largest packaging fair, in Hyderabad, Southern India.
Solutions that really dispense with everything that is not absolutely necessary – this is what is meant when KOLLMORGEN talks about Simple Machine Design. The experts in servo drive technology and motion control will show at PackPlus South why this new simplicity shines directly on the real spirit of the times for machinery and plant engineering. KOLLMORGEN will prove this statement
Preferably maintenancefree, flexible and easy to use. These wishes of the foodstuffs and packaging industry will in future ensure even more that machines are built that have simple modular structures. “New Gen Machine Design – Now”: KOLLMORGEN will show in Hall 2, on Stand 2.57 just what role drive technology plays in the process, amongst other things with the decentralised AKD-N servo controller series.
the equipment will also become a lot easier. KOLLMORGEN has honed this trend-setting drive technology in such a way that the centralised and decentralised benefits can be exploited with just a standard
These robust devices can, thanks to Slimmed down: with its decentralised servo drives and its single cable connection technique, KOLLMORGEN opens new their compact dimensions and high routes to a slim hygienic design for machinery and plant. degree of protection, be integrated very easily close to the motor in machinery cable – irrespective of which motor is just designs. Furthermore, the in need of connection to which recovery single cable connection system. Whether it’s a robust resolver or technique with an only a high definition multi-turn sensor: in this eleven millimetre thin hybrid way KOLLMORGEN lowers the costs of cable between the controller warehousing and variety management. and the motor lowers the Furthermore, individual drive axles can – installation costs. Together for instance during commissioning – be with the high grade steel more easily functionally adapted without AKMH servo motors, cleaning constant need to also re-lay the cables.
New Industrial Cellular Gateway from Prosoft offers secure connections to remote devices No WiFi? Prosoft got you covered. With their ICX30-HWC Industrial Cellular Gateway you can now have remote monitoring of devices where WiFi is not possible. The industrial cellular gateway provides secure wireless Ethernet and serial connectivity to remote devices and equipment over 3G cellular service. These include PLCs, RTUs, DCS systems, instruments, electronic billboards and communication towers. The industrial cellular gateway is ideal for programming and maintenance, remote data collection, location-based monitoring and SCADA
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applications. Remote devices are accessed using secure VPN tunnels over Internet connections. In addition, the EtherNet/IP™ Class 3 Server allows diagnostic data to be sent to a Rockwell Automation ControlLogix® or CompactLogix system. The ICX30-HWC supports cellular networks worldwide, including 3G GSM, WCDMA and HSPA+ Networks, among others. Visit http://psft.com/icx30hwcappr for
The ICX30-HWC allows remote site access and communication to PLCs, RTUs, and other Ethernet and serial devices.
complete list of features, video and other information. August 2014
The Data Matrix Code allows intelligent Tool holder Management Clamping Technology/Tool holders On the way to â&#x20AC;&#x153;Industry 4.0â&#x20AC;?, or the dawn of the 4th industrial revolution, SCHUNK the competence leader for clamping technology and gripping systems is setting another miles-tone: Numerous SCHUNK precision tool holders can be marked with an individual data ma-trix code now, which allows an intelligent tool holder management. Regardless of whether it is done manually by smart phone, or fully automated with a ma-chine tool scanner, every tool holder can be reliably identified with the help of a code, and together with the corresponding data base system, they can be exactly assigned. Within the framework of intelligent manufacturing processes, it is possible to generate a precise history together with the data from the superior cloud, with sites of operation, used
August 2014
tools, service life, and machining parameters. According to the individual systematic arrangement of documents, the data matrix code can be individually defined. In contrast to the glued on RFID tags, which require the re-balancing of the tool holders, and under unfavorable conditions Tool holder marking forthe smart factory: with a data matrix code, these tags might get SCHUNK tool holders can be clearly identified and assigned. lost, the data matrix code however, is permanent and has no influence on the balancing quality. The TRIBOS polygonal tool holder without any individual marking can be done at every additional charge. TENDO hydraulic expansion tool holder For further details visit www.in.schunk.com (ex-cept TENDO E compact), and at every
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Hexagon Calibration Laboratory Receives Prestigious ISO/IEC 17025: 2005 Accreditation Hexagon Metrology India Pvt. Ltd. is proud to announce that its Coordinate Measuring Machine (CMM) laboratory in Noida, India has received ISO/IEC 17025:2005 accreditation from National Accreditation Board for Testing and Calibration Laboratories (NABL), validating international standards requirements for testing and calibration services. With this lab, Hexagon Metrology is the only coordinate measuring machine manufacturer in India to receive this accreditation. NABL (National Accreditation Board for Testing and Calibration Laboratories) is the accreditation body for testing and
calibration of laboratories in India. It operates as an autonomous body under the aegis of the Department of Science and Technology (DST), Ministry of Science and Technology, Government of India. The laboratory accreditation services to testing and calibration laboratories are provided in accordance with ISO/ IEC 17025:2005. Hexagon Metrology India received this accreditation by demonstrating technical competence for product compliance testing, calibration and also for the operation, quality system and effectiveness of its laboratory. ISO/IEC 17025:2005 not only considers management and technical expertise, but also emphasizes continual product and process improvement. The assessment report contains the evaluation of technical manpower, all relevant material examined, test witnessed including those of replicate testing/ measurement, compliance to ISO/IEC 17025:2005 and NABL specific criteria.
Anup Verma Managing Director Hexagon Metrology India Pvt
“Achieving ISO accreditation further affirms Hexagon Metrology’s commitment to providing our customers and suppliers with the best possible conformance to testing and calibration services for coordinate measuring machines. We are very proud of the excellent effort of our manufacturing team that has helped accomplish this status. We will also look in future to add the all laser parameter (error mapping) in the Laboratory Scope and Arm Calibration which will also be a first on its kind in India.”
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18 Machines, 10000 Sq Feet Haas@IMTS Booth S-8119
The laboratory has two features capability to provide - At Lab and At Customer’s Site: 1. Squareness of plain XY, YZ, XZ up to 2000 mm with measuring capability of 1.5+L/300 Micron 2. CMM verification as per (ISO 10360-2) up to 2000 mm with measuring capability of 1.5+L/300 Micron This newly accredited CMM facility is committed to meeting customers’ need for high quality testing/calibration reports. With this lab, the company will be geared to further eliminate the need for re-testing of products, thereby saving time and money. Companies interested in enjoying the benefits of our precision measurement solutions, including having a NABL certified CMM, can contact at contact.in@hexagonmetrology.com.
IMTS is the premier manufacturing technology show in the Americas. For 2014, the show is expected to bring together more than 100,000 visitors from 112 countries to see more than 1900 exhibitors from around the world. This year, Haas will have 18 machines on display in 10,000 square feet of booth space, as well as 7 additional machines in vendor booths. Here’s a list of what’s new since last IMTS: UMC-750SS High-Speed Universal Machining Center, DM-1 40-Taper Drill/Mill Center, ST-55 LargeThrough-Bore Turning Center, ST-15 Small-Footprint Big-Bore Turning Center, ST-25 Compact Big-Bore Turning Center, ST-35 Mid-Size BigBore Turning Center, Redesigned TL-1 Toolroom Lathe, 6000-rpm Live Tooling for Turning Centers, TRT100 Compact, High-Speed, Dual-Axis Rotary Table, 15,000-rpm 40-Taper Inline DirectDrive Spindles and Through-Tool Air Blast. For more information about Haas Automation and Haas products, visit www.HaasCNC.com.
August 2014
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We are interested to subscribe “Industrial Business MART” as per the selected option: One Year (12 issues) at `1200 Three Years (36 issues) at `3000 You save `600 Five years (60 issues) at `4800 You save `1200 Name ................................................................................................. Designation ............................................................ Company............................................................................................................................................................................. Address............................................................................................................................................................................... City ........................................................................ Pin ................................... Tel ............................................................. Mob ............................................................ Email ............................................................................................................ Enclosed please find Cheque No ................ dated ................. of .............................Bank favoring “MEDIAMART INFOTECH”.
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3 in 1 Prepaid Meter (Dual Source) from Elmeasure
Kerala to Empower Youth through YES
Recovering electricity dues remain one of the major challenges in the power sector. Most distribution companies face serious problems in recovering electricity bills especially from government departments/ apartment blocks/ commercial complex etc. ElMeasure has developed a unique 3 in 1 Contactless Prepaid Energy Meter were in process parameters such as water, gas etc can be integrated and its consumption can be monitored along with electrical parameters. The design is completely
Young Entrepreneurs Summit (YES) is a flagship event to establish Kerala as a vibrant Entrepreneurial State. This is an international summit aimed at fostering the growth of entrepreneurship in young minds
Main Features - Compact wall mounting design - Dual Source Measurement (EB & DG) - 3 in 1 meter with option to integrate process parameters. - Pre-paid metering system using contactless smart cards - Accuracy Class 1.0 - Cost effective â&#x20AC;&#x2DC;Pay as you useâ&#x20AC;&#x2122; three phase electricity metering Application - Shopping Malls / Multiplexes - Residential Townships / Apartments - Commercial Buildings - Employee Quarters Advantages - Upfront payment for electricity and hence low over heads for service providers. - Advanced RF card technology - Tamper proof construction - Cost of manpower for billing / collection is substantially reduced. - This avoids the hassles of human intervention as there is no need to enter the data into the meter. This makes the system more user friendly. - Displays balance energy in the meter, thus enabling the consumer to plan when to recharge. - No billing disputes - Allows consumer to budget electricity expenses - Helps consumer to contribute towards energy conservation. - Available in single phase and three phase system
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microcontroller based thus providing an effective and reliable solution to the service providers. The service provider needs to just install the meter and further activities involve the consumer. It is sufficient for the service provider to have just one manpower to recharge the card as per the consumerâ&#x20AC;&#x2122;s request. The consumer will have to display the card in the front fascia of the meter for three seconds. The advanced microcontroller electronics inside the meter stores the number of units recharged and measures the energy consumption. When the purchased units are used up by the consumer the meter disconnects the power supply until the next recharge. For further details visit www.elmeasure.com
and at creating an enabling environment for startups highlights in the state across all sectors. YES will showcase the existing facilities and support services available to prospective young entrepreneurs to realize their business dreams. The summit will emphasize the combined initiatives of agencies like KSIDC, KFC, TBI, Technopark, Infopark, and KINFRA in creating a holistic ecosystem conducive for young entrepreneurs. YES will also become a platform for young innovators to share their innovative ideas. At the event, the final selected innovators/ ideas will be rewarded and the event will also honour selected successful startups across the state. Those with innovative ideas can participate in the contest for the most innovative idea wherein the top 3 innovations shall be given prize money of Rs 1 Lakh, Rs 50,000 and Rs 30,000 respectively. The remaining 7 innovations will be awarded Rs.25, 000 each. Successful start-ups will also be given an opportunity to showcase their products / services in the exhibition being organised alongside YES. For more details visit www.yeskerala.org
August 2014
THE LAST LEAF Dear All, Inspired by the likes of Warren Buffet, Gates Foundation and Azim Remji Foundation, these days philanthropy and CSR has become a subject that gets discussed and practised more often than earlier days. However, there is a need of it to grow exponentially similar to some of the other exponential growths in the society. From April 2014, Indian companies falling under the ambit of the Government’s recent CSR rules have been made to shoulder the responsibility of spending 2% of their profits on charitable clauses. This ruling would eventually lead to generation of USD 3.5 billion of CSR spending annually. This should be referred in context of Indian poverty which is estimated at approximately 650 million people (53 % of Indian population). Muhammad Yunus has had phenomenal success in helping people lift themselves out of poverty in rural Bangladesh by providing them with credit without requiring collateral. Yunus developed his revolutionary micro-credit system with the belief that it would be a cost effective and scalable weapon to fight poverty. He founded Grameen Bank in 1983, which is owned by the rural poor, whom it serves. The bank has provided more than USD 4.8 billion to over 8 million borrowers in rural Bangladesh, with a repayment of 97 % . Today, Grameen methods (micro-credit programs) are being applied by more than 250 institutions in nearly 100 countries. This program has been viewed as “the single most important development in the third world in the last 100 years”. Shri.M.George Muthoot, Chairman of Muthoot group in Kerala, is crowned today as the ‘banker for every unbanked Indian’ since he has built a strong network of 4500 branches across the country. He works on the philosophy ‘unchanging values in changing times’. Ray Anderson founded Interface, the company that makes those adorable Flor carpet tiles. He was a serious carpet guy, focused on building his company and making great products. Then he read Paul Hawken’s book The Ecology of Commerce. Something clicked: with his company’s global reach and manufacturing footprint, he was in a position to do something very real, very important, in building a sustainable world. Anderson focused the company’s attention on sustainable decision making, taking a hard look at suppliers, manufacturing processes, and the beginning-to-end life cycle of all its products. (For example: If you can’t find a place to recycle a worn or damaged Flor tile, Interface invites you to send it back to them and they’ll do it for you.) They call this drive Mission Zero: “our promise to eliminate any negative impact our company may have on the environment by the year 2020.” The result : the company’s profitability improved. We need today, Thought Leaders who are openers of mind, like the ones above. One such action is the formation of GAP (Global Action on Poverty) which is a global platform to alleviate poverty by bringing about a marriage of thought and action, beginning with the Indian sub-continent. It is a call for individuals and corporates to come together to be the changemakers. More details available on <http://globalactiononpoverty.org/> As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board (EAB) August 2014
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