Volume 11 Issue 7 January 2015 Pages 68 ` 100
a i g d n n i s’ I r c i t e n y i l w a g n o A n n p i a a i r t d m a u E D In t n g c i o B a t f try c s a u u p n d Im ool In Ma ine T Mach
s SME’ r o f ining a r n T izatio Mind n a g he Or t n i ip lues ersh a d V a f e L so urial Role e n e pr ady e R T Entre Io ings h t e Mak
: w a ish out
n e R nate ab
io s s l a ng a P i ti s i n im te x o a P India r M w e a h omR Price rketing, Renis t s u C ace: Colin s and Ma Onf tor Sale c Dire
January 2015
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RELIABILITY. PRICE. REPUTATION.
Haas UMC-750SS Super Speed, 5-Axis Universal Machining Center
= TOTAL CUSTOMER VALUE. WE KNOW what it’s like. We’re MACHINISTS, too. We CUT METAL every day. Haas Factory Outlet
That’s why we’re driven to make sure that every Haas CNC machine is trustworthy, affordable, and always backed by the industry’s best after-sale service. | www.HaasCNC.com
Sales: Ahmedabad: 079-32405007, Bangalore: 080-41179452/53, Chennai: 044-65156052, Coimbatore: 0422-2413924 Delhi: 0124-4367619, Kolhapur: 0231-2677979, Mumbai: 022-39136041, Pune: 020-32935433
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January 2015
Global leaders in the manufacture of precision die cast & sand cast metal products and sub-assemblies Markets Served: Electrical Lighting Appliances Power Tools Telecom Instrumentation
Sigma Electric Manufacturing Corporation Headquarters: USA Garner NC. T: +1.919.773.0011
Manufacturing Location: India Pune. T: +91.2135.307.100
ISO 9001:2008
BS OHSAS 18001:2007
January 2015
www.sigmaelectric.com
Manufacturing Location: India Jaipur. T: +91.141.233.2833 ISO 14001:2004
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Dr M Ayyappan, the CMD of HLL (center) handing over the dividend cheque to Union Minister for Health and Family Welfare Shri Jagat Prakash Nadda in the presence of Union Health Secretary Shri Luv Verma and others
ew Government’s development agenda t Maharashtra Economic Summit 2015 Debasree Das
VINTECH AIR CONTROL ENGINEERS AND CONSULTANTS “Sai Raghavendra”, 207, Dr.Radhakrishna Salai, Ramakrishna Nagar, Valasaravakkam, Chennai - 600087 Phone Nos: 044-2486 6221, 044-2486 6821, 044-6563 1221 Fax: 044-2486 6321 E-mail: vintechair@gmail.com | vintechchennai@yahoo.co.in 4
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Wish you all a very happy and prosperous new year. The Indian manufacturing industry is starting with a positive note with IMTEX 2015 exhibition scheduled from 22nd of this month, one of the popular and largest metal cutting and machine tools shows in Asia. With India fast growing as the preferred manufacturing destination, and the new initiatives like ‘Make in India’ by PMO getting the momentum, IMTEX plays a major role in facilitating global manufacturers to establish their facilities locally. IMTMA is able to accommodate around 700 exhibitors from 25 countries and IMTEX 2015 spreads over 9 stalls across BIEC and the visitors are going to have hard time reaching the new innovations
Foreword
Hi Readers,
within the stipulated time of seven days. This edition is focussed on IMTEX as well as on the latest developments on Machine Tools. We wish all the very best for all stake holders in making IMTEX a grand success. For the last 40 years Renishaw is innovating cutting edge products enhancing and ensuring the best technology available to their customer network. They are having big plans for India with announcement of India’s first Additive Manufacturing Technology and Technical Centre at Pune and at IMTEX they are equipped with new introductions which includes high-speed contact scanning system for CNC machine tools, new range of modular fixtures for metrology applications, a miniature encoder system along with active demonstrations of its 5-axis scanning technology and equator gauging systems. Director of Sales & Marketing in India for Renishaw, Mr. Colin R Price shares their recent plans at IMTEX as well as future plans for India which is featured in the On Face column. The main feature on Big Analytics impact on the Indian Machine Tool industry is penned down by Rajesh Angadi. For Indians practising or thinking about spirituality, one has to get materialistic interests! Time has come to change this myth.. Once you go through the article on Entrepreneur Leadership by Pavan Sriram in this issue, you can find how different a leader runs his life. Stress is part of it. During my regular discussions with Mr. A S Shetty of Sedvik Industries he told about his new found interest in spiritual life and how
Hari Shanker Managing Editor
graduated over 60 years, on a retirement package, leaving all
it is helping him to cure his physical disabilities. We are starting a new column called Entrepreneur Spirituality by Mr. Shetty, and I am sure it will help our readers. We can increase our knowledge base by sharing. It’s like boomerang. You give, and it reaches back to you. We look forward your experiences from your expertise which can be shared with our readers. MART can only survive through you. And to grow we need you to write back with your comments and feedbacks. Till then let me take leave to prepare the next edition of MART, SMART! Signing Off,
January 2015
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Cover Story 8
Big Data Analytics Impact on Indian Machine Tool Industry
14 IMTEX 2015: Empowering Manufacturing India
26
On Face
Columns 36
Mind Training for SME’s
38
Roles of Values in the Organization
A S Shetty
P S Satish
40
The Choice Is Yours - Part IV
44
Entrepreneurial Leadership
46
Make things IoT Ready
Reena Jabran
Pavan Sriram Vinay Nathan
Volume 11 Issue 7 January 2015 Annual Subscription `1200 Member INS Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre Kabre P S Satish J R Mahajan LD Bhakre
MediaMart Infotech
Siji Nair
Sandeep Hingne
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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business Mart is a monthly journal published from Thiruvananthapuram.
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Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every effo January 2015 employees accept any responsibilities for any errors or omissions. Š All Rights Reserved
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First fully automated crane solution for Indian Ford press and stamping line
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MACHINE TOOLS
Big Data Analytics’ Impact on Indian Machine Tool Industry India stands 12th in production and 7th in the consumption of machine tools in the world as per the latest survey. The country is set to become a key player in the global machine tools industry and is likely to see substantial high-end machine tool manufacturing. Powerful data-driven analytics also help to solve previous unsolvable (and even unknown) problems that undermine efficiency in complex manufacturing environments. Similarly, the power of data to support improvement efforts in related areas, such as quality and production planning, is growing as companies get better at storing, sharing, integrating and understanding their data more quickly and easily.
Rajesh Angadi
Machines and Machine Tools make up the core around which all industrial manufacturing is built. Developing nations like India have to put special stress on machine tools, accessories and components. India has progressed immensely in the previous decades and there has been a huge rise in the number of machinery exporters, manufacturers, machinery equipment & components exporters, machinery and machinery spares and accessories suppliers in all parts of India. Since time immemorial, machines and machine tools have been used by us to lighten the human workload. The Indian machine manufacturers and exporters community stands apart; in their pursuance of a systematic approach to quality control and product standardization coupled with a long history of engineering excellence. Machine tools can be powered from a variety of sources. Human and animal power are options, as is energy
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1959 CNC Machine: Milwaukee-Matic-II was first machine with a tool changer (Picture Courtesy: www.cnccookbook.com)
captured through the use of waterwheels. However, machine tools really began to develop after the development of the steam engine, leading to the Industrial Revolution. Today, most are powered by electricity. Machine tools can be operated manually, or under automatic control. Early machines used flywheels to
stabilize their motion and had complex systems of gears and levers to control the machine and the piece being worked on. Soon after World War II, the numerical control (NC) machine was developed. NC machines used a series of numbers punched on paper tape or punch cards
to control their motion. In the 1960s, computers were added to give even more flexibility to the process. Such machines became known as computerized numerical control (CNC) machines. Indian Machine Tool Manufacturers’ Association (IMTMA)
January 2015
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After independence in 1947, the Indian Machine Tool industry also received a facelift with the inception of Indian Machine Tool Manufacturer’s Association (IMTMA). The association has been started for promotional support then, representing the entire manufacturing industry today.
Industry
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It does so with the aim to assist to the membership to become cost effective, technology driven, and ever responsive to customer’s changing needs. And that is precisely why IMTMA is today recognized as the sole voice of the Indian machine tool industry - its membership constituting over 90 per cent of this strategic sector in the country.
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The Indian Machine Tool Manufacturers’ Association (IMTMA) is an apex body representing the interests of the machine tool industry in the country. Established in the year 1947, the organization is involved in enhancing competitiveness of the Indian machine tool industry. It is also a member of some of the most distinguished organizations across the world. IMTMA has initiated several programmes to boost the machine tool industry and increase sales and export volumes. It maintains most of the comprehensive database of foreign importers of Indian machine tools and related products. Furthermore, it disseminates the most useful information on R&D and latest manufacturing technologies to help its members become globally competitive. Indian Machine Tool Manufacturers’ Association - IMTMA is deeply committed to support its membership to increase competitiveness, enhance efficiency, improve productivity, and ensure growth and prosperity.
Monte Carlo simulation Dynamically identifies bottlenecks and impact of interventions Prduction and distribution planning Determines optimal product allocation across combinations of substitute production lines, given technical limits, opportunity costs, and service levels Capacity planning Evaluates where additional capacity is required when link between resources and output is unclear/complex Value-in-use modelling Measures impact of different grades of raw meterials across integrated value chain Demand and pricing optimization Optimizes SKU’ volumes across regional production centers, given each SKU’ net profit contribution to a given demand center Process parameter optimization Evaluates optimal technical parameters for improved productivity in the chemicalsynthesis process ‘Extrapolation over top 5 companies in each sector, assuming tools are applicable to only 30 % of areas covered withina company and that -3% additional earnings before interest, taxes, depriciation and amortization (EBITDA) are unlocked ‘Electric power and natural gas’Stock-keeping unit
IMTMA proactively assists the machine tool industry and its membership by acting as a catalyst. IMTMA has mostly over the years deeply committed itself to support the industry to increase competitiveness, technology, productivity and quality to ensure its overall advancement and growth. The Association is also very
much proactive in taking new initiatives to promote advancement of metalworking manufacturing industry in India. IMTMA plays a crucial role in the growth and development of this industry. Indian Machine Tool Industry India stands 12th in production and 7th in the consumption of machine tools in the world
as per the latest survey. The country is set to become a key player in the global machine tools industry and is likely to see substantial high-end machine tool manufacturing. Industry experts say that the phenomenon is linked to the spurt in manufacturing, for which the machine tools sector serves as the mother industry. Since, the manufacturing
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capacity is stagnating and the growth rate for the machine tools industry is falling in developed economies, shifting machine tool capacity to lowcost high skill geographies like India, has become imperative. The Indian Machine tool Industry has around 1000 units in the production of machine tools, accessories/attachments, subsystems and parts.
better at storing, sharing, integrating, and understanding their data more quickly and easily.
Of these, around 20 in the large scale sector account for 70 percent of the turnover and the rest are in the SME sector of the industry. Approximately, 75 per cent of the Indian machine tool producers are ISO certified. While the large organized players cater to India’s heavy and medium industries, the small-scale sector meets the demand of ancillary and other units.
In our experience, many find it useful to set up special data-optimization labs or cells within their existing operations units. This approach typically requires forming a small team of econometrics specialists, operations-research experts, and statisticians familiar with the appropriate tools.
Big Data and Analytics’ impact on Machine Tool Industry The application of larger data sets, faster computational power, and more advanced analytic techniques are spurring progress on a range of lean-management priorities. Sophisticated modeling can help to identify waste, for example, thus empowering workers and opening up new frontiers where lean problem solving can support continuous improvement. Powerful data-driven analytics also can help to solve previous unsolvable (and even unknown) problems that undermine efficiency in complex manufacturing environments: hidden bottlenecks, operational rigidities, and areas of excessive variability. Similarly, the power of data to support improvement efforts in related areas, such as quality and production planning, is growing as companies get
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Nonetheless, to get the most from data-fueled lean production, companies have to adjust their traditional approach to kaizen (the philosophy of continuous improvement).
By connecting these analytics experts with their frontline colleagues, companies can begin to identify opportunities for improvement projects that will increase performance and help operators learn to apply their lean problem-solving skills in new ways. For example, a pharmaceutical company wanted to get to the root causes of variability in an important production process. Operators suspected that some 50 variables were involved but couldn’t determine the relationships between them to improve overall efficiency. Working closely with data specialists, the operators used neural networks (a machinelearning technique) to model the potential combinations and effects of the variables. Ultimately, it determined that five of them mattered most. Once the primary drivers were clear, the operators focused their efforts on optimizing the relevant parameters and then managing them as part of routine plant operations. This helped the company to
improve yields by 30 percent. Similarly, a leading steel producer used advanced analytics to identify and capture margin-improvement opportunities worth more than $200 million a year across its production value chain. This result is noteworthy because the company already had a 15year history of deploying lean approaches and had recently won an award for quality and process excellence. The steelmaker began with a Monte Carlo simulation, widely used in biology, computational physics, engineering, finance, and insurance to model ranges of possible outcomes and their probabilities. Manufacturing companies can adapt these methods to model their own uncertainties by running thousands of simulations using historical plant data to identify the probabilities of breakdowns, as well as variations in cycle times and in the availability of multiple pieces of equipment across parts of a production process. The steelmaker focused on what it thought was the principal bottleneck in an important process, where previous continuousimprovement efforts had already helped to raise output by 10 percent. When statisticians analyzed the historical data, however, they recognized that the process suffered from multiple bottlenecks, which shifted under different conditions. The part of the process that the operators traditionally focused on had a 60 percent probability of causing problems, but two other parts could also cripple output, though they were somewhat less likely to do so.
Mining company, for instance, used it to challenge a project’s capital assumptions, in part by deploying historical data on various disruptions—for example, rainfall patterns—to model the effect of floods and other natural events on the company’s mines. This effort helped it to optimize handling and storage capacity across its whole network of facilities, thus lowering the related capital expenditures by 20 percent. Big data and Analytics will transform the Indian Machine tools sector, but the industry must undergo fundamental changes before stakeholders can capture its full value. The combination Big Data with advanced analytics and lean management will lead to tens of billions of dollars in higher earnings for large manufacturers due to predictive and prescriptive decision making. References – 1) McKinsey and Company- Big Data Analytics 2) McKinsey and Company – Big Data Innovation for Machine Tool Industry 3) Indian Machine Tool Industry (IMTMA) The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.
December 2014 January 2015
Automatic setting of parts and tools is about to be
revolutionised...
Y
X
...see how at IMTEX Hall 4, Stand B106 • Simple to learn and use • Faster to payback and increase profits • Easy to justify compared to manual alternatives
Be there – everyone else will be! Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com
January 2015
www.renishaw.co.in
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COVER STORY
Empowering Manufacturing India
Debashri Das
For a developing country like India, manufacturing industries play a crucial role leading to an upsurge in the global exports. Being the sole voice of machine tool industry in India, IMTMA has taken the initiative to further strengthen the manufacturing base of the nation. IMTEX2015, organized by IMTIMA is going to display complete range of technology innovation providing wide platform to the ancillary and manufacturing industries to boost there productivity. In this article, we are trying to find out how IMTEX exibition is going to make India grow as a manufacturing hub.
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January 2015
Manufacturing industries fuel the economic growth of the country. A spectacular growth has been noticed in the recent years in the area of Indian manufacturing which has enabled the nation to further grow as a business centre attracting the global players to invest in the country. With the availability of skilled manpower and advanced technology, our country is evolving successfully to mark its presence as a producer of world-class products. As Indian Machine Tool Manufacturer’s Association (IMTMA) is completely dedicated towards machine tool industries of India (which also comes under manufacturing sector), it has taken initiatives to host IMTEX2015 which is scheduled to run from 22nd-28th January, 2015 at BIEC, Bangalore. This 17th flagship event
Avinash Chabukswar Managing Director C-Tech Engineers Pvt Ltd IMTEX is a showcase where all over world players in machine tool are visiting/ showcasing, We can showcase our product as well as can have idea about what is going on in global scenario to improve our machines.
Heller India exhibits at Hall no: 3A, Stall no: A125 Heller India Pvt Ltd is a supplier and manufacturer of cnc machines service provider of maintenance, repairing services of cnc machines. The company is going to exhibit components which are machined on Heller machines in India and worldwide and
are very critical in terms of accuracies and production volumes. Their range of display is – 6 Cylinder Engine Block 4 Cylinder Engine Block 4 Cylinder Engine Block 6 Cylinder Crankshaft Axle Casing for Tractors
From IMTEX exhibition, our expectation is to get getting feeling from our customer on the market situation and future growth prospectus. IMTEX is a one of the best podium on which all customer Mahesh Tyagi Managing Director Heller India Pvt Ltd
January January2015 2015
will come together to share their plans which will help us in planning our efforts in the growing market.
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will display the complete range of technology and innovations with the objective of ‘Enabling manufacturing excellence through worldclass productivity and cost competitiveness’. IMTEX series being a niche B2B trade fair has always promoted the manufacturing industries as a one-stop forum where business delegates from approximately 25 countries especially machine tool users, technocrats, policy-makers, experts of manufacturing, academia, researchers, technology graduates and budding engineers across the world can interact about the
IMTEX brings in the Quality over the world, so that the
be Engineering, Automotive, Aerospace, Chemical & Medical Equipments
customer will have the
and other sophisticated
knowledge of developments
equipment like CNC Machine for different processes. IMTEX 2015 is really a window to
machine Tools from all
UCR Prasad Proprietor, J R Rao & Company
taking place in the products processes, the cost involved to select the needs to suit their requirements for their present & future Investment looking in to the growth areas of their interest, may it
the world of manufacturing equipments of the future with the display from renowned manufactures of the world.
Walter Tools exhibits at Hall no: 5, Stall no: A106 With the Power of 4 brands Walter, Walter Titex, Walter Prototyp & Walter Multiply it brings together more than 350 years of experience in cutting tool innovation. The company is globally acclaimed as the “ONE” source for Complete Machining Solutions. Walter offers a complete range of metal cutting tools for turning, milling, drilling and threading. This year Walter is going to exhibit DC170 & M4000 at IMTEX2015. With DC170, Walter presents the first representative of a new
performance class of carbide drilling tools Technological progress made visible – with a new design of lands, DC170 is unique. The copper-colored finish with unmistakable channel structure conceals four tangible features of a new performance class for drilling ISO-P and ISO-K materials. As the new icon of drilling, DC170 makes its appearance on the international stage of metal machining at IMTEX 2015 in Bangalore. Visibly new, visibly different – a unique design of lands and copper-coloured finish symbolise a new performance class for drills. Walter will be offering the first two models in the dimensions 16xDc and 20xDc. The newly developed DC170 offers more process reliability, stability, running smoothness and efficiency than carbide drills with traditional geometries. Its longer tool life, higher hole quality and less expensive manufacturing features make the product more appealing to the visitors. M4000 – High performance made universal
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System tools, i.e. those that can be used universally for numerous machining requirements, reduce the complexity and susceptibility to errors in production, thus making it more cost-efficient. The latest example of this product philosophy from the Walter Group is the new M4000 range with system of indexable insert. Walter has consistently implemented the idea of a system concept: The new inserts and cutting bodies are manufactured in a way that offsets CO2 emissions. The M4000 – four square indexable inserts that can be used in three different types of milling cutters and master many common milling operations, for example, face milling, shoulder milling or chamfering in all steel, stainless steels, cast iron, and even difficult-to-cut materials. M4000 inserts can therefore be used more universally than their specialised relatives in the Walter BLAXX and Walter Xtratec® ranges. However, just like its two cousins, it is coated with the high-performance cutting material Tiger•tec Silver®.
Pawel Duzniak President Walter Europe & India
At IMTEX, on 22 ndJanuary 2015, Walter India will be presenting its latest developments in drilling, milling, turning and threading with the motto ‘What counts is competence’, an innovation that will set new standards in the industry – and drilling will be given a new look. Our aim is to constantly set new standards in metal cutting in order to advance our customers’ businesses.
January 2015
January January2015 2014
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the vision of prospective customer in choosing the right product. IMTEX can dispel this phenomenon by providing insight into working of these upcoming units with iron-hand viz checking for
Anand Mishra Director, Accurate Cutting System Pvt Ltd
adherence to international/ national norms, displaying flawless clientele lists, conformance to acceptable
It’s no secret that
factory working conditions
mushrooming of industrial
etc. We wish IMTEX the
start-ups has blurred
very best for future shows.
latest technologies, how to improve them and can provide more effective solutions to the consumers. GN Mewada, Proprietor, Mahavir Machine Tools commented, “ IMTEX2015 is a good platform to interact with more people in this field. We wish it will take the country forward.” IMTEX2015 boosting Indian manufacturing Showcasing the buoyant trends in the manufacturing sector, IMTEX2015 is going to boost it by letting the professionals to witness the live display of the products and upgrade their technological knowledge. With the upgrade of technical know-how, the industrialists would be able to know the latest technology available in
the global market which would motivate the competitive spirits impelling them for emphasizing upon innovations and further improvements in the existing product. It is going to be the largest exhibition of South and South-East Asia, near about 700 companies are going to participate in it this year. This huge participation will enable the visitors to networking with industry professionals, consultants as well as heads of the companies. The other ways through which IMTEX will boost manufacturing sector are: • By giving the opportunity to witness the applications of the showcased products. • To interact with
Askar Microns exhibits at Hall No: 2A, Stall No: B102 Askar CNC machines deals with Spinner series, spin flat series, Spin train series, smart mill series and spin turn series. The company is going to exhibit CNC slant Bed Machine and Flat Bed CNC Lathe at IMTEX exhibition. CNC SLANT BED MACHINE OF 3000 mm ABC MODEL: SPINNER 25 / 3000 mm. The machine has already proved its mettle at the Railway Workshops across the country and the shaft production has started successfully. The Spinner 25 / 3000 mm machine is built with a heavy duty single piece casting. The complete machine structure is
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FLAT BED CNC LATHE of 2000 mm ABC with LINEAR MOTION GUIDEWAYS optimally designed using FEM. ASKAR is now proud to display this true ‘MAKE IN INDIA’ machine to Indian customers and demonstrate to the world that Indian entrepreneurs and engineers are as good as the
best anywhere in the world. Spin Flat, the Flat bed CNC lathe with LM Guides for both X and Z axes movements, has gone through 3 versions and has now stabilized in the market. The whole concept of building the Flat Bed machine with LM Guide is unique. Rigidity of cutting shafts both large in diameter and length. Shafts length of 1000 mm to 3000 mm have already been proven. Large dia Hollow tube boring upto 1000 mm with special anti-vibration boring bars have also been proven.
K S Raju Managing Director Askar Microns
As usual we expect severe competition and display of machines with new technology. This time we anticipate lot of rush in the fair as there is push for MAKE IN INDIA. With this background we expect this IMTEX should be key to overcome several manufacturing limitation of the country.
January 2015
Elscint Automation exhibits at Hall no:3A, Stall no: H104 Elscint is a leader in Vibratory Bowl Feeder technology. It has been serving the world’s industry by providing small part handling solutions using vibratory bowl feeders, linear feeders, small parts conveyor feeders, rotary or centrifugal feeders etc. Elscint is going to exhibit Elscint Rotary Feeder, VBF 400 Cast Aluminum Bowl, VBF 630 Bowl and VBF 250 Cast Aluminum Bowl.
• The exhibitors through their discussions with the visitors will also become aware of the changing needs of the customers and will be able to find out some solutions to cope with it.
Monish Shete CEO, Elscint Automation Elscint will be displaying its various products at IMTEX 2015. Especially interesting would be its high speed “Centrifugal / Rotary Feeder” for Inline drippers which is being displayed for the first time in India.
January 2015
manufacturers from overseas and gaining an insight in to the technology they are using and how to make their effective implementation in the Indian market.
Visitors as well as the exhibitors will share their priceless knowledge at the International Seminar on Machining Technology on advanced solutions of metalcutting to improve product quality and the productivity. The seminar will bring close people from different segments of manufacturing industries of India- machine tools, tool rooms, valves
and pumps, engineering, aerospace, automotive and auto components, consumer durables and railway and defense establishments. International metal-cutting technology experts from USA, Israel, Germany, Sweden, Japan, India and UK will assist the session. Extending over 5 concurrent technical sessions and 2 key notes, this international seminar will take in key areas of technology associated with the systems of metal-cutting. Apart from the above said factors, IMTMA’s initiative towards linking industry and academy at i2 pavilion of IMTEX2015 also encourages the technology grads and the educational institutes to know the present condition of the machine tool industry. The participating institutes will
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understand the demands of the different industries and hence can train and educate their students accordingly. Business generation through IMTEX exhibition Indian manufacturers of machine-tool are facing economy slowdown since 1999, and when she is rapidly gearing up harping on the note of optimism to become a global hub for manufacturing, IMTEX 2015 with its drawing in of business entrepreneurs from all over the world is leading to huge business generation and encourages them to invest in India. The exhibitors’ list is inclusive of group participants too from different nations like Czech Republic, Germany, Japan, Spain, China, the US, Taiwan and Italy. Some of the technologies display here will be introduced for the first time in the Indian market and this fact makes the exhibition
even more interesting. It is a good fortune to be in midst of bustling business activities at various halls spreading across 48000 sq. meters of exhibition ground, to gain experience where look upon deals getting accomplished, enquiries being worked up and contacts being made. With all these opportunities to the participants, it is believed that IMTEX 2015 will leave behind the early records in booking of orders. Dinesh Kumar, Assistant ManagerCommercial & Logistics of Dormer Tools India Pvt Ltd stated that IMTEX would also generate business through • Meeting with top management & all concerned people like purchase, tooling, machining and many more • Understanding the customer current application in details, the customer’s concerns with current suppliers (delivery/ quality/services etc)
Bringing the Dormer, Pramet and Carboloy brands together onto onestand demonstrates the full extent of our wide product offering to the market. Our common success is built on providing consistent product quality, durable tool life, a versatile tool Gautam Ahuja Managing Director Dormer Tools India Pvt Ltd
• Knowing customer’s expectations while changing supplier for their particular application. • Realizing why they want to change supplier. With special focus of IMTEX
assortment and a simple customer experience in every aspect. on machine tool industry which is the integral part of manufacturing sector, the exhibition will fueled the global competition to output capital goods which in turn will result into the production of the manufactured goods.
Dormer Exhibits at Hall no: 3C Stall No: B104 Dormer is one of the leading producers of solid carbide and high speed steel rotary cutting tools. Their product programme is inclusive of threading tools, milling and drilling to serve the basic
machining purposes. At IMTEX the company is going to exhibit new milling insert ADMX07, new PVD milling grade M8340 and its new CNMX19 insert, a new Chip Breaker TF.
IMTEX 2015 provides a fantastic opportunity for us to showcase our newly expanded and extremely versatile product portfolio to the market. India continues to be a vital region for Dormer Pramet as we look to expand our presence throughout Asia, grow sales and
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Fabrizio Resmini
enhance our reputation for
President
delivering practical support to
Dormer Pramet
customers of all sizes.
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Pramet’s new milling insert ADMX07, the latest addition to its AD family offers diameters down to 10mm for a variety of applications and materials will be on display at IMTEX. Also there will be Pramet’s new PVD milling grade for general applications - M8340 – which offers enhanced wear resistance, consistent performance and process reliability. Pramet’s expertise within the railway industry will also be showcased through the addition of its new CNMX19 insert, a new Chip Breaker TF specifically designed for the re-turning of wheel-sets. Meanwhile, visitors to the stand will be able to find out more about Dormer’s expanded range of solid carbide milling cutters. This includes adding multi-material cutters, a ball nose range, corner radius end mills and
cutters for difficult to machine materials. Dormer has also introduced a range of taps for material specific applications branded “Shark Line”. All Shark taps feature a colored ring that signifies the specific material type it is suited to. The program encompasses spiral point taps for through-hole applications, spiral flute taps for threading blind holes and, in the case of white ring taps for cast iron, straight flute taps for both through or blind holes.
January 2015 December January 2014 2015
January 2015
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Emphasis of IMTEX2015 on ‘Make in India’ Despite of the outstanding performance by the Indian big shots entrepreneurs, import of the products still rules over the machine tool industries of our nation. A definite trend in the indigenization of machines has been witnessed in the recent years which further accelerated with ‘Make in India’ campaign launched by PM Modi. ‘Make in India’ machine tools have the greatest impact upon the country’s economic output ratios. IMTEX 2015 will work as a catalyst to ‘Make in India’ for the first time giving impetus to the economy of
India. Indian government’s announcement of various schemes associated with indigenization of the machines will exert immeasurable value to the delegates and exhibitors. With the increasing interest of overseas countries like Japan and China (who are also participating at IMTEX 2015) in the Indian manufacturing sector, the exhibition is expected to increase the FDI in manufacturing units through the corporations from abroad business players. The exhibition will encourage more companies to establish manufacturing base in India, making it a hub for exports. Hopes from IMTEX 2015 IMTEX has achieved an entirely different dimension for the
Auram Machines exhibits at Hall no: 3B, Stall no: A121 AURAM a well-known brand in Drilling & Tapping Machines since 1985, now offers an extra edge on account of its association with ‘KTK’ a multinational brand. The
Devrat Madhavi Executive Director Auram Machines India Pvt Ltd
IMTEX is the best place to display what we have invented for manufacturer’s routine machine requirements.
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principle oriented organization Auram Machines (India) Pvt. Ltd. (AMIPL) was incorporated with the objective of marketing the indigenously developed ‘AURAM’ products & also sourcing the augmented range of machine tools of reputed makes worldwide. The company today works as a solution & consultative oriented machine tool organization, basically for all Drilling & Tapping needs.
In our ongoing efforts to intensify our product brands Dormer, Pramet & Carboloy in Indian Market, IMTEX2015 is the platform where we can start with business generation activities in a wider way. As a result, we are sure we can get many opportunities
Dinesh Kumar Assistant Manager Commercial & Logistics Dormer Tools India Pvt Ltd
exchange and transfer of technology through joint ventures. Innumerable companies of India are getting benefits through such exchanges. IMTEX always evolve out as a pioneer brand to lay out the latest technologies and solutions of the manufacturing industries across the world. L Krishnan, the President of IMTMA is very optimistic about the exhibition this time saying that the business generation at IMTEX 2015 will surpass the previous edition. Visitors at the show will be captivated by the evolving trends in micromachining, duplex machines, multi-axis and additive.
either to develop new relationship or strengthen existing relationship to establish our brands in Indian Market.
This exhibition will consolidate international and domestic visitors from the metal cutting industries of China, USA, Japan, South Asia as well as Europe. The event will mainly feature latest innovations in the technologies of tooling for accurate finish and cost-effectiveness in every operation of metal-processing.
Concurrent exhibition: Tooltech 2015
IMTMA (Indian Machine Tool Manufacturer’s Association), the organizer of IMTEX trade shows, since its emergence in 1947, has been recognized as the voice of the machine tool industries of India. The activities and initiatives taken by IMTMA are focused mainly at giving something in return for the industry, by the industry and to the industry of India.
Tooltech 2015, a premier Trade Fair of India, will continue from 22nd-28th January, 2015 at BIEC of Bangalore. It is an international exhibition where the main focus will be on cutting tools, abrasive tools and products, robots, safety equipment, CAD/CAM, machine tool accessories, hydraulic and pneumatic systems, hand held tools, metrology, tooling systems and instrumentation.
Whether it is organizing the biggest ‘IMTEX’ – a slot b2b exhibition or interim on an assortment of machining technologies, conducting ‘Technology Mission’ for the CEOs of International shows on trade or hosting ‘Finishing School’ programs for fresh grads to provide them an expert touch, or arranging ‘Productivity Championship Awards’ to find out the out of
January 2015
Abhijat Equipments exhibits at Hall No: 1A, Stall No: B112 ‘ABHIJAT ‘ manufactures various machine tools since last 30 Years such as single spindle automatic lathe, second operation turret lathe. The company will showcase innovative CNC machines at IMTEX2015. Six Station CNC Turret Lathe Machine Model Autocut-32 The product is with- Neri Controller, VFD Motor for
spindle drive, Hydraulic collet chucking arrangement, 32 mm round collet capacity, hydraulic operated cross slide in auto cycle and has centralized lubrication.
The product is with – Neri controller, 4 position turret mounted on linear slide, 2 Tool holders mounted on linear slide, manual lubrication and VFD for spindle drive.
CNC Turning Machine Model –Deepak- 42
Single Spindle Automatic Lathe Machine Model AL 32.
The product is with Siemens 808 controller, 3 Live tooling in one direction mounted on linear slide. It has part catcher for part pick up, automatic centralized lubrication arrangement, 42 mm round bar collet capacity and 3 cutting tools on linear slide.
The product is with cross drilling attachment, tool Holders on vertical slide, tail stock, cross slide and double vertical slide.
CNC Turning Machine Model – Deepak- E-32
January 2015
Three axis CNC Turn Mill lathe machine Model AJINKYA.3X-42 This exhibited product is with 42mm collet chuck, slides with X, Y and Z axis movement, live tools along and across the axis 3 numbers each, spindle drive and spindle orientation. It is developed for the first time in India.
Sachin Doshi Director Abhijat Equipments Pvt Ltd
In IMTEX we have opportunity to exhibit our key CNC products and their specifications to important Indian and overseas customers.
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Grind Master exhibits at Hall no: 2A, Stall no: B106 Mission Critical Microfinishing Machines to Global Automotive OEMs such as Shanghai General Motors, SAIC, Renault Nissan, Kirloskar Toyota, SGMW and
Grind Master is one of the few machine tool builders from India competing on a global level with Japanese and German companies, supplying
The new Crankshaft Microfinisher is designed to bring down set up change time by more than 50%. It is also space saving. The Dynamic Balancing Machine being introduced has much higher accuracy and repeatability as compared to the competing machines. Both these Mohini Kelkar Managing Director Grind Master Machines Pvt Ltd
technologies will be extremely beneficial for our Industry. We are also sure that this will catch attention of Auto OEMS.
sight talents of the machine tool industry, IMTMA is doing an incredible job towards supporting the machine tool industry to boom on a global level.
The body of IMTMA consists of members elected every year from amongst the Association Members. Executive Committee governs IMTMA which is headed by its officebearers-the President and the
Great Wall. With “Widest Range of Metal Finishing Machinery in the World”, Grind Master has developed home grown technology and knowhow. Grind Master is showcasing the following products: a. Microfinishing Machine for Crankshafts & Camshafts b. Dynamic Balancing Machine for Crankshafts – India Models built in collaboration with
Vice President. IMTEX has in fact, turned into that ultimate platform where industry captains and the consumers can develop their manufacturing capacities. To
Balance Engineering, USA. c. Gear Tooth Chamfering and deburring machine Built in collaboration with SAMPUTENSILI, Italy. d. Nano finish range of machines – CNC Microfinisher SMP-500 which is very flexible machine that is extremely easy to set for different jobs – used for superfinishing transmission shafts, Steering Rack Bars, Turbo charger shafts etc. e.Robotic Machining Cell
sum up, we can say that IMTEX will go on playing the pivotal role in improving output quality of the manufacturing industries boosting the economy of India as well.
Proteck Machinery exhibits at Hall no: 5, Stall no: B119 Proteck is one of the leading machine tool manufacturing company and an agency house. They have an established integrated manufacturing facility in Chennai where they manufacture high performance CNC turning centers and drill mill machines for crank shaft applications. They also manufacture high performance laser cutting machines and press brakes. Proteck is going to display the following products M/s. Fuji Machine Mfg Co., Ltd,
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Japan : Compact CNC Turning Center model DLFn M/s. Tsugami Precision Engineering India Ltd: CNC Precision Automatic Lathe Model MO6JC. M/s. Ashwini Engineering Industries, Bangalore : Tool Presetter Apart from the above, product information of the reputed machine tool manufacturers whom they represent in India will be available in the stall by way of catalogues, posters, samples and video
presentations. Few of them are:Proteck Machinery Pvt Ltd, India - Large swing CNC lathes for crankshaft and axle applications Reishauer AG, Switzerland - Gear Grinding machine, Grinding Wheels & Diamond Dresser. Nissin Manufacturing Co.,Ltd, Japan – Honing machine. Sarix SA, Switzerland - Micro EDM. MJC Engineering & Technology,
USA - Spinning and flow forming machines. Toyo Advanced Technologies Co.,Ltd, Japan - Internal Grinding Machines. Enshu Limited, Japan - Vertical and Horizontal machining centers.
January 2015
January 2015
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Hall 3C Hall 3B
Hall 3 A Hall 2A
ATM
www
Haas Automation Inc. Hall No: 3B Stall No: C105
TMC Measuring Instruments Hall No: 3B Stall No: A103
PL
Baker Gauges India Hall No: 3A Stall No: B128
DMG MORI SEIKI India
Losma India Pvt Ltd
Hall No: 3A Stall No: B107
Hall No: 3A Stall No: G105
Accurate Engineering
Vargus Limited
Hall No: 3B Stall No: C104
Hall No: 3A Stall No: A141
Kabelschlepp India Hall No: 3C Stall No: D122 FP
Kumbhojkar Plastic
CC
K C Precision
Hall No: 3C Stall No: D138
Hall No: 3C Stall No: B122
We have been participating
Sandvik Asia Pvt Ltd Hall No: 3B Stall No: C102
Strategi Automation Solutions Hall No: 3C Stall No: A133
in IMTEX continuously since
Taegutec India Hall No: 3A Stall No: B109
1998. IMTEX is a wonderful platform to see the latest in
Gudel India
technology and innovation
Hall No: 4 Stall No: A104
in Indian manufacturing. We have been able to
Quaker Chemical India Hall No: 3C Stall No: C108
showcase our latest product and service offerings at
Arun K Menon
IMTEX and we look forward
Blaser Swisslube
Fouding Director, Strategi
to meet our customers and
Automation Solutions
vendors at the show.
Hall No: 3A Stall No: B113
igus India Pvt Ltd
Hall No: 5 Stall No: C107 24
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Wendt India Limited Hall No: 4 Stall No: A106
IMEXSU Group Hall No: 2A Stall No: E101
Cimtrix Systems Hall No: 5 Stall No: A119
LAKE
January 2015
Hall 2B Hall 1 B
Hall 1 A
Kennametal India Ltd
Airtech Pvt Ltd
Hall No: 1A Stall No: B101
Hall No: 1B Stall No: A105
VIP PARKING
well in India due to boost in manufacturing sector and backup by the Indian
Starrag India
government with their Make in India campaign.
Hall No: 1A Stall No: B105 CO
Good boost has been given in the field of Aerospace, segment. I hope the tooling
Rupen Vikamsey
industry in India through
Managing Director, Orbit
IMTEX will achieve a good
Corporate & Leisure Travels
Rest room
Benco Thermal Technologies
Defense and Energy
Hall No: 1A Stall No: A117
Food Court ATM
ATM
www
Internet Lounge
boost due to the spurt in
The machine tool industry
manufacturing across all
has started performing
sectors.
Schunk Intec India Hall No: 2B Stall No: A106
VIP
Ambulance Fire Tender
Harting India Pvt Ltd Hall No: 2B Stall No: G104
Seco Tools India
EP
Hall No: 3A Stall No: A116
Entrance Plaza First Aid
PL
Protocol Lounge
CO
Camp Office
CC
Conference Centre
Renishaw Metrology Systems
FP
Food Plaza
Hall No: 4 Stall No: B106
VIP
VIP Alightning Point
Precision Automation & Robotics India Accurate Gauging
Hall No: 2A Stall No: E104
Hall No: 4 Stall No: B104
Bosch Rexroth India Hall No: 3B Stall No: C119
January 2015
EP
MAIN ENTRANCE
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ON FACE
A qualified graduate in Mechanical Engineering from UK, Colin R Price has assumed the role of Director of Sales & Marketing in India in conjunction with other sales responsibility for Renishaw’s rest of world regions. since October 2010. He served his apprenticeship within the Aerospace industry and has been working for Renishaw Metrology Systems Pvt Ltd since 1989 as a Manufacturing Supervisor and then Production Manager at Renishaw, based in New Mills, Wotton-under-Edge in the South West of England. In 1999, Price moved to UK Sales and the position of Area Sales Manager covering the south west region of England. After 3 years he was promoted to the position of Business Manager for MT and Calibration Products. He is working with the Indian sales force to help develop business and support activities. He can be reached at colin.price@renishaw.com 26
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January 2015
“Renishaw is Passionate about Maximising Customer Potential” Renishaw, after coming into existence in 1973, has made a significant contribution in measurement, precision machining, spectroscopy and motion control. Their innovative products advance the operational performance of the customer. Colin Price, Director Sales and Marketing, Renishaw shares some facts about their presentation at IMTEX 2015 and their latest enhancements. “Applying Innovation” is the slogan of Renishaw. Can you brief about the new innovations Renishaw going to offer at IMTEX 2015? Renishaw has been at the forefront of innovation in its industry sectors for over 40 years, aided by its exceptionally high levels of investment in R&D and its global presence. The company is passionate about ensuring its customers benefit from the best technology and expertise available to maximise their potential. Renishaw announced back in October of our plans to set up India’s first Additive Manufacturing Technology and Technical Centre based in Pune. We will initially have three AM machines processing different material powders. This move in itself will open up exciting opportunities for the Indian market and show that we are serious about this technology. I believe the additive market is relatively still new and the opportunities vast. There has been a real ‘buzz’ about the additive technology over the last two years and whilst it is an exciting technology the application of it is critical and should be applied correctly. Additive is not a replacement for subtractive manufacturing and radical new approaches to design should be applied to
January January2015 2015
ensure that the component design is optimized to meet the true capability of what additive can provide. The applications and machines behind additive will develop and just as CNC did many years ago will evolve quickly as the technology becomes main stream and accepted across all the broad manufacturing fraternity. We are also launching a machine tool part setter and tool setter probe which will be a revolution in itself. Major new introductions include a high-speed contact scanning system for CNC machine tools, a family of products for the measurement of aerospace blades, a new range of modular fixtures for metrology applications, and
a miniature encoder system. The company will also have active demonstrations of its 5-axis scanning technology for CMMs, plus a demonstration of its Equator gauging system in an automated production cell, together with new process monitoring software.
benefits of process control, enabling fast and accurate form and profile data capture from both prismatic and complex 3D components. For blade manufacture, the SPRINT system provides
Can you brief about SPRINT™ high-speed contact scanning system? SPRINT™ high-speed contact scanning system Renishaw’s game-changing contact scanning system opens up completely new process control opportunities for highvalue CNC machine tools. The SPRINT™ system incorporates a new generation of on-machine scanning technology that will deliver a step-change in the
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(OCS), a gas knife lens window protection system, and a high capacity filtration system. These updates give the user tighter control over the build process, enabling users to create even better components. We featured your 3D printed metal bike in our October 2014 edition, which you are displaying at IMTEX. How your new capabilities benefit the industry?
unprecedented capability for blade tip refurbishment and root blending applications. For multi-task machining applications, the SPRINT machine tool scanning system offers users completely new process control capabilities, including exceptionally repeatable diameter measurement cycles. Additional functionality offered by the SPRINT system provides a rapid health-check of a CNC machine tool’s linear and rotary axes in seconds, making it possible to implement a daily machine monitoring regime with little or no operator involvement.
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new range offers a wide choice of base plates and components available in M4, M6 and M8 thread sizes, and can be utilised for measurement applications across multiple industries, such as aerospace, automotive and medical. About your latest enhancements in metal 3D printing?
About Renishaw fixtures: the new single source for metrology fixturing?
Renishaw’s laser melting systems utilise a pioneering, additive manufacturing process capable of producing fully dense metal parts direct from 3D CAD, using a high-powered fibre laser. Parts are built from a range of fine metal powders that are fully melted in a tightly controlled atmosphere, in layer thicknesses ranging from 20 to 100 microns.
Following the acquisition of R&R Sales LLC in 2012, Renishaw has developed an extensive new range of modular fixturing designed specifically for co-ordinate measuring machines (CMMs), vision systems and its Equator™ gauging system. Visitors to IMTEX 2015 will see that the
The AM250, Renishaw’s first additive manufacturing machine is now available with PlusPac – an add-on kit which transforms the machine to meet the demand for cleaner process environments, improved surface finish and precision. PlusPac includes new Optical Control Software
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Empire Cycles, based in Bolton, UK, designed the mountain bike to take advantage of Renishaw’s additive manufacturing technology, allowing them to create a titanium alloy frame that would be both strong and light using topological optimisation. Individual sections have been bonded together and the new frame is some 33% lighter than the original. How IMTEX can help Renishaw to further strengthen its presence in India? Renishaw has its presence in India since more than 2 decades; IMTEX is a platform that will help us to showcase Renishaw complete line of business model across various industries. Now, the nation’s emphasis is mainly on ‘Make in India’. How this can be a success in making India one of the largest manufacturing base in the world? Any plans of fresh investments in your Indian manufacturing facilities? Renishaw Metrology Systems Ltd India has several operations; in Pune we have a software development
group and also electronics and mechanical assembly for a range of products supplied all over the world. We have our sales and marketing function, with offices across the country, which is responsible for providing the Indian market place with innovative product solutions and support.In India we have over 300 staff divided between software development, manufacturing, and sales and support. We see India as an important market and we will continue to invest and expand to match market demands and expectations. New product launches and technologies will also necessitate the need to increase resource when and as required.This same philosophy is applied to all markets globally. In October, the British Deputy Prime Minister, Nick Clegg, announced our plans to set up our first Indian Additive Manufacturing Technology and Technical Centre based in Pune. We will initially have three AM machines processing different material powders. This move in itself will open up exciting opportunities for the Indian market and show that we are serious about this technology. I believe the additive market is relatively new and the opportunities are vast. There has been a real ‘buzz’ about the additive technology over the last two years and whilst it is an exciting technology the application of it is critical and should be applied correctly. The applications and machines behind additive will develop and just as CNC did many years ago will evolve quickly as the technology becomes main stream and accepted widely across a broad spectrum of manufacturing sectors.
December 2015 January 2014
January 2015
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MACHINE TOOLS
Emergence of Vegetable Oil based Cutting Fluids for Boosting Cutting Performance The increasing demand for biodegradable materials has impelled the entrepreneurs to opt for vegetable oils for the presentation of an innovative vegetable oil based cutting fluids so as to combine the properties of better environment compatibility and higher conductivity of heat into one fluid and hence enhancing the cutting performance. Vrushal Phadnis At present nearly all metal cutting machines in the industry working with cutting fluids use products containing Mineral Oil. The recent years have seen a dramatic increase in prices of petroleum products, owing to the weakening of the Rupee and the demand - supply situation. Metal working fluids (MWF), the raw materials of which are majorly dependent on petroleum derivates have taken a direct hit, forcing suppliers to increase their prices over 15-20% in a short span of time. Considering the uncertainty of petroleum product prices and supply side constraints, MWF manufacturers now a days are constantly on a lookout to reduce dependency on petroleum. This has led to various developments in Synthetic products that fulfill the requirements of lubrication, corrosion prevention and dissipation of heat from the tool and work piece. However, a parallel line of development is in the field of renewable & bio-based products that are reasonably stable in product costing & supply, i.e. products derived from Vegetable oils. Vegetable oils, owing to their high polar properties adhere better to metal surfaces thereby creating a more durable lubricating film than conventionally used mineral oil based products.
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This new technology of Vegetable oil based products enables the lubricating film to withstand high cutting forces, in turn improving cutting performance and key measurement parameters such as insert life and surface finish. Additionally, the eco-compatible nature gives it an edge over conventional products to comply with environmental and health safety norms. A comparative study conducted in June 2014 at a leading manufacturer of Aluminium & Steel parts for the Tractor industry in Bangalore revealed an increase in the life of carbide inserts by over 35% [350 components / insert edge] using Vegetable oil based fluids, compared to a good quality mineral oil based fluid [260 components / insert edge] used in the same machining conditions.
Faridabad based manufacturer of transmission parts recently faced a serious accident due to fire that originated in their grinding machine due to overheating of mineral oil based grinding fluid. After a root cause analysis (RCA) it was ascertained that the flash point of the oil used was in lowmedium range of 160-180 degree celsius and this led to the fire. Oil chillers were installed to cool the oil to required temperature, however this had an impact on the energy costs.
Hard to cut metals such as Stainless Steel and Titanium used in Aerospace which require higher cutting forces and speeds often face the issue of overheating & inadequate insertion of life, putting a limitation on machine speed feeds. Vegetable oils maintaining a more durable film are able to withstand high cutting speeds, without overheating of the component or tool, thereby facilitating faster machining of these metals and improving production numbers.
Taking cognizance of the accident & rising energy costs, the company shifted to Vegetable based cutting oils, which for the same viscosity of oil have a flash point in the range of 230 - 260 degree Celsius. This helped the company in keeping the oil cool naturally, and eliminated the requirement of the oil chillers as well, reducing energy requirements. Additionally, the environmental impact of the production, use and disposal of vegetable oil based products is far less than
that of mineral oil based products. Vegetable oils, having higher organic content are easy to treat for disposal and lead to lesser Chemical OxygenDemand (COD) and Biological Oxygen Demand (BOD) in Effluent Treatment Plants (ETPs). Using the latest renewable resource additives in combination with effective microbial control chemistry have led to development of very performance driven, effective and environmentally responsible fluids, which have a bright future in the metal working industry. Vrushal Phadnis has completed Mechanical Engineering from Pune University and has been part of several management training programs. At present, Vrushal Phadnis is the CoFounder & Director at Taurlube Petrochemicals Pvt Ltd. He also holds the position of Director at Losma India Pvt Ltd, subsidiary of Losma S.p.A. Italy. He can be reached at vrushal.phadnis@taurlube.com
January 2015
January 2015
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MACHINE TOOLS
Special High-Frequency Spindle by SMZ Italia Committed by more than twenty years in the overhaul of spindles of all types and brands, SMZ in Volpiano is equipped to handle a comprehensive product portfolio. The corporate know-how is the result of accurate procedures defined over the years, the adoption of special-high accuracy machinery and equipment, the experience required in the repair of parts manufactured with different design approaches, specific for each supplier. In spite of all difficulties deriving from the widely differentiated features of products, spindles come out of SMZ “as new” and sometimes, even better. The definition of spindle in the Treccani encyclopedia is “machine tool shaft that transmits motion to the tool or workpiece”, which conveys a pretty clear and intuitive picture of this transmission organ. It may seem a simple subject, with low technological content. But very soon, the reassuring picture that is forming in our mind is dissolved by the words of Georg von Slawik, Managing Director at SMZ, since 1992 as overhaul service provider for all types of spindles and power spindles for milling, grinding, holemaking, boring and turning. “The spindle is a complex and articulated mechanical/ electronic (mechatronic) device that performs a highly critical function within the machine tool. It’s not a mere chance that the word comes from the French mandarin, which is
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the horizontal bar of the scale that supports the two trays, whereby perfect symmetry is essential for the correct operation of the measuring device.” Spindle Complexity “If you realize the ‘critical role’ of a spindle, you understand and recognize the value of our work: if a machine stops for failure, this causes downtime and additional costs. For
Surendra Kumar
end users, big importers and machine tool manufacturers, it is therefore essential to rely on specialists like us, who can solve the problem very quickly and effectively”, says Georg von Slawik, who founded the business in 1992 together with Ewald Zech. “Within one week, we can deliver 80% of products overhauled; with accurately defined, fully automated protocols, we can execute orders and deliver at short deadlines”. The technological evolution of a company like SMZ must necessarily progress with the complexity of the products they repair and overhaul: tests and upgrades are essential to deliver the expected result, i.e. a spindle that works perfectly and lasts over time.
by it to SHAR (India’s Space Research Centre responsible for its launch of vehicles to the Moon and to Mars). This spindle with a nose-length of nearly half a meter (and total length of 1 meter) weighing almost 120 kgs is capable of rotating at 10,000 r.p.m. with a power of 10 kW. It is being used for the machining of difficult, space-age materials most accurately. The overall performance of the spindle is excellent, the run out of the spindle shaft after assembly to the machine is only in the order of 10-20 microns, current drawn is 8.8A against rated 23A, no chattering is noticed on finished product and it is running very quiet.
The crowning glory of SMZ Italia’s entry into India came with the supply of a very special high-frequency spindle
What is the overhaul workflow of a spindle like, exactly? “The first phase is disassembling, including a check of the motor
Different phases of revisions
January 2015
and electric parts, failure analysis, detail measurement, technical report and cost estimate of the entire service”, explains the Managing Director. “All details are measured in a thermostatic room to identify the operations required to restore tolerances and fix damages. Then, ledges and bearing seats are ground, the tool shank is finished; in case of bigger damage, these operations are carried out after chrome plating. All of these operations, aimed at restoring the required geometric tolerance values, are performed in house”. The balancing of all rotary parts is the stage that comes before assembling. Concurrently with assembling, all details that have been re-machined or replaced during overhaul are tested and measured. Mr. A. Balamurali, Manager for machining at SHAR’s Solid Propellant Plant (SPP) has to say this about the spindle received “I want to inform you that the Spindle supplied by SMZ Italia (Model SMZ 1290) is very good and we already tested and machined one job which took 10 days to complete.” Similarly, Mr. Badriprasad of Rane (Madras) Limited, a reputed manufacturer of autocomponents based at Mysore, reported “We purchased from SMZ Italia a 15 kWHF spindle with120 mm OD and max. speed of 51,000 r.p.m. More than 1 year has passed since then. We are fully satisfied and plan to import more of these from SMZ”. Strict Testing Parameters “The spindle is run-in in a thermostatic environment on dedicated test benches provided with temperature and vibration data collection and logging equipment. Also testing is articulated in different stages: tool shank taper rotation error
January January2015 2015
verification; rotation error verification with rod at 300mm; tool retain strength verification; phonic wheel calibration. Motor verification also requires PC-based checking and logging of electric parameters, says Adriano Menegazzo, Sales Manager. “The testing certificate we release at the end of the process to certify the successful outcome of all operations is the final result of a strict process based on specific parameters, including vibration, temperature and geometric rotation values. The specifications adopted by SMZ in each step have lower tolerance values than those applied by the power spindle manufacturers themselves. Not only one of our added values is the capacity to make modifications, but also, if necessary, can extend the component’s operating life and quality”. 2000 overhauled parts annually “We execute the entire cycle discussed above for each of 2000 and more parts we overhaul every year. Among these, approximately 750 are repaired in Italy at the Volpaino site, near Turin, while the others are overhauled in the German and Polish sites”, says von Slawik. As the entire overhaul process is carried out within a short time, it is essential to have a well-furbished spare part warehouse, qualified staff for each operation, in-house equipment to perform all necessary grinding operations to restore the required geometric tolerances. “For this reason, we have acquired a wide range of universal bearings, so as to enable us to handle unexpected technical issues that would otherwise be unsurpassable.” “In view of the articulated
If you realize the ‘critical role’ of a spindle, you understand and recognize the value of our work: if a machine stops for failure, this causes downtime and additional costs. For end users, big importers and machine tool manufacturers, it is therefore Georg von Slawik
Managing Director SMZ
overhaul workflow, our mission is also to spread the culture of preventive maintenance among customers through targeted sales initiatives. For instance, I can mention invitations addressed to specific customers and demonstrations organized in our sites to show proper practices that help avoid repair and overhaul through accurate preventive maintenance”, adds von Slawik. SMZ’ Initiative to boost economy “For business like ours, organization efficiency is a must”-states Georg von Slawik, “both in a lively market with high productivity and profitability, and probably even more in case of shrinking business, when sales initiative must be more intensive, especially to acquire new customers”. What does this effort mean, in practice? “We have deployed new organization concepts, trying to introduce a new teamspirit among our staff, while also adapting our facilities with the creation of new workshop areas. We have recently expanded workshop and
essential to rely on specialists like us, who can solve the problem very quickly and effectively warehouse, from a footprint of one thousand square meters to approximately twice as much. This is a significant step, as also the development of industrial logistics should fit into the strategy of improving the quality of customer service”. SMZ Italia is supported by the cream of Italian technologists, and can do wonders to India’s economy. Its repairing capabilities remain untested yet by the Indian industry, hindered only by the rigid attitude of the Indian customs against goods sent abroad for repairs. Our Hon. Prime Minister Modi announced recently at Vigyan Bhawan, New Delhi that his government was starting with ‘trust in the individual’. If the Indian customs could respond in the same spirit, crores worth of machinery lying idle here awaiting repairs abroad could become operational. SMZ Italia could contribute well. SMZ Italia is represented by Precision International in India headed by its CEO Surendra Kumar. He has completed B.E. in Mechanical Engineering from IIT, Roorkee. He can be reached at precinter@gmail.com
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CASE STUDY
A Revolution in Traditional Job Order Metal Cutting Clamping Technology/Tool holders At Ingienieurbüro Martin Braun, an up-and-coming job order machining company in En-kenback-Alsenborn, Germany, collet and weld-on chucks was regarded for a long time as effective universal tool holders. It wasn’t until the engineering firm won a series contract that they became aware of the enormous potential of the new hydraulic expansion holders. Since then, the engineering firm has truly exploded onto the large-volume metal cutting scene using the powerful TENDO E compact from SCHUNK, the competence leader in clamping technology and gripping systems – especially the extremely economical 16-mm version. It is rare for a toolholder to enjoy the level of success of the SCHUNK TENDO E compact hydraulic expansion holder. When it was launched in 2010, it broke through the known limits of hydraulic toolholding overnight, making it possible for the first time to fully apply the specialized characteristics of high-precision clamping technology to large-volume or-ders. The powerhouses have already brought about a radical change in approach, especially in series production, where service life and workpiece quality are strictly monitored. SCHUNK is now taking this one step further with the launch of the 16-mm clamping diameter: without intermediate sleeves, the highly attractive tools with the 16-mm shank can now be clamped directly. Torque transmissions of up to 700 Nm – 60% higher than those of conventional hydraulic expansion holders and 15% higher than those of heat shrink toolholders – can be achieved at this size with a dry-clamped shank. And that with the full performance spectrum of hydraulic expansion toolholders, too: a perfect concentricity of < 0.003 mm, an unclamping length of 2.5 x D and optimum vibration
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dampening. Enormous Differences in Tool Wear Flexible job order machining companies are in an especially good position to benefit from the powerhouses, a fact emphasized by Martin Braun, owner of the engineering firm and metal cutting company of the same name. Braun and his 7-person team use robust machine tools primarily to machine individual components and small batch quantities using steel, stainless steel, aluminum and plastic, including a number of prototypes for industrial clients in the Kaiserslautern region of Germany. They also have a water jet cutter for exotic metals. Customers value the company above all for its flexibility and solid experience, especially when it comes to machining parts as efficiently as possible. Like many job order metal cutting companies, Martin Braun relied for a long time on weld-on chucks for high metal cutting volumes due to their low starting price and simple tool-changing mechanisms. Their disadvantages in terms of precision and surface finish
were simply accepted as part of the deal. “As long as you’re only cutting or machining small se-ries, it’s hard to judge just how much the tools wear – there are hardly ever any problems,” explains Braun. “We usually work with batch sizes between 1 and 300. With that kind of amount, it’s almost impossible to calculate tool costs accurately.” It was only when they started working on larger series of 4,000 steel pieces each that the team began to ask themselves questions. At 4,000 rpm and with a drive force of 1,000 mm/min, the vibrations and thermal conditions generated by the machinery meant that the team had to re-tighten the clamping screw after every 20-30 workpieces. “The cutter sometimes had 3 to 4 mm of vertical play,” says Mr. Braun. “It was worn out after 100 to 180 pieces.” But why? “Weld-on chucks always push the cutter slightly to the side, so it has an unequal load. With a high in-feed and drive force, this effect can be multiplied to such an extent that there’s no contact at all for one or two cuts.” Ever the pragmatist, Martin Braun quickly realized that this couldn’t go on. Nevertheless, he admits to being incredulous when he first heard that a hydraulic expansion
TENDO E compact, 16 mm : The highly affordable SCHUNK TENDO E compact hydraulic expansion holder is also available for direct clamping of tools with a 16-mm shank. It offers the ideal conditions for using high-efficiency tools and machining methods.
holder, of all things, would be the solution to his problem. “To me, hydraulic expansion holders were only ever used for precision machining operations such as finishing. Until we did the tests with the TENDO E compact, I was convinced that they couldn’t be used to cut all the way into the material
January 2015
– especially not with older machines and control systems, some of which put a huge strain on the tools. Tripling the Service Life As you can imagine, he was surprised by the results: believe it or not, when machining 25 mm-thick ST52 retaining plates for construction machinery at 4,000 rpm with a drive force of 1,000 mm/min and a cutting depth starting at 13 mm, a 16-mm carbide cutter now gets through 400 workpieces, beating the 100 to 180 that the weld-on chuck managed hands-down. “With the TENDO E compact, you notice that the cutter is a lot more quiet. The surface is also much more even, as each cut removes the same amount of material. On top of that, we have also seen huge improvements in process stability and dimensional accuracy,” Braun confirms. The oil-filled expansion chambers reliably dampen the vibrations generated by machining, peak loads are absorbed and the tolls’ cutting depth is stabilized. This benefits the cutting edge of the tool, as it extends the tool life and prevents chatter marks on the workpiece surface. The even load profile also results in an extended spindle and spindle bearing life span. A simple Allen key is all that is needed to change the tool in seconds without con-suming extra energy or affecting process reliability. “We no longer keep roughing and finishing separate,” explains Martin Braun. “With the TENDO E compact, I’ve got a chuck that really can do it all.” When machining stainless steel, Mr. Braun reports that the chuck guarantees a good surface for precise fittings, while it can also cut all the way into normal steel. “We don’t need a huge outlay for tools, we don’t need expensive
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cutting equipment and yet we can still produce great surfaces.” Braun also says that the powerful hydraulic expansion holder comes out on top in terms of affordability: “The toolholder costs about 160 euros, while a single cutter would set us back about 60. When you take into account the tripled service life, it doesn’t take long to make the best decision. The investment pays off quickly – especially with 4,000 parts running through the system over three whole months.” High Level of Flexibility The metal cutting specialist currently has two clamping diameters: the 20-mm versions are used as output chucks for a variety of machining tasks, and their clamping diameter can be reduced by up to 3 mm using intermediate sleeves. The new 16-mm version, on the other hand, is used for direct clamping in applications that are both highly demanding and eco-nomical. “A 16-mm cutter doesn’t cost even half as much as the 20-mm tools, but it offers higher speeds, a greater drive force and perfect chamfering of corners,” explains Braun. Any of new machines will be fitted with the TENDO E compact from the start, he tells us. “For 5-axis cutters, the precise toolholding, reliable dampening and precise run-out accu-racy absolutely make sense,” says Braun. And while he admits that it may not be as robust as older machines, he believes that the more dynamic machining of the TENDO E compact outweighs this minor drawback. The precise, powerful toolholder is available in clamping diameters of 12 mm, 16 mm, 20 mm and 32 mm, and is compatible with interfaces ranging from HSK-A63, HSK-A100, SK40 and
High-volume metal cutting 1+2+3 : The TENDO E compact can withstand even the heavy demands of high-volume metal cutting. It offers many times the service life of weld-on toolholders.
SK50 to JIS-BT30, JIS-BT40 and JIS-BT50. The TENDO E compact is manufactured at SCHUNK’s headquarters in Lauffen, Germany, and can be combined with intermediate sleeves and tool extensions to
handle a wide range of applications. The author HeinoldKostner is the Head of Product & Portfolio Management for Clamping Technology at SCHUNK Lauffen.
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3535
ENTREPRENEUR SPIRITUALITY
Mind Training for SME’s From this edition we are starting a new column – Entrepreneur Spirituality. During the journey of entrepreneurship one encounters a lot of problems. A spiritual bent of mind helps a lot to overcome these problems. The undersigned had the unique personal experience of getting himself cured of his severe leg muscle pain which is also called Sciatica without any medications or surgical treatments. This is an amazing and revolutionary approach to treating mind body disorders. Similar disorders could have happened to others also in the back, neck, shoulder or buttocks. This incidence took place about four years back. One evening I dropped my wife at the local train station for her to catch the train leaving for Mangalore which happens to be her native place. When I was waiting for the train suddenly I felt a tingling sensation in my right leg for a brief period. Such a thing had happened for the first time and I wondered why it was happening and then I forgot about it that evening. The next day morning when I got up and tried to take a few steps, I experienced severe muscle pain in my right leg. I was very much worried and started applying pain balm and pouring hot water on the affected portion of leg several times a day. When there was no reduction in the pain I consulted an orthopedic surgeon. He asked me whether I was having diabetics or high blood pressure. I answered in the negative. He prescribed for me pain-killer tablets, anti- inflammatory pills and nerve tonic tablets and asked me to come back to him after about two weeks. I felt no improvements and still I used
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to feel excruciating pain in the leg when trying to take a few steps. I got worried and talked to a few of my friends and relatives. Whatever advice they gave was not much of help. I started seriously searching the internet for any useful information on remedial measures. I went again to my doctor after about two weeks. After examining my leg he told me that I may have to get MRI test done and if necessary undergo surgery. I became panicky and at any rate I wanted to avoid any surgical treatment. I wanted to try alternate medical treatments like ayurveda, accupunture etc. At one place in the internet I saw there was a suggestion of accupunture treatment for curing leg pains. I enquired at some of the acupuncture treatment centers in Bangalore. I was told that I could try first one course treatment and if the problem still persisted one more course would have to be taken. With great intensity I continued my search in the internet for any information on proper cures. To my great luck I saw a statement from one Mr.Adam Rostocki saying that - “For more than twenty five years I suffered from back-
pain, undergone several treatments and finally got information as how to cure my back-pain and now completely got cured”. He had published an E- Book for sale explaining the ordeals he had gone through regarding his back pain and finally how he got himself cured of his back-pain for ever. I purchased the E-book immediately and went through the book thoroughly. In that book he had mentioned that one Professor Dr John Sarno who was the head of the Clinical Rehabilitation Medicine, New York, first discovered that tension is the underlying cause of most back, neck, buttock, shoulder and leg pain. He had treated several patients to cure their back, neck, leg and shoulder pain. Most of the patients got cured by simply attending his
A S Shetty
We have a conscious mind and a subconscious mind. The subconscious mind was first identified by Dr Sigmund Freud during the beginning of 19th century. The subconscious mind stores all your feelings like jealousy, inferiority complex, hatred, anger and guilt feelings. When any of the negative feelings crosses beyond a limit which is termed as buried rage it starts affecting the brain and the brain starts working erratically. The autonomic branch of the central nervous system controls the involuntary systems such as blood circulation and functions outside our awareness.
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lectures and reading his books. I ordered and purchased three books written by him on back pain problems. In a nutshell, what he means is as follows: We have a conscious mind and a subconscious mind. The subconscious mind was first identified by Dr Sigmund Freud during the beginning of 19th century. The subconscious mind stores all your feelings like jealousy, inferiority complex, hatred, anger and guilt feelings. When any of the negative feelings crosses beyond a limit which is termed as buried rage it starts affecting the brain and the brain starts working erratically. The autonomic branch of the central nervous system controls the involuntary systems such as blood circulation and functions outside our awareness. Due to the erratic functioning of the brain the autonomic blood flow to a specific part of the body reduces, resulting in mild oxygen deprivation to your muscles and nerves and it starts causing pain in that area. Treatments including surgical treatments for pain in one’s back, shoulder, neck, leg, buttocks are a multibillion dollar business in the USA. According to Dr. Sarno, 80 to 90% of Americans experience pain in the neck, shoulder, leg or back during their life span. The majority of the medical profession there has been stubbornly resisting considering these pains as mind body (psychosomatic) disorders. Experience suggests that in the United States only 10 to 20% of people with psychosomatic disorders are able to accept the fact that their symptoms are emotional in origin. Many medical
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Due to the erratic functioning of the brain the autonomic blood flow to a specific part of the body reduces, resulting in mild oxygen deprivation to your muscles and nerves and it starts causing pain in that area. Treatments including surgical treatments for pain in one’s back,shoulder, neck, leg, buttocks are a multibillion dollar business in the USA. practitioners are downright hostile to the idea. The treatment method is to start with self analysis and find out which of the negative feelings is affecting you most. It is a sort of mind conditioning and having an internal dialogue with your brain literally. I am normally a positive minded person. I don’t normally get affected by jealousy, hatred, inferiority complex, anger etc. I was wondering what type of negative feeling I was developing. After reading and rereading the four books and conditioning the mind I analyzed myself and found out that I was internally facing during those days for about eight months one major problem. i.e. Guilt feelings. The feeling of guilt is particularly painful to one’s self esteem and image. It is strongly repressed by the subconscious in order to protect the positive image of the self. During this period, my company was involved with the development of a special purpose rollforming machine for a multinational company. The machine specifications to be met were as per their
Principal’s specifications. I had quoted a delivery period of 6 to 8 months for the machine and it was getting delayed beyond one year. I used to get almost every week calls from my customer’s end as to when the machine was going to be ready. Because of the delay the customer’s whole project was getting affected. Dr. Sarno writes in his book that once you indentify your buried rage and you are aware of it, your recovery from the pain gets started. You have to acknowledge it and accept it as a learning experience. You should start thinking that you are quite normal. You should not think about it and live in the past. Accept it as a part of your existence. You should often imagine that your brain would send normal blood flow to your affected area. You should start having a strong faith in yourself that your pain would certainly get cured soon. In the meantime you should continue with your normal physical activities, exercise etc. and take no medications. I had read and reread the books several times written by Adam Rostocki and the three
books written by Professor Dr. Sarno and started conditioning my mind. The results were amazing because, there was no medication involved and simply mind conditioning. Within about four weeks of my starting to follow the instructions of Dr. Sarno my Sciatica got reduced slowly and finally completely cured. This story could have found a place to be published in a different forum or context. But I am citing this story now in the context of my working as an entrepreneur. The moral of my story is never and never carry your Guilt Feelings. The author A S Shetty, with vast industrial experience of more than 28 years is a mechanical engineering graduate from IIT BHU and a Post Graduate in Welding Technology from Germany. He is one of the leading experts in Rollforming Technology in India. Apart from steering the growth of his company Sedvik Industries Pvt Ltd, he is also helping companies to promote Rollforming Technology as a consultant. In this new series on SME Entrepreneur Spirituality Article series, he is penning down his experiences and you can reach him at sedvik@vsnl.com
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3737
MANUFACTURING EXCELLENCE
Roles of Values in the Organization Managing a SME in India - Part 25 We are guided consciously and unconsciously by the core values we consider. Personal values guide our decisions and actions to a great extent. But if applied with a conscious decision, it gives more benefit. Like individual has his own values, companies also should be guided by its values. As a continuation of last article, we will discuss on few more points about “Roles of Values in the Organization” to manage SME’s better in India.
P S Satish
36. Role of Values in the Organization Values define what is important for us. Values are fundamental beliefs. This word has come from Latin language word ‘valere’ meaning to be of worth.Values define what we stand for. In a company, it guides conduct, activities and goals of the company. All of us have something or the other which we want to hold to our chest as most valuable to us. These values may be viewed as positive or negative. Values serve as moral compass that directs our motivations, decisions and actions. For example, I consider high customer focus and speed of communication as one of the important things for me. These have become core values for me. That means, in my every action towards serving Customer, these points will come to fore front. We are guided consciously and unconsciously by the core values we consider. Many may not be able to express clearly or articulate well but we should agree that everyone has some values. Personal values guide our decisions and actions to a great extent. But if applied with a conscious decision, it gives more benefit. We are likely to apply more when we
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Gustof Larson, co-founder of Volvo, Sweden said, ‘Cars are driven by people. The guiding principle behind everything we make at Volvo cars, therefore, is and must remain – safety’. Even today Volvo Vehicles are considered to be very safe. The values of the co-founder are sustained for generations. Another value of Volvo is concern for the environment. If you want to be a supplier for Volvo, Environment Management System (EMS) certification as per ISO14001 is a must. are reminded of our values. This is the reason, after attending a lecture on values and benefits, we tend to apply consciously. Like individual has his own values, companies also should be guided by its values. This becomes the foundation of the company along with the vision and mission. Vision statement defines which mountain you want to climb and
where is it located, mission statements seeks answer to question of why want to climb the mountain, values define principles you want to adhere to no matter what mountain you want to climb. The founder of Robert BoschGroup said, ‘It is an unbearable thought to me that someone points out that I
have made inferior Products’, ‘Rather lose money than the trust of Customer’ - these powerful thoughts of Founder and he demonstrated these values in his life. These values have become one of guiding values of the company and hence has survived successfully more than 100 years. When the values of the
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company is spelt out clearly, every decision of the company will be guided by that. Employees will embrace. It can happen that the individual values of the employee may differ from that of values of the company. The employees should contribute better, have more job satisfaction, be loyal when his personal values have congruence with that of the company. Incongruence will also help company to get different perspective for a betterdecision. Note that every one interprets values from their own perspective. William C. Miller, founder of ‘Values centered Innovation’ and with decades of research on values of human beings and linking those to the way the person innovates. I had the opportunity to interact with him and also to attend some of his lectures. His findings are marvelous. He gives one example of a company struggling to get ISO 9000 certification. The CEO tries to convince telling employees that ISO is nothing but writing procedures of those things being done. But it didn’t work. Then he tried to bring two values to forefront. One is ‘quality’ and other is ‘Unity of thought, word and action’. The later values mean in the context of ISO certification implementation is that to do what is mind, then write that as procedures and implement. Any disturbance of this alignment would hamper in proper implementation of system. The CEO was able to bring to fore-front these values among employees and they in turn leads to improvements to implement system. Best companies develop core values that impact their company culture, brand and business strategies – making them unique. Few examples of Values of the companies –‘Do more with less’, ’ Embrace and
January January2015 2015
drive change’, ‘Satisfying and delighting our Customers’, ‘Integrity’, ‘Learn,educate and innovate’ etc. I give here some points that will help companies to identify and appreciate Values • The values we demonstrate in our actions are called enacted values. Those values we believe in are espoused values. The congruence between these two is important especially in leadership positions. Any gap here will be perceived as lack of Integrity. • Values vary across country cultures. For example, Individualism as a value is high in United States but medium to low in India. Appreciate the variation when dealing with a group with mixed cultures. • In a Company, typically core values will be that of Founder.
interviews will help to check whether company is living up to the values proclaimed • Keep the number of values of the company between five to seven. Too many values may dilute the thinking. Define each value in very few words • It is very difficult to practice all values on day to day basis. The top management should take up job of repeating importance of values in all opportunities while interacting with the Employees. • Talk about values of the company in employee gatherings, weekly or monthly meetings and any such opportunities. By telling repeatedly, values will get registered. • Focus on trainings and seminars to instill the values you want to nurture till it
becomes part of organization culture • Make sure that new employees are familiarized with the company values and put to suitable trainings By following values at the backend will increase value to Customer at the front end. By clearly defining values and following the image of the company will enhance and will become one of the strength of the company. I will continue the series of article in the next issue. Please send your inputs,remarks,suggestions to P S Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q 103, MantriParadise Apartments,Bannerghatta Road, Bangalore-560076. Do visit www.satishps.com Have a good day.
• Over the period, values can be reviewed. To identify the values, review milestones company has achieved in the past and see in those cases what values were demonstrated consistently. • Identify core values of managers, partners and key persons while fixing values of the company. • You cannot ask everyone in the company for their opinion on values and voting system will not work in fixing values of the company. Facilitation process will help. • While recruiting an employee, check whether he brings in new values and whether he can align to the values of the company. • In performance review of employees, include a point on level of demonstration of core values of the company • Employees survey, executive
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3939
BEHAVIOR MANAGEMENT
The Choice Is Yours - Part IV One always has a choice to choose his/her Behaviour in this World. The Behaviour is what makes the Person you want to be. The Choice is Yours. The Choice is Yours - a series of 12 articles based on Behavioural Science and its impact on Managing Self and Others. These articles bring in all that you want to know about Human Behaviour and its Impact on an Individual’s Personal and Professional life.
Reena Jabran
Turning the Fourth Leaf...
When I observe myself and the people around me, I see that most of us have Repetitive Behavioural Patterns. The other day I went to a restaurant which I usually go and ordered for a coffee, I saw that I invariably sat on the same chair and looked for the same person to cater to my order. There is a beautiful park near my house and I sit on the same bench and take the same route. Many a times we repeat our Actions and Behaviour...... Don’t we? It was a while that I had called Mr Neuron. I dialled his number and waited. He picked up the phone and excitedly said, ‘Hi Reena, Wish you, your family and your friends a very Happy New Year. I have been
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reading your articles and it is well penned. I see that now you are writing about the Behaviour of a person in the outer world. Hmm..... Good. For your further journey in this direction, I would recommend you to approach my mentor Coach A. He would be able to guide you better. Have a wonderful year and take care’. He hung up the phone and messaged me Coach A’s number. Suddenly I realised that I had built a beautiful bond with Mr Neuron and thanked
him mentally for being there for me.
Repetitive Thoughts and Beliefs
Remembering that I had to carry on with my work, I called up Coach A and requested for an audience. He asked me to come in the next day as he was busy cleaning his home that day. He said that he had a ritual of cleaning his house every Sunday and did not allow people to visit him that particular day. I was amazed with his statement. Anyway, I decided to meet him as told.
An elderly man in his late 70’s, well groomed and standing tall, opened the door for me. He was indeed very handsome and would definitely give the Hollywood stars a run for their money. I entered a well furnished, absolutely clean and well maintained house. I was scared to even sit on the sofa and for the first time went over my manners again and again so that I do not default in my
January 2015
courteous actions. A well-mannered housekeeper brought in a glass of water for me. In my fear to be perfect, I spilled some water. I smiled and looked away from the gentleman, as though nothing happened. ‘Well dear, wish you a Great Year ahead. I have gone through your articles,’ said Coach A . He sat down and continued, ‘I observe that you have touched upon the Topic of Changing Beliefs in your last article. I shall describe to you what happens to our behaviour when it is formulated.’
‘When actions are performed again and again on the pretext of Discipline, care need to be taken that it does not become a repetitive or patterned behaviour. Generating choices to get to the same results would be healthier. As a child if the parents insist on the same thing been done again and again, there is a possibility that the child will not deviate from the same pattern for the fear that something terrible would happen.’
‘Once the behaviour is formulated, went tend to do the same thing again and again. Repetitive thoughts and beliefs play an important role in people’s subjective lives as in their Physical, Emotional and Spiritual Well-being. When the repetitive thoughts are positive and choices are generated to strengthen them from all directions, the outcome is very productive and effective. For example, achieving your immediate goal at work, taking the effort to build healthy relationships with dear and near ones, remembering that important project you need to complete, taking the extra step to trim yourself at the gym, in all these we keep repeating and reminding ourselves in case we deviate.’
‘We tend to get locked into specific rituals that we firmly believe will keep us safe. These rituals usually contain precise rules of how to perform them. These behaviours are often very persistent and no matter how much we try to reassure that the ritual is not necessary, we still follow the pattern and that becomes a habit. Repetitive behaviour are behaviours that are done over and over again, often with the underlying belief that if the behaviour are not done, or not done in a particular manner, then some awful thing that the person is worried about will happen. These may be formulated during childhood, and it keeps going fresh even when the person grows up to become an adult. The patterns can sometime sink into the subconscious mind and we become unaware of these Behaviour Patterns.’
‘At the same time, many potential effects of repetitive thought, like getting mentally lost in your depressed mood preventing you from taking actions that would cheer you up, mentally stuck over an argument preventing your blood pressure from recovering, holding on to your patterned ritual that you do everyday which cannot be defaulted – all leads to affect your Daily Existence. ‘
I needed some time to think on what he said, so I interrupted him by saying, ‘Would it be proper to say that actions like cleaning our hands and the place around us again and again so that we are free from diseases and infection, checking out food and water for the fear of contracting infection, counting again and again so that you don’t make a mistake, checking work many times to make sure
January 2015
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we have done it perfectly, feeling worried when things do not go the way we want it to – all these can be included in repetitive behaviour.’
results. So, if we want different results, do things differently.’ ‘The root of behaviour change and building better habits is your identity. Each action you perform is driven by the fundamental belief that - It is possible. So if you change your identity then it is easier to change your actions.’
‘Yes, true. There are other examples which are more complicated and detrimental. Though subtle, it is sometimes dangerous too.’, Coach A went on to explain. ‘Certain patterned behaviour is created by oneself in order to escape situations and challenges. When certain behaviours find a comfort or success they are often repeated. The more repetition the more strength the behaviour gains. Once formed strongly, then it is difficult to shift and it sometimes proves to be dangerous or detrimental to oneself and all around. A few examples are inflicting wounds on self when angry, using the same abusive words again and again, creating a particular tantrum or acting in a particular manner to get the work done, doing crazy things for getting attention, throwing things around, and become physically abusive. These behaviours can be predicted by a near and dear one.’ ‘Repetitive behaviours can make life difficult for self and others. These behaviours often take up a lot of time making it difficult to get other things done, and therefore less time to celebrate life. Life becomes very monotonous and boring. Life becomes mechanical.’ ‘At the same time my dear remember, if the patterned behaviour causes high levels of stress when not adhered to it is called the obsessive compulsive disorder and it is definitely cause for anxiety. If the patterned behaviour is to bring about self-discipline and
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As a child if the parents insist on the same thing been done again and again, there is a possibility that the child will not deviate from the same pattern for the fear that something terrible would happen. does not affect if not adhered to, then it would be healthy for the individual. Being aware of the actions and behaviour and flexible in generating other choices too; would enhance the efficiency of the person.’ Changing Beliefs I felt good that a very heavy subject was made so simple by Coach A that I started to relax on my sofa and forgetting my manners stretched myself very comfortably. I saw that Coach A was not perturbed by my actions. Good God, I told myself, ‘He is not a person who has a OCD situation’ I looked at Coach A and asked ‘So, if the behaviour is detrimental to one, how do we change it?’ Changing his posture, he said , ‘All personal breakthrough begin with a change in beliefs. Beliefs are any ideas you think are true about yourself, others and life. Clarity about what you believe, who you are and
what you want, and why you want it can be like a beacon on a clear night, guiding you to the fulfilment of your desires.’ ‘Unfortunately, most of us are not aware of our beliefs, many of which we acquire as children. We can live our whole life unaware of how our beliefs affect our feelings, thoughts and actions.’ ‘To make it clearer about the previous topic I said, most of us are held back by the patterns we weave around us. It is natural for us to do this since we look for ways to make our lives more comfortable. Usually it is our patterns of behaviour that makes us look for the easy way out. We are comfortable doing things the same way and uncomfortable doing things we have never done before. This can sometimes be a barrier when we want to do what is really worth doing. ‘As somebody said, ‘If you keep doing the same thing, then you will keep getting the same
With this Coach A said, ‘I have given you enough to think about. I need you to go and pen down what your repetitive behaviours are how they become barriers in your growth. I also want you to think about the defeating beliefs that you have become comfortable with and now reconsider changing it.’ Trusting Coach A, i promised him that i would definitely look into it and think about it and get back to him the coming month. Feeling good that the year has started well for me, I thanked Coach A and started back to my home. The author Reena Jabran is a student of Psychology and today she is a coach and mentor in the Technology called Neuro Linguistic Programming [NLP] which she believes originates from Neuro-science. She heads the organization called ‘Jayakartha’ who are enablers of Personal and Organizational Excellence through Behavioural and Attitudinal changes. She has coached more than 600 students from all over the world in NLP, and more than 25,000 participants has attended her seminars in the past 14 years. She is accredited to an International body to issue Practitioner and Master Practitioner Certificates. Her corporate trainings has its core in this technology. You can access her at www.jayakartha.com She loves writing and reflects the technology in her works.
January 2015
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TALENT MANAGEMENT
Entrepreneurial Leadership Is there such a thing as “Entrepreneurial Leadership”? Is it different than Leadership alone and/ or Entrepreneurship? Is their commonality between them, which makes it logical to combine such distinct concepts? Pavan Sriram When you hear the word
Successful leaders
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They execute through inspiration and develop implementation capacity networks through a complex web of aligned relationships.
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an art, it means orchestrating
firms face today, a new type
the totality of the enterprise
of “entrepreneurial” leader
with energy, self-confidence,
distinct from other behavioural
persistence, and learning
forms of managerial leadership
capabilities.
is required.
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It’s argued that one could
Researchers have attempted
associate entrepreneurs with
in the past two decades to
leadership functions such
merge these two distinct
as providing vision to the
terminologies into an
development of a new product,
integrative one. In fact Gordon
service, or an organization
January 2015
as a whole. Entrepreneurial
entrepreneurial
leadership deals with concepts
leader is not easy,
and ideas, and these are often
as it requires a lot
related to problems which
of effort and people
are not of an organizational
do not appreciate
nature. Instead, they tend to
what you do. This is
be individual characteristics
why some successful
or behaviours. They include
leaders never
vision, problem solving,
become successful
decision-making, risk taking,
entrepreneurs.
and strategic initiatives.
When you talk about
Are Leadership, Management
entrepreneurship, it’s
and Entrepreneurship
a vibrant process of
mutually exclusive?
forward looking change
Entrepreneurial leadership is what you do when no one else is watching – be it an Olympic athlete challenging himself in silence to break new barriers, to a long distance runner dealing with the agony of distance or for an orchestra conductor who balances the different skills and sounds to turn it into pure melody. There are usually two terms used to describe this,
and creation. It calls for energy and passion towards
In many ways organisations
passion is infectious; others
creation and implementation
provide a great laboratory
feel it and want to get on
of newer ideas and creative
for their emerging leaders to
board with such leaders.
solutions for businesses to
test their entrepreneurship
grow and the willingness to
leadership metal. While
take “calculated risks’ – risks
those who make such
requiring time, equity, to
choices learn from the early
formulate an effective business
experience of the first contact
strategy; the fundamental
of their entrepreneurship
skill of building resources and,
leadership style with possible
finally, the vision to recognize
opportunities to help them
• Entrepreneurial leaders
opportunity where others
achieve their goals.
lead change – a defined
see chaos, contradiction, and
So what does it look like?
“willingness and intent”.
confusion.
As a leader if you have the
Are Entrepreneurial Leaders
and ‘Entrepreneurial’ or
born or made?
‘Intrapreneurial’ Leaders - here
willingness, you will take those measured risks and the intent
What differentiates Leaders
are few examples from my
• They look for opportunities in the unlikeliest of places. Constantly checking, correcting and balancing their own behaviour to suit needs and challenges.
dissatisfaction with the present, a vision for how things should be, and a clear idea of the first steps that need to be taken.
to make choices, moving in a
This is a question endlessly
own experience of having
positive direction. Combine
debated in most of the
• And the most critical of them
worked with some of the best
“willingness and intent”
corporate circles today. Do
all – Stepping out of their
entrepreneurial-led companies
and you have a compelling
or Can organisations provide
comfort zone. In fact they
and their leaders:-
combination for people to
that platform for leaders
rarely get stuck in a routine.
follow you whether you are
to test waters and come
• An Entrepreneurial Leader
corporate leader or a budding
out successful. Let’s look
makes the people connect and
entrepreneur. And those who
at the term “Intrapreneur”
strives to bring out the best in
demonstrate this leadership
for a minute – it’s basically
people. They see a persona, not
can’t put their mantle down
an Entrepreneur except
a person. They identify, assess
because it is a state of being
that he/ she focuses inward
and build people to work for a
for them, inextricably linked
in an organisation - on
bigger cause.
with who they are.
ways his business can act
“The passion and drive of entrepreneurs move the world of business forward as they challenge the unknown and continuously create the future” - Kuratko Being an excellent
January 2015
“entrepreneurially” from within established set of protocols and standards. Intrapreneurship is becoming a widely used term given that companies are struggling to find ways to maintain their competitive edge in today’s business.
• They have fire in their bellies. Passion is such a key part of being a great leader that if you don’t have it, you simply can’t be a great leader. Think of all the great leaders who started the biggest firms throughout the ages and try to name one that did not have passion. And
Entrepreneurial leaders learn to confront risk and protect the downside by figuring out the odds of success, working out what the worst possible consequences would be, then deciding whether to accept. Do write to me at pavan@ittige.com on how your organisation is identifying and encouraging entrepreneurial leadership. Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to improve learning outcomes.
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45
AUTOMATION
Make things IoT Ready: Kick-start your smart, connected product revolution In last couple of months, we have seen the Indian PM going the extra mile for attracting global investment with the Make in India & Digital India program. This has sparked a great deal of interest and we see a lot of excitement in the industry in launching initiatives to help advance these two programs. Vinay Nathan Make in India will drive innovation across the manufacturing sector while Digital India focuses on digital infrastructure, delivering services digitally. At Altizon we believe Industrial IoT will drive the next innovation by helping to provide Indian manufacturing a competitive advantage in building connected, smart products. Why make your existing products, smart and connected? Today every industry has one common business pressure i.e. to deliver more value to their customer with the existing products. This means offering personalised customer experience at each touch point thus ensuring customer delight. For tapping the customer insights, we need to understand the usage pattern of the existing customer. This
pattern can be understood by remotely tracking your devices on the field. Manufacturers today have little or no insights into how their machines are being utilized on the field. This information is vital for continuous product improvement and new product development. Thus, the need for smart and connected product ecosystem arises.
Industrial IoT will drive the smart product revolution across businesses which will lay the foundation for smart city, smart grid, smart plant, smart utility etc. Make IoT ready products at birth The development of new products and services that will be IoT ready at birth, will
make it possible for industry to get a larger percentage of their product portfolio connected thereby gaining exponential impact from this scaled customer insight. As both public and large private enterprise learn to work within these emerging production frameworks, weâ&#x20AC;&#x2122;ll see new efficiencies in terms of material usage, and shipping and transportation needs. This will also enable a new relationship with the end consumers, promoting greater feedback and transparency, and allowing for unprecedented levels of customization. A typical plant has thousands of instruments, components and machines with some degree of embedded intelligence which can be used for real-time OEE,
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December 2015 January 2014
performance and condition based monitoring. But this data is locked or rarely available to be leveraged for making any meaningful analysis at a corporate level. For unlocking and exploiting this humungous data set, we need to have all the component, instruments, PLC or any SPM (Special purpose machines) to be IoT ready at birth. The benefits of having them IoT ready at birth are as follows: • Reliable real-time monitoring of your machines • Real-time tracking of your assets on the shop floor • Drive better forecasting of your spare parts and consumables demand by aggregating data directly from your products on the field • Condition based monitoring for mission critical applications • Improve plant efficiency by changing from reactive maintenance to proactive • Installed base analysis leads to reduced maintenance cost and faster return on investment • Reliable data storage – ability to handle network and power outage Thus making products IoT ready will reap benefits not only for the OEM who supplies them, but also the
January January2015 2015
system integrator who will look at product availability and end users who want to reduce process variations in their plant. Research firm Gartner estimates that 26 billion IoT-ready products will be in service by 2020. That’s an average of 3.3 devices for every man, woman and child on the planet. And that doesn’t include the projected 7.3 billion smartphones and tablets. Making your products IoT ready NOW As with any new paradigm leveraging the Industrial internet requires planning and insight on building smart & connected products. One needs to first assess the product portfolio to map logical product families for a connected smart product initiative. At first one would look to get an existing product connected to share vital operational parameters for a point application like customer support that establishes an ROI for the initiative. The assessment would typically lead to a prototyping activity followed field trials before the final production runs take place. Also a typical Industrial IoT product development cycle, involves an integration between the IT (information technology) and OT (operation technology) technologies. This includes building a secure, reliable, scalable, manageable, data infrastructure layer that all these connected smart products can talk to.
At Altizon, we have developed our fast track launch program for making your products IoT ready in 12 weeks. This is possible due to our rich Partner ecosystem which includes device partners, application partner, consultants and system integrators. We have developed our Ready to go Aliot Appliance, Aliot SDK, Hardware plug-in and also developed custom sensor appliances for specific need. Realizing the potential of IoT ready products It is time for us to listen to our machines talk. The first step is hold an ear closer to your product by making it IoT ready. Let the Industrial Internet revolution begin first at home. Image courtesy: 1: https://www. maynoothuniversity.ie/ electronic-engineering 2: http://www. redesignrevolution.com/artist-
refineries-byproducts/ 3: http://www.grandmumbai. com/mumbai-night-tour.html 4: http://thinkprogress.org/ climate/2009/12/17/205204/ biden-announces-5-billionexpansion-of-advanced-energymanufacturing-tax-credit/ 5: http://energy.gov/articles/ innovative-nanocoatingsunlock-potential-major-energyand-cost-savings-airlineindustry 6: http://www. businessreviewaustralia.com/ leadership/439/AustralianConstruction-Industry-BuildsWorkforce 7: http://www.ausarabexplore. info/gallery/gallery.html The author Vinay Nathan is the CEO and Co-Founder of Altizon System. He has more than 13 years of varied experience across sales, marketing, engineering and product management. Most recently, he worked as VP Sales at Persistent Systems. He was also Co-Chair TiECON Pune 2014 & Fellow of the Startup Leadership Program. He has bagged 3 US patents and 4 patents are still pending. He has completed MS in Computer Science from University of Southern California, LA and a BS in Computer Engineering from University of Pune. He can be reached at vinay@altizon.com
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4747
QUALITY
Learn & Find the real key to Sustainability IndiZEN 2015 – 6th National Convention on Operational Excellence What actions are required for the Indian manufacturing sector to take this giant leap forward? How can this vital sector double in size and take on the world? What are the challenges and solutions? Indizen 2015 a National Convention on Operational Excellence by Kaizen Institute promotes this change. Divyakumar M Soneji
“ ‘Make In India’, ‘Zero Defect, Zero Waste’, From current 12% - 14% to 25% share of GDP through Manufacturing”…., says our Prime Minister Shri Narendra Modi. How will these visions become a reality? Simpler Labor Law’s, Cheaper Capital, Less Government Control …. are some of the most commonly cited requirements for Industrial Growth. Undoubtedly these are critical, but on the flip side looking inwards is critical too! Operation Efficiency and Excellence leading to better Quality, Speed and Accuracy are vital for Make In India to deliver! If Laws and Cheaper Capital are external changes, driving improvements within one four walls, is purely internal & can be set in motion now!
Far too often the greatest challenge faced by the CEOs is “Sustaining Change”. This happens because of absence of structured process control, problem solving routines managed by those closest to the processes. The root cause lies in the following tendencies:
IndiZen 2015 promotes this change! The change that we need to drive internally in each enterprise!
2. Prevalent tendency to treat people on the workplace without respect. Indian labor laws have created two classes of workmen, commonly described as ‘permanent’ and ‘contract’. The ‘contract’ manpower is temporary hands anyway; even the ‘permanent’ ones are not trusted enough to be allowed to control their own processes autonomously.
India has a great diversity in the maturity levels within different industries from an Operation’s point of view. There are some that are mature, but most pursue Operational Excellence (OE) in bits & pieces. They follow random, tool based, isolated improvements without effective employee engagement & without aligning efforts to serve business priorities.
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1. Prevalent mindsets of ‘managing by results’. Traditional managers proudly proclaim themselves to be ‘result oriented managers’; never realizing that results are but a byproduct of processes!
3. Absence of ‘Standard Work’. Quality system requirements have brought in SOPs, but they are rarely prepared by users!
They are made by engineers in English (not the local lingo), are full of text & confined to files - which emerge only during external audits! SOPs are not ‘Standard Work’.
scheduled on 17th and 18th February @ Hotel Hyatt Regency, Pune, India.
Initial investment in setting up manufacturing facilities has to be the current focus. However, 4. Visual Controls are not unless the Indian made goods understood, & consequently, match up to the demand of very poorly practiced. The quality, cost & delivery expected visuals that are put up do not aid by the world market, all these process ‘control’! opportunities will be short-lived. Being operationally excellent With its focus on Operational is a pre-requisite for global Excellence and theme of competitiveness. However, the “Sustained Operational real challenge is retaining the Excellence – Key to long-term competitiveness for the long success of ‘Make in India’”, haul. There are hundreds of the India Business Unit and books that teach the tools of Global leader in Operational OE, but there are few that teach Excellence, Kaizen Institute is the tools/ methods/ practices/ of all set to present INDIZEN 2015, sustaining OE. the 6th National Convention on Operational Excellence Given this background, Kaizen
January 2015
The Indian Prime Minister is passionately promoting ‘Make in India’ as one of the key components of his governments’ strategy to accelerate Indian economic growth. He also looks at this as a means to generating employment
Vinod Grover Founding Director Kaizen Institute India
Institute India decided to explore the theme ‘Sustained Operational Excellence – Key to long-term success of ‘Make in India’ for IndiZen 2015. About IndiZEN 2015 This event brings you an inspiring opening & closing keynote speakers, face-to-face Q&As with India’s leading Operational Excellence (OE) experts. There are three tracks in this two days event: 1. Knowledge/ Learning tracks, 2. Excellence Inside Tours (visit world class facilities/ factories as Seeing is Believing!), and the most awaited 3. National OE Case Study Competition. This national convention will give you everything you need to be more focused, energized and successful in the domain of Operational Excellence. We invite you to IndiZEN 2015, where you can learn more about the “Sustained Operational Excellence”, share your learning & experience & network with like-minded people. IndiZEN 2015 is going to be the place to learn about the ways to sustain operational excellence. You will gain insights on how you can become an active learning organization and build the
January January2015 2015
opportunities for millions of Indian youth entering the job market every year!
capability of your people by engaging their hearts & minds. Indizen 2015 has become one of India’s most important annual gatherings of professionals and experts in the Operational Excellence/ Lean/ KAIZEN domain. IndiZEN 2015 will be the sixth edition, and is now accepted by the industry as the platform for leaders in the Operational Excellence domain to share, learn and network. Kaizen Institute is the Global Pioneer in the Operational Excellence domain with a presence in Thirty+ countries, with nearly three decades of Leadership in this domain. We have developed concepts, intellectual models and published books that are considered the industry gold standard. Round the globe we are supporting thousands of organization to implement their Operational Excellence/ Manufacturing Excellence/ Continuous Improvement/Lean strategies, dove tailing into their Business Excellence initiatives. Block your dates, be there to learn & find the real key to Sustainability. The author Divyakumar M Soneji is Head - Marketing of Kaizen Institute India and can be reached at dsoneji@kaizen.com
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ACADEMY
i2Pavilion @ IMTEX 2015: Triggering Academy-Industry Bondage Since time immemorial, academy has played a significant role in enhancing the performance of different industries of India. Despite the fact, still a wide gap exists between the industry and academy. To bridge the gap and to increase the contribution of the academy towards industries, IMTMA has taken an initiative to invite the institutions to showcase their research work at i2 pavilion of IMTEX2015. Interactions between industry and academy are developing at a fast pace as it helps to shape the human resources and a source of innumerable innovative ideas for practical research. These interactions ultimately facilitate the economic development of a country. Many schemes have been implemented till date for bridging the gap between the industries and academy. One such initiative has been taken by Indian Machine Tool Manufacturer’s Association (IMTMA) to make the students of engineering acquainted with the industries of machine tool in India. Academy at IMTEX2015 IMTMA always aims to link academy and industry and hence it goes on taking steps for it through providing platforms to the academic institutions of India to take part in this prestigious exhibition of Indian Machine tool-IMTEX every year. It is going to give R&D institutions and academies of our country to showcase their proficiency in research work to the whole world. This informative show will definitely enable the students to gain a clear knowledge of what is happening in the industry and how the academies can train their students to cope with it. Here, they will get the
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Debashri Das
opportunity to learn about different companies and the technology innovations both overseas as well as indigenous. The institutions interested in highlighting their services, technologies as well as other works can participate in i2 pavilion. This year approximately 25 colleges are becoming a part of it.
We would like to showcase
Need to participate in Academia pavilion of IMTEX
inventions to produce the
IMTEX 2015 with its displaying of exhaustive range of machine tools and other technologies is undoubtedly going to attract a lot of business entrepreneurs, budding engineers, consultants, technocrats and others dealing in this sector from all over the world. The academies should not lag behind and should come forward to be its part because of the following reasons: • Through the display of the posters, the academies can offer some new technologies to the industries. • Educational organizations and R&D institutions through their interactions with the industry experts can identify the industry needs. • Participating students and professors can witness the best practices in the sector of metalworking.
our research inventions in the coming IMTEX 2015 to benefit the society. Hope the manufacturing industries will make use our
Ganesh Udupa, Professor, Department of Mechanical Engineering, Amrita University • The industries can pick up the products of the institutions by having a look at their displayed posters and by communicating with them about the product for exploiting it commercially. A maximum of 25 colleges are allowed to take part in it through the display of two products from each institution. The institution with the best display of the poster will be awarded with cash prizes of Rs50, 000 (1st prize), Rs25000 (2nd prizes, the prize will be given to two colleges), Rs15000 (3rd prize) and four consolation prizes of Rs5000. Theme at the i2 pavilion IMTEX with its main focus on metal-cutting technology is
product or to come up with a new start-up company which are beneficial to the society. encouraging the students to actively become a part of this industry through filling up of a registration form which will be absolutely free. Focusing on the need to strengthen the different industries, IMTMA apart from metal forming and metal-cutting, has tried to include some other themes too. • Energy efficient induction melting furnaces • Industrial power and energy meeting and network • Virtual manufacturing and robotic applications, • Machine based cutting processes,
January 2015
robotic system, solar vehicle for material transport system, selfcentering revolving drill and universal measuring machine.
• Advancement of modular machines assisting cutting and drilling The new theme of advanced machines assisting cutting and drilling will be the main attraction which will become even more interesting with the huge posters displayed there. These various independent themes like power and energy, robotics, cutting processes and others will serve different industries. Participants will take more interest as the platform will provide them a wider opportunity to interact with professionals related with different field. When it was first started, only 18 institutions were taking part in it, but with the passage of time and continuous effort of IMTMA, now the number of academic participants has grown to 25. This fact gives the perfect evidence of IMTMA’s relentless labor to link the industry with the academy to give the Indian industries skilled manpower and hence boosting the productivity and profitability indirectly. Some students of MSRIT, Bangalore considered the last show at IMTEX academia pavilion to be informative. They enjoyed their interaction with numerous companies’ experts and learned about wide range of cutting equipments and showcased tools of various types.
January January2015 2015
Last year 25 institutions participated and the noteworthy thing is that one UK academic institution also became a part of it. Visitors and exhibitors in search of new technology visit the different academic stalls to increase their knowledge on products and processes dealing with it. In this manner, this initiative of IMTMA is spreading and very soon it will be able to draw more global academic traffic to play pivotal role in making India grow as a manufacturing hub. Ganesh Udupa, Professor of Department of Mechanical Engineering, Amrita University is optimistic about his presentation this year commenting, “ We are exhibiting again our research work in IMTEX because our research attracted many people and we won the Prize for our work during IMTEX 2014 and the exhibitions were very good. Both the exhibitors and the visitors came to our booth in the search for new technologies to improve processes and products and to find ways to initiate start-up companies. We also made some contacts and the exhibition is a great opportunity for us to learn the state of the art techniques and processes and the tools used in the manufacturing industries”. This year Amrita School of Engineering is going to display posters of brain-controlled
Some of the colleges which are going to participate in academy pavilion of IMTEX 2015 are Amrita Vishwa Veedyapeetham, IIT-Bombay, NMAM Institute of Technology- Karnataka, PSG College of Technology, Robotics and AutomationCoimbatore and others. Boosting industry through academy Despite the industries’ increasing interest to link them with the academy, still many of them hesitate to invest in the academic sector. As Lecturer of Amrita School of Engineering, Mr. Surendran has put it, “The academic institutions still lack funds and the industries are not much willing to invest a considerable sum to the academies. As a result, both suffer”. Unless the industries taking initiatives to boost the academy further either through commercial investments or in some other way, we cannot expect the industries to grow rapidly in the future years too. Realizing this importance, IMTMA who always worked for the industry, by the industry and to the industry has invited many colleges across India so that the institutions can understand different aspects of the Indian industries. Through interacting with global business professionals and especially manufacturing players, both the visitors as well as the academic participants will gain
Sreedhara Advisor-Technology of IMTMA The academies with their research work will collaborate with the industries in India. The academies are working hard and hope the industries will have positive attitude towards it.
an insight into how to train their students so that they can benefit the industry and hence, in return, the country’s GDP. Moreover, at academia i2 pavilion of IMTEX 2015, the engineering institutions will get other advantages like: • To participate in the contests of award winning. • Can interact with IMTMA officials of Technology Centre • The participants can take part in sponsored activities • Can create network with big players of industries. Therefore, we can say that Academia pavilion will be a unique platform which will definitely help both the academy and the industry to come forward for a sustainable relationship.
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FAIR MART
EMO 2015 – The world of Machine Tools and Metalworking under one roof EMO MILANO 2015, organized by CECIMO, will take place from 5th-10th of October 2015 at the exhibition centre of Fiera Milano, Rho. The spotlight will be on the wide offer of machine tools available, capable of attracting users from all the main sectors that use metal working systems. Machines to build the future, cutting-edge solutions that give the possibility of achieving what mankind has imagined, and technologies on which the improvement of the quality of life depends: this and much more will be on display at EMO MILANO 2015. EMO runs every two years in Hannover and Milan alternatively, will take place from the 5th to the 10th of October 2015. The spotlight will be on the wide offer of machine tools available, capable of attracting users from all the main sectors that use metal working systems. The 2015 edition of EMO is promoted by CECIMO, European Association of the Machine Tool Industries.
Mark your dates!
The undisputed leading exhibition of the sector, EMO is a point of reference for the operators of the manufacturing sector, who will meet at an event that like no other is capable of promoting the contact between the demand
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and the offer of manufacturing systems, irrespective of sector trends. EMO is the ideal place to make new contacts and cultivate your existing customer base. The previous edition, EMO 2013 at Hannover, Germany, attracted 2,100 exhibitors from 43 different nations and close to 145,000 visitors from more than 100 nations. Make your presence felt
when senior decision-makers plan their buying strategies and look for deals that will ensure another successful year of trading. The exhibit profile include metal forming and metal-cutting machine tools, machines for welding, for thermal and surface treatments, robots, automation hardware and software, assembling, tools, parts, components, accessories, metrology and quality control systems for
safety and environmental protection. Hence businessmen desirous of benefitting from this global platform, should plan their business visit to EMO 2015 using Orbit’s expertise and track record. After all, it pays to attend one of the world’s leading and unarguably the most influencing trade fair for Machine Tools & Metalworking, with India’s foremost trade fair travel company.
Indian Machine Tool and Automation Expo
Power Elec-East Expo
India Steel 2015
January 9-11, 2015 ARK Hotel, Rudrapur
February 21-23, 2015
April 16-18, 2015
Milan Mela Exhibition Complex, Kolkata
Bombay Exhibition Centre, Mumbai
This biggest trade fair of India exhibited automation products and machine tools. The fair was attended by entrepreneurs, retailers and manufacturers.
The exhibition will showcase the power packed potential of the eastern regions of India displaying the products of electrical and electronic industries. It will be organized by FairAct.
This fair is a joint initiative of FICCI and Ministry of Steel, Govt. of India which will showcase Steel making Plant and Equipment, Steel cutting machines, Steel rolling etc.
www.toolautomationexpo.com
www.fairact.in
www.indiasteelexpo.in
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January 2015
January 2015
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53
PUMPS & VALVES
Wet balancing solution by Grundfos S-tube® reduces vibration Closed impellers have been around for decades, but until now, they have had issues with vibration, clogging and inefficiency in wastewater applications. This has impelled Grundfos to design S-Tube® waste-water pump impeller whose wet balancing solution cuts vibration upto 70%. When Grundfos engineers
Searching for a cure to
developed the S-tube®
vibration
impeller, they looked at three main issues: - efficiency - clogging
issue with impellers – and it challenged the new Grundfos S-tube® in the beginning. In early lab tests, the impeller
- vibration
was efficient and robust, but it
They began by conquering
can cause premature wear
the first two concerns, says
of components, damage to
Flemming Lykholt-Ustrup, Head
mechanical shaft seals, copper
of Mechanics and Hydraulics
windings, loss of power and
at Grundfos Holding A/S. The
even pump failure.
Grundfos S-tube® impellers not only allowed a noncompromised, free spherical passage throughout the pump, but they also improved the efficiency over traditional
vibrated excessively. Vibration
vibration to levels lower than
FlemmingLykholt-Ustrup. “But
Typically, the acceptable
those of wastewater pumps
this is not sufficient due to the
vibration levels for pump
with multi-vane impellers, says
unsteady pressure forces.”
impellers vary between 3-7
Flemming Lykholt-Ustrup.
mm/sec. These standards apply to multi-vane impellers
channel impellers by 20%.
and pumps using clean
The final issue to tackle was
no standards for wastewater
thus vibration.
single-channel impeller
“With a multi-vane impeller, fluid and pressure are more evenly distributed around the complete circumference of the impeller, whereas the pressure distribution is asymmetrical around a single channel impeller,” explains Flemming Lykholt-Ustrup. “The traditional and well-known single channel impeller has the strong advantage of offering high hydraulic efficiency, but
54
Vibration has always been an
water, however. There are
pumps. Therefore, there are often higher vibration levels in wastewater pumps. This is due to the hydrodynamic characteristics of a single channel pump and the varying solids and air content of wastewater together with variations in the incoming
approach to reduce imbalance
answer
in pumps: wet balancing.
One specific type of vibration
“Wet balancing is a statically
is imbalance, or the vibration
and dynamically balancing
caused by rotating machinery.
method similar to that we
One of the main tasks of
use when we balance the
the Grundfos S-tube® is to
tires of our cars,” he explains.
reduce the vibration level
“The difference is that for
and consequently the noise
wet balancing, the impeller is
level to minimum in order to
in perfect balance when the
ensure the longest life for vital
pump housing and the impeller
components such as bearings
are submerged in or filled with
and the shaft seal faces.
water. Being in perfect balance
flow. Although not ideal, the
“The traditional approach
wastewater treatment industry
to reducing imbalance and
has largely tolerated higher
running the motor smoothly is
levels of vibration.
to minimize the imbalance in
it is well known for potential
Grundfos set out to change
problems with vibration.”
these standards by reducing
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Grundfos took another Wet balancing brings the
the rotating components and thereby avoid vibration,” says
under water, we ensure the optimum operating conditions. In some cases we meet vibration levels below those known for standard norm motors.” He adds that the pump industry has previously
January 2015
attempted similar methods of
acting on the impeller when it
wet balancing without success.
is pumping – the direct force
Wet balancing involves introducing a deliberate mechanical unbalance to counteract the unsteady dynamic forces originating from pressure fluctuations within the pump. This approach cannot address the full spectrum of unsteady forces, he says, but does deal with a major source of excitation. To reduce the basic excitation in the pump, Grundfos combined the unsteady hydraulic forces with the unsteady mechanical forces that come from wet balancing in order to obtain a state of equilibrium, he explains. “We calculate the forces
January 2015
and the torque – and those obviously change, depending on how much flow is going through the pump,” he says. “We cannot make all these forces go to zero. This is something we need to balance out. So we have made our own little cookbook in how to do it – how to put the impeller off balance.” Tests showed a significant reduction in vibration. By introducing wet balancing in its single-channel S-tube® impellers, Grundfos reduced vibration levels by 50-70%, says FlemmingLykholt-Ustrup. These results mean sturdier
Figure 1: S-tube performance in a Grundfos SL1 15 kW wastewater pump. More than half of the pump’s flow range is above 75% hydraulic efficiency
and more reliable pumps for Grundfos, he adds, because
impellers and rotors is essential
functioning of the pump
the dynamic balancing of the
to prolong the reliability and
system.
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MATERIAL HANDLING
First fully automated crane solution for Indian Ford press and stamping line Sparkline, STAHL CraneSystems’ Indian crane building partner, has developed fully automated process cranes for a new Ford plant in India. The crane builder supplied a total of seven cranes – equipped with winches, wire rope hoists and crane components from STAHL CraneSystems. The cranes operate on two levels and in some cases can travel over one another. Wireless communication between the crane bridges and a complex anti-collision system permit the cranes to operate in various safety zones. Ford specified high speeds for the lifting and travel motions to enable the press and stamping line to be retooled quickly. “A high-end crane system of this type is unique in India at present,” Sparkline Managing Director Doshi explains proudly. Automation results in higher productivity Ford manufactures vehicle body components on the newly erected press and stamping line in Sanand, India. The tools in the presses must be changed regularly – this is usually timeconsuming: the crane has to be summoned and moved into position, the operator must attach the tool, lift it carefully out of the machine, move it to the storage point and then set it down. Now he must take up the next tool, move the crane back to the machine and insert the heavy load into the press with millimetre accuracy. Retooling is fully automated in the new plant in Sanand – this saves valuable minutes and thus increases the productivity of the whole system. When the operator has entered the destination number of the tool, the crane travels to the position selected at a speed of up to 60 m/min, following prescribed routes and detouring around safety areas. Sparkline’s cranes meet Ford’s strict specifications with their positional accuracy of ±6 mm.
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When the crane reaches the machine, a grab lifts the tool, the crane travels automatically to the storage area and sets the tool down in a free space. Experts on the spot Most of Ford’s specifications for the crane system could only be built in customised design. STAHL CraneSystems started assisting its Indian crane building partner Sparkline with its expertise at an early stage, when the components were being selected and calculated. STAHL CraneSystems’ Indian team and experts from Germany were already at the table during the important preliminary discussions between Sparkline and Ford’s engineers. The Sparkline/STAHL CraneSystems team was thus able to offer convincing solutions for all the requirements when its quotation was presented and its technical flexibility even exceeded the high expectations of Ford’s team. State of the art crane technology from Germany
State of the art production at Ford India. Automatic process cranes with STAHL CraneSystems components are used for retooling the press and stamping lines.
The heart of the crane systems are SHW 8 rope winches from STAHL CraneSystems. During production in Künzelsau they were equipped for particularly high speeds and operating with tool grabs.
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The heart of the systems are modified winches from STAHL CraneSystems. During production in Künzelsau, South Germany, they were prepared for mounting the grabs, designed for a hoisting speed of up to 9 m/min and equipped with a second brake to meet the high safety requirements. STAHL CraneSystems supplied a total of 6 frequencycontrolled SHWF 8 winches with safe working loads between 50 and 63 tonnes, and four ASF 7 wire rope hoists with safe working loads between 20 and 32 tonnes. The wheelblocks and travel drives were also supplied from Germany. Sparkline designed and built the cranes and grabs and programmed the controls. Intelligent crane control was required to operate the complex crane system safely and cost-effectively. The cranes operate on two levels and communicate by wireless to prevent collisions. Laserbased distance meters supply positional data. The control is a Siemens S7 PLC combined with latest generation inverters. Designing the safety features of the system was also demanding, as the specified
American Standard CMAA 70 – Class D (for heavy duty) had to be brought into line with Indian industrial standards. Sparkline’s crane builders rose to this challenge too. German-Indian partnership STAHL CraneSystems has been building up the crane technology market in India together with Indian crane building partners since 1999. Sparkline, as specialist for material flow solutions in the automotive industry, is now one of the largest purchasers of STAHL CraneSystems chain hoists in the world. The crane builder has its own chain hoist warehouse to supply standard products to its Indian partners quickly. They have two state of the art crane building facilities in Pune, India.
Operating on more than one level: effective collision protection is essential to prevent the bridge cranes and semi-portal cranes colliding. thanked Sparkline for its outstanding work and the successful completion of the project: “Thank you for your patience! In-house, we promised to get the best crane system in this region, a system meeting all Ford’s global standards. Now we have it,”
wrote Jose Conce Romero, one of Ford’s project managers, on completion. Jose is a crane expert in Ford’s global organisation. An excellent basis for more Sparkline/STAHL CraneSystems projects, as an extension to the plant could be scheduled in just two or three years.
Commended on completion Sparkline delivered the completed crane system just 9 months after receiving the order, in March 2013. The cranes were erected over the following months and commissioned in March 2014. Sparkline received more post from Ford in July 2014: the automobile manufacturer
Fast tool change from the air: the cranes approach the desired tool position at a speed of up to 60 m/min, take up the tool and transport it to the designated storage area. Equipping the press with the next tool is also automatic.
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POWERELEC-EAST Expo to showcase strength in East and Northeast The electrical and electronics
environment will encourage
of Commerce & Industries,
The Expo is making special
industry will converge in
the industry to make its
and Consumer Electronics and
efforts to invite key visitors, not
Kolkata to demonstrate its
presence felt in the region.
Appliances Manufacturers
only from this region but also
strength and explore business
However, with topography
Association.
from the rest of India and more
opportunities in the fast
of the region and its distance
developing East and Northeast
from other regions, particularly
regions. The occasion will be
in the case of North-Eastern
the POWERELEC-EAST Expo, an
Region, makes it difficult for
International Power, Electrical
the development to take place.
and Electronics Expo, which
Naturally, special efforts are
will be held from 21st to 23rd
needed to bring the regions
February 2015 at The Milan
closer to the national stream.
POWERELEC-EAST Expo is one such small step in this direction by like-minded businesses. This
importantly, neighbouring countries in the SAARC and ASEAN regions.
is the first time an industry-
Interesting events such as
specific Exhibition on the
interactive programmes for
sector is being held in this
utilities and the user industries
part of India and preliminary
as well as B-to-B meetings
interaction with prospective
are being planned on the
POWERELEC-EAST Expo is
exhibitors is very positive with
sidelines of the exhibition.
supported by important bodies
encouraging response to the
The Exhibition will therefore
The untapped potential of the
like; Calcutta Electrical Traders
Event from them. Foreign
provide excellent opportunity
East and Northeast regions
Association, The Bengal
companies from China, Taiwan,
to participants for promotion
has always attracted industries
Chamber of Commerce &
Malaysia and Sri Lanka will also
of their products and
Industry, Indo-African Chamber
participate.
technologies.
Mela Exhibition Complex in Kolkata.
in the past and the changed
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Güdel Introduces the Base-RAP© Dress-out Solution Standard routing and protection solutions for cable management from TrackMotion cable carrier to robot base. Cables for robot workcells are in constant motion and fail quickly if not properly managed which is why Güdel developed Base-RAP for TrackMotion© floor and overhead modules. If dress packs for robots are an afterthought, especially at the base of a robot, premature cable failure is virtually certain. Güdel’s Base-RAP (Routing and Protection) solution provides cable management and protection features to prevent cable problems between the energy chain of TrackMotion modules and the base of the robot.
Key components of BaseRAP include protective cable conduit, brackets, and quick access mounting clips. Conduits are two piece split loom construction and available in several sizes to protect cables from tangling, flapping and interference with robot motion. All brackets are designed and configured to safeguard against stress and unnecessary motion, and appropriate bend radii are maintained to prevent premature cable failure. Quick access clips are designed for easy replacement of cables
without special tools. Integrators use their expertise to determine what cables and hoses are needed to fill cable carriers on TrackMotion modules. Now, with BaseRAP, integrators have the first standardized cable dress-out protection system explicitly for cable management around the robot base of linear motion devices. To learn more about
how Güdel can supply the ideal Base-RAP solution check with your account representative, use the company’s online contact form or call (734) 2140000. For further details visit www.gudel.com
Bureau Veritas releases a new international guide to enhance the safety of battery management systems (BMS) Bureau Veritas has released a guide to identify and enhance existing operational safety standards for battery management systems (BMS). The goal is to help industries that use BMS systems improve the safety and reliability of their energy storage devices, thus optimising the overall performance of their products. Based on international standards in force (IEC 61508, EN50126/128/129, ISO 26262), the Functional and Safety Guide for Battery Management System (BMS*) assessment & certification guide puts forth a comprehensive approach to managing risks associated with BMS systems. In addition to creating a consistent frame of reference, Bureau Veritas has identified the various risks to be taken into account for the design and use of energy storage devices to ensure safe and reliable operation in all
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industrial applications. The risks and requirements identified in this new frame of reference apply to both stationary batteries (local energy storage, smart grids, auxiliary power systems, etc.) and batteries used to power embedded applications (electric vehicles, rail transport, aeronautics, defence, etc.). The guide highlights several significant points, including the need to: •federate and involve all industry stakeholders (designers, integrators and users) in risk management and continuous enhancement initiatives, •systematically take account of the full life cycle of equipment when assessing risks (from the design phase through to activation and use), •devote the same level of attention to software
components of BMS systems as to the equipment itself. François-Xavier Tobo, Safety and Operations Manager at Bureau Veritas, stated: “Batteries and BMS systems will be central to the main technological innovations of the future: smart grids, renewable energy, 100% electric cars and more. Risk reduction and performance levels of energy storage devices have become major issues from an economic, industrial and environmental perspective. By putting forth its risk management expertise in this guide, Bureau Veritas is contributing to the energy transition of tomorrow.”
BMS Guide can be downloaded for free from this link: http:// bureauveritas-evenements. com/bms/index.php
January 2015
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Clamping force gauge Testit, clamping force measurement over machine control Hainbuch and Siemens enter into partnership The Siemens Sinumerik CNC controllers have been getting the maximum productivity out of each machine for over 50 years. Now they have another partner on their side: the Hainbuch Testit software. It is available on a data carrier for installation on Siemens CNC controllers [Sinumerik 840 D sl plus PCU50]. This means that a separate laptop is not needed anymore and manufacturing with »theoretical clamping forces« is also a thing of the past. Thanks to Testit, the operator always knows which clamping forces exist and where, and the actual maintenance status of the clamping device. And given the safety standard DIN EN 1550, it is a »must have«. This means: The Testit clamping force gauge together with the Siemens CNC controller executes a target-actual comparison of the maintenance status of a clamping device. If the limit values are underranged, a warning message is output.
Perfect, don’t you think? Trust is good, control is better Based on his apprenticeship a machine operator or programmer has been taught to work in such a manner that a workpiece does not get destructed, e.g. when programming the manufacturing steps he builds in a lot of safety measures to minimize this risk. However, in reality, effective measurement data regarding the holding forces of a clamping device, and also in regards to the clamping forces of the clamping cylinder itself can only be obtained as vague reference values. A machine operator who knows how dependent the holding forces of a clamping device derive from its current maintenance status are, or from the centrifugal force losses while turning with jaw chucks, is extremely sceptical of such makeshift calculations and hence builds in a high safety value. Machining of easily
deformable components is also extremely critical. Usually only a very small margin of holding force is available. If an item is clamped too strongly, a sensitive component will be excessively deformed. Applying to little clamping force results in an inefficient set-up for rational machining.
data is demanded! It not only functions perfectly for outer diameters and during rotation, it also precisely measures the holding force of mandrels for inner diameters.
Safe results - even with mandrels
- Can be used rotating [under RPM] and for stationary applications
However, the globalization of markets requires an optimum of the machining process. Those who face stiff competition can no longer afford to manufacture just by »feeling«. Measurement
Key advantages: - Clamping force measurement for O.D. and I.D. clamping
- Direct input onto the Siemens CNC controller For further details write to M´la Sales Corporation at info@mlasales.com
HARTING Electronics receives “Factory of the Year” award The specialist publication “Produktion” and the corporate consultancy A.T. Kearney have named the subsidiary company HARTING Electronics, based at Plant 1 in Espelkamp, as the overall winner of the “Factory of the Year” award. “Factory of the Year/Global Excellence in Operations (GEO)” is the most wellestablished benchmark competition for the manufacturing industry in Germany having been launched in 1992.
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Torsten Ratzmann, Senior Vice President Production and Logistics at the HARTING Technology Group, was delighted with the award: “It is like winning the Champions League. Our continual efforts to achieve streamlined and effective production processes have been acknowledged with receipt of the overall winner award.” Above all, the jury lauded “outstanding continuous development over a period of years” in its verdict and the “strong focus on people and employees.” Its reasons
also including HARTING having “clear orientation on strengths and differentiation in global competition.” The jurors went on to praise the “extremely good production system focused on continuous improvement” and the “development of in-house systems e.g. for electroplating to ensure technical
differentiation.” “I wish to thank all HARTING employees. This award provides us with an incentive to further improve our processes in future,” remarked Ratzmann.
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THE LAST LEAF Dear Readers, Wishing all the readers and your loved ones a very Happy, Successful and Safe New Year ! The best event to witness about the latest technology and innovation is the CES exhibition that happens every January in USA. It is a good place to spot the trends that will dominate the tech world in the coming months. It appears that the cloud will be a big facilitator to enable easy execution of cross ecosystem chatter between devices and technology. One of the most hyped products at display this year at CES were the Drones – mainly in the Quadcopter format that is more stable. This is estimated to be a $ 130 million market in 2015, although two key issues that are dogging in the field – regulation and power. In addition, there have been several launches of latest cell phones, wearables, 4K / 8K televisions and other IoT products aimed at comfort, convenience and safety of our daily lives. There were some innovation awards announced at the show – Mercedes F015 Luxury in Motion got the one for Best Automotive Technology. In USA, three Colorado State University Venture Accelerator companies received their first funding recently, under the program, that aims to give student-led startups a chance to develop viable businesses. Quadshox, a company that intends to revolutionize manual wheelchair suspension, took the top prize. Second place went to Change Composites, a company that plans to produce the safest, most environmentally friendly bicycle helmet on the market.Third place winner was Purenfusion, a health food company committed to bring basic, real nutrition back into people’s diets through its Dotz organic cube supplements. Taiwan, the East Asian island with 23 million people, has an important link in the global high-tech supply chain and will definitely play a significant role in 2015. It has a half-trillion dollar economy depending mainly on manufacturing. Taiwanese PC developer Acer, smartphone maker HTC and you-name-it-we-build-it assembler Foxconn know their future depends largely on what they do themselves rather than for others. Foxconn, struggling against competition for Apple assembly contracts, is said to be developing electric vehicles, robotic tools and its own smartphone depending on whose buzz you believe. With costs rising in China, Taiwan is becoming the best place to incubate young inventors owing to growing material incentives being offered by the government. Back home in India, with revenues touching $2.6 billion and 25 factories spread across four continents, Sun Pharma is India’s most valuable pharma firm and features among the world’s top five generics makers. Its scorching sales growth of 33% annually in the past decade has been fueled mainly by acquisitions, notably in the U.S., where it’s now the largest Indian generics player. All of this action has propelled Sun’s stock–it’s up 44% in the past year compared to the stock market’s 30% rise over the same period–and lifted its founder Dilip Shanghvi to the position of India’s second-richest person, after Reliance Industries’ Mukesh Ambani. Earlier in 2012, he stepped down as Sun’s Chairman (he remains Managing Director) ceding the spot to Israel Makov, former President of generics giant Teva Pharmaceuticals, which the observer’s say, was a ‘masterstroke’ (Courtesy : Forbes.com). We need your input on any industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about a better tomorrow. Till then, Happy Technology! Manoj Kabre Member, Editorial Advisory Board
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