MART December 2015

Volume 12 Issue 5 December 2015 ` 100

LATEST INNOVAT IONS

VOITH AIMS TO KAIZEN-IZE

MANUFACTURING IN INDIA FOCUS ON CORPORATE SOCIAL RESPONSIBILITY INDUSTRIAL AUTOMATION AND FUTURE FACTORY WITH INFORMATION TECHNOLOGY

India’s DIGITAL DRIVE will enable Competitive SMART MANUFACTURING Deceember 2015

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UMC-750SS at

HAASTEC PUNE SHOW 9-12, December 2015 10 a.m. to 6 p.m.

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OTHER MACHINES ON DISPLAY:

ST-35, VF-7/50, DT-1, VF-2SS, ST-10Y Super Mini Mill, VF-2 SHOW DETAILS:

Date: 9-12, December 2015 Time: 10 a.m. to 6 p.m.

Venue: Hall – B, Plot No. C-181, Auto Cluster

Exhibition Center , Pimpri - Chinchwad Pune, Maharashtra: 411019 December 2015

Deceember 2015

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December 2015

Inviting Distributors (Across India) SCHUNK Intec India Private limited, a 100% subsidiary of SCHUNK GmbH & Co. KG, Germany, a family owned organisation and competence leader in Clamping and Gripping System with a heritage of innovation and market leadership for over 70 years invites distribution associates to partner its ambitious growth plan in India.

Consideration Essentials: • Established and resourceful sales partners in the Metal Cutting and industrial products areana.

• A well trained techno Savvy field presence.

• Thorough Regional market knowledge, presence and penetration with a successful business track record of over 3 years.

• A minimum business revenue of 10 Crores Ruppees per year in Tier-1 industrial locations and a minimum of 5 Crores Ruppees per year in Tier-2 industrial locations.

• Showroom and warehouse facility with a possibility to stock SCHUNK products worth 10 Lakhs rupees or more.

• Transparent and open approach to information sharing.

Deceember 2015

Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding. www.gb.schunk.com/Lehmann

© 2015 SCHUNK GmbH & Co. KG

You are invited to write to us if the above philosophy is in line with your growth plans.

Contact details: Marketing Manager Email: schunk.india@gmail.com Website: www.in.schunk.com Address: No. 80 B, Yeshwanthpur Industrial Suburbs, Bangalore, 560022. www.martupdate.com

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NURTURING MANUFACTURING

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December 2015

foreword Instability, Commitment!

Hi Readers, Our best wishes remain to those souls broken, lost, befallen by the sudden devastating flood at Chennai! There were experiences shared by our readers of travelling through boats, spending nights starving! Panel discussions on what should be a proper city planning and urban management often follow in news channels across the globe after these natural disasters hit some places but execution remains futile in most cases.

The prime time concern is now on the historical climate deal getting inked at Paris. All 196 countries across the world are signing the agreement to work towards fossil fuel-driven economies which will slow down the global warming. India, playing a crucial role in this deal, has already submitted its plan of actions till 2030. But how many people living in India are really concerned of this climate deal when most percentage of them spend days starving, looking for shelter and security? A scorching summer, dry monsoon or rainy winter seasons are though attracting common people’s attention, but the real after effects are yet to realise for most of the population. When scientists are worried of the El-Nino effects, the maximum people are worried to find their comfort zone by installing air conditioners or room heaters.

The question remains underneath is how long!!

Recently, The State Government of Delhi has taken actions to make odd even day to run vehicles. Also it has been announced to remove diesel running vehicles from Capital’s roads.

The Government of India is introducing taxes in the name of ‘Swachch Bharat’ when still in urban locality most of us prefer to throw wastes on roads and keep the municipality vehicle garbage-free! Also, there is nowhere the required awareness of separating solid wastes with that of recyclable ones. How much audience in a movie-hall quit smoking being inspired truly by the advertisement of “Iss Shahar ko Ab Hua Kya”! Instead, they feel superior by smoking irresponsibly in public places. So, infusing restrictions or taxing common people will not help in keeping earth safe. What is required is awareness campaign from central to district level to literate people to live and let live.

Industry plays a major role in ensuring proper measures in implementing a green and clean environment through its products and manufacturing techniques. With corporate social responsibility we can contribute constructively to climate change actions set by the governments. We need to take it seriously rather than using it as a tool for marketing promotions and publicity. For more than five years, industry expert Mr. Satish P S is writing column on empowering the SMEs in our country and in this edition he is talking about CSR – Corporate Social Responsibility and how organizations can initiate actions which can support bigger interest of our habitat.

In this edition our main story is Industrial and Factory Automation. We have included our regular contents in this issue with updated technical and management articles. We look forward your suggestions to make MART, SMART. Signing off to meet you next year!

Till then, Happy Reading with MART!

Deceember 2015

Hari Shanker hari@martinfotech.in

www.martupdate.com

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36 MAIN FEATURE

10 INNOVATIONS

26

India’s Digital Drive will Enable Competitive Smart Manufacturing Industry

30

Industrial Automation and Future Factory with Information Technology

34 Industry 4.0: Triggering Smart Factories of the future 38 “Acceptability of Automation Solutions needs to be improved”

58 Smart Lighting: Showing the way for Smart Cities Volume 12 Issue 5 December 2015 Annual Subscription `1200 Member INS Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre

MediaMart Infotech

Siji Nair

Sandeep Hingne

Digital Edition at

B/28/1, Katjunagar, Near Kalimandir Kolkata - 700032 Mob: +91 9038000711

9830122946 Email: info@Martinfotech.in Visit www.Martupdate.com

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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manne the Publisher no any of its employees accept any responsibilities for any errors or omissions. © All Rights Reserved December 2015

CONTENTS 54

Haresh K. Sippy Managing Director, TEMA India

ON FACE

46 FAIR MART

Columns

64 Focus on Corporate Social Responsibility 66 Interviewing Essentials for Managers 68 Specialists or Generalists: who will have Advantage in 2016?

50 SUCCEESS STORY

70 CASE STUDY

76 FEATURE ARTICLE

78 97

MART UPDATE THE LAST LEAF

Managing Editor

Hari Shanker

Associate Editor Hiya Chakrabarti

General Manager

Priya Kundu

HR & Admin

Sonalisa Dey

Creative Assistant

Sayan Chaudhuri

Sales Team

Subramaniam V C R Sathyanunni K Ravindranath

• Five years (60 issues) at `4800 You save `1200 • Three Years (36 issues) at `3000 You save `600 • One Year (12 issues) at `1200 Send your subscriptions to: The Circulation Manager - MART Mediamart Infotech, B /28/1, Katjunagar, Near Kalimandir, Kolkata - 700032 Mobile: +91 9038 000711 Email: mart@martinfotech.in Web: www.martupdate.com & www.martonline.in

IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post. m. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 er whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither Deceember 2015

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Renishaw unveils Inspection Plus with SupaTouch optimisation delivering intelligent speed

I N N O VAT I O N

Roughing Head with Steadyline Workpiece

Probe trigger sequence

Intelligent software optimises on-machine probing cycles Renishaw, a market-leading engineering technologies company, will introduce Inspection Plus with SupaTouch optimisation at EMO 2015, Milan, Italy (5th-10th October, hall 5 stand D15). This enhanced software package automatically optimises onmachine measurement cycles to minimise cycle time and maximise productivity.

The software features an easy-

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to-use optimisation process to automatically determine and select the highest feedrates a machine tool can achieve whilst maintaining measurement accuracy. It also uses intelligent in-cycle decision making to implement either a one or two-touch probing strategy for each measurement routine.

Inspection Plus with SupaTouch optimisation eliminates the need for manual optimisation of on-machine positioning feedrates, measurement feedrates and strategies. When

compared with traditional software cycles, it provides a significant cycle time reduction of up to 60% on CNC machine tools.

To ensure maximum accuracy, the software detects any measurements taken during machine acceleration or deceleration phases and compensates for errors by taking corrective action and remeasuring. It also introduces a calibration process that improves measurement repeatability in all directions

and improves the accuracy of probe positioning during multi-axis vector moves.

Inspection Plus with SupaTouch optimisation enhances the many proven benefits of Renishaw’s established Inspection Plus software. With this new software, users can significantly improve cycle times and on-machine measurement results, maximising the productivity and profitability of their machine tools.

December 2015

More Information

Smart Focus Pure Energy With just a few settings you will achieve best cutting results up to 100 mm – even under challenging conditions.

Sharp-edged cut surfaces on the top and bottom side of the material

Precise holes 1:1 with Contour Cut Low angular deviations & smooth surfaces

Marking

High cut quality & contour accuracy

cutting and welding india Phone: +91 20 26741042 | Fax: +91 20 26741001 vertrieb@kjellberg.de | www.kjellberg.de Made in Germany

Deceember 2015

SMART FOCUS

Plasma Cutting Units

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I N N O VAT I O N

Pramet Expands Shoulder Milling Range

Offering a depth of cut up to 108mm, the cutters are suitable for use with Pramet’s versatile ADMX 16 inserts and support medium machining of most engineering materials including cast iron, stainless steel and aluminium alloys.

Pramet’s popular shoulder

performance and reliability

MF is a sharp and highly

LNGU/LNMU16 assortment to

milling range has been

for a variety of operations

positive geometry, ideal for

provide greater choice.

expanded with a new program

including shoulder milling,

light machining and finishing

of cutters, geometries and

grooving and contouring.

operations. MM is a universal

inserts. This includes a program of helical cutters for roughing applications.

of our most popular inserts.

The creation of a new milling

sharp and highly positive geometry with estabilised cutting edge for finishing and semi-roughing operations.

are now available offering a range of sizes from 0.8mm to 4.0mm. New geometries include F, M and R for

The large clearance between

cutter further expands this

the cutting teeth, combined

versatile program. Customers

For use with shoulder milling

steel and cast iron. A highly

with internal coolant delivery,

can now use the same insert

inserts ADMX11 and ADMX16,

positive geometry FA is for

promotes efficient chip

type for several milling

as well as the LNGX12 range,

copper and aluminium. An

evacuation. The axial clamping

cutters and applications,

the new geometries’ positive

overview of all the new

of inserts on the end teeth

offering a more efficient and

rake angle provides low

indexable ranges launched by

increases milling stability. This

reliable service.”

cutting resistance, reduced

Dormer Pramet in November

cutting forces and less power

2015 is available in its latest

consumption. Meanwhile,

product brochure. To order

Pramet has also expanded

a printed copy or for more

its range of inserts for

information contact your

economical shoulder milling.

local Dormer Pramet sales

New radii and geometries

office. For more details visit

have been added to the

www.dormerpramet.com

creates less noise and vibration which, in turn, also reduces tool wear. Karel Tiefenbach, indexable milling product manager at Dormer Pramet, said: “The new range of helical cutters offers additional

12

“Our ADMX 16 range is one

A further four radii options

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As part of the launch, two new positive geometries – MF and MM – have been added for milling stainless steel, super alloys, low carbon steel and non-ferrous materials.

machining stainless steel,

December 2015

I N N O VAT I O N

UMB800: World’s Smallest Ultrasonic Sensor

The UMB800 from Pepperl+Fuchs is the world’s smallest ultrasonic sensor in solid stainless steel. It is made entirely from FDA-compliant materials. With its large detection range and highly compact design, it opens up new automation possibilities in hygienic applications.

The new sensors in the UMB800 series feature hygienic housing that is made entirely from V4A stainless steel. The surface roughness of the housing is less than 0.8µm, minimizing the risk of microbial contamination. The outer skin is hermetically sealed and free from gaps. The sensor can withstand steam jet treatment and aggressive cleaning agents.

It features IP68/IP69K degrees of protection and ECOLAB certification. No cleaning processes need to be changed when the sensor is installed in

Deceember 2015

existing systems.

At 18mm in diameter and 55mm in length, the UMB800 is the world’s smallest ultrasonic sensor in solid stainless steel.

The compact design does not reduce its performance: It provides an exceptionally wide measuring range from a dead band of only 70mm and a detection range of 800mm.

The sensor complies with the guidelines of the European Hygienic Engineering and Design Group (EHEDG). All materials are FDA-compliant.

The certification covers its

aggressive environments, such as

specially developed hygienic

in the chemical or vulcanization

mounting bracket. No tools

industry. The same is true for

are required for assembly.

systems in which robust cleaning

The sensor is resistant to

methods are used. Typical

significant temperature

applications include packaging

fluctuations and remains

food in thermoformed trays and

functional at a continuous

measuring the fill level in receiving

operating temperature of up

tanks, as well as applications in

to 85°C.

car tyre production or processes

The UMB800 series is primarily designed for use in hygiene applications (food and pharmaceuticals). It

in electroplating and painting systems, e.g., to detect parts moving into and out of an acid bath.

demonstrates its strengths

For more details visit

when used in applications in

www.pepperl-fuchs.com

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3 in 1 Prepaid Meter (Dual Source)

I N N O VAT I O N

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 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 consumer’s request. The

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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.

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 ‘Pay as you use’ 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 For more details visit www.elmeasure.com

December 2015

Deceember 2015

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De Dietrich expands its enamelled piping range!

I N N O VAT I O N

By reorganizing its product range, De Dietrich aims to become a major player on the piping market for the chemical and pharmaceutical industry.

As a key leader in the

the system. The De Dietrich

In that last case the plastic

Another distinctive feature is

enamelled equipment sector,

glass-lined piping range thus

lining have problems with

the company’s engineering

particularly in reactors, De

benefits from the same quality

accidental collapse.

and consultancy skills, allowing

Dietrich relies on its technical

of enamel as used for the

expertise to propose a

reactors. A distinctive feature

standard range of enamelled

of De Dietrich’s enamel is that

piping, which is both attractive

it is manufactured on-site, in

and available at short notice.

France, allowing control over

In order to meet the market’s

the quality of the Group’s

objectives, the company has

whole range of equipment.

made a stock of over 12,000 items available, covering the whole range of the sector’s standard needs.

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The current piping range is particularly suitable for transporting acid and alkaline fluids, abrasive solutions

The process peripherals

and high-temperature fluids

(piping, pumps, valves,

in atmospheric or pressure

columns, gaskets, etc.) are

conditions and in vacuum-

components that are as

high vacuum application in

important as the “heart” of

combination with temperature.

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Our range is designed for projects of all sizes and types: new installations or maintenance, always respecting the requirements of the most demanding markets.

Corrosion-resistant, nonadhesive, pure, easy to clean and without catalytic effect, the components of De Dietrich piping are used by over 200 clients worldwide, in a quality that has made the company’s success.

it to take part in large-scale projects. Worldwide, clients can rely on the group’s expertise in selecting the standard product best suited to their needs in order to optimize the operating life and the dimensioning of the equipment. De Dietrich can additionally provide tailormade solutions when required.

Finally, the glass-lined piping range is offered at highly competitive prices, making it the most attractive offer in terms of cost-performance ratio.

December 2015

New Ultra High Torque 22ECT Brushless Slotless Motor

I N N O VAT I O N

The 22ECT is available in 60 and 82 mm length versions, with hall sensors and 3 different coils to match your speed and voltage requirements. Upon request, Portescap can provide options for customization including gearboxes, encoders, coil variations and mechanical interface modifications.

Portescap introduces the

and joule losses, the primary

the electro-mechanical

in 60 and 82 mm length

newest addition to our Ultra

causes for motor stator

motor design and material

versions, with hall sensors

EC™ mini motor platform,

heating. The result is the new

selection for 22ECT. Due to

and 3 different coils to match

the 22ECT brushless motor,

22ECT stays cooler and offers

the multipolar design, these

your speed and voltage

designed specifically to

greater power density than

motors possess the torque

requirements. Upon request,

deliver ultra high torque in a

equivalent models within its

capabilities of much bigger

Portescap can provide options

compact size. With the unique

target operating zone. With

motors. The advantages

for customization including

coil technology and a patent

maximum continuous torque

of the 22ECT make it a

gearboxes, encoders, coil

pending multipolar rotor

up to 98.5 mNm and higher

good choice for geared

variations and mechanical

design, the 22ECT has been

stall torque, 22ECT motors

applications because of its

interface modifications.

developed to be one of the

are ideally suited for use in

minimal speed drop and

most advanced and highest

applications such as Industrial

low motor heating under

Portescap is globally ISO

performing brushless slotless

automation, power tools &

load. Their low inertia design

9001:2008 certified, and their

motors in its class.

robotics.

makes them an exceptional

production site in India is also

The 22ECT is constructed

Portescap succeeds in

option for applications

ISO 13485, ISO14001:2004 and

with an enhanced high

providing a high quality, long

requiring fast stopping,

OHSAS 18001:2007 certified.

efficiency magnetic circuit that

lasting & high performance

starting and acceleration.

For more details write to

significantly reduces both iron

brushless motor by optimizing

The 22ECT is available

sales.asia@portescap.com

Deceember 2015

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SCHUNK tops its PGN-plus mega-seller and celebrates the premiere of the new E-version

I N N O VAT I O N

World premiere: The SCHUNK PGN-plus-E is the world’s first digitally controlled mechatronic gripper with patented multi-tooth guidance. It is also a part of the new “Generation Permanent” from SCHUNK.

Premiere of the “Generation Permanent”: an enlarged supporting dimension of the multi-tooth guidance and continuous lubrication pocket in the multi-tooth guide contour distinguish the SCHUNK PGN-plus-P.

The premiere of the “Generation Permanent” from SCHUNK promises a hot show season: with the new SCHUNK PGN-plus-P, the competence leader for clamping technology and gripping systems is once again raising the bar with pneumatically powered universal grippers. The electric SCHUNK PGN-Plus-E applies the high-performance features of the pneumatic flagship directly in the area of mechatronic handling.

“Improving on proven technology” is SCHUNK’s motto for the development of the next generation of its mega-seller. Three technical

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innovations distinguish the newcomer SCHUNK PGNplus-P. First, there is the improved multi-tooth guidance.

By enlarging supporting dimensions between the six load-bearing shoulders of the patented multi-tooth guidance, higher moment can be accommodated and thus longer fingers can be used.

In order to ensure a perfect fit, each individual base jaw undergoes elaborate manual grinding, and is individually adapted to the respective housing in the new gripper generation. Secondly, permanent lubrication is provided via the continuous lubrication pocket in the

guidance.

planned.

For short strokes in particular, the principle of minimum quantity lubrication particularly ensures quick and even distribution of the lubricant such that the gripper is nearly maintenance-free and its service life is extended.

Finally, the SCHUNK PGNplus-P has an enlarged drive piston area, whereby gripping force is increased and higher workpiece weights can be handled.In the first step, the new gripper benchmark is being introduced in sizes 50 to 125. Expansion to all existing PGN-plus unit sizes is

Mechatronic universal genius With the SCHUNK PGN-plus-E, the world’s first digitally controlled mechatronic gripper with patented multi-tooth guidance, SCHUNK is applying the service package of its new pneumatic do-it-all SCHUNK PGN-plus-P directly to the area of electrical handling. Like its role model, the SCHUNK PGN-plus-E also has modified the multi-tooth guidance for the accommodation of higher moment, a continuous lubrication pocket in the guide contour, and the proven diagonal-pull kinematics with

December 2015

a high surface coverage in all stroke positions.

The mechatronic universal gripper is powered by a brushless DC servo motor.

Therefore, permanently high process stability and a long service life with minimal maintenance requirements are guaranteed. The mechatronic universal gripper makes the switch from pneumatic to electric components particularly easy: it has an identical screw connection pattern to its pneumatic counterpart, and the 24-V gripper is easily controlled via digital I/O. Up to two gripping positions can also be monitored by means of an additional M8 standard connection.

The required control and power electronics are already fully integrated into the compact module, so no additional space is needed in the control cabinet – in stark contrast to most of the mechatronic modules in the market, where control units require a great deal of space and sometimes even additional control cabinets.

Neither extensive mechatronic know-how nor additional programming are necessary for commissioning. Therefore, the universal gripper represents a milestone on the road to efficient, easy-to-use electric handling solutions. The gripping force of the SCHUNK PGN-plus-E can be adjusted in four levels. The grippers will initially be available in size 80 in the spring of 2016. Additional sizes are planned.

Wide accessory program

Both the SCHUNK PGN-plus-P and the SCHUNK PGNplus-E benefit from a unique accessory program. Nearly the entire spectrum of conceivable automation applications can be implemented in reliable processes with the universal gripper modules, from machine loading in machining centres and foundries to assembly applications in the automotive and electronics industries, and even sensitive handling tasks in the medical and pharmaceutical sectors.

The universal grippers are equally well-suited for use in areas with high temperatures, contamination, and aggressive media, as well as for cleanrooms. On request, the modules are available with spring safety, mechanical gripping force maintenance, compensation units for compensating angular misalignment, dust-proof versions, or as special highprecision versions. In addition, a broad spectrum of sensors is available, from inductive proximity switches to magnetic switches, and position sensors.

Instead of many isolated applications, users can reduce their coordination costs with the standardised gripper programme, in addition to speeding up their parts procurement process, and the SCHUNK Longlife Warranty for the pneumatic SCHUNK PGNplus modules even enables TCO planning of the total costs throughout the entire life of a system.

For more details visit www.in.schunk.com

PRIMO™ revolutionises automatic setting of parts and tools...

Y

X

• Simple to learn and use • Faster to payback and increase profits • Easy to justify compared to manual alternatives

Don’t get behind – get in front call +91 20 6674 6200 or visit www.renishaw.co.in/primo

Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com

www.renishaw.co.in Deceember 2015

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Introducing Unidrive HS30 and HS70 – drives designed for high speeds

I N N O VAT I O N

The Unidrive HS30 and HS70 variable speed drives, capable of output frequencies of 3,000Hz, are perfectly suited to high speed applications frequently required for automotive & aeronautical engine and transmission line test equipment, machine tool manufacture and centrifuges for the food & beverage and oil industries.

Emerson has expanded its Control Techniques variable speed drive range with two new models designed specifically for applications which demand high speeds.

The Unidrive HS30 and HS70 variable speed drives, capable of output frequencies of 3,000Hz, are perfectly suited to high speed applications frequently required for automotive & aeronautical engine and transmission line test equipment, machine tool manufacture and centrifuges for the food & beverage and oil industries.

Unidrive HS70 and HS30 are essentially designed with the same specifications as the standard Control Techniques Unidrive M700 and Unidrive M300 variable speed drives, however, unlike the Unidrive M models, HS30 and HS70 have

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been engineered specifically for high speed applications.

The new drives are controlled products under new laws in the EU and USA covering the export of ‘dual use’ goods, software and technology. This refers to items normally used for civilian purposes but which may have military applications, or may contribute to the proliferation of weapons of mass destruction.

OEMS and machine builders which incorporate high speed drives in their designs are responsible for checking and evaluating whether or not their machines comply with, or contravene, the relevant legislation. In order to assist its customers, Control Techniques has introduced the Unidrive HS range of high frequency variable speed drives.

Unidrive HS70 offers classleading induction, permanent magnet and servo motor performance, with onboard real time Ethernet. It provides maximum control of high speed motors and incorporates an on-board Advanced Motion Controller and PLC. Different variations of Unidrive HS70 are available, including models with on-board Ethernet, RS485 and Dual Safe Torque Off (Dual STO).

Unidrive HS30 is designed for applications that require cost effective integration into safety systems and incorporates Dual STO and advanced Rotor Flux Control of open loop induction motors.

The existing Unidrive M models, which are restricted to a frequency of 550Hz, are

uncontrolled products in the eyes of the new laws in the EU and USA restricting the sale of variable speed drives with an output frequency of higher than 600Hz. This means no export restrictions reply.

In order to comply with the new legislation, businesses which export goods or machines that incorporate goods classed as dual use under the terms of the EU regulation to locations outside the EU must apply for the relevant export licences from their respective governments.

The changes also have an effect on the documentation required in any transaction, as well as the measures which are taken to securely store the controlled goods.

For more details visit www.emersonindustrial.com

December 2015

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I N N O VAT I O N

New ACU 8 Cabinet Solution Expands Bonfiglioli Drive Portfolio

This 6 phase / 12 pulse compact drive brings benefits such as cost effectiveness and energy saving by reducing harmonics distortion.

Bonfiglioli Riduttori

cooling fan, which makes

S.p.A., a global designer

the ACU 8 suitable for

and manufacturer of

heavy industries with harsh

gearmotors, drive systems

environments in industries

and planetary gearboxes,

like mining, metals and

announces a new frequency

paper.

inverter series, the ACU8 Cabinet Solution, which expands its drive portfolio.

protection (IP54), these compact devices can be

Specially designed to meet

installed almost anywhere in

the customer requirements

the plant. The ACU 8 parallel

with a wide range of options,

connection (Modular system

such as PLC functions and

loop configuration

Bonfiglioli is committed to

• Liquid cooled system for space saving and high power density

providing one of the best products in High Power Density (370 ), and the most efficient and energy saving solution.

Benefits: • PLC functions with

• 6 phase / 12 pulse for cost effectiveness and energy saving • Multi communication protocols available

Graphical Software tool

Key Features:

above 400KW) is well

• Volumetric flow control

feedback sensors, ACU 8

optimized by synchronizing

for fans and pump

• Power ratings: 200 KW to 1200 KW

Cabinet solution can be

AC output current with a

applications

flexibly integrated into any

view to not using any output

automation process by using

filters.

either standard control mode or bus communication protocols.

22

With a high degree of

control.

ACU 8 series also offers the “Must” by controlling either Induction or PM

The liquid cooled version

(permanent magnet) motors

does not require a large

in sensorless or closed loop

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• 525V and 690V supply voltages for heavy industry

• Voltage ratings: 400V, 525V, 690V

and steel industry

• Safety: STO ( Safe Torque Off, SIL2)

• Modular system scalable

• Conformity: CE

for power requests • High precision closed

For more details visit www.bonfiglioli.com

December 2015

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India’s No.1 Entrance Automation and Loading Bay Equipment Company offers High Speed Doors

I N N O VAT I O N

High Speed Doors designed and manufactured by Gandhi Automations are sturdy, dependable and are the ideal solution for medium and large entrances. The doors are manufactured with European collaboration and technology with innovative and creative engineering

Fast moving functional and reliable doors are needed in industrial and commercial contexts. Gandhi designed and manufactured High Speed Doors are versatile and solid ensuring long-lasting reliability. The modular structure of the curtains, assembled and joined by anodized aluminium extrusions, provides for a wide

range of polyester sections available in a variety of colours.

Wide, full-width window panels ensure a safer traffic and allow more light in. Their fast and easy replacement, in case of accidental tearing, saves money and time.

The alternating metal tubular structure there inserted ensures high wind-resistance.

Prime High Speed Doors are the ideal solution for internal and external entrances and effectively operate in any situation, even when strong winds are blowing and in rooms with high volume traffic. Sturdy and dependable, Prime is the intelligent door for medium and large entrances.

For further details contact: Gandhi Automations Pvt Ltd Chawda Commercial Centre Link Road, Malad (W) Mumbai – 400064, India, Off : +91 22 66720200 / 66720300(200 Lines) Fax : +91 22 66720201 Email : sales@geapl.co.in Website : www.geapl.co.in

Gandhi Rolling Shutters - Quality Engineered Each of our Rolling Shutters is designed to the clients specifications conforming to IS 6248 and solidly constructed to promote trouble-free operation and long life.

Gandhi Automations Pvt Ltd, India’s No. 1 Entrance Automation & Loading Bay Equipment Company, is the only manufacturer of Rolling Shutters certified to ISO 9001 - 2008 quality management system. This has resulted in the implementation of continuous improvement in personnel training, production, inspection, equipment calibration, machinery maintenance, logistics and customer relations. The product engineering team uses the latest software combined

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with technologically advanced machinery to offer to the customer a well-engineered product. Over years of meticulously working on the design, fabrication and installation, Gandhi Automations has developed technical expertise in manufacturing various kinds of Automated Rolling Shutters. The Research and Development team with its extensive know-how and experience are able to produce specific types of Rolling Shutters unique to certain sites and client

requirements. A consistent quality product has thus become the hallmark of Gandhi Automations’ manufacturing process right through installation to after sales service.

Gandhi Rolling Shutters are ideal for situations where side room is at a premium and security is required. Our Rolling Shutters require very little headroom above the structural opening.

They combine strength with elegance along with durability

and are designed for both external and internal applications. Gandhi Rolling Shutters are fabricated of interlocking Galvanized Insulated and Non Insulated, Stainless Steel, patented Aluminum or Polycarbonate profiles and patented MS Rolling Grills.

Gandhi Rolling Shutters fit openings to a maximum width of 30,000 mm and height of 40,000 mm with an endless array of options to satisfy both aesthetic considerations as well as working requirement.

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MAIN FEATURE

India’s Digital Drive will Enable Competitive Smart Manufacturing Industry In the technology sector, we frequently hear several mantras coming from the Indian government in terms of ambitions for the country: the desire to ‘Make in India’, to enable and obtain the benefits of a ‘Digital India’, and to build a number of ‘Smart Cities’. In addition, more recently, there has also been a focus on ‘Smart Manufacturing’, looking at how India could be a global leader in manufacturing by adopting global best practices.

Nitin Dahad nitin@techspark.com

What ties all of this together is the technology platform – the underlying thread is a digital infrastructure or network, coupled with communications technology. This article looks at some of the recent trends in the technology sector that are enabling ‘smart’ everything, and then a look at the more recent debate on smart manufacturing and its role in transforming India into a globally competitive manufacturer, especially with the drive behind the Make in India campaign.

Tech trends and key moments for India on a global stage As someone who’s observed the evolution of the Indian technology sector since 1993, I’ve seen a huge transformation in this sector

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and it’s come a long way in the way digital technologies have been embraced.

worth of deals were signed between the British and Indian prime ministers.

In September 2015, there was a wave of euphoria about India as Prime Minister Narendra Modi visited and wooed the who’s who of Silicon Valley, USA. He seemed to have rock star status as many of the CEOs of Silicon Valley tried to jump on the India bandwagon to raise their profile among India’s 1.2 billion plus population.

Building on this, his UK visit during Diwali season also saw renewed interest in India as PM Modi once again received a rock star welcome (including a performance in front of around 60,000 people at the world famous Wembley stadium). While in London, some £9 billion

With all this interest, is it going to translate into something bigger in terms of triggering an innovation ecosystem that enables India to become a new digital superpower? Will this innovation ecosystem then translate to manufacturing to enable products to be designed and made in India rather than just assembled in India from foreign sourced components?

Will India embrace smart manufacturing?

Well the answer is probably.

This seems to be the first time in the last 20 or so years that the world has actually taken India seriously, not just

imagined as a place where there’s huge poverty and where the tech sector is just a cheap software offshoring destination.

While Prime Minister Modi was in Silicon Valley, one of the big announcements resulting from the visit was from Qualcomm, who announced its intention to invest up to $150 million in Indian startup companies across all stages as part of its commitment to India.

Kartheepan Madasamy, who heads up Qualcomm Ventures in India, said that Qualcomm is investing directly in the Indian mobile and internet start-up sector to foster the local ecosystem – it already has more than 20 Indian companies as part of its global portfolio, and

December 2015

Industry 4.0 Graphic: Source: Bitkom, Germany

includes hardware, software platforms, e-commerce, healthcare, location based services and retail technology.

The company’s executive chairman, Dr. Paul E. Jacobs, commented, “We share Prime Minister Narendra Modi’s vision to transform India into a digitally empowered society and knowledge economy.

India is at the cusp of a technology revolution and mobile technologies will lay the foundation for Digital India. We are committed to providing local innovative start-ups with the support needed to help India’s IoE [internet of everything] ecosystem grow, increasing consumer choice and availability.”

With large firms like Qualcomm looking at startups in this way, it’s no surprise that the tech entrepreneur ecosystem in India is also growing, and

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contributing to the digital India that the government envisions. It is clear that ‘startups’ in India are the new Bollywood – everyone wants to do a startup, and doing a startup is now considered glamorous. But beyond startups, there is a lot more happening in India that aligns with the global technology trends in connectivity and IoT (internet of things).

of India.

A real application of this is in smart cities. A recent announcement from Reliance Energy/Intel will enable a smart city pilot to build a smart sustainable city network in Mumbai.

In the first phase, Reliance will connect smart meters, streetlights and distribution automation equipment in Mumbai. This will be the first roll-out in India of smart meters fully compliant to the communication standards recently adopted in the machine-to-machine (M2M) roadmap by the government

This is part of a larger plan to develop industrial corridors or regions of industrial development connecting big metropolitan cities. The Delhi-Mumbai Industrial Corridor (DMIC), the ChennaiBangalore Industrial Corridor (CBIC) and the BangaloreMumbai Economic Corridor (BMEC) are examples of this approach. Many industrial and commercial centres are expected to be recreated as smart cities along these corridors. About seven new smart cities are expected to be developed as the nodes of the corridor in its first phase along

Smart cities are of course the one of the big initiatives of the Indian government. It plans to build 100 new smart cities besides developing modern satellite towns around existing cities under its smart city program, with an allocation of INR 70.6 Billion (US$ 1.2 Billion) for smart cities in the Union Budget for 2014-15.

the Delhi-Mumbai Industrial Corridor (DMIC), which is spread across six states.

Continuing the smart city theme, the ‘Pune Safe City Project’ was recently inaugurated by the government of Maharashtra with the aim to help enhance the safety and security of Pune city inhabitants. With the new system, the city of Pune in Maharashtra will benefit from a state-of-theart 24×7 video surveillance and security command centre.

The Pune Safe City project has already enabled successful detection of events such as theft, traffic violation, chain snatching and high profile robberies and murder cases amongst others and this project has helped in solving crime in a short time which has resulted in increasing the efficiency of policing. The project covers an area of 640 sq. km with 1250+ IP (internet protocol)

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cameras 440 junctions, command and control centre and viewing stations at police stations in the city.

Taking ‘smart’ to the next level: smart manufacturing The core of all the applications described above is connected devices, generation of live realtime data, data analytics, and then an action based on the analysis and required outcome.

This is ideal in the context of manufacturing and industrial automation. At a smart manufacturing summit organised by the CII recently in Delhi, the Indian government outlined its ‘Smart Manufacturing 2025 Roadmap’. It said that Indian manufacturing is on the verge of a transformation and by leveraging the advantages of ‘Industry 4.0’ (another label given to the concept of smart manufacturing), this could

support the growth of an efficient and cost competitive manufacturing sector.

For this though, Indian industry needs to create a relevant technology-driven skills base to enable this smart manufacturing. In particular, technology teaching and usage in colleges and schools needs to be aligned to workplace skills requirements. This requires collaboration between industry, academia, and research and development institutions to create a multidisciplinary curriculum as well as ecosystem to support this transformation.

Bosch also recently organized a smart manufacturing conclave in Mumbai, looking at ‘Industry 4.0’ solutions, and the possibilities and opportunities of connected manufacturing technology in India. In fact it has given an additional spin to the government campaign

by suggesting that industry should ‘Make it smart in India’.

Connected manufacturing provides better opportunities to react more nimbly to market requirements, reduce manufacturing downtimes, and improve efficiency of supply chains. These are all factors that would help contribute to increasing competitiveness of the Indian manufacturing sector.

drive for Digital India and Make

What’s clear is that technology is beginning to underpin many sectors in India just as it has been in many other nations. This is supported by huge growth in the tech startup ecosystem, not just for pure tech applications, but for all kinds of everyday challenges for consumers and businesses. With large firms willing to invest in growing these startups, and particularly in the connected devices and connected machines space, it won’t be long before this

US, Asia and Latin America. He is

in India will lead to a growth in smart manufacturing and higher levels of automation in the manufacturing sector.

The author Nitin Dahad is a consultant, advisor and mentor to the technology, industrial and media sector, to develop global market strategies and programs based on nearly 30 years’ experience across Europe, founder of TechSpark, a market growth consultancy, and The Next Silicon Valley, an online tech innovation magazine. He previously took British startup ARC International to successful market growth in the USA and a listing on the London Stock Exchange in 2000, and also founded The Chilli in 2002, one of the early magazines that supported tech entrepreneurs back in 2002.

Industrial automation in action: source: High Value Manufacturing Catapult, UK

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MAIN FEATURE

Industrial Automation and Future Factory with Information Technology It is obvious that the economy is an important aspect of society, and as the economy has evolved over time, so have societies. Over the past millennia, several major social transformations have determined the course of humanity, including the agricultural, industrial and information and service revolutions.

Rajesh Angadi rajesh_angadi@hotmail.com

From the extensive changes introduced by those eras, it can be seen that as shifts to a new industrial base have occurred, business models and manufacturing systems have adapted respectively, since manufacturing demands are always related to the needs of societies. As a result, manufacturing paradigms have also evolved across the centuries. However, addressing product demands does not on its own make manufacturing companies competitive. It should be considered that currently manufacturing industries are undergoing rapid changes, which are driven by globalization and the exploitation of the early and late phases of production chains. By adding intelligent assistance systems to enable workers to focus on creative and value-adding tasks and achieve a reduction of routine and stress-intensive labour, and to facilitate the transfer of knowledge among workers and manufacturing systems as a whole.

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The importance of such knowledge and skills is cumulative, as products, systems and business environments become more and more complex and technology-intensive. This is leading to a trend of perceiving knowledge as capital, with the goal of using and exploiting information across traditional boundaries as successfully as possible. A company’s ability to manage and use the knowledge about market, product, and production environment will increasingly exert an influence on its competitiveness and capacity for innovation. For this reason, the inclusion of appropriate IT systems in manufacturing is essential.

Depending on their degree of maturity, such systems support the management of knowledge and complexity throughout value chains, i.e. the full range of value adding activities in production across multiple organization units, via visualization, integration and connection and intelligent analysis of production systems. Value chain systems

need to become more adaptable, agile and resilient and need to be optimized with regard to capital expenditure.

(HMI), Programmable logic controllers (PLC), Motor control and sensors need to be connected in a scalable and efficient way. The Internet of The concept of Factory Things (IoT) is enabling machines Automation started in 1986 and the automation systems to and dealt primarily with the securely connect to each other, automation of manufacturing, in an enterprise and to the rest quality control and material of the supply chain and offer handling processes. The idea was information that can be used to employ automation to save up for operative and analytical on the labor cost, reduce human purposes. error, save energy and materials and to improve quality, accuracy Market & Trends and precision. Various concepts The global industrial automation & technologies like DCS, PLC, Industrial PC, Computer Numeric market is forecasted to reach more than $200 billion by 2015, Control Network, Wireless buoyed by improved economies sensor networks, Industrial worldwide. Purchased largely Ethernet etc. have emerged for manufacturing processes, and evolved over the years. In today’s world, in order to remain industrial automation equipment is a key factor in a country’s gross competitive and thrive, many domestic product (GDP) and, as businesses are increasingly IMS Research notes, generally turning to advanced industrial indicative of economic health. automation to maximize productivity, economies of scale The biggest change to the factory of the future will come from and quality. The increasingly technology. Future factories connected world is inevitably in the pursuit of sustainability, connecting the factory floors. productivity & efficiency are Human machine interfaces

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Image courtesy: dc-corp.resource.bosch.com

The concept of Factory Automation started in 1986 and dealt primarily with the automation of manufacturing, quality control and material handling processes. The idea was to employ automation to save up on the labor cost, reduce human error, save energy and materials and to improve quality, accuracy and precision.

adopting Factory Automation which will enable a truly integrated enterprise. Advanced controls, automation systems, and sensors are being used to improve industrial process control and energy efficiency in industrial settings. Whether reducing energy consumption or monitoring equipment for maintenance purposes, sensors, and wireless controls provide real-time data and the ability to configure and control plant related functions. The Integrated enterprise provides for an effective interaction between the factory floor and the enterprise across all end users, enabling organizations to gain a competitive edge in the global market. The organizations are also leveraging the benefits of IoT (Internet of Things) to connect data-driven devices to optimize their operations and improve decision making thus impacting revenues & profitability.

What will the production world of the future look like? How will humans and machines communicate with each other?

Will our working worlds be adaptable to our needs? In the factory of the future humans will have to come to terms with an increasingly complex world of processes, machines and components. This will require new operating concepts for

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optimized human-machine operations. Nimble, adaptive and intelligent manufacturing processes will be the measurement of success. The combination of “virtual” and “real” in order to get a full view of the complete value chain will allow factories to produce more rapidly, more efficiently and with greater output using fewer resources. Businesses will also be able to respond more quickly to the market, serving increased demand for individual products.

Majority of manufacturing plants and production facilities around the world are putting into place systems that will make them adaptive, fully connected, analytical and more efficient.

This models brings the beginning of a new phase of manufacturing characterized by complete automation and involving an increased use of technology and field devices in and outside of the manufacturing facility.

It represents the convergence of the mechanical age initiated by the industrial revolution and the digital age, in which massive amounts of information can be stored and then retrieved from data banks in the blink of an eye. Factories of the future are oriented toward ensuring the availability of all relevant information in real time through the connectivity of all elements participating in the value

chain, as well as providing the ability to deduce the optimal value chain processes from this data at the demand of the individual customer. Through the interaction of humans, objects and systems a dynamic, realtime optimized and self-organizing value chain will evolve. This value chain can be multi-vendor capable and can be adjusted for different business aims, such as costs, availability and resource consumption.

The factory of the future will increase global competitiveness and will require an unprecedented integration of systems across domains, hierarchy boundaries and life cycle phases. Many factors can contribute to establishing factories of the future, but consensus-based standards are indispensable in this process.

Factory Automation Factory Automation constitute of five major components - PLC (Programmable Logic Controllers), HMI (Human Machine Interface) , Sensor, Motor Control / Drives which are interconnected by Industrial communication protocols.

•PLC is the brain of an industrial automation system; it provides relay control, motion control, industrial input and output

process control, distributed system, and networking control. PLCs often need to work in harsh environmental conditions, withstanding heat, cold, moisture, vibration and other extreme conditions while providing precise, deterministic and real-time controls to the other parts of the industrial automation system through reliable communication links.

•HMI is the graphical user interface for industrial control.

It provides a command input and feedback output interface for controlling the industrial machinery. An HMI is connected through common communication links to other parts of industrial systems.

•Industrial drives are motor controllers used for controlling optimal motor operation. They are used in a very diverse range of industrial applications and come with a wide range of voltage and power levels. Industrial drives include but are not limited to AC and DC drives as well as servo drives that use a motor feedback system to control and adjust the behavior and performance of servo mechanisms.

•Sensors are the hands and legs of the industrial automation system that monitor the industrial operation conditions, inspections, measurements, and

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more, in real time. A sensor in the industrial environment is either continuously or periodically measuring vital parameters such as temperature, pressure, flow, etc. Monitoring and maintaining process variables at the appropriate levels is extremely critical in industrial automation and process control. They are an integral part of industrial automation systems and provide trigger point and feedback for system control.

•Communication is the backbone of all the industrial components for efficient automation.

The most common being Industrial Ethernet and Fieldbus communication protocols with master and slave functionality including EtherCAT®, Ethernet/ IP, PROFIBUS®, PROFINET®, POWERLINK and SERCOS III. Wireless connectivity holds enormous promises for advance factory automation. Zigbee, Sub 1-GHz Smart Mesh, 6LoWPAN, ANT+ and evolving standards are enabling machines and the automation systems to securely connect to each other, in an enterprise and to the rest of the supply chain.

With globalization, all companies are now competing with other global companies, rather than just local players. The world has also become a common marketplace, and the need to have a hyperefficient plant that is also flexible to meet changing customer demands is driving companies to explore factory of the future initiatives.

1) From capacity to capabilityManufacturing flexibility is critical to respond to variable market demand and achieve high levels of customer fulfillment.

2) New production modelsLeading manufacturers are moving away from mass production. Enterprises will give up the basic make-to-stock (MTS) approach. They will embrace more make-to-order (MTO), configure-to-order (CTO) and engineer-to-order (ETO) production models, and become more demand driven.

3) Profitable proximity sourcing and production- Manufacturers across different sectors are busy creating more modular products based on common platforms and configurable options. An increasing number

of manufacturers will adopt hybrid production and sourcing strategies to implement this change. Manufacturers will produce modular platforms centrally, while leveraging suppliers, distributors, or retailers to tailor final products locally to better serve local customer demands.

opportunities for industrial system developers to successfully address new challenges where systems require technologies to meet stringent requirements for high reliability in mission-critical environments. The success of an advance factory automation system design depends on few key factors.

4) Workforce engagementDespite a continuing trend to greater plant automation, people will remain at the center of the factory of the future.

People will provide the degree of flexibility and decision-making capabilities required to deal with increasing operational complexity. This workforce will have to be more fully engaged with the overall business and at every level of the company including front-line workers on the plant floor, sharing knowledge to further improve production processes. Factories will be managed through higher levels of collaboration, with a greater emphasis on involving employees, customers, and partners in both processes and strategic decision making.

Semiconductor Portfolio specific

In today’s factory automation market, new technology brings

•Specialized product portfolio for Harsh Environments.

•Reliable and efficient communication network that connects all the components of the factory to work together effectively.

•Energy Efficiency is also a must have from a sustainability perspective.

•Long product life supply policy.

•Flexible and future-proof embedded processors.

•Solutions that meet industry safety needs (IEC61508, SIL) •Space efficient solutions.

System specific –

Product Innovation

Market

Production Environment

Competition

A company’s ability to manage and use the knowledge about market, product, and production environment will increasingly exert an influence on its competitiveness and capacity for innovation.

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•The primary challenge of sensing in industrial environments is conditioning low signal levels in the presence of high noise and high-surge voltage.

•Industrial-specific reference design and development tools.

•Production-ready comprehensive software, including communication protocols and signal chain solution.

With Factory Automation, industrial companies can build one common, converged, and rugged plant-to-business network. This way, we can: •Connect factory automation and control systems to IT systems with standards-based Internet Protocol-networking.

Integrate manufacturing systems and business systems to bring everything online on a single network for greater flexibility and awareness.

•Improve operational efficiency and cut costs with highly secure remote access also protect critical manufacturing assets with industry-leading security features •Speed response time to issues on the plant floor •Mitigate risks by improving network uptime and equipment availability. Improve visibility and resiliency to reduce expensive unplanned downtime.

Dramatically reduce the time needed to identify and debug causes of downtime.

• Adapt to changes quickly, whether they’re new product introductions, planned productline changeovers, adjustments due to component supply, or shifts in the mix of product demand.

• Gain awareness of changes in real time — from the enterprise to the plant floor—through mobile devices, video monitors

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that communicate over the converged network.

These benefits will help us to make more strategic business decisions backed by real-time data from the plant floor.

Factory Automation provides the breadth of plant infrastructure capabilities across networking, wireless, security, physical video, computing, and communications.

In this way, the solution can flexibly support the current and future business needs of manufacturers. It meets the requirements of both business IT and operational technology in a highly secure, reliable, and integrated platform.

Internet of Things (IoT) which help for real-time visibility and business intelligence is well within the reach. Companies around the world are adopting new plant architectures which takes advantage of the pervasive connectivity and actionable data provided by the IoT. By converging factory-based operational technologies with global IT networks, companies are increasing uptime and improving operational equipment effectiveness intelligence — from the plant floor through the supply chain which means less downtime, higher productivity, greater resiliency, and the agility to respond to rapidly changing customer and market needs.

The author 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 Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.

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MAIN FEATURE

Industry 4.0: Triggering Smart Factories of the future After Industrial revolutions of 1, 2 and 3, now we see another phase change in the mode of industrialization - Industry 4.0. The main agent of this change being intricately networked systems on the internet backbone riding on a matured automation and computer industry. Few innovations standing out are the Internet of Things, Automated drones, Intelligent robots, self navigating automobiles, 3D printers, Smart grid, universal GPS etc. This change is leading to extensive use of networked information system with very small time constant of response.

Somnath Sircar somnath@algonics.com

Industry 1,2,3 The taming of potent energy in natural resources like coal ushered in the industrial age. This came thousands of years after humans learnt to harness animal power to aid their own muscle power, mainly in agriculture. The gigantic steam boilers and flywheels depict this phase.

This aided steam hammers for forging, locomotives and ships for transportation and

gave humans the power to do what could not be conceived before. This was Industry 1.0 Industry 2.0 was the second wave of Industrial revolution with organized labor force to achieve unprecedented economy of scale that came along with production lines.

This is when human standard of living improved along with change of social structure.

Automobiles, electricity, mass transport, air travel and

urbanization came into being.

Also came along the military industrial complex. Man reached moon and invented to harness nuclear power.

From the early seventies, the advent of electronics along with programmable algorithmic systems changed the way industry worked.

Thus automation brought in this third revolution.

Programmable Logic Controller (PLCs), DCS,

Robotics, Computers and integration with ERPs (software) brought in unprecedented levels of quality and scale along with lowering of production costs.

This is the present phase.

Industry has become ever more capital intensive and labour force has been largely replaced by automated systems. Organized retailing, consumer brands, global marketing and distribution networks came into

After Industrial revolutions of 1, 2 and 3, now we see another phase change in the mode of industrialization - Industry 4.0 Steam engine

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Mass production

Internet technology

Internet of things

December 2015

Drones taking up security surveillance and even logistics services. Customized medicines getting manufactured as per individual DNA profiles are in the making. This flexibility of manufacturing is a departure from the days of mass manufacture without sacrificing the quality and value. It is also making industry more service oriented than product based.

being with multinational corporations becoming the backbone of economy.

But now we see another phase change in the mode of industrialization. The main agent of this change being intricately networked systems on the internet backbone riding on a matured automation and computer industry. Few innovations standing out are the Internet of Things, Automated drones, Intelligent robots, self navigating automobiles, 3D printers, Smart grid, universal GPS etc. This change is leading to extensive use of networked information system with very small time constant of response.

Trends in industry: The present capital intensive industrial revolution fueled by mass production and economy of scale is about to be impacted. The benefits of “made to design” systems along with the cost advantages of mass

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production is being achieved for the first time. Recently I bought a computer where I could choose all the individual details of screen size, keyboard options, RAM, HDD and all other details and it was automatically manufactured and delivered at most competitive price.

This idea of production is proliferating. Days are not far, where we shall be able to choose from hundreds of car design in software, tweak them as per our preference and get it produced in flexible manufacturing systems.

With such smart manufacturing systems, the advantages of relocating factories at countries with lower wages shall get diminished as impact of labour wages shall continue to get lesser. Industry is also turning ever more service oriented in this scheme of things. If driver less cars become ubiquitous, owning a car may not be a priority when you can order a car service from point A to B at

any point of time without the hassles of maintaining it.

The next generation of smart air conditioners shall be able to talk to the smart grid for their energy consumption and small solar power plants shall become common phenomenon in synch with the smart grid. There can be differential tariff for an air conditioner in comparison to lighting load in such scenario.

In fact, days may not be far when an energy tariff may differ based on the setting of your room temperature.

Tyre manufacturers now have to keep a traceability of each individual manufactured tyre with respect to date and time of the machinery involved in making it all the way down to the rubber production plantation. This is not particular to tyres, but are becoming mandatory for most items requiring extensive networking of data.

Advent of the idea: Industry 4.0 is being

spearheaded by Germany.

China, Japan, South Korea and USA are also taking the lead, but rest of the industrialized world is yet to get going according to professor Detlef Zühlke, a lead researcher in the factories of the future.

Similar concept is also being talked about in US and larger English speaking industrialized nations as ‘industrial internet’ or ‘internet of everything’.

Almost all iindustries of the industrial world have recognized this and want to digitize their entire value chain by 2020. German industrial companies alone are investing EUR 40 billion for this transformation.

The concept hinges on the ongoing fourth industrial revolution based on a matured I.T infrastructure and the connectedness of everything on the internet with ever increasing bandwidth and reach.

Recently we saw that 1 billion (about 17% of humanity)

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people got connected to a single website (Facebook) in a day. With whole of humanity networked together, the threshold of a new industrial setup is on the making.

Early Signs: The early signs of a sea change is visible in the ways industries are run. Till date industrial efficiency depended on economy of scale and computerized process control to achieve highest value and quality. But today we see the same value and quality in small batches with the advent of flexible manufacturing and control.

We see intelligent devices directly communicating with each other giving values inconceivable before. Like driver-less cars intelligently interacting with road signs and other cars to practically eliminate chances of accident, reducing pollution and increasing efficiency, not to say releasing the burden of the driver. Drones taking up security surveillance

and even logistics services.

Customized medicines getting manufactured as per individual DNA profiles are in the making. This flexibility of manufacturing is a departure from the days of “one size fits all” or “mass manufacturing” without sacrificing the quality and value. It is also making industry more service oriented than product based.

Unidirectional urbanization shall hold little advantage compared to pockets of smart urbanization. People shall be able to do their jobs flexi time and without physically meeting at a place.

Innovation shall hold the key while the mass job market shall be more service oriented rather than production oriented.

Impact on Society:

Smart Factories of the future:

The major impact on society shall be the effect on organized workforce.

As in each past industrial evolutions, the type of jobs shall see a sea change. The concept of mass organized workforce that came into being with Industry 2.0 shall get disintegrated. Large number or people meeting at a place in precise time to make a process run is becoming redundant in view of Industry 4.0. The need to relocate production facilities to lower wage nations for mass production shall not hold much advantage with Industry 4.0.

The smart factories shall be integration of generalized production modules oriented and connected by software and communication system to achieve a definite product. Thus setting up of a production system shall be similar to loading some software available production modules, much like our laptop being connected with printer, or home theater or the like. The success of such systems also depends on common interface standards similar to what we have in internet like HTML5, PDF etc. Setting up of a factory shall be like choosing readily

available standard production modules and loading a suitable software among them reducing capital investment and time.

Industry 4.0 aims to achieve production-related advantages by creating a networked, flexible, and dynamically self-organizing manufacturing process for highly customizable products. It is expected to be accompanied by a paradigm shift that could justifiably be called the fourth industrial revolution. The result will appear to be revolutionary from today’s point of view, but ultimately it will involve a large number of development steps in an evolutionary process.

The Author Mr. Somnath

Sircar who graduated from IIT Roorkee and post graduated from IIT Delhi is the founder CEO (Director) of Algonics Systems Pvt. Ltd. Sircar is a member of Govt. of West Bengal sector committee on IT Hardware and Software. Sircar is a member (past president) of Rotary Club and involved in different social activities. He is also a member of IEEE.

The smart factories shall be integration of generalized production modules oriented and connected by software and communication system to achieve a definite product.

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MAIN FEATURE

“Acceptability of Automation Solutions needs to be improved” Sameer Gandhi Managing Director, Omron Automation India

OMRON CORPORATION is a global leader in the field of automation based on its core technology of sensing and control. OMRON’s business fields cover a broad spectrum, ranging from industrial automation and electronic components to automotive electronic components, social infrastructure systems, healthcare, and environmental solutions.

Mr. Sameer Gandhi brings with him an experience of over 24 years across multiple disciplines and vertical industries. As Managing Director, Omron Industrial Automation, he is instrumental in conceptualizing and executing strategies for the India business. Endowed with an agile personality and multifaceted skill- set, his responsibilities are to bring global best practices and technologies to critical Indian industries and steer the growth and expansion of Omron Industrial Automation in India. Mr. Gandhi explains the future of Automation in India to our readers, excerpts.

Automation is the key of global manufacturing today.

How far India has advanced in heralding Automation into manufacturing?

The industrial automation market has been witnessing a considerable growth over the last few years fuelled by many macro and micro level factors such as growing population, disposable incomes, ever increasing need of complying to global standards, the constant need for improving operational excellence at best ROI, desire for zerodefects, productivity & quality improvement , etc. As per varied market reports, the

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automation market in India is expected to have a CAGR of 10-12% during 2015-2020. The initiatives like Make in India & Skill India are surely expected to bring in further growth to the sector over the coming years.

Talking about the sectors and geographies, northern & western regions in the country are the key growth drivers owing to presence of many special economic zones and automotive manufacturing hubs. Other key segments which are expected to have a positive outcome on the sector are: Pharmaceuticals,

Food n Beverage, FMCG, Infrastructure and Engineering components.

One of the main concerns in India is acceptability for the automation solutions which is not up to the desired level (especially in the SME sector) as compared to many other international markets. But we can surely summarize that the picture is changing slowly but steadily and definitely though.

What are the new technologies that are driving significant advances in the area of Industrial Automation?

Some of the key technologies which have a huge potential to shape up the dynamics of the sector are usage of vision systems in quality inspection and utilization of Big Data in manufacturing processes. I believe that proper application of Big Data in manufacturing can lead to significant improvement in productivity as well as reduction in down-time and ensuring quality for the customer.

Omron’s latest technological innovation allows PLCs and vision systems to interact directly with the enterprise resource planning (ERP) layer, ensuring realistic

December 2015

Omron Robotic solutions and demos displayed at the Automation Centre at Mumbai

Omron Automation Centre at Mumbai

Big Data processing to improve productivity and aid predictive maintenance, and much more. Our Sysmac NJ controller can read and write, to and from a SQL server at high speed. One practical application of this trend is serialization or traceability, which is being adopted by the market.

Another very important emerging trend is Industry 4.0. A recent report by HIS technology forecasts that industrial automation is expected to make up the majority of the Internet of Things (IOT) by 2025, with Internet Protocol (IP)addressable devices as the key enabler.

Quality enhancement is one of the key elements of Industrial Automation. What steps your organization initiating to ensure quality products?

Quality has always been the prime focus area for OMRON. All the products that we manufacture and sell are in line with the global standards

Deceember 2015

like UL, CE, CCC, CSA, VDE and TUV. Our safety products come with IEC/ISO standards.

the same worker is skilled up to operate that new machine which comes in.

Automation has a concept that it results in lower staff addition which can result in huge unemployment. How far it is a fact and what are the alternatives to this?

What are the core manufacturing industries that apply Industrial Automation the most?

This is a myth. Automation does not lead to unemployment because it does not lead to deskilling of people. It is an enabler to improve productivity and reduce cost, which in turn spurs demand and provide employment to more people with higher skill sets. As the scale of the operations rise in size, the manufacturers have to bring in automation to increase the productivity of their manpower and relieve the workers from monotonous (and sometimes dangerous) jobs. This ultimately leads to a rise in production and a decrease in the cost to the consumer, which in turn spurs market growth and investment in another machine. In this way,

As mentioned above, Automotive, Food n Beverage, Packaging, Pharmaceuticals, and Infrastructure are some of the key industries leading in the application of varied automation technologies.

Where do you see India in progress with its counterparts in applying Industrial Automation into its manufacturing units in the next five years?

Along with the expected CAGR of 10-12% during 20152020 , as already mentioned , the market is expected to gain significant push via the initiatives like Make in India & Skill India. .

Factory automation in India is expected to be close to the automation level of the developed manufacturing

countries at least in sectors like pharmaceutical, F&B and automotive.

This will be driven by a combination of factors, but mostly, regulation, export requirements and the desire to position quality as a value differentiator.

What are the deficits India is facing when it comes to factory automation?

One of the basic challenges is the level of acceptance amongst end users to invest in something that is adding to the cost. Hence the focus on ROI takes centre-stage.

However, acceptability is going higher off late, which is good for the industry. Lack of skilled manpower is another challenge. An automation system needs the right set of skills right from the point of conception to deployment to maintenance which becomes very challenging sometimes.

This is also one of the reasons why we have invested in setting up three training centres and Automation Centre in India.

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39

MAIN FEATURE

ESPRIT 2015 to increase Productivity and Automation CAM industry innovator DP Technology Corporation released its new version of its pioneering flagship product ESPRIT® during March 2015. ESPRIT helps increase productivity for a full range of machine tool applications by generating more efficient toolpaths while also saving time by providing substantial improvements in computer numerical control (CNC) programming productivity. Besides increasing productivity, the release also provides many new and improved features specifically in the areas of intelligent machining, strategic machining, CAD-CAM data exchange and Cloud-Enabled CAM

Intelligent Machining Intelligent machining features in ESPRIT 2015 accelerates the machining process by providing new and unique 5-Axis cycles that reduce cycle time. This makes it possible to completely machine blades

in a single setup. ESPRIT’s

“ESPRIT 2015 offers unique

Communication Director of

5-Axis Blade Roughing tool

features in 5-axis to make

DP Technology. “ESPRIT 2015

motion is morphed across

complex machining more

blade roughing enables users

the blade from any size stock

efficient, allowing users to have

to remove material down to

shape to uniformly offset

more tool path options with

uniform stock around the

stock allowance so it can be

features like blade roughing

blade and eliminates the need

immediately followed by a

and chamfering.” said Cedric

to follow semi-finish cycles.

finishing cycle.

Simard, Global Marketing &

Users in the aerospace, energy,

ESPRIT 2015 5Axis Blade Roughing cycle makes it possible to completely machine blades in a single setup.

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December 2015

New Bottom Up roughing strategy in ESPRIT 2015, combined with ESPRIT ProfitMilling cycles, allows you to take advantage of large incremental cutting depths.

The new ESPRIT 2015 Bottom Up strategy produces a more accurate stock model in less time.

medical and automotive

the tool must enter through a

strategy helps take ESPRIT’s

productivity. ProfitMilling

industries will benefit the

restricted opening. The shape

ProfitMilling high speed

optimizes toolpaths with

most from these time-saving

of the toolpath is an offset of

material removal cycle to the

engagement angle, chip load,

operations for precision parts.”

the port surfaces, starting at

next level. The new Bottom Up

lateral cutter force and material

the surface and proceeding

strategy lets you attain a small

removal rate to massively

inward at a constant stepover.

residual stock height during

reduce cycle time and increase

the stock removal process.

tool life.

The Port Roughing cycle, another intelligent machining improvement in ESPRIT 2015, is a brand new 5-Axis cycle.

It creates a 5-axis roughing operation to remove the material inside an area where

Productivity Boost ESPRIT 2015 also includes features that increase machining productivity. The new Bottom Up roughing

Even more, it can be combined with ProfitMilling – our unique high-speed machining roughing technology – for a major improvement in overall

Strategic machining The strategic machining capabilities of ESPRIT 2015 have been expanded with

ESPRIT 2015 Conical Wrap Contouring allows one linear axis to remain at a constant value while the tool path is wrapped on the feature which is around a conical shape

The new ESPRIT 2015 5-Axis Chamfering strategy chamfers edges lying along a 3D curve.

Deceember 2015

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41

milling and their geometry

-- are now available through

automation capabilities for

generates lower cutting forces

ESPRIT FX data exchange from

multi-tasking machines with

in soft materials and unstable

Dassault Systemes CATIA,

mill, turn and drill capabilities.

setups which increases tool

Parametric Technology Pro/

Available for the Facing,

life. Barrel-shaped cutters

ENGINEER and Siemens NX/

Contouring and Pocketing

are now supported in 5-Axis

UG. The additional information

milling cycles, the new

Blade and Composite cycles.

obtained from these geometry

stock automation function

Barrel-shaped cutters provide

types can be easily manipulated

maintains awareness of the

a much better surface finish

to cover complex areas for

stock removed by previous

than ball end mills because

roughing operations or extend

operations to generate cutting

their geometry provides

surfaces to get a better finish

passes only in areas where

a larger effective radius

on edges.

stock remains. This function

of engagement, resulting

greatly reduces air cutting

in smaller cusps between

which in turn drastically

toolpaths.

completely redesigned stock

reduces cycle time.

CAD to CAM Additional strategic machining

ESPRIT 2015 provides another important improvement to shorten programming time by increasing the accuracy of automated feature

improvements have been

New data exchange features in

made by providing support

ESPRIT 2015 make it easier ever

Auto Chain support for solid

for slot mill tools in the Port

before to move information

faces, loops and edges lets

Milling and Composite cycles.

from your CAD system into the

you create chain features

Slot mill tools save machining

CAM environment. Three new

directly on solid models. In

time on operations as tee-

geometry types -- sketches,

addition, a redesigned wall

slotting and square shoulder

feature profiles and curves

feature recognition command

recognition. The enhanced

automatically recognizes the upper and lower limits of walls, even tapered walls, in a solid model.

Cloud-Enabled CAM ESPRIT 2015 allows you to select tools based on the features of your parts in minutes — saving you the drudgery of flipping through catalogs to find ideal tooling. With the ESPRIT MachiningCloud Connection, programmers have access to complete and up-to-date tooling product data, cutting hours of programming time by eliminating manual tool creation. ESPRIT 2015 simplifies the selection of cutting tools and automatically obtains the recommended ones.

For more details visit www.dptechnology.com

ESPRIT 2015 Barrel-shaped cutter support allows you to take full advantage of side tools and provides a higher quality surface finish.

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December 2015

Driving manufacturing processes of the future

7 – 9 April 2016 Helipad Exhibition & Convention Centre Gandhinagar (Near Ahmedabad), Gujarat, India www.spsautomation-india.com Platinum partners

For further details, kindly contact: Anand Nair +91 11 6676 2310 anand.nair@india.messefrankfurt.com Talat Shekasan +91 22 6144 5957 talat.shekasan@india.messefrankfurt.com Silver partner

Co-located shows:

Supported by

Deceember 2015

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43

MAIN FEATURE

‘RAMP’- First of its kind Real time & Automated Shop-floor productivity tracking monitoring solution

Ricoh India launches a fully automated real time shop-floor productivity tracking & monitoring solution ‘RAMP’. The new solution from Ricoh will transformthe shop-floor/ factory transaction reporting and will enable manufacturing companies achieve higher productivity by connecting shop-floor to the top floor through real time monitoring and reporting of machine performance, productivity, downtimes, production output, etc.

44

The solution will bring a lot of

and compiled, that is made

relief to the manufacturing

available the next day, and is

sector in India, where the

often inaccurate or doctored

most crucial part, i.e. the

, resulting in poor decision

shop-floor is still isolated from

making. Most of the CXOs are

the rest of the IT network in

unable to monitor progress

the organization. Due to this,

of productivity initiatives and

the most crucial shop floor

processes. The complexity

data on production quantity

increases when there are

and man-machine utilization,

diverse machines with mix of

etc.is manually collected

new and legacy technologies

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that are big impediment for any IT enablement on the machines.

‘RAMP’ also known as Realtime Automated Machine Productivity system is going to change all of the above, as it provides for an off-the-shelf hardware for data capture that connects directly to machines like CNC, Heavy

Presses, Injection Moulding Machines, Textile Machinery, etc. and capture signals on production & productivity, and a fully customizable reporting software for providing standard or customized reports on any device viz. desktops, laptops, hand-held, etc.

Reports on critical

December 2015

The new ESPRIT 2015 Bottom Up strategy produces a more accurate stock model in less time.

parameters like hourly parts count, machine down time, Total Predictive Maintenance (TPM) parameterslile- OEE, Availability of Machine (A), Performance Efficiency (P), Quality Rate (Q), and Maintenance Reports like – Downtime, Mean Time Between Failures (MTBF), Mean Time to Repair (MTTR), etc. are provided real-time, and are made available on email, desktop or web. The solution also provides for the email or SMS alerts on critical events like production

shortfall, high rejection rates, critical machine breakdown, operator absenteeism, etc.

The solution is going to provide a host of benefits to the manufacturing companies like tracking of production quantity, improved machine availability, enhanced operator productivity & efficiency, stream-lined shop-floor transaction reporting, tracking & improving, OEE, etc.

For more details visit www.ricoh.co.in

Ricoh India presents a one-stop solution to all the concerns through RAMP soulution. Connects shop-floor to top floor through real time monitoring &reporting

More than just a pretty face.

Expand your options with Graphite® HMIs.

Connect more devices with plug-in modules and support for 300+ protocols.

Red Lion’s Graphite advanced operator panels are the industry’s first rugged HMI solution to combine flexible plug-in modules with built-in protocol conversion, data logging and web-based monitoring. From factories to extreme remote locations, Graphite HMIs enable customers worldwide to connect, monitor and control processes across a broad range of industries to meet all of your industrial automation needs.

Visit www.redlion.net/Graphite to learn more.

Download HMI Brochure

+91-9844876540 I india@redlion.net I www.redlion.net © 2015 Red Lion Controls, Inc. All Rights Reserved.

Deceember 2015

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45

FAIR MART

Enhanced Maintenance Practices leads to increase in Productivity Indian Maintenance Scenario

The productivity levels of SMEs operating in manufacturing industries across India is considered very low due to frequent equipment breakdowns, machine defects, as well as manpower inefficiencies, which result in increased expenses and ultimately lower competitiveness at the market place. One of root causes of this problem can be found in – improper/ in appropriate maintenance practices of machines and equipment (which are often times also outdated and need to be revamped), long set-up and tool change-over times, as well as losses due to corrosion.

Currently, India’s manufacturing sector contributes about 16% to the GDP, and India’s share in world manufacturing is only 1.8%.

This is in stark contrast to China; where manufacturing contributes 34% to the GDP and is 13.7% of world manufacturing – up from 2.9% in 1991.

India’s growth has been on the back of a booming services sector which contributes 62.5% of the GDP. These statistics clearly indicate that while manufacturing has not been the engine of growth for the Indian economy, it now needs to grow at a much faster rate.

With changing global realities,

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the manufacturing sector will need to be the bulwark of employment creation over the next decade, in contrast to current employment of only 9% of India’s working population. India’s long touted demographic dividend can only then be sufficiently exploited through the systematic growth of this sector.

An increase in exports of India manufactured products is imperative to achieve the desired growth rate in manufacturing. The share of manufacturing in India’s total merchandise exports has remained largely stagnant and was 61.5% in 2010-11.

Industrial Maintenance is of primary importance to the Indian industry. Due to lack of adequate maintenance practices and management of machines (knowledge of methodologies and practices) and operations, many firms, particularly SMEs have experienced deterioration of productivity levels (due to increased breakdowns, longer setup and changeover times), quality of products (increased defective products over a period of time) workplace safety, along with an increase in operational and maintenance costs rendering the industry uncompetitive in the long run.

Indian SME’s are losing at least 25-30% of their capacity by not following TPM practices.

Presently there are no studies to indicate the number of companies practising TPM in India. However, based on expert observations, the number of firms implementing TPM seems to be very meagre.

The productivity levels of Indian SMEs are generally rather low in comparison to firms situated in developed countries. The absence of the proper industrial maintenance practices and management can be identified as one of the main causes for this problem, as it leads to frequent equipment

December 2015

Due to lack of adequate maintenance practices and management of machines and operations, many firms, particularly SMEs have experienced deterioration of productivity levels, quality of products, workplace safety, along with an increase in operational and maintenance costs rendering the industry uncompetitive in the long run.

breakdowns and accidents at the shop floor. Statistics reveal that due to corrosion and its consequences, India’s industrial sectors are losing about 1.5 trillion Indian Rupees every year which is equivalent to 3.5% of GDP.The demand for corrosion free material is on the rise in high-end industries including oil and gas, energy and shipping, railways, ports etc.

The cost of corrosion is not just expressed in financial terms. Beyond the huge direct outlay of funds to repair and/ or replace corroded and/ or decaying structures are the indirect costs (natural resources, potential hazards and lost opportunities / opportunity costs). Indian Industry needs to get geared up front and empower itself to combat corrosion, which can be best achieved through a collaborative effort of various stakeholders (including

Deceember 2015

government and private sector).

Losses in production levels of 10-20%, defects of 5-10% and maintenance costs of 15-20% can be addressed by suitable practices of TPM methodologies. Damages due to corrosion and inadequate maintenance / operational practices lead to losses in production and unscheduled shut downs in plants and installations and more importantly, pose severe safety hazards.

Material corrosion is considered to be one of the life-limiting factors in production, manufacturing and infrastructure. As the requirements for improved productivity and cost effectiveness increase, combined with an increased attention to safety, activities related to industrial maintenance play an increasingly important role.

Cost reduction is an important issue facing the Indian manufacturing industries.

While many systems have been implemented to control costs such as total quality management and ISO standards, more needs to be done to address specific issues, which tend to escape the purview of such general systems.

To comply with continuously increasing buyer demands for high quality and reliability at competitive cost levels, SME suppliers in several manufacturing sectors are continuously and thoroughly assessed for price as well as the quality of their work. Buyers are looking for defects per million parts, which on average should not exceed a certain threshold.

As there is also a trend towards error free deliveries at all times, the challenge is not only to reach the demanded targets,

but also to achieve those without price increases, in the shortest time possible and to maintain them over the long term.

Experts estimate that enhanced maintenance practices could lead to an increase in productivity levels of 10-15% within a period of 1824 months. However, in order to materialize this potential, a wide-spread skill development programme is required, which builds the competences and capacities of industry and counterpart organisations alike.

Expertise in the area of Industrial maintenance are currently anchored within a very limited circle of experts across the country which is not sufficient to cover a wide range of companies and provide highly needed supports to the large number of SMEs which currently suffer from shortfalls in the industrial maintenance domain.

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47

FAIR MART

“IM Expo is directed towards promoting innovations and service solutions�

A Shivkumar Chairman, Industrial Maintenance Expo 2015 Industrial Maintenance Expo is a 3 day event being held from 18th December to the 20th December 2015 at the Auto Cluster Exhibition Centre in Pune. This event showcases products like various products and services related to Maintenance, Service and Care for the Indian Industry etc in the Industrial Products segment.

Mr. A Shivkumar, Chairman of IM Expo 2015 as well as the Chief Executive Ewac Alloys (A wholly owned subsidiary of L & T) share with our readers the new innovations awaiting at IM Expo and its significance.

Can you let us know what

corrosion India loses around

waits at 5th IMEXPO 2105?

$70 billion or equivalent to 4

The productivity levels of Indian SMEs are generally

48

per cent of its gross domestic product (GDP) to corrosion.

rather low when compared

To meet these challenges,

to firms situated in

maintenance has to use latest

developed countries. The

technology and management

absence of proper industrial

skills in all spheres of

maintenance practices

activities to perform its

and management can be

effective role in profitability

identified as one of the core

of the company. This event is

reasons for this problem, as it

directed towards promoting

leads to frequent equipment

innovations and various

breakdowns and accidents on

service solutions between

the shop floor. For example,

industrial professionals of the

statistics reveal that due to

respective areas.

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This Exhibition would Showcase & address the Technicalities of maintenance system & solutions to educate, create awareness and demonstrate the Technical features of the products, especially relating to maintenance, service & repair to the Trade & Industry.

second time, which is a

Why Pune, and the opportunities for the exhibitors?

area is home to a substantial

CII decided to host this expo in Pune for the

hub of manufacturing activity for the country.

With the large number of automotive plants, ancillary industries, small and medium enterprises, etc present in the region, our objective was to reach out to as large a population as possible. The dynamic and vibrant Pune presence of industrial maintenance organizations as well.

Through this series of Expo

December 2015

in the industrial clusters,

Confederation of Indian

maintenance leaders are using

Industry (CII) embarked

this unique platform to spread

on the skills journey two

awareness in terms of tools

decades ago with a set of

and technologies to more than

guiding principles for its skill

30000 workers across New

initiatives, CII has been a

Delhi, Pune & Coimbatore

catalyst in the way India now

during the last 5 years.

looks at skills. It is well known

The awareness program organized to learn best practices in Maintenance during the expo?

The program today is a collaborative efforts of several divisions of CII. CII Institute of Quality which imparts training on TPM by which we have helped 186 companies achieve maintenance cost reduction to the tune of 30% and productivity improvement by 1.5 times by applying TPM practices - which include Indian

that skill and knowledge are the fulcrums to a nation’s development and economic augmentation of any country.

Finding and keeping workers with the knowledge and skills to get the job done is critical in today’s workplace and it could be the determining factor in the success of the business.

Can you put some light on the new innovations expected in the show?

Oil Corporation, Chennai

The strategic role of

Petroleum Corporation, and

computerized maintenance is

Tata Steel Group, where TPM

to introduce new approaches

trained 3250 engineers.

and – most importantly – new

CII - Avantha Centre for Competitiveness for SMEs have imparted corrosion management services to 780 organisations and trained 1860 senior & Middle level managers and engineers.

tools to integrate all the employees involved in the process, whether internal or external, and enable them to interact with one another. Therefore it plays the main role in defining how human, economic, and

India with its increasing youth population (currently 60 per cent of the population are between 16 and 29 years) has an unprecedented opportunity to accelerate growth. However, to harness this opportunity and pave the way for a globally competitive workforce, it is necessary to

technical resources must

enhance skill levels.

remote access.

Deceember 2015

be coordinated in order to achieve the business goal.

The maintenance sector is going through new and innovative technologies like Innovative sensing solutions, Intelligent Condition monitoring, Cloud based

IMX 2015 Pune: Improve Maintenance Technique & Productivity CII has been instrumental in launching the quality and TPM movement in India; many Indian companies were successful in getting the coveted Deming Award and TPM awards from Japan, following the tradition and footsteps, through Industrial Maintenance Expo, CII intends to drive a Maintenance Movement in India.

Industrial Maintenance Expo is such delivery vehicle and an excellent platform for Industry technicians to know more about the ways and means of maintenance techniques and also address the challenges and the needs of the Industry.

The purpose of this expo is to demonstrate the latest maintenance tools and techniques to the industry and achieve overall improved profitability of the industry through better maintenance processes especially when the world looks at India as a place where productivity and quality are of highest levels with an objective of help companies.

Maintain a competitive advantage with existing assets, Improve performance of existing assets, Ensure the performance of new assets, Reduce costs to maintain and operate new and existing assets, Increase productivity and reduce downtime, Extend the life of aging assets and work smarter with fewer resources.

And identify - Latest Maintenance Technology, Servicing, Repair, Maintenance & Practices / Techniques, Repair Techniques / Standards, Latest Service & Maintenance Manuals & Tools on their usage, Efficiency & effectiveness Products, their features, applications, Benefits of usage

of Genuine Spare Parts, its benefits, etc.

With the focus on Capital Intensive Sectors namely: Engineering/Manufacturing, Power Plant, Petro chemicals and refinery, Textile, Energy, Chemicals, Cement IMX 2015 - Fifth in the series, the maiden edition was held in New Delhi in August 2010, which was inaugurated by Late Mr Vilas Rao Deshmukh, Hon’ble Minister for Heavy Industries and Public Enterprises, that was followed

by Pune in November 2011, Inaugurated by S Sunderasan Secretary, Ministry of Heavy Industries and Public Enterprises, Newdelhi as a concurrent show at IETF 2013 which was inaugurated by Mr Ambuj Sharma, Additional Secretary, Ministry of Heavy Industries and Public Enterprises, the last show held at Coimbatore in September 2014 was inaugurated

by Mr P Rathakrishnan, Hon’ble Minister of State, Heavy Industries and Public Enterprises.

This the series of show especially at the industrial clusters CII has been enhancing the awareness about Industrial Maintenance with the support of Ministry of Heavy Industries since inception.

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49

SUCCESS STORY

Voith aims to Kaizen-ize Manufacturing in India Voith Industrial services India(VIIN) with broad range of technical services under the belt, calls itself as “The One Stop Technical Service Provider” to the Indian Automotive Industry. It is working to build a better and more effective manufacturing environment by bringing the best practices in Plant Maintenance and delivering competitive edge to its customers by saving cost.

Jitendra Singh Jitendra.Singh@voith.com

Voith Industrial Services India (VIIN) is the youngest division of Voith Group in India. VIIN started its journey in 2010 with its first Paint shop Maintenance contract. In 5 years it expanded significantly providing Technical services for the automotive industry, auto ancillaries

and off highway equipment industries (Construction & Farm Equipment). Currently it operates at more than 25 sites, with more than 35 customers and with nearly 1000 employees in India working 24x7 at various customer locations.

With its unique KPI based

ownership driven model and drive to deliver benefit to the

have resulted in significant growth of Voith year on year.

customer by saving costs in

While automobiles and auto

the form of Kaizen, VIIN is

component manufacturing

getting appreciated for its

are the two most talked

increased drive for safety,

about business segments,

bringing best practices in

industrial services specifically

maintenance, implementing

directed at them seldom

innovative solutions in the

find serious takers. Vehicle

form of Kaizen. All these

manufacturing plants across

“To start something like this, one should know how an automotive plant runs. If one is willing to undertake a task, the foremost responsibility lies in the sense of ownership. Germans take ownership of what they do.

We are trying to inculcate that sense of ownership in the current workforce that is driving the automotive manufacturing setup in India. For example if an OEM tells us to take the ownership of an assembly line, we do that. In case if any issue arises, we are liable for it. We openly take the ownership of whatever we do.”

Sudhir Gurtoo Managing Director, Voith Industrial Services India

50

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December 2015

Robotics based maintenance services and Projects is a key focus area for VIIN

VIIN is the key and reliable partner in providing Paint Shop Maintenance services & projects solution

segments are the backbone

A strong Project &

/ polythene etc. Reusable

there will be someone from

of entire production and

Automation team offers

crates are definitely a pain

Voith Industrial Services.

demand-supply equation in

solutions such as BIW Jigs &

relief to the Indian Logistics.

He might be working on

the vehicle market. Work

Fixtures, Paint shop projects

These reusable crates help

breakdown maintenance or

stoppage or temporary

such as modifications,

in reduction of damages,

PM (predictive maintenance),

shutdown of a busy assembly

installations, Paint defect

better utilization of storage

he might be working on

line often leads to huge

analysis, Energy audits, Plant

space, reduction of multiple

production support services.

losses for the manufacturer.

audits, PLC Programming and

handling, reduction in

Our experts work at all times

To avoid such losses before

End to End solution in Utilities

scrap, saves overall supply

including the Sundays, 365

they occur, automakers rope

area for ducting, HVAC and

chain cost, better tracking

days in the year,” he adds.

in Technical service providers

Air Handling Units.

and monitoring, inventory

such as Voith.

VIIN also specializes to

VIIN the youngest arm of

provide production support

Voith group in India, focusses

services like Assembly of

on three broad service lines:

Wheels & Tires and Value

It offers KPI based

added assemblies.

management, easy packing and unpacking.

24x7 Service Sudhir Gurtoo, Managing Director, Voith Industrial

comprehensive services

Along with this they are

Services India, himself an

encompassing preventive,

providing ecofriendly

automotive industry veteran

predictive and breakdown

solutions to Indian Logistics

who has been serving

maintenance of production

by using “Reusable crating

the industry for nearly

shop which includes

solutions”.Currently a large

three decades emphasizes

Powertrain, Machine shop,

portion of automotive parts

that to ensure that the

Body shop, Assembly

supplier uses corrugated

production equipment

shop, Fabrication shop &

boxes to deploy automotive

operates smoothly across

Paint shop. It takes care

parts to the Original

various automotive plants

of complete operation &

Equipment Manufacturers

in India, VIIN maintenance

maintenance of Utilities

(OEM’s). These use & throw

experts are present at the

that includes generators,

non–reusable boxes are

respective (customer) sites

compressors, HVAC system,

mainly made of paper /

at all times. “If you visit any

HT substation, chillers etc.

cardboard / foam / wood

of our customer’s plant,

Deceember 2015

Giving an example without disclosing the name of his customer, Gurtoo says, that VIIN has deployed upto 70 experts from its Indian team inside an automaker’s plant to perform functions across a number of service lines.

According to him, plant maintenance alone can have a team of 10-50 experts deputed in three shifts, depending upon the size and requirement of the OEM on the shop floor.

Highlighting the importance of predictive maintenance, he says “in one such case we detected an early failure

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51

of a fan where a blade had developed a crack.

That could have possibly resulted into shutting down the production.

While we managed to save the damages and costs by fixing the problem before it occurred.”

Initial hiccups A big challenge which Gurtoo often faces is the time associated with returns on proven investments. “If there is a brilliant idea but investing in that can start paying back only after two years, the customers usually delay the problem or reject the same. My understanding so far says that the companies want to put money into the product specific areas as

a priority rather than the plant. In most of the cases where they are investing in the manufacturing facility, they wish to start reaping the benefits within the first two years,” he explains.

However, on the other hand, VIIN, which also provides industrial services to the growing tier one suppliers besides the OEMs, is seeing a trend where the latter are increasingly focusing on kaizen practices such as brainstorming new ways to cut costs, save energy units, reduce the waste of natural resources and other areas. Voith’s experts who spend considerable time on the shop floor (knowing the entire layout and flow of work) pitch in with new ideas.

These ideas are later studied,

The author Jitendra Singh is

analyzed and implemented.

currently working as Head

“Majority of these ideas

of Business Development

end up benefitting our

with Voith Industrial Services

customers,” he says.

pioneering the concept

Giving a connect to one of these ideas, he underlines that “press shop, paint shop (because of the room-sized owens) within an automotive manufacturing plant are energy guzzlers. Even the conveyors and big fans installed to take care of the air flow consume a lot of energy. We can tweak the existing setup to save up on the consumption of energy

of Production Process Outsourcing (PPO) in India. He is also responsible for Strategy formulation & roll out, Sales & Marketing and New Product development & introduction.

He is Mechanical Engineer & MBA with 24 years of rich experience of Automotive Industry, working in functions like Production, Projects, Service / Concept Marketing,

units, which are usually

Customer Support &

proven on paper. We have

Aftermarket. Before working

to ensure fix returns to the

with Voith he worked with

customer, our processes are

TATA Motors, Cummins

very methodical.”

and Eaton.

Service Portfolio includes various production support services including turnkey Project managment of setting up complete Wheel & Tyre assembly line

Operation & Maintenance of Utilities includes Compressors, generators, HVAC system, Chillers etc

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ON FACE

Make, Innovate and Skill India Haresh K. Sippy Managing Director, TEMA India

Mr. Haresh K. Sippy is currently the Managing Director of TEMA India and is a pioneer in design technology and fabrication methodology in the field of process equipment manufacturing. He is a visionary leader with strong business acumen to identify small opportunities that could have the potential for tremendous business growth.

Mr. Sippy founded TEMA India Limited in 1984 and quickly scaled up the company to become one of the largest manufacturers of Shell-&-Tube Heat Exchangers in India. He also holds Indian patent for ‘shrink ring’ technology pertaining to Screw Plug Heat Exchangers and is credited to turn the company into a global supplier of heat exchangers.

Mr. Sippy is an engineering graduate with over 35 years of experience in the field of Shell & Tube Heat Exchangers He is an active member of American Society of Mechanical Engineers (ASME) and Heat Transfer Research, Inc. (HTRI). He shares his experience with our readers, excerpts…

Tell us about the inception and the success journey of TEMA India.

Fresh after graduation in engineering, I ventured successfully into manufacturing of Sampling Bombs which resulted in import substitution for ESSO refinery (now known as Hindustan Petroleum Corporation Limited HPCL) and Oil and Natural Gas Corporation Limited (ONGC). In 1975, I started LEO Engineering Works to

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manufacture Shell and Tube heat exchangers. In 1984 with Mr. Chetan Doshi and Mr. Khushroo Bulsara we formed a Private Limited company which got its present name TEMA India Limited in 2003, which designs and manufactures process equipment to Indian Oil & Gas and Petrochemical majors. In time it has became one of the largest manufacturers of Shell and Tube Heat Exchangers in India. Aided by experience in the Indian market and driven

by focus on continuous innovation, the company gradually developed its overseas business and today derives significant portion of its revenues from export of Shell & Tube heat exchangers to Middle East, Europe and US. What are the innovations going on in the field of Heat Transfer? Tell us about TEMA’s contribution in it?

Heat Transfer itself is a vast subject. Though for any Heat Exchanger whether

it is a simple Shell and Tube or a complex Screw Plug or a Helixchanger, the basic design remains unchanged yet there are constant innovations going on from the metallurgies of the materials to the manufacturing process keeping in mind their efficiency and ease of maintenance in service.

We specialise in design and fabrication of Shell and Tube HEx’s especially the High Pressure High Temperature Screw Plug type Heat

December 2015

TEMA India Limited designs and manufactures process equipment to Indian Oil & Gas and Petrochemical majors and in time it has became one of the largest manufacturers of Shell and Tube Heat Exchangers in India.

exchangers and majority of those are used in Refineries where dirty service is a rule.

Our proprietary design has made onsite maintenance easier where shut down times are minimal and are very critical.

of heat exchangers. We are in the process of developing another proprietary technology which also will be patented soon.

Can you brief about your products and services?

Our market segment is very wide. It covers Refineries, Petrochemical plants, FPSO, Fertiliser and Power plants as part of the energy sector which includes Process Licensors and EPC contractors world-wide.

Although TEMA specialises in Screw Plug/Breach Lock heat exchangers, it designs a wide range of heat exchangers for all type of fluids and services, Shell and Tube exchangers/ reactors, Rod-Baffle heat exchangers, Helixchagners, SAC Condensers and HighPressure/Low-Pressure Feed Water heaters.

Your latest innovations?

We already have a patented design for added steel on channel barrel for Screw Plug HEx’s which makes maintenance hassle free and thereby solving the most critical problem faced in the maintenance of these types

Deceember 2015

What are your major markets?

Who are the major clients of TEMA? All major refineries like HPCL, BPCL, IOCL, Reliance, Essar, MRPL, NRL, CPCL, reputed fertiliser companies like Kribhco, GNFC, IFFCO, NFL, Chambal, power giants like NTPC, engineering service providers like EIL, TOYO, UHDE, Technimont, Technicas, CB & I, Petrofac, CTCI, Chiyoda, Technip, Jacobs and end users like KNPC and Petrobras - are on

our prestigious clients list.

What is your annual turnover?

The company shall achieve a turnover of 300 crores this year and plans to raise this to 500 crores by 2017.

Can you brief about your manufacturing facility?

We have three manufacturing facilities. They are as follows: 1. Tema Achhad (Unit-I): Maharashtra ASME U, U2, S, R and NB certified. It is located on the Mumbai-Ahmedabad National Highway No. 8, approx. 150 kms from Mumbai & 20 kms from Vapi in Gujarat.

2. Tema Kherdi (Unit-II): Union Territory ASME U, U2 & NB certified 3. Tema Panoli (Unit-III): Gujarat ASME U & NB certified The total covered area is 50,000 sq. meters. The installed manufacturing capacity per month is 15,000 metric tonnes and can

handle various materials of construction like CS, SS, AS, NF, CLAD, DSS/SDSS. The machining facilities are state of the art with deep hole drilling machines equipped with BTA technology which can drill upto 1500 mm in horizontal axis, we have successfully drilled upto 750 mm on job and cleared mock-up of 1000 mm.

The facilities are equipped to undertake all types of welding – GTAW, SMAW, GMAW and SAW. Moreover TEMA is capable of manufacturing critical equipments involving overlaying of materials such as stainless steel, Duplex and Nickel alloys.

It is well supported by welding stations capable of overlaying using GMAW/SAW and strip cladding.

The highest crane capacity on a single hook is 185 MT which can be augmented to

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lift 235 MT. Your take on ‘Make in India’.

The only way we can sustain our growth rate is to Make in India. This will enable us to increase our employment and thereby the buying power. Moreover as we produce more we reduce our dependence on imports and boost our exports. We also have the advantage of having largest youth population in the world that needs to be employed, that’ll only be possible when we train our manpower. That’s to say Skill India and Make in India go hand in hand..... one is incomplete without the other. Although we Indians are a talented lot we are not industrious. We are quite lazy in our ways. The only place we need to ape the west is in their work culture. What’s the difference between the Indians at the highest levels abroad and us? Only the work culture. We too need

to adopt their Work culture, but not necessarily their technology. We have more than enough talent and with perseverance we can acquire experience. This is the path to innovation. The reason we are still dependent on technology from the west is because we do not have faith in our capabilities - our youth.

We rather use the short cut of importing technology. Unless there’s a technology tie-up with a firm abroad, we are not willing to take chances. We chose to remain dependent.

We call ourselves a free country we celebrate our Independence Day then why are we so dependent? Why don’t we allow home grown technology to flourish? Why don’t we have confidence in ourselves? Because we are insecure.

Not any more.

Today we have the backing of the Government, this was never there before. The

slogan “Innovate in India” sounds like music to the ears.

Our youth, our scientists and our engineers are now being encouraged to apply science to produce home grown technologies Yes Innovate in India.

Make in India... Innovate in India...Skill India...This combination is sure to wake up the Sleeping Giant.

The Giant must have stirred in his sleep to make his presence felt and the world noticed... what happens when the Giant sits up?

Suggestions, to the budding entrepreneurs in the field of Heat Transfer.

As stated earlier Heat Transfer is a vast field, Shell and Tube covers the largest area in the field. Heat transfer is one of the most important industrial processes and needs a heat exchanger for heating or cooling. Efficient

addition, removal and transfer of heat from one process stream to another is essential in any industrial facility. Heat exchange requirements can be in every segment starting from food storage, refrigeration, airconditioning, automobiles, oil & gas, fertiliser, pharmaceutical and power generation which in itself is a very big area – right from solar, thermal and nuclear. With such a vast spectrum it is very important to know which field one would like to get into as all the fields are lucrative and the approach methodology is different for each. Further I along with likeminded people is setting up Heat Transfer Society of India (HTSI). The membership of the society will be available for a nominal fee for all the budding and experienced engineers in the field. The society would work towards knowledge sharing, benchmarking and establishing codes and standards pertaining to Heat Transfer.

Under the aegis of Mr. Sippy, TEMA transformed into a firm which provides end-to-end solution in process, thermal and mechanical engineering. TEMA simplifies complicated designs to designs which have minimal maintenance. TEMA manufactures all types of Heat Exchangers and also provides in-situ operational maintenance and breakdown repair services.

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MAIN FEATURE

Smart Lighting: Showing the way for Smart Cities Given how they save important resources and curb energy as well as maintenance costs, smart lighting systems can serve as the perfect trigger to get the Smart Cities programme going, since this is also based on a similar agenda of saving costs and resources on consistent, long term basis

VP Mahendru vpmahendru@eonelectric.com

It was the ancient seers who revealed that light comprises the original source of all existence within the cosmos, which gradually led to the evolution of the universe as we know it. As the NDA Government revs up plans to create 100 Smart Cities, light or, more appropriately, smart LED lighting systems could lead the way in developing these Smart Cities across India.

Smart cities are meant to make life more efficient, safe, graceful, sustainable and less expensive via the use of digital technology that saves energy and minimises usage of resources. Since smart LED Lighting systems do precisely this, their usage in Smart Cities is integral to them. With energy

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efficiency and sustainability emerging as universal buzzwords to combat the dangerous consequences of climate change, the world is discovering the advantages of switching to LED technology from CFLs and other forms of conventional lighting. As CFLs contain mercury, they can be extremely dangerous for people and the environment in case of accidental breakage or during disposal of CFLs after end of its life.

to maintain and safer to

investments in planning,

use too. Moreover, unlike

creation and maintenance,

traditional lighting systems,

smart LED Lighting systems

LEDs could integrate sensors

can lead to annual savings

and remote controls. As a

of around 30% through

result, individual LED Lights

lower energy consumption

can be switched “ON”,

and minimal maintenance

“OFF” or “Dimmed” and

expenses. Of course

“Brightened” automatically as

compared to conventional

per pre-programmed or as per

incandescent lamps, LED

convenience, depending upon

lamps save 80% electricity bill.

Efficiency and Savings

lower lumen depreciation,

requirements during varying hours of the day or in different seasons. Additionally, LEDs ensure improved visibility, more focussed light, minimum

Although LEDs need a little more initial investment compared to conventional lights, long life and many other associated benefits of LED Lights make them more cost effective since they are more energy efficient, last much longer, are cheaper

wasted illumination and are an instant source of light, apart from lower electricity bills.

Apart from the above, smart street lighting can be integrated with intelligent systems such as traffic light controls, closed circuit security cameras, digital signage and electric vehicle charging stations, among others. But for this to happen, smart lights

By using LEDs in all streets,

need to be based upon open,

homes and offices of Smart

adaptable systems, rather

Cities, tremendous savings

than closed, proprietary ones.

are being ensured. Since each

Through open systems, smart

Smart City will need immense

LED Lighting could become an

December 2015

Smart cities are meant to make life more efficient, safe, graceful, sustainable and less expensive via the use of digital technology that saves energy and minimises usage of resources.

integral part of the Internet of Things (IoT) or, as some call it, the Internet of Everything.

Accordingly, it’s clear that the emergence of Smart Cities will give a great fillip to the LED Industry and allied smart system sectors to make them a fast track ground reality. Solar and other renewable energy sources could substantially benefit from the needs of Smart Cities, since the use of clean, sustainable resources and raw materials would be one of the pivots of this programme.

For example, Smart Grids could act as the hubs of the power network within Smart Cities, whereby energy from diverse sources (conventional electricity and solar power) could be integrated and combined on the Grid for subsequent distribution within the city’s

Deceember 2015

electricity networks.

IoT-ready Devices Similarly, lighting and other devices would need to be IoT ready to form an intrinsic part of the Smart Cities programme.

Besides lowering overall costs for various utilities, IoT-ready systems would make operations more efficient, smarter, safer, sustainable and innovative.

Being connected to an IoT Grid or Cloud, comprehensive data could be garnered as per the programming of each device.

Decoding of this Big Data will foster proper understanding about the peak hours of use and promote intelligent usage so that wastage is minimised and savings optimised. A lighting, security or water system connected to an IoT grid can increase savings of that particular resource, leading to lower overall costs. In this manner, Smart Grids reduce transmission and distribution losses by monitoring daily

electricity usage and quickly detecting any loss / leakage during transmission or through theft of power – not so un-common in India.

Therefore, the more the number of devices connected to a Smart Grid, the greater will be benefits and savings in resources as well as costs.

Such smart systems will be a great boon for lighting, power and other allied utilities and companies, who will benefit immensely from regulated usage and minimal loss of resources, leading to greater profitability for all stakeholders.

The success of such smart systems will make certain the Government’s Smart Cities programme forms part of its ultimate success story, propelling India faster into the league of developed Nations.

The author V P Mahendru, a graduate from Delhi University, is a dynamic and energetic

personality well known in the business and social circles.

He has been the President of Indian Electrical & Electronics Manufacturers Association (IEEMA) for the year 2001-02; President of Rotary Club Jalandhar; President of Northern India Switchgear Manufacturers Association (NISMA); President of Federation of Engineering Industries of India (FEII) and others. He is also member of the Governing Body of the Bureau of Indian Standards (BIS/ISI) contributing to the strategic policies for formulation and implementation of Indian Standards for various electrical and electronic equipment.

He is an executive member of various policy-making bodies of Government of India, including the Central Consumer Protection Council of India, National Productivity Council, etc. In 1958, he promoted Eon Electric Limited for manufacturing and marketing Electrical Distribution and Safety Equipment.

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FEATURE ARTICLE

Tribological Wear Analysis This article relates to the application of metal cutting tools and the loads generated in machining processes. This article explains interactions between the cut chip and the tool via the theories of tribology, a relatively new area of metalcutting load analysis. Tribology studies how surfaces in contact with each other interact at certain temperatures and pressures.

Patrick de Vos seco.india@secotools.com

Toolwear theories In a metal cutting operation, a tool deforms the workpiece material and causes it to shear away in the form of chips. The deformation process generates heat and pressure, loads that eventually cause the tool to wear out or fail. Traditional wear theory says the failures result from friction between the chip and tool, which are in contact but not attached to one another.

Recent research into cutting tool failure mechanisms, however, has determined that the pressures and temperatures in metalcutting, especially those generated when machining high-performance workpiece materials, are such that traditional wear theory does not fully describe what occurs at the chip/tool interface.

Tribological research has determined that the cutting process does not simply involve

a single shearing event and subsequent disconnection of chip and tool. In fact, secondary and tertiary connections and disconnections also occur. The chip shears away, adheres to the rake face and then shears away again before finally sliding off the tool. The main wear mechanism is repeated shearing, not friction.

Figures 1 and 2 illustrate the metalcutting process as described via tribology. Figure 1 shows preliminary deformation

of the workpiece material in Zone 5. Zone 3 is the separation zone, also called the stagnation point, because the relative movement of the workpiece material and tool at that area is essentially zero. Initial shearing takes place in Primary Shearing Zone 1, where the material shears off and the chip forms.

Then, in Secondary Shearing Zone 2, the chip is in contact with the rake face. The high pressures cause the chip to adhere to the

Preliminary Deformation In Zone

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December 2015

Different Wear Phenomena

rake face of the tool.

Figure 2 provides a closer look at the action in Zone 2. In Zone A, the workpiece material presses against the cutting edge with extreme force and begins to stick to the tool. In Zone B, the material adheres to the rake face. In Zone C, the chip shears away from the rake face and slides across it, ending contact between it and the tool.

Figure 1 also shows secondary shearing on the tool flank in Zone 4. The same shearing and adhering sequence that occurs in Zone 2 on the rake face also

happens on the flank. The events in Zone 4 produce flank wear, which is more predictable than the rake face wear in Zone 2 and is relatively harmless. In some workpiece materials, however, shearing on the flank face results in surface hardening or work hardening that has a detrimental effect on the cutting tool and workpiece.

Built-up edge Adhering of workpiece material to the tool rake face begins in thin layers and builds as further layers accumulate. This process can lead to a negative

phenomenon known as built-up edge. If a significant amount of material accumulates on the tool, it can change the profile of the cutting edge. The built-up material can also break off and damage the edge. In perhaps the worst case, the edge buildup may be deposited on to the workpiece. In any or all of these situations, edge buildup makes the cutting process unpredictable and uncontrollable. The main focus of tribology is learning what causes built-up edge and what can be done to minimise the problem.

Two aspects of the cutting process contribute to attachment of the chip to the rake face. One factor is the very high pressures and temperatures that exist in the cutting zone.

The other factor is the relatively slow speed of the chip across the tool rake face, beginning with zero motion at the stagnation point. When two materials are in contact with each other under high pressure and temperature, and move slowly, the conditions are prime for them to adhere to one another and for built-up edge to form.

Minimising adherence and the

Built-Up wwEdge

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61

chances for forming built-up edge involves reducing the contact time between the chip and the rake face. The most straightforward solution is to increase the cutting speed and apply a sharper tool. Faster cutting speeds reduce the time the tool and workpiece material are in contact with each other.

The resulting higher process temperatures can also reduce the strength of any edge buildup or eliminate it entirely. The sharper tool has a higher approach angle that forces the chip to travel a longer distance over a set period of time, i.e. move more quickly.

occurs but has not been a critical problem in familiar materials such as higher-carbon steels.

Application of correct machining parameters generally eliminates adhesion and prevents built-up edge. Further, there is no issue in extremely short-chipping materials such as cast iron. Longchipping materials, on the other hand, automatically produce longer contact time between the chip and tool, creating more risk for adherence between them. When machining materials such as low carbon steels and aluminium, the possibility of built-up edge is greater.

Material tendencies

Built-up edge is most prevalent when machining materials with high ductility, high adhesion tendencies and abrasiveness. A prime example is the family of aerospace and energy industry materials encompassing titaniums, nickel-based alloys and heat-resistant metals.

Additional factors promoting

Tribology has gained attention recently because the possibility of built-up edge formation is much greater in workpiece materials that were not commonly machined 20 years ago. For example, the phenomenon of built-up edge

edge buildup are the high pressure and temperatures that are generated when machining these tough alloys that have poor thermal conductivity.

And in general, cutting speeds for these materials are usually slower than average.

and rake face and thereby reduce the chance for adhesion.

Neither approach is fully proven, and in some circumstances either can be effective.

In addition to maximising cutting speeds and tool sharpness, there are approaches to controlling built-up edge that focus on the surface condition of the tool.

Somewhat surprisingly, there are two essentially opposing schools of thought on the subject. One approach says that if the surface of the tool is smoother, there will be less energy generated as the chip glides over the tool face. Lower temperatures and less contact reduce tendencies for built-up edge. Contrary to that theory is the concept that a rougher tool surface, formed with ridges or features on the scale of microns, will result in less contact between the chip

The research and theories of tribology, and the process and tool technologies developed to deal with issues such as built-up edge (see sidebar), focus on the goal of producing machined surface quality that meets customer requirements.

Next to dimensional and shape requirements, surface roughness is very often how part quality is defined. Especially in aerospace and nuclear applications, surface finish is a top priority because machining imperfections can represent the origin of cracks in critical aircraft and power generation components.

Conclusion: progress via tribology

Built-up edge will result in poor surface finishes and a need to

Relation Between Surface Texture and the Machining Process Physics

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December 2015

View of a Chip Segment

change tools frequently. With efforts including tribological research, progress has been made in limiting the occurrence and effects of built-up edge. The progress can be quantified in terms of cost to performance: specifically, how much it costs to generate one square millimeter of correctly machined workpiece surface.

Over the last five years, the cost-to-performance ratio for finishing titanium has improved by close to 20 times. Advances in both cutting tool materials and tool geometries have contributed to the success, but most important are carefully developed combinations of the two. Knowledge of the tribological mechanisms involved in tool application can enable machinists to control phenomena such as built-up edge and produce desired surface finishes at lower costs, thereby maximising productivity and profitability.

Sidebar: Application of tribological findings Tooling engineers apply the findings of tribological research in the development of tools and machining processes. On the process side, application of higher cutting speeds and sharp cutting edge geometries is effective in controlling formation of built-up edge in many circumstances. Other tool geometry choices, such as use of positive rake tools, can help direct cut material away from the workpiece.

Tool coatings are a proven way to reduce adhesion of workpiece material to the cutting tool. Lubricious coatings such as TiN have traditionally been used to ease chip flow in steel machining, as have diamond coatings in aluminium machining applications.

Recent development efforts

Deceember 2015

put strong emphasis on a coating’s role in minimising edge buildup. For example, the newest generation of Seco’s CVD aluminium-oxide DuratomicŽ coating is based on tribological principles.

Development engineers manipulated coating components in response to expanded knowledge of the interactions between the chips and the cutting tool.

Another example of Seco coatings aimed at controlling built-up edge is the new silver PVD uni-coating developed for MS2050 milling inserts.

The coating has high heat resistance capabilities and also practically eliminates the occurrence of built-up edge when cutting sticky materials such as titanium. With the absence of built-up edge, the inserts last about 50 percent longer and run at much higher cutting parameters as compared with existing tools.

At the leading edge of tribological research are efforts to make phenomena such as edge buildup positive contributors to machining productivity. In some cases, a thin layer of workpiece material on the surface of the cutting tool can slow the progress of wear. The challenge is to limit this tool protection layer to a thickness that does not affect tool geometry and also does not separate from the tool surface.

Continual introduction of new high-performance alloys that pose increasingly tougher machining challenges make tribological research a dynamic field. Developers of cutting tools and machining processes are using the new perspective provided by tribology to respond to and solve the challenges in innovative ways.

For further details visit www.secotools.com/in

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MANUFACTURING EXCELLENCE

Focus on Corporate Social Responsibility Managing a SME in India - Part 36

As a continuation of last article, we will discuss on few more points on Corporate Social Responsibility (CSR) and how to manage SME’s better in India. CSR is a voluntary action by the companies to take of society above that of meeting minimum legal requirements. Through a law by the Government, companies are forced now to look at CSR more seriously.

P S Satish gotopssatish@gmail.com

48. Focus on Corporate Social responsibility (CSR) – Part 1 We notice that sometimes it becomes a fashion to talk about environment, Green and corporate social responsibility.

It is important to understand the spirit behind this and see how we can contribute in this area. Contribution here is not meant in terms of donating some money to some schools or orphanage that too among lot of publicity to reduce the guilt of having spoiled the environment and made money unethically. In this article, we try to discuss in detail about CSR and how companies can really initiate and support for the bigger interest of the humankind.

In any industrial magazine or blog today, one key topic today is about Volkswagen (VW). It is about how a company of decades old could tamper the software to cheat the regulatory bodies and

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Customers. With this act, they also eroded long standing trust. Question that comes now is – Did they act responsibly?

Were they legal?

Answer looks like no to both the questions.

VW claims of supporting poor and society by lot of contributions through NGOs and foundations. Have they fulfilled CSR obligations?

Can we call an act which was done to gain market share and profits at the cost of environment and not following legality a CSR? What is missing in VW is missing alignment of thinking and doing. There was a monkey sitting on a tree close to the river. There was rush of water in the river for some reason and monkey saw one of the fish was struggling. Monkey thought of saving fish and immediately it rushed down and brought up fish from

water. Naturally fish died after few minutes. Monkey’s intention to save fish was good but the act was bad. One basic principle of CSR is to think or do the things in correct way and results will be right for all concerned.

Look at business ethics code of ABB – “ At ABB performance is measured not only by the results achieved but also how these results were achieved “. Similarly look at Philosophy of Toyota (First of 4Ps of Toyota. Other 3Ps are People, Product and Process) –“Toyota is a vehicle to add value to Customers, Employees, Shareholders, community and society at large”. When the companies are driven by core values to take care of employees, society and environment and takes action accordingly, they are automatically doing CSR activities.

To understand CSR better

and how CSR came in to more focus, we need to understand ‘Sustained development’.

Every company wants to grow.

There is nothing wrong in it and it is necessary to provide a better standard of living to the employees and make more profits. But question is growth at what cost? Should we grow spoiling the environment, exploiting the employees, not following law of land and not caring for society? To answer these conflicting questions the word sustained development came in picture meaning, ‘Company’s development by contributing to economy, doing business in an ethical way, taking care of the employees and families, concerned about environment and taking active role in improving society’.

To put sustained development in a simple way, companies should focus on triple bottom lines. That is Profit (Economic), Planet (Environment) and People (Society). Anyway,

December 2015

Environment Society

Profit

Sustainable Development

companies will focus on bottom line Economics and other two factors namely Environment and society is likely to be neglected. Any activities towards these two later factors may be called as CSR In fact, CSR is a voluntary action by the companies to take of society above that of meeting minimum legal requirements. Through a law by the Government, companies are forced now to look at CSR more seriously. Companies are also forced to take look at CSR for following reasons – • Consumers and Investors are expecting organizations to behave more responsibly • Consumer awareness on environment and ethical aspects • Legislations to protect environment • Acceptance of legal and best practices globally Corporate social responsibility is also called corporate citizenship, corporate conscience, corporate responsibility, corporate social performance, sustainable responsible business and

Deceember 2015

responsible business. Of all these, the word CSR is most popular.

environment for a better tomorrow and for sustained development of the country.

on external stake holders and not to the employees of the company

CSR is summation of economic responsibility (required), legal responsibility (required), ethical responsibility (expected) and philanthropic responsibility (desired).

Let us look at CSR Act 2013 which is done basically to institutionalise philanthropy and accountability.

Activities should not be in the region of operations of the company

CSR Act 2013 in India Many companies like Tata, Bosch have been doing CSR activities for decades much before any Act came in picture.

In fact, if we take our former kings, you will find about their concern for welfare of citizens, following right path, respect for law, collecting only taxes which are appropriate and providing wells & roads in the town etc. That means giving back to society is in our blood. But as more companies came in picture, faster growth of population, unhealthy competition and dwindling resources made Government of India to remind companies of their responsibilities to society through so called CSR act that came in 2013. Through this act, Government feels that companies can support them to educate society, protect

For which companies CSR Act is applicable?

Contributions to funds such as PM relief fund is considered as CSR

Companies meeting any one of the following criteria –

Actions to be taken by the companies

o Having net profit before tax (PBT) of at-least 5 crore Rupees in a financial year o Net worth of at-least 500 crore rupees o Turnover of at-least 1000 crore rupees in a financial year

- Need to establish CSR committee - Set CSR activities - Report in financial statements - Companies can also carry out activities through a foundation formed by the company specifically set up for this purpose

If a company meets any one of the criteria, then they have to spend at-least 2% of companies average Profit before tax for the previous 3 years.

Allowed CSR activities under the CSR Act 2013 - Training - Education - Sanitation - Environment sustainability Some guides from the Act Expenditure must be spent

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.

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TALENT MANAGEMENT

Interviewing Essentials for Managers Interviewing is really more art than science and, all-too-often, prospective candidates who look good on paper and ace the interview process completely choke once they actually get the job.

Pavan Sriram pavan@ittige.com

Making the wrong hiring choices is costly and time consuming for organizations of all sizes. Bad hires are more than an inconvenience: they’re expensive. According to a recent 2015 research from CareerBuilder, 41% of companies say that a bad hire costs them three times their salary package.

Conducting successful

interviews is one of the traits that a good hiring manager must possess and while doing that he must remember that it isn’t simply checking off a list of job requirements, but to see the person behind the resume.

Effective and efficient interviewing requires advanced preparation and a structured approach. In addition to carefully constructing job-

related questions, managers must ensure organisational protocols and must also make certain that their assessments and recommendations remain unbiased.

How can managers better their chances of making a good hire?

Unlike HR, the majority of hiring managers have had no formal interview training. There

are no interview courses in any MBA or general business or university programs that I’m aware of. For the most part, they conduct interviews so infrequently that they have no chance of developing the skill on the job.

At ITTIGE Learning, we help clients use the Outcome-Based Interviewing (OBI) process to facilitate managers on how to

An Interview isn’t simply checking off a list of job requirements, but to see the person behind the resume

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Effective interviewing requires advanced preparation and a structured approach

structure an interview making it more job focussed.

In this article, I want to make a modest attempt to share fundamental tips outlined below that will help you and your managers to hone your interviewing skills and improve the chances of choosing the best people for the job. a. Structuring the interview Interviewing managers may mistakenly use a job candidate’s resumé as a guide for structuring the interview.

Generally, the resumé only provides information the candidate wants to reveal.

Following the resumé throughout the interviewing process allows the candidate to control the interview, not the interviewing manager.

Managers must establish a set structure, to be applied consistently, for each interview to accomplish efficient and accurate interviews. b. Set the Tone Interviewing managers may set the tone of the interview by first greeting the candidate and then engaging the candidate in casual conversation to create a calm and relaxed atmosphere.

Deceember 2015

Comfortable and secure candidates may communicate more honestly.

They may ask about the person’s hobbies, interests, travel, or city of residence.

However, they must remember to avoid sensitive areas that the candidate doesn’t want to reveal early on in the interview.

The formal interview may then begin through a simple transition question, such as, “What do you know about the organization?” or “How did you hear about this job opening?” c. Provide an Overview Managers should provide the candidate with an overview of the interview process. For example, how the interview will proceed and what will be covered - job experience, education, interests.

Additionally, a comprehensive overview will explain that after discussing the candidate’s background, the manager will ask for information about the job, the organization, and answer any questions the candidate might have. d. Review the Job Before going in for the interview process, it is very

important that you define the position well. You will have to mention the skill, required experience and KRA’s of the job, so that the candidate knows what is expected out of him or her in the interview process. However, they should be careful to limit comments to the specific facts about the job as it currently exists. e. Discuss and Probe In discussing a candidate’s work experience, the interviewing manager should ask prepared questions first, following up any responses that deserve further probing.

A good hiring manager is not the one who asks the correct behavioural questions; instead a good hiring manager is one who makes note of the answer of the candidates and probes further to get more out of the candidate. f. Candidate’s Interests and Self-Assessment After discussing a candidate’s education and work experience, the manager may then ask a few questions about a candidate’s activities and interests to get a broader perspective. Candidates may also be asked to

provide a self-assessment, summarizing personal and professional strengths, as well as “developmental needs” or qualities that the individual might want to change or improve. g. Closing the Interview In the final portion of the interview, the candidate should be given an opportunity to ask questions about the organization and the job. Managers should thank the candidate for the time spent on the interview and keep them informed of the next steps in the hiring process. Unless your organisation is not able to match the job criterion for the candidate, managers must be transparent with their inputs and make the candidates understand that as well.

I look forward to hear from you at pavan@ittige.com on how you are creating an interview culture within your organisation by developing manager’s assessment skills that lead to wise hiring decisions.

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.ittige.com

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67

MANAGEMENT

Specialists or Generalists: who will have Advantage in 2016?

When it comes to determining valuable assets at work, employees come to mind first. And then we have to ask, who would bring in success — the person who knows how to wear many hats well, or the person who has mastered a specific skill? For example, web design and development is one such niche that demands complete dedication and in-depth knowledge of the latest tools and practices. There are pros and cons to both specialists and generalists; the deciding factor is how their skills are utilized.

Sonia Chugh soniachugh21@gmail.com

Specialists: pros and cons A specialist has chosen an area to specialize in after thorough evaluation and study. Not only do they have enough experience to produce desired deliverables, but they are also well-

equipped to handle future changes, should they arise.

Specialists focus on a single area, which can come with many pros.

For instance, specialist web designers know their platform well and

can produce the required outcomes. By default, they have the know-how necessary to deal with any hiccups along the way when it comes to a particular area of expertise. And from a business perspective, a specialist web designer,

developer, or quality analyst generally seems more marketable and has greater success selling their services.

However, from an organizational perspective, hiring a specialist is not always the ideal solution by

From a business perspective, a specialist web designer, developer, or quality analyst generally seems more marketable and has greater success selling their services

Generalists enjoy better chances of success than specialists because they always have a variety of services to offer

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Picture Courtesy: @SoniaSpecialist

default. At times, the work may slow down, or the work in a particular technology may taper off. This is an instance in which a specialist may feel the need to draw on other skills, but would not have the variety a generalist does.

new innovations in IT, many organizations prefer to hire people who can do more than one thing (and do them with precision). This tends to cut costs and ensure that certain processes will be less timeconsuming or cumbersome.

Not every organization would prefer to hire a specialist web developer or database manager, if only because the market is too narrow to provide easy compensation.

With many specialties at risk of becoming obsolete due to the arrival of new ones, a specialist could potentially be seen as less valuable if other skills end up being required for a job.

A generalist web developer has a wide array of skills — everything from developing a site to performing a quality check and even coming up with a design template.

Keeping this in mind, a generalist may be an easy sell because their variety of skills don’t always come with the higher price tag of someone who specializes in one specific area.

Generalists: pros and cons

The internet has become too complex for someone with limited skills to master, which tends to put generalists in a better position nowadays.

Typically, generalists enjoy better chances of success than specialists because they always have a variety of services to offer. And with

Deceember 2015

An important thing to

consider when deciding between a specialist and a generalist is that the latter should not be mistaken for someone who lacks skills; in reality, they have skills that delve into most web-based needs today. Meanwhile, specialists will always have the upper hand when it comes to getting the job done in a highly specific area.

What matters most is what your organization is looking for and which of the two can meet your needs.

The author Sonia Chugh is known as “D Specialist” among her peers, Sonia is an experienced sales and marketing professional.

A certified marketing automation and salesforce expert with over 10 years of comprehensive experience as a skilled demand generation and sales leader. She has been recognized for successfully driving best-in-class integrated

email marketing campaigns and demand generation programs.

As a seasoned professional, you can always expect some great tips from her on sales & marketing strategies, marketing automation, digital marketing and social media marketing.

As a person, she is a selfmotivated, pro-active and a hard working individual who doesn’t hesitate in going extra mile to meet the goal. She just love being around with people and enjoys whatever she does. When she is not working, she utilizes such time to go for shopping, have coffees with her friends, reading or listening music or going for a long drive. She firmly believes and follows two mantras in her life i.e “ Best is yet to come” and “Great things come to those who don’t wait”! You can connect with her through Twitter: @SoniaSpecialist/ Linkedin: SoniaSpecilaist and Web:SoniaSpecialist.branded.me

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CASE STUDY

New machining centre convinces Hockley Pattern to move to Delcam’s PowerMILL An investment in a new Mazak machining centre convinced Neil and Gareth Williams, Joint Managing Directors of Halesowen-based Hockley Pattern, that the time had come to move up to Delcam’s PowerMILL CAM software for five-axis and high-speed machining

One of the UK’s leading toolmakersfor the aerospace and automotive industries, Hockley Pattern specialises in turnkey tooling packages for the production of composite components, together with all the associated jigs and fixtures for trimming, drilling, checking, assembling and bonding those parts. The company boasts an impressive list of clients in both sectors, having supplied the likes ofAirbus,Bombardier, Rolls Royce, Spirit

Aerostructures, Triumph Structures, GE Aviation, GKN, Bentley, BMW and Jaguar Land Rover.

The company was founded by Neil and Gareth’s father in 1979 and is now jointly managed by the two brothers. Since moving to its current site in Halesowen six years ago, it has doubled its turnover, increased its workforce to 53 people and now has the strongest order book since it started trading.

The brothersdecided to invest in a Mazak VTC 800 five-axis machining centre to expand the company’sexisting machining capacity, in particular to accommodate a large tooling order from Airbus.

They believed the machine would be ideally suited to the production of the large, complex tooling required in a variety of different materials by the aerospace industry.

However, he was less confident in the capabilities of the

company’s CAM system.

“We were making a significant investment in a machine that had the potential to process difficult-to-machine materials, much more quickly and to exceptionally high tolerances,” remembered Neil Williams.

“There didn’t seem to be much point in making that investment without a CAM system that could help us take full advantage of the machine’s capabilities. We had been

Delcam’s PowerMILL has brought many benefits to Hockley Pattern, including faster programming of drilling routines

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thinking about switching to Delcam software for some time and the new five-axis machine meant it was definitely time to make the change.”

“Our aim is always to keep on improving and developing our manufacturing procedures to ensure that we can support all of our customers’ needs,” continued Mr. Williams. “Even during the last recession, we kept on investing in new equipment. This not only ensures that we stay competitive, it also means that we can continue to deliver the highest quality tooling.”

As CNC Manager, Darren Laker was responsible for supervising the transition to the new software. “We had one programmer that had used PowerMILL in a previous job, which meant we could start using the software almost immediately,” he recalled.

“However, he had only used the software for three-axis programming so Delcam put one of its experts on-site for an intense session in five-axis operation. Similarly, we had on-site support when we needed to add some extra options for the new machine to the standard post-processor.”

The benefits of the change soon became apparent. “With our previous software, the tool wouldn’t always be retracted far enough from the job so we had to check everything really carefully before we sent toolpaths to the machine or we would risk gouging the part,” said Mr. Laker. “With PowerMILL, we haven’t seen

Deceember 2015

any similar problems. I’m sure the reliability comes from the fact that Delcam has its own manufacturing facility where it can test its software on real jobs.”

“Programming our drilling routines has become much faster,” he added. “With PowerMILL, you can detect all the holes in a model and group them by size automatically ready for drilling. Previously, we had to select, measure and program each hole individually.

This took far longer and there was always a chance of missing a hole in our more complex parts.”

PowerMILL’s built-in CAD tools are also a big help, for example, when programmers want to add run-off surfaces to models or to cap holes before generating milling toolpaths. Models don’t have to be sent back to the CAD office for modification, which could cause delays, especially at the weekends when there wouldn’t be any CAD staff on-site.

Even though Mr. Laker knows thatthere is plenty more to come as his team becomes more familiar with PowerMILL, he is already convinced that the change was the right decision.

“Most people I talk to about our business ask if I use Delcam software,” he claimed. “I’m very pleased that I can now say “Yes” because of the credibility that comes from being a Delcam user.”

For more details visit www.delcam.com

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CASE STUDY

The Strong and Silent Type Even if you’re a big fan of high-performance cars and motorsport, chances are you have never heard of wheel manufacturer and Haas customer 2Elle Engineering, based a stone’s throw from Venice, Italy.

“Our customers are big name companies,” says 2Elle founder and owner Luigi Lucaora. “For example: BMW, Mercedes, Audi, German tuning house Brabus, and several race teams in different categories, from F1 to Paris Dakar. But, you won’t see the ‘two L’ name on any of our products. We like to keep our brand below the radar, so we can work for all the big marques without compromise.

We supply some of the best high-performance wheels in the world, and almost no one except the customer knows they come from here.”

Mr. Lucaora is at pains to stress that despite its low profile, 2Elle is much more than a busy CNC machine shop. “I spent eighteen years as an engineer in the industry,” he says, “so

first and foremost, we develop new materials, new technology – such as hybrids, and lighter, stronger wheel designs for the fastest cars in the world.”

Before the company moved to its current premises in 2008, 2Elle didn’t make anything in-house. “We only did the engineering, development, and quality control,” explains Mr. Lucaora. “We subcontracted machining for 2 years, and then, when we invested in our first CNC machine tools, we decided immediately to start up with Haas CNC machines.

Our subcontractor already used them and we’d heard many good things. We bought three Haas CNC lathes – two ST 40s, an ST-30, and a Haas vertical machining center, a VM-6.”

So, choice of machine tools

aside, how does a company like 2Elle – an engineering start-up in a very competitive global niche – get a foothold and thrive in the midst of one of the most severe financial and economic crises in history?

“It was one particular order that really kick-started the company,” Mr. Lucaora reveals.

“An important German tuning company offered me a large contract if I promised to meet certain delivery criteria. I went to the bank with their letter of intent, and that was enough of a business plan for them to lend us the money to move to this new factory. Since then, we have grown at least twenty percent each year. Last year, we managed forty percent! In just 7 years, we’ve come from nothing to a turnover of around five

million Euros!”

The 2Elle factory may appear cavernous, but the empty space soon will be filled, as deliveries of blank wheels arrive from the company’s forging supplier in the U.S. “We receive three or four shipping containers every month. In total, we currently produce between 1000 and 1200 finished units a month.”

When it comes to developing new designs and new materials, Mr. Lucaora’s technical background and experience enables the company to compete with the very best wheel manufacturers. “We do a lot of laboratory tests and comparison tests,” he says. “We also look at how much the tyre and wheel can be distressed when we do finite element analysis, and we also fit tyres

2Elle work to develop new materials, new technology – such as hybrids, and lighter, stronger wheel designs for the fastest cars in the world

Haas customer 2Elle Engineering is based in Italy and supplies high performance wheels for motor companies involved in F1 to Paris Dakar

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2Elle currently produce between 1000 and 1200 finished units a month

The company’s Haas VM-6 operates for at least two and a half shifts a day, mostly manned

to the wheels and do practical tests to understand better how the wheel will behave in real-life.”

provides the accuracy and fine surface finishes mould makers and other high-precision industries demand.

The company’s Haas VM-6 operates for at least two and a half shifts a day, mostly manned. “During the day, we load the machine with just one wheel at a time,” says Mr. Lucaora. “But, at 10 p.m., we load two wheels and set the machine working overnight, ’til 4 a.m. The next shift comes in and unloads the parts at 6 a.m.”

“The shapes we’re machining are similar to moulds, so the VM-6’s high-speed spindle and feeds are perfect,” says Mr Lucaora. “The table is T-slotted in X and Y, which makes it easy to secure our parts. We’re also buying a smaller Haas VM-3 mould-making machine, for some new hybrid wheel projects we’re working on. These wheels will be made using alloy hubs coupled to carbon fibre rims, so the engineering and machining challenges will be interesting.”

The Haas VM-6 is a 40-taper mould-making machine with 12,000-rpm spindle and travels of 1626 x 813 x 762 mm. The Haas-built 12,000-rpm inline direct-drive spindle, combined with the Haas high-speed control with full look-ahead,

With his growing fleet, Mr. Lucaora has also noticed a few other advantages that come with investing in Haas CNC

machine tools. “The machines are very easy for the operators to programme and use,” he says. “This is important. They have to work on different machines, so they need to be comfortable with the control.

“Not only are the Haas machines easy to use, but we have also noticed that, in comparison with other machines – and we have several types in our factory – the service and support are far superior.

The Haas Factory Outlet in Milan, operated by Celeada, supplies the machines, and both the commercial and also the technical service are extremely quick and efficient. I can’t afford for any of the machines to stop for any reason. We have a full order book for the next year, so if I stop one or two machines

for a month, it is a nightmare!”

Mr. Lucaora makes regular trips to the company’s forgings supplier, in the U.S. “I was there on a visit when it was Haas’ 30year anniversary celebration,” he says, “so I dropped by the factory and had a guided tour of the facility. I was very impressed with the company’s organisation and quality. They use hundreds of their own machines to make new Haas machines, in a very high-volume production environment.”

If your plan is to supply the world’s best high-performance automotive companies, knowing your CNC machine tools are up to the job is essential. “I think the fact that Haas use their own machines says a lot about their belief in the product.”

2Elle founder and owner Luigi Lucaora

Mr. Lucaora has also noticed a few other advantages that come with investing in Haas CNC machine tools. “The machines are very easy for the operators to programme and use. This is important as they have to work on different machines, so they need to be comfortable with the control.”

Deceember 2015

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73

CASE STUDY

Axle supplier – Approaching Zero Scrap In-process probing reduces downtime and sees scrap rates approach zero at Albion Automotive

Albion Automotive’s axle design and manufacturing comes from an established track record of reliability and engineering quality. Albion products have been specified by truck users for most of this century, and the Glasgow plant now embraces a just-in-time philosophy to develop a product range that will carry its customers into the next century.

Samina Khalid Samina.Khalid@renishaw.com

A programme exists

machining system, the

whilst on the right-hand

the fixture. Mr Kirkwood

at Albion Automotive

first of its kind, with a

side a 100cwt component

explained, “We load the

that sees the company

fixed 6-metre bed, fitted

for an 18-tonne truck was

machining programmes

continually upgrading its

with two Sempuco rotary

being loaded by hoist into

into the Univer 6 manually

production capabilities with

tables, giving us a fourth

its fixture.

or from a laptop computer.

the latest CNC machine

axis and allowing pendulum

tool technology, part of

machining. The machine

a process of continual

is fitted with a 52-tool

improvement. The company

magazine that allows us

took delivery earlier this year of a turnkey Univer 6 flexible machining centre fitted with Renishaw probing.

74

to machine ten different axle components”. Whilst he spoke, the machine was producing a front axle beam for a 7.5 tonne truck.

Held in a ‘yoke fixture’ on

Manufacturing Engineer,

the left-hand side of the

Robert Kirkwood

6-metre table, the beam

explained, “The Univer 6

would be delivered as a

is a customised vertical

fully machined component,

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The cell operates in three shifts in a 24-hour day, the pendulum machining having eliminated downtime.

The probe enables the length of each axle beam to be measured, setting the offsets. We also have limits set into the control

However, a key component

whereby if the part is too

enabling continual

long it will rejected. This

machining is a Renishaw

has allowed us to machine

MP3 probe with radio

100% accurately forged

transmission, integrated

components and gain an

into the machining centre

unexpected area of cost

for measuring of the

control as each rejected

exact position of the

part is now returned to

forged front axle within

the supplier. The Renishaw

December 2015

probing system is detecting inferior supplied forged components, something that was not possible before.”

The Univer 6 machines the complete axle to a tolerance of 3 microns, drilling and reaming the mounting holes for the chassis and the bore hole for the king pin, together with a host of other operations.

Mr Kirkwood continued, “Using Renishaw’s probe tells us where to machine the king pin hole and boss, which is critical, especially when we put a cross

those holes have to be in relation to one another”.

The Renishaw MP3 radio transmission system, stipulated by Albion, does not require line of sight between the probe signal transmitter and the receiver, which can be mounted anywhere within 10 metres of the probe.

So far, the results of Albion’s continual improvement policy look good - machining of axles on the Univer 6 with Renishaw in-cycle probing has seen scrap rates approach zero, with greatly improved throughput times.

hole through the king pin

For further details visit

bore, because each of

www.renishaw.com

Deceember 2015

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75

FEATURE ARTICLE

DYNEO® Motors and Drives Solutions Dyneo® combines Emerson’s permanent magnet solutions for variable speed drives and synchronous motor technologies. These solutions are the outcome of tried and trusted technology with over 15 years of experience and the largest industrial base installed worldwide. Dyneo® delivers reliability, robustness, a wide range of options, flexible adaptation, easy commissioning and a short return on investment.

The latest developments offer users simplicity of installation equivalent to an IEC induction motor. Continuing with the proven design of Dyneo® solutions, the product portfolio has recently been completed by a series of permanent magnet synchronous motors (LSRPM – 1500 rpm), that are directly mechanically interchangeable with all standard IEC 3430-1 motors (frame size, flange, shaft end). This new variant immediately offers a premium energy efficient solution without modifying existing IEC equipment. Easy

integration comes with two economic advantages, as the financial savings generated for installation are combined with financial savings for operation, which grow over the life cycle of the motor.

A compact range, significantly smaller and lighter, is also available to offer even more flexibility at the customer’s site. This variant is particularly appreciated by equipment manufacturers as it reduces dimensions and optimizes machines, simplifying lifting resources and reducing

transport costs.

A permanent magnet motor must be controlled with an electronic variable speed drive, it is therefore essential for the assembly, commissioning and configuration of the overall setup to be as simple as possible.

This has been achieved thanks to Dyneo® solutions, that incorporate total sensorless control mode for most process applications (pumps, compressors, fans, boosters, centrifuges, separators, etc.).

The motor control is optimized, without a position feedback and

connecting cable to the drive.

Potential disturbance due to the motor encoder or feedback connections are therefore eliminated, once again reinforcing the reliability of the motor & drive package.

Emerson Dyneo® solutions LSRPM (IP55) / PLSRPM (IP23) permanent magnet motors are perfectly matched with Emerson variable speed drive ranges: Powerdrive F300 (IP20 drives to be integrated in the unit or cabinet for ventilation, pumping and compression applications), Powerdrive MD2

Emerson industrial Automation has led the energy efficiency market for many years and aims to provide ever more effective, ergonomic and modular drive systems.

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December 2015

Easier than ever to implement and adapt for variable speed applications with the highest levels of energy efficiency!

The company’s Haas VM-6 operates for at least two and a half shifts a day, mostly manned

The Dyneo® LSRPM motor is modular: set-up with feet, flanges, smooth or threaded holes and many associated options to simplify the installation

(complete IP21 or IP54 solutions ready to use for process applications) and Unidrive M (IP20 drives to be integrated in the unit or cabinet for all other applications), that are easy to integrate and quick to configure thanks to software and firmware specifically designed for the Dyneo solution motor.

A motor-drive assembly from a single manufacturer offers the assurance of optimum performance thanks to components designed to operate together, along with the global guarantee of a single point of contact, from technical specifications through installation and after-sales service to maintenance.

Dyneo® solutions offer rapid returns on investment as well as one of the best overall ownership costs on the market.

Dyneo® motor technology: This motor with robust mechanical design uses the same components as the induction motor, however, unlike the latter, the Dyneo® motor’s magnetic flux is not developed by the stator but is

Deceember 2015

directly created from a set of permanent magnets inserted in the rotor. With an AC induction motor, the speed of rotation of the rotor is slower than the stator frequency. With the Dyneo® motor, the magnetic flux remains synchronized with the frequency induced by the stator. Rotor losses for the induction motor represent almost one third of total losses, whereas the rotor losses for the Dyneo® motor are negligible.

At rated speed, motors in the Dyneo® range achieve efficiency levels equivalent to IE4 or NEMA Super Premium, which are therefore well above highefficiency induction motors.

This efficiency gap becomes even more significant when operating at less than rated speed, which is often the case in variable speed applications! The payback time compared to a conventional solution is usually very short.

By maintaining the position of the stator at 90° to the magnetic flux at all times, the Dyneo® solution guarantees optimal torque over the whole speed range, with no de-rating or forced ventilation, and can achieve speeds of around 5500

rpm, demonstrably higher than traditional technologies. This solution is particularly effective for applications requiring high torque at high speeds.

Motors in the Dyneo® range are designed to rotate faster than induction motors, allowing the motor speed to be adapted to that of the driven machine, thus eliminating transmission devices such as gearboxes.

The Dyneo® LSRPM motor is modular: set-up with feet, flanges, smooth or threaded holes and many associated options to simplify the installation.

Dyneo® solutions meet all environmental requirements while attempting to optimise productivity and satisfy the need for savings faced by most industries, regardless of the application (fluid management, belt systems, extrusion, transformation, generators, etc.).

As part of Emerson Industrial Automation, Control Techniques and Leroy-Somer have operated globally as sister companies for many years, each with their individual areas of expertise

and specialist technologies. Now our combined business allows us to provide optimized drive and motor technology, develop perfect industry-specific and customized automation solutions, with strong local technical and sales support on a global scale.

For more information visit www.

EmersonIndustrial.com/Automation Emerson Industrial Automation, a business of Emerson, is a global technology provider that enables productivity, efficiency and quality gains for customers across a spectrum of industries.

Our products include alternators, electric motors and drives, electrical distribution devices and mechanical power transmission, fluid automation and ultrasonic joining solutions. Emerson brands include Appleton, ASCO, Branson Ultrasonics, Browning, Control Techniques, Kop-Flex, Leroy-Somer, McGill, Morse, Numatics, O-Z/ Gedney, Rollway, SealMaster and System Plast.

For more details write to Rajan Rengan at rengan.rajan@ emerson.com or visit www. emersonIndustrialautomation.com

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77

MART UPDATE

Grind Master bags SME Business Excellence Award Karur Vysya Bank and Dun &

26 Awardees from amongst

Bradstreet (D&B) launched an

100,000 Plus nominations.

awards initiative to recognize

Grind Master bagged the

and felicitate SMEs who have

award in the Mid Corporate

demonstrated exemplary

segment under Engineering

performance in their respective

& Machinery sector.

fields. A rigorous Filtering and Selection narrowed to

The award was presented

“Award from Dun & Bradstreet which is Internationally well known is a great honour for us. I think it is a result of our efforts in Exceeding Customer Expectations with Innovative and Trustworthy Solutions Created with Passion and Expertise. Grind Master is now Globally known as Leader in Metal Finishing & Nanofinishing Technologies.”

Mohini Kelkar

at a grand ceremony on

with a Turnover of more than

Monday, 23rd November 2015

Rs.120 Crores. As one of the

at New Delhi by Shri Jayant

large machine tool builders in

Sinha, Minister of State for

India it qualified in the “Mid-

Finance, Government of

Corporate” Category, thus also

India. The event, attended by

reflecting the transformation

eminent business leaders and

into a Professionally Managed

senior government officials,

Business.

also included the release of

Managing Director, Grindmaster

the publication “Leading

I have personally witnessed the journey of Grind Master for the past 32 years. It has been a really exciting journey, and gives me great satisfaction and pleasure that we emerging on a national and international stage as a trustworthy and passionate machine builder. I would like to personally thank all our customers, suppliers, well wishers, associates for their enthusiasm and support in this journey. Looking forward to an exciting future.”

SMEs of India 2015”. Sameer Kelkar, Executive Director at Grind Master represented Grind Master at the award program.

With a track record of developing breakthrough technologies including Microfinishing, Dynamic Balancing and Robotic Automation in the last few years, Grind Master represents

The award selection

India on the global stage with

was based on all round

a very strong Export record.

performance and track

Recently completing the 50th

record of the nominees. Grind

machine in China, Grind Master

Master has been growing at a

has created a brand known for

Sameer Kelkar

phenomenal rate in the past

expertise, innovation in metal

Executive Director, Grind Master

few years, closing FY14-15

finishing internationally.

BAUMA 2016: Automation and resource-efficiency remain a top priority There are still six months to go before the start of the world’s largest trade fair on construction and building material machinery, but one thing is already clear: the next edition of bauma will showcase all the latest technology. Top themes in all the sections of the exhibition will once more be resource- and energy-efficiency. The 31st edition of the World’s Leading Trade Fair

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for Construction Machinery, Building Material Machines, Mining Machines, Construction Vehicles and Construction Equipment takes place from April 11 to 17, 2016 at the Messe München exhibition center in Munich.

Johann Sailer, Chairman of the VDMA Association for Construction Machinery and

Building Material Machines, confirms that “in building material machinery and systems, the trend towards automation is continuing, and this is coupled with an increase in resourceefficiency.” At the same time, he observed, there is strong global demand for energy-efficient precast concrete components and building materials.

A presentation on Bauma 2016 was presented by Mr. Rajesh Nath, Managing Director, VDMA India and Mr. Igor Palka, Chief Operating Officer, MMI India on 4th of December 2015 at Kolkata.

Mr. Olaf Iverson, Consul Generol of Federal Republic of Germany, Kolkata was the chief guest of the event organized by VDMA India. For more information do visitwww.bauma.de

December 2015

3

HARTING has now joined the Industrial Internet Consortium (IIC) Over 200 members/ Driving forward technological developments

HARTING has been represented on numerousnational and

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internationalcommittees, associations and organizations for many years. This enables the Technology Group to drive forward technological developments as a pioneer,

“The developments triggered by the Internet of Things will remain the mega issue over the coming years. HARTING will play an active role in the testing of new technologies.

Our membership of IIC means we are always on the pulse of the latest developments,�

Dr. Frank Brode Senior Vice President, NewTechnologies,HARTING.

Deceember 2015

SMPS

DC/DC Converter

Water Proof SMPS

Adaptor 3 Phase Transformer LED Drivers on the one hand, and allows for industrial deployment. It HARTING to benefit from the was founded in March 2014 by experience of other companies in the UScompaniesAT&T, Cisco, the sector on the other.

General Electric, IBM and Intel.

Over 200 companies, which HARTING also recently became a now also include HARTING, member of theTransformer Industrial Internet 1 Phase Batterybelong Chargerto the organization Solar Lartern Consortium (IIC). This association worldwide. headquartered Needham in City the (Haryana) India. Tel: +91-171-2801711/3291897 65, Laxmi Vihar,inJandli, Ambala US state of Massachusettsaims more details visit Fax : +91-171-2801289 MobileFor : +91-9416020078/9215720078 to develop internet technologies www.HARTING.com

Email : nacei@rediffmail.com / naceiamb@gmail.com Website : www.nacei.com

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HaasTec Pune 2015 Event set for December The popular HaasTec show is returning to India this year. Managed by the Haas Factory Outlet (HFO) in India (Phillipscorp, CNCSSIPL division), the HaasTec will take place on 09th – 12th December at Auto Cluster, PCMC, Pune.

In line with previous HaasTec events, a number of innovative, affordable Haas CNC machine tools will be on view. Machines like UMC-750 five-axis universal machining centre and the ST-35 big bore CNC lathe will be on display. All of the Haas CNC machine tools on display will be powered and performing demonstrations, cutting metal.

Haas specialists from the HFO will be available to guide visitors through the demonstrations and answer any questions about the machines. The UMC-750 fiveaxis vertical machining centre offers a capacity of 762 x 508

x 508 mm in the X, Y and Z-axis respectively. It features a two-axis inbuilt trunnion rotary table and a 40-taper, 22.4 kW, 12000 rpm direct drive spindle. Other features of this advanced machine include a 40+1 side mount tool changer, 25.4 m/min rapids, co-ordinate rotation and scaling, rigid tapping, a wireless intuitive probing system and a 284 litre flood coolant system.

The Haas ST-35 big bore CNC lathe can accommodate bars up to 102 mm in diameter and offers a capacity of 533 (dia) x 660 mm (length) with 806 mm of swing. The 29.8 kW, 2400 rpm spindle is served by a two-speed gearbox, while additional features include a 381 mm chuck, 12-station bolt-on turret and rigid tapping capability.

Other Haas CNC machine

tool models scheduled to appear at both HaasTec events include the ST-10Y turning center with Y-axis, the ever popular DT-1 Drill Tap machine with new 30 taper 15,000 rpm spindle, a VF-2 VMC, a VF-2SS, Mini Mill and the VF-7/50 VMC. Visitors are invited to bring along components or drawings for a full evaluation of optimized machining solutions. Indeed, the HaasTec events will

also feature a number of the company’s industrial partners, all able to offer complementary technologies and advice.

Demonstrations, tours and a live Q&A counter will be among other event highlights. Pre-register on www.haascnc.com/openhouseto be a part of this Grand Customer Event. For further details write to Mr. Nikhil Modi – Marketing Associate atMarketing.india@ phillipscorp.com

Think small, but think green: IE3 motors from 0.12 kW Bargteheide – NORD

electric motors, and have only

may wish to go

DRIVESYSTEMS will expand the

recently been introduced into

beyond current

IE3 premium efficiency motor

the international standard IEC

legal obligations.

range to include 0.12 kW motors

60034-30-1. Legally, there is

They will find

from January 2016. Adding this

no immediate need to act on

that NORD

smaller size to the IE3 portfolio

motors this small: at this time,

DRIVESYSTEMS

will make it easier to equip entire

IE3 requirements within the EU

now enables

plants with eco-friendly, highly

only apply to motors rated at

them to pursue

efficient drive systems. Systems

7.5 kW or higher.

ecological

in the 0.12 kW to 0.75 kW rated power range are used in a large share of all drive applications.

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Even in 2017, when smaller performance ratings are due to be included, this will only

However, the efficiency

extend to 0.75 kW or larger

percentiles for this performance

systems. Still, users with a

class have been defined only in

particular concern for the

the last stage of the European

environment and those seeking

Union Ecodesign Directive for

to truly maximize efficiency

www.martupdate.com

solutions throughout all drive applications.

NORD supplies

Small 0.12 kW motors, which abound in many applications, are now available from NORD DRIVESYSTEMS with an IE3 premium efficiency rating

the compact IE3 motors in IEC frame sizes. Changing the specifications to IE3 is a smooth process that will not require

physical design changes to machinery and equipment.

For more details visit www.nord.com

December 2015

Deceember 2015

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Eplan Data Portal: More than 100 Manufacturers A parts data wizard has made the integration of product data into the Eplan Data Portal much easier. This benefits both the manufacturer and the user.

For the first time, more than 100 manufacturers will be represented in the portal when SPS IPC Drives in November starts. With comprehensive device data, the more than 90,000 portal users worldwide will be able to simplify and accelerate their engineering processes. The necessary macros, component data and 3D data for the construction of a virtual control cabinet can be easily and directly integrated into the CAE design With start of the SPS IPC drives, the Eplan Data Portal breaks a remarkable record. Over 100 manufacturers - many of them from the European, Asian and US-American markets - will have integrated their manufacturer data into the portal.

In mid October, there were already 99 manufacturers with over half a million qualified device and product data entries listed in the portal - at the fair end of November there should be around 110 manufacturers.

The number of new members is also interesting: In 2015 alone, Eplan was able to gain 30 new manufacturers.

One factor contributing to this extraordinary success is

the new parts data wizard for manufacturers, among other things. Based on Excel technology, manufacturer data can now be made available more easily in the portal and at the push of a button.

Manufacturers don’t need any special know-how- the technology can also distinguish between the commercial and graphics data within the listed allocations and collate it all together intuitively.

Over ten manufacturers of clamps, cables, connectors and sensors have already experienced the simplicity of this new integration. A Further 1.2m Device Data Entries per Configurator But it doesn’t end with the more than half a million integrated manufacturer data files: Those who use measuring instruments benefit from additional 1.2m variations in device data which can be configured in any specification. In addition to this, the measuring instrument manufacturer Endress+Hauser has already integrated existing web configurators into the Eplan Data Portal interface via web front-end. Based on the Eplan Engineering Configuration (EEC), which is online in the background, and in combination with the Data Portal, a plethora of potential variations can be configured online.

Global Expansion

New manufacturers within the field of measurement technology include Janitza with its digital panel meters, Ziehl with its measurement and monitoring systems and Flowserve, a US-American manufacturer of measuring instruments.

Device data - like those of Janitza or Noark depicted here can be inserted into the Eplan project with ease.

Other new members from the USA are Mencom, Priority Wire 1.2m device data entries can be configured with & Cable and the Endress+Hauser configurator integrated into ComtranCable the Eplan Data Portal.

- all successful cable manufacturers, manufacturer of automation Molex from the cable technology and Roxtec, a Swedish manufacturer of and connector field and housing accessories and cable Hubbell, also a US-American penetration. Kabelschlepp manufacturer of connectors. has employed energy chains The Eplan Data Portal is and conveying systems, therefore becoming the Hirschmann is involved with its international hub of product ethernet switches and other data. The most significant manufacturers such as Citel, new member from China is HBM, Klemsan, Lumberg, Chint - one of Asia’s largest Promet and Sensopart complete manufacturers of automation the portal with their data. technology. Noark, a subsidiary Conclusion: of Chint, has also made contactors and circuit breakers available in the portal.

Liaoning Create Cable from China produces cables and Ningbo GOOSVN Electronic is a manufacturer of connectors and addresses the Asia-Pacific market. It goes without saying that European manufacturers have also joined - for example, ILME, an Italian manufacturer of electrical connectors, KEBA, an Austrian

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Users benefit from highquality product and device data, whose wide range offers international manufacturers an ideal, flexible platform for true “global engineering”. The data can be incorporated into the project 1:1 and guarantee users quick, efficient design while taking into account the current manufacturer data. The huge diversity of devices allows maximum freedom within engineering.

December 2015

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Pramet unravel turning dilemma with new ranges Pramet has introduced two new positive geometries and grades for turning applications in difficult to machine materials.

Suitable for a variety of turning applications, the SF and SM geometries have been launched to support the machining of materials such as high temperature alloys and stainless steel. Part of

Dormer Pramet’s second product launch of 2015, the SF geometry features a sharp, positive rake of 14.5°.

It is suitable for finishing applications in continuous cut with very low forces.

The SM geometry has a positive rake of 13° and is a wear-resistant, universal geometry for medium machining (finishing up to roughing) and suitable for continuous and interrupted cut. Both geometries are available in a variety of grades and have been designed to promote low cutting forces and prevent work-hardening. This helps to reduce the risk of vibration when turning thin-walled components. In addition to the new geometries, two new turning grades have been unveiled by the global

cutting tool manufacturer.

The PVD coated T6310 grade features a special sintering process which enhances cutting edge reliability and strength. Its new substrate with intermediate Cobalt content provides additional hardness and increased abrasion resistance to offer greater reliability and prolonged tool life.

The T6310’s triple coating provides durability for higher cutting speeds used when machining stainless steel, heat-treated and hardened materials. It is suitable for use with the new SM and SF geometries, as well as Pramet’s existing NF and RM geometries, with a total of 89 inserts now available.

good heat conductivity and high wear resistance required for turning titanium and alloys. Its fine grain substrate with low Cobalt content offers resistance to pitting as well as plastic deformation.

It is available in the new SF geometry.

Meanwhile, Pramet’s new H07 uncoated grade offers

For more details visit www.dormerpramet.com

TEMA India Bags Best Global SME 2015 Award Dun & Bradstreet and The Karur Vysya Bank felicitate leading SMEs at the SME Business Excellence Awards 2015 held in New Delhi Mumbai, November 24, 2015: With an objective of bringing to the fore the success stories and potential of the leading Small and Medium Enterprises (SMEs) Dun & Bradstreet and The Karur Vysya Bank Ltd. joined hands to recognize and applaud the leading SMEs of India through SME Business Excellence Awards 2015 on November 23, 2015 in Delhi. TEMA India, one of the leading manufacturers of heat exchangers in the country, was recognized as the Best Global Business SME 2015.

SMEs are widely known as the backbone of industrial development. India is home for

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nearly 48 million SMEs which contribute more than 45% towards country’s industrial output, generating 40% of total exports and producing 1.3 million jobs every year. Though the Indian entrepreneurs have contributed immensely to the country’s economic and international evolution, yet the sector continues to struggle with the darkness of ignorance and lack of interest from masses.

Commenting on the development, Mr. Haresh Sippy, Managing Director, TEMA India, said “The small and medium scale enterprises

play a crucial role in the socioeconomic growth story of India.

By facilitating employment and business avenues in rural and urban India, the sector provides equitable and inclusive growth across local economies. But in the changing times there is a heightened need to bring to light the success stories of the sector in an attempt to not only showcase the might of SMEs but also to attract, inspire and motivate entrepreneurs. I am deeply grateful towards Dun & Bradstreet for conceptualizing the SME Business Excellence Awards initiative which provides a platform for SMEs to showcase their performance and

contributions to the growth of the nation”.

He further said, “This award highlights the high morale and the synergy that exists in team TEMA. I offer my deepest gratitude to all the employees of TEMA India who helped us to achieve this award.”

The ceremony also marked the release of sixth edition of Dun & Bradstreet’s premier publication ‘Leading SMEs of India 2015’ a leading compendium on the Indian SME industry, by chief guest Shri Jayant Sinha, Minister of State for Finance, Ministry of Finance, Government of India.

December 2015

Omron aims to strengthen presence in SME segment Omron Electronic Components, one of the business units of Omron Automation, held a technology show to showcase its end-to-end solution capabilities, equipped with advanced sensing and control technology, today at Gurgaon, NCR. Theinitiative was aimed at updating its business partners and end-customers on the company’s innovation-led offerings while also reaching out to prospective and long-tail customers.

The event saw the presence of more than 100 participants from all over the country representing myriad sectors in the small and medium industry segment such as automotive, industrial, telecom, lighting, home appliances, medical equipment, etc.

Some of the key solutions on display were the entire portfolio of Omron Relays, Switches, Connectors, Sensors; Sensors for Security and Automation and high power industrial relays.

Business partners attending the discussion at Omron Electronic Components Technology Show

“Omron is making continuous efforts to position itself as a ‘total solution provider’ providing value-based customised solutions. These kinds of platforms help us to capture the desired ‘mind –share’ amongst the target audience leading to stronger ‘business –share’ in the long run. We are striving to expand our penetration amongst SMEs – which have surfaced as one of potential segments driving the industrial and inclusive growth in the country.”

Vinod Raphael Country Business Head -India, Omron Electronic Components

Deceember 2015

The demonstration of Omron’s Human Vision Component – capable of recognising face, age and controlling gestures – aroused great interest amongst the attendees who were amused to experience Omron’s sensing & control technology based forte in creating harmony between humans and machines.

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De Dietrich® embraces Green Chemistry and establishes a partnership with SAS PIVERT In April 2015, De Dietrich® and SAS PIVERT signed a partnership agreement to equip the BIOGIS Center and to combine the resources of both companies to develop innovative plantbased chemistry solutions.

This partnership allows both companies to share their expertise and industrialize new processes using bio-based raw materials, particularly oilseed biomass. “Sustainable development is a value shared by both of our companies. We are very pleased to initiate this partnership.” declared De Dietrich® President and CEO Daniel Steck at the time.

“Research advances in catalytic chemistry require adaptable equipment capable of working in diverse conditions in order to develop sustainable and competitive solutions. We work

towards this goal with De Dietrich, to develop innovative plant-based chemistry solutions.” declared SAS PIVERT CEO Gilles Ravot.

The BIOGIS Center is equipped with a complete and innovative reaction and distillation system which is entirely remote controlled (utilities and automation), allowing distillations and reaction mixtures (homogenization, suspension, dispersion, crystallization...) to be performed on a variety of oilseed biomasses.

Within this partnership, De Dietrich® contributes its particular expertise in managing projects and studies up to their market release, as well as carrying out user training.

The new processes designed within the BIOGIS Center will allow SAS PIVERT’s industrial partners to be at the cutting edge of innovation in plant-based chemistry.

Thanks to this partnership, new molecules and new processes stemming from research will be available for industrial use.

Opening up innovation, from plants to chemistry BIOGIS Center is a unique technological platform dedicated to the development of plant chemistry products and processes designed to valorise the entire plant.

Operational since autumn 2015, it includes several thematic labs including a catalytic chemistry lab operated under

the aegis of the partnership.

The processes developed are guided by the principle of sustainable development, using a renewable raw material that is both promising and competitive: oilseed biomass.

Drawing on its expertise and experience, De Dietrich® has developed solutions and equipment aiming on the one hand to transform plant-based material and on the other hand to optimize the energy consumption of this type of material.

New Plasma Cutting Electrodes Help Owners of Hypertherm HySpeed Systems Double Their Current Consumable Life Hypertherm, a manufacturer of plasma, laser, and waterjet cutting systems, is introducing new SilverPlus® electrodes for its HySpeed® HSD130 plasma cutting systems.

Like all versions of Hypertherm’s SilverPlus electrode, this electrode is proven in Hypertherm laboratory testing to last more than twice as long as a standard copper tipped electrode. In addition, the electrode delivers a very consistent range 4 and 5 cut quality throughout its life helping HySpeed plasma owners lower their operating cost and enjoy improved cut quality.

The electrodes, protected by patent, are created by fusing a

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solid silver tip on to a copper electrode base and then inserting a hafnium pin into the tip. This serves to dramatically slow the electrode’s wear rate as silver disperses heat better than copper. Hypertherm’s electrodes are further differentiated by a superior bond between the hafnium and silver for more consistent wear rates, deeper pit depths, and more robustness to ramp down errors and hard failures.

“Our SilverPlus electrodes have long been recognized for delivering proven performance benefits to owners and operators of our HyPerformance systems,” says Martin Geheran, a consumables product manager at Hypertherm. “Now HySpeed

plasma system owners can enjoy that same benefit while reducing their overall operating cost through the purchase of fewer electrodes and even nozzles, as the increased electrode life also translates into double the nozzle life.”

Using genuine Hypertherm consumables for your Hypertherm plasma cutting system is the only way to ensure optimal performance.

Patented technology and precision manufacturing combine to deliver increased cut speed, better edge quality, and longer consumable life. In addition, genuine Hypertherm consumables are backed by industry-leading service and training through Hypertherm’s HySupport program. To learn more about the SilverPlus electrode, please visit http:// www.hypertherm.com/ SilverPlus

December 2015

World’s first for long travels: 40 percent lighter cables for e-chains Reduce weight and driving force with igus single core motor cables made of copper-coated aluminium The new chainflex motor cables CF430.D and CF440 (unshielded and shielded) from igus save significant system weight for long travel applications using energy chains. In this way, the use of smaller e-chains can reduce cost and enhance both the energy efficiency and the service life of energy chain systems. As for all chainflex cables, igus offers a unique 36-month warranty for its durability.

Whether in plant construction, mechanical engineering, cranes, ships or conveyor technology, the travel distances in dynamic applications are becoming increasingly longer whilst speeds and number of movements are rising. This leads to everincreasing stress on cables that are constantly in motion. The motion plastics specialist igus has developed extremely lightweight single core motor cables for energy chains for long travels, the chainflex types CF430.D and CF440. By the use of a special stranded conductor, the cables are up to 40 percent lighter

than standard copper cables.

Depending on the cable length and cross-section, the savings potential of the new motor cables can be up to several tonnes, offering a considerable saving on required drive force.

Material combination gives numerous advantages “This weight reduction is possible by the use of a stranded conductor made of the special material CCA,” explains Rainer Rössel, head of the chainflex cables division at igus. “Here, the cable core is made of lightweight aluminium coated with copper, known as copper-clad aluminium or CCA.” The combination of these two metals has a number of advantages. Compared to solid copper cables, the CCA cable benefits from the lower density and thus the lower weight of aluminium. When compared to a pure aluminium conductor this one offers the big advantage that the cross-contacting is ensured by the copper coating.

Furthermore, the copper layer also contributes enormously

to the durability of the entire conductor with a stranding structure optimised for the constant bending in the energy chain.

Developed for use in e-chains igus has created a special stranding method for its CCA lightweights, and the insulation jacket material has been further enhanced for use in energy chains. igus has already demonstrated the long service life in operation in their own test lab. The chainflex CF430.D and CF440 types have already completed more than 17 million strokes without failure in

continuous movement. And the marathon test continues to run. The outer jacket is made of a high-quality mix of thermoplastic elastomers (TPE) makes them extremely resistant to abrasion and bending, making them ideal for extremely high loads even at low temperatures and for outdoor use. These cables, designed for very long travel lengths outdoors, can be ordered as shielded or unshielded options.

The cables are also resistant to UV and ozone.

For further details visit www.igus.com

Save 50% power through Energy Saving LED Tube Light Pyrotech offers Energy Saving LED Tube Light for office lightning & retail store display applications as per industry standards with optimum thermal management & highly efficient constant current driver having short circuit & open circuit protection in aluminum housing. With these lights you can save upto 50% power over conventional

Deceember 2015

tube lights.

The salient features of these LED Tubelights are upto 50% power saving, 220V AC/ 24V AC and no UV or IR radiation. These are manufactured in-house using latest machinery. For more details write to mktg@ pyrotechlighting.com or visit www.pyrotechlighting.com

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Better Engineering means Higher Productivity in Titanium and Stainless Steel with New VariMill III ER from WIDIA With a new seven-flute, eccentric relief (ER) design, the newest addition to the WIDIA VariMill family, the VariMill III ER solid-carbide end mill, is engineered for higher metal removal, longer tool life, and improved surface finishes in demanding workpiece materials such as titaniums and stainless steels.

“OEMs and tier suppliers in the aerospace and energy segments who regularly face working in high-strength, lowweight titaniums and stainless steels will want to see how the VariMill III ER together with the new WIDIA Victory Grade WS15PE can improve performance,” says Ron West, WIDIA product manager. A newly developed coating and proprietary pre- and postcoat treatment significantly improves cutting edge consistency. Consistent cutting edges mean higher metalremoval rates, longer tool

life, and improved workpiece surface finishes in expensive demanding materials.

The tool is designed to be a true finishing endmill with the ability to take up to 30% radial engagement.

“This also means VariMill III ER customers can use high-speed machining techniques such as peel milling or trochoidal machining in high-strength alloys,” West adds.

Demanding markets such as aerospace and energy are defined by the need for increased efficiency. In response, WIDIA is offering the VariMill III ER in a full line of options, including two, three, and five times diameter length-of-cut and all common aerospace radii and chamfered corners, metric and inch. With more and more additive layer manufacturing in the aerospace field, the trend going forward

will be from roughing to semi-finishing and finishing operations, perfect for the increased efficiencies VariMill III ER provides.

VariMill III ER is true finishing endmill for higher metal VariMill III ER removal rates, longer tool life, and improved surface end mills also come standard finishes in demanding workpiece materials such as with the titaniums and stainless steels SAFE-LOCK™ option by Haimer, eliminating available on iPad™ and other pull-out risk, and making the digital devices, NOVO helps tool assembly more stable users define machining features, and concentric, which in turn such as ramping or slotting in increases surface finish and specific work materials, and then tool life. immediately reduces the product set to those like VariMill that Featured in NOVO can do the job. This provides far more useful process knowledge Moreover, VariMill solid-carbide than any online catalog alone, all end mills are available through obtained in a fraction of the time.

NOVO™, WIDIA’s digital process knowledge application. With For more details visit powerful process knowledge www.widia.com/novo

CST is now InnoVista Sensors Consequent to the sale of some of the activities of its portfolio (Brands: BEI Kimco, BEI Sensors, Kavlico, Crydom and Newall), Custom Sensors & Technologies (CST) is reorganising itself with a new name, InnoVista Sensors™.

As of, December 1st, 2015, the company InnoVista Sensors™ is created with the Crouzet Aerospace, Crouzet Automation, Crouzet Control, Crouzet Motors, Crouzet Switches and Systron Donner Inertial commercial brands.

With its dynamic and wellestablished commercial brands, this change of identity relies on a dual ambition: Increase its

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presence in the sensors and other components markets at the heart of Automated Systems and critical applications, and Strengthen the innovation policy as a major axis for development.

Through its recognised expertise, reliability and adaptability, the company is strengthening its investment towards Excellence and Innovation. This evolution confirms a renewed commitment to bring the performance enhancing solutions that will meet current and future market demands.

InnoVista Sensors will

be a trusted partner of choice to face industrial challenges of today and tomorrow, a worldwide industrial specialist of sensors, controllers and actuators for automated systems. Through its brands, Crouzet Aerospace, Crouzet Automation, Crouzet Control, Crouzet Motors, Crouzet Switches and Systron Donner

Inertial, InnoVista Sensors offers a wide range of reliable, efficient and customisable components dedicated to the aerospace & defence, transportation and industrial market and segments.

For more details contact InnoVista Sensors Tel: +91 80 41132204/ 05 Email: india@ cstsensors.com

December 2015

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CIS CISU 01035

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MAX GR TAPE NET

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HMS Industrial Networks presents new solutions for the Industrial Internet of Things at SPS/IPC/Drives in Nuremberg HMS Industrial Networks will present a number of new industrial communication innovations for the Industrial Internet of Things at the SPS/IPC/Drives fair in Nuremberg, Germany, 24-26 November. The new solutions and prototypes enable communication between operational technology (OT) on the factory floor and Information Technology (IT) resulting in unprecedented efficiency gains.

to communicate their operation status to IT systems enabling predictive maintenance.

They will also allow machine builders to become service providers and sell maintenance as a service. IT systems can analyze information from real-time industrial systems and present KPIs and statistics from previously unattainable OT systems.

HMS Industrial Networks presents new solutions for the Industrial Internet of Things

At SPS/IPC/Drives in Nuremberg, HMS presented:

HMS Industrial Networks presented a number of new industrial communication innovations for the Industrial Internet of Things at the SPS/IPC/Drives fair in Nuremberg, Germany last month. The new solutions and prototypes enable communication between operational technology (OT) on the factory floor and Information Technology (IT) resulting in unprecedented efficiency gains. PROFIBUS/ PROFINET to .NET gateways and solutions for embedded IIoT are two examples of what HMS presented at SPS/ IPC Drives in Nuremberg.

New “edge connectivity gateways” enable access to OT information from the IT-level giving business intelligence systems unprecedented access to live information from production facilities. Among other things, HMS will present new gateways for connecting PROFINET and PROFIBUS to .NET on the IT level.

Another piece of news is an “embedded IIoT” solution where integrated Anybus chips, bricks and modules open a direct channel to the IT level making the host machine “IIoT-ready.”

The benefits of Industrial IoT

HMS’s proven and trusted Netbiter solution already connects thousands of drives, generators, UPSs and other OT-machines to the cloud where they can be monitored and controlled remotely.

HMS now presents new solutions for connectivity to 3rd party clouds such as

Building on 25 years of experience in industrial communication, HMS’s Industrial IoT solutions will be a game-changer for many machine builders and plant owners. For example, they will allow machines

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IT/OT Bridging solutions

Cloud solutions

Thingworks, Oracle and SAP. Connection to these clouds can be made using HMS’s new IT/OT bridging solutions.

Industrial Networking HMS’s current product portfolio for industrial networking is already connecting more than 3 million automation devices around the world. Many of these devices get connected to some kind of controlling system – a basic form of IIoT. At the SPS/IPC/Drives fair, HMS also presents a new OPC UA solution for the German “Industrie 4.0” initiative meaning that an OPC UA server is offered inside the Anybus communication solutions providing data from the factory floor.

“For us at HMS Industrial Networks, the Industrial Internet of Things is nothing new,” says Jörgen Palmhager, COO, at HMS Industrial Networks. “We have been ‘Connecting Devices’ for more than 20 years and enabled millions of machines to communicate with controlling networks.

Through our HMS Labs

initiative, we have been working with Industrial IoT for several years and while other companies are still discussing IIoT roadmaps, we are presenting actual prototypes, products and solutions – innovations which will provide substantial value as users can do predictive maintenance, KPI-followup, machine analytics, data mining, big data processing, production statistics and much more. Industrial IoT will be a game-changer for many automation companies and HMS is technologically very well positioned to help customers realize the promises of IIoT. ” HMS Industrial Networks is the leading independent supplier of products for industrial communication including remote management. HMS develops and manufactures solutions for connecting automation devices and systems to industrialnetworks under the Netbiter, Anybus and IXXAT brands. For more details visit www.anybus.com

December 2015

Q4X Laser Distance Sensor: Superior Performance for Challenging Applications Banner Engineering announces the Q4X laser distance sensor.

Featuring superior, versatile sensing performance, the Q4X reliably detects distance changes as small as 1 mm and covers a 25 to 300 mm range across multiple target colors, materials and surfaces. With the ability to detect presence/absence of a target or an object’s orientation, the Q4X solves a variety of sensing applications.

The Q4X is optimal for difficult distance-based sensing applications as it easily detects objects regardless of target surface reflectivity, including black foam on black plastic, black rubber in front of metal, multicolor packaging and targets of all colors. Additionally, the

Deceember 2015

sensor provides superior resistance to ambient light interference.

user setup utilizing three tactile buttons conveniently located below the display.

“The Q4X was designed to be a problem solver for our customers,” said Dennis Smith, Technical Marketing Manager at Banner Engineering. “With a wide, reliable sensing range, best-in-class excess gain, intuitive operation, high visibility and durable construction, the Q4X solves the most challenging applications.”

To accommodate diverse industries and applications, the Q4X provides reliable detection of:

Offering a simplified user experience, the Q4X provides a clear distance readout from the highly visible, angled four-digit display that is easily viewed from multiple vantage points.

The Q4X also offers intuitive

*Black foam in front of black plastic in automotive interior and exterior assembly *Parts of varying colors in consumer packaged goods and automotive industries

beverage and cosmetics *Part-in-place for poke-yoke or error proofing of assembly steps *Small parts for automated assembly processes, such as caps, seals, o-rings, washers, vials and jars *A wide array of parts in vibratory feeder bowl equipment, including part level detection in the bowl (bowl empty, bowl full), and part present in the feeder track (i.e. track full)

*Black rubber in front of metal in robotic assembly, especially automotive

*Any challenging part-detection application

*Multicolored packaging and secondary packaging in food,

For more details visit www.bannerengineering.com

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Red Lion Appoints New Executives to Support “Customer First” Vision Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking,announced that the company is enhancing its focus on customer service with the appointment of Paul De Sousa as Director of Customer Engagement. In addition, Scott Rose has been promoted to Director of Technical Services, an expanded role that unifies sales engineering and technical support management. In these positions, both executives will be integral to executing Red Lion’s “Customer First” vision, a corporate initiative designed to make it easier for distributor and end-user organizations to do business with Red Lion worldwide.

“Paul’s extensive experience in customer service and organizational efficiency nicely complements Scott’s engineering and technical aptitude. Together they will

manage all aspects of service and support by instilling a culture focused on our putting distributors and end users first,” said Mike Granby, President, Red Lion Controls. “In today’s world of choice, Red Lion values and understands the importance of solidworking relationships.

This is why we are rolling out our ‘Customer First’ program to further build on a strong heritage of being a responsive company that customers trust.”

Paul’s customer-focused background builds on 20 years’ experience in customer relations and call center management at leading manufacturing companies, which include his most recent position as Executive Director of Global Customer Services/ Consumer Experience at Moen International. He also served as Vice President of Customer Care with American

Standard Companies, and VP of Service Operations with Netgrocer where he helped design and implement business performance models.

“JoiningRed Lion offers me an exciting opportunity to make a difference by applying my customer relations and operations experience on a global scale,” said De Sousa.

“Knowing that satisfied customers are key to our success, I look forward to working alongside Scott and Red Lion’s service and support teams to provide the best possible customer service in the industrial automation and networking industry.”

With more than 20 years of electronics and engineering experience, Scott has been with Red Lion since its acquisition of Sixnet in 2011.

His technical support and

management background is well suited to helping organizations prepare their systems for the Industrial Internet of Things (IIoT). To better assist customers and distributors in meeting this challenge, Scott’s expanded sales engineering and technical support role will ensure that Red Lion provides superior service and support at every step of the pre- and post-sale implementation process.

For more information or to reach customer service,please visit www.redlion.net/support

Proven / Reliable Soft Starters for LT/HT Pumps/Compressors The complex process of starting an Induction Motor is intelligently controlled, simplified and a smooth jerkless start with reduced starting current is achieved with Jayashree HFSR Soft Starters.

Jayashree is pioneer in design & manufacture of harmonic free series Reactor type SoftStarters.

With continuous upgradation and adoption of new techniques our Soft Starters

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are most Ideal for Starting Induction motors.

* Ideal for Pumps/Compressors/

The latest models incorporate a HMI control which shows the starting / running performance of motor and keeps log of motor performance and parameters.

* Can reduce starting current

* Available for 415V/3.3/6.6/11 KV with motor rating up to 35 MW

For more details contact :-

* HMI/PLC control with data logging

Pune 411026

* CPRI tested & approved

crusher

up to 1.5 X FLC * Thousands of units in operation over last 35 years.

Jayashree Electron Pvt. Ltd EL-12, J Block, MIDC, Bhosari Phone:- 020 46768998 E-mail :- sales@jayashree.co.in

December 2015

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ABB Delivers its 10 Millionth Variable Speed Drive ABB’s technology is cutting energy consumption in applications including pumps, fans, hoists, conveyors, mixers, propulsion - in industry sectors including water, oil, gas, cement, mining, food and beverages.

The ten millionth ABB low voltage drive rolled off the production line at ABB’s Beijing factory in November. The ten millionth drive is going to Wuhan Guide Electric Co., Ltd. in China, a system integrator manufacturing electric control systems for port cranes.

Drive number 10 million is an ACS880 industrial drive, part of ABB’s all-compatible drives portfolio. Compatible with virtually all types of

processes, motors, automation systems and users, they are designed to tackle any motor-driven application in any industry, whatever the power range. The innovation behind all-compatibility is the new drive architecture, which simplifies operation, optimizes energy efficiency and helps maximize process output.

The ACS880 series consists of single drives, multidrives and drive modules.

ABB developed its first AC drive in the 1970s, and today they offer the most advanced range of variable speed drives in the world. ABB drives cover a wide power and voltage range, including voltages up to 13.8 kilovolts and power up to 100 megawatts.

Using variable speed drives

to intelligently control motors increases energy efficiency. Over the 40 years that ABB has been delivering millions of drives to all industries, a huge amount of energy has been saved. The installed base of ABB drives saved 445 terawatt-hours (TWh) in 2014 alone, equivalent to the consumption per year of more than 110 million households in the EU. If that 445 TWh would have been generated by fossil fuel-powered electricity plants, ABB drives reduced CO2 emissions in 2014 by about 370 million metric tons, corresponding to the

The outstanding direct torque control (DTC) motor control technology and built-in crane control software of ABB’s industrial drives help us to maximize crane performance. For our customers – the ports – ABB industrial drives mean improved safety, high availability, and high total efficiency, resulting in lower energy costs,” Li Xiang CTO, Wuhan Guide Electric Group

ACS880 industrial drives series is part of ABB’s all-compatible drives series.

The ten millionth drive will control a port crane. yearly emissions of more than 90 million cars.

For more details visit http:// new.abb.com/drives/lowvoltage-ac/industrial-drives

Electrical Third Party Inspection and Industrial Services from Precision Precision Inspection Services offers various kinds of technical services for your Industrial ane Commercial needs such as:- Electrical Safety Audit.

– For Chemical Industries, Malls, Hotels, Residential and Commercial buildings etc. as per IS/BIS norms. Vendor Assessment. – To check quality, workmanship, capability of manufacturing unit for its

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product through different clients. Third Party Inspection.

– For all type of electrical and Instrumentation equipments like HT/LT Panels, Transformer, Cables, Motors, Gauges, Transmitter, Flameproof/ Whether proof Equipments and other small equipments and accessories.

Third Party inspection/

Second party Inspection Job/ Technical Supports & Service/ Subcontracts. – In process stage Inspection, Final Stage Inspection, Commissioning Inspection, Review of Quality Plan, Datasheet, GTP, FAT, SAT etc. Calibration of Measuring Instruments, Calibration, Testing, Maintenance of all types of relays and Sub Contract for electrical work installation,

erection, testing etc.

For more details contact Precision Inspection Services, ​ Unit Of Precision Group, 28, Haria Industrial Estate, Nr. Capitol Hotel , Majiwade, Thane (W) – 400602 Mob: +91 8655097710 Email : elec@ precisiongroup.org web : www.precisiongroup.org

December 2015

COMAU and B&R assimilate robotics into machine control

Walter Burgstaller (Sales Director - Europe at B&R, left) and Tobias Daniel (Head of Sales & Marketing at COMAU Robotics) presented openROBOTICS for the first time at SPS IPC Drives 2015.

With the introduction of openROBOTICS, partners COMAU and B&R are opening up new dimensions of robotics integration for machinery and production lines. The solution is based on a full lineup of COMAU robots that handle payloads ranging from 3 to 650 kilograms.

Perfectly synchronized

“With completely uniform programming for every component in the line – including the robotics – our customers around the world gain the full benefit of holistic approaches to operation, diagnostics and maintenance,” says Tobias Daniel, head of sales and marketing at COMAU Robotics. “You won’t find another solution like this on the market.” Traditionally, robotics and machinery have always relied on separate controllers or gateways.

engineering environment,”

Deceember 2015

COMAU robots all over the world can now be completely and seamlessly integrated into machines and production lines equipped with B&R automation components.

“The customer simply selects the desired COMAU robot in the Automation Studio explains Walter Burgstaller, B&R’s European sales director. “With mapp technology, the robot can then be effortlessly incorporated in – and perfectly synchronized with – the machine’s automation software. Conventional solutions with cumbersome interfaces will never achieve this kind of usability and performance.”

For more details visit www.br-automation.com

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February 2014 2015 November December

THE LAST LEAF Dear Readers, As part of the visit by the Indian Prime Minister Narendra Modi to the UK, the first one in a decade, the UK and India reaffirmed the importance of addressing climate change and promoting secure, affordable and sustainable supplies of energy. The package encompasses £3.2 billion of commercial agreements, joint research programmes and initiatives to share technical, scientific, and financial and policy expertise. In one of the forums in India, the Union Minister of State (IC) for Power, Coal and New & Renewable Energy announced that by 2017, India should not need to import thermal coal except for the coastal power plants. (Courtesy: globalenergyworld.com) Zone Startups India, a joint venture of Toronto-based Ryerson Futures Inc. and the Bombay Stock Exchange Institute, recently picked five Indian startups for its accelerator program, amongst 300 startups. They will be incubated in the Digital Media Zone (DMZ) of Ryerson University in Canada, which is ranked fifth in the world by the University Business Incubator Index. Two of the winners are from Bangalore – Lightmetrics and Plackal – two from Delhi – Neuron and Swift File Transfer – and the fifth one, Surveylytics, is from Thane, a satellite town of Mumbai, where Zone Startups India is based. The main criterion for selection was the potential of the business to go global. The selected startups can leverage their presence in Canada for launch and expansion into North America. “It’s an opportunity for Indian startups to experience the North American market first hand and develop valuable connections,” says Jens Michael Schaal, commercial counsellor in Delhi for the state of Ontario, Canada. (Courtesy: techinasia.com) Billions in Change is a movement founded by billionaire philanthropist Manoj Bhargava, creator of 5-hour Energy. Along with its accompanying film with the same name, Billions in Change seeks to solve the world’s most pressing problems by promoting the adoption of inventions that can improve humanity. He has committed to spending his wealth to improve humanity. But instead of conventional charity, he’s focused on inventions that address the root causes of pressing global problems. According to him, nearly every global problem boils down to three issues: energy, water and health. One of the products, called Free Electric, that he soon plans to launch in India, is a reclining hybrid stationary bicycle that generates electricity. Pedaling spins a flywheel, which powers a turbine generator, which charges a battery.

An hour of pedaling will produce a day’s worth of power for a rural household—enough to provide lighting, run a small fan, and charge a mobile device. This electricity comes with no utility bill, generates zero pollution, and produces no waste. Bhargava plans to deploy 10,000 bikes to India in 2016, with pilot tests commencing in Uttarakhand before a nationwide rollout. While initial manufacturing of Free Electric, which is set to begin within the next few months, will take place in the United States and India, Bhargava intends for Free Electric eventually to be produced worldwide— but only if he can ensure that no one cuts any corners. Free Electric is one of numerous potentially world-changing products being developed at Stage 2 Innovations. Another is the Rain Maker, a water-purification technology that uses an evaporative process—similar to how the sun makes rainclouds—to turn salty or polluted water into clean water for drinking and agriculture. Rain Maker units are designed to work at any scale. A single unit, suitable for a village, can clean 1,000 gallons of water per hour. Larger volumes could be handled by employing multiple units in series.

We need your input on any industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our readers about a better tomorrow.

Till then, Happy Technology!

Manoj Kabre Member, Editorial Advisory Board

Deceember 2015

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December 2015

Pressure Range

Capacity

Discription

Sr No

M3/Min

CFM

Bar

1

Lubricated SCREW Compressor

0.23 to 43.70

8 to 1545

8 to 13

2

Oil Free SCREW Compressor

5.30 to 51.40

187 to 1815

8 to 10

3

Lubricated PISTON Compressor

.125 to 6.20

4.5 to 219

8 to 40

4

Oil Free PISTON Compressor

.156 to 1.30

6 to 45

8 to 40

5

BOGE FLEXPET

1.55 to 17.9

54 to 634

40

BOGE AIR. THE AIR TO WORK.

BOGE India , No. 216, Third Link Street, Industrial Estate, Nehru Nagar, Kottivakkam, Chennai - 600 096, india@boge.com* www.boge.in Chennai Mr. F C Jayakaran

: +91 9600041656 : fc .jayakaran@boge .com

/ Chennai Mr. Muthu Ganesan : +91 9003172111 : muthu.ganesan@boge.com

Hyderabad Mr.W.Narendra

: +91 9704770930 : w. narendra@boge.com

/ Mumbai Mr. Hasan Hasware : +91 9840956161 : h.hasware@boge.com

Delhi Mr. Deepesh Upadhyay

: +91 9818556732 : d.upadhyay@boge.com

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Kemppi India Private Limited Lakshmi Towers, 2/770, Kazura Garden, 1st Street, Neelankarai, Chennai - 600 041 Phone: 044-45671200 Email: sales.india@kemppi.com Web: www.kemppi.com www.martupdate.com

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