Volume 10 Issue 7 January 2014 Pages 52 `100
Rittal Base/ Plinth System: Flex-Block
Machine gives a new dimension to medical industry Design for Manufacturability
The Doorway to Forming
Journey Towards Excellence Startup Management Best Practices Are SME’s supported Financially? January 2014
Carboloy is a ‘Customer Delight’ Gautam K Ahuja, Managing Director, Dormer Tools www.martonline.in
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January 2014
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January 2014
2014 is going to be crucial for India. Another five months, India is going to have a new Prime Minister for sure, expecting to recover the country from the current economic confusions and stupidity. No doubt our beloved Shri.Manmohan Singh is a great economist, but he literally failed his image as the Prime Minister of world’s largest democracy, even the global media has been portraying him as a helpless puppet throughout the past. Across the world, we can see Indians leading in all diversified fields – manufacturing, science, sports, and we do have capable leaders who could be fit to run our country. What we lack is the willingness of leadership to see the country and its growth above political, regional and race issues and most importantly personal benefits. It was inspiring to listen to the speech of one of the Prime Ministerial candidate Narendra Modi projected from BJP talking about manufacturing growth, need based human power development some of which our country must have implemented before years. Let’s hope the words of our leaders are not deceiving and whoever comes to lead us, reach newer heights - the dream of 125 crores plus growing population. The electrical and electronics manufacturing industry started 2014 with a bang with the successful Elecrama exhibition at Bangalore during the second week of this month. Waiting in line to follow the success is IMTEX Forming 2014 - the year’s most premium metalworking show onFormingtechnologies with the concurrent fair Tooltech 2014 showcasing more than 600 exhibitors across the globe. Industries from aerospace, automobiles, auto-components, defense, oil and gas, medical, space, nuclear, telecommunications are expected to visit to experience the latest offerings from the machine tool industry. We are featuring the biggest metal forming show of South and South East Asia, which begins from this 23rd as our MART feature.
Foreword
First of all wish you all and family a very healthy and prosperous New Year. Radiant Orchard – a captivating, innovative, magical, enigmatic purple is announced as the color of 2014. This was done by Pantone, a wholly owned subsidiary of X-Rite, which is a global color authority providing professional color standards for the design industries for more than last fifty years. Pantone has been announcing a color every year, considering different segments including entertainment industry, travelling, destinations, socio-economic conditions, sports with careful considerations globally. PANTONE 17-5641 Emerald was announced as the color of the year for 2013 - itsymbolisedgrowth, renewal and prosperity. MART takes up Radiant Orchard to begin 2014 which is an invitation to innovation, expanded creativity and originality, inspiring confident and emanates great joy, love and health.
Hari Shanker Managing Editor
Dear Readers,
India largely depends upon imports of equipments in most sophisticated industries like aviation, defense, medical etc. With Indian manufacturing coming par to the global standards, there is a growth in local manufacturing in these sectors, not only in the domestic market share but also in exports. In our MART Focus this edition, we are featuring the growth in the medical engineering sector in India. Sandeep Hingne, an industry expert with more than 20 years of experience in the IT and Non IT sector, is guiding MART for the last six months, and from this month has agreed to be part of our Editorial Advisory Board. He pens down an article on Design in Manufacturability which is included in this edition. We are sure our readers will be highly rewarded by his experience. Financial stability is crucial in person or of any industry or economy. For an SME in its initial period support from the financial institutions inspires to reach their goal to stability. Saumya features in detail about the story in Finance MART, and so are our regular contents for your reading delight. Let me take leave to prepare the next edition of MART and we look forward your suggestions and guidance to make MART, Smart! January 2014
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MART Feature 8
The Doorway to Forming Ceramic Injection Molding
16 “Trend Change in MIM Industry”
18 Kennametal Launches NOVO™ New developments in
22 understanding rotary axes performance
MART Focus 24 Machine gives a new
dimension to medical industry
26 Haas technology implanted at PPM
On Face
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Gautam K Ahuja, Managing Director, Dormer Tools
Columns 28
Who does not believe that great products have great designs? Sandeep Higne
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Journey Towards Excellence
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Startup Management Best Practices: Situational Management
P S Satish
Tomasz Tunguz
Volume 10 Issue 7 January 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 January 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
Fair Mart
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Feature Article 40
Clamping Technology/ Stationary Workholding Powerhouse for 5-axis machining from Schunk
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Energy-efficient pump drive solutions
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Rittal base/ plinth system: Flex-Block
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Ascent
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Mart Update
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The Last Leaf Advertisement & Circulation
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MART FEATURE
The Doorway to Forming
Debolina Dutta editor@martinfotech.in
IMTEX FORMING the year’s most awaiting event for the machine tool sector is ready to gear up for a new one. The hi-tech fair proposes to open a stage before the world to witness the latest trend in the machine tool sector. Rare is the event when opportunities are lot. IMTEX the year’s most glitzy event from the Indian Machine Tool Industry is again on focus with its International Forming Technology Exhibition - IMTEX FORMING 2014 and concurrent show Tooltech 2014. The specialized b2b fair is the most hi-tech exhibition on the contemporary technological trends in metalworking machine tools and manufacturing solutions from all over the world. The truly business oriented exhibition,
IMTEX, along with its concurrent exhibition Tooltech, is now the largest show of its kind in South and Southeast Asia catapulting the bulk amount of visitors both from the domestic and the international sectors. Exhibitors from across 400 and a participation from 25 countries including India will be in the focus this year out of which key countries participating are Australia, Germany, France, Korea, Switzerland, Turkey, Sweden, Japan,
“Over the years IMTEX has been a driving force for the exponential growth of Indian Machine Tool Industry. The key emphasis of IMTEX Forming 2014 is to enable manufacturing excellence through superior technologies, world-class productivity and cost-competitiveness. IMTEX Forming 2014 promises to be a specialized-trade fair on metal forming machine tool industry that will attract buyers and manufacturing professionals and will enhance technological efficiency across various sectors.” Shailesh Sheth Media Chairman, IMTEX FORMING 2014
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Thailand, UK, USA etc. with a group participation of four countries like China, Czech Republic, Germany & Taiwan. It’s a globalized mission for new innovative methods, style and the basic design that constitute the potentiality of a fair like IMTEX --- a fair that is not limited to the marginal field of study and introspection. The fair will be held from 23rd to 28th January and the 6 day show which is the flagship event of the Indian Machine Tool Manufactures’ Association (IMTMA) will be organized at IMTMA’s own state-of-the-art exhibition facility – Bangalore International Exhibition Centre (BIEC), Tumkur Road. The highlights of the show Most commonly like the other years the exhibition on the forming technology proposes a viable focus on the exhaustive range of forming technologies predominantly in metallurgical items in the January 2014
globally renowned IMTEX brand where the new entries can get the opportunities to make the best ambition in the most effective way to catch the global pull ups. The global brand IMTMA as a brand of internationally acclaimed organization will chiefly concentrate on the layout of the very latest machine equipment, processors, tools, accessories, software and raw materials as well as feed stocks required to manufacture formed parts in diverse engineering applications. The highlights of the show will display ‘live technologies’ in the forming segment such like laser, servo presses, robotics & automation, welding & joining, and wire-forming & drawing along with an international seminar on Forming Technology one day before the event to address the latest trends & developments and research in forming technology. The concurrent Tooltech 2014 which is 16th in the series will chiefly concentrate on featuring recent innovations and tooling technologies for precision, finish of dies & moulds, forming tools, machine accessories, metrology and CAD/CAM. The Corporate giant of the show who can lead it up High officials from ISRO, Bharat Heavy Electricals (BHEL), DRDO, Society of Indian Automobile Manufacturers’ (SIAM), Naval Dockyard are expected to make a valid presence in the event. The chief comprehensive part includes the industries that mainly offer work on the aerospace, automobiles, auto component, defense, capital goods, electrical & electronics, earth moving & construction, food processing and dairy equipment, railways, infrastructure, oil & gas equipment, pharma equipment, space & nuclear, telecom and so on. Among the industry giants the key exhibit sectors are: Electro pneumatics & Hydraulics, Hindustan Hydraulics, ISGEC, Ashok Manufacturing, Bystronic, LVD-Strippit, Salvagnini Italia, Murata Machinery, Yamazaki Mazak etc. will make their significant presence to the add factor. The opportunity to showcase the R & D capability is one of the key leads to display skill to the world Setting up of the academic pavilion to focus the R&D capabilities of the Indian January 2014
IMTEX 2014 Media Chairman Shailesh Sheth, IMTMA President L Krishnan and IMTMA Executive Director V Anbu announcing IMTEX 2014 to the Media at Bangalore Academics is a great opportunity for the apprentice and the entrepreneur no doubt. The aim is much- in- need to provide an opportunity for Indian academics; the potentiality to showcase their R&D capabilities in Metal working field. IMTMA’s academic pavilion will highlight the issues for the subsequent growth in this sector. It is an excellent way to form alliances and partnerships as well as to exchange technology know-how and develop vendor bases. The fair will be concentrating on the latest growth on the technological development. There will be innovative presentation on the part of the exhibitors attending the super tech expo of Bangalore that will be contributing to the symposium as the most coveted zone for industry bulk. IMTEX provides the right platform for the company to engage with many customers, who are always scouting for a tool that is safer and reliable. FEIN is the inventor of power tools and with such a history; they constantly upgrade and launch revolutionary products every now and then. At IMTEX, they are
planning to launch few products like automatic metal core drilling machine, cordless fastening tool and the new angle grinders. There will be a live demo of the new products at the event for the visitors to feel and understand the features of the tools. They are sure that FEIN will be setting new standards in the industry with our latest innovations. Ameer A Munaff, Managing Director, FEIN Power Tools India Private Limited, said exclusively to MART about their participation in IMTEX 2014, “In this competitive market, success of an enterprise largely depends on its innovative abilities, the manner in which it can launch new products at cost-effective price points and promote the same as distinct from the wide range of similar products available in the market.” FEIN’s professional tools will bring a huge difference in the Indian market by way of giving cost effective and efficient solutions for the toughest industrial applications for day to day work. “Though there are a lot of manufacturers and service providers in the Indian market, there is still a wide gap when it comes to both ends meet as India
“IMTEX-2014 would be an ideal platform to get the best exposure and showcase our products, technology and services to the Indian Market. We would use this opportunity to launch few products in the Indian Market. We are the inventors of Power Tools and are very proud to be in India. India is a very significant, important and interesting market for the FEIN group. The presence here highlights the strategic importance of the Indian market for us. IMTEX 2012 had a footfall of 40,000 and this year we are expecting more visitors from decision making category. ” Ameer A Munaff Managing Director, FEIN Power Tools India Private Limited www.martonline.in
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is still a virgin market when it comes to online selling and trade shows like IMTEX helps companies like us to directly engage with the customers. IMTEX 2012 generated orders worth of 3,900 million which is expected grow this year and pumping of such huge amount in to this industry is sure to create a much needed momentum to kick start the year on a positive note.” he further added. FEIN falling in the power tools category has a lot to gain from this concurrent show Tooltech 2014. Generally, metal forming involves tools and the idea of bringing in Tooltech as a concurrent show is welcoming. It is very good to run two events together which will constitute of more people from different domains and different disciplines which are really needed to make sustainable conversions. Being in the tool industry it will be a good platform for all companies to meet and make network. There is no better way to reach buyers, generate leads, close deals, expand market share, and strengthen your brand – all in one place. Against the background of a crisis that keeps dragging on, the success of an event such as IMTEX along with ToolTech reflects a definite improvement in the level of industrial output, the vigour of subcontractors and the motivation of their professional and institutional representatives in bringing them together and promoting their know-how. Abhinav Sood, Sales Leader of Hypertherm India said that the main highlight of Hypertherm India will be the newly launched Powermax125®, a 125-amp air plasma system that features a 100% duty cycle for maximum work efficiency and productivity. Powermax125 can be used for both handheld and mechanized cutting and gouging, and is capable of cutting 38mm-thick metals, and pierce metals up to 25mm-thick.
In addition, they will also conduct a live cutting demonstration that features our HPR260XD mechanized plasma system, CAM nesting software, EDGE Pro® CNC and ArcGlide® THC to showcase the efficiency and strength of Hypertherm’s Integrated Cutting Solution. Despite having more advantages and value as compared tooxyfuel, plasma is still less widely utilised. Through our demonstrations, IMTEX visitors will be able to witness the productivity advantage that plasma has over oxyfuel. They will also introduce Hypertherm’s proprietary technologies - True Hole™, Rapid Part™, HDi thin stainless steel – in detail to visitors. Lastly, at the show, visitors will also have the opportunity to interact with their latest torch and consumables range of products available at the booth, including their Hypro2000 and Duramax retrofit torches, SilverPlus and CopperPlus electrode upgrades. Maximizing productivity and lowering manufacturing costs are important considerations for any businesses, be it global MNCs or local SMEs. As such, adoption of technology is an essential investment that is inevitable. Trade shows like IMTEX Forming and Tooltech are very important marketing platforms for companies to present their products and showcase their latest technologies to manufacturers and industry professionals. With an international presence, IMTEX and Tooltech attract visitors from all over India, as well as global customers. This provides exhibitors with an avenue to reach out to customers and showcase latest manufacturing technologies. Financial development and economic growth are interlinked, and as domestic consumption and the export market grow, manufacturing growth will follow. Talking about the experiences that
“We are going to launch our Latest CNC Abrasive Waterjet cutting machine Which is having unique and advanced feature making it top of the product line. The major advantage of this improvement will be on production and quality of the output. The per meter cutting cost will be reduced drastically. Making this machine’s return on investment period much shorter.” Jayesh Patel Marketing Director, Ainnovative International Limited
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Powermax125®, a 125-amp air plasma system that features a 100% duty cycle for maximum work efficiency and productivity will be the hightlight of Hypertherm India stall at IMTEX 2014 Abhinav Sood bears in his mind about IMTEX is as a reputable trade show within the Indian metal industry, IMTEX attracts many potential buyers into the market. Exhibiting at IMTEX gives them the opportunity to showcase their latest technologies, while connecting with potential buyers and valued channel partners. Hypertherm values such faceto-face interactions, as they are essential in helping us to strengthen current relationships. As a dedicated platform where industry professionals gather, IMTEX provides companies with opportunities to educate visitors on the benefits of plasma and to showcase the plasma advantage. Participating at IMTEX has helped to enhance the Indian market’s awareness of Hypertherm’s brand and products, and at the same time, reinforce their commitment to the local industry by making their support known to current and potential end-users and partners. According to Jayesh Patel, Marketing Director, Ainnovative International Limited, IMTEX is the platform where they can showcase their latest product and technology by which companies can increase awareness about strength of their product and company. IMTEX is the biggest stage where maximum exhibitors display latest technology through which they can increase productivity and reduce cost of production and which ultimately helpful for the growth of Indian Economy. Companies can get return on investment by participating in IMTEX, it is the only reason they consistently participating in this exhibition and all are hopeful to get same response for capital machinery industry in future also. November January 2014 2013
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“During IMTEX 2014, we will showcase Hypertherm’s latest products and technologies, and these include our manual and mechaniszed cutting systems, long-life torches and consumables, and our Built for Business - Integrated Cutting Solutions. We will also conduct live cutting demonstrations to showcase the consistent, superior cut quality produced by Hypertherm’s manual and mechanized systems. Through participating in IMTEX, we wish to inform visitors about the intrinsic benefits of utilizing Hypertherm technologies,which are superior and economical in metal cutting applications.” Abhinav Sood Sales Leader, Hypertherm India The last edition of IMTEX was an ideal platform where companies got the best exposure to showcase their products, technology and services to the Indian market. They used the opportunity to launch few products in the last edition of IMTEX and they will continue to do so this year too. The trade event brought high quality buyers and trade visitors from India and other parts of the world. It was an exceptional medium for exchanging interaction amongst leading manufacturers, suppliers, customers and users of the emergent Indian and global Market. On a vast space it is a weighty issue to run two events together which will constitute more people from different domains and different disciplines which are really needed to make sustainable conversions. Now the corporate companies from the tool industry want to utilize this stage being a good platform it necessarily hopes to draw a bulk amount of companies to meet and to span the network. There is no better way to reach buyers, close deals, expand market share, and strengthen a specific brand for a company– all in one place. Against the background of a crisis that keeps dragging on, the success of an event such as IMTEX along with Tooltech reflects a definite improvement in the level of industrial output, the vigor of subcontractors and the motivation of their professional and institutional representatives in bringing them together and promoting their know-how. IMTEX Forming 2014 is a greatly expanded fair that includes all forming technologies predominantly in metals, plastics, ceramics, composites and exotic materials; manifestation of which is one ultimate objective: enabling manufacturing
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excellence through superior technologies, world-class productivity and costcompetitiveness. The exhibition promises to showcase contemporary innovations ranging from the most efficient and advanced machineries to the rudimentary level. Sharing his views on the Machine Tool industry, L.Krishnan, President , IMTMA, said, “The Machine Tool Industry has sustained performance during the economic slowdown. The current market size of the machine tool industry stands at US$ 2050 million of which the domestic production makes for around 33% of the total consumption. The last 2 quarters have shown signs of improvement in order inflow. The key user industries such as the Automobile, Auto Components, Defense, Aerospace and Power are set to fuel the growth of Indian machine tool industry”. The new launch will make cutting age sharp projects of the varied tooltech technology. Such as Hypertherm’s Powermax125 that includes cut speeds that are up to five times faster than oxyfuel on 12 mm mild steel, more torch options than competitive systems so owners can choose the right torch for their particular application, SpringStart™ technology for a more reliable torch, and Smart Sense™ technology that automatically adjusts the air pressure for the best cutting and gouging performance. Apart from the Powermax125, the full range of systems in the Powermax air plasma series are metal , interior construction, automotive, CNC Abrasive Waterjet cutting machine etc. With appraisal in need and expectation in high IMTEX-2014 would be an ideal platform to get the best exposure to showcase products, technology and services to the Indian Market.
The Chief Operator of the show Now it is the biggest role for IMTMA to reap the fruits of the grain. Constituted in the year 1946 for promotional support, Indian Machine Tool Manufacturers’ Association (IMTMA) is a Single Point of Contact which is meant for the Machine Tool Industry, by the machine tool industry and from the machine tool industry of India. The apex body of machine tool industry in the country, IMTMA has a membership of about 475 companies both from the public and private sectors, manufacturing a wide range of metal-cutting and metal-forming machines, accessories, cutting tools and other ancillary equipment. IMTMA plays a key role in the growth and development of this industry sector which forms the base for all manufacturing activities. Hopefully the manufacturing sector results in 15% of India’s GDP. Now the Indian machine tool industry sustains its performance in tough times. And the dreams come true when the Association has over the years transformed itself to focus on issues of productivity, quality, technology, new product development, design, customer satisfaction etc. for enhancing competitiveness of the industry in both domestic and overseas markets and the trend has reached to such an extent when it expects to generate business enquiries worth Rs. 2,800 Cr. As metal industry is one of its strong fortes with many in the industry IMTMA paves way for IMTEX to provide the right platform for the customers scouting for a tool that is safer and reliable. The evolutionary steps are happening every now and then; up gradation and the downslide is the very course of nature. Some of the old products are on the way to come back in their new form like as automatic metal core, drilling machine, cordless fastening tool and the new angle grinders. And the advantage of making a live demo is the very heart and soul of the fair for the visitors to feeland understand the features of the tools. And above all the key factors is to make the standardization of the products. Rests lie in the lap of the future. So thumb up for a better IMTEX.
January 2014
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ON FACE
Carboloy is a ‘Customer Delight’ Carboloy is a leading carbide technology and metalworking application company which was launched during IMTEX 2013. At the eve of their first anniversary celebration of Carboloy, Gautam K Ahuja, the Managing Director of Dormer Tools India Pvt Ltd spoke exclusively with MART about the experiences that they have got during last one year.
Carboloy is celebrating its first anniversary this month after its global launch at IMTEX 2013. So how is your journey so far? Carboloy was launched in January 2013, mainly during IMTEX, as part of its Global launch, starting from India. This has been a first for any company to start operations from India. The journey of the first year has been full of learning, excitement and hectic activity. There have been a lot of challenges which we have overcome. The advantage of being new is that we have nothing to lose, and only to gain. There has been tremendous product support, due to the high consistency of our products being offered. How Carboloy was accepted in the market, and what’s your market share in India today? Carboloy has been welcomed by the industry due to the strong legacy of the brand, and the concept of providing good quality, high tool life, consistent products, and quick delivery at a reasonable price. Many of our competitors falter on the above, and we are creating a niche for ourselves. Carboloy is known for solving customer’s ever-increasing demands for greater productivity, quality and costeffectiveness. Carboloy secures a consistent product quality through rigid methods and quality
standards in its production facilities in Europe. Carboloy is getting a very good response from customers, since the tests are outperforming most competitors. In the fiercely competitive world of cutting tools, we are improving sales every month, and it will take some time till we are able to get some reasonable market share. We look forward to create ‘customer delight’ by providing the above. You launched Carboloy during one of the difficult economic conditions globally and in the Indian perspective. Can you share the experience? We try to find positives even in the difficult economic conditions. The customers are generally having lower production levels, but for us being new, even that volume is good enough. Another advantage of the tough situation is that everybody wants to lower their manufacturing cost and looking at good alternatives. This opens the door for us, and we are definitely able to give some advantage to customers due to the high tool life. Thirdly, due to the lower production levels, the customers have time to conduct thorough trials, and always welcome new suggestions. Apart from India how many other countries Carboloy is offered? We have started from India and China in 2013, and now Carboloy will enter into other Asian countries. Any products that made global impact within this short period of time?
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During the second half of 2013, we have launched a full new series of grades and geometry for steel and Cast Iron machining, which are the pre-dominant materials in India. We have received overwhelming response from the customers, since these products have been launched considering Indian conditions of input materials. Does Carboloy plans to have its manufacturing facility in India? We are in the nascent stage, and are looking forward to generate high volume sales. Once we have good volume, we will start manufacturing in India, which may not be very far, considering our aggressive growth path. We look forward to India being a growing economy for the next 3-4 years, and Carboloy as one of the strong brands in the Indian cutting tool industry.
January 2014
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MACHINE TOOLS
Ceramic Injection Molding “Trend Change in MIM Industry”
Manjunath manju.k@indo-mim.com
Our world has become micro-sized to that an extent that when we all take a look at the manufacturing space around us, we realize that everything has shrunk to become miniature with the latest technologies. It appears that the world is moving to micro and nano technologies – be it a mobile phone or a key-hole surgery leading to a significant revolution in manufacturing technologies. MIM technology has been one of such niche metal forming technologies that has made manufacturing of tiny complex shapes a reality. Indo-MIM, based in Bangalore, India, has been operating in the field of MIM technology since fifteen years and has mastered the injection molding technology by producing as many as 3500 varieties of parts with more complex and near net shapes. These are being used in various diverse applications like Automobiles, Medical, Aero space, Electricals and Electronics, Consumables etc. As a company, Indo-MIM has added expertise in the field of tooling, process design and monitoring, as well as the inspection criteria of the final finished parts. They have always been adding value to the customer application by working closely with the customer engineers and understanding the requirements thoroughly well ahead of taking up the manufacturing activity. This
has helped them to accomplish “first time right” and has been an influential factor in their “Just in time” deliveries. The world number one company “Indo-MIM” is equipped with the world’s best machines right from the start to end of the process. IndoMIM, as a company, can help manufacture metal and ceramic components of small to large volumes and has adopted and ventured into micro molding of metal and ceramic parts with high precision features and accuracy with sharp edges, using Micro system technology (MST). The company has capability to prototype and produce parts with different specification based on the application and the customer requirements. Ceramic has been a material of preference for demanding parts that require high
resistance to heat, corrosion, and wear. Today, Indo-MIM’s Ceramic Injection Molding (CIM) services make it possible to manufacture this durable material into small and microsized parts with complex geometries. CIM is ideal for high volume production of complex, tight tolerance components, ceramic injection molding offers significant advantages over conventional forming methods : • Cost effective technique for complex designs • Ability to produce net or nearnet shape parts • Very tight tolerance control • Low-cost, high volume manufacturing runs Ceramic is comprised of inorganic, non-metallic material. Explained simply, any solid material that is not a plastic
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or metal can be defined as a ceramic. In applications where plastic or metals won’t effectively function, ceramic has been the solution. Limitations of Technologies: Manufacturing small and complex shapes in volume before the advent of CIM had significant limitations and the obvious challenge for ceramics is the inherent fragility of parts prior to sintering and the hardness of the material, which makes machining processes difficult and expensive post sintering. Dry pressing or extrusion, are well-suited for high volume production, but they can produce only relatively simple shapes. For more complex shapes, tight tolerances and improved surface finish, secondary machining is generally required owing to which CIM came to the rescue January 2014
and allowed for features such as re-entrant angles, multi-shaped blind holes, screw threads, surface profiles, perpendicular holes, undercuts and intricate cavities. Ceramic parts are produced in the following variety of materials: 1) Alumina (from 96% to 99.9%): Applicable for parts that require good wear and corrosion resistance, such as in electrically insulating bodies, chemical operations, industrial machinery and the vacuum industry. Maximum Temperature of use being from 1200-1600 ° C. 2) Zirconia (YSZ): This is for demanding applications where the strength of alumina is insufficient and is available in white and black. The maximum temperature of use being 1200° C. 3) Zirconia toughed Alumina (ZTA): Applicable for parts with excellent surface quality requirements and reproduction of fine details. It delivers good wear resistance and high strength in applications such as biomedical, micro-engineering, and fiber optics. The maximum temperature of use is up to 1200° C. Ceramic Injection Molding Process: Throughout the CIM process, the top priorities are to uphold quality and precision. Customer specifications are kept in mind before initiating the process. The CIM process begins with
very fine ceramic powders. The powders are compounded with polymer binders to produce a pelletized feedstock. During molding, binders melt to form a liquid medium that carries the ceramic powders into the mold during the injection stage. Using an injection molding machine similar to that used in conventional plastic molding, the feedstock is forced into a mold cavity forming a net shape part. Molds can be single-cavity or multi-cavity configurations. After forming, the part goes through a two-stage process. First it’s debinding to remove the binder, followed by sintering in a high temperature furnace to form a fully dense ceramic component. Sintering is the process of heating the material to a temperature below the melting point but high enough to allow fusion of individual particles and densification of the material. During sintering, the component shrinks by as much as 20% while retaining the original geometric shape. With good process control, it is possible to achieve a uniform and repeatable shrinkage leading to tight tolerances, obviating any need for machining of the part afterwards. Advantages of CIM: First, during the design phases, Indo-MIM conducts mold flow simulation and analysis in order to optimize the part and mold design. By performing
this analysis early in the design process, prior to commissioning the injection mold, many problems can be addressed and improvements can be implemented quickly at low cost and without causing expensive delays in the production schedule.
Anything which makes things
A second key factor in achieving tight tolerances and high repeatability is quality control during the mixing process to create a homogeneous pelletized feedstock. The ceramic particles must have a consistent size and they must be distributed evenly in the polymer binder. The use of sub-micron powders allows for smaller features that would otherwise not be possible with larger granulate-based forming methods such as dry pressing and such precautions are well taken care in advance to avoid any mishap. And the third critical refinement implemented is cavity pressure containment and control. Cavity pressure is the process variable that correlates most directly with part quality.
part-to- part variation and
Ceramic materials are tough enough to withstand acid corrosion, extreme heat, heavy friction, high pressure, ongoing abrasion, and exposure. CIM- A trend change:
January 2014
simpler and convenient, do have a strong hold than the others and same goes for Ceramics Injection Molding too. This new process is attractive because it is repeatable and customers receive highly consistent quality with little with fewer rejects and proven statistical process control, incoming regular checks by the customer is no longer required. The advanced CIM process gives engineers more versatility in the use of ceramics when designing new products and replacing plastic and metal components that fail to perform adequately and this changing trend, in turn, has allowed production engineers and product designers to improve productivity, lower manufacturing costs and improve product performance. The author Manjunath K is the Deputy Manager Ceramics with Indo MIM Bangalore. An MBA with Diploma and (AMEC) in Ceramic technology Manjunath is having around 15 years of industry experience in Ceramics and Refractories including Bio-Ceramics and Technical Ceramics. www.martonline.in
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MACHINE TOOLS
Kennametal Launches NOVO™ Digital Intelligence to Accelerate Productivity in Customer Manufacturing Processes Revolutionary solution integrates collective machining knowledge and experience to dramatically change the way that work gets done. Tool selection, tool configuration, and the best applicable tooling advice based on the customer’s part and process requirements are all at the touch of a few mouse clicks in Kennametal’s revolutionary NOVO™. CAD models, complete assembly lists, automated job report functionality and much more all promise new levels of process planning efficiency. Here, a model of an HTS Drill Assembly is shown with all associated inserts, adaptors, and spare parts. NOVO™ accomplishes in minutes what formerly took hours and yields an optimized solution backed by Kennametal expertise, every time. In a revolutionary development designed to address the critical need for improved productivity and process knowledge for manufacturing companies, Kennametal is launching NOVO™, a new set of digital tools that promises far-reaching improvements in manufacturing efficiencies. “This is a huge leap beyond simply providing a digital version of the tool and its physical properties,” says John Jacko, VP & Chief Marketing Officer at Kennametal. “With NOVO™’s embedded intelligence in application engineering and process planning, Kennametal and our partners are opening the path to a completely connected digital art-to-partto-profit process. NOVO™ is a big step in bringing such a vision to reality.” Experience Powering Productivity Online catalogs and tool selectors have become common options for manufacturers looking for the latest tool solutions for their production process. NOVO™ goes far beyond the concept of the online catalog by integrating the application engineering and production experience of Kennametal’s 75-year history. “This is the true integration of our knowledge with our customers’,” says Francois Gau, Vice President, Strategic Marketing and New Business Development. “Simply put, NOVO™ is a process enabler – a true digital assistant with data-rich machining strategies that starts working from the moment you receive a parts drawing. With a refined and intuitive tool advisor, tool selector, and tool configurator, everything down the line gets more efficient—from parts
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quoting through programming, presetting, and production. The result is the absolute assurance you have the right tool to do the job.” NOVO™ is process knowledge delivered via the Machining Cloud™. It stands alongside such web-available solutions as MTConnect™ for data gathering and ISO 13399 for standardizing tool data. NOVO™ solves many challenges for process planners, manufacturing engineers, and those who want the most efficient machining strategies based on the features of their parts. Customers are able to access NOVO™ via a PC application and tablet solutions coming later this fall. With the
click of a button, the user will have access to all of the knowledge from more than 50,000 branded Kennametal products to achieve a more productive solution in a fraction of the time spent searching catalogs. “NOVO™ works like a process planner,” explains Thomas Long, head of the newly formed Virtual Machining RDE department at Kennametal. “It works from the feature back to the machining strategy and then finds the best tools for each strategy. In addition, each project is tied to application data gleaned from Kennametal’s experts and decades of experience. Search for a specific Kennametal part and you also get models and all associated inserts, January 2014
adaptors, and spare parts. Not only does it accomplish in minutes what formerly took hours, it yields an optimized solution, backed by Kennametal expertise, every time.” Addressing the Skills Gap Facing ever-increasing demands for productivity and efficiency, manufacturing technology providers have responded with computer-driven machine tools, digital-based computer-aided design and manufacturing software (CAD/CAM), and significant advances in tooling. Yet one major barrier threatens this scenario: a significantly widening skills gap as older workers retire and new workers fail to engage in manufacturing careers. “To effectively bridge the skills gap for our customers, we have developed this innovative platform to distribute the collected knowledge of Kennametal,” says Gau. “More than a catalog, NOVO™ brings users into a community, harnessing all ongoing expertise, and providing fast access to best-in-class process knowledge. The result empowers users by providing the right solutions specifically tailored to their operations. It solves problems instead of managing data.” Only the Beginning The vision for NOVO™ is to be integrated with major CAD/CAM packages and machine tool CNC controls, so designers or programmers will have instant access to Kennametal knowledge at the touch of a button without having to leave their function. “NOVO™ means new way of doing things– the ability to get information quickly combined with the best strategy on how to use it,” Gau says. For more information, visit www.
kennametal.com/NOVO. NOVO™ Fact Sheet 1: The Data Community NOVO™ is process knowledge delivered via the cloud. It stands alongside such webavailable solutions as MTConnect™ for data gathering and ISO 13399 for standardizing tool data. Kennametal is collaborating with the following industry leaders are collaborating to power NOVO™ and the Machining Cloud: ESPRIT CAD/CAM Software by DPTechnology, WinTool, Siemens PLM Software, Zoller. The community of data users includes but is not limited to: Manufacturing engineers, production planners, CNC programmers, CNC operators, design engineers, quality control, purchasing and maintenance and plant management. All users in such a diverse data community can stay in their environment. Rather than forcing changes in behavior, NOVO™ instead streamlines access to digital knowledge through established data exchange systems, accessible via a PC application and tablet solutions coming later this fall. NOVO™ Fact Sheet 2: The Machining Cloud Application powered by NOVO™ NOVO™ is comprised of four major functional tools: 1. Tool Advisor 2. Tool Selector 3. Tool Configurator 4. Job Functionality NOVO™ can be used in a number of intuitive ways. Users can begin by: -defining machining features to determine the best machining sequence to do the job, or searching for a preferred tool and grade. NOVO™ smart filters take the task of selecting ALL cutting tool components from hours to minutes, while users get the assurance that the list is comprehensive and correct. 1. The Tool Advisor is a rules engine application which provides cutting tool recommendations. Example: “I need to make a 12mm hole x 40mm deep” Define Machining Features
In each comprehensive report, NOVO™ provides all associated data for each tool assembly, including detailed dimensional data and the application parameters to machine the component. January 2014
-Face milling, slotting, blind hole, etc… -NOVO™ immediately reduces the product set to those that can do the job, taking into account:
When identifying tools needed to machine the component pictured above, NOVO™ provides the user with one comprehensive report listing all necessary tools, and detailed dimensional data and application parameters for each tool. The result empowers users by providing the right solutions specifically tailored to their operations. Constraints Requirements - Geometric, Material, Tolerance, Machine Machining Sequences -Rough, Finish, Rough and Finish (single tool, multi tools), Multistep operations - i.e. Drill and Tap. NOVO™ then ranks the results based on knowledge-based rules to best meet the challenges of the application as defined by: Customer Requirements, -Operating Environment and User Preferences 2. The Tool Selector provides the user with a method of selecting cutting tools from a tree structure using hierarchy / parametric search using fits-with / works-with technology. Example: “I Need a 20mm by 5xD Solid Carbide Drill Grade KC7315” Quick Search -Where customers know what product they are looking for, catalog number or product description. Or, search using smart attribute filters -By selecting the product attributes the software down-selects the products that are available to do the job Fits-With / Works-With technology for assembly build -After the tool item is selected, NOVO also gives the options on what cutting item and adaptive item fits (and also “works with”) NOVO™ smart filters take the task of www.martonline.in
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-Pictures and Models Sharing -Easy to e-mail to other users, will appear in their cloud list -Easily convert into shopping cart for purchasing via Kennametal Konnect -Easy to copy-paste into other systems NOVO™ Fact Sheet 3: The Knowledge NOVO™ will utilize cloud functionality so everything is up-to-date, assuring users have access to the latest available tool information for process improvement. More than a catalog, NOVO™ brings users into a community, enabling collaboration. All jobs are stored on the Machining Cloud and can be easily shared with fellow NOVO users. The dimensional data of the tool items and assemblies can be output in an XML format that can be imported directly into CAM and tool management systems to eliminate the need for manual data entry.
In addition, the results of NOVO™ use can be easily downloadable into standard report formats including: All tooling dimensional data, Application data, such as speeds and feeds and CAD models and graphics. Reports can be shared enterprise-wide via
“Up to 90 percent of our calls are verification requests -- people wanting to be sure they’re choosing the right products,” says Dan Dunmire, Kennametal Customer Application Support (CAS) manager. “Using NOVO™, we can now pull up their tool in seconds; see the assemblies and all of the parts that they need; and plug in speeds and feeds for their particular processes. We can easily review different scenarios, apply their information, save to a PDF file, and email it out. Customers know in minutes they have the right tool, as well as all the related components necessary for what they want to do. ”Kennametal Celebrating its 75th year as an industrial technology leader, Kennametal Inc. delivers productivity to customers seeking peak performance in demanding environments. The company provides innovative wear-resistant
selecting all cutting tool components from hours to minutes. 3. In both cases, NOVO™’s Tool Configurator then provides all CAD files and graphic support for all tool components and their assembly – a major time savings for customers. 4. NOVO™’s Job Functionality stores all tool list and CAD files for future use. Example: “I want to save a list of tools required for a job for future reference or purchase” The Job Functionality is a cloud-based repository that is linked to a user by a unique i.d. where tool lists can be stored for future use, editing, copying, and sharing. Can easily download into attractive standard report forms -Includes tooling commercial and dimensional data and weights -Feed and Speed
email and are able to be copied and pasted into enterprise resource planning (ERP), manufacturing execution systems (MES) or other software-based applications as necessary. NOVO™ in Action Kennametal is actively using NOVO™ in a unique area – customer support. The company receives hundreds of calls and emails daily, with inquiries ranging from designing equipment and processes to end-user issues.
products, application engineering and services backed by advanced material 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. Recognized among the “World’s Most Ethical Companies” (Ethisphere); “Outstanding Corporate Innovator” (Product Development Management Association); and “America’s Safest Companies” (EHS Today) with a focus on 100% safety, Kennametal and its foundation invest in technical education, industrial technologies and material science to deliver the promise of progress and economic prosperity to people everywhere. For more information, visit the company’s website at www.kennametal.com.
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21
MACHINE TOOLS
New developments in understanding rotary axes performance Renishaw has further extended its solutions for checking the alignment and positioning performance of machine tool rotary axes with the launch of new off axis rotary software for its XR20-W rotary axis calibrator. The new software for the highly successful XR20-W now allows it to be used to measure the rotary positioning accuracy of an axis on many configurations of five axis machine tools, where the XR20-W often cannot be mounted on the centre of rotation. Together with Renishaw’s existing AxiSet™ Check-Up system, which provides machine users with a fast and accurate health check of rotary axis and pivot points, users now have comprehensive tools to identify errors with their rotary axes. XR20-W for use ‘off axis’ The XR20-W rotary axis calibrator combines with Renishaw’s XL-80 laser interferometer to allow rotary axis positioning performance to be measured with ± 1 arc sec accuracy. With the new “off axis” test capability,
users can now test more types of machine tools than was previously possible with XR20-W, giving a better return on investment and, in the case of service companies, offering a more attractive service to their customers. The method for off axis measurement works by synchronising movement of rotary and linear axes so that the XL-80’s laser beam is kept aligned throughout the test. Because the linear axis is moving, the measurements made by the XR20-W may include additional angular errors (e.g. pitch) from the linear axis. These contributory angular errors are then measured separately (using the XL-80 laser and angular optics) and removed from the initial rotary axis results. The end result is a set of data reflecting only the errors from the rotary axis itself.
AxiSet Check-Up
The Off axis rotary software is provided as an extra cost option for XR20-W and includes a suite of software utilities, part program generators and an electronic format manual. The manualdetails all the requirements for the mounting
XR20-W rotary axis calibrator off axis
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set-up and associated custom hardware manufacture. AxiSetTM Check-up Key to precision machining is the ability to understand the location of the centres of rotations of the rotary axes relative to the machine’s linear axes. Without accurate data about these ‘pivot points’, a machine’s controller will be unable to reliably control the relative positions of the tool and the component as the rotary axes are moving, leading to inconsistent machining results. Renishaw’sAxiSetCheckup provides accurate and repeatable results using automated probing routines to gather performance data from a reference artefact, and includes simple yet powerful analysis. Alignment and positioning performance January 2014
checks are carried out rapidly to benchmark and monitor complex machines over time. All tests utilise existing spindle-mounted Renishaw touch probes, which are standard option on most multi-axis machines, with probing routines generated using machine-specific macro software supplied with Checkup. To ensure the highest accuracy, the use of OMP400 or RMP600 touch probes with patented Rengage™ strain gauge technology is recommended. Set-up is fast and simple. To perform the test a user quickly locates a supplied calibration sphere within the machine tool’s working envelope using a magnetic mount. Using the supplied custom macro software, a touch probe is then programmed to automatically take reference measurements around the sphere. Measurement results from the test are output to a PC and presented in a Microsoft Excel spreadsheet, enabling easy to understand analysis of data in different formats. These include a graphical representation of performance that highlights tracking and centring errors, a function that compares two sets of data from the same machine, a simple ‘pass’ or ‘fail’ test against the user’s pre-defined tolerances, and a history screen that allows comparisons of the performance of rotary axes over time. Other checks and tests To ensure the optimum analysis of rotary axis performance using Check-Up, it is important that machine’s standard three linear axes are also performing within specification. This should be determined and corrected if necessary using Renishaw’s XL-80 laser calibration system,
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and then regularly checked using a Renishaw QC20-W ballbar. Together with the XR20-W rotary axis calibrator and AxiSetCheck-up these powerful performance testing products combine to ensure the highest quality parts can be consistently produced by five axis machining centres and multi-tasking machines. This portfolio of products provides an unparalleled machine diagnostic solution, targeted at removing variation from the machining process, helping to maximise productive metal cutting. Renishaw is a global company with core skills in measurement, motion control, spectroscopy and precision machining. We develop innovative products that significantly advance our customers’ operational performance - from improving manufacturing efficiencies and raising product quality, to maximising research capabilities and improving the efficacy of medical procedures. Their products are used for applications as diverse as machine tool automation, co-ordinate measurement, additive manufacturing, gauging, Raman spectroscopy, machine calibration, position feedback, CAD/CAM dentistry, shape memory alloys, large scale surveying, stereotactic neurosurgery, and medical diagnostics. In all of these areas they aim to be a long-term partner, offering superior products that meet our customers’ needs both today and into the future, backed up by responsive, expert technical and commercial support. More information about Renishaw’s calibration and performance monitoring products can be found at www.renishaw.com/ calibrationandwww.renishaw. com/AxiSet
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MEDICAL ENGINEERING
Machine gives a new dimension to medical industry
Saumya Bhattacharya editormart@gmail.com
Medical industry to grow $ 7.8 billion by 2016 In today’s world machines are not machines anymore, they have become life supports for the people. Every segment of medical science, farming, pharmaceutical firms etc is depending upon the new technologies available to the society. Different departments engineering offer a great deal of relationship among them. The Indian medical devices manufacturing industry forms a small part of the total
registered manufacturing industry. There are around 356 registered units that are
Top Global Medical Device Companies Rank Company Name Total Revenue
Market Capitalization
1
Johnson & Johnson
$ 28.6 billion
$258.2 billion
2
Siemens
$18.7 billion
$104.6 billion
$18.3 billion
$260.2 billion
3 General Electric Co. 4 Medtronic Inc.
$16.7 billion
$56.4 billion
5 Baxter International Inc.
$14.3 billion
$35.8 billion
Source: Capital IQ and company data 24
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producing medical devices of a total value Rs 300 crore. Of the total number of medical devices manufactured only 14 -15 devices are regulated by the government of India under the Drug and Cosmetics Act. Like for every industry the government of India enacted a new law, the Central Devices Act (CDA), aimed to regulate the entire medical device industry and to give it more human face. The Department of Health Research has decided to set up a Medical Technology Assessment Board to evaluate all kinds of Medical Technologies available in India, either indigenous or imported. It is also true that among all registered manufacturing units only 0.19 percent are January 2014
engaged in production of medical devices.
“There is slow growth of Medical Equipment Industry and domestic market in India due to increased import dependability due to very low import duties on Medical Devices. There is a robust growth in Exports of over 10% to 15%.”
According to an industry report the Indian medical device and equipment market is likely to grow to around $ 5.8 billion by 2014 and to $ 7.8 billion by 2016. India’s medical device market is currently the fourth largest market in Asia with 700 medical device makers, and it ranks among the top 20 in the world. With more recent trends like greater availability of health insurance, the medical device segment is going to remain strong in upcoming years. The medical devices and equipment industry, valued at US$ 2.5 billion and it contributes only 6% to the India’s healthcare sector which is about US$ 40 billion. As per the Global Medical Device Nomenclature (GMDN) the medical equipment industry caters about 14,000 different products. An official report states that financial support in the form of fiscal benefits, technological advancements and policy changes are bound to create a strong opportunity for India to build a global competitive edge in the healthcare sector. According to the Deputy Drugs Controller of India, the government has allocated Rs 3,000 crore (US$ 482.32 million) in the 12th Five-Year Plan (2012–17) for development of the medical device sector. With medical devices to be brought under the ambit of the Drugs and Cosmetics (Amendment) Bill, 2013, the Government is looking to strengthen its infrastructure to oversee this sector. Significant efforts have been made in the medical technology system to stimulate innovation so that the opportunities provided in the Indian market can be capitalized by the companies working in this field and patients in Indian stand
Rajiv Nath Forum CoordinatorAssociation of Indian Medical Device Industry (AIMED) to benefit. Under the direct route the Government of India has permitted 100% foreign direct investment in the medical devices industry. The medical devices sector has significantly brought down the incidence of illness among patients and society has benefitted because of the significantly improved healthcare system in the country. However, there still needs to be done more. The penetration of medical devices is low and inadequate due to high costs that are unaffordable by a large section of the population. India’s one of the leading medical equipment manufacturing company, Cura deals with the products like Digital Radiography system, Computed radiography system, HF x-ray system, Preowned CT, MRI, Mammo and BMD, ECG, Patient Monitors, Treadmill etc. and their clients are corporate companies, diagnostic centers and the Govt. and private healthcare providers. Advances in electronics, miniaturization, visualization, and computing power has changed the scenario of medical equipment manufacturing industry and also breakthroughs in imaging acquisition, resolution, transmission, and manipulation made imaging faster, smaller, more
“The technologic imperative that has been the driving force advancing radiology over the past 30 years has produced new approaches to the acquisition of medical images and placed radiology at the leading edge of the computertechnology era of modern medicine”. Vijai Shankar Raja Managing Director, CURA Healthcare Pvt Ltd January 2014
precise, and less invasive. This has led to broader use of imaging for more conditions and for more patients. The AIMED White Paper on Medical Device Industry which is done by Dr. Pritam Dutta of Health Economic Division, PHFI (Public Health Foundation of India) showed that import constitutes a substantial part of the medical device market in India. Market for medical device was around 13,000 crores during 2009‐10, of which almost seventy per cent is imported. Currently 1.14 per cent of global import of medical devices takes place in India, which in turn constitutes less than 0.6 per cent of total imports of India for the year 2012. Similarly, its export constitutes less than 0.5 per cent of total exports of 2012. In the year 2012, total value of imports of medical devices was 13,520 crores and export was 6,362 crores and thus the total volume of trade is 19,882 crores. There is a steady decline in the share of both imports and exports in total trade. In fact, as percentage of import of manufacturing products, there is a constant decline in share of medical devices. During 2002 this was close to three percent (2.87%). There was continuous decline in share since then and in 2008 the share reached the nadir of 1.57 per cent, only to recover marginally during the subsequent periods. The country has already made a mark in pharmaceuticals, development of new chemical entities and clinical research. The time has now come for India to take its place in the medical devices space. This medical device engineering opportunity is bigger than the Information Technology (IT) boom and we need to capitalize. www.martonline.in
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CASE STUDY
Haas technology implanted at PPM
Matt Bailey press@mbmc-uk.com
Before he founded his company 40-years ago, Fran Phillips was a lone machinist – a hands-on guy with a mill and a lathe during the space-race era, when NASA was spending liberally to make JFK’s promise a reality and every willing and able machine shop in the country could benefit. One of the parts Fran made at that time is still on the moon, precisely where the Apollo astronauts left it. One of the parts he made more recently, by contrast - just as out-of-reach, but much closer to home, is lodged precisely and for all time in his own spine. Like many thousands of patients around the world, Fran Phillips lives with an implant made on Haas CNC machine tools by Elmwood, New Jersey-based Phillips Precision Medicraft (PPM). Located less than 20 miles from New York City, PPM has grown to become a recognized leader in manufacturing advanced orthopaedic implants, instrumentation and sterilised delivery systems. The company uses 40 Haas CNC milling machines and 6 Haas CNC turning centres, and specializes in implants for the knee, hip, elbow, shoulder and spine, as well as the instrumentation and tooling necessary to install such devices in the body. “We purchased our first Haas mill in 1992 and have continued investing in Haas technology ever since,” states John Phillips, Fran’s eldest son and PPM’s President of Operations. “Standardizing on the Haas platform makes it easier to schedule work and to move employees from machine to machine.” PPM provides a made-to-order service for orthopaedic industry customers that include Stryker, Zimmer and Biomet, to name but a few. The company’s machining capability helps facilitate a complete ‘art-topart’ offer, using Haas Super VF series mills and SL series turning centres.
20 years, but we’ve retired only a few,” says John. “Most of them run 20 hours a day, but still produce the same quality as when they were new. We certainly get our money’s worth. In our opinion, the ratio of performance to price offered by Haas cannot be matched.”
“We’ve had Haas machines for the past
PPM isn’t making commodity parts; the
components produced on the long lines of neatly laid out machines contain high precision, high complexity features. “Take this hip broach, for example,” says John, holding a part approximately 10” long with tapered cutting tooth geometry at one end, transposing to hexagon geometry at the other. “It would normally be produced on a CNC grinding machine, but we use Haas fourth axis and right-angle head technology to introduce a tool at such an angle and high RPM that we’re able to simulate a five-axis application, producing the broach with a tool geometry that cannot be duplicated using grinding technology. The resulting broach offers a very aggressive cutting tooth design, which the doctors love because they can get in and out very quickly, reducing surgery times.” John Phillips says that the company rarely gets much advance notice of what parts will be required, or when. As a result, the flexibility of the Haas machines is another vital
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element in the day-to-day success of the business. PPM can offer up to 60 different sizes of conical stems [for example] at the touch of a ‘start’ button, often in batches up to 1200 or 1500 a month. At the same time, the company will often produce custom runs of just 5, 20 or 100 off. PPM’s conical stems are complex titanium parts that utilize several Haas machines for operations that include close angular tapers, milling, drilling, tapping, turning and broaching hexagons. It’s all a far cry from the business that Fran Phillips started in his basement back in 1967. However, from modest beginnings the business soon grew and moved to a 40-man machine shop in the 70s before a strategic shift in the early 80s was to shape the future of PPM thereafter. “Basically we upgraded to the manufacture of medical devices and never looked back,” says John. “No one was in orthopaedics back then so it was a major opportunity for the business. Obviously nowadays it’s a whole different game – we made a concerted effort to invest a few million dollars to build our quality systems, procedures and control plans to ISO 13485 standards, which is what we’ve done. After all, the key to our success – the most important thing we build – is not for sale: our reputation.” Today, the pressures faced by PPM centre largely on customers seeking offshore solutions, typically from China, Malaysia and other low-cost areas of the world. As a result, the company has created a niche for machining high-end medical components, which “no one else wants to cut because it’s just not profitable for them”.
John Phillips describes PPM’s manufacturing style as “probably a little different”, positively “attacking CAD models in Pro-Engineer and then generating our machine code in the same CAD package, returning seamlessly what the client ordered from solid geometry to the reality of actual products manufactured exactly to specification. “Using Haas technology we get greedy; we utilise a fourth axis rotary head we are able to machine four sides of the workpiece and then with one fixture, flip it and we’re done in two operations before it goes into our finishing department for deburring,” he adds. Typical materials processed on the Haas machines include 17/4 stainless steel, 400 and 300 series stainless steel,
titanium, cobalt chrome and PEEK (PolyEtherEtherKetone). In terms of the latter, PPM has just secured its first order for PEEK, and these parts will also be produced using Haas technology. “We’re a no-debt operation – we buy our equipment, pay it off and move on,” explains John. “The Haas machines are particularly good for us, as is the price structure. The machines we acquired weren’t $500,000 like some makes; they were a lot less, so we had the means to bring them in as needed and we could own them outright. In addition, for the size of product that we manufacture, the machining envelopes and tables are just the right size and the machines have no problem holding the close tolerances our parts require.” John Phillips and his family understand fully the importance of the parts they are making, the difference they can make to a recipient’s life and the need to pay close attention to specifications and quality. “My father has just turned 73,” says John, “but when he was 62 he had only recently begun to enjoy a reduced work schedule and was spending more time playing his favorite game, golf. However, he fractured his L4 lumber spine and couldn’t walk. He was on pain pills and clutching chairs to move around. Here was a guy coming into his golden years and wanting to enjoy himself and suddenly he’s debilitated! Well that same guy now has new PPM spine parts and you would never know he had a problem. In fact, he just won his golf club championship!”
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27
DESIGN
Who does not believe that great products have great designs?
Sandeep A Hingne sandeephingne@gmail.com
Described by Wikipedia –as design for manufacturability (also sometimes known as design for manufacturing), DFM is the general engineering art of designing products in such a way that they are easy to manufacture. The basic idea exists in almost all engineering disciplines, but of course the details differ widely depending on the manufacturing technology. This design practice focuses not only on the design aspect of a part, but also on the producibility. In simple language, it means relative ease to manufacture a product, part, or assembly.
DFM guidelines help to precisely define
DFM- The article below talks about how simplicity in design can produce worthy products
project execution At times; we wonder
•Describes the process of designing or engineering a product so as to facilitate the entire manufacturing process, in order to reduce its manufacturing costs •Allows potential problems to be fixed in the design phase, which is the least expensive place to address them The design of the component can have an enormous effect on the cost of manufacturing. Other factors may affect the manufacturability, e.g., the type of raw material, the form of the raw material, dimensional tolerances, and secondary processing such as finishing. The design stage is very important in product design.
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various tolerances, rules, and common manufacturing checks related to DFM. (A new heading here could be good, perhaps something like Application) Application / Practical Illustrations of DFM DFM is widely used in industry sectors like automotive, aviation, pharmaceuticals, and why concepts like DFM/DFSS are being talked about and what is so special about them. Well, to give a candid answer I can say that as the world has progressed over the years in terms of products, innovations, technology, and alternate materials, our end consumers have become more and more aware about the expected performance from the product or service that they wish to buy/purchase vis-à-vis cost aspects. There has been a great level of alacrity in the recent past and it is in this regard that organizations have started thinking in a direction where the first design of the product is increasingly becoming the final one without minimal alterations. This results in abysmal R&D + V&V (verification and validation) costs...
Most of the product lifecycle costs are committed at the design stage. The product design is not just based on good design, but it should be possible to produce by manufacturing as well. Often, an otherwise good design is difficult or impossible to produce.
The organizations that succeed in this
If these DFM guidelines are not followed, it will result in iterative design, loss of manufacturing time, and an overall longer time to market. Hence, many organizations have adopted the concept of design for manufacturing. Depending on various types of manufacturing processes, there are set guidelines for DFM practices. These
DFM consists of six basic requirements:
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aspect command the fastest speed for introducing their product in the market. This was not the case in the 20th century when we were using horses for the transportation of goods and people.
1. Cost 2. Delivery 3. Safety 4. Quality
5. Features/benefits perceived by the consumer 6. Reliability An Industrial product designer has to keep the following four things in mind while designing a new product from scratch: 1. Not only basic, but a detailed/exhaustive understanding of all manufacturing processes involved in the entire cycle 2. Development of these processes 3. Governing mechanism of these processes 4. How these processes can be refined over and over again So based on all of the above, DFM can be simply defined as a process by which every aspect (evident/covert) of the product and process associated is completely analyzed to ensure (1) lowest possible manufacturing cost, (2) least manufacturing time, and (3) highest rate of first-time right. Organizations like GE, Motorola, etc. have their own definitions owing to diverse product bandwidth, but all essentially culminate into the same at a macro level. Talking at micro level one, we can say that there are: 1. Functional aspects, like stringentness of the tolerances associated with the part’s major dimensions 2. Child part aspects, like mechanical dimensions and part approval/qualification report should be in line with design specifications when the first piece is being proved 3. Manufacturing aspects, like process capability index (CpK) should be more January 2014
than 1.67 at all times, so that the critical part dimensions fall under the bell curve of a normal process and all dimensions are within specs at all times. This would enable no room for any rework/rectification. All lessons learnt during the proving process need to be treated from a systematic and statistical perspective to achieve the best objectives. 4. Compliance evaluation should also be routed through the statistical perspective. Pictorially, DFM can be explained as per the illustrations below: (1) For reticle assembly from Texas Instruments, the right-hand side design is created after the DFM perspective
(2) For a motor drive: Some of the prominent examples are: 1. For C17 Helicopter: Landing Gear Bulk head, McDonnell Douglas brought down the number of detailed parts from 72 to 2, and fasteners from 1,720 to 35. 2. Similarly for Long Bow Apache Helicopter, the total parts count for the co-pilot instrument cluster came down to 12 from 87. Now a days, many organizations due to lack of time and under the situation of “fastest to market” opt for shortcuts in design process and try to copy/steal competitor’s data / specifications / features
Retaining Ring 4PLS Retaining Ring 2PLS Spring Sets 5PLS
Reticle Carriage Sub Assembly
CAM Spring (2x)
Shaft SHM
Shaft 2PLS
Housing Retaining Ring Screw Pin Flanged Bearing 2PLS 4PLS (Locktite operation Coupling (Drill and Pin required) operation required) Bracket
Shaft (2x)
Cover 16 Gage
Housing
Base
Motor Screw Plastic Bush
1. Concept generation 2. Feasibility and analysis
End Plate
3. Design: Preliminary/intermediate/final
Sensor Stand-Off(2)
4. Manufacture: Prototypes plus V&V, and then final production of parts
End Plate Screw(2)
(3) For a controller assembly: Earth Lead
5. Assembly of child parts
Pressure Regulator
Pressure Regulator
Connector Tube Assembly
Sensor Plastic Cover
Sensor Nut Strap Screw Plastic Cover
6. Product launch PCB Assembly
Adapter Nut
PCB Assembly Metal Frame
o Benchmarking (BM): The evaluation and analysis of a company’s own products/ services and practices against the toughest competition/forefront product available in market.
The 7 steps of a typical product development process are as under:
Set Screw Alumunium Machined
There have been some new concepts like BM/CI and RE:
o Reverse Engineering (RE): The systematic disassembly of the product to know its intent/purpose technology used in manufacture, and aim of replication under the parent brand name.
Cover Screw
Motor
In 2012, Apple was awarded over $1 billion after it convinced a jury in US court that Samsung copied various iPhone features like using fingers to pinch and zoom on the screen - along with design touches like the phone’s flat, black glass screen etc.
o Competitive Intelligence (CI): Gathering all possible types of information about one’s nearest affecting product to find out its key objectives/USPs.
RETICLE CARRIAGE Bushing SUBASSY (3x)
(2) For a motor drive:
Bush
/ products (whatever applicable) and offer a new product in the market for the consumers with some cosmetic features added or deleted. I am sure, the readers are aware about past and ongoing lawsuits (approx. or so) in different countries over patent / design of smartphones and tablet computers.
Adapter Nut Board Snaps Through Holes
Nut Knob
7. Improvements/lessons learnt At every stage, the designer has to be alert and careful, as even one miss at an early stage can cost the organization a bomb. To substantiate, Ricoh had to bear the cost of more than half a million dollars as against $35/$200 and $400 if the error could have been detected at design, before part procurement and start of regular
Knob January 2014
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production, respectively. This translates into an astronomical 17,000 times of the cost associated at design stage. So, one can imagine the impact of such an incident. If the 90-10 rule is being applied, then it can be said that 90% of the product’s costs are determined during the first 10% of the development time. The following picture depicts a practical illustration of the same: In order to achieve a first-time defect-free design, the designer needs to: 1. Involve all stakeholders right from the first day of the design, so that all nascent aspects can be conceptualized concurrently 2. Have a well-defined product development process 3. Document at each and every stage 4. Have an unbiased and ruthless review process without any interference/bias 5. Include aspects such as top-down approach plus symmetry or orientation, and self-locating parts 6. Have minimal parts 7. Have a modular design 8. Adopt use of standard components 9. Design parts for multi-functionality/ multi-use wherever applicable
10. Have minimal handling while maximizing compliance Since I strongly believe that “making simple things is extremely difficult,” I am summing up below with the advantages of DFM scores: – 1. Less parts for design/documentation/ revision/manufacture 2. Less time for manufacture, culminating into faster time for market introduction 3. Less costs associated at every stage of the process
5. Lesser waste generation, as solutions/ designs are simpler 6. Higher quality levels 7. Higher profit margins 8. More competitive over other products in the market To make designers’ life simple, there have been a few new tools/software’s developed (such as Boothroyd Dewhurst), which has inbuilt features like product design and manufacturability.
Remarks
While logging off for the time being, a “good food for thought” could be design for quality (DFQ). Some glaring examples from the global automotive industry are listed below:
Approximately 1,00,000 per manufacturer
Potential explosion of airbags
The associated cost of recall and rectification can run into billions of dollars, heavily impacting the bottom line of any organization.
Toyota
Approximately 2,50,000
Weak part in the electronic brake system, leading to potential failure
Chevrolet
Approximately 3,00,000
Power-assisted brake system could lead to potential failure
Manufacturer Nissan Honda Mazda
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compromising on basic intent
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4. Lower complexity level without
Vehicles involved
Sources: www.gsmarena.com / www.dfma.com / The author, Sandeep A Hingne, is based out of Pune and currently working as CEO of a leading tier 1 automotive component manufacturing organization. A Mechanical engineer with MBA in International Trade, he has close to 21 years of work experience in Manufacturing and IT organizations. January 2014
FINANCE MART
Saumya Bhattacharya editormart@gmail.com
Are SME’s supported Financially?
The Government of India has enacted Micro, Small and Medium Enterprises Development (MSMED) Act, 2006 to give definition and guidelines to the MSM enterprises. There are lots of schemes provided by the Central Government to support the small scale industries but unfortunately sometimes it doesn’t reach to them properly because some companies are not well informed and also there is a communication gap between the banks and the MSM enterprises. But this scenario is changing now for the betterment of the industry. Banks are lending to the Micro and Small enterprises who are engaged in the manufacture or production of goods and that is also specified in the first schedule to the Industries (Development and regulation) Act, 1951. However, to provide bank loans which are up to Rs 5 crore to Micro and Small Enterprises is defined in terms of investment in equipment under MSMED Act, 2006. The loan which is being provided to these companies is the 20% to 30% of their annual turnovers and the interest rates are 10% to 12% monthly though it depends on the product which the company
“There is a pressure on banks from the government to provide loans to the SME’s so that they can grow and they are also considered as the priority sectors. Some banks are reluctant to provide loans to the small scale industries because it’s not a profitable business for them but because of the pressure given by the government banks are providing many schemes to the industry. ” Alok Garg Managing Director, Optomech industries. SBI has a collection of products or schemes to provide enterprise specific requirements of SME Units both to the manufacturing and trade and services sector. To empower the women entrepreneurs in retail, trade business SBI provides ‘Stree Shakti’ scheme loans and if
account of their service or commodity with customized MIS availability. On the other hand Power Jyoti Current Account which is one stop solution for fee collection of educational institutions, recruitment agencies and other SME customers. The highlight of the product is that the funds
SME Credit Card by SBI provides loans for the micro enterprises including SSI units, small business enterprises, professional and self employed persons, small retail traders, transport operators etc for meeting any kind of credit requirement including purchase of shops, maximum limit being Rs 10 lakhs including term loan & working capital loan. The loan will be sanctioned for 3 years with an annual review. This product has simplified sanction process without requirement of elaborate financial data. The borrower will be provided a photo identity card and a passbook giving details of the limit and validity of the facility. A cheque book marked as SME Credit Card and a pass book would be issued to the customer. has taken loan for. There is something called holiday period for the SME companies after which the interest rates got implemented. State Bank of India is one of the leading nationalized banks in India and it has got separate MSM division to look after the SME sector or the industry and they have been playing a vital role in the development of the small and medium scale
January 2014
a small business company employs 51% women to their company, bank has a special service for them like giving concession in the margins and in the interest rates also. Bank provides a business to business payment solution which is a complete IT solution to corporate needs and for dealers and retailers where they can pool periodical remittances in the pooling
could be transferred without the remitter having an account in our bank. They have also customized Power Jyoti for brokers. Worldwide, the micro small and medium enterprises (MSMEs) have been accepted as the engine of economic growth and for promoting equitable development. The major advantage of the sector is its employment potential at low
capital cost. The labour intensity of the MSME sector is much higher than that of the large enterprises. The MSMEs constitute over 90% of total enterprises in most of the economies and are credited with generating the highest rates of employment growth and account for a major share of industrial production and exports. In India too, the MSMEs play a pivotal role in the overall industrial economy of the country. In recent years the MSME sector has consistently registered higher growth rate compared to the overall industrial sector. With its agility and dynamism, the sector has shown admirable innovativeness and adaptability to survive the recent economic downturn and recession. As per available statistics, this sector employs an estimated 59.7 million persons spread over 26.1 million enterprises. It is estimated that in terms of value, MSME sector accounts for about 45% of the manufacturing output and around 40% of the total export of the country.
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31
MANUFACTURING EXCELLENCE
Journey Towards Excellence
P S Satish gotopssatish@gmail.com
Managing a SME in India - Part 13 As a continuation of last article, we will discuss on few more points to manage SME’s better in India
“When you are setting your goals in life or business, think in terms of decades and just years” Paul J Meyer
25. Focus on long term Recently I came across a quote, ‘When you are setting your goals in life or business, think in terms of decades and just years – Paul J.Meyer’. This is very apt for our SMEs. Many of our decisions including many of our Government, is of short term. We see companies thinking of 1-2 years or may be 5 years. The thrust on quarter to quarter financial figure improvements drives companies to take shortcuts hampering long term perspective. Emphasis on survival strategy seems too high than on strategies for long term sustenance. I was helping a company to improve their supply chain process. I talked to whole purchase team to understand the gap and told CEO on the need of proper organization structure, trainings and purchase strategies needed to benefit in long term. I was shocked at the feedback from CEO. He said that there is a problem with a particular supplier and expected me to follow up every day to ensure supplies. All the members in purchase were driven like this as chasers and no one was
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thinking on how to improve the situation by getting into the root. It is not the problem of the purchase team and they had to work as per CEO’s instruction. I am not against short term corrective actions to ensure production requirements are fulfilled. Missing point was their inability to see long term actions in parallel. Such actions need lot of thinking,efforts and also patience. The CEO in question could not understand this and I had to leave this assignment. Even today after 2 years, purchase team is running around without direction and I was told that their velocity of running has increased. They have become good chasers instead of strategic purchasers. In this article, we try to understand few areas companies should focus for long term sustenance. Today Customers have many choices,
competition is increasing, technology is exploding and boundaries among countries are shrinking. With usage of internet, Customers have access to all informations to take a well informed decision to buy a product. Looking at this trend, it is all the more important to look at strengthening fundamentals so that company will not lose out against upcoming challenges.
products and services. Focusing on a single product or service may be risky in the long term. Think of how to expand. Do not focus too much on single customer. See how to spread risk among many customers from different sectors. One particular sector may seem very attractive now but think about future of sector and look at changes you need to make. Spread also increases opportunities for growth.
• Work on processes
• Increase sales
The strength of the company lies in establishing the processes & systems and continuously work on improving them. Documentation is very important. I have seen companies without focus on documentation where individuals learn and leave the company but organization does not learn.
Chances of survival in long term is higher if the size of the company is growing big. Focus on increasing in sales to expand. Set up a good marketing team to tap the market.
Persons joining afresh starts again from basics. Insist that every process and procedure is written down, followed and continuously improved. You cannot improve anything without fixing basic standard.
• Management focus CEO or owner should focus on planning, developing people, building relationship and developing new products or services. He should work on defining vision, mission and values. Develop people to take care of day to day affairs of business. With firefighting approach by CEO, company will not survive for long.
• Increase varieties in the basket
• Financial discipline
Focus to diversify your
Have a control mechanism
Have a control mechanism to know to how each paisa is coming and how is it spent. Develop among employees an attitude of entrepreniual thinking where each cares while earning and spending.
JanuaryJ 2014
to know to how each paisa is coming and how is it spent. Develop among employees an attitude of entrepreniual thinking where each cares while earning and spending. • Management information system (MIS) Decision to be based on Data. Work on to decide what type of Data suited for the business. Data should not be collected for the sake of it but it should give indications for the improvement of process. The type of Data to be gathered is different for different departments. • Work on intellectual investments Typical focus is investment on physical assets. This trend is changing slowly to invest on information and intangibles. It could be on branding, technical know-how, patents, trademarks, reputation(CSR, ethics) and market know-how. Work on these closely which will give long term dividends. Let me give you an example. When Kellogg’s came to India, everybody sceptical on who would buy such an expensive cornflakes. Kellogg’s strategy was different. They continuously worked on introducing global brand linked to high quality and nutritious food. They increased their sales gradually and are able to a great extent penetrate brand to young children who are going to be future customers for life time. • Emphasis on maintenance Ensure there is a system to maintain all equipment including tools and moulds if any properly and regularly. I have seen this as weak area in many companies. Shift the ownership to users of equipment to do regular maintenance and observe
January 2014
abnormalities.
VIBRO FINISHING MACHINE
• Compete on Value Avoid competing on price with your competitors. This is a vicious circle and difficult to come out. Companies focusing long term will focus on how to increase the value the Customer perceives than getting into a price war. Continuously work on increasing the value by way of increase of quality, performance, service etc. Develop a differentiator compared to competitor which will increase the value. • Loyal work force Work on creating work force who stays with the company for long time. Money alone cannot bring loyalty. Respect for their work, appreciating their contribution, including them in the decision process and fair treatment will make employees to stay in company for many years. It is important to create a culture of long retention of people.
Vijimech Vibro Finishing Machine is a metallic bowl. Metallic bowl is filled with ceramic/ suitable abrasive media and the components to be processed. This principle is utilized to remove the burrs from the component and generate better surface finish. The finishing machine is available in various models.
For details contact us.
Premium Vijimech Pvt. Ltd.
Plot No. 3815, Phase – IV, G.I.D.C. Vatva, Ahmedabad - 382445 Mobile : 9712987467 E-mail :- sales@vijimech.com Website :- www.vibrodeburring.com
As a conclusion, companies should work long term sustenance without sacrificing short term objectives. We should develop patience. No set of actions will ensure that we reach the destination from current level where we are in. The volatility and dynamism is very high in between and employees have to be taught to get into problem solving mode to overcome challenges that appear often. 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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33
TOMASZ’s CORNER
Startup Management Best Practices: Situational Management
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. The first management technique is called Situational Management, one that my wife, a terrific manager at Google, taught me. A manager’s most important function in a startup is to motivate employees to accomplish the business’s goal. Each employee’s motivation to work will vary with time, which means a manager’s style and goals should respond to those changes. The same management style doesn’t work across all employees, nor can one management style be applied to an employee over their career. In other words, effective management depends on the situation. At the highest level, there are four basic situations: The image above is a 2x2 matrix with employee skill (defined as the ability to complete the job asked of them) on the x-axis and employee motivation on the y-axis. Each quadrant contains one situation: Low motivation, low skill: this one is pretty easy. The person hasn’t been placed in the right role or hasn’t been able to understand how to be effective within the company. It’s time for the company and employee to part ways. High motivation, low skill: the most typical state for an employee to be in after he has been hired or promoted. He is excited and energetic but unfamiliar with the particulars of the job, or the company, or the culture. Somewhat counterintuitively, the best management technique in this situation is micromanagement. Despite its reputation, micromanagement is a powerful management tool in this situation. The manager must convert
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the employee’s motivation into skill so the employee will become effective and feel valued. The best way to do this is by frequent check-ins, updates, and feedback. Applied this way, micromanagement provides the employee very fast and very short learning cycles. Each day, the employee receives a mini-review of his work. Within a few weeks, the employee have learnt quite a bit and become productive. Low motivation, high skill: aka burnout. Employees reach this stage after working hard for an extended period of time. The biggest risk for managers with employees in this quadrant is losing them to another employer because of frustration or
disillusionment. A manager ought to put this employee “out to pasture” for a week or a few weeks, meaning allowing her to work on self-directed projects or projects of passion to recharge her motivation. High motivation, high skill: this quadrant contains high-performing employees, the ideal state. The best management advice is to get out of the way. Situational management is a simplifying framework to help managers identify the state of each employee and provide the right support to help them fulfill their potential. Source: www.tomtunguz.com January 2014
January 2014
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35
INFORMATION TECHNOLOGY
DiSC: Software to boost Productivity and Efficiency
Prashant Katikar Prashant.katikar@ deveninfotech.com
Indian manufacturing sector is one of the largest in the world and contributes approx 20% to our national GDP. Some of the numbers available from 2009-2010 suggest that, GDP contribution of manufacturing sector was as large as 15.6%. It has grown steadily over last 3-4 years. This surely indicates prominence of this sector in nations economic development and also criticality in keeping growth in our employable workforce in this sector. So it is important to have manufacturing sector sustain and grow with adequate efforts on innovation, skills development, and technology fronts.
There is good degree of competitiveness that exists in this sector like many other sectors, however managers and leaders of this industry must primarily focuses on productivity and efficiency of ‘manufacturing sector’. Deven InfoTech Pvt Ltd, a Pune/Aurangabad based start-up company has discovered opportunities in this sector to automate workflows, track, monitor and optimize resources deployed in this sector. Our study shows that, particularly small and medium enterprises struggle to
find right software solutions to manage their business and achieve efficiency and productivity. There are numerous software solutions that exist from India and overseas. However, they mostly focus on traditional aspects, business processes of an organization and have lesser focus on workflows, workforce efficiencies and effectiveness, equipment maintenance, downtime, supplier chain streamlining, productivity boost, costing and few such critical aspects.
Deven Infotech aims to be a leader in providing user friendly and cost effective IT solutions to small and medium enterprises. Engineering and services industry is our main focus industry workflow oriented collaborative solutions is our speciality. Laxmikant Bhakre Director, Deven InfoTech Pvt Ltd
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Right from its inception, Deven InfoTech management decided to focus on creating innovative, user friendly and practical industry solutions, develop IP and frameworks which can be used to develop solutions for variety of industry segments. Deven InfoTech management decided consciously not to enter into classical IT service market offering resources for hiring by its client. Within first six months of its launch, Deven InfoTech’s EasyBuild (a solution for construction industry) and DiSC (Deven Industrial Solution Customizer) are being implemented at several client locations. Our solutions are being implemented in industry segments that include Construction Industry, Realty Management, Manufacturing Industry, Press Shops, and Tool Rooms, Food and Beverage Industry and Hospitality segments. All the Deven Infotech solutions are developed on Cloud Platform and are being January 2014
offered in Software as a Service (SaaS) model. Our development and implementation support centers are located in Aurangabad & Pune. We have experienced professionals who are capable of understanding client needs, map those to our DiSC and other solutions/ frameworks and arrive at quickly deployable solutions. Industries and enterprises who wish to deploy quick and cost effective solutions without going through painful experience of ERP implementations are finding Deven Infotech Solutions very useful. Deven InfoTech DiSC framework helps automate business processes including sales and marketing, material management, production planning, production management, quality assurance, commercials, preventive maintenance, project management and employee workflow management. Our mission is to help enterprises achieve excellence in their industries with fresh, cross-industry perspective. At Deven InfoTech, we know the particulars of your business and deliver solutions with the precision you require. With an advanced global delivery platform, we can share knowledge and efficiently manage projects across our global network. It allows us to provide you with the most cost-effective and comprehensive, end-to-end, advanced Optimal Business Solutions. Our optimal business solutions and strategic consulting help you transform your business, with minimal risk, work stress and disruption. We give your organization greater flexibility, efficiency at lower costs. Position your business to thrive in the future. DiSC – Silent features DiSC solution has some 155+ business functions covering wide functional areas of a manufacturing industry. DiSC is implemented or being implemented in various SME manufacturing units at Pune, Nasik and Aurangabad areas today and this
January 2014
healthy and growing list includes some 22+ organizations. Some features of DiSC are listed below: - System can be accessed from anywhere in the world and anytime. Even using smart phone, you can access the system. - System is capable of delivering reports at pre determined times using CRON job like features and management does not need to depend on people to get the reports. - System is hosted on high availability servers with back-up provision and very high uptime of 99%+. - System has built in workflows and integration with email and SMS services for Alerts & Reminders. - System is multi company and multi location capable - System is capable of doing PO and Invoice like transaction’s integration with financial accounting systems like Talley and Ex (Subject to their database is accessible to us)
documented in the SOW. - System is based on DISC framework and uses open source technology. - There is a data back-up facility available via menu - System is very good in look and feel - We have made every attempt to ensure that, system is easy to use even by junior and less educated, less skilled employees - System provides user with lot of best practices and seed data to begin with such as departments, designations, tasks, activities etc - Easy accessibility of support team (Pune and Aurangabad) and most issues can be resolved over a quick phone call - Free from data theft and virus attacks
- System does not require any investment in server hardware, database, operating system or any such software at client location.
The author Prashant Katikar is the Director of Deven Infotech Pvt Ltd. He has more than 25 years of experience in software products and solution design, development, and implementations world-wide. He worked in USA for 5+ years including work experience with some of the finest manufacturing organizations in USA. Prashant travelled to almost 15+ countries and had opportunity to understand various industries, their business processes and solutions they needed. In his early part of career, he worked with core manufacturing companies including Garware Polyster Ltd, DGP Windsor India Ltd, and UMI and used to understand and develop software solutions.
- System will be customized as per customer needs discussed and
For further details do visit www.deveninfotech.com
- System has high degree of data integration where user does not need to enter the same data twice in the system. - System menu and data access can be controlled by configuring who should have what kind of access without programmer intervention.
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37
FAIR MART
Weld India 2014: Beyond Welding Best of the best opportunities for welding and fabrication companies With Weld India 2014, it is time to embrace another one of the biggest trade expositions in India. Like the past seven flourishing years this time IIW is going to organize their 8th edition of Weld India Series of Exhibition from 10-12 April, 2014 at Pragati Maidan, New Delhi. More than 250 high profile exhibitors across the globe and over 10,000 key visitors are expected to attend the Weld India 2014 Exhibition. This fair is going to present a golden opportunity for the leaders in the welding industry and allied fields to attract the prospective Indian consumers and gain a foothold in the ‘India of the Future”. Weld India is an exclusive exposition of products related to welding and cutting industry and its allied products. This year Weld India will provide an exceptional opportunity not only to the companies related to welding technologies like Arc Welding, Solid State Processes, Brazing, Soldering, Adhesive Bonding, Plastic Welding, Metallurgy, Material Testing Techniques including NDT, Health & Safety, Robotics & Automation, Beam Processes & Special Processes including Nano Joining etc. but also to the large scale of user industry ranging from fabrication and construction to metal coating and other allied fields, under one roof to provide for a comprehensive insight into technology and markets. While speaking about the Weld India 2014, R Srinivasan, Vice President, The Indian Institute of Welding and Exhibition Committee Chairman mentioned that the
Weld India show in India is considered as the biggest welding show. This was started in India in the year 2005 In Mumbai with an area of less than 1100 sqm. The Manufacturers of the welding products found that this is the place for them to be in and found the responses very encouraging. The Indian Institute of welding sole aim is to impart the knowledge base of the welding in the country decided to expand this and organize in various important cites of the country. The weld India exhibition was later held in Chennai in 2006, 2008 and in 2011. The weld India was held in Mumbai in 2009 and 2010 in Kolkata. “The exhibition was held in Bangalore in 2013 and now In Delhi in 2014. This year show is “BEYOND WELDING” normally the average visitors turn out is over 6000 in each of the big cities. This event is organized for the first time In India with the association of FABTECH the largest exhibition company in America and is the part of The American Welding Society, ” he added It is a known fact that Weld India is a very serious business for the welding industry. The weld India 2014 in April will have the largest participation of the
“The Indian Institute of welding has decided to conduct exclusive health check up of the welders who visit the exhibition as our responsibility for the welding community as the welders are the backbone of the fabrication Industry. We are in the advance stages of discussions with various Insurance companies to come out with an economic insurance plans for the welders of the country. We hope some companies will understand the need of protection of the health of these Rust collared employees of the country by suitable devising Insurance packages for the benefit of the country.” R Srinivasan Exhibition Committee Chairman Weld India Vice President, The Indian Institute of Welding
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welding fraternity besides the large scale fabricators and non welding companies. The emphasis is given to include large scale welding automation, robotics, use of welding software’s for designs welding simulators and other developments that are taking place is being highlighted which will give an opportunity to the fabricators and manufacturers to introduce the latest welding and manufacturing techniques in their plants meet the global challenges that are being faced by the industries in the country. Imports are playing a major role in the Welding industry in India and regarding this Parimal Biswas, Honorary General Secretary, The Indian Institute of Welding, said, “Overseas participation is crucial to know about the latest offerings in the market. Imports play a vital role in the development of welding science and technology in our country weather it is for the welding consumables or welding equipment are the basic raw materials.” The manufacturers outside India are now realizing the large manufacturing potential of the Country and wants to have large scale representation in India by way of setting up distribution centers or appointing business development tie Ups. “This year we have large scale overseas participation from major countries like USA, Germany, Sweden, China , Japan, Singapore, Austria, Turkey, UK and from other European countries which surely will give an opportunity to work towards Indigenous development of import substitution”, he added. With technical expertise in the field of welding science and technology is getting improved, export in the field of welding, fabrication and construction business in India is growing and the result is the large contracts are being offered to Indian manufacturers through various channels of business. India is the hub of many January 2014
industries for manufacturing; Automobile is one such sector which has definitely has done remarkably well in the last few decades. The global turnkey projects in the Middle East and in African countries are depending purely on Indian expertise and manpower. Major welding products companies in India are the main exporters of the finished product to various manufacturers of the European countries. Today India is considered as a Global Sourcing country by the developed countries. To publicize a fair in India as well as in the world promotional tools are required so for that reason the Weld India 2014 will have large scale media publicity from end Jan till first week of April in all the Dailies of the countries. The weld India is held simultaneously with the International Welding congress. The 64 member countries of the International Institute of welding have already uploaded in their web sites and the response from overseas countries are excellent. Participation by the MSME, NSIDC, Educational Institutions and training bodies, use of safety equipments, are the new dimension to the exhibition this time. This time an opportunity is being extended to the exhibitors to have full live demonstration of their products are being arranged. Apart from the lots of Indian companies which are participating in this fair many overseas companies are also participating and most welding product manufacturers of the country have decided and booked large space of the exhibitors. As On date 85% of the total space is fully booked. Manufacturers like ESAB, Bohler, ADOR, L&T, D&HScehron, Oerlikon, Panasonic, Kemmpi, Fronious, Kobe, Koikki, Fine
Large scale mobilization of the potential visitors to the exhibition, Display of high quality and new development products by the Manufacturers, wider geographical representation of the companies, Media publicity highlighting the welders’ health check up camps, arrangement to make live demonstration of the welding products for the first time in an exhibition are the major measurers that the organizers are planning. Parimal Biswas Honorary General Secretary, The Indian Institute of Welding
arc automation, Messers, Lincoln, Linde, OTC, Hypertherme etc and a host of Robot companies. Large contingents of manufacturers from China have booked a special exclusive pavilion. Along with the Weld India 2014, this time the IIW International Congress 2014 is also being organized by the Indian Institute of Welding. The 3 day International Congress which will be organized simultaneously will have about 135 technical papers being deliberated from 25 countries. While talking about how IIW International Congress 2014 is going to help the fair this time, Pabitra Kumar Das, President, The Indian Institute of Welding said, “This is the first time that weld India is being organized in association with Fabtech USA. The objective is to broaden the scope of the fair and include user industries and all other industries where welding is involved as a major process of joining or maintenance.” Fabtech is the exhibition partner of the American Welding Society and one of the world’s largest metal forming, fabricating, welding and finishing exposition with consists of 4 major associations viz “Fabricators & Manufacturers Association, International, Society of Manufacturing Engineers, Chemical Coaters and Precision Metal forming Association. The
“The IIW is the premier professional body in promoting welding science and technology and associated with Ministry of HRD and also with National Skill Development Corporation as a knowledge partner in Welding Training. This is the first time that the Exhibition and the congress is being held together in New Delhi, and this will give a big exposure to IIW India and also have the advantage of presence of a large number of eminent delegates, authors, visitors and functionaries of large welding companies across the world. This paves the way to showcase Indian welding and fabrication industry to world.” Pabitra Kumar Das President,The Indian Institute of Welding
January 2014
participation of all involved with welding under one roof will facilitate more effective B2B exchanges. In the congress, special emphasis is being accorded to welding education and skill development and a special plenary session will be held to be addressed by senior level officials from the government and private agencies involved in the massive skill development initiative being taken on hand by the Government of India. Thus the exhibition would provide an ideal platform where the attending delegates and dignitaries can attend both the congress and the fair at the same place and time. The objective of the conference is to facilitate the authors and delegates of India and neighboring countries to attend at a lower cost and to promote regional cooperation among these countries. The delegates who are going to participate here are expecting to come from Bangladesh, Sri Lanka, Myanmar, Pakistan, USA, Italy, UK, Korea, Turkey, Finland, Germany, Denmark, Austria, Canada, France, Slovenia among others and the footfalls with the importance of this mega event are being projected to visit from the welding & allied industries through widespread publicity particularly in Delhi and NCR and it could reach at least 10,000 footfalls in exhibition. The event is managed by CEC Exhibitions Private Limited based at Pala, Kottayam, Kerala. For last two years CEC is succesfully managing Weld India for The Indian Institute of Welding. For more details do write to Project Director, Biju Thomas Panjikunnel, CEC Exhibitions Pvt Ltd, # XII / 418, PRA22, Pravithanam.P.O Pala, Kottayam Dt, Kerala - 686 575 Mobile: Tel : + 91 94951 95000, 97456 03455 Tel: + 91 4822 247469 E-mail: info@weldindia.com, mail@cecexpo.com www.martonline.in
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AUTOMATION
Clamping Technology/ Stationary Workholding Powerhouse for 5-axis machining from Schunk The KONTEC KSX NC vise from SCHUNK is a powerful clamping system for simultaneous 5-axis machining. The compact, and easily accessible clamping system from the competence leader for clamping technology and gripping systems disposes of tool-free adjustable clamping forces between 4 and 40 kN, which are measured directly at the workpiece. This is a great deal of power for a safe hold, even for minimum clamping surfaces. The support surfaces at a height of 211 mm ensure that the workpieces are easily accessible from all sides. With just one lever rotation, they are quickly clamped resistant to vibrations, and have a high repeat accuracy. Since the unit is draw bar actuated, the bending load at the base body is strongly reduced. Moreover, the long guiding system and the arrangement of the clamping mechanism ensure a very stiff, dimensionally stable set-up. These are ideal preconditions for precise machining of the second side. The drive and the adjustment mechanism of the 5-axis clamping vise are completely encapsulated and thus protected against chips, dirt, and coolant, and the easyto-clean design avoids build-up of chip clusters. The KONTEC KSX fits smoothly into the SCHUNK modular system for highly efficient workpiece clamping. Therefore the
present on the Indian market since 2001 and is today the largest manufacturer
clamping pins of the VERO-S quick-change
Toolholding systems, lathe chucks,
pallet system can be directly integrated
stationary workholding and chuck jaws – At
into the base body of the 5-axis clamping
SCHUNK you are profiting from a complete
vise. Combined with the quick-change
product range and business activities from
pallet system it can be quickly exchanged
the world’s largest supplier and market
Experienced staff in the office as well as
and with a maximum repeat accuracy on
leader in toolholding and workholding.
the sales engineers guarantee a quick
the machine table.
No matter which specific requirement
Optionally, the vise of the innovative
you will have in the field of toolholding
family-owned company can be equipped
and workholding - Schunk product variety
with standard, aluminum, or special 5-axis
and technical creativity is offering you a
top jaws, pendulum plates and many other
spectrum of optimum solutions. All from
standard chuck jaws from the world’s
one source.
largest standard chuck jaw program from SCHUNK. The clamping range of the KONTEC KSX lies between 0 - 250 mm. By using draw bar and base body extensions, the clamping range can be enlarged to 749 mm. Schunk - Your Partner for Toolholding and
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Workholding, Solutions from one source
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No matter if tool- or workpiece clamping - Schunk quality ensures you precision, efficiency and process reliability. Located in Bangalores Yeswanthpur Industrial Suburbs Schunk India is one of the world wide subsidiaries of SCHUNK GmbH & Co. KG in Lauffen / Germany. SCHUNK is
of clamping technology worldwide and European market leader of grippers for industry robots.
proceeding of your inquiries and orders and assist you competently in solutionfinding for your projects and products choice. Further their stock ensures optimum availability and rapid delivery of Schunk popular products. At SCHUNK you get everything from one supplier, single components as well as complete system solutions. For further details write to Schunk Intec India Private Limited, 80-B, Yeshwanthpur Industrial Suburbs, Bangalore – 560022 Tel: +91 80 40538999 Email: Info@in.schunk.com Web: www.schunk.com January 2014
PUMPS
Energy-efficient pump drive solutions Permanently full speed? Not such a good idea for pump drives! Speed control balanced to actual requirements greatly enhances the energy efficiency of pump systems. NORD DRIVESYSTEMS supplies complete pre-assembled distributed drive units for a wide performance range to 22 kW. In addition to energy savings of up to 60%, users benefit from reduced noise emissions, low wear, and increased plant service life as well as the ecological advantages. The SK 200E series comprises reliable and economical frequency inverters especially tailored to pump applications that precisely adjust power output as required. They are compatible with mains voltages worldwide. NORD configures complete drive systems for various application areas (IP55/IP66, ATEX zone 22/3D). Integrated process and PI controller functions enable the fully automated control of process variables and compensation of disturbances – in stand-alone and mobile applications as well as in complex setups with several drives. Thanks to two analog inputs, the inverters can directly process sensor data such as pressure or flow rate. Optional signal and power plug connectors facilitate handling and ensure compatibility. A programmable energy-saving function automatically reacts to partial load operation – increasing efficiency and significantly reducing running costs. Operation is straightforward and flexible via control terminals, bus, or via an optional potentiometer that enables adjustments directly at the inverter. Up to four operation modes can be stored, saving setup time; for instance during cleaning cycles or media changes. The customized parameters can be quickly exported to other units via a pluggable storage module, the system bus, or Ethernet interfaces. With control cabinets no longer required, the decentralized option minimizes cabling effort for users, and since the inverter is supplied pre-assembled the electrotechnical effort during installation is minimal. Nord Drivesystems develops, produces and sells drive technologies with around 3.000 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies applicationspecific concepts and solutions, even for
January 2014
special applications, for example with energy-saving drives or explosion-protected systems. Gross sales amounted to approx. EUR 450 mn in the 2012 business year. The company founded in 1965 now has over 35 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm,
electric motors with powers from 0.12 kW to 200 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units. For further details write to NORD Drivesystems Pvt Ltd, 282/2, 283/2, Village Mann,Tal. Mulshi, Adj. Hinjewadi MIDC II, Pune - 411057 Tel: +91 9765490890 Email: jyoti.mishra@nord.com Visit: www.nord.com www.martonline.in
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MACHINE TOOLS
Rittal base/ plinth system: Faster assembly and logistics Flex-Block
There is still plenty of scope for innovations in enclosure technology, as demonstrated by Rittal with its new base/plinth system, Flex-Block. The striking features of this accessory innovation are its simple, fast, tool-free assembly, and enhanced user-friendliness during the transportation and assembly of enclosures. Switchgear assemblers can enjoy significant time and money savings, thanks to more efficient assembly and logistical processes.
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Until now, the assembly of sheet steel enclosure base/plinths was a fairly timeconsuming process. The new Flex-Block base/plinth system developed by Rittal will speed this up considerably. Fast, tool-free assembly of individual components means that base/plinth systems can now be assembled in next to no time.
in position, therefore, assemblers can transport the enclosure conveniently and flexibly from one assembly station to the next using a lifting truck, for installation at its final destination. Once the enclosure is configured, the trim panels are simply clipped into position on the base/plinth in just a few actions.
The new base/plinth system comprises four symmetrical corner modules and covers made of plastic, plus sheet steel side trim panels. The modular design and increased assembly space allow the four corner pieces, which support the entire weight of the enclosure, to be quickly and easily fitted underneath the enclosure right from the start. Without the trim panels
The robust, 100 mm high plastic corner modules are designed for loads of up to 15,000 N and additionally have hexagonal slots to accommodate adaptor sleeves for stacking 200 mm high base/plinths. Levelling feet or twin castors are likewise accommodated. The system accessories permit tool-free baying of the base/plinth, and may be configured individually for each
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enclosure panel, for example with cable clamp rails. The new FlexBlock base/plinth system is available for all sizes in the TS, SE 8 and CM enclosure series, the TP console systems, and the PC case systems. The dimensions range from 400/500 mm to 1,800/500 mm (optionally width or depth). Rittal additionally offers widths in 300 mm for the LCP Liquid Cooling Package climate controlled enclosure. The new Flex-Block quick-assembly system was launched on the market in August 2012, and is offered alongside the existing range with sheet steel base/plinths. For further details visit www.rittal.com
January 2014
ASCENT
EMQ reaches budding Engineers EMQ Technologies is going to offer a 3 days training course, Lean Six Sigma Green Belt Training Course, for engineering colleges and the reason to choose LSSGB training at EMQ Technologies is to give participants a rare opportunity of having direct interaction with the industry people. The whole training course is divided into session’s like, pre class room session – enter the class with basic knowledge, post class room session and coaching, trainer support during pre and post class room session and opportunity to present own case studies in-front-of panel juries & industry professionals. Participants will be supported by training materials like books, study materials, quality diary, video clips, case studies, free evaluation software and basic manuals for software and they also can participate in Annual Mega Quality Event i.e. Learn from the Experts & Network with professionals. This course is available through Onsite Program, Public Training Program and Campus Training Program. Participants have to carry their own laptop with Windows XP/ Vista / 7 Installed in their laptop or they can hire laptop with an extra payment. For organization’s project presentation in annual event they need to pay an amount of Rs 15,000 extra for each Case study. The course will introduce to the participants to the various tools of quality management. They also can improve their skills using DMAIC, Lean (waste removal) and Six Sigma (variation removal) tools and
Lean Six Sigma is a managerial concept combining with “Lean” which concentrates on reducing wastes and “Six Sigma” which focuses on removing defects @ 3.4 DPMO. Nowadays Lean Six Sigma is a tool following by most of the manufacturing & services industries worldwide. I believe “Certificate in Lean Six Sigma Green Belt” course by EMQ Technologies will enable all Engineering & Management students for better career and who can help industry from Day-1 to fight against defects & wastes to build a best organization Somnath Chakraborty Business Head – EMQ Technologies techniques. The course will help to challenge norms and transform businesses by applying business process modeling, simulation and optimization tools. Collection and analyzing of data will help to take correct decisions for improvement projects and root causes. Develop and implement solutions and ensure problems are solved permanently saving time, effort and money through running a Project. In order to be successful, Green Belt Lean Six Sigma practitioners need to combine technical ability with the interpersonal skills required to influence decisions and drive change. The Green Belt training program
takes a systematic approach to the syllabus, following a DMAIC-based framework, (Define, Measure, Analyze, Improve and Control), and it also covers the soft skills needed to make you genuinely effective. This Green Belt course is delivered through a variety of training techniques, including lectures, group exercises, and simulations, case studies, and discussions. The participants will also receive access to all of the required software tools, course material, and Pre-Training & Post- training support from trainer via email, phone or Skype. For participation contact +91 9903871301 or +91 9474621510
Royal College Celebrates its 10th Anniversary One of the reputed Engineering Institutions in Kerala, Royal College of Engineering & Technology that has been producing future Technocrats of our country every year celebrates 10th anniversary from 16th to 22nd January 2014. Many programs of social and educational importance are being organised in connection with the decenniao celebrations. Engineers conference, enterprenuership seminar, media conference, school science fest, inter collegiate techinal fair etc are among the many attractions of the event. Job fair and career development sessions have also been organised. Several companies have agreed to participate and
many engineering colleges have promised to send their students also. It is recognized by All India Council for Technical Education and affiliated to University of Calicut. They are the only remote centre of IIT Bombay among the Self Financing Institutions under Calicut University. Royal College of
“Marching towards being one of the best Next Gen Engineering Institutions in our state, I am pleased to disclose our decision to fulfill commitment towards the Society utilizing the Engineering skills of our entire Royal Community.I would like to beckon all the Engineering aspirants to be the ‘Royal Engineers’ being at RCET.” Mansoor Ali T M CAO, Royal College of Engineering & Technology January 2014
Engineering & Technology (RCET) is one of the new generation engineering colleges which, in very short span, after coming into existence in the year 2003, has carved a niche of its own in the field of technical education in Kerala. RCET has a remarkable placement record and most students have their careers charted out well before they complete graduation. The institution is Located in Thrissur district which is the Cultural Capital of Kerala, a short trip from Cochin International Airport of 65 Km, will bring you to a wonderful Campus surrounded by 35 Acres of lush and serene natural beauty. www.martonline.in
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MART UPDATE
More manufacturers with 350,000 data The EPLAN Data Portal now provides over 350,000 component data from 56 manufacturers. New additions include General Electric (GE) in the field of highvoltage current switchgear, Numatics with fluid power components, Murrelektronik, for example with field distributors, Omron, and cable manufacturers Schweiger, Sigmatec, Stego and TKD Kabel. Efficient design starts with the smallest unit – with a standardised component that is added to the respective design project via EPLAN Data Portal. With this, users work more rapidly, more efficiently and with data approved by the manufacturer. 48 manufacturers were already represented in the portal – now a further eight manufacturers have been integrated and product catalogues have been updated. The first example is GE: The manufacturer has saved 700 new part records in the field of highvoltage switchgear with corresponding illustrations. Macros of the switchgear simplify the electrical design with EPLAN. The automation manufacturer
Murrelektronik is also new to the portal. Field distributors, cables, protective devices, voltage sources and PLC components have now been integrated into the portal. Users profit from over 270 records with images including 2D and 3D macros. Another new member in the portal is the American company Numatics, a leading component manufacturer in the field of fluid power engineering. Over 100,000 records of fluid valves can now be added to the design rapidly. A Schweiger GmbH is also currently offering over 130 data records and PDF documents with the new motor connection system EcoMolded. Standard types of the overmoulded plug connections for Siemens, Fanuc, SEW, Bosch Rexroth, Beckhoff, B&R, Elau and other applications are available as catalogue products. Other new arrivals in the portal are Sigmatek with PLC components, Omron, Stego and TKD Kabel. Product catalogues updated Manufacturers that are already represented in the portal such as Phoenix Contact have extended their product portfolio. Over 20,000 new and revised data are currently available – around 12,400 of them macros, 600 of which are in 3D. B&R has added over 2,500 parts in the field of voltage sources, generators,
PLC and plug connectors. Companies such as ABB, Weidmüller and Sick have included additional parts and Festo has also increased its range in the EPLAN Data Portal. With currently 34,000 records – of which about 20,000 are functional macros and almost 9,000 are 2D graphic macros – the company from Esslingen covers a wide spectrum of fluid power and electrical engineering parts and also components for mechanical and process engineering. By integrating all product areas of their portfolio, Festo takes on a pioneering role here. The EPLAN Data Portal is a central platform on which more and more manufacturers, and a growing number of EPLAN users (currently 47,000 users), are relying on. Both sides profit from wellprepared data. The EPLAN Data Portal hence combines two worlds – that of the component manufacturer and that of the joint users. For further details visit www.eplan.in
Surfex introduces RBF-1 Surface Finishing Equipment Company have introduced Mini but High Production Shot Blasting Machine – Rotary Barrel Type. This machine houses a barrel having effective volumetric capacity 1.5 Cft. And load carrying capacity 100 kg. approx. while the barrel rotates, a small size and compact Blast Wheel throws abrasive on tumbling components inside the barrel. The Shot Blast Cleaning cycle of components depends upon the initial condition of the components and degree of cleaning required and type of Blast media used. The Machine can give all types of finish. The Machine is fitted with Cartridge
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Type Dust Collector which constantly removes the dust etc. from the Abrasive Circulation System and ensures emission standard as per International Specifications. A Electric Timer is also provided for times control operation of the equipment. The Machine does not use costly compressed air and require only 5 HP to operate. The Electric Controls are centrally located and incorporates all safety features. The Machine is designed for shot blast cleaning of small or medium size Iron, Steel, Alloy & Non-Ferrous Castings, Forgings, Heat treated parts etc. at the lowest possible prices.
For further details write to Surface Finishing Equipment Company, E-100, MIA, Phase-II, Basni, Jodhpur - 342 005, Rajasthan Tel: +91 291 2740128 E-mail: sfec@sify.com Visit: www.sfecindia.net January 2014
Water will flow with Havells Havells Launches Self-Priming Monoblock Pumps One of the leading Fast Moving Electrical Goods (FMEG) Company, Havells India Limited, is entering into a new business segment with the launch of Self-Priming Monoblock Pumps to cater to the water needs for homes and commercial establishments across Northern India. They are also putting a strong global footprint in the market. The product in next few months will be available across the country. The product comes in two variants - Monoblock Pump V2 with 0.5 HP capacity & Monoblock Pump S1 & S2 with 1HP capacity and 0.5HP capacity respectively. • Offers 2 years warranty against manufacturing defects • To target Rs. 100 crore revenue from this segment by end of 2014-15 • To enhance production capacity in next three months As part of their philosophy of introducing energy efficient products for the people, the range of new pumps are powered by energy efficient motor with 2900 RPM and high suction with self-priming of up to 8 meters. The pumps can carry a maximum working pressure of 5 kg/cm and have a wide voltage operating range of 180240 volts. The pump comes with Class F insulation and IP-55 protection. With the launch of Self Priming Mono Block pumps, the company intends to target the overall Rs 5000cr pump market. The pump will be manufactured at company’s
motor plant at Neemrana, Rajasthan. Currently, the plant will be manufacturing 10,000 units a month and the capacity will be enhanced to 25,000 units a month over next three months. As part of their commitment to offer greater customer satisfaction to its customers, Havells has pioneered the concept of door-to-door service and created incomparable service network in the electrical and domestic appliances industry. Currently the company has over 1000 service personnel and technicians across the country in over 400 cities. The company has established a state-of-the-art call center in Delhi where customers can choose to talk in nine different languages like English, Hindi, Bengali, Tamil, Malayalam, Telugu, Kannada, Gujarati and Marathi. The call center ensures all complaints are addressed in 24-48 hours depending on the location thus ensuring minimum inconvenience to customers. While speaking to the media at the time of the launching of the product, Mr. Rakesh Mehrotra, Associate Director, Havells India Limited, said, “Innovation has been the hallmark of Havells and we continue to launch range of high quality products, keeping in mind the requirements of our valuable customers. The launch of the state-of-the-art water pump is in line with our customer-centric philosophy. Till now we were present only at electrical counters but with the launch of the pump we would also make our move to hardware and sanitary counters.”
“There is a high demand of pumps in the state and our dealers and distributors always wanted us to launch this product. The highly energy efficient pump is one of its kind in the industry. Our focus for the rest of the year would be to strengthen our network and add more dealers/ distributors”, he further added. The U.P region is critical for the company’s long term growth and currently contributes close to 12% to its overall revenues. To further bolster its growth and increase the revenue contribution from the UP region, the company will augment its market presence in the region by adding more dealers and Havells Galaxy stores, apart from launching new products from time to time. Currently there are 220 ‘Havells Galaxy’ across India and 32 in Uttar Pradesh. The company plans to open 43 ‘Havells Galaxy’ in the state by end of FY 2014-15. For more information please contact: Havells India Limited Amit Sharma Tel : +91 9911236700/+91 9811499946 Email: amit1.sharma@havells.com
Meena Cast introduces Air Cooled Cylinder Blocks Liners in the market Meena Cast is the manufacturer of air cooled cylinder blocks liners by centrifugal and shell mould casting process. Their ultra modern plant is equipped by casting process, machining process and testing laboratory and having yearly production capacity of one lakh pieces of air cooled cylinder blocks liners made from standard and quality cast iron and other allied materials. These products are manufactured for various engine requirements in domestic and international market which are in accordance with stringent quality January 2014
standards. The production is carried out keeping into consideration the need to have strict tolerances for such products which ensures that the liners are optimally fitted within the engine block. The additional quality features of such air cooled cylinder liner are the material used, the structure defined for various engine purposes and the surface quality. Their products range contains Dry Sleeves (FullyFinished and Semi-Finished), Wet Liners & Air-Cooled (Finned) Blocks of any size, model & series applicable with engines of compressors, marine and diesel engines, vehicles, generators and earth moving
equipments. For further details: Meena Cast Pvt Ltd Tel: +91 9824226454 E-mail: meenacast@gmail.com Web site: www.meenacast.com www.martonline.in
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New Aerotech MPS-SV series offers choice of DC servomotor or stepper motor All MPS-SV stages feature a precision-ground ball screw and preloaded crossed-roller bearings. This provides smooth and accurate geometric performance, high accuracy and repeatability and 0.05 Âľm minimum incremental motions. There is also a lead-screw driver option for more cost-sensitive applications. MPS-SV lift stages from Aerotech provide high performance in a All drive train compact, economical design. mechanics are designed for high to both English and metric optical reliability and extended service breadboards. life. A multitude of adapter brackets and MPS-SV stages are available with mounting compatibility inherent in vacuum preparation to 10-6 Torr the entire MPS stage family allow that includes a vacuum-rated easy assembly of multi-axis stage Multi-axis stage configurations can be assembled easily using MPS connector. An optional mounting configurations. linear and rotary stages in combination with the lift stage. plate provides direct mounting For further details visit www.aerotech.com Compact new MPS-SV lift stages from Aerotech deliver high performance elevation motion control for both laboratory research and high reliability production processes. The series includes two sizes (as small as 210 mm long x 52.4 mm wide x 38 mm high) and a choice of DC servomotor with rotary encoder or stepper motor.
Metavis introduces Filter Particulate Analysis System The presence of particulate contamination in a liquid system is acknowledged to be a major factor governing the life and reliability of that system. The presence of particles residual from the manufacturing and assembly processes will cause a substantial increase in the wear rates to the system during the initial run-up and early life, and may even cause catastrophic failures.
programmable motorized x-y-z stage to capture image sequentially as per a predefined matrix. There is an auto focusing arrangement to take care of the any unevenness in the filter paper while capturing the sequential images. A special filer holder is installed to place the filter on the microscope stage and a proprietary particulate is also installed to analysis the software.
In order to achieve reliable performance of components and system, control over the amount of particles introduced during the build phase is necessary, and measurement of particulate contaminants is the basis of control.
Methodology
The FPAS series of equipments have been developed to fulfill the requirements of the automotive industry. This microscopic image analysis based equipment measures the cleanliness level of the components by particulate counting. The results are reported as per international ISO standard ISO 16232. The System The system consists of an upright nikon microscope with a high resolution digital camera. A computer controlled
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The components are cleaned by oil, alcohol or any other solvent which is collected and filtered through a membrane filter using a vacuum pump. The dirt particles are collected on the filter which then dried in an oven at a special temperature and time. The dried filter is placed on microscope where a series of images are capture sequentially using the computer controlled x y stage and auto focus system attached to the microscope.
User can get the individual particle details when clicked on the particle of the image, like feret diameter, area, type of particle (reflective / non reflective).
Particulate analysis software
The particles in the image can be overlayed with the different colors as per different user defined or standard classes and the report are generated accordingly.
The advanced but user friendly software for Particular Analysis makes a single high resolution image (mosaic) by joining the images. The mosaic is analyzed to create a complete map of the filter.
For further details: Medimage Technologies Pvt Ltd Tel: 040 23075680 Email: info@metavis.com Website: www.metavis.com January 2014
VARGUS offers TT & TM Gen software in online and desktop versions VARGUS Ltd, a world-leading manufacturer of high-quality thread cutting, grooving and deburring tools for the metals and plastics industries, has launched VARGUS GEN. VARDEX’s industry leading TT and TM GEN software programs will now provide its advanced thread turning and thread milling tool selection and CNC program generation capabilities in both online and desktop versions. VARGUS GEN Online is a new interactive software program suitable for the most popular web browsing environments. This version ensures that the most updated TT and TM Gen programs are always available online. VARGUS GEN Desktop is a standalone software application for MS-Windows based operating systems that can be downloaded to customer computers. Automatic updates are available for this version whenever the user is online. VARGUS GEN reflects Vargus Ltd’s ongoing
commitment to innovation through the development of new technologies to help its customers select the right tooling solution for the right job. “Vargus is not only a producer of tools, but a provider of solutions. Therefore our focus is on helping our customers select the tools they need to program their applications as quickly and easily as possible. Vardex’s TT and TM Gen software applications are available in both online and downloadable formats, providing the most advanced and up-todate tool selection, machining conditions and CNC programming data for our customers in 15 languages,” said David Wolfe, VP Sales and Marketing, Vargus Ltd. Both TT and TM Gen software programs are upgraded with a new graphic user interface and improved functionality to enhance program usability.
“VARGUS GEN will prove to be an ally of our customers for optimizing threading tools and threading program which can lead to reduction in cost per piece. Vargus India team will be happy to extend training support to all their customers for VARGUS GEN.”
Upgraded features and functionality include: 1. Aesthetic Graphic User Interface (GUI): New clean GUI design for easier navigation and data entry. 2. Improved Tab Navigation: Users can easily navigate between tabs to check previously defined data, whereby the active tab displays the current stage in the process. 3. Faster Data Inputting: Users can make changes without having to re-enter data that was not changed in previous steps. 4. New TM GEN Summary Tab: Displays program data in a clear graphical format with pictures illustrating the definition of each parameter. For more information, please contact: Vargus India, Tel: +91 2135 654748 Email: info@vargusindia.com Website: www.vargus.com
Ashok Makhija Director, Vargus India
Electromech introduces Lacing Machine Trimfit 100 is a coil binding machine used in the production of motor manufacturing lines. The machine is equiped with servo in combination with PLC, enhances the adaptability of he machine to cover wide range of motors and alternators. Change over from 2 pole to 4 pole or alternate coil to continuous coil binding is just a choice of program. The small foot print of the machine enables the flexible production line configurartion and
January 2014
efficient utilisation of production floor. The product is a creation of the organisations experience and technological strength and is strongly supported by superior engineering resources and services to re-enforce the motor and alternator manufacturing in Indian industry. For details log on www.electromechindia.com
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Standard Techno Cast moves ahead with precision investment casting Standard Techno Cast has arrangement to cast virtually any metal-alloys such as Steel, Alloy steel, Carbon steel, Nickel based steel, Super alloys, Hast alloys, Inconel, Monel, Ductile irons, Aluminum alloys, Copper based alloys, Bronze alloys and many other ferrous and non-ferrous metals. Their plant is set up with the latest, sophisticated and ultra modern infrastructure and machines. They have testing equipments, instruments and facilities to maintain quality assurance to a high precision degree of accuracy required in process. Standard Techno Cast is having experience of 25 years in casting field and their skills in casting made them highly qualified company and they produce quality Investment Casting. They are also having
the team of field experienced engineers, skilled workers, operators, inspection staff and modern management staff. Standard Techno Cast is specialist in Precision Investment Casting for the components applicable to the Industrial Valves and Pumps, Impellers, Material Handling Equipments, Automobile, Dairy Machinery & Equipments, Industrial Clamps, Pneumatic Tools & Controls, Steam traps, Textile & Pharmaceutical Machinery, Agricultural Machineries, Engines, Cranes, Earthmoving equipments, Electrical Engineering, Fire Fighting Equipments, Flow Meters, Gymnastic Equipments, & General Engineering. Standard Techno Cast is ISO 9001-2000 certified manufacturer of Precision Investment Casting by lost wax process. They can undertake the Precision
Investment Casting by ferrous or nonferrous materials as per Drawing, Specification and Sample of customers. Their ability of making Investment Casting from a few grams to 150 kgs per single piece. For further details: Standard Techno Cast Tel: +91 9228222631 (Mr. H.C. PATEL) E-mail: standard_technocast@ rediffmail.com Web Site: www.standardtechnocast.com
Red Lion adds new Sixnet EtherTRAK I/O Module and enhanced RTU Firmware Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking has announced a new EtherTRAK-2 I/O module (E2-MIX20884-D) and enhanced firmware for its Sixnet series RTUs. Red Lion’s new Sixnet EtherTRAK-2I/O module ideals with both distributed and local I/O applications that require a high density of mixed I/O types. The E2-MIX20884-D module offers dual Ethernet ports that allow it to be used in fault-tolerant ring topologies, and provides the following inputs and outputs: • Discrete: up to 20 inputs, including four isolated high-speed counters, and eight outputs • Analog: eight 4-20mA inputs and four 0-20mA, 4-20mA, 0-5V outputs This high-density of mixed I/O allows customers to reduce costs versus traditional single-function I/O. The module’s four isolated, high-speed counter inputs can be used for metering and flow rate applications such as those in oil and gas and water/wastewater applications. “The rugged design of our Sixnet
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RTUs and EtherTRAK-2 I/O modules allow them to be used in virtually any harsh, remote application,” said Jacob Colegrove, product manager at Red Lion Controls. “Furthermore, recent firmware enhancements provide several capabilities to increase system reliability and to simplify remote management of our RTUs”, he added.
• Simple Network Time Protocol (SNTP) Synch Bit: indicates when the SNTP time synchronization is successful. Monitors connected RTUs against a time server to ensure system clocks are synchronized.
With enhanced firmware, Red Lion’s RTUs provide a simple yet powerful means to reliably monitor and control remote sites around the clock in extreme environments. The new firmware, which applies to Sixnet series ST-IPm-6350, VT-mIPm-245-D, VT-mIPm-135-D, VT-IPm2m-213-D and VTIPm2m-113-D RTUs, provides functionality that includes:
For more on the Red Lion Sixnet series RTUs and EtherTRAK-2 I/O modules, please visitwww.redlion.net/EtherTRAK-2.
• Atomic Configuration Loading: automates the remote configuration process to help customers save time by batch loading hundreds of RTUs. Either manually or through command line, users can create a configuration and load it to the RTU. • UDR-A Protocol: authenticated protocol that enables customers to better protect assets by limiting RTU access based on user-specific credentials.
• Datalog Status Bits: increases diagnostics by indicating when datalog configurations have been loaded to the RTU.
About Red Lion Controls As the global experts in communication, monitoring and control for industrial automation and networking, Red Lion has been delivering innovative solutions for over forty years. Our award-winning technology enables companies worldwide to gain real-time data visibility that drives productivity. Product brands include Red Lion, N-Tron and Sixnet. With headquarters in York, Pennsylvania, the company has offices across the Americas, Asia-Pacific and Europe. For more information, please visit: www.redlion.net/together January 2014
THE LAST LEAF Dear All, Wishing all our readers a very Happy and Prosperous New Year 2014. May this New Year bring in a lot of energy and cheer so that it enables us all to accomplish success and prosperity. As the year 2013 came to a close, Indian pharmaceutical companies that get a large part of their revenue through exports,had something to cheer about, owing to a 25% growth in US business in 2013 to clock the total exports at Rs.79,500crores. Furthermore, Indian exports to the US are set to grow at over 20% a year over the next four years on launch of more complex generic products and biosimilars. Sector experts said the trend is evident from recent acquisitions, such as Torrent’s purchase of Elder in December and AurobindoPharma buying Celon in August. On the front of non-conventional source of energy, Bangaloreis is working progressively in the direction of having lean and green manufacturing, keeping in mind the greenery and the comfortable weather in and around the city. It has 5 KW of energy density per square metre, compared to Freiburg that has only 1 KW of energy density per square metre. It is said that Freiburg in Germany, which is one of the leaders in solar energy, is the ‘Solar City’ since it has been the most successful in the fields of renewable energy research and marketing. Although only 200 MW of solar power generation facility has been created in Karnataka, given the potential, this should be multiplied ten times in the next 6 to 7 years. India is poised to become the solar energy leader in the world considering the solar energy density across the country. To talk about the development outside India, Israel’s tech startups and advanced farming techniques are combining to create a new world of high-tech agriculture. Because of the tough farming conditions, Israel has 100 years’ experience of tackling agricultural problems–heat, salinity and drought–that today are experienced globally. The success of Israel’s high-tech industry is due to the strong involvement of the government’s Technological Incubators Program, which was established in 1991. Increasingly, both in Israel and in other countries, crop cultivation doesn’t take place in open fields and doesn’t use rainwater as the main source of irrigation. Nowadays, tomatoes and peppers often never see any soil; instead they are watered and fertilized by drip irrigation pipes in computerized green houses. 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) January 2014
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