Volume 10 Issue 8 February 2014 Pages 52 `100
Special Program for Micro Cutting Tool holding Systems from Schunk India
Expediting the growth of Indian Economy Reverse Engineering with 3D Measurement Growing with Global Acceptance Energy Managment System boosts Industrial Productivity Virtual Instrumentation: The Next Gen Industry
“FARO expects to grow 20-25% in APAC region this year� February 2014
ON FACE Harkiran Sandhu Country Manager, FARO Singapore www.martonline.in
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“I marvel every day at how people can excel - and that’s what really gets me going.” Satya Naryana Nadella CEO, Microsoft Corporation As expected Indian born 47 year old Indian American Satya Naraya Nadella became the third CEO of Microsft, succeeding Steve Ballmer. He dide his basic schooling from Hyderabad Public School at Begumpet, Andhra Pradesh and took his B.Tech graduation from Mangalore University through Manipal Insitutute of Technology, Karnataka. To pursue higher studies in Computer he moved to US and he earned an MS in Computer Science from University of Wisconsin-Mulwaukee and an MBA from University of Chicago Booth School of Business. After an initial career with Sun Microsystems, Satya started his journey to the top of Microsoft in 1992, and he worked in different platforms and led major and prestigious projects.
Foreword
Dear Readers,
Finance Minister P Chidambaram presented his vote on account this month keeping the general elections in mind, a custom followed by all his predecessors, to cover up the serious issues with eye washing sops and schemes to fool the hundred crore population. We have given a short brief on his budget in our economic column of this edition. I completely agree with the FM that our manufacturing sector is doing very bad and tax reliefs will surely give some motivation for increasing the sales of automobile sector. How sincere was he in supporting the manufacturing industry at this point of time with these tax cuts, is what needs to be introspected. For the last five to six years world economy is going through a rough patch and all developing countries faced the slow down. Comparing to our neighboring countries as well as other developing nations we have seen our economy falling down due to the political uncertainty and credibility, distancing global investors to keep their trust on our economy. We expect these concerns to be addressed with proper forecasting and planning rather than election based people favorable schemes. With the strength and potential India offers in the future, an able and stable leadership can turn the country into steady growth within no time. It’s the time we should wait for getting this stability the real challenge for India Inc.
Hari Shanker Managing Editor
It’s not a big news today that Indians are leading different big corporates in the world. Even when our economy is struggling, more and more executives of Indian origin like Indra Nooyi, Chairperson and CEO of PepsiCo, Ajay Banga, CEO of Mastercard Inc, Vikram Pandit, ex CEO of Citibank are expected to lead multinational companies and are making a mark at the global level. These leaders empower their teams to spread their business across the globe and bring stable growth to their respective organizations, showcasing the talent and strength we have in our people. Even in the political circle, we have Indians like Piyush Bobby Jindal, currently Governor of Louisiana and the Vice Chairman of the Republican Governors Association racing for the top leadership at United States. Unfortunately back in India we are facing leaders who can sincerely lead our country into a stable economy.
In this edition of MART we are featuring our cover story on the latest techniques in the testing and measuring industry. We have included articles by Ravindra Kondekar, Chairman and Managing Director, K C Precision and Sunil Kumar, General Manager – Energy Management System, Elmeasure along with an interview with Harikiran Sandhu, Country Manager, Faro Singapore on the subject. We are sure you will find our other regular inputs interesting and it adds to your technical knowhow. Let me take leave preparing the next edition of MART on the latest welding techniques and about the industrial safety. Looking forward your feedback to make MART, Smart! February 2014
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MART Feature Expediting the growth of Indian Economy
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10 Easing Critical Component Manufacturing with Renishaw
12 Reverse Engineering with 3D Measurement
14 Growing with Global Acceptance
16 Energy Managment
System boosts Industrial Productivity
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Yeast foam detected, overflow stopped – level switch in brewery applications
MART Focus 22 Powerful test systems for test benches and vehicles
Harkiran Sandhu Country Manager, Faro Singapore
24 Virtual Instrumentation: The Next Gen Industry
On Face
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Columns Journey Towards Excellence
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P S Satish
36 Startup Management Best Practices Startup Team Sizes Tomasz Tunguz
Volume 10 Issue 8 February 2014 Annual Subscription `1200 Member INS Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre Mahesh R P Sandeep Higne
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Managing Editor Hari Shanker hari@martinfotech.in
Editorial Team Saumya Bhattacharya +91 9038005670 Debolina Dutta
Executive Director
Creative Assistant
Siji Nair sijicn@gmail.com
Sayan Chaudhuri
Accounts Subhojit Dey accounts@martinfotech.in
Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2n Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed February 2014 Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every eff employees accept any responsibilities for any errors or omissions. © All Rights Reserved
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Green In
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Fair Mart
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Case Study
Feature Article 38
New JumboFlex 50 Completes the Schmalz Tube Lifter Family
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Risk more weight
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Special Program for Micro Cutting Kennametal’s Beyond offers new Solid Carbide Drill for maximum results
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Mart Update
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The Last Leaf Advertisement & Circulation
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MART FEATURE
Expediting the growth of Indian Economy
Saumya Bhattacharya editormart@gmail.com
It is a known fact that India is growing financially for the last two decades in such a way that even many developed countries around the world have failed to match up with this development. Testing and measuring is one of the fastest growing sectors that has played major role in making Indian economy a success story. India is now being acknowledged as the top quality manufacturing company for the testing and measuring equipments by the world leaders of this segment. As the new technologies like touch screen, android, 4G have taken centre stage in this decade T&M industry is compelled to make necessary arrangements to embrace this new technologies and as a result testing and measuring equipments succeeded to create a buzz in this sector. Truly Test and Measurement (T&M) instruments are considered as the backbone of all manufacturing and service industries for several decades. Testing and measurement equipments are constantly getting a tough competition by the core industry devices. Hard to say whether this scenario has changed or not but definitely after playing a role of a second fiddle for quite some time T&M instruments have come to the age where it can be recognized as star performers in the industry. The T&M industry in India used to grow up by 11 per cent. The total market size today stands close to Rs 10 billion in a fiscal year. Technologies which are changing day by day, the growing demands for the new applications and the advanced industrial environments are surely stimulating T&M manufacturers to keep in sync. Fortunately for these reasons the T&M industry has witnessed many changes in terms of technology upgradation, price competency and new products over the last few years. There is a tremendous demand of T&M equipments in the sectors like Aerospace and defence and as it is expected the budget for defence will grow further in the near future the T&M equipment companies can have bigger smile on their faces for the longer time. Apart from Aerospace and defence the sectors like telecom, manufacturing, government and education sectors are also the prevalent growth drivers for T&M in India. Testing and measurement tools help engineers to speed up their performance of computing and networking through highspeed serial technologies. With the growing number of technologies
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like 3G, 4G, Wi-Fi and LTE(wireless communication of high speed data for mobile phones) in the field of communication and telecom sector where wireless networks and mobile devices are also the common phenomenon for people fuelled the growth of T&M industry in this new age world.
demanding in the market and more userfriendly for all.
It is said that necessity is the mother of all inventions and for that reason when this necessity drives an industry to improve their product features and if the demand graph increases industry also changes their product profile and same thing happened with testing and measuring equipment manufacturers who improve and incorporate features like multichannel testing, higher bandwidth and smoother computer interface with user-friendly software to make their product more
Like any other developing countries in the world, Indian market is also moving ahead and the increasing number of services in various industries which includes automotive, food and beverages, textiles, construction, entertainment and hospitality services will need sophisticated test instruments at various check points of every stage to minimize repairs and maximize the adaptability for the people whom the product was made for.
Even the transition from analogue to digital and from standalone instrument to a total test solution and development of application-specific test instruments are the primary transitions.
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Testing and measuring industry also play a vital role in jewelry, electroplate and research and development industry where products are examined in a way that it never create any detrimental effect on the consumers. Even the bio-tech and infrastructure industry are using testing and measuring equipments for betterment of the sector. Both are different sector but only the excise duty and the sales tax of the electronic products are high in India and for that reason the leaders of the industry are expecting to have a more simplified and reasonable structure of taxes to keep the production cost lower than the present time. T&M manufacturers are also faced with the challenges of a shorter turnaround time which includes areas starting from designing to volume production and it is increasingly becoming shorter due to the market competition. Maintaining the standard of the elements of designing is quite difficult as it is regularly being developed in different places and it is important to have common industry standard test tools that make whole industry possible to share information and resolve problems swiftly. Day by day technologies are increasingly becoming an intricate part of testing and measuring industry and they are driving T&M manufacturers to improve and incorporate new features to establish their credibility in the manufacturing sector. The hastening rate of technology changes the means of the new product entries and the verification stage of the industry. It is an industry which is driven by the demands of the market and the concerned companies are successfully taking it in the zenith not only keeping in mind of the product features and also meeting up the ever changing demands of the manufacturing industry in India and abroad. The two major reasons can be underlined for the growth of testing and measuring industry in India1. As per the demand of a product is concerned in Indian market, the population of India which is more than 10 billion does help in a positive way because demand grows with population. Unlike China, which has a population of more than India, grown in industries because of the demand made by the people and succeeded in making indigenous products which has been distributed to all over the world, India makes itself a demanding market for the global electronic giants like Apple February 2014
Projected Market Size for Test & Measurement 2013-14 INR (million)
CAGR (%) (2010–2014)
General Purpose Test Equipment Market
9500
12.0
Fibre Optic Test Equipment Market
800
9.0
Wireless Communication Test Equipment Market
860.02
26.0
Lab Analytical InstrumentationMarket
25400
24.8
Inc, Samsung, Sony, LG and Panasonic but India lacks indigenous products to be sold in the global market and that is why Indian market is still depending upon the imported products and Chinese companies have a great share of product range in India. Economy grows only when a country successfully mixed up their indigenous products with foreign products and for non-deficit economy export plays a major role because revenue generates only from export. T&M industry is highly developed in the countries of these giants. India basically lacked such giants to fill the gap of the ‘necessity’ in the ‘necessity makes way for innovation’. The then ongoing industry in India preferred the core industry devices. The dive of these big giants in Indian market made way for many local wannabe entrepreneurs to enter the sector, leading to creation of some successful brands like Micromax. But the consumer, maybe in Indian or global platform, is brand addict. People are choosy when it comes to electronics, colloquially called ‘techies’. The customer demand for quality has increased by a multitude in recent times. This makes both the global giants and the local industry fetch for better testing and measuring facilities. 2. The large drive of quality management, large scale implementation of TQM in industries. The need felt by the domestic industries to make an attempt of the famous Japanese ‘zero defect’ manufacturing. All these factors call for stringent testing and measuring policies which depend on better testing and measuring industry. Industries have started focusing on efficiency, quality and lesser
defects in production and development. The Testing and measuring industry plays a major role in achieving these goals. In current age three basic branches of engineering i.e. Mechanical, Electronics and Computer science see their own future, in the industry, in a symbiotic relationship and the net growth of the industry then depends on the improvement in the all the fields and not just a single one of them. Precision manufacturing is becoming the backbone of the production and the mechanical industries. Emerging SPM manufacturers which are getting good worldwide recognition in these fields, such as Grind Master Machines Pvt Ltd, focus on nanometer finishing of components. For the other fields which tend to grow in a symbiotic relationship with these industries have to focus similarly on precision and accuracy. A better T&M industry becomes a key to such circumstances. A proper merging of such precision focused industries from various fields is what leads the direction for the growth of industries in India. The current industry trends show significant scope for the already established and emerging T&M industries too. Many international testing and measuring industries such as Tecktronix and many others are entering the Indian T&M industry with their branches here. Hence for the local T&M industry it is both an opportunity as well as a challenge. A Frost & Sullivan research on Indian Test & Measurement shows that the domestic demand has risen over the past 18 months, to make the test and measurement market realize opportunities from every sector in India. www.martonline.in
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Easing Critical Component Manufacturing with Renishaw Associated Tools, a Kolkata based Indian manufacturing company, uses BFW, LMW and Hurco machine tools, each one fitted with Renishaw touch trigger inspection probes and tool setting systems, for supplying products to the defence industry. Since adopting the machine tool probes, Associated Tools have benefited from an elimination of component rejections, and a 66% reduction in tooling set up times. The demand for the production of defence components is growing by the day in India, and by their very nature, precision manufacture of these components is critical. H J Bishnu, now Director of Associated Tools, took on the responsibility for the manufacturing unit in 2005 and filled the company’s workshop with the very latest manufacturing technology, including LMW, BFW and Hurco CNC machine tools – all equipped with a variety of Renishaw touch trigger probes and tool setters. Investing only in machines was not enough However, when he first took charge, there were various issues surrounding the production techniques. Bishnu recalls, “after investing so much in CNC machines, we were still facing problems with slow machining cycle times, setup idle times, inconsistencies in quality and operator errors”. Initially in 2005, the process for loading components required manual indexing and a manual dialling system with nine indexing positions. Each manual indexing process took around 45 minutes. This, followed by a further 30 minutes while the machine checked the position, made the set up a slow and inefficient process. In addition, the result of manual indexing and operator errors means that the inconsistency in quality was 5% and the rejection rate 1.5%. The tool setting process was also manual, which again contributed to time delays each time a new tool was set. Before long, Mr Bishnu, a BTech graduate from the Halida Institute of Technology, realised that investment in CNC machine technology alone was not enough.
The OMP60 and OTS optical tool setting probe on a machine tool at Associated Tooling.
He had visited SECO, Pune, and had seen first hand the benefits of Renishaw’s touch trigger and tool setting probes, and decided they would have a great impact on his own machining process. Dramatic results With the introduction of Renishaw’s OMP60 touch trigger probe and OTS contact tool setting probe, Associated Tools began to see dramatic results. Introduction of a CNC 4th axis and OMP60 makes indexing automatic. For every indexing position, the reference point is set automatically, meaning that the component setting time is reduced to 20 minutes and the rate of scrap is reduced to almost zero percent.The cable-free OTS optical tool setting and broken tool detection probe also brought about successful process improvements; the tool setting time was dramatically reduced and also benefited from increased accuracy.
“Since we started using Renishaw probes and software, we have been able to consistently manufacture critical components for the defence industry. There has been a reduction of 66% in set up time and we have stopped talking about component rejections and manual errors, as these have been eliminated completely.” H J Bishnu Director , Associated Tools has noticed dramatic results with the introduction of Renishaw’s OMP60 touch trigger probe.
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Even the tool life was optimised. Associated Tools – well placed to compete for high accuracy work With two decades of experience in manufacturing valves, a special unit for manufacturing products for the defence industry and the increased accuracy and decreased set up times resulting from Renishaw probing techniques, Associated Tools is now on track for growth. With the focus on manufacturing and supplying components to factories in Kolkata, Ishapur and Thirchi, Associated Tools aims to double or triple its defence unit turnover. With rapid process development, stable and predictable processes and automated machines, Associated Tools is well placed to compete for high accuracy work. Outstanding efficiency Associated Tools has proven how the correct integration of Renishaw’s touch trigger probes and broken tool detection systems, in combination with the innovative software required, can result in a highly efficient system for the manufacture of precision components for the defence industry. For further details contact www.renishaw.com November February January 2014 2013
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Reverse Engineering with 3D Measurement Reverse Engineering is the process of duplicating an existing product without the aid of drawings, documentation, or computer models. In ordinary engineering, the product designer creates a drawing showing how an object is to be built, and then the object is manufactured by following the design drawing. In reverse engineering, the steps are inverted. First, engineers identify the system components and their interrelationships. The object is taken apart to discover its structure, function, and operation. Duplication of the part is enabled by capturing physical dimensions, features, and material properties. Next, a CAD drawing or other representation of the system is created. Then a reproduction of the original system is accurately created based on that drawing. Why reverse engineering is needed A common scenario in which reverse engineering is needed is as follows: a company has a machine. A part fails and a replacement part is needed. But the manufacturer has discontinued the machine and no longer makes parts for it. The machine owner can reverse engineer a replacement part from the failed part, preventing the machine from going out of service. Reverse engineering can shortcut product development time. It quickly captures a product in 3D digital form and exports the data for rapid prototyping, tooling, or manufacturing. There are many other situations in which reverse engineering can be used: • Substituting an original part design that has inadequate or no documentation available.
• Redesigning a part to eliminate a bad feature or to reinforce good features.
computational fluid dynamics on parts for which no design information is available.
• Analyzing competitor products.
How objects are measured for reverse engineering
• Supporting new modifications where original CAD models cannot. • Updating obsolete products with current technology. • Updating or creating as-built documentation. • Supplying a part with little downtime that is mission-critical to a system, reproduced in large quantities, or reflects a big investment. • Performing fine element analysis or
To reverse engineer an object, you need to know its physical dimensions. Unless the dimensions are extremely precise, the reverse engineered product will not be an accurate reproduction of the original and may not function. Parts may be measured carefully by hand using calipers, micrometers, and other similar tools. In modern reverse engineering, a coordinate measuring machine (CMM) can measure the geometry of an object faster and more accurately than these traditional hand tools. A typical CMM measures three orthogonal axes, X, Y, and Z, operating in a 3D coordinate system. Each axis has a scale that indicates the position of a point on that axis. CMMs use touch probes to record points as the probe contacts the surface of the part being measured. Points are measured one at a time until the CMM collects enough data for the software to determine lengths, diameters, angles, and other geometric elements. The machine reads input from the touch probe as directed by the operator or software. Then the XYZ coordinates of each point are
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February January 2014
used to determine size and position. A CMM can measure dimensions either through contact with the object or with a laser scanner. The point cloud collected is converted into surfaces. This measurement data is then exported to a CAD package for refinement, analysis, and generation of cut tool paths for CAM. Portable CMMs 3D measurement arms are portable CMMs that operate much in same manner as traditional CMMs in that they determine and record the location of a probe in 3D space and report the results through software. One of the main benefits of a portable CMM over a traditional, or fixed, CMM is portability. Portable CMMs are considerably smaller and lighter and can therefore be taken to the part needing inspection. This removes the need to take the part to the CMM and minimizes machine downtime and quality bottlenecks. Furthermore, portable CMMs do not require the controlled temperature conditions that traditional CMMs demand. Portable CMMs are also easier to use and substantially less expensive than traditional CMMs. A laser line scanner can be attached to a measurement arm to allow for noncontact measurement. A laser scanner can quickly capture data to create a point cloud of millions of points of data that can be used to create a CAD file. The benefits of adding a laser scanning probe to a measurement arm include not only the speed in collecting large amounts of data, but also the ease-of-use and lower risk of impacting a part during measurement. The FARO ScanArm The FARO ScanArm is a portable CMM ideally suited for reverse engineering applications. Non-contact measurement is usually a faster way to inspect and measure parts, and industry as a whole is moving away from hard probing toward laser scanning. One key advantage of laser scanning is that soft, deformable, and complex shapes can be easily inspected without coming into contact with the part. The core of the system is the FaroArm, an articulating measurement arm that captures dimensional data by hard probing the surface being measured. With contact measurement repeatability up to .024mm and accuracy up to ±.034mm, the FaroArm weighs 11.3kg or less. A FARO Laser Line Probe (LLP) can be
February 2014
combined with the FaroArm to add laser scanning capability to the ScanArm. The advantage of the LLP is that the laser probe is small enough to remain attached to the ScanArm so the system can operate as a contact (hard probing) or non-contact (scanning) device without any alterations to the machine itself. The FARO LLP is the smallest and lightest laser probe on the market today, weighing less than half a pound. Measurements are accurate up to 35µm (+0.0014 inch). That accuracy, combined with light weight, means the user can perform reverse engineering functions without fatigue. A triangulation process is used to find the position of objects in 3D space. A laser stripe emitted by a diode is projected onto the surface being measured. A camera looks at the laser stripe from a known angle and determines the location for each point on the line. High frame rates and high resolution image sensors improve scanning speed and produce high-density point clouds capable of detecting finer details. A major advantage of the FARO ScanArm is that it is a portable solution. They system can easily be carried to the part or machine to be measured. Operating temperature range is 50 to 140o F. Fixed CMMs, by comparison, are large machines that require their own specialized air conditioned rooms to strictly control temperature and conditions. Because the fixed CMM is immobile, objects to be measured must be transported to and from the inspection area, which can present a challenge depending on weight and size. Reverse engineering success stories The Andretti Autosport team has the most wins of any Indy car team. To make sure each race car leaves the shop with the same design set-up specifications, the Andretti team reverse engineers
sanctioned parts and carbon fiber components for their cars. They use the FARO ScanArm to scan incoming parts and the entire race car assembly for proper set-up. Having FARO in-house enables Andretti technicians to measure and inspect parts, scan models, and verify set-ups. It also eliminates the time and expense of paying outside service providers to do their reverse engineering measurements. Trinity Forge is a closed-die forging plant that specializes in complex shapes in a wide variety of sizes. To meet the stringent specifications of their customers, Trinity uses the FARO ScanArm daily to inspect dies when they come off the CNC machines, to track die wear, and to reverse engineer products that may not have prints or legacy data available. The speed at which they can now operate is a great value to the company. Conclusion Reverse engineering is an important discipline that can greatly extend the useful life of machines by allowing the machine owner to fabricate his or her own parts when the OEM has discontinued the product. Reverse engineering also enables parts to be updated with new technology or redesigned to add new features or even eliminate flaws. The easiest, fastest, and most affordable way to measure parts and products for reverse engineering is with a lightweight portable CMM that offers both contact and non-contact measurement. The combination of these benefits – as manifested in the FARO ScanArm – provides a fast and efficient solution for today’s competitive needs. The author Dan Alred is Product Marketing Manager of FARO Technologies, Inc. and he can be contacted at dan.alred@faro.com
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MART FEATURE
Growing with Global Acceptance
Ravindra Kondekar md@kcpindia.com
Indian Measuring Industry Measurement is a very important process for analyzing the quality of a product. Precise and accurate measurement gives you the feedback for making the product perfect. In current scenario, highly sophisticated testing & measuring instruments are available to ensure the product is made exactly as per the specification, which in turn capable to deliver the desired performance. The world is witnessing rapid technological growth in every field and in recent years, due to the significant shift in manufacturing sector of measuring equipment from conventional type to sophisticated measuring is mainly contributed for delivering the very best. In India, National Physical laboratory, New Delhi (NPL) & National Accreditation Board for Testing and Calibration Laboratories (NABL) have played a very important role in raising the quality standards of Indian manufacturer. ‘NPL’ has made available the International standards for Testing & Calibration Laboratories & NABL which is an autonomous body under the aegis of Department of Science & Technology, Government of India, empowering the Indian industries to enhance the quality and reliability of Indian goods in the domestic market and exports, thereby, catalyses the growth of Indian economy. There are more than two thousand accredited Testing & Calibration
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laboratories all over India, contributing to produce the best quality products with compliance to the International standard In coming years, India will be the world’s major stake holder in the area of manufacturing of quality measuring & testing instrument, ‘KCP’ is a leading name from India in the area of manufacturing and supply of the best measuring instrument from ‘Metrology’ to the world. ‘KCP’ is engaged in offering one stop gauging solution to the Industries where all gauging needs are met under one roof. Indian Technology - Global Acceptance:India is progressing well from last two decades, largely focusing on to improve the manufacturing techniques to produce most precise and accurate products. As you know this sector is mostly captured by tiny and medium scale industry. Manufacturers have realized the global competition and started upgrading their
manufacturing set up to deliver best measuring equipment in the market conforming to the International standards. Also, the measuring & testing instrument manufactured by Indian industries have global acceptance. Thanks to NABL for their assistance to the Indian industries for percolating quality awareness in depth. Qualified Manpower:Considering the current pace of growth of India economy there could be shortage of qualified manpower in this sector. It is observed that the young generation is inclined towards soft work but in manufacturing sector where hard work is essential is now suffering a lot. There is a need to create awareness among the students to understand their capabilities and interest to choose the right opportunity. Also, there is a need of multiple training centers all over India to provide specific technical training to the
February 2014
students which can create more qualified manpower to meet the growing needs.
s
ies g Ser
Technology Update:To be in the market, it is essential to comply the present requirements of quality standard which are very stringent. Hence, manufacturer needs to update technologically and at service. Testing and measuring industry is reciprocating very well to the requirements. To compare the current technology with 20 years back, there is not much change in the basic measuring instrument but difference is in handling of these instruments. The handling skill required for these instruments is drastically reduced with automation and software. Also, there is latest equipment available which are dominating the market most are noncontact type of measurement devices and there are few Indian manufacturer of these products. Future Market:At present, the market for Testing & Measuring instrument is somewhere around Rs. 1500 crore and looking at the growing demand and hope in next five years it should be doubled. Every manufacturing sector requires the testing and measuring instruments. The major demand at 75% is from automobile sector. The current market trend is focused on sophisticated instrument of quality, reliability and affordable price. Automobile sector is driving this market. Automobile product is a combination of whole engineering and is an assembly of multiple component. Hence, there is major demand for testing and measuring instruments Indian Market:Over the years, this Industry is dominated by Europe and USA. Now, Indian manufacturers could develop import substitute to most of the overseas product which in turn saves lot of foreign exchange. Also, the cost of Indian product of same quality as compared to the overseas product is less than half which resulted to be competitive with the world. The Industry is mostly dependent on
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KCP has an array of high end products in the field of dimensional metrology. There are very few manufacturers’ of this product in the world and now, KCP is the only one from India.They have also developed some special techniques to enhance the required characteristics of the material. KCP gauges thus have strong dimensional stability and greater wear resistance. Being a precision instrument manufacturer they are aware that precision of all the engineered products in the market actually begins from us. And this sense of responsibility always makes there endeavor harder.
Type of set M8
Long Gauge Block Specifications - Range available over 100 mm ? to 500 mm in Grade K, Grade 0, Grade 1 & Grade 2 as per ISO 3650/DIN 861 standards. - Manufactured from special grade of Alloy steel, for greater wear resistance and for superior surface finish. - Holes are provided at both ends of Gauge blocks for combinations with the help of Gauge block clamp. - Gauge Blocks are available in standard as well as customized sizes. Along with standard sets, individual Gauge Block is also available.
Size in mm 125,150,175,200,250
Quantity 8 nos.
300,400 & 500 M5
600,700,800,900 & 1000
Automobile Industry. The growth is largely depending on the performance of the Automobile Industry. Huge market is available for Indian manufacturer within India. Also, the Chinese manufacturers are spreading their wings in Indian market. As long as Indian manufacturers produce best quality with competitive price till then there is no worry. The author Ravindra Kondekar is a well known name in the field of metrology having experience of over 21 years. He is
5 nos.
the founder Chairman & Managing Director of K.C.Precision (KCP). He defined the road map for all technology and innovation at KCP and came up with fine products that proved to be import substitute. He made KCP a one-stop gauging solution. Under his dynamic leadership his company has created a global footprint by serving over 25 countries. His entrepreneurship has been greatly acclaimed and awarded. He is also involved in many social activities and initiated works for environment conservation. www.martonline.in
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MART FEATURE
Energy Managment System Boosts Industrial Productivity
Suniil kumar marketing@elmeasure.com
In the last decade there has been tremendous industrial growth and this has increased the demand for power. Power is scarce and there is a growing gap between supply and demand. This has fuelled the need for quality energy management products. Customers are now veering towards digital testing and measuring products that is more accurate than the analog version. This trend augurs well for the future growth. Energy Management System With a competitive economy and soaring power cost around the world, many organizations are now in the process of implementing energy conservation measures. Energy management represents a significant opportunity for organizations to reduce their energy use while maintaining or boosting productivity. The Power monitoring software with the measuring equipment in a single basket of products helps to provide a successful implementation of Energy Management System. ElMeasure as a solution provider with domain expertise and technology installed Energy Management System for all types of organizations in India and overseas. ELNet is ElMeasure’s Energy Management Software that is being installed in more than 100 to 125 organizations every year and they are aiming for doubling the installation in the coming year. Increasingly, measuring industries that are providing Energy Management System have started seeing the highest growth rates. Matured technology With the Indian economy opening up, Indian manufactures had to compete with global players. This has
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enabled them to lay more stress on R&D which has helped them to bring out innovative products with the latest technology. Over the last decade country’s exports have tripled which is an indication that Indian manufactures are recognized to be at par with developed countries. ElMeasure’s rapid growth since its inception is due to its capability to churn out innovative energy management products that the market requires. ElMeasure is now present in more than 30 countries with Japan being our major market which speaks volumes about the quality and technology of their products. Future prospect Currently manufacturers see a large potential for T&M Instruments industry both nationally and globally. ElMeasure being in the energy field has seen incredible growth due to scarcity of energy globally. The lack of electrical power to meet demand has forced people to monitor and measure consumption both internally due to cost factors and externally by government agencies. ElMeasure sees great potential in the industry for testing and metering instruments in the days ahead
Energy Efficiency The fast pace of development and growth has increased the demand for power. The scarcity of power globally has led to the exploitation of fossil fuels leading to environmental damage and global warming. Today although one has realized the need for Energy Management, there is a lack of direction in addressing the issue. They facilitate the consumers by promoting the concepts of Energy Management and educating them in utilizing the power rationally. They also offer customized solutions rather than merely offer products that do not yield any benefit to the customer. Product offerings Elmeasure provides solutions for Measuring, Monitoring & Controlling electrical energy and their product range includes BEMS (Building Energy Management System) with complete automation and control features. To compliment it they have products like Prepaid Energy Meter with an option to integrate process parameters with electrical parameters and protection, Power Distribution Unit, Multifunction Meters, Digital Panel Meters and control products such as Compact Demand Controllers with 4 relay output and 4
row LED display meter with auto scaling, Power Factor controllers, Motor Protection Systems, Earth Leakage Relay etc. Most of their products can accept digital input for cost effective networking, 4 digital outputs with full flexibility for controlling. Another unique product that has been launched recently is ‘GenPro’, a Generator Monitoring Unit with a dual display system. This product has received critical acclaim from generator manufactures and OEM’s. State Of The Art ElMeasure has established an in-house state of the art Research and Development facility at its Bangalore plant. The R & D centre has been recognised by the Department of Scientific and Industrial Research (DSIR), Government of India for both hardware and firmware development in sharp difference to many of their competitors. This has enabled them to rapidly translate their ideas and concepts into products and customized solutions. Their R&D team has developed world class products and they can boast of being the “No 1” as far as the product range, quality and superiority are concerned their products have obtained Trade mark, CE certification
February 2014
and UL certification. One independent review agency has shortlisted them as part of the 20 Most Promising Utilities Tech Solution Providers for the year 2013. ElMeasure products are designed with the latest technology MSP and highly reliable SMT components. The advanced reflow soldering reinforces the reliability aspect. Most of their products are designed with a platform to accommodate customization with ease. The above platform has helped roll out over 50 different customized products at a faster rate. They have the latest web based EMS software that can be integrated with ElMeasure meters or other well known brand of meters. This feature empowers customers to get accurate and real time data to analyze, generate reports and identify the opportunities of energy savings, from any part of the world. ELNet PPS is a web based software used to recharge the Prepaid Meter over the internet. Recently lunched product Aggregator AG1000 enables to store the data internally (up to 64GB) and send the data to remote server using GPRS or local server using Ethernet or Wifi. With the data storage in the aggregator redundancy can be achieved. Future Plans Elmeasure has grown 25-30% every year. They are already on target to achieve 50 Crores sales for the financial year 2013 -2014 and they are confident to cross the 100 crores mark by the year 2016. They are also hoping to achieve this target by broadening our product base, provide solution based engineering, and acquisitions.
February 2014
ElMeasure has grown rapidly over the last couple of years in terms of bottom line and head count. Keeping their future growth in mind, they have purchased 3 acres of land in the KIADB Hardware Park, near Devanahalli, Bangalore and plans are in full swing to start construction of a state of the art manufacturing plant by early March 2014. Technological superiority ElMeasure considered as a leader when one considers
expertise in the field and the current technology being implemented in our testing and measurement equipment. Their top management team is the veterans in their respective field and our R&D team can fall back on 100 years of combined industry experience that our leadership possess. They use some of the latest technology available to give their end user a technologically advanced quality product. Texas Instruments (TI), one of the largest manufacturers of
semiconductors, recognised ElMeasure as one of the top and first five companies using their latest technology products. Many products introduced into the market by ElMeasure have the distinction of being the first of its kind in the market by an Indian Manufacturer. The pace at which they introduce products into the market is another factor that proves that ElMeasure possess product expertise and knowledge and hence able to deliver to the customers.
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MART FEATURE
Yeast foam detected, overflow stopped – level switch in brewery applications Yeast is an essential ingredient of the fermentation process for brewers. But yeast can also be a problem forthe brewery. Recently Baumer helped the Carlsberg brewery solve a problem with left over yeast from the fermentation process – by using the CleverLevel switch. the yeast will settle to the
the traditional fork simply
bottom of the fermentation tank. The yeast is then removed and reused for several fermentation processes before finally being stored in an excess yeast tank and sold off as animal feed. In this final stage of filling the excess yeast tanks, Carlsberg experienced overflow problems due to the heavy build-up of foam which was preventing triggering of the traditional level vibrating forks.
can’t recognise the range and condition of media. The CleverLevel is maintenance free due to the minimal installation depth of 15 mm and the self-draining sensor tip. It is also approved to both 3A and EHEDG standards. It can be configured visually and easily via the dedicated software and the FlexProgrammer. The switching range can
Figure 1: CleverLevel – Level switch LFFS/LBFS and configuration tool FlexProgrammer
The Carlsberg brewery was
and runs day and night.
founded in 1847 and is today
Carlsberg produces 2.2 million
the fourth largest brewery in
hectoliters of beer annually
the world. The production and
and employs around 45.000
distribution center is located
staff worldwide. Every day
in Fredericia (Denmark)
Carlsberg sells around 120 million beers globally. Baumer has been supplying Carlsberg with instrumentation for more than 10 years. Initially to the beer production lines near Copenhagen and since the relocation in 2008 to Carlsberg’s new production
Figure 2: Heavy build-up of foam in the excess yeast tanks
and distribution center in
Figure 3: CleverLevel switch for detecting the filling level in the excess yeast tank
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Fredericia. Fermentation
The solution for Carlsberg was
be adjusted as required
is the process by which
using the Baumer CleverLevel
to ignore foams during
yeast converts the glucose
switch for detecting the filling
maximum or minimum
in the wort to alcohol and
level in the yeast tanks. The
monitoring.
carbon dioxide gas – giving
CleverLevel uses the frequency
This function can also be
the beer its alcohol content
sweep technology and is a
used when the level switch is
and its carbonation. When
level switch universal for all
supposed to ignore adhesive
fermentation is nearly
types of media, whether the
substances, as for example in
complete (the process takes
media is wet, dry, sticky or
tanks with liquid chocolate.
around 4 to 6 days), most of
in this case foam – whereas
Even when the tank is February 2014
Figure 4: CleverLevel switch for detecting the filling level in the excess yeast tank
empty, the sensor and tank wall are covered with chocolate. When configured accordingly, the CleverLevel will only be triggered when the tank is actually full or empty. The graphic configuration software also increases user friendliness. Using traditional forks one version is needed for dry media (powder, grain etc.) one version for wet media and one version for sticky media. The CleverLevel can be used through the entire process, from when the barley arrives in the storage tanks to the finished beer. The change-over from
the traditional fork to the CleverLevel has completely eliminated the problem with overflow in the excess yeast tanks. The benefit to Carlsberg has been a more environmentally friendly solution, as left over yeast is not entering the sewage system due to overflow. There has also been a cost saving benefit to Carlsberg due to process optimization and less required maintenance. The Author Thomas Jydby Hedemark is the Industry Segment Manager for Food & Beverage, Baumer. More Information on www.baumer.com/brewery
“The CleverLevel switch has solved our problems with overflow in the excess yeast tanks due to its unique and easy configuration options. We are now considering using the CleverLevel switch in our CIP caustic tanks, where we experience similar issues with foam and overflow”. Lone Højbjerg Petersen Maintenance Coordinator Carlsberg, Denmark
February 2014
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ON FACE
“FARO expects to grow 20-25% in APAC region this year” FARO is the global technology company that develops and markets computeraided coordinate measurement devices and software. As a pioneer and market leader in portable computer-aided measurement, FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate, reliable, and easy to use. The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs. Worldwide, approximately 15,000 customers are operating more than 30,000 installations of FARO’s systems. Based in India, Harkiran Sandhu the Country Manager for FARO Singapore, spearheads the entire operations of FARO for India, South East Asia, Australia and New Zealand. In a brief conversation with MART, he speaks in detail about FARO’s present business and further plans, excerpts.
How is Indian technology matching up with the international quality standard in the testing and measuring market? Manufacturers in India refer to international standards when it comes to quality benchmarking. Naturally, they spare no effort to ensure that their equipment and products match up to those strict standards, standing up to close scrutiny. In this regard, FARO is glad that its ISO-certified devices allow customers to achieve various certifications in their respective industries, including ISO and API accreditations to name a few. What is your view on availability of qualified manpower in India for this industry? Skilled manpower is one of the most valuable resources for a company. Recruiting and retaining the right people with relevant skills is a challenge that companies all over the world face constantly. Even as companies strive to retain its best talents, staff turnover is still a real concern because it impacts the quality and productivity of a company.
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By making our products more user-friendly, FARO mitigates the issue through reducing training times and minimizes the negative impact of turnover. Are Indian companies continuously updating their services with latest technologies when it comes to testing and measuring equipment industry? Increasingly, manufacturers have higher demands for precision and speed in quality checks. As their products and measurement needs both become more complex, quality control and inspection tasks are becoming more intricate, requiring more sophisticated measuring high-precision equipment like FARO’s. Since quality is of essence, high-precision equipment like FARO’s becomes crucial for manufacturers. For this reason, FARO has observed higher levels of awareness and seen more opportunities for education or conversion. What are some key market trends? Tell us about the latest equipment that are dominating the market.
According to IT analyst house Gartner’s first forecast of the consumer and enterprise 3D printer (3DP) market, worldwide shipments of 3DPs priced less than $100,000 will grow 49 percent in 2013 to reach a total of 56,507 units. That number is expected to further increase in 2014, growing 75 percent to 98,065 units, followed by a near doubling of unit shipments in 2015. 3D printers, scanners, design tools and materials will continue to advance. With that, applications of 3D print technology will naturally become more widespread, as the cost of complexity of creating 3D printed items decrease. In addition, our observations indicate that 3D printing is indeed gaining popularity. For one, it is increasingly common for tradeshow organizers to have a dedicated feature area for 3D printing-related technologies, a move that is well received by both exhibitors and visitors. In particular, companies that do rapid prototyping appreciate 3D printing, because it positively impacts their product design process by way
of two very important factors – time and confidentiality. With 3D printing, designers are able to manufacture a mockup quickly for analysis and evaluation, and it eliminates the need for model fabrication at an external vendor’s facility, both of which are attractive attributes. We have developed several products to target specific market needs. FARO’s Laser Scanner line of products (FARO Laser Scanner Focus3D and Focus3D X 330) and FARO® Edge ScanArm ES, offer users powerful functionality and simplicity in small packages. These portable devices are capable of capturing highresolution point clouds that can be processed into data models for re-production of objects. The digitized information allows key design specifications and requirements of the prototype to be checked or modified easily and quickly. What will the testing and measuring market size be in future and what will the growth rate be? As mentioned earlier, we notice an increase in February 2014
Die & Mold, Shipbuilding, Architecture, Heritage, Forensic, Plant Management, and Mining. This year, we expect slightly stronger demands from the Automotive, Metal Fabrication and Aerospace markets. What are the challenges to market growth?
The new FARO® Laser Scanner Focus3D X 330 is a high-speed 3D laser scanner for detailed measurement and documentation. The Focus3D X 330 surpasses previous models in functionality and performance. In short, the device has a greater scanning range (up to 330 meters), the ability to scan in direct sunlight, and possesses an integrated GPS receiver that correlates individual scans in post-processing, making it ideal for surveying based applications. The Focus3D X 330 also boasts of increased measurement accuracy and better noise reduction. Well-loved features of its predecessor’s compact size, lightweight and ease of use remain an attraction for users.
complexity of metrology needs across manufacturing sectors. This should translate to more business enquiries for the testing and measuring market in general. FARO anticipates a 20-25% year on year growth for our business in the APAC region for 2014. What are the industrial sectors that consume most of the testing and measuring instruments? As a global 3D measurement solutions company, FARO serves a broad range of industries. The company’s products are used widely in various applications in many industries and sectors, including Automotive, Aerospace, Heavy Machinery, February 2014
The key challenge is the lack of awareness for, as well as willingness to adopt, new technology. Many Indian companies are still stuck in old, traditional ways of measurement because the knowledge and understanding of the benefits of new 3D metrology technology is limited. FARO firmly believes that by sharing this knowledge with companies and future generations of engineers, it will help boost the industry’s growth. For this reason, FARO chose to partner educational institutions, giving engineering students opportunities to operate and utilize our devices in their learning. What are some of the market opportunities and threats faced by industry players? India is a market with much potential, with growing literacy levels and a thriving talent pool. Manufacturers are beginning to understand and see the importance of having quality tools to achieve superior work performance, and that is promising. However, in trying to maintain the bottom line, companies may not immediately see the benefits of investing in expensive equipment. These users may compromise and settle for substandard tools or even attempt develop their own quick fixes, thereby slowing the progress that the testing and measuring market has made. Again, FARO hopes to counter those threats through education and eventually bring these users to adopting new technology.
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With the last nine years of networking and publishing of MART, we have succesfully made place in the Indian Manufacturing Industry. Our growth was always triggered by the changes undertaken as per the needs of the industry. The contents of MART is unique, with regular columns by industry experts in the diversified feilds of engineering manufacturing, technical features, news updates, interviews, case studies, trade fair informations etc. The guidance and support of the experienced industry professionals through our Editorial Advisory Board have helped us to understand the need of the indian Manufacturer better and produce a journal which is used by the industry as an utility.
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21
MART FOCUS
Powerful test systems for test benches and vehicles
IXXAT has extended its FRC-EP series with the new, compact FRC-EP170With the FRC-EP series, which consists of the FRCEP170 and the FRC-EP190, IXXAT offers universally usable hardware platforms for applications on the test bench or in the vehicle, attractive for their high performance, favorable prices, broad range of applications, and support for a wide variety of software solutions. These devices have FlexRay, CAN, CAN
The handy FRC-EP170 was developed for
FD, LIN, K-Line, USB, Ethernet, EtherCAT,
use in vehicles. Its main application areas
Bluetooth, and RS232 interfaces, along
are gateway solutions for connection to
with analog and digital I/O. Expansion slots
different ECU integration levels, prototype
make it simple to add other interfaces,
controllers, expansion of data loggers with
including WLAN, GSM, or GPS. This makes
additional interfaces, and wireless signal
the devices scalable, adaptable to specific
display using off-the-shelf mobile phones or
Development and manufacturing takes
applications, and ready for the future.
tablet PCs.
place at the head office in Halmstad,
With the new FRC-EP170, IXXAT has now
Demanding Restbus simulation and
introduced a very compact, cost-effective
gateway solutions can be implemented
variant of the familiar FRC-EP190. Both
quickly and easily based on either device,
devices have the same processor and the
using the corresponding software
same operating system, making the new
packages from IXXAT. There are also
variant completely software-compatible
extensive development packages available
and just as powerful.
for the development of specific solutions.
Thanks to the large number of identical interfaces and its galvanic isolation, extended scalability, and especially its optional EtherCAT slave functionality, the primary target application of the FRC-EP190 is integration with test benches in the automotive communications world.
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Custom functions and applications can be implemented quickly and easily by customers in-house thanks to the use
independent supplier of embedded network technology for automation devices. HMS develops and manufactures solutions for interfacing automation devices to industrial networks.
Sweden. Local sales and support is provided by the HMS branch offices in Chicago, Beijing, Karlsruhe, Milan, Mulhouse and Tokyo. HMS employs over 240 people and reported sales of â‚Ź42.5 million in 2011. HMS was formed in 1988 and is listed on the NASDAQ OMX Nordic Exchange in Stockholm in the category Small Cap, Information Technology with ISIN SE0002136242.
of the Linux operating system and the
For further information contact HMS
availability of a free Software Development
Industrial Networks Tel: +91 20 2563 0211
Kit.
email: in-sales@hms.se
HMS Industrial Networks is the leading
Web: www.ixxat.de
February 2014
February 2014
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23
MART FOCUS
Virtual Instrumentation: The Next Gen Industry The rapid adoption of the PC in the last 20 years catalyzed a revolution in instrumentation for test, measurement, and automation. One major development resulting from the ubiquity of the PC is the concept of virtual instrumentation, which offers several benefits to engineers and scientists who require increased productivity, accuracy, and performance. Virtual Instrumentation A virtual instrument consists of an industry-standard computer or workstation equipped with powerful application software, cost-effective hardware such as plug-in boards, and driver software, which together perform the functions of traditional instruments. Virtual instruments represent a fundamental shift from traditional hardware-centered instrumentation systems to softwarecentered systems that exploit the computing power, productivity, display, and connectivity capabilities of popular desktop computers and workstations. Although the PC and integrated circuit technology have experienced significant advances in the last two decades, it is software that truly provides the leverage to build on this powerful hardware foundation to create virtual instruments, providing better ways to innovate and significantly reduce cost. With virtual instruments, engineers and scientists build measurement and automation systems that suit their needs exactly (user-defined) instead of being limited by traditional fixedfunction instruments (vendor-defined). Virtual Instruments versus Traditional Instruments Stand-alone traditional instruments such as oscilloscopes and waveform generators are very powerful, expensive, and designed to perform one or more specific tasks defined by the vendor. However, the user generally cannot extend or customize them. The knobs and buttons on the instrument, the built-in circuitry, and the functions available to the user, are all specific to the nature of the instrument. In addition, special technology and costly components must be developed to build these instruments, making them very expensive and slow to adapt. Virtual instruments, by virtue of being PC-based, inherently take advantage of
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the benefits from the latest technology incorporated into off-the-shelf PCs. These advances in technology and performance, which are quickly closing the gap between stand-alone instruments and PCs, include powerful processors such as the Pentium 4 and operating systems and technologies such as Microsoft Windows XP, .NET, and Apple Mac OS X. In addition to incorporating powerful features, these platforms also offer easy access to powerful tools such as the Internet. Traditional instruments also frequently lack portability, whereas virtual instruments running on notebooks automatically incorporate their portable nature. Engineers and scientists whose needs, applications, and requirements change very quickly, need flexibility to create their own solutions. You can adapt a virtual instrument to your particular needs without having to replace the entire device because of the application software installed on the PC and the wide range of available plug-in hardware. Flexibility Except for the specialized components and circuitry found in traditional instruments, the general architecture of stand-alone instruments is very similar to that of a PCbased virtual instrument. Both require one or more microprocessors, communication ports (for example, serial and GPIB), and display capabilities, as well as data acquisition modules. What makes one different from the other is their flexibility and the fact that you can modify and adapt the instrument to your particular needs. A traditional instrument might contain an integrated circuit to perform a particular set of data processing functions; in a virtual instrument, these functions would be performed by software running on the PC processor. You can extend the set of functions easily, limited only by the power of the software used.
Lower Cost By employing virtual instrumentation solutions, you can lower capital costs, system development costs, and system maintenance costs, while improving time to market and the quality of your own products. Plug-In and Networked Hardware There is a wide variety of available hardware that you can either plug into the computer or access through a network. These devices offer a wide range of data acquisition capabilities at a significantly lower cost than that of dedicated devices. As integrated circuit technology advances, and off-the-shelf components become cheaper and more powerful, so do the boards that use them. With these advances in technology come an increase in data acquisition rates, measurement accuracy, precision, and better signal isolation. Depending on the particular application, the hardware you choose might include analog input or output, digital input or output, counters, timers, filters, simultaneous sampling, and waveform generation capabilities. The wide gamut of boards and hardware could include any one of these features or a combination of them. Software in Virtual Instrumentation Software is the most important component of a virtual instrument. With the right software tool, engineers and scientists can efficiently create their own applications, by designing and integrating the routines that a particular process requires. They can also create an appropriate user interface that best suits the purpose of the application and those who will interact with it. They can define how and when the application acquires data from the device, how it processes, manipulates and stores the data, and how the results are presented to the user. February 2014
LabVIEW Ideal for Creating Virtual Instruments LabVIEW is an integral part of virtual instrumentation because it provides an easy-to-use application development environment designed specifically with the needs of engineers and scientists in mind. LabVIEW offers powerful features that make is easy to connect to a wide variety of hardware and other software. Graphical Programming One of the most powerful features that LabVIEW offers engineers and scientists is its graphical programming environment. With LabVIEW, you can design custom virtual instruments by creating a graphical user interface on the computer screen through which you 1. Operate the instrumentation program 2. Control selected hardware 3. Analyze acquired data 4. Display results Figure 1. LabVIEW Virtual Instrument Front Panel
You can customize front panels with knobs, buttons, dials, and graphs to emulate control panels of traditional instruments, create custom test panels, or visually represent the control and operation of processes. The similarity between standard flow charts and graphical programs shortens the learning curve associated with traditional, text-based languages. You determine the behavior of the virtual instruments by connecting icons together to create block diagrams, which are natural design notations for scientists and engineers. With graphical programming, you can develop systems more rapidly than with conventional programming languages, while retaining the power and flexibility needed to create a variety of applications. Connectivity and Instrument Control Virtual instrumentation software productivity comes about because the software includes built-in knowledge of hardware integration. Designed to create test, measurement, and control systems, virtual instrumentation software includes extensive functionality for I/O of almost any kind. LabVIEW has ready-to-use libraries for integrating stand-alone instruments, data acquisition devices, motion control and vision products, GPIB/IEEE 488 and serial/RS-232 devices, and PLCs, among others, to build a complete measurement
February 2014
Figure 2. LabVIEW Virtual Instrument Block Diagram
and automation solution. LabVIEW also incorporates major instrumentation standards such as VISA, an interoperable standard for GPIB, serial, and VXI instrumentation; PXI and software and hardware based on the PXI Systems Alliance Compact PCI standard; IVI interchangeable virtual instrument drivers; and VXI plug & play, a driver standard for VXI instrumentation; PXI and software and hardware based on the PXI Systems Alliance Compact PCI standard; IVI
interchangeable virtual instrument drivers; and VXI plug & play, a driver standard for VXI instruments. Open Environment Although LabVIEW provides the tools required for most applications, LabVIEW also is an open development environment. Standardization of software relies greatly on the ability of the package you select to work well with other software, www.martonline.in
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measurement and control hardware, and open standards, which define interoperability between multiple vendors. By selecting software that meets these criteria, you ensure that the company and applications take advantage of the products offered by several suppliers. In addition, conforming to open commercial standards reduces overall system cost. A large number of third-party hardware and software vendors develop and maintain hundreds of LabVIEW libraries and instrument drivers to help you easily use their products with LabVIEW. However, this is not the only way to provide connectivity to LabVIEW-based applications. LabVIEW offers simple ways to incorporate ActiveX software, dynamic link libraries (DLLs), and shared libraries from other tools. In addition, you can share LabVIEW code as a DLL, built executable, or using ActiveX. LabVIEW also offers a full range of options for communications and data standards, such as TCP/IP, OPC, SQL database connectivity, and XML data formats. Reduces Cost and Preserves Investment Because you can use a single computer equipped with LabVIEW for countless applications and purposes, it is a versatile product. It is not only versatile but also extremely cost-effective. Virtual instrumentation with LabVIEW proves to be economical, not only in the reduced development costs but also in its preservation of capital investment over a long period of time. As your needs change, you can modify systems easily without the need to buy new equipment. You can create complete instrumentation libraries for less than the cost of a single traditional, commercial instrument. Multiple Platforms The majority of computer systems use some variation of the Microsoft Windows operating system. Nevertheless, other options offer clear advantages for certain types of applications. Real-time and embedded development continues to grow rapidly in most industries, as computing power is packaged into smaller and more specialized packages. Minimizing losses resulting from changing to new platforms is important and choosing the right software for this purpose is a key factor.
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LabVIEW minimizes this concern, because it runs on Windows 2000, NT, XP, Me, 98, 95, and NT embedded, as well as Mac OS, Sun Solaris, and Linux. LabVIEW also compiles code to run on the VenturCom ETS real-time operating system through the LabVIEW Real-Time Module. Given the importance of legacy systems, National Instruments continues to make available older versions of LabVIEW for Windows, Mac OS, and Sun operating systems. LabVIEW is platform independent; virtual instruments that you write in one platform can transparently be ported to any other LabVIEW platform by simply opening the virtual instrument. Because LabVIEW applications are portable across platforms, you can be assured that your work today will be applicable in the future. As new computer technologies emerge, you can easily migrate your applications to new platforms and operating systems. In addition, because you can create platform-independent virtual instruments by porting applications between platforms, you save development time and other inconveniences related to platform portability. Distributed Development You can easily develop distributed applications with LabVIEW, even across different platforms. With easy-to-use server tools, you can offload processor-intensive routines to other machines for faster execution, or create remote monitoring and control applications. Powerful server technology can simplify the task of developing large, multicomputer applications. In addition, LabVIEW includes standard networking technologies such as TCP/IP, and incorporates robust publish and subscribe protocols. Analysis Capabilities Virtual instrumentation software requires comprehensive analysis and signal processing tools, because the application does not just stop when the data is collected. High-speed measurement applications in machine monitoring and control systems usually require order analysis for accurate vibration data. Closed-loop, embedded control systems might need point-by-point averaging for control algorithms to maintain stability. In addition to the advanced analysis libraries already included in LabVIEW, National Instruments provides add-on software such
as the LabVIEW Signal Processing Toolset, the LabVIEW Sound and Vibration Toolkit, and the LabVIEW Order Analysis Toolkit to complement analysis offerings. Visualization Capabilities LabVIEW includes a wide array of builtin visualization tools to present data on the user interface of the virtual instrument -- for charting and graphing as well as 2D and 3D visualization. You can instantly reconfigure attributes of the data presentation, such as colors, font size, graph types, and more, as well as dynamically rotate, zoom, and pan these graphs with the mouse. Rather than programming graphics and all custom attributes from scratch, you can simply drag-and-drop these objects onto the instrument front panels. Flexibility and Scalability -- Key Advantages Engineers and scientists have needs and requirements that can change rapidly. They also need to have maintainable, extensible solutions that can be used for a long time. By creating virtual instruments based on powerful development software such as LabVIEW, you inherently design an open framework that seamlessly integrates software and hardware. This ensures that your applications not only work well today but that you can easily integrate new technologies in the future as they become available, or extend your solutions beyond the original scope, as new requirements are identified. Moreover, every application has its own unique requirements that require a broad range of solutions. Virtual Instrumentation in the Engineering Process Virtual instruments provide significant advantages in every stage of the engineering process, from research and design to manufacturing test. Research and Design In research and design, engineers and scientists demand rapid development and prototyping capabilities. With virtual instruments, you can quickly develop a program, take measurements from an instrument to test a prototype, and analyze results, all in a fraction of the time required to build tests with traditional instruments. When you need flexibility, an scalable open platform is essential, from the desktop, to embedded systems, to distributed February 2014
networks. The demanding requirements of research and development (R&D) applications require seamless software and hardware integration. Whether you need to interface stand-alone instruments using GPIB or directly acquire signals into the computer with a data acquisition board and signal conditioning hardware, LabVIEW makes integration simple. With virtual instruments, you also can automate a testing procedure, eliminating the possibility of human error and ensuring the consistency of the results by not introducing unknown or unexpected variables. Development Test and Validation With the flexibility and power of virtual instruments, you can easily build complex test procedures. For automated design verification testing, you can create test routines in LabVIEW and integrate software such as National Instruments TestStand, which offers powerful test management capabilities. One of the many advantages these tools offer across the organization is code reuse. You develop code in the design process, and then plug these same programs into functional tools for validation, test, or manufacturing. Manufacturing Test Decreasing test time and simplifying development of test procedures are primary goals in manufacturing test. Virtual instruments based on LabVIEW combined with powerful test management software such as TestStand deliver high performance to meet those needs. These tools meet rigorous throughput requirements with a high-speed, multithreaded engine for running multiple test sequences in parallel. TestStand easily manages test sequencing, execution, and reporting based on routines written in LabVIEW. TestStand integrates the creation of test code in LabVIEW. TestStand also can reuse code created in R&D or design and validation. If you have manufacturing test applications, you can take full advantage of the work already done in the product life cycle. Manufacturing Manufacturing applications require software to be reliable, high in February 2014
performance, and interoperable. Virtual instruments based on LabVIEW offer all these advantages, by integrating features such as alarm management, historical data trending, security, networking, industrial I/O, and enterprise connectivity. With this functionality, you can easily connect to many types of industrial devices such as PLCs, industrial networks, distributed I/O, and plug-in data acquisition boards. By sharing code across the enterprise, manufacturing can use the same LabVIEW applications developed in R&D or validation, and integrate seamlessly with manufacturing test processes. Virtual Instruments beyond the Personal Computer Recently, commercial PC technologies have begun migrating into embedded systems. Examples include Windows CE, Intel x86-based processors, PCI and CompactPCI buses, and Ethernet for embedded development. Because virtual instrumentation relies so heavily on commercial technologies for cost and performance advantages, it also has expanded to encompass more embedded and real-time capabilities. For example, LabVIEW runs on Linux as well as the embedded ETS real-time operating system from VenturCom on specific embedded targets. The option of using virtual and real-time capabilities. For example, LabVIEW runs on Linux as well as the embedded ETS real-time operating system from VenturCom on specific embedded targets. The option of using virtual instrumentation as a scalable framework that extends from the desktop to embedded devices should be considered a tool in the complete toolbox of an embedded systems developer. A dramatic technology change example that affects embedded systems development is networking and the Web. With the ubiquity of PCs, Ethernet now dominates as the standard network infrastructure for companies worldwide. In addition, the popularity of the Web interface in the PC world has overflowed into the development of cell phones, PDAs, and now industrial data acquisition and control systems. Because virtual instrumentation software can combine one development environment for both desktop and real-time systems using cross-platform
compiled technology, you can capitalize on the built-in Web servers and easy-touse networking functionality of desktop software and target it to real-time and embedded systems. For example, you could use LabVIEW to simply configure a built-in Web server to export an application interface to defined secure machines on the network on Windows, and then download that application to run on a headless embedded system that can fit in the user’s hand. This procedure happens with no additional programming required on the embedded system. You then can deploy that embedded system, power it, connect to the application from a remote secure machine via Ethernet, and interface to it using a standard Web browser. For more sophisticated networking applications, you can graphically program TCP/IP or other methods with which you are already familiar in LabVIEW and then run them in the embedded system. Embedded systems development is one of the fastest growing segments of engineering, and will continue to be for the foreseeable future as consumers demand smarter cars, appliances, homes, and so on. The evolution of these commercial technologies will propel virtual instrumentation into being more applicable to a growing number of applications. Leading companies that provide virtual instrumentation software and hardware tools need to invest in expertise and product development to serve this growing set of applications. For example, for its flagship virtual instrumentation software platform, LabVIEW, National Instruments has described a vision that includes the ability to scale from development for desktop operating systems, to embedded real-time systems, to handheld personal digital assistant targets, to FPGA-based hardware, and even to enabling smart sensors. Next-generation virtual instrumentation tools need to include networking technology for quick and easy integration of Bluetooth, wireless Ethernet, and other standards. In addition to using these technologies, virtual instrumentation software needs a better way to describe and design timing and synchronization relationships between distributed systems in an intuitive way to help faster development and control of these often embedded systems. www.martonline.in
27
MANUFACTURING EXCELLENCE
Journey Towards Excellence
P S Satish gotopssatish@gmail.com
Managing a SME in India - Part 14 As a continuation of last article, we will discuss on few more points to manage SME’s better in India 26. Focus on Audit and Review I was helping a company on overall improvement. After identifying the gap between where they are and where they could be, lot of efforts were done by the company in forming team, giving them trainings and providing adequate resources. Everything went on well and CEO was very happy to see the progress. When I met him after one year, he had a grouse that whatever was set as a process is gradually dwindling. No wonder. We see it everywhere. This is the reason why third party quality certification audit agencies have audits at a definite frequency to check whether system is sustained and also to ensure gaps are closed then and there. In Bangalore, there is a lot of debate going on usage humps on roads. Though there is a standard on formation of humps, it is not followed fully and individuals are also putting humps as they like leading to many accidents. Many times,
humps are not distinguished with typical yellow and white color giving tough time for vehicle drivers especially in night. Simple audit or regular review by corporation would bring problems to surface for corrective actions. Audit and review are powerful tools of management for journey towards excellence. There is no ideal system which will last for ever without a check point in between. The deterioration over the period appears in thermodynamics as entropy. As per law of thermodynamics, though quantity of energy in the universe is conserved, it may lose quality over time. Sliding towards disorder is law of nature and no exception to companies. Hot milk in room over the period becomes cold and attains uniformity with room temperature. Where there was an order of temperature difference slowly become disorder of uniformity. In order to avoid deterioration of system or process over
Humps are not distinguished with typical yellow and white color giving tough time for vehicle drivers especially in night. Simple audit or regular review by corporation would bring problems to surface for corrective actions
the period, companies should develop a mechanism of review and audit. How do we do that?. ISO prescribes powerful tool of internal audit and management review. How effectively SMEs are using this?. I will share some points to make use of these tools in a better way – •Management should not do review as a ritual. They should involve fully with a clear agenda. •In the reviews allow participants to express frankly. It should become a platform where everyone has an opportunity to interact with the management. Constructive criticism to be encouraged. •Critical points for discussions and decisions to be addressed in agenda and have enough time for it.
Audit and review are powerful tools of management for journey towards excellence.
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•The review meeting should not be a forum for giving
information and blaming others. This platform should be used for making decisions. • Every review should document the decision taken and actions needed indicating who is responsible, when it will be done, supporting resources needed etc. • The person heading the review should listen to each one attentively and not to thrust points on them. Encouraging collective decision will motivate them to come out with more ideas. •Every review should follow PDCA (Plan-Do-Check-Act) cycle where each points discussed in earlier reviews are checked for effectiveness and any course correction needed is taken. •Every participant should be made to understand the value of time. Discipline of fixed start & end point and to cover agreed points within time is a must for high productivity
February January 2014
•Each manager should spend time with key employees under him/her to do a review at a definite frequency. It could be say weekly at a fixed time and fixed duration. The focus of this review could be to discuss any critical issues of the week, alignment to long term goal, any resource constraints etc. It will become a platform for employees to express and gives confidence of management support. I had a boss who used to review with me every fifteen days at a fixed time and he used to discuss all major happenings within two weeks and relook at points we talked in previous meeting. He had an exclusive review book for me so that he would know which points are discussed when and agreed actions. Because of this mechanism, our relationship improved very much. A good practice to look at. •Make it a practice to conduct annual review of key colleagues directly under you. It should not be done as ritual but should support growth of individual as well as the organization. During review identify areas where employees have done very well, areas and tasks that could be improved, personal improvements needed, trainings required and targets for the next year. Do not generalise statements but express with examples of situation. Annual review also called appraisal is a powerful tool for employee development. Document the agreed points and make it a point to review every quarter to check not only on focus & fulfilment but also do any course corrections needed. •Internal audit at a definite frequency is one of requirement in ISO quality system certification process. It demands that each process or clause is checked by an trained internal auditor at a fixed frequency to check for any gaps and improvements • Concept of ISO internal audit can be used by management February 2014
differently. Check randomly if a process or a system is working well or not. E.g. take a random case of customer complaint to check how this is addressed. Walk into shop floor to check randomly any abnormalities and demand correction. • Follow practice of ‘Gemba’. That means to go to the place where incident happened or a process followed to physically see for yourself. This is better than discussing in board room. • Documentation is the key to get benefit of reviews and internal audits. Take photos wherever is necessary. The organizational learnings will improve with this. • Develop culture of problem solving where everyone keeps on solving every issues encountered. • At the end of review and internal audit, focus on how to improve the process to close the gap than just commenting on the result
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• Self-assessment is one of another powerful tool for improvements. Encourage all to do it at individual level or at organizational level. It is difficult for anyone to lie to one self. There is a saying in Germany, ‘Vertrauen ist gut, aber Kontrolle ist besser’ which means, ‘Trust is good but checking is better’. Too much of review with micromanagement is counterproductive. I had a boss who wanted to review my every action on daily basis which turned out to be a disaster.Develop mechanism of review and internal audit with right frequency and the company will gain a lot. I will continue the series of article in the next issue. Please send your inputs,remarks,suggestions toP.S.Satish,Mentor and Capability Developer, M/s Saraswati Industrial Services, Q 103,MantriParadiseApart ments,Bannerghatta Road, Bangalore-560076. Do visit www. satishps.com. Have agood day.
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29
GREEN IN
Thinking Green Freudenberg’s contribution to better air quality in India As one of the most important global economic hub, India has invariably witnessed a significant increase in energy consumption, triggering a rise in CO2 output. The Freudenberg Group, an innovative and values-based technology company, is instrumental in reducing potentially harmful emissions. The Company, having held business ties to India for more than 90 years, today has a broadly-diversified range of products and solutions which underscore the Group’s commitment to environmental protection and responsible corporate citizenship in India. Freudenberg’s solutions for better air quality Eagle Burgmann India, a Freudenberg Group company, owns a wind turbine of 350KW capacity, which generates approximately 400,000 units of power per year. Recently, further investment has been made in a second wind turbine of 5KW with a solar power generation facility at the plant in Pune, which produces about 50 units of power per day. The power generated is for instance used for lighting areas of the plant. Company vehicles are also a concern. As the high traffic volume impairs air quality, pollution checks are regularly carried out on all the companyowned vehicles, as well as on employee vehicles. Employees are encouraged to use bicycles and the carpool wherever possible. Today’s economic and environmental mega-trends call for massive improvements in the efficient use of existing energy sources. For more than 50 years, Freudenberg has supplied innovative filter systems: solutions that make processes more economical, conserve resources, protect people and the environment against fine particles and help improve air quality. At production plants, filters also make a key contribution not only to health and safety but
also to process optimization and product quality. For example, Freudenberg offers the Viledon® eee.Sy, which stands for “energy-efficiency-enhancement system”. This turnkey system enhances energy efficiency and utilizes the waste heat of gas turbines, engines and compressors in hot and humid climates. Due to its eco-friendly design, installing Viledon® eee.Sy gives companies the opportunity to claim “carbon credits”, thereby protecting the environment. Filters are also used in medical technology for checking contamination. For instance Pyramid Filters, part of Freudenberg Filtration Technologies India, develops air filter elements and systems for clean room applications, not only in the medical but also the pharmaceutical, food and chemical industries. Freudenberg filters are used widely throughout the automotive industry. Here, highly-efficient cabin air filters ensure a steady supply of clean air in the passenger compartment. The majority of new cars are equipped with Freudenberg cabin air filters. A comprehensive portfolio of filters for rooms and cleaners rounds off the range. Freudenberg Filtration Technologies India, located in Pune, is ISO-14001 certified
and uses energy-efficient equipment which requires less energy and therefore contributes to lowering CO2 emissions. Alongside sustainable production, the range of filter products themselves, also have a stake in the future of good air quality. LESS emissions of CO2 Freudenberg’s Low Emission Sealing Solutions campaign - LESS for short - includes effective products for CO2 avoidance. The gas lubricated mechanical seal Levitex, developed by Freudenberg Sealing Technologies, runs on a cushion of air thereby generating 90 percent less friction loss compared to a conventional crankshaft seal. The development of Levitex is an important step toward the creation of completely frictionless sealing technology in engines and drastically lowers CO2 emissions and energy consumption. Specialty lubricants are also an effective approach to CO2 reduction at industrial plants and production facilities as they improve machine efficiency. For example, the use of polyglycol oils instead of conventional oils can raise transmission efficiency by up to 15 percent, resulting in similar energy savings. Different measures have been
“Holistic, compatible solutions are a primary concern of the Freudenberg Group and firmly anchored in our Business Principles. This includes the manufacture of environmentally beneficial products, eco-compatible production, as well as the responsible acquisition and usage of raw materials.” Dr. Jörg Matthias Grossmann Regional Representative of the Freudenberg Group in India and Chief Financial Officer of Freudenberg Chemical Specialities.
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taken at all 30 Freudenberg Group Indian sites designed to keep the workplace “green” and the air clean. Employees work continuously on feasible solutions for ecologically-sound manufacturing. The Group’s commitment to environmental protection is also evidenced by a whole host of products and solutions aimed at reducing air pollution. New trees and plants for Bangalore A further example of sustainability is the Klüber Lubrication site project in Bangalore. On entering the facility, one first notices the hundreds of trees on the site. Every visitor is asked to plant a tree. This way, guests not only contribute positively to the environment, they also enjoy taking part in what has now become a Klüber custom. The site currently has over 100 different species of flora and fauna. To avoid drawing water from the city water supply or groundwater, the trees and plants are watered with collected rain runoffs. For further information please visit www.freudenberg.in February 2014
31 2014www.martonline.in February
February www.martonline.in 31 2014
FAIR MART
Partner Kerala turns big hit, 100 EOIS signed for 64 projects The two-day Partner Kerala Meet organised by Department of Urban Affairs (DUA),Kerala has turned out to be a huge success with 100 Expression of Interest (EoIs) signed for developing 64 projects at a total cost of Rs 4291.89 crore.
Addressing a press conference here on this month Hon’ble Minister for Urban Affairs, Government of Kerala Shri Manjalamkuzhi Ali said that the Meet was a big hit among the investors as the government managed to attract investors for twothird of the projects showcased at the meet aimed at helping the cash-strapped local bodies to find partners to develop various infrastructure. The local bodies and development authorities had showcased 84 projects worth Rs 6500 crores at the meet. “We are promoting a new investment culture. It’s a new beginning in the state as the local investors who used to shy away from making investments in the state have come forward to partner with the government to develop projects in their respective home towns,” the Minister said and added that once the respective municipalities finalise the projects, the government will initiate steps to give other
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clearances to the projects within a month. Of the 60 projects for which the investors have signed EoIs, four each EoIs have been signed for Rs 85 crore-Tunnel Marine Aquarium of the Greater Cochin Development Authority (GCDA) and Shakthan Nagar redevelopment project of Thrissur Corporation (Rs 700 crore), three each for GCDA’s shopping mall at Ambedkar Stadium (Rs 126 crore) and Nadakkavu area development of Kozhikode Corporation (Rs 20 crore). Kollam Mayor Prasanna Earnest, Kochi Deputy Mayor B Bhadra, Kalamassery Municipal Chairman Jammal Manakkadan, Kollam Development Authority Chairman A K Hafeez, Pala Municipal Chairman Kuriakose Padavan and GCDA Chairman N Venugopal attended the press conference. Later, the valedictory function of the meet was inaugurated by Minister for
Panchayats and Social Justice Dr M K Muneer and presided over by Minster for Urban Affairs Shri Manjalamkuzhi Ali. Chief Minister Oommen Chandy Hon’ble Chief Minister Shri Oommen Chandy on said Kerala was the best State in India to start business considering the huge possibilities and opportunities offered by its fast-growing cities and the support offered by the government. Addressing the investors at an interactive session organised as part of the two-day Partner Kerala urban development meet here, the Chief Minister said “Kerala should create opportunities from within the State to revamp its infrastructure.” Pointing out that Kerala’s youth has started showing entrepreneurship capabilities, Shri Chandy said the recently introduced student entrepreneurship programme received big response and the Kochi Start-
February 2014
up village was an example for this. On the huge turnout of investors at the Meet, the Chief Minister said that the government was seeking solid financial resources to turn the proposals presented at the meet into reality. “Most of our popular ventures have been put in hold due to lack of funds. It is in this context, we decided to promote the public private partnership model,” the Chief Minister said. Shri Chandy said that the Department of Urban Affairs would immediately make arrangements to strengthen the PPP cell under the guidance of the Minister Manjalam Kuzhi Ali to expedite the process of launching the projects. During his interactive session, Shri Chandy said that the projects would be given a single-window clearance by the respective local bodies to ensure that the projects were completed on time. He said the State was waiting for the central government’s nod for the KochiCoimbatore industrial corridor. He said the government had reached a political agreement to build an electronic city in Amballur near here, but some concerns regarding its impact on the environment needs to addressed. Responding to a query on the legal obstacles to use agricultural land for infrastructure development, he said any such development can be done only in compliance with paddy-wetlands protection law and should be in the best interest of the general public. He said that government will soon resolve issues relating to certain regions being included in zone 3 under the Coastal Regulatory Zone Act. “There is some
confusion with regard to the Act as many of the panchayats have been recently converted into Municipalities. The government is seriously looking into the issue and will do the needful soon,” he added. Hon’ble Minister for Ports and Fisheries Shri K Babu said that the fact that the change in Kerala’s mindset to bring in more private investments through events like Partner Kerala itself was a big achievement. Hon’ble Minister for Public Works Department Shri P K Ibrahim Kunju said this PPP model envisaged in the Partner Kerala meet was slightly different from the traditional PPP mode of project implementation. “The projects shortlisted in the Partner Kerala will be implemented in close association with the local bodies and will be in the best interest of both the parties,” he added. Thiruvananthapuram Mayor Adv K Chandrika, Kollam Mayor Prasanna Earnest, Kozhikode Mayor A K Premajam, Dominic Presentation MLA, Hibi Eden MLA, Benny Behanan MLA and Ludy Louis MLA were present on the occasion. Union Minister for Overseas Indian Affairs Shri Vayalar Ravi said that the Partner Kerala Meet was an innovative model which could be replicated elsewhere in the country.
“The Meet is a bold attempt to attract local investors to partner with the government. This is a good opportunity for local investors to be part of the nation building. It also ensures good returns for the investors,” the Minister said. State Minister for Urban Affairs and Welfare of Minorities Manjalamkuzhi Ali said that the government would ensure that the investments made by the private players in the projects would be safe. “Though we are committed to ensure that the investors get good returns for their investments, not a single piece of government land will be given to private players,” the Minister said. He said that the government devised the Meet as the Public Private Partnership (PPP) was the best model to develop assets lying with the local bodies. “We are considering to launch a new department to oversee proper implementation of PPP projects. The infrastructure projects required for each local body will be finalised only after consultations with respective municipal councils,” the Minister added.
The meet would help corporations, municipalities and development authorities to attract investments for the infrastructure projects that could benefit people.
Earlier, in the introductory session, presenting a paper on the public private participation in local self-governments, Shri E K Prakash, Special Secretary to Finance Department, said Kerala’s economic indicators such as purchasing power were strong enough for attracting investments.
“This Meet is a new platform for the local bodies to find funds for the development projects. The rest of the country could follow this model to develop the urban centres,” Shri Vayalar Ravi said inaugurating the “Partner Kerala”
He said that the government was seeking private partnership in projects which were in the best interest of the general public. ”The ultimate aim of the government is to improve the quality of life of people in Kerala,” he added.
“Today, around 1,000 innovative business ideas are waiting to get an opportunity to be part of the start-up village. Even small ventures at the Village have gained global attention, in the past, the government’s ventures mainly focused on education, health and social development. Though this helped the State to carve its own niche, Kerala lagged behind others in infrastructure development.” Vayalar Ravi Union Minister for Overseas Indian Affairs February 2014
urban development meet organised by Department of Urban Affairs (DUA) here.
Shri Dominic Presentation MLA, Shri Hibi Eden MLA, Shri Benny Behanan MLA, Shri Therambil Ramakrishnan, Smt A.K. Premajam, Kozhikode Mayor, Adv K. Chandrika, Thiruvananthapuram Mayor, Shri Jamal Manakkadan, Chairman, Chamber of Municipal Chairmen, Kochi deputy mayor Smt B Bhadra, GCDA Chairman Shri N Venugopal and Urban Affairs director Shri Devadasan were present on the occasion.
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33
CASE STUDY
Tough drives for fast climbers
Jyoti Mishra jyoti.mishra@nord.com
Nord Drivesystem supplies STROS for international projects STROS, the largest manufacturer of construction hoists in the Czech Republic, supplies customers all over the world. Three systems ship per week. Eight of the high-rises at “Moscow City”, a major construction project in Russia, are being built or have already been completed with STROS hoists. The hoists reach heights of 300 m or more and have to withstand wind speeds of up to 20 m/s. Safety is therefore fundamental. STROS has been working with NORD DRIVESYSTEMS as its singlesource drive supplier for more than 15 years. STROS specializes in rack-
The NOV series of personnel
control panel that allows the
and-pinion mast-climbing
and material hoists reaches
operator to select the floor
equipment which allows for
maximum lifting speeds of 100
number, the hoist provides the
extended service heights
m/min and load capacities up to
same level of control comfort
and can be quickly installed.
3,200 kg.
as a standard elevator in an
The gearbox output shaft is fitted with a gear that meshes with a rack attached to the guide mast. This robust drive method withstands extreme environmental conditions over long time periods. Apart from building equipment hire and construction companies, STROS frequently supplies power plants, industrial plants, and offshore facilities. Completed projects include locations beyond the Arctic Circle and in the tough climatic conditions of the tropics.
Moscow City construction project The highest hoist to date was erected at the “Moscow City” construction site. The complex consists of several high-rise buildings, eight of which are equipped with STROS hoists. One of the hoists serves the Mercury City Tower which at 340 m is currently the tallest building in Europe. The NOV 2032 hoist has a 350 m lifting height, a 2 ton load capacity and a 70 m/min rating. With a
apartment block. The drive unit consists of three helical bevel geared motors with external braking resistors. “The motors are equipped with electromagnetic disc brakes which can be released by hand”, says Zdenek Coubal, Chairman of STROS. “This is a custom solution from NORD DRIVESYSTEMS. And it exemplifies our cooperation: whatever new challenges we meet, NORD provides consulting and tests and develops a solution.” A control cabinet inverter with hoist function controls all three motors. It enables soft starts and stops and high leveling precision. Coubal says, “We are
STROS hoist at the “Moscow City” International Business Center construction site which includesthe highest building in Europe
working very closely with the construction companies. They say that our technology saves time and money.” Patented safety device The STROS engineering team has designed a mechanism to safely stop hoist cages in the event of a failure. If the nominal lowering speed is exceeded, the safety device will trip and engage its pinion The NOV 2032 personnel and material hoist in Moscow has a 2 ton load capacity and is driven by three geared motors and a control cabinet inverter from NORD
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with the rack to gradually stop the hoist cage. The centrifugal
mechanism is individually set for each machine model. The STROS safety device is certified by the internationally recognized German technical testing authority TÜV SÜD. Cooperation with NORD The cooperation with NORD as their sole drive supplier began in 1997. At that time, STROS’ predecessor company made the first serious foray into international markets. NORD FebruaryJ 2014
Coubal says, “NORD is very
equipment. This new field
good as a one-stop supplier.
makes up a large part of STROS
They suggest the best solution
projects today. For example,
for any application that crops
the company built a 150 m
up in our everyday business.
high permanent elevator on a
For example, we are not limited
chimney at the Siekierki power
to standard gearboxes. The
station in Poland’s capital
units are assembled exactly
Warsaw. The NOV 514 elevator
to fit the requirements. And
has a load capacity of 500 kg
NORD customizes drives for
and a rated speed of 46 m/min.
us when we need it, supplying
The elevator was equipped
reinforced bearings or special
with a frequency inverter
gear case materials, or ATEX
which ensures soft starting and
and NEC-compliant drives for
braking and includes a POSICON
refinery applications.”
position control. The project
Higher requirements Initially, STROS only used geared motors. As the Drive unit positioned on top of the hoist cage: three autonomous helical bevel geared motors from NORD ensure high reliability
A NORD frequency inverter enables smooth starts and stops
Pohánĕcí Technika, s.r.o., the
manufacturer built only relatively slow hoists at that
was immediately followed by a contract for a second, 200 m high elevator for another chimney at the same plant. Conclusion
time, start and stop control
If a hoist does not work, the
via the motor switch was fully
entire construction site will
sufficient at speeds up to 40 m/
come to a standstill. Therefore,
min. But with the growth of the
the drive must never break
customer list, the projects grew
down under any circumstances.
accordingly. STROS started
The NORD concept for STROS
building hoists for higher and
hoisting equipment with
higher buildings. Consequently,
up to three autonomously
the cages had to travel faster
working drives prevents costly
to decrease waiting times.
downtimes. Looking back on 15
New models have rated speeds
years with NORD as their sole
of 55 to 100 m/min and are
drive supplier, STROS Chairman
always equipped with variable
Coubal says, “NORD technology
frequency drives. In addition to
is reliable, and the service is
geared motors, NORD supplies
excellent.” And how is the
control cabinet inverters
outlook? “According to the trend
that control motor speed
in the USA, Canada, and Russia,
and enable precise braking.
we can expect more demand
Sophisticated positioning and
for greater-performance drives
safety functions such as STO
and inverters due to increasingly
and SS1 for safety requirements
larger cages, load capacity, and
up to SIL3 are also available.
speed. We have our work cut out
Another diversification: special and permanent elevators
The finishing machine is available in various models.
Zdenek Coubal, Chairman of STROS at the 2013 BAUMA fair for construction machinery
for us.” Nord Drivesystems develops, produces and sells drive
Czech subsidiary of NORD
The 2008 collapse of the
DRIVESYSTEMS, convinced the
construction industry severely
management in the course of
affected suppliers such
the first trial projects. NORD
as STROS. To survive, the
in the industry. In addition to
supplied the reliable, long-living
company sought applications
standard drives, NORD supplies
For further details write to Nord
products STROS needed. But
for its technology apart
application-specific concepts
Drivesystems Pvt Ltd, 282/2,
even then, the most important
from construction hoists
and solutions, even for special
283/2, Village Mann, Tal. Mulshi,
factor for STROS was NORD’s
and branched into hoists for
applications, for example
Adj. Hinjewadi MIDC II, Pune
ability to guarantee service
permanent use on buildings,
with energy-saving drives or
- 411057 Tel: 09765490890 Visit:
even in remote locations.
chimneys, or technological
explosion-protected systems.
www.nord.com
February 2014
technologies with around 3.000 employees, and is one of the international leaders
The drive for the NOV 514 permanent elevator at the Siekierki power plant in Warsaw integrates positioning functions
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35
TOMASZ’s CORNER
Startup Management Best Practices Startup Team Sizes
Tomasz Tunguz ttunguz@gmail.com
Tomasz Tunguz, a venture capitalist at Redpoint Ventures, an IT venture fund with offices in Silicon Valley, China and Brazil continues his column in MART. You can follow him on twitter @ttunguz. At its core, a startup’s advantage in the market is the speed created by focus. When a team is well orchestrated, they can accomplish amazing things. Creating an environment that fosters communication best is therefore an essential part of startup management. But how best to do it? Founders have to balance spanof-control with span-of-managerialresponsibility. In an article this week’s New Yorker, Amazon’s founder/CEO Jeff Bezos is quoted on the subject with a contrarian point of view: Communication is a sign of dysfunction. It means people aren’t working together in a close, organic way. We should be trying to figure out a way for teams to communicate less with each other, not more. Bezos reduces communication with the two pizza box team. He reasons, if you can’t feed a team with two pizzas, it’s too large. Metcalfe’s Law shows that the number of relationships within a team
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increases geometrically as the team grows. Most agree that smaller teams reduce communication overhead, improve focuse and produce more. But how should a startup manage lots of small teams? How many reports to a manager and how many managers? At Google, I measured the product manager to engineer ratios across different projects in the company. More generally, this metric is called the span of control. On average, the ratio was 1:7. But we observed enormous variance. Search engineering saw ratios of 1:20 or higher. Newer consumer products might have 2 to 4 engineers per PM. Why such variance? The best reasoning I’ve found is Peter Drucker’s. Drucker created a complementary concept called span of managerial responsibility which he defined as: “the extent to which teaching and assistance are needed.” In other words, very senior engineering teams, like the ones on Google Search Quality, don’t need
much teaching and assistance most often because they have extensive experience. These team can thrive at spans of control of 15+. More junior teams, teams new to a field or teams building a new kind of product will demand greater managerial responsibility, which means smaller teams. Some startups pursue flat organizations without managers or with rotating managers. 37Signals and Valve employ very flat management structures which enable employees to self-organize. These novel management styles can be effective, but only when the span of managerial responsibility doesn’t demand lots of assistance. There is no universal optimal team size, according to research. But the best team size for a startup is the one that balances span-of-control and span-of-managerialresponsibility. And if that’s too hard to figure out, 7 is a good first stab. Source: www.tomtunguz.com
February 2014
February 2014
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HANDLING
New JumboFlex 50 Completes the Schmalz Tube Lifter Family Vacuum specialist Schmalz is rounding out its series of tube lifters that feature one-hand operation for frequent, fast movement of light goods. The new JumboFlex 50 offers a maximum load of 50 kilograms. Following on the proven JumboFlex 20 and JumboFlex 35, Schmalz now offers the right handling solution for every small load up to 50 kilograms. change adapter – an important advantage in a market segment in which frequently changing transport goods are part of everyday business. The round suction pad is used for handling barrels and buckets. Double and quadruple suction pads are used for handling wooden panels, metal sheets and other large workpieces. The sack gripper can transport plastic and paper sacks as well as baggage safely and reliably. The new vacuum tube lifter JumboFlex 50 from Schmalz is perfect for frequent, Even small load carriers and quick transport of goods weighing up to 50 kg commercially available boxes
The innovative addition to the JumboFlex 50 is the new operator handle. Schmalz’ engineers developed it in cooperation with the Ergonomics faculty at the Technischen Universität München (Technical University of Munich), and adapted it to the heavier load. The redesigned button can be controlled with either one or two fingers. In combination with the larger soft touch inserts on the control handle, this allows users to precisely and safely handle loads of up
to 50 kilograms with one hand. The reduction in the unit’s overall height also allows a greater lifting force. Proven features of the tube lifters JumboFlex 20 and 35, such as the intuitive operation for right or left-handed users and the precise control of lifting speed, have been retained. Different suction pads are available for various applications. These suction pads can be replaced easily and without using tools thanks to the standard integrated quick-
The JumboFlex 50’s different suction pads can be switched easily thanks to the quick-change adapter
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weighing up to 50 kilograms can be lifted and transported ergonomically with the JumboFlex 50. In addition, workpieces can be picked up from the sides, which further expands the range of applications. The suction pads, which can be swiveled by 90°, then automatically bring the load into the horizontal position after handling. The tube lifter JumboFlex 50 is also available in a special A2 version for use in the food and beverage industry. An electrical pump with a suction rate of 67 m3/h (50 Hz) or 80 m3/h (60 Hz) is responsible for vacuum generation. With the optional radio remote control SRC, the operator can switch the vacuum generator on and off directly on the operator handle. This reduces energy consumption by up to 40 percent. The maximum lift speed is 1 m/second. The continuously rotatable lifting unit, which is attached to the crane system, ensures optimal handling and a high level of flexibility in daily use. Together with Schmalz’ responsive aluminum cranes, the JumboFlex 50 is the perfect handling solution for quick goods handling that combines
Jumboflex 50 is an ergonomic handling system for single hand operation, the conventional methods presently used of handling with chain hoists upon a production line, can be replaced with the vacuum tube lifting system “Jumboflex’. It is much faster than a chain hoist as you can achieve lifting speeds upto 70 meters / minute against 4 mts/min of chain hoist, thus enabling more productivity and ergonomic handling. The factory automation market is growing more than twice as quickly as industrial production as a whole. This is partly because the efficacy of discrete automation is “becoming increasingly important, offering scope for increased penetration to drive growth”. Another factor is that wages in India have now risen to the point that will trigger a surge in automation investments to increase productivity. Philip J Mani Managing Director Schmalz India Pvt Ltd
energy efficiency, ergonomic conditions and simple operation. For further details email: schmalz@schmalz.co.in or visit www.schmalz.com February 2014
BEARINGS
Risk more weight Linear technology that is lubrication-free and dirt resistant – now withstands the weight of a well-equipped middle-class estate car (up to 2 t). The new “Drylin W” linear guide size 25 from igus connects these characteristics. Previously, a lubrication-free and cheap alternative to linear guide systems that run on ball bearings was developed with the “Drylin W” system. As early as the construction stage, the flexible and modular design with its most different accessories allows more freedom of design. New fields of application for the manifold linear guide systems such as in agricultural machines, automobile construction, but also in the field of medicine technology or packing industry, offers now the high-load version in the size 25. Like all members of the “Drylin W” family, the new version consist of three simple basic elements: a guide rail made of hardanodised aluminium, the housing bearings made of zinc die casting and the gliding foil made of the tribo-optimized plastic iglidur J200. The W25 double guide rail has a 25mm shaft diameter and 120mm distance between shaft centres. Compared to the other drylin W sizes, these new dimensions give a higher load capacity, up to two tonnes, as well as resisting higher mo-
Igus now introduces the fourth size in the “Drylin W” linear guide family: the size 25 (above). With a load of up to 2 tonnes possible, it can easily move the load of a properly equipped middle class estate car linearly - maintenance-free and without lubrication
ments. Statically each of the four bearing housings made of zinc die-casting can take up to 480 kg. A gliding foil made of iglidur
aluminium as friction partner.
J200 is responsible for the lubrication-
All four sizes of the “Drylin W” system
free travel of high loads at low friction
are easy to mount because the double rail
values and most minimal wear, especially
makes the costly alignment of two parallel
developed for the use with hard-anodised
shafts or guides unnecessary. The rails are
available up to a length of four meters. For longer travels, the rails can be easily placed in sequence. The factory-made attached bevel allows gliding of the glide elements from one rail to the other. The system is available from stock. The terms “igus, chainflex, readycable, easychain, e-chain, e-chainsystems, energy chain, energy chain system, flizz, readychain, triflex, twisterchain, invis, drylin, iglidur, igubal, xiros, xirodur, plastics for longer life, manus, vector“ are legally protected trademarks in the Federal Republic of Germany and, where applicable, in some foreign countries.
Also the new size has been designed according to the successful principle of the “Drylin W” system: double guide rail made of hard-anodised aluminium. Its counterpart is the guide slide that consists of four zinc die casting bearings, equipped with a sliding foil made of the tribo-optimized plastic iglidur J200.
February 2014
For more details visit our website www.igus.in or write to Vinayak Shetty at vinayak@igus.in
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AUTOMATION
Special Program for Micro Cutting Tool holding Systems from Schunk India No matter where tool holders are used: mold making, dental technology, medical tech-nology, clock- and jewelry industry – the number of high-precision applications in the field of micro cutting has enormously increased in the past few years. Since conventional clamping systems most often reach their limits, SCHUNK, the competence leader of clamping technology and gripping system has enlarged its precision tool holder program for micro cutting. New interfaces and a higher degree of standardization will help the user increase process reliability and efficiency of demanding precision applications. SCHUNK developed and patented their TRIBOS polygonal clamping technology which was specifically made for micro cutting. At a truerunning and repeat accuracy of less than 0.003 mm at an actual clamping length of 2.5 x D,and a balancing grade of G 2.5 at 25.000 rpm, the HSCcompatible tool holders of the TRIBOS family measure up to highest stan-dards.They are suitable for every tool shank of h6 quality, and depending on the type, they were tested at up to 205.000 rpm. Since the mountings have no moving parts, they are mechanically sound, and therefore clamping is almost maintenance and wear-free. Even after several thousand clamping cycles no material fatigue occurs.This is a decisive advan-tage towards other clamping technologies, where the true-running accuracy diminishes in the course of time. Since a hydraulic clamping device is used, tool
change with the TRIBOS can be done in a few seconds. High performance for 5-axis machining “With the special program for micro cutting SCHUNK has responded to the strongly increasing demand“, said Heinold Kostner, Head of Product and Portfolio Management Clamping Technology at SCHUNK in Lauffen. “Many users have recognized that the high absolute accuracy, dynamics, and the excellent rigidity and damping values of TRIBOS help to achieve best surface qualities and long tool lives. It is our aim to enlarge our standard program in one single step as far as possible so that most of these enquiries are covered right from the start.” And the results tell its own story: The TRIBOS-Mini which has been designed for rapid micro applications, will be soon available for the trend-
In the mold making industry the TRIBOS-RM is used for present-ing fine structures very precisely.
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In the field of dental technologythe TRIBOS polygonal technology is used for milling zircon at maximum precision.
setting high-speed spindle interface HSK-E 20. The newly standardized interface achieves an excellent precision at high speeds, which many steep taper interfaces cannot keep up with. Moreover, its special requirement is lower than of the HSK-E 25 interface. Particularly for highly efficient 5-axis machining, SCHUNK offersthe robust TRIBOS-RM version with an extended L1 dimension of 78 mm. The overlong high performer is versatile in use: in addition to direct clamping, it is also suitable for clamping smaller shank diameters. In this case they are combined with the standardized intermediate sleeves GZB-S. In order to ensure precise machining in areas which are difficult to access, the mounting can be also combined with the standardized tool extension TRIBOS-SVL Mini.In the first step, the universal 5-axis expert is available for interfaces HSK-A 32, HSK-A40, HSK-E 32 and HKS-E 40, and they have a shank diameter of 12 mm.
Further interfaces Beside the two new products, SCHUNK has enlarged its program so that, many former spe-cial solutions are now standard products.Therefore they can be ordered faster and more efficiently. TRIBOSMini with ø 1 mm, 1.5 mm, 2 mm, 3 mm, 4 mm,6 mm and 1/8’’ will be standardized, as well as the robust TRIBOS-RM with ø 3 mm, 4 mm ,6 mm, 8 mm, 10 mm , 12 mm and 1/8’’. In addition to the available interfaces HSK-A 25, -A 32, -A 40, -E 25, -E 32, -E 40 both mountings will be also offered for HSK-E 20, HSK-F 32, BT 30,and SK 30 in the future. In the field of dental technology it is important that no chips or grinding dust seep into the mounting or spindle. For this purpose, SCHUNK will continue to offer high-precision mountings in a sealed version. The SCHUNK program also includes handy and costefficient clamping devices, which quickly allow a process reliable tool change. February 2014
February 2014
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MACHINE TOOLS
Kennametal’s Beyond offers new Solid Carbide Drill for maximum results Ultimate production tool for aluminum workpieces with its new ‘Beyond’ grade of fine-grain carbide and unique point geometry, the new HPS solid-carbide drill from Kennametal is achieving excellent metal-removal rates and extremely long tool life, making it the ultimate tool for holemaking in aluminum. Maintaining crucial production schedules while controlling costs is extremely hard when it comes to making highprecision holes in aluminum. Superhard polycrystalline diamond (PCD) drills are being chosen in up to 80 percent of transportation industry applications to date for cylinder blocks, cylinder heads, gear boxes, suspension parts, and many other critical components. The downside is premium PCD solutions come at a premium price, making it extremely difficult for automotive industry suppliers and others to control costs and still maintain stringent production schedules. Kennametal’s Beyond KN15 carbide grade is specifically tailored for aluminum machining and features a highly polished surface that reduces friction on flutes, margins, and cutting edges. This results in superior chip evacuation, even in minimumquantity lubrication (MQL) processes. Drill design features include a proprietary 135-degree high-performance drill point for excellent centering capabilities and improved feeds, and sharp cutting edges that lower cutting forces and extend tool life. An enlarged spiral flute design further speeds chip evacuation and reduces cutting forces. Diameters range from 3.0 to 20.0 mm
customers seeking peak performance in
(0.118 to 0.787 in.) and lengths of 3XD
demanding environments. The company
and 5XD (through-coolant). Inch, metric,
provides innovative wear-resistant
fractions, and tapping sizes are also
products, application engineering and
available.
services backed by advanced material
Kennametal is celebrating its 75th year as an industrial technology leader, Kennametal Inc. delivers productivity to
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science, serving customers in 60 countries across diverse sectors of aerospace, earthworks, energy, industrial production, transportation and infrastructure.
With approximately 14,000 employees and nearly $3 billion in sales, the company realizes half of its revenue from outside North America, and 40% globally from innovations introduced in the past five years. For more information visit www.kennametal.com
February 2014
February 2014
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MART UPDATE
1500 Visit HaasTEC India 2014 The fourth edition of the increasingly popular HaasTEC Open House took place on 16th-19th January to widespread acclaim from the event’s 1500 attendees. Staged in Navi Mumbai, a rapidly expanding township in western India, visitors came from across the vast state of Maharashtra. Maharashtra is the most industrialised state in India, contributing an impressive 18% of the country’s total industrial output. This is one of the main reasons why the local Haas Factory Outlet (HFO), a division of CNC Servicing and Solutions India Pvt Ltd, has recently set up a new HFO facility here. This new HFO facility at Navi Mumbai provided the venue for HaasTEC 2014, where visitors found a wide selection of Haas technology on display, including many innovative yet affordable CNC machines. These included the dual spindle DS-30Y turning centre with Y-axis, and the
ever popular DT-1 Drill Tap machine. All the Haas machines on display were under power, underlining the event’s theme ‘Innovative Demos’: Haas machines cutting parts you haven’t seen before. Terrence Miranda, Haas India Managing Director said, “The enthusiastic response and widespread participation of our customers and global partners in the recently concluded HaasTEC show highlights the usefulness and importance of these events in India. They provide a platform to comprehensively showcase the latest trends in CNC machine tools, tooling, CADCAM, measurement and work holding solutions.”
As with previous HaasTECs, a number of Haas Automation India’s industry partners, some 14 in total, supported the event. Among their number was Renishaw, a leading global specialist in metrology. “We feel immensely satisfied having participated at the HaasTEC in Navi Mumbai,” said Renishaw’s Shreyansh Hippargi. “All the Haas team put in a lot of effort to ensure that customers and partners were at ease. Congratulations to the entire Haas team and we wish them the best of luck for future HaasTEC events!” he further stated. Nitin Wakode at Mastercam was equally complimentary said, “Technology is a great tool but the people who support it make a difference. HaasTEC was a great show in all aspects.”
Red Lion’s NT24k wins Golden Mousetrap Award Modular Industrial Switches recognized for Innovation and Versatility in Automation and Control Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced that its N-Tron series NT24k managed Gigabit Ethernet switches were awarded the Golden Mousetrap for Industrial Networking Technologies in the Automation and Control category. The awards, presented by Design News, celebrate the companies, products and people who are energizing North American
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design, engineering and manufacturing. Available in rack mount and DIN rail models, Red Lion’s NT24k switches provide modular versatility to customers through hot-swappable copper and fiber Fast Ethernet and Gigabit connectivity options. With all-Gigabit capability and a diverse array of connectivity options, the NT24k switches deliver configuration flexibility that meets industrial networking
requirements across industries such as factory automation, utilities, video surveillance, security, transportation and alternative energy. Previously, the NT24k won the Automation World “First Team Supplier” Award and the Control Engineering China “Best Product of the Year” award in the Networking Communications category. For further information visit www.redlion.net
February January 2014
Lapp Group presents cabling solutions for greater efficiency at Hannover Messe Saving space, increasing efficiency, reducing costs At this year’s Hannover Messe, the Lapp Group will be presenting cabling solutions that help increase efficiency in production. The new Industrial Ethernet cables of the ETHERLINE® EC series feature a space and cost-saving star quad design. The Lapp Group is also expanding its range to include Industrial Ethernet cables with a PUR sheath, which have UL approval and a 1000 V rating.
with moulded connectors: for particularly low space requirements, optimised cables with M8 connectors are available, in an angled or straight version.
omitted. Particularly for smaller drives, the relative cost structure for a feedback cable and an M23 connector should not be underestimated. The reduction in wiring work also delivers benefits with regard to installation. In terms of cables suitable for power chains, the decreased space requirement in the guide chain is also an important point, especially as conventional servo and rotary encoder cables must be a certain minimum distance from each other for reasons of electromagnetic compatibility.
Another new feature is an additional UL approval for the existing ETHERLINE® Industrial Ethernet cables with PUR outer sheath, which now have a 1000 V rating according to UL AWM Style 51576. Data network cables without this The new Industrial Ethernet cables of the ETHERLINE® EC series are rating previously almost 10% thinner than conventional cables had to be installed so that they were separated from control cables. The new ÖLFLEX® SERVO 7DSL hybrid For the wiring of machinery and control This change means the cables can run cable reduces material expenses and cabinets as well as for device technology, directly adjacent to live cables in a cable installation effort, and improves the Lapp is introducing two new M12 Power harness. relative cost structure - especially for connectors for connecting or installing smaller drives. New connectors from in devices: UNITRONIC® M12 Power with The Lapp Group also supports the trend Lapp simplify assembly and maintenance, T coding and EPIC® M12 Power with S towards a single-cable solution with the thereby reducing costs – and their high coding. The connectors are small and new ÖLFLEX® SERVO 7DSL hybrid cable. protection rating means they also offer the robust, meaning that terminal devices can While it used to be commonplace to highest level of safety. The Lapp Group will be much more compact. The excellent connect the servo drive and inverter with be presenting these and other innovations protection against dust and water two cables - a servo cable for the power at Stand C03 in Hall 11 of the Hannover penetration ensures the highest level of supply to the motor and an encoder cable Messe. safety even in the most adverse conditions. for transporting data on the position and speed of the motor – nowadays hybrid The four cores of the new Industrial cables can fulfil Ethernet cable of the ETHERLINE® EC both functions at series are routed in parallel as a star The ÖLFLEX® SERVO 7DSL hybrid cable reduces the same time. quad instead of using “twisted pairs”. material expenses and installation effort, and The secret is that Dispensing with the twisting reduces the improves the relative cost structure the encoder/ outer diameter of the cables by almost 10%. resolver signals are This is of particular relevance, as Industrial The connectors are available in straight modulated to the supply voltage of the Ethernet is increasingly being used in and angled versions with screw terminals feedback system. sensor/actuator applications where there for custom cable assemblies. A simple is often little space available, for instance screwdriver is sufficient for connecting Lapp hybrid cables are tailored to the when active distributors or switches are power cores – this simplifies assembly and digital interface HIPERFACE DSL® from used in the field. For wiring within a control maintenance, therefore reducing costs. The SICK, which offers robust and interferencecabinet, small bending radii are required. UNITRONIC® M12 Power model has M12 T free transmission of data between the The new cable is also better suited for this coding for 12 A/60 V, while the EPIC® M12 controller and motor. Thanks to the wellapplication. The star quad design not only Power connector features M12 S coding for known RS485 standard, transmission rates saves space here, but also materials - and 12 A/ 630 V. of 9375 MBaud are possible with cable therefore reduces costs. lengths of up to 100 metres. In a set-up like With the innovations being presented at this, the cable has a bending radius of 7.5 The ETHERLINE® EC cables are available in Hannover Messe 2014, the Lapp Group is times the cable diameter for flexible use three versions: the two cables with 7-wire helping its customers to save materials and 5 times the cable diameter for fixed strand structure and PVC or PUR outer and space and therefore reduce costs installation. Significant potential for savings sheath are suitable for flexible use and a in the manufacture of their products. It results from the fact that only one cable is further 19-wire cable with PUR sheath is is effectively handing them a tool with now required for both power and data, and suitable for highly flexible applications. All which to achieve greater efficiency and the separate rotary encoder cable together cables have UL approval. For these cables, competitiveness. with the relevant connector can now be Lapp Group also already offers assemblies February 2014
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HARTING Han-Eco series offers new advantages New monoblock inserts for higher contact densities in the Han-Eco series are expanding deployment possibilities. In addition, the proven Han-Eco “click and mate” snap-in function offers significant handling advantages thanks to tool-less installation.
The new monoblocks E, which have been developed primarily for use in housings from the Han-Eco series, have seen the proven Han-Eco “click and mate” snapin function retained, i.e. the simple and completely tool-free mounting of the insert.
The Han-Eco series comprises robust connector housings made of glass-fiber reinforced high-performance plastics. The series has established itself on the market over the last year and a half thanks to its ability to offer advantages such as weight savings and savings in time during assembly and installation.
A special feature of the new Han-Eco monoblocks E is that they achieve up to 67 percent higher contact density compared to Han E standard screw inserts of the same size. The inserts feature a pre-leading PE contact (ground) and the possibility of a six-fold coding system. This results in contact numbers of 10+PE, 14+PE, 20+PE
and 28+PE for the four sizes. Moreover, it is also possible to combine a monoblock E with modules from the Han-Modular series in housing from the Han-Eco series. Another possibility for use is in the Han-Modular docking frame. The new contacts are based on the proven Han® E contacts with screw termination. The monoblocks E have a rated voltage of 500 V and a rated current of 16 A. The cable connection cross-section is 0.75 mm2 (AWG 18) minimum and 2.5 mm2 (AWG 14) maximum. For further information contact India: Website: www.HARTING.in
Prashant Katikar Awarded as Most Talented Leader by Asian Outsourcing Congress Prashant Katikar, Director of Deven InfoTech Pvt Ltd was awarded this year with “The 30 Most Talented Leaders (Outsourcing Industry)” by Asian Outsourcing Congress in a function scheduled at Taj Lands End, Mumbai. The award was presented to Prashant in the presence of Senior Leaders at a Glittering ceremony at Taj Hotel. The award function was attended by imminent industry professionals from major IT hubs in India like Bangalore, Pune, Chennai, Hyderabad, Delhi and also delegates from Germany, Philippines, Singapore, and USA. The 30 Most talented leaders in outsourcing industry award recognizes the most eminent professionals for their superlative achievements in the field of outsourcing. The Awards are intensely researched. The research cell consists of experienced post graduates in History & Management. It is the iconic job of the research cell to produce a shortlist of Individuals from a preliminary list of hundreds of IT/Software industry professionals in India and neighboring Asian countries who are doing extraordinary work and track the record of their achievements. The shortlist is then reviewed by a Jury comprising of senior professionals from across the globe. The
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Jury and Council of Board Members selected Prashant Katikar as the recipient of this award. In the past Prashant has worked in USA for 5+ years and has been part of some of the prestigious IT firms like HTC Inc based in Novi (Michigan) city in USA, Cybage Software Pvt Ltd and Persistent Systems Ltd. Prashant Katikar is Director and cofounder at Deven InfoTech, a software development company established in 2012 and with offices in Pune and Aurangabad. Chairman of Deven Group Balkrishna Bhakre and Managing Director of Deven InfoTech Pvt Ltd Laxmikant Bhakre congratulated Prashant on this occasion along with his other colleagues. Prashant has played a key role in shaping up Deven InfoTech. Deven InfoTech offers unique cloud based software products and solutions to automobile, manufacturing and service industry with focus on small and medium enterprises. Deven InfoTech has successfully completed software solution implementations at 20+
organizations in the past one year and has been at the forefront and committed to make the latest technology available to the areas like Aurangabad, Nasik, Pune and Mumbai. Company has plans to take these offerings to the wider market within India and overseas in next 1-2 years. On this occasion Balkrishna Bhakre, CMD said that, Deven InfoTech brings high tech solutions to the Aurangabad region and makes them accessible to the local industry easily, solutions are very user friendly and those will help industries to enhance their efficiency and productivity. We have also generated employment opportunities for youth in the region, which helps in avoiding their migration to Pune and Mumbai like regions.
February January 2014
‘iglidur on tour’ @ India Igus celebrated the beginning of an adventurous world wide tour with an event in Cologne to mark the 30th anniversary of its ‘iglidur’ polymer bearings and the 50th anniversary of the company as a whole, igus GmbH is sending a small, retrofitted car on a round-the-world trip. In cooperation with the Institute of Automotive Engineering at Cologne University of Applied Sciences, the vehicle has been fitted with iglidur bearings in all possible mechanical mechanisms without compromising safety.
igus bearings have been fitted at 56 points to demonstrate the capabilities of igus tribopolymers: to reduce costs and improve technology.” The small car will travel across 20 countries over a period of nine months. The disassembled and retrofitted vehicle components were displayed at the event to provide visitors with a first-hand experience of where the bearings are being used.
The project was officially presented at last year’s plastics trade fair ‘K’ and the retrofitting work began shortly after. CEO Frank Blase welcomed guests to the official launch of the journey at igus’ head quarters, Cologne: Blase states “We are using all our years of expertise in the field of ‘motion plastics’ – plastic components that drive, support and supply – to send a small car around the world.
During the event, Gerhard Baus, authorised representative of Bearings at igus GmbH, looked back at how bearing products have developed over the last 30 years. “Over the years, the research we have conducted has enabled us to continually optimise the materials used for polymer bearings in terms of wear and friction,” Baus emphasised. “There are now around 100 different formulas, including 45 catalogue materials that can be ordered ex stock. For almost every area of application, we offer a special bearing that meets the relevant requirements.” All igus polymer plain bearings contain millions of tiny little solid lubricants. These make external lubrication unnecessary and prevent dirt from sticking to the bearings.
The development of polymer bearings at igus
One in two bearings are used in the automotive sector Markus Feth, Head of the Automotive Division at igus, highlighted the importance for the plastic specialists: “Fifty percent of all the bearings we manufacture are used in cars. As parts are always precisely tailored to customers’ needs, not only are our standard products used, but also a broad range of custom-made solutions.” As soon as the official event was over, the car set off on its journey to India. On arrival, it will be exhibited at the ‘Auto Expo’ trade fair before crossing the country. In the months that follow, it will then visit China and other Asian countries. The tour can be followed at blog.igus.de/iglidurontour. Reports, videos and photos will provide exciting insights into the ‘iglidur on tour’ journey.
Dhananjay Bhosale bags “Jesse Shwayder Award of Excellence” Dhananjay Bhosale, Director Design and Development of Samsonite South Asia Pvt Ltd based at Nasik, India bagged this year’s prestigious Samsonite Jesse Shwayder Award of Excellence. This award ceremony took place during Samsonite annual Global Sales Meet, this time it was in Phuket, Thailand. This has been awarded to an employee who have achieved great success through coherent, strategic and innovative approach in their field of operations which helped the company in achieving good business results. This is a Global award and employee from other countries compete into. February 2014
Three Major Criterion on which the nominees assessed are:Achievement - This measures the business achievement of nominee in his area of responsibility. Strategic Thinking & Approach - This measures the Nominee’s understanding of the core direction and objective of the company and how successful the nominee applies his strategic thinking and approach in meeting the company’s objectives. Innovations for continuous success - This measures how the nominee can prompt for continuous success and improvement by innovative practices.
Nominations are scrutinized by a panel appointed by CEO on each country level. Best ones are collected at Hongkong office from all the countries. Judging panel consists of Asia Executive Committee Members (AECM), appointed by President, takes the final decision. www.martonline.in
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Elecon wins prestigious order worth Rs. 246.78 Crores Elecon Engineering Company Limited announced that its subsidiary company,i.e. Elecon EPC Projects Limited, one of the India’s largest Material Handling Equipments and Transmission Products manufactures, has been awarded an order from NTPC LIMITED of Rs. 246.78 crores for Ex-works (India) supply for coal handling plant package of Gadarwara Super Thermal Power Projects, Stage – I (2x800MW). Established in 1951, Elecon Engineering Company Ltd of Vallabh Vidyanagar, Gujarat, India, pioneered the manufacture of material handling equipment. During these six decades, Elecon has designed and implemented several landmark
projects in India as well as abroad. From a modest start of design and manufacture of Elevators and Conveyors from which incidentally, the company derives its corporate identity. viz. “Elecon”. It has grown over the years to be known as a pioneer of the concept of mechanized way of Bulk Material Handling Equipment in India.
“We are pleased to have procured a prestigious order worth Rs. 246.78 crores. Elecon has always been at the forefront of innovations and technology in the manufacturing and engineering sector. It is a big achievement for all at Elecon as we continue to maintain a healthy order book month on month.” Prayasvin Patel Chairman and Managing Director Elecon Engineering
During the span of more than 6 decades, Elecon has encompassed all the major core sectors through its supplies of highly sophisticated equipment bearing ample testimony of the symbolic mark of Elecon’s unbeatable technology. Elecon has thus, made its presence felt through consistent and satisfactory performance of its equipment in such core sectors as fertilizer, cement, coal/power generation, chemical, steel plant and port mechanization etc., across the country.
Oldham’s BM 25 to remain in its Product Portfolio Transportable, Multi-Gas Area Monitor with Five Simultaneous “Plug & Play” Sensors Oldham is pleased to confirm that the popular multi-gas area monitor, the BM 25, remains in its product range after the sale of Oldham to Industrial Safety Technologies (IST) on October 31, 2013. The BM 25, originally designed by Oldham, has always been manufactured Oldham since its original launch, and will continue in the Oldham business under IST ownership. Powered by a NiMH battery pack, the BM 25 offers up to 170 hours of continuous run time. Other standard features include STEL and TWA values, as well as a datalogging capacity of more than four months. Multiple units can be grouped using optional alarm transfer kits. This protects larger areas by transferring alarms from one BM 25 to the next. An intrinsically safe
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trickle charger is also available for longterm area monitoring in classified zones. The BM 25 is a rugged, durable mobile monitoring system with global certifications, long run times, flexible signal options, and a wide array of applications. The device detects one to five gases for mobile or temporary work applications, team protection, and area surveillance or places where fixed detection systems are not suitable. The BM 25 has been sold in more than 60 countries and with ATEX and CSA certifications, will continue to be available globally from Oldham. Visit www.oldhamgas.com for more information on the BM 25. February January 2014
THE LAST LEAF Dear All, 2014 has begun as an year of accomplishments for Indian-born achievers. Their focus on Innovation and Creative application of science and technology has helped the society at large. An India-born engineer-scientist, whose work in the United States is at the heart of the current high speed WiFi and 4G mobile systems, has been awarded the 2014 Marconi Prize, a Nobel equivalent for technology pioneers. Coimbatore-native and Stanford University Professor Emeritus Arogyaswami Joseph Paulraj, simply known as ‘’Paul’’ has been recognized for his work in inventing and advancing MIMO (Multiple Input Multiple Output) technology, a key enabler of wireless broadband services that has revolutionized high speed delivery of multimedia across the world. The Marconi Prize comes with a $ 100000 prize. Its previous winners include world wide web pioneer Tim Berners-Lee, Internet legend Vint Cerf, Google search maestro Larry Page, and cell phone inventor Martin Cooper. India-born IIT-Madras alumni and PhD from Brown University, Meera Chandrasekhar, professor of physics and astronomy and Curator’s Teaching Professor of Physics at the University of Missouri, also has won Baylor University’s 2014 Robert Foster Cherry Award for Great Teaching. Chandrasekhar will receive the $250,000 award. She has done work that explored polarization by using natural phenomena as well as modern-day applications, ranging from 3D movies to engineering design. Starting Feb. 15, UK bio-tech company Oxitec will begin releasing genetically modified (GM) mosquitoes in Nuevo Chorillo, Panama. It will release 240,000 GM mosquitoes a week. Female Anopheles mosquitoes spread malaria, dengue, and other diseases. The idea is to release male mosquitoes genetically engineered to produce offspring that will die, thus decreasing the population and the spread of disease. Earlier Oxitec already released 3 million GM mosquitoes in a Cayman Islands field test in 2010, which decreased mosquite population by as much as 80 percent within three months in the region (Courtsey : Epoch Times) At Virginia Tech, Y.H. Percival Zhang & his team constructed Sugar-powered biobatteries that could serve as a next-generation green power source. A non-natural synthetic enzymatic pathway was made that could strip all charge potentials from the sugar to generate electricity in an enzymatic fuel cell. AA alkaline and lithium batteries have an energy density of about 150 to 250 Wh/kg-1, whereas Sugar batteries have an energy density of more than 2,000 Wh/kg-1 – ten times higher another innovation ! As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board (EAB) February 2014
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RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012-2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month
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February 2014