MART July 2016 by MART INFOMEDIA PRIVATE LIMITED

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Volume 13 Issue 1 July 2016 ` 100

ANNIVERSARY

EMERGING TECHNOLOGIES

INDUSTRY 4.0 Industrial Internet of Things IoT Will Drive Operational Efficiency Robotic Automation & Machining Artificial Intelligence Metal 3D printing Metal Injection Molding Technology Digital Computing

EMERGING Manufacturing

TECHNOLOGIES July 2016

Inkjet Technology Global Footprint www.martupdate.com

"Most preferred Steel Plant maker up to 1 Million ton capacity per annum - Globally”

Successful Commissioning

of Overseas Turnkey Projects in 2016

Watani Iron And Steel Co., Riyadh, Saudi Arabia: 3 sets of 12 MW – 1.5 MW / 30 Ton Induction Melting cum Sintering Furnaces with Transformers and Automation.

Darfala for Iron Melting and Steel Manufacturing, Riyadh, Saudi Arabia: 4 MW / 10 Ton Induction Melting Furnace, Continuous Casting Machine, Electrical and Cooling Systems, Material Handling Equipment, Air Pollution Control System, Laboratory Equipment and all other Auxiliaries for the plant.

Electrotherm is proud to announce successful commissioning of following overseas turnkey projects during 2016: ·

Ueno Corporation, Dammam, Saudi Arabia: 5 MW / 12 Ton Induction Melting Furnace, Continuous Casting Machine, Electrical and Cooling Systems, Material Handling Equipment, Air Pollution Control System, Laboratory Equipment and all other Auxiliaries for the plant.

Steefo Industries (CIM Metal, Burkina Faso, Africa): 6 MW / 15 Ton Induction Melting Furnace, 2- Strand Continuous Casting Machine, Air Pollution Control System and Electrical equipment.

Alvand Foolad Arya · Co., Qazwin, Iran: 5 MW / 12 Ton Induction Melting cum Sintering Furnace, Continuous Casting Machine, Electrical and Cooling Systems, Material Handling Equipment, Laboratory Equipment and other Auxiliaries for the plant.

Saleh Steel Industries Ltd., Chittagong, Bangladesh: 4.5 MW / 10 Ton Induction Melting Furnace, Electrical and Cooling Systems.

RWANDA MALAWI

Creative Carbon Pvt. Ltd. (Endmor Steel, Kenya): 4 MW / 10 Ton and 3.5 MW / 8 Ton Induction Melting Furnaces, Continuous Casting Machine, Electrical and Cooling Systems.

India's best; globally admired

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Chakada Steel & Re-Rolling Mills (Pvt. ) Ltd., Dhaka, Bangladesh: 6 MW / 15 Ton Induction Melting Furnace, Continuous Casting Machine, Electrical & Cooling Systems.

GABON

Tag Electrocasting Technologies Pvt. Ltd. (Pioneer Metal), Johannesburg, South Africa: 750 - 150 KW/2 Ton Induction Melting Furnace, Electrical and Cooling Systems for Copper Melting.

BURKINA FASO GUINEA

Founderie Du Congo SA, Brazzaville, Republic of Congo: 4 MW / 12 Ton and 6 MW / 15 Ton, Induction Melting Furnaces, Electrical and Cooling Systems.

Kavir Damghan Steel Co., Damghan, Iran: 10 MW / 25 Ton Induction Melting cum Sintering Furnace, 6/11 meter radius 2-Strand Continuous Casting Machine (with provision for 3rd strand), Electrical and Cooling Systems, Material Handling Equipment, Air Pollution Control System, Laboratory Equipment and all other Auxiliaries for the plant.

ELECTROTHERM® (INDIA) LIMITED 72, PALODIA, (VIA THALTEJ) AHMEDABAD, GUJARAT- 382 115, INDIA Phone: + 91 2717- 660 550, Email: mkt@electrotherm.com Website: www.electrothermenp.com

July 2016

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July 2016

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July 2016

foreword

Volume 13 Issue 1 July 2016 Annual Subscription `1200 Member INS

TECHNOLOGY@ Change

Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish

Hi Readers, It’s the proud moment for all of us at TEAM MART to bring out this 12th Anniversary edition of Industrial Business MART magazine, with the sole purpose of serving our engineering manufacturing sector. With the guidance of our Editorial Advisory Members, who are experts in the diversified fields of Manufacturing, we are constantly improving our contents in MART and able to bring out with a monthly above product sourcing. Embracing technological advantage was one of the prime reasons for our success, and our theme for this edition is the “Emerging Technologies in Manufacturing Industry”. Thanks to “Make In India” and the recent GST initiatives, India as the manufacturing brand is getting momentum in the global arena. For the last couple of decades manufacturing in India has been witnessing technological upgradations, but in a very slow pace. Jugaad Technology instead of latest automation techniques was the preference, but with the changing conditions within the country, the biggest challenge manufacturing face in India is to embrace the emerging technologies for better productivity and product quality. With the fourth industrial revolution led by Mobile and Internet is making its steps in the global scenario, Indian companies are already in the fray with diversified solutions. From mere product prototyping, to the possibility of commercial production of critical complex components, Additive Manufacturing is already in work in several companies across India. Complimenting Government initiatives Indian as well as renowned global manufacturing corporates is investing on facilities for indigenous manufacturing of Defence, Aviation, and Medical Sector etc. Admitting the fact that the sentiments in manufacturing are low, we are still to recover from the recession caused by the financial meltdown; the intelligent steps by an entrepreneur can sure create opportunities to his business. In this edition, we are featuring interviews of industry experts about the emerging technologies available in our country, along with the latest technologies offered!

Hari Shanker hari@martinfotech.in

One of the biggest challenges MART is facing today is to improve its readership – in the print, desktop or in the mobile platform. The only concession we do have is your continued patronage, as a valuable reader, advertiser enabling to set higher standards in publishing. This can only be possible with your valuable feedbacks, suggestions and constructive criticism. We wait to hear from you, and wishing a very happy anniversary

J R Mahajan LD Bhakre S M Dangi Sandeep Hingne

Managing Editor

Hari Shanker

Associate Editor

Hiya Chakrabarti

Executive Director

Siji Nair

General Manager

Priya Kundu

Senior Creative

Sayan Chaudhuri

Correspondent

Arnab Mondal

Editorial Assistant

Pramod Pillai

Regional Office Chennai

Subramaniam V +91 8925 847523

Bangalore Delhi

Manvendra Sharma +91 9845 108361 Vidya Rao +91 98189 88694

• Five years (60 issues) at `4800 You save `1200 • Three Years (36 issues) at `3000 You save `600 • One Year (12 issues) at `1200 Send your subscriptions to: The Circulation Manager - Mart Infomedia Private Limited C-507, Wisteria Fortune, Bhumkar Chowk Marunji Road Near New Poona Bakery, Wakad Pune - 411057 Tel: +91 70 3093 2700 Email: mart@martinfotech.in Web: www.martupdate.com & www.martonline.in

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Digital Edition at July 2016

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July 2016

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Embrace New Technologies, Ensure Smart Manufacturing

18 IoT Will Drive the Digital Transformation of Manufacturing Industry

Reflecting on the Past to Advance the Industrial Internet of Things

22 Industry 4.0 will Dominate

Manufacturing in the Near Future

26 “Machine Tool 4.0” as a milestone on the road to digital transformation

32 Artificial Intelligence for Intelligent Manufacturing

36 IoT Will Drive Operational Efficiency and Productivity in Manufacturing

40 Metal 3D printing pushes the boundaries in Moto2™ through defiant innovation

Manufacturing Leveraging Solutions by Digital Computing

48 Pocket milling in titanium is an extremely tough challenge

3D Printing Revolutionized the Concept of Manufacturing

Metal Injection Molding Technology for Complex and Intricate Parts Manufacturing

62 Quality Is the Key for Global Footprint 66 Keep your mould running well 68 Robotic Automation & Machining Will Transform Modern Manufacturing

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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manne the Publisher no any of its employees accept any responsibilities for any errors or omissions. © All Rights Reserved July 2016

CONTENTS 72 ElectroMech Cranes for Valmont’s Long Poles Handling Needs

74 Automation, Waste Reduction & Energy Efficiency

New plastic strain wave gearing enables low priced 6-axis robot

78 Adopting New Technology Inevitable for Global Footprint

Dormer’s PFX Range for Deep-hole Drilling Needs 1

84 Conducive atmosphere created by the Government for the growth of SMEs

86 New Schmalz Bag Suction Cup for High Speed Packaging Processes

88 Manufacturers Upbeat on Sophisticated Interlinking of Whole Process with Advanced Technologies

92 Magnesia Drywalls for a Greener India 94 Push for FDI Will Push Local Manufacutrers’s Competitiveness

100 Heavy Duty Machining - but safe 106 Laser Replacing Continous Inkjet Technology

110 New Schmalz Bag Suction Cup for High Speed Packaging Processes

114 Innovation Is a Must for Growth 118 Product Development Is Important for Competitiveness in Manufacturing

120 Learning On The Go 122 Visual Boards for Performance

Monitoring and Better Decision Making

IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post. m. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 er whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither July 2016

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July 2016

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www.renishaw.co.in July 2016

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Embrace New Technologies, Ensure Smart Manufacturing Indian manufacturing sector stands at crossroads: it is yet to fully recover from the jitters of the post meltdown era and it awaits the growth prospect that lies yonder.

Arnab Mondal arnab@martupdate.com

The meltdown era after the peak of economic upsurge till 2008 has rendered manufacturing sector cautious, much as it has other sectors as well. Global economic expansion led industrial manufacturers to invest in new equipment and technologies designed to improve operational performance. As the markets unexpectedly crashed, the manufacturing industries paid a steep price for having bought at the top of the cycle. The payoff took years to realize. The tentative steps that many industrial manufacturing companies are taking today are tinged with the recollection of this turmoil. Simultaneously, economic growth is yet to become particularly robust. China has struggled with its

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supply-demand mismatch for quite a while and taken on the infesting global economies with its products, dampening the domestic manufactures’ hope for a level playing ground.

the thrust of the government on the manufacturing sector through dedicated ‘Make in India’ programme, adoption of emerging technologies is inevitable.

The Eurozone’s future is still uncertain. For the time being “the prevent defense” — avoiding possible big losses by taking few chances — may be the best strategy.

Manufacturing sector in India is undeniably in the midst of a technological renaissance that is transforming the look, systems, and processes of the modern factory.

However, the manufacturing sector, being the cradle of innovation and technical change, has always occupied an extraordinary position in the economy. The majority of innovations are introduced first and commercialized in this sector, making it the main engine of technical change and economic growth.

In today’s leading-edge capabilities, it is reasonable to envision and prepare for a data-driven manufacturing plant where all internal and external activities are connected through the same information platform. Customers, designers, and operators can share information on everything right from initial concepts, to installation, to performance feedback throughout the life cycle.

Technological change, in turn, is a crucial driver of competitiveness in the manufacturing industry. Given

But what breakthrough equipment, ideas, and processes

will have the greatest impact on factory environments? The following four technology categories are already driving much of the change. Internet of Things (IoT): The connected plant is an idea that has been evolving in the manufacturing industry for some time. Internet of Things (IoT) is based on expanding the power of the web to link machines, sensors, computers, and humans in order to enable new levels of information monitoring, collection, processing, and analysis. This system of interconnectivity provides more precision and can translate collected data into insights that help to determine the parameters of performance in a plant, how they impact performance, and most importantly they can be improved. For industrial manufacturing,

July 2016

IoT in a manufacturing plant provides better precision and insights from collected data that help to determine the parameters of performance in a plant, how they impact performance, and most importantly they can be improved.

Cobotics ensures better coordination between human and machine making assembly chain faster and safer

the next generation of IoT technology is well beyond just real-time monitoring, it sets up connected information platforms that leverage data and advanced analytics to deliver higherquality, more durable, and more reliable products. Prior to investing in IoT, manufacturers must determine precisely what data is most valuable to collect, as well as gauge the efficacy of the analytical structures that will be used to assess the data. In addition, next-generation equipment will require a nextgeneration mix of workers, which should include employees who can design and build IoT products as well as data scientists who can analyze output. Robotics: Robotics is also termed as automation in some spheres which has been evolving in China over the last decade as increased labour costs and increasing industrial demand necessitated the growth of automation and Robotics. However, the

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technology has taken new proportion in the modern manufacturing globally. According to the International Federation of Robotics, the number of shipments of multipurpose industrial robots in China roughly doubled to an estimated 75,000 in 2015 since 2013, with that number forecast to double yet again to 150,000 by 2018. Since Robotics is programmed machines to perform certain tasks, it still is a belief that unmanned control technologies may not address all productivity concerns. Some manufacturers believe that greater automation is harmful, resulting in less innovation because only people can develop ideas to improve processes and products. Stemming from this line of thinking, robotic implementation is evolving on a different path globally. In many cases, robots are employed to complement rather than replace manual workers. This concept, known

as “cobotics,” joins operators and machines in order to make complex parts of the assembly process faster, easier, and safer. “Cobotics” is rapidly gaining momentum, and successful implementations to date have focused largely on specific ergonomically challenging tasks within the aerospace and automotive industries. But these applications are expected to expand as automation developers introduce more sophisticated sensors and more adaptable, highly functional robotic equipment that are capable of making humans and machines interact deftly on the factory floor. Augmented reality: Recent advances in computer vision, computer science, information technology, and engineering have enabled manufacturers to deliver real-time information and guidance at the point of use. Users simply follow the text, graphics, audio, and other virtual enhancements superimposed

onto goggles or real assemblies as they perform complex tasks on the factory floor. These tools can simultaneously assess the accuracy and timing of these tasks, and notify the operator of quality risks. Industrial manufacturers are using this technology to provide hands-free training, enable faster responses to maintenance requests, track inventory, increase safety, and provide a real-time view of manufacturing operations. In more than a few instances, these added services could be sold as add-ons to the equipment itself, creating a new revenue stream for industrial manufacturing firms. Among the possible applications is an assembly-line instructional feature in which video clips or text instructions walk workers through complex processes step-by-step. Mistakes resulting from fatigue or on-the-job pressure are eliminated. Another possibility involves using data and physical evidence retrieved by augmented reality on the factory floor to design new

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equipment that addresses the shortcomings of present-day devices on the assembly line. 3D printing: 3D printing technology produces solid objects from digital designs by building up multiple layers of plastic, resin, or other materials in a precisely determined shape. It is also known as additive manufacturing. Early adopters among industrial manufacturers are using 3D printing to manufacture parts in small lots for product prototypes, to reduce designto-manufacturing cycle times, and to dramatically alter the economics of production. 3D printing is still in its nascent stage, and the technology is currently limited in the performance specifications of the products it can produce. But manufacturers must begin planning for the incorporation of this technology. As an initial step, 3D printing technology

can be applied to the product development and prototyping process by manufacturers, where its speed and flexibility can result innovation and reduce production time. The next step could be to use 3D printing to make highly specialized, low-volume parts that are components or subassemblies of finished products, or to create tools for the molding, casting, or forming of products. Industrial manufacturers should consider investments in emerging technologies through three paths of analysis: 1. Determine the specific areas to improve in your organization, or what performance target a technology investment is trying to achieve. How will the investment impact cost, quality, labor, or other strategic concerns? How will the new technology help

differentiate the value you provide to customers? Will it create capacity or generate productivity in the constrained parts of your operations? Will the technology provide increased flexibility to help you deal with uncertainty? 2. Understand how the new technologies will enable that level of performance — and weigh the value of achieving that performance against the cost of the technology. What level of output should the facility be able to create today, and how much improvement can be expected over time as the technology continues to evolve? Who are the current industry leaders in each technology category, and what tangible impact is their technology having? What is the clock speed of the technology, and how feasible is it that it will evolve to reliably deliver on the performance goals?

3. Understand the operational and organizational implications of the technology and how it aligns with the factory of the future vision. How does it help or hurt operators or the culture? How should teaming and incentives models evolve to optimize new technology? How scalable is the technology? How well does it integrate into a company’s technology backbone and global footprint? Despite the risks — and despite recent history — industrial manufacturing companies cannot afford to ignore adapting to these advancement in technology. By embracing them now, they can improve productivity in their own plants, compete against rivals, and maintain an edge with customers who are seeking their own gains from innovation.

Augmented reality can offer real time guidance to the users through text, graphics, audio and other virtual enhancements

Using 3D printing for product prototyping has made design-tomanufacturing cycle much faster

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July 2016

GETTING THE JOB DONE. TOGETHER

Dormer and Pramet have joined forces. Together, we oﬀer a comprehensive range of indexable and rotary cutting tools. Our real oﬀer, though, is about much more. Yes, our products are consistently high quality, easily available and come with the advice and guidance you

have the right to expect. But we also believe in taking time to build a clear understanding of your business needs. This not only ensures we give you exactly the support you need, but helps build trust – the foundation for all true partnerships. That’s how we get the job done. Simply Reliable.

www.dormerpramet.com July 2016

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IoT Will Drive the digital Transformation of Manufacturing Industry

Suniel Kumar

Managing Director & Founder, Nexiot

Nexiot is an Internet of Things (IoT) & Electronics innovation company. Led by a group of experienced technocrats with expertise in electronics, sensors, wireless, robotics & information technology domains with global exposure, the company is strongly positioned to provide superior solutions for Smart water-energy-resources management, Automation & Beacon based applications to customers across the Globe. The company is also a pioneer in offering most comprehensive Certification Programs for IoT System Design to build competency to design & implement end-to-end IoT solutions…

Manufacturing has grown exponentially. What are the upcoming technological trends in manufacturing across the world? Across the world, there is trend of integrating the process – materials – people onto a single platform. This is for reasons of better productivity and efficient resource management. All this is to impact and improve bottom lines for the organizations, which is critical in current scenario.

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How much has India advanced to adapt with digital manufacturing? The Digital Manufacturing adoption is inevitable for the emerging India as an Industrial power. The pace of adoption needs acceleration and a more incentivised push from government as well. Some of our Indian cities like Pune, Mumbai, Bangalore, Chennai, Hyderabad being Information Technology hubs as well is a great advantage for pushing digital manufacturing adoption across the country and

further can bring new global opportunities. Tell us about Nexiotinception, its mission and the clients from manufacturing segment. Nexiot™ started in 2013 with research and development activities in areas of smart automation and smart power. The motivation was to apply renewable energy for powering internet of things & automation applications. We have focussed towards smart resources

management with our own patented products for smart water & energy management solutions. These are relevant for remote monitoring applications in Industrial sectors. We have also ventured into IoT consulting and education space to support start-ups & entrepreneurs to accelerate IoT adoption in the Industry. What are the latest technologies in offer from Nexiot and how these can benchmark productivity? Our patented Smart Meter

July 2016

IoT has a significant role to play in the manufacturing sector, Remote Logistics – Resources & Asset Management is one area that can be impacted significantly to bring better efficiency and productivity.

reading solutions can be applied for various applications. These can avoid manpower needs for monitoring and controlling applications. Indian SMEs are one of the key players in manufacturing. How many SMEs have really adapted this new concept of Digital manufacturing? What factors, according to you, are making them reluctant in adapting latest trends? Yes, SME’s are Key – We see good awareness of digital manufacturing concepts amongst SME’s

but adoption needs to accelerate. Digital Manufacturing – IoT being new ideas, there is concern on measurable return on investment. We need more success stories to be shared to address this. How IoT can help manufacturing sector in the next five years? IoT has a significant role to play in the manufacturing sector, Remote Logistics – Resources & Asset Management is one area that can be impacted significantly to bring better efficiency and productivity.

Personnel & Industrial Safety is another area that will see benefits from IoT adoption. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? - Management Buy-in for IoT Adoption - Measured RoI success stories in Indian context - Examples of Indian success stories applied in other countries ‘Start up India, Stand up India’ – the initiative taken by

the Government of India has gained wide attention. Being a start-up, what difficulties/ advantages you have received from the Government? ‘Start up India, Stand up India’: Taxation is still a concerning aspect, it needs to be simplified on compliance as well. Well, the initiative is a motivating indicator of recognition of Start ups/SME for Nation building. Initiatives like smart cities are a great business opportunity for start ups like us. This offers a clear immediate local market opportunity which can be scaled up globally.

Some of our Indian cities like Pune, Mumbai, Bangalore, Chennai, Hyderabad being Information Technology hubs as well is a great advantage for pushing digital manufacturing adoption across the country and further can bring new global opportunities.

July 2016

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Reflecting on the Past to Advance the Industrial Internet of Things Whenever we can take a moment to reflect, it is possible to find patterns that can help clarify future projections. One such pattern can be seen in the preservation of infrastructure value associated with the four previous industrial revolutions.

Colin Geis asia@redlion.net

Historically, the idea of extending the lifespan of equipment in industrial applications is not a new or marvel concept. As in the past, leveraging existing equipment not only saves money, but can also strengthen a company’s foundation. Industry, as it is currently understood, began with the first industrial revolution (~1780 -1840), which involved the migration from piecemeal production by hand to machineassisted production. This change was pushed by readily available energy from water and steam to power factory machines and tools. These initial advancements were followed by the second industrial revolution (~1870 -1914), which introduced

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newer technology and electric power sources to factories. By providing round-the-clock light, electricity enabled more continuous manufacturing, allowing workers to produce goods during the day and night. Much of the equipment from the first industrial revolution, however, was still functional and in operation. Rather than replace working machinery, it was simply retrofitted with electric engines in place of steam-driven versions. This required only nominal investments to extend equipment lifespan while still benefiting from the increased capabilities of consistently available grid power. The third industrial revolution (~1947-2010), more popularly referred to as the Digital Revolution, traces its roots to the invention of the transistor.

The transistor enabled the development of computers that spread to factory floors in the form of automation equipment to support manufacturing goals of waste reduction and production enhancement. While the automation of factory equipment increased production efficiency, it also required the purchase and implementation of vast amounts of new tools and machinery. These additions enabled factories to once again take production to the next level by further increasing output and reducing loss. Production began occurring in manufacturing cells with local control and monitoring. Maximizing efficiency of a single step within production required workers to supervise certain aspects of machine operation, such as watching over machine

resources and monitoring equipment status. The current or fourth industrial revolution – the Industrial Internet of Things (IIoT) – is once again focused on refining processes to reduce waste and downtime by connecting all aspects of the supply chain to enable data communication between deployed equipment and processes. Where the Digital Revolution enabled the automation of production, the fourth revolution focuses on coalescing and connecting the vast amounts of data currently spread throughout organizations. Extracting data from existing equipment provides operational intelligence and visibility to increase production efficiency and reduce the time-to-market for produced goods.

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Extracting data from existing equipment provides operational intelligence and visibility to increase production efficiency and reduce the time-to-market for produced goods.

The integration of production information can present complicated scenarios for existing facilities designed to optimize individualized processes. Some obstacles can be easily overcome through the use of media converters that provide the ability to change between cable media types (e.g., Ethernet to fiber optic or RS-232 serial to Ethernet) to physically connect equipment. A more difficult situation arises when it is not just a physical connection barring communication, but a logical one. For instance,

factory equipment designed to perform a particular task uses protocols defined around unique parameters and are therefore not shared by other machines or machine components. Communication between disparate protocols (e.g., Siemens S7 TCP/IP to Allen-Bradley DF1 serial) requires the use of IIoT-ready protocol convertors like Red Lion’s Data Station Plus, which is designed to allow the interchange of data despite differences in source programming.

When equipment from disparate manufacturers is connected, organizations can more easily access operational data to improve process visibility and therefore, drive productivity and operational efficiencies through real-time communication and data processing.

support new capabilities to drive IIoT advancements. As a result, the benefits that began with continuous power and production— and then switched to increased efficiency—will next drive truly smarter production enabled by data interchange and analysis.

In this fourth revolution, forward-thinking manufacturers can once again take advantage of existing equipment investments by retrofitting current machinery with industrial automation and networking devices that

As we’ve seen with past trends, advances that extend the lifespan of existing equipment stand to realize greater returns and success. For further details visit www.redlion.net

Communication between disparate protocols (e.g., Siemens S7 TCP/IP to Allen-Bradley DF1 serial) requires the use of IIoT-ready protocol convertors like Red Lion’s Data Station Plus, which is designed to allow the interchange of data despite differences in source programming.

July 2016

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Industry 4.0 Will Dominate Manufacturing in the Near Future

Sameer Gandhi Managing Director, Omron Automation

Driven by the motto ‘Quality First’ OMRON AUTOMATION INDIA, part of the global leader in sensing and control technology OMRON CORPORATION, has been catering to industries across segments since 1996 with industrial components, automotive system, sensing and safety, Motion & Drivers and Software based on its core technology sensing and control. Mr. Sameer Gandhi, Managing Director, OMRON AUTOMATION INDIA, illustrates how the idea of a data driven ‘connected shopfloor’ is grabbing the attention of the manufacturers for overall improved performance. He is an industry veteran, with over two decades of experience in multiple disciplines of sales, operations and P&L leadership and vertical industries including Minerals and Cement, Pulp & Paper and Robotics. As MD of OMRON AUTOMATION INDIA, he focuses on bringing global best practices and technologies to critical Indian industries.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? Industry 4.0 is one of the key technologies being adopted by many progressive manufacturing giants across varied sectors. It’s actually a melange of many futuristic and advanced concepts and

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technologies which have the potential of transforming the production scenario in the 21st century, mainly comprises of a ‘connected shopfloor’ where data is collected from various sensors and other input devices to be used for predictive maintenance, better control and long term analysis. Many of the manufacturing companies in India are actively looking at

adopting this technology and we believe that this’ll come to dominate in the future.

efficiencies but also a sea

What are the upcoming technological trends in manufacturing across the globe?

among suppliers, producers,

The trend is to create a fully integrated and automated

there are sectors, such

ecosystem to realise optimized production flow, leading to not only greater

change in the traditional production relationships and customers—as well as between human and machine. As mentioned above, as automotive, which are striving to match pace with the changing dynamics, however, a major chunk still

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Plan

Team

Objective

ERP Priority

ROI

The ERP system can do a more long term trend analysis of this data and, for instance, guide the plant operators to order sensors depending upon the usage and inventory available.

needs to invest in ‘futureready’ facilities which can provide the best match between labour – cost advantage and new digital technologies in order to enhance and sustain competitiveness. How is your company adapting the upcoming technologies? Taking cognisance of the emerging trends and Omron’s prowess in ‘Sensing and Control + Think’ technology, we have been introducing innovative and useful solutions for the manufacturing sector. One of these is the I/O link – majorly targeting the automotive industry manufacturing. This basically comprises of sensors and other products that link the data up from the sensors and other components to the PLC. Any smart device or sensor in the field today has a lot of data related to the device or sensor itself.

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But so far, this data is not accessible beyond this device. We can now access this data from the sensors in real time, without using diagnostic tools. We are even able to predict a failure, which will reduce the downtime for the customer. Our PLCs already have the capability of reading and writing data directly to an ERP (without requiring any gateway PCs). So now the data captured by the I/O Link and transferred to the PLCs can be easily integrated with an ERP system thus completing the IoT chain. The ERP system can do a more long term trend analysis of this data and, for instance, guide the plant operators to order sensors depending upon the usage and inventory available. The possibilities are immense and this is actually a game changer. How much an engineer graduated from India is skilled to implement

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the latest trends in manufacturing? How gaps can be filled? One of the major concerns facing Indian economy is the availability of skilled manpower. While we’ve a large talent pool of engineers coming out every year, unfortunately, many of these engineers are not well versed with contemporary technologies like Robotics, IoT, etc. So they need to be ‘skilled up’. Industrial Automation is an investment and if the manufacturer does not have the right set of people to manage it, it is certainly not going to work for them. It is of little use if it is not deployed, operated and maintained by the people equipped with the right skill sets.

I would like to highlight here the efforts Omron is putting in to bridge the gap. We have developed dedicated training centres at Omron where our customers, employees as well as our channel partners are provided trainings. We’ve also tied up with AIA to provide equipment and other training facilities to various educational institutes. Another notable initiative is our one-of-its kind Automation Centre at Mumbai, which not only showcases our complete technology prowess but also act as a learning centre for our customers. One of the most notable areas in the centre is the “Tsunagi Lab” which provides the complete integration experience of OMRON to OMRON and third party components

so that the team and the patrons are able to learn and handle the technologies which are in the scope of the total solution. We also have resources designed especially for the young and budding engineers. One of them is an e-learning platform which offers around 15 modules in the automation & control domain free of cost. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? What are the challenges SMEs face in implementing these technologies? The SME sector still lags behind in getting equipped

and adopting the right set of latest technologies. I would like to give an indicator here extracted from a study conducted by RBI. It shows companies with annualised sales of over Rs. 1,000 crore were growing, while SMEs were not. One of the basic challenges for the low level of acceptance amongst them is their concern towards investing in something that is adding to the cost. The analysis of RoI needs to include the impact of other factors like quality and productivity improvements along with cost. Lack of skilled manpower is another challenge which makes them wary in adopting newer technology and solutions as it again needs investment.

The analysis of RoI needs to include the impact of other factors like quality and productivity improvements along with cost.

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July 2016

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“Machine Tool 4.0” as a Milestone on the road to Digital Transformation

DMG MORI and Schaeffler Technologies will be presenting the innovation project “Machine Tool 4.0” as a milestone on the road to future-orientated production, process and maintenance optimisation at the EMO in Milan.

Calculable availability of means of production ranks as a decisive factor in the realisation of cyber-physical production networks. This has led to the optimisation of service and maintenance processes progressively moving away from the back

burner and into the limelight. That is why DMG MORI has collaborated with Schaeffler Technologie to start the innovation project “Machine Tool 4.0” taking the mill/turn centre DMC 80 FD duoBLOCK® as a specific example. To achieve their aims more than 60 sensors

have been installed on elementary components of the FD machine. Together with other (obligatory) status information, all data are now captured in realtime and analysed using specially

developed algorithms. As a result, the evaluation of the data provides qualified insights into the probable occurrence of different process and production faults. This in turn enables users to take targeted measures in advance

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July 2016

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Although not visible from the outside, the two DMC 80 FD duoBLOCK® machines of the innovation project “machine tool 4.0” are nevertheless packed full with intelligent sensors as the basis of condition-oriented service and maintenance. To achieve this more than 60 sensors have been installed on elementary components of the FD machine.

for the first time, where currently unplanned machine downtimes quickly render capacity planning a waste of time. Energy and running costs have also been reduced significantly in addition to the increase in availability and simultaneous reduction of service costs. This new “knowledge” also constitutes the basis for the sustainable optimisation of processes, products and machines. Future-orientated joint project “Industry 4.0” is the hot topic of the moment. The fundamental ambition of the 4th industrial revolution is the individualised manufacture of products in digitalized, decentralised, self-controlling cyberphysical production systems. On this basis every customer is to be offered his/ her

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product customised to the conditions of mass production and have it delivered within the shortest possible time. So much to the vision. The status quo, of course, looks very different. Not even basic and more importantly globally coordinated rules and standards are in place yet. But DMG MORI and Schaeffler Technologies were no longer willing to wait. With their innovation project “Machine Tool 4.0” they have together developed an intelligent machine – namely the DMC 80 FD duoBLOCK® turn/mill centre. An example of this future-orientated “Machine Tool 4.0” will be on show at the DMG MORI stand in Milan. The second prototype will then already be up and running and in everyday use for series production in the Schaeffler Höchstadt plant and from there will enhance the EMO

presentation with status data from the shopfloor. Successful interplay of mechanics, electronics and information technology Both machines have an identical integral Industry 4.0 concept, from the sensor to the cloud, that connects existing technology with the new possibilities of digitalization and data analysis and thus masters the close interplay of mechanics, electronics and information technology. Comprehensively equipped with intelligent sensors, operating status and process data are collected here continuously in realtime and saved and processed both locally on the machine in CELOS® as well as in the cloud. In addition, the collected data are analysed in the cloud using specially developed algorithms in order to detect potential

faults or problems in the process by means of qualified forecasts. This status information is then fed back to the machine. DMG MORI has developed a special CELOS® APP – the “Condition Analyzer” – that functions as the information centre on the ERGOline® control with CELOS® and via which all status information is visualised and from where the operator can immediately initiate any actions that might be necessary. A small factory of the future within the factory of today “The DMC 80 FD duoBLOCK® is an absolutely high-end product“, explains Alfred Geißler as the Managing Director of DECKEL MAHO Pfronten GmbH, which is responsible at DMG MORI for the innovation project “Machine Tool 4.0”. And he goes on to stress: “With its pallet

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changer, numerous tools and complex capabilities of up to 5-axis simultaneous milling in combination with sophisticated turning processes the machine is perfect for giving a representative documentation of the utilizable value of sensorintegrated intelligence.” Gained in practice, for use in practice Seen from a practical point of view this applies to an even greater extent to a second machine already installed in the Schaeffler plant in Höchstadt, as the manager of the business division production machines

at Schaeffler Technologies, Martin Schreiber explains: “With our products we are both a system partner of international machine tool construction as well as a user of machine tools. So with our investment in a new DMC 80 FD duoBLOCK® we have combined what is necessary with future-orientated developments, in that we as a user can now gain important experience with an intelligent machine directly from the factory environment and then as a system supplier pass on this plus in competence to our customers and partners.” Enabling customer benefit to be experienced

“The presentation of customer benefit is the focus of the innovation project”, stresses Alfred Geißler: “With the “Machine Tool 4.0” we demonstrate what can already be implemented today, enable the possibilities of Industry 4.0 to be actually experienced and show ways in which companies can master entry into the digitalized world of production on their own.” Intelligence as a standard The fact that even as a “Machine Tool 4.0” the DMC 80 FD duoBLOCK® still remains in principle a normal high-tech standard machine from the DMG MORI

portfolio is bound to build confidence among users. Alfred Geißler: “The entire control and operation is not different from that of a standard turn/mill centre. This applies in particular to the CELOS® user interface as a centre of communication and organisation.” The only new elements are the machine’s internal network to which all additional sensors, actuators and evaluation units are connected and the CELOS® APP “Condition Analyzer” as an information centre on the machine. Linking in the cloud is effected via a gateway. Both the Profibus in the PLC for

Comprehensively equipped with intelligent sensors, operating status and process data are collected continuously for the DMC 80 FD duoBLOCK® in realtime and saved, processed and analysed both locally on the machine in CELOS® as well as in the cloud.

July 2016

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In context of a specific investment DMG MORI and Schaeffler Technologies conjointly have started the innovation project “Machine Tool 4.0” by the example of the turn & mill machining centre DMC 80 FD duoBLOCK®.

time-critical and processrelevant data and the OPC UA protocol to the HumanMachine-Interface (HMI) for other information are used to ensure the data exchange to the machine controller with CELOS®. Knowledge-based added value A total of more than 60 additional sensors continuously measure vibrations, forces, temperatures and pressures on the sensor-intelligent DMC 80 FD duoBLOCK® and report the results to the evaluation unit via which the information is both sent to CELOS® and made available to the cloud. Whereby the results of both pilot machines are analytically evaluated in the cloud thus increasing the quality of the forecast even further. Maximum availability

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“Every day and every detected deviation from the preset standard parameters will enhance the informative value of the data analysis”, promises Alfred Geißler. After all the algorithms were permanently updated on the basis of the continuous data evaluation, so that ever more targeted status information with ever more qualified predictions of occurrence could be derived. And Martin Schreiber stresses: “This should enable us to come ever closer to maximum possible availability via the intelligence of the machine, sensors and evaluation.” Whereby, according to Martin Schreiber, the higher availability is the result of better machine utilization and more efficient planning of maintenance measures. ”In addition“, maintains Alfred Geissler, “the overall machining value added is higher due to the numerous possibilities arising from

process and production optimization. And what is more thanks to the knowledge base described above, it is possible to make reliable forecasts concerning the quality of the workpiece during or rather immediately after production.” Cooperative partnership It will be interesting to see how the customers react to the innovation project “Machine Tool 4.0”. The EMO presentation is already a milestone for DMG MORI and Schaeffler Technologies – especially in view of the close cooperative partnership between the companies that took place within the framework of the project. “It would never have been possible to realise such a complex task in such a short time and with such high (practicable) quality had we worked alone”, sums up Alfred Geißler. Finally, Martin Schreiber brings the

customers on board as well: “The close interconnection between manufacturers and suppliers is only the beginning. More than anything Industry 4.0 needs open interaction between all the parties involved in the value-added chain.” Data protection and data security Whereby DMG MORI and Schaeffler Technologies are fully aware that the issues of data protection and data security will be the next great challenges that need to be addressed if the elementary confidence so vital for Industry 4.0 solutions is to be achieved. “We are all wellacquainted with the problem of handling sensitive data“, they all claim in unison. “That is why we will do everything in our power to work together with users and other potential partners to find a secure communication environment,” both Alfred Geißler and Martin Schreiber agree.

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Artificial Intelligence for Intelligent Manufacturing Artificial Intelligence is the science concerned with the creation of machine intelligence which is able to perform tasks, only performed by people. Much of this machine intelligence is symbolic and heuristic. Artificial intelligence (AI) is intelligence exhibited by machines.

Rajesh Angadi rajeshangadi2013@gmail.com

Artificial Intelligence is the science concerned with the creation of machine intelligence which is able to perform tasks, only performed by people. Much of this machine intelligence is symbolic and heuristic. Artificial Intelligence (AI) is intelligence exhibited by machines. In computer science, an ideal “intelligent” machine is a flexible rational agent that perceives its environment and takes actions that maximize its chance of success at some goal. Colloquially, the term “Artificial Intelligence” is applied when a machine mimics “cognitive” functions that humans associate with other human minds, such as “learning” and “problem solving”. AI research is divided into subfields that focus on specific problems or on specific approaches or on the use of a particular tool or towards

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satisfying particular applications. The central problems (or goals) of AI research include reasoning, knowledge, planning, learning, natural language processing (communication), perception and the ability to move and manipulate objects. Approaches include statistical methods, computational intelligence, soft computing (e.g. machine learning), and traditional symbolic AI. Many tools are used in AI, including versions of search and mathematical optimization, logic, methods based on probability and economics. The AI field draws upon computer science, mathematics, psychology, linguistics, philosophy, neuroscience and artificial psychology. Globalization of the world economy and growth of competition in the market impose increasingly greater demands on modern entrepreneurs. Currently,

management and control of production enterprises is impossible without an application of appropriate tools supporting decision making at each stage of a company’s functioning from designing through to product exploitation. CIM (Computer Integrated Manufacturing) Systems are an example of such available tools that enable composite automatization of technological and organizational preparation for manufacture, current supervision, technological process control, organization and management. The development of CIM Systems has, in recent years, been directed at applying the methods of artificial intelligence to support decision processes and production control as well as monitoring, simulation and technological process diagnosis. Intelligent Manufacturing is:

“A set of methods, procedures and tools (e.g. CAD, CAP, CAM) equipped with artificial intelligence tools and supporting designing, planning and manufacturing.” The following, among others, are the basic constituent elements of Intelligent Manufacturing Systems mentioned as follows: - Intelligent machines and tools, i.e. numerically controlled machines and robots, - Intelligent manufacturing systems, and - Intelligent management systems. The concept of intelligent manufacturing combines the ability of decision-making support systems in generative systems to obtain knowledge, to learn and to adapt to a changing environment and to the actual arrangement of

July 2016

The development of CIM (Computer Integrated Manufacturing) Systems has, in recent years, been directed at applying the methods of artificial intelligence to support decision processes and production control as well as monitoring, simulation and technological process diagnosis.

The nature of intelligent manufacturing is system’s possibility to learn and its self-development as well as the possibility to generate information necessary to control the integrated production system.

system components. The nature of intelligent manufacturing is system’s possibility to learn and its self-development as well as the possibility to generate information necessary to control the integrated production system. Designing Intelligent Manufacturing System Intelligent Manufacturing System of a production enterprise denotes a manufacturing systems integrated with information system which provides necessary information, enables its analysis and use of analytical and simulation - based decision making models in order to assist decision making at each stage of decision process, as well as it is capable of learning and adapting to the dynamically changing environment and the current arrangement of system components. In other words, it is a decision supporting system based on the applied methods and tools of artificial intelligence

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able to solve complex decision problems, semi structured or non-structured, requiring the processing of incomplete, unreliable, contradictory, or difficult to formalize knowledge. The demands towards Intelligent Management Systems in a production enterprise are as follows: - A possibility of collecting and processing different types of information from all sources, both internal and external, in order to acquire and model knowledge necessary to make decisions at all levels of decision process in an enterprise. At the same time a possibility of modeling knowledge and processes, based on human thinking, is required. - In a decision process, at decision selecting, the decision maker’s subjective evaluation based on his experience and intuition should be taken into account in IMS. - There should be a possibility

of preliminary information handling and analysis with analytical methods as well as modern artificial intelligence technologies. - A possibility of detecting emergency and critical situations and of prompt reaction to them. There must be a possibility of situational data analysis in real time, necessary in an emergency inside the production system or in its surroundings. - A possibility to allow for complexity and comprehensiveness of decisionmaking issues in strategic management support. - Taking into account the lack of stability and change dynamics, both in the surroundings and inside the enterprise, the IMSs under design should have the capability for learning from experience and adaptingthe experience to intensive alteration of working conditions. In intelligent manufacturing systems, the following selected

contemporary methods and techniques of knowledge and decision process modeling should be integrated: - Artificial neural networks – the most fascinating tool of artificial intelligence, capable of modeling extremely complex functions and, to some extent, copying the learning activity in the human brain. - Fuzzy logic – technologies and methods of natural language formalization, linguistic and quality knowledge processing and fuzzification. - Genetic algorithms and methods of evolutionary modeling – learning algorithms based on theoreticalachievements of the theory of evolution, enriching the artificial intelligence techniques. The combination of these tools, in which knowledge is represented symbolically, with the traditional expert system will make it possible to create

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complex programmatic tools for solving difficult decision-making problems at each stage of enterprise functioning. Artificial Intelligence and Control Engineering Artificial Intelligence (AI) relates to control engineering when embedded software helps with situational awareness. The software algorithm looks at feedback from a situation, then actuates the decision (closedloop control) without human consultation, or the software recommends a course of action with human consultation (open-loop control). Control engineering or control systems engineering is the engineering discipline that applies control theory to design systems with desired behaviors. The practice uses sensors to measure the output performance of the device being controlled and those measurements can be used to give feedback to the input actuators that can make corrections toward desired performance. Control engineering is the engineering

There are two major divisions in control theory, namely, classical and modern, which have direct implications over the control engineering applications. The scope of classical control theory is limited to single-input and single-output (SISO) system design, except when analyzing for disturbance rejection using a second input. The system analysis is carried out in the time domain using differential equations, in the complex-s domain with the Laplace transform while modern control theory is carried out in the state space, and can deal with multiple-input and multipleoutput (MIMO) systems. This overcomes the limitations of classical control theory in

FUZZIFY INPUTS

INPUT

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discipline that focuses on the modeling of a diverse range of dynamic systems (e.g. mechanical systems) and the design of controllers that will cause these systems to behave in the desired manner. Although such controllers need not be electrical many are and hence control engineering is often viewed as a subfield of electrical engineering.

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DEFUZZIFY

Therefore, at the design stage either digital component are mapped into the continuous domain and the design is carried out in the continuous domain, or analog components are mapped into discrete domain and design is carried out there.

the rollers and an operator is standing in a certain location. If the machine is unattended at that particular moment, embedded code may begin an orderly shutdown as the best response. Control Engineering relates to the next big thing (TNBT) which is the second generation of smartphones, which have the software capacity to provide situational awareness. TNBT devices will be able to recognize what is going on inside your area or site and determine when something is out of normal but not yet in alarm. Information for this awareness may come from traditional fixed sensors or even by listening for sound patterns such as hisses, whistles, clangs, and bangs. TNBT devices will become true operator assistants; always watching and always listening for out-of-normal conditions or for events that require manual intervention.

In manufacturing, a machine running a web-based process may have similar situational awareness. There may be a perfectly good reason to leave the machine running when the last material runs through

Seven Artificial Intelligence (AI) tools have proved to be useful with sensor systems: Knowledge-based systems, fuzzy logic, automatic knowledge acquisition, neural networks, genetic algorithms, case-

more sophisticated design problems. Control engineering was all about continuous systems. Development of computer control tools posed a requirement of discrete control system engineering because the communications between the computer-based digital controller and the physical system are governed by a computer clock. The equivalent to Laplace transform in the discrete domain is the Z-transform. Today, many of the control systems are computer controlled and they consist of both digital and analog components.

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based reasoning, and ambientintelligence. Applications of these tools within sensor systems have become more widespread due to the power and affordability of present-day computers. The appropriate deployment of the new AI tools will contribute to the creation of more competitive sensor systems and applications. Artificial Intelligence (AI) helps computing in four ways: 1. Natural language understanding to improve communication. 2. Machine reasoning to provide inference, theorem-proving, cooperation, and relevant solutions. 3. Knowledge representation for perception, path planning, modeling, and problem solving.

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4. Knowledge acquisition using sensors to learn automatically for navigation and problem solving. Artificial intelligence’s ability to function as a safety measure and provide another set of eyes, so to speak, can be extremely beneficial to worker safety in manufacturing. It can also enhance our ability to understand what’s happening around us and offer solutions that might not be readily available. Will Artificial Intelligence (AI) take control of human race for Intelligent Manufacturing? The answer to this question seems to be positive. Several experts of AI have similar comment as “everything that

humans can do machines can do”. Stephen Hawking also warned us during an interview with BBC that “The development of full artificial intelligence could spell the end of the human race.” Ex Machina, a recent enthralling science-fiction film presents the possibility of a robot that has cognitive capability to think, feel and even manipulate human beings. Self-driving cars, Siri on your iPhone, weather forecasts, face recognition on your Facebook photos, etc are all examples. A Japanese company with Deep Knowledge found out an Artificial Intelligence (AI) as one of the directors due to its ability to predict market trend that is “not immediately obvious to humans”. Replacing human with robot

in manufacturing is a trend that we can’t stop or avoid. As technology advances, the low cost, high-accuracy and efficiency of robot is going to benefit the human society as a whole on a broader level. The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.

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IoT Will Drive Operational Efficiency and Productivity in Manufacturing

Rashmi Ranjan Mohapatra Managing Director, Kemppi

Rashmi Ranjan Mohapatra, Managing Director, Kemppi India, has an illustrious portfolio to his name. He worked with Linde and ADOR WELDING, was consultant to the Government of Netherlands, External Affairs Ministry, is a Managing Committee member of IIW â&#x20AC;&#x201C; Chennai and is currently in the panel of CII (CONFEDERATION OF INDIAN INDUSTRY) for Skill Development and Entrepreneurship. Prior to studying International Marketing from Netherlands, he obtained his B.Tech and MBA from Trichy. While talking to MART, he elaborates how IoT , a concept erstwhile attached to IT sector is fast becoming part of mainstream manufacturing. Kemppi India is a wholly owned subsidiary of Finland based Kemppi OY which has been a major name in welding technology and solutions over six decades. Kemppi India is relatively new given its first commercial production started at Chennai in 2011. However, the company already manufactures 40 products, is designing new product models, and acts as a strategic location for the South East Asian and Asia Pacific markets.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian Manufacturing? It is a tricky question. When we look back on dismantling the license raj 25 year ago we come across some interesting statistics.

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a. The share of manufacturing in 1991 was 16.41% in 1989-90. b. Today it stands at 16.2% of the GDP in 2015 -16. c. This is intriguing! As it has dropped during this period. d. While the GDP has grown four times during this period in pure value terms manufacturing has grown almost same time over this

period. e. But it should have increased its share to the GDP as well!! During this growth of 4 times over 25 years Indian manufacturing has witnessed many changes in technology. Currently the dominating ones are: i. Internet of Things: The

Internet of Things (IoT) is the network of physical devices, vehicles, buildings and other items - embedded with electronics, software, sensors, actuators, and network connectivity that enable these objects to collect and exchange data. In 2013 the Global Standards Initiative on Internet of Things (IoT-GSI) defined the

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Experts estimate that the IoT will consist of almost 50 billion objects by 2020.

IoT as “the infrastructure of the information society.” The IoT allows objects to be sensed and controlled remotely across existing network infrastructure, creating opportunities for more direct integration of the physical world into computerbased systems, and resulting in improved efficiency, accuracy and economic benefit. When IoT is augmented with sensors and actuators, the technology becomes an instance of the more general class of cyber-physical systems, which also encompasses technologies such as smart grids, smart homes, intelligent transportation and smart cities. Each thing is uniquely identifiable through its embedded computing system but is able to interoperate within the existing internet infrastructure. Experts estimate that the IoT will consist of almost 50 billion objects by 2020. ii. Big Data: Big Data is a term for data sets that are so large or complex that traditional data processing applications are inadequate. Challenges include analysis, capture, data curation, search, sharing, storage, transfer, visualization,

July 2016

querying, updating and information privacy. The term often refers simply to the use of predictive analytics, user behaviour analytics, or certain other advanced data analytics methods that extract value from data, and seldom to a particular size of data set. Accuracy in big data may lead to more confident decision making, and better decisions can result in greater operational efficiency, cost reduction and reduced risk. iii. Predictive Analysis: Predictive Analytics encompasses a variety of statistical techniques from predictive modelling, machine learning, and data mining that analyze current and historical facts to make predictions about future or otherwise unknown events. In business, predictive models exploit patterns found in historical and transactional data to identify risks and opportunities. Models capture relationships among many factors to allow assessment of risk or potential associated with a particular set of conditions, guiding decision making for candidate transactions. The defining functional effect of these

technical approaches is that predictive analytics provides a predictive score (probability) for each individual (customer, employee, healthcare patient, product SKU, vehicle, component, machine, or other organizational unit) in order to determine, inform, or influence organizational processes that pertain across large numbers of individuals, such as in marketing, credit risk assessment, fraud detection, manufacturing, healthcare, and government operations including law enforcement.

Indian companies are in thick of these changes. Let us look at this aspect from two angles:

(* source: Wikipedia)

b. The Industrial Machines: These are undergoing dramatic shift in their manufacturing and interface. The old traditional machines are getting converted to more and more digital and getting linked to the internet. Whether it is a moving truck or a robot in an automobile line, everything is tracked on line. The communication is almost getting seamless now.

What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this? Internet of Things is expanding rapidly across the globe. It is not only the electronics products now. IoT has made good inroads to even industrial machines. As machines go digital, the interface becomes easier – communication between machines starts bringing in a new dimension to the “wired” world. Digital machines are now able to talk to each other!

a. The Pure Electronics and Smart Gadgets: When we talk about these gadgets eg. Smart bands, gadgets to track diabetes, sleep monitor, distress call signals and so on. The landscape in this type of hardware manufacturing is changing and it is changing big time. This is a good and welcome step as we need to get out of the “back end office of IT” tag!!

How is your company adapting the upcoming technologies? Kemppi has been a pioneer in technology. We were the first ones to bring in the “inverter” technology to the welding world in 1977. In

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1993 we presented the first digital welding machine to the world in terms of PRO. Software became an integral part of Kemppi welding machine. To address the challenges of the welder we brought the software in 2005. There has been no looking back since then. We brought the first version of welding management in 2008. In 2014 we have launched the world’s first Total Welding Management System.

The interaction between the colleges and industry is picking up. In western countries the research conducted at the universities is closely linked to the industry. Some sparks have started flying in India and that is critical.

How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled?

The skill development program is a big step towards bridging the gap. New skill development institutes are embracing a totally new curriculum suited for the industry. That is the first and remarkable step towards bringing the two worlds closer.

Our structure of education system is archaic. There is little connection between the colleges/universities and the industry. This renders a new engineer completely at a loss when he comes to the real world from the college. We have been witnessing a shift during the last five years.

This phenomenon is across the levels in the industry. Be it a graduate, diploma or even an ITI, they are at a loss when they step in to the real world.

Trainers in the institutes are critical. “Train the trainers” will be the key to make the competency level at the institutes to be at the desired level.

Get the industry involved in formulating the policy for the institutes and link it to research and development.

to deliver global competent products? The challenges SMEs face in implementing these technologies?

While these points seem prophetic it has been a challenge and will continue to remain so for the next few years as we gain momentum.

I would slightly disagree that SMEs are the most prominent part of manufacturing. At one end of the spectrum are innumerable tin pot workshops, employing handfuls of people and outdated methods. What India lacks is a Mittelstand of midsized, labour-hungry firms. Even during the boom years, it created many more jobs in construction than in manufacturing. It is hard for India’s young to raise their sights when they are carrying bricks on their heads.

What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? The Big Data and Predictive Analytics are coming in to force more and more in the manufacturing. This is a signal towards the better things to come in future. The operational efficiency will be better and driving productivity across the levels of the manufacturing industry. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies

To fill this “missing middle” the government should remove some of the bureaucratic bricks that now weigh on the heads of India’s entrepreneurs. These include India’s notorious labour laws which, on paper, prevent factories firing anyone without

As machines go digital, the interface becomes easier – communication between machines starts bringing in a new dimension to the “wired” world.

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July 2016

the state’s permission. It is true that by hiring labour from third parties the country’s employers have blunted the law’s effect. But in doing so they have also blunted their own incentive to train their workers - and lead to more abuse. The challenges faced by SMEs in implementing these technologies are primarily: i. Vision ii. Entrepreneurial ability iii. Skill How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? The Government of India is helping the SME to increase the productivity. It means i. Labour Productivity: The skill development program of the Government is addressed to take care of this gap of the existing work force and the incoming ones. ii. Capital Productivity: Indian SMEs should make the best use the capital available. Government has also brought in MUDRA (Micro Units Development and Refinance Agency)bank to facilitate the SME., is a new institution setup by the Government of India for development of micro units and refinance of MFIs to encourage entrepreneurship in India & provide the funding to the non corporate small business sector.) What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? Process changes are a must in the Indian manufacturing scenario to make it globally acceptable and competitive.

July 2016

Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? Most of the new age start ups are primarily from the IT stable. The Big Data, IoT or Predictive Analysis are like the common tools for this domain. The usage is definitely there. But I would look forward to this technology developing and shaping new products in the manufacturing industry and propelling India forward. What are your views / comments with regard to Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness? The major objectives behind the ‘Make in India’ initiative are job creation and skill enhancement in 25 sectors of the economy, including automobiles, aviation, biotechnology, chemicals, construction, defence manufacturing, electrical machinery, electronic systems and mining. The government has been trying to sell its idea of ‘Make in India’ to the other countries. But there has not been a big bang success. To ensure the ‘Make in India’ juggernaut rolls in all its might, the government has brought in “Skill India” program to impart skilling to the work force and give a thrust to the ongoing saga in manufacturing. While it is great to promote ‘Make in India’, I would keenly look forward to the ‘Makers of India’. Who are going to make it happen? Where are they and at what level? We need to first create a pool of ‘Makers of India’ to make it happen in India!!

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Metal 3D Printing pushes the Boundaries in Moto2™ through Defiant Innovation In the high-octane world of MotoGP™ motorcycle racing, technical enhancements can have a big impact. Race winning Moto2 team TransFIORmers is using cutting edge additive manufacturing (metal 3D printing) technology in an unconventional front suspension system to gain a significant competitive advantage.

Samina Khalid Samina.Khalid@renishaw.com

Background Motorcycles ridden in the MotoGP World Championships are special; the general public can’t buy them and they can’t be used on a public road. As prototype racing bikes they

are custom-built to outdo their rivals and maximise performance on the track. Moto2, the second of the three MotoGP classes, was created in 2010. Its official engine is a 600cc fourstroke production engine,

currently supplied by Honda. The French Moto2 team TransFIORmers, based in Perigueux, South West France, is revolutionising front suspension design in order to stay ahead of the pack.

TransFIORmers is led by former 250cc World Championship rider Christian Boudinot, and the team’s unconventional suspension system was inspired by the seminal work of the legendary French motorbike designer Claude Fior.

“The weight reduction that metal 3D printing has achieved for us in our wishbone component has enabled us to bypass traditional weight transfer phenomenon and the problems associated with ‘brake dive’. More than that, it’s allowed us to design a part that is not only lighter, but far more rigid at the same time.” TransFIORmers, France

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July 2016

Renishaw sponsered transFIORmers moto2 motorcycle

Boudinot’s former friend and mentor, Fior, recognised the gains to be made from isolating the front suspension from steering forces. Resolving issues of ‘brake dive’, the design enables later braking into a corner and faster acceleration out. Instead of the more traditional telescopic front fork suspension, the TransFIORmers motorcycle employs a rigid front fork suspension system separated from the chassis using two wishbones.

July 2016

To further advance the development of its innovative design, TransFIORmers approached I3D Concept, a world-class expert in metal additive design and manufacturing techniques. Using Renishaw’s AM250 additive manufacturing system, I3D Concept worked in partnership with the TransFIORmers team to optimise the design of its upper wishbone component, one of two attaching the front fork to the chassis and critical to the bike’s steering.

Challenges In the development of new components in Moto2 bike design, achieving a weight reduction is a priority. In particular, reducing the ‘unsprung mass’ of the bike is a key consideration. The lower the unsprung mass, the better the suspension is in terms of vibration (chattering) management and responsiveness to both braking and acceleration. Of equal importance is the speed with which the design

of a new component can be modified, and how long it takes to remanufacture. Achieving perfection in a highly competitive environment demands fast and accurate component iteration. In a high reliability environment, mechanical strength is a further prime consideration. The TransFIORmers’ wishbone component needs to assure best possible rigidity, while handling significant levels of dynamic steering force.

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“To improve overall motorcycle performance, reducing the weight of all components located behind the shock absorbers is absolutely vital. Failure to optimise component weights can have an adverse effect on vibration, braking and acceleration, so weight reduction is a really high priority,” says Jérôme Aldeguer, Mechanical Engineer, TransFIORmers. Solution TransFIORmers’ original wishbone component was hand-fabricated in steel, with the assembly comprising of twelve separately machined and welded parts. I3D Concept consolidated the design into a single piece component, greatly reducing assembly time. The company produced the metal 3D printed wishbone using a Renishaw AM250 additive manufacturing system; initially prototyping in stainless steel (inox) and finally manufacturing a lighter weight part in titanium.

Key to the new 3D component design was an iterative process of topological optimisation, whereby the wishbone layout was successively rationalised in software within tight space constraints to withstand a set of predefined front fork loading conditions. Once the final component design was validated using digital CAD software, the build preparation file was prepared offline prior to export to the additive manufacturing system. Within the CAD software, I3D Concept was able to assess whether the parameters were effectively predetermined or whether they required tweaking to match the specific metal powder characteristics and the complex target geometries of the TransFIORmers wishbone. Importantly, using the AM250’s dedicated Optical Control System (OCS) software, I3D Concept was able to very accurately control laser steering which helped to enhance precision, definition of

features and surface finish. Results By taking an additive manufacturing approach to Moto2 bike design, TransFIORmers succeeded in dramatically reducing the weight of its critical wishbone front suspension component by a factor of 40%. Comparing the one-piece titanium component with the original welded steel component, a weight saving of 600 g was achieved. Metal 3D printing has also provided TransFIORmers with much finer control over component tolerances and the flexibility to very quickly iterate wishbone geometries to match specific chassis and kinematic requirements. “The weight reduction that metal 3D printing has achieved for us in our wishbone component has enabled us to bypass traditional weight transfer phenomenon and the problems associated with ‘brake dive’. More than that, it’s allowed us to design a

part that is not only lighter, but far more rigid at the same time,” explains Jérôme Aldeguer, Mechanical Engineer, TransFIORmers. With an ultimate tensile strength in excess of 1100 MPa when processed using additive manufacturing, and near perfect 99.7% densities, the titanium Ti6AI4V alloy used has delivered a radical new wishbone offering far greater rigidity than the original multipart, hand-assembled steel component. Thanks to additive manufacturing, TransFIORmers’ prototype wishbone development has become a highly efficient and cost effective process. Extensive part machining and assembly time overheads have been removed and design iterations and manufacturing have been made many times faster. In June 2016 the team won its first ever Moto2 GP race at the FIM CEV European Championship event in Barcelona.

Wishbone component in CAD software

Metal 3D printed 1 part titanium component

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July 2016

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July 2016

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Manufacturing Leveraging Solutions by Digital Computing

Ajay Deshkar CEO, 3D Engineering Automation LLP

Ajay Deshkar, CEO of 3D Engineering Automation LLP has years of expertise in Manufacturing, Engineering and Special Machinery, Products & Tool Design. His vast experience portfolio includes serving the engineering (products and services) divisions of Expert Global in 1999 of which he was a member Board for 15 years & heading design and development of Tools and SPMs at, Paramount Tools for 10 years. Currently, he heads implementation of engineering product solutions from Siemens PLM, ANSYS & EOS GmbH to the manufacturing industries in India. In conversation with MART, he talks about how digital computing has revolutionized the solutions to the manufacturing industry...

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian Manufacturing? The market is abuzz with the advent of Industry 4.0, a term that has been coined to represent the fourth industrial revolution. The digital computing industry had been providing ‘point-solutions’ to the manufacturing world. These technologies are CAD, CAM and CAE. CAE (Computer Aided Engineering) or design simulation too has started

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becoming a more design centric technology rather than the high end use it had in the past. Technologies that are now emerging is the configuration of these technologies in one platform through an integration tool and having interfaces with information interfaces with computers or even mobile phones. Applications such as WhatsApp can now be configured with the information highway. Another term that is often used is OIT (Internet of Things) and this too finds its way into

all this integration. PDM (product data Management) and PLM (Product Lifecycle Management) solutions with digital manufacturing solutions and MES for monitored manufacturing are the technologies that are making inroads in the manufacturing world. While most of the above technologies are still considered ‘virtual’ by most traditional manufacturing companies, a more ‘brickand-mortar’ manufacturing technology that has had

a huge impact on the way manufacturing can be done is Additive Manufacturing. This technology has now emerged as a production method rather than a ‘proto-making’ technology that it was in the initial two decades of its existence. It is predicted that more than 50% of the product made on 3D printing would be directly used parts. What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this?

July 2016

CAE (Computer Aided Engineering) or design simulation too has started becoming a more design centric technology rather than the high end use it had in the past.

These technologies – CAD, CAM and CAE have reached a plateau globally though India still has to walk a few more years to see the complete penetration of these point solutions. Mid and small sized manufacturing companies in India have not yet come to terms with a total IT integration and hence find it hard to maintain ‘enterprise’ solutions like PDM and PLM. There have been several companies that ventured into the use of these solutions to manage the explosion of CAD data, though fall short of providing the required infrastructure and mindshare for the extraction of benefits that these technologies provide. How is your company adapting the upcoming technologies? 3D Engineering has been in the forefront of bringing Engineering solutions to manufacturing companies in India. We have been partners with Siemens PLM solutions since 1999 and have been representing EOS, the German leaders in Additive

July 2016

Manufacturing for the past 7 years. Recently we also have signed up with Ansys software for their simulation solutions. 3D Engineering is committed to grow with manufacturing companies and ensure return of investments to their investments in these technologies How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled? When I studied engineering and even post graduated in Tool engineering about 28 years back, we had no computers. Last year when my son passed his engineering, he had no drawing boards!! There has been a paradigm shift in which design and manufacturing is taught in industry today. My personal view about this is that, though these changes are evident and necessary, there has to be a drawing board connection to study drawing to make better mechanical engineers. Using computers restricts skill development. As noted above, manufacturing

floor still has a lot of 2D printed drawings as a language of communication, which the students are missing out on. There of course is a stronger need to make mechanical engineers more industry ready, before which the exodus of all types of engineers to the attractive IT companies need to stop. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? A strong desire to implement trending technologies, coupled with an equally compatible implementation partner who can measure the success of implementation and monitor the stages post implementation is an example of closely controlled technology adaptation. Technologies do not primarily fail because they are inadequate or are an overkill. It is knowing the ‘what’ and ‘how’ pieces of the jigsaw that need to be closely deliberated. Indian SMEs are the most prominent part of

manufacturing. Are they ready with the latest technologies to deliver globally competent products? The challenges SMEs face in implementing these technologies? SMEs are the most competent pieces of technology drivers in the industry. I say this because there is a flexibility and nimbleness that SMEs have to adopt to these technologies. The key to the success of implementation of emerging technologies at SMEs is the OEs that they work with and the consulting partners they engage with. As highlighted above SMEs which once were a ready field for fresh engineers to play around and experiment is finding a dearth of talent pool due to the attraction of higher pastures in IT. Manpower retention and costs remain the tallest challenges to cross for SMEs. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? The Make in India, Skill development drive and financial support for

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investments in R&D have been helping SMEs, though there is a lot yet to be done. Like the farmers fight for price protection of their produce, SMEs too should have a mechanism with which their margins should be protected to help them reinvest some of their earnings in the technologies. Not many can afford to do that today. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? We need to begin at the source, i.e. changes in the manpower that goes in the manufacturing. Methods to channelize engineering education to ensure it is more industry oriented, initiatives that encourage growth in the manufacturing sector, industry-academia

interface, more investments in academia to ensure that it is lucrative for higher talents, a close monitoring of private technology institutes, the list can go on.

What are your views / comments with regard to Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness?

Then there has to be changes to how to market the manufacturing globally and bring about schemes that promote technology investments, making it within reach for industries. Cost pressures do not allow quality to prosper. There has to be stricter quality adherence that the industry needs to adopt to be globally competitive.

Make in India is a very bright and welcome step by the government – especially for manufacturing is in its nascent stages in my opinion. The concept is extremely positive and has a string patriotic connect. This however needs to be backed by policies that help better implementation of the concept. In an open economy that India has started to become, we cannot have import embargoes and until products made India are not competitive enough, if selling products in India is not competitive, why would companies make in India? I have a very strong opinion on implementation of Make in India concept in the agriculture sector though. In my opinion,

Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? Most start-ups have based their business models around IT and retail. I am yet to see a real dent that manufacturing startups have made.

India can reach a supreme position if enough efforts go in making the agricultural produce in India. Today this is not very well organized. Please give a brief about your industry, services and offerings? Started in 1999, 3D Engineering has grown to be one of the largest engineering solutions company in India. It has consistently grown over the last few years – about 10 times in the last 7 years. 3D Engineering has a very light 45-member team distributed in sales, technical and back office and has served over 650 customers in varied industry segments such as: Machinery and equipment manufacturers, Auto suppliers (Tier – 1 & Tier – 2), Academic institutions, Engineering Services Providers and Defense & Federal establishments.

PDM (product data Management) and PLM (Product Lifecycle Management) solutions with digital manufacturing solutions and MES for monitored manufacturing are the technologies that are making inroads in the manufacturing world.

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July 2016

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Pocket Milling in Titanium is an Extremely Tough Challenge Walter AG offers bespoke concepts for the aerospace industry The demand for titanium materials in the aerospace industry is rising. Experts are predicting an average increase of 20% over the next five years. This will have consequences for the manufacturing plants, since processing titanium usually requires long machine running times. Walter AG supports its aerospace customers with new tools and extensive knowledge of components. The aim is to manufacture titanium components cost-effectively and in a time-saving manner.

Dirk Masur

The aircraft industry readily uses titanium, for highly stressed structural components in particular: Door frames, landing gear mounts and wing

attachments â&#x20AC;&#x201C; all these components typically have a high machining content, it is not unusual for the volume of swarf produced to exceed that of the finished

component. This is primarily due to the fact that a large number of pockets are cut from solid forgings. Deep and shallow pockets, 5-axis pockets, triangular pockets

â&#x20AC;&#x201C; often with very thin walls or bottom faces ; these pose a huge challenge for milling which, logically, is the machining technology for these structural components.

The landing gear mounts in modern aircraft are typical titanium structural components with large numbers of pockets.

M3255 tangential porcupine milling cutter : When roughing pockets or shoulders, or in other words, when high metal removal rates are needed.

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July 2016

M4002 Universal face milling cutter : The M4002 is a high-feed milling cutter suitable for facing, interpolation and part plunging.

Walter Prototyp Ti40 solid carbide milling cutter: The Walter Prototyp Ti40 is the titanium specialist among solid carbide end milling cutters.

Indexable inserts and solid carbide milling cutters help to maintain the balance here. The main focus is on process reliability since these structural components are extremely expensive. At the same time, cost

July 2016

pressure from the market demands high machining and productivity performance. Typical when titanium machining, the material’s low thermal conductivity and its tendency to vibrate require a very rigid machine concept

as well as optimum cutting edge preparation. Dirk Masur, Component Manager Aerospace at Walter AG in Tübingen, Germany, together with his colleagues, works with titanium components and their special properties

on a daily basis: “We focus on complete solutions,” he explains. “This means that we coordinate all aspects, such as the tool design, CAM program and machining strategy, with the application in accordance with best

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practice considerations.” The result is modern tool concepts which, in turn, are matched to the tasks in question, such as roughing, semi-finishing or finishing. Last but not least, according to Masur, the development of productive and reliable strategies at Walter is based on knowledge of components which has been built up over a number of decades: “Being part of a global network is something we consider to be extremely important. Our expertise is based on intensive partnerships with focus customers, universities and machine tool manufacturers. Together, we are continually developing the machining operations for key components. This is how we ensure that we are always using the very latest technology.” In the end, the machining specialists from Tübingen

provide their customers with bespoke processes which enable maximum machining volumes. The key here is to match the processes with the available machine type capacity, for example, to gain maximum output even from machines with a lower performance. “The machining operations are simulated and verified before the handover,” Masur stresses, “this means that the user does not have any unpleasant surprises in terms of cost-effectiveness or process reliability.” Representative test in titanium Since there are virtually never any real test components readily available in the world of aerospace, nor any large structural parts, the experts at Walter AG demonstrated the performance of their current tool generations on a generic component. This is made of the commercially available material Ti6Al4V (3.7164). The

experts at Walter designed the component with a range of typical pocket shapes which are the same as or similar to those which can be found on real components. This means that the machining results can be transferred one to one. The plan includes a task for a quartet or tools: The M3255 tangential porcupine milling cutter, the M4002 high-feed face milling cutter (roughing operations), the Ti40 solid carbide end milling cutter and the modular ConeFit variant with Ti50 changeable head (semi-finishing and finishing operations). This is a combination which is possible in reality, for example when machining landing gear mounts. The coatings, as well as the macro geometry and micro geometry of the two solid carbide tools are designed specifically for titanium machining. The M3255 and M4002 milling cutters were given indexable

Lightweight and high-strength – properties characteristic of titanium materials Titanium materials are classified under the group of materials which are difficult to machine (ISO S). They have a low thermal conductivity, which means that the thermal load on tool cutting edges is very high. A low modulus of elasticity also encourages vibration during machining operations. Ti6Al4V is the most frequently used type of titanium material in the aerospace industry. However, Ti-5-55-3 and Ti-10-2-3 are also increasingly being used, e.g. for landing gear components. Both materials have a higher thermal stability than Ti6Al4V and can only be machined with reduced cutting speeds. Ti6Al4V thermal conductivity: 7.56 W/ mK (steel Ck45: 51.9 W/mK) Ti6Al4V elasticity modulus:= 110 kN/ mm2 (steel Ck45: 210 kN/mm2) Ti6Al4V density = 4.4 g/cm3 (steel = 7.85 g/cm3) Tensile strength of Rm Ti6Al4V = 900 N/mm2

ConeFit interface Ti50, and shank: The Walter Prototyp Ti50, ConeFit version, is a flexible solution for the semi-finishing and finishing of titanium structural components. An extensive range of shanks enables it to be easily adapted to various pocket depths.

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July 2016

But what about Aluminium? Aluminium is an integral part of the ensemble of materials used in modern aircraft. It continues to play an important role, despite the increase in the use of composites. This is also partly because the development of new alloys with improved properties is ongoing. The current trend is towards aluminium-lithium wrought alloys.

Al-Li alloys are lighter than

solutions matched to

other Al alloys and have a

the application, just with

higher modulus of elasticity

the tool and machine

– welcome properties

concepts optimised for

for the aircraft industry.

aluminium.

Workpieces made from these lightweight materials are often similar to those made from titanium. Both have a large number of pockets – and consequently high volumes of swarf. The main difference is that aluminium machining is a HSC (High Speed Cutting) process. There is no more talk of materials being “difficult to cut” or “reduced cutting data”. On the contrary – Vc values when milling above 3000 m/min are not uncommon. On the other hand, cutting speeds which are too low result in the formation of built-up edges – and thus to lower tool life. In the same way as titanium machining, working with aluminium also requires a great deal of expertise and component knowledge where the aim is to develop cost-effective, reliable processes. Here too, the focus is on complete

July 2016

Hence why Walter AG has recently introduced a new milling cutter – an aluminium specialist through and through – which is tailored precisely to the requirements profile of the aircraft industry: The M2131 ramping milling cutter

M2131 ramping milling cutter: The new M2131 ramping milling cutter from Walter AG specialises in HSC machining of aluminium materials.

with 90° indexable inserts. Its speciality is ramping

inserts. This refers to an

resistance to flank face wear

entirely new PVD variant,

as well as extremely high

manufactured using

cutting edge stability. “Field

the “HiPIMS method”.

tests have confirmed the

“HiPIMS” stands for “High

technological advantages of

Power Impulse Magnetron

the new indexable inserts

Sputtering”. The special

in comparison to standard

feature of this physical

types,” explains Wolfgang

coating process is that it

Vötsch, Product Manager

produces an extremely

for Milling at Walter AG in

resilient and smooth PVD

Tübingen. “Our application

coating. The benefit of

engineers have achieved

this new variant is the

increases in tool life of up

huge reduction in friction

to 200% with ease. In one

The highlight of the new

– and thus less formation

case, we even succeeded in

tool is, however, the

of built-up edges. It also

reaching an increase of almost

WNN15 grade indexable

provides extremely high

400%!”

and pocket milling. Walter manufactures the milling bodies with the highest possible concentricity, the indexable inserts having protection against centrifugal force. The milling cutter is also pre-balanced. Measures which guarantee that high process reliability is achieved in HSC machining.

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inserts made from the new Walter WSM45X cutting tool material. The extremely tough CVD coating is ideally suited to ISO S and ISO M applications. The following overviews show example machining rates and tool life, which could be implemented when machining pockets on a generic component: 1. M3255 tangential porcupine milling cutter / D = 50, z = 5 / WSM45X: Roughing – Pocket: 274 x 120 x 74 mm: vc = 40 m/min, fz= 0.15 mm, ap= 37.0 mm (2 steps), ae= 30.0 mm (concentric tool path) The result: Machining volume: 212 cm³/min, tool life:

70 mins (t/pocket: 14 mins) 2. Ti50 ConeFit Prototyp / D = 25, z = 5 / solid carbide changeable head: Semi-finishing and finishing – Pocket: 274 x 120 x 74 mm: vc= 90 m/min, fz= 0.1 mm, ap= 16.0-22.0 mm (variable), ae= 3.7 mm (semi-finishing), 0.3 mm (finishing) The result: Machining volume: 33 cm³/min, tool life: 60 mins (t/pocket: 14 mins) 3. M4002 high-feed face milling cutter / D = 50, z = 5 / WSM45X: Roughing – Pocket: 254 x 127 x 42 mm: vc= 60 m/min, fz= 0.7 mm, ap= 1.5 mm, ae= 50 mm The result: Machining

volume: 93 cm³/min, tool life: 40 mins (t/pocket: 10 mins) Milling with a difference: High dynamic cutting A very good example of an intelligent machining strategy is “high dynamic cutting” (HDC). This improves both costefficiency and process reliability. With high dynamic cutting, the machining conditions remain constant – along, therefore, with the forces applied to the tool cutting edges and the process temperature. The corresponding functions are provided by modern CAM software. Advantages: Better performance and greater process reliability. The constant engagement

condition generates lower vibration – and thus results in a higher tool life at a lower tool wear rate. This, in turn, enables higher cutting lengths and machining volumes. At the same time, energy consumption at the spindle is reduced. The Walter Prototyp Ti40 solid carbide milling cutter is perfectly suited to this machining strategy. 4. Ti40 Prototyp / D = 20, z = 5 / solid carbide end milling cutter for titanium materials: High dynamic cutting, triangular pocket: 200 x 92 x 48 mm: vc= 115 m/min, fz= 0.134 mm, ap= 47.5 mm, ae= 2 mm The result: Machining volume 139 cm³/min (t/pocket: 9 mins)

Using a generic component made from Ti6Al4V, the aerospace experts at Walter AG demonstrated typical processes for structural components.

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July 2016

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3D Printing Revolutionized the Concept of Manufacturing Manish Kothari Managing Director, Rhino Machines Pvt. Ltd.

Started in 1983 as a consultancy firm, Rhino Machines evolved as a full-fledged manufacturer of conventional green sand, pouring and centrifugal casting products in 1991. In 1995, the company joined hands with French firm Fondarc to strengthen capabilities bringing new technologies into the markets. Today, they are adopting latest technologies in their manufacturing process.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing?

What are the upcoming technological trends in manufacturing across the globe? How are Indian companies catching up with this?

There is not a very big change in the basic manufacturing methodology in India per se. However, few new technologies are enabling the industry to improve their productivity, reduce manufacturing time. One example is use of 3D printing in rapid prototyping, business development, modelling which have enabled industries in reducing the product development cycle and also improve the product with a better visualisation. Foundries in particular will find this very useful in pattern making and reduce their cycle time drastically.

For manufacturing machines i.e. fabrication, machining and assembly there are no particular new trends to our knowledge. The modern techniques have been available in the world for quite some time but yet to be fully adopted in India. The complete change requires a holistic change from raw materials to the processing. To increase use of CNC technology, the component raw material quality needs to be improved. For example castings produced in hand moulding or conventional moulding need to be shifted to high pressure and modern techniques to

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allow direct use in CNC. In fabrication, use of press metal modern techniques is yet to be adopted wholesome, due to high cost limitations. All said, the awareness of modern techniques and the cost-benefit analysis is yet to be propagated to the smaller industries and the awareness needs to be increased. How is your company adapting the upcoming technologies? We have adopted some of the technologies which were available for many years, but lack of finance proved to be a hindrance for us in adopting those technologies. We have started with converting all our designing and drawings to 3D platform for mechanical as well as electrical, thus improving the

mistake proofing in drawings. We have used 3D printing to visualise and demonstrate large projects on a smaller scale in short time. This has greatly enabled us to share the solutions and also visualise the projects better. Our organisation has always focussed on Lean techniques in its products and this has led to a great appreciation for our ECOFLEX & MULTIFLEX â&#x20AC;&#x201C; both product lines recognised for energy efficiency, higher productivity and lower space. The organisation is now embracing Cloud Computing and Interfacing with its machines to utilise the latest trend of data acquisition, analysis, reporting and actions. How much an engineer graduated from India is skilled to implement the latest trends

July 2016

S1- Green Sand Reclamation Plant - 1st Plant in India Implementing the emerging process need of the country Plant installed at Aquasub, Coimbatore

S1 - Green Sand Reclamation for Moulding Addressing the need replacing 3 Million MT of Sand / year in India and conserve resources, fuel and reduce carbon footprint

in manufacturing? If there are any gaps, how can they be filled? Unfortunately, there are very few institutions who have really taken this task on hand, and due to this the skill gap of student is very high. Then it depends on the individual how they learn at the cost of the company. It is very rare to find industry ready skills in the engineers. Having recognised this gap, Rhino Machines joined ACE Foundation â&#x20AC;&#x201C; a not for profit organistion in 2014 and has started bridging this skill gap through training in the industry while the students are in college. Students are exposed to modern machines, training in Industrial Automation, 3D Printing and its use, Casting Industry, Life skills such as communication, reporting i.e. empowering them to be industry ready. Projects on actual problems in the Industry are given to students such as waste dust to convert to useful bricks. Hands on interaction and exposure in the industry will for sure improve the skill gap. The industry has to participate in the education programs, and provide the platform to

July 2016

the universities, and in turn the engineering colleges also need to start internship programs in the industry. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? For a long time India was taking advantage of low labour costs, poor labour laws. However, as in most developing countries, the costs of manpower are increasing, accompanied with increasing avenues of spending money. The industry has started to shift its focus from pure manpower and labour oriented working to adapting a median path of improving productivity. Evaluation of manufacturing in units per man per month have started, and suddenly they have realised that it is essential to embrace and adapt to the advanced technologies for sustenance. One of the best examples for our foundry industry has been setting up of two mechanised and semiautomated plants in Howrah â&#x20AC;&#x201C; which was predominantly a manual moulding with very low space & human resource utilisation, and the inability of

the foundry to cater to the rising demand of quantity and quality.

challenges faced by the industry to adapt new technologies.

Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? The challenges SMEs face in implementing these technologies?

How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment?

The Indian industry has a long way to go in adapting the new technologies, and at this moment, is struggling to meet the global competition. We are not able to become net exporter, but still import so many goods just due to lack of the required manufacturing infrastructure in terms of volume and value. Though the last 2 years there has been a change in trend, the path is long. SMEs face the challenges of finance costs, availability of finance, complex procedures and on top of that lack of awareness in the institutions as well as the industry on the policies and options available. Apart from finance two more important factors also exist â&#x20AC;&#x201C; one is the lack of skill in the operations & maintenance levels, second is the cost of the solutions. These two are equally important

The government has created an environment of positivity, and trying to bridge the divide between industry and government. However, the roots of sluggishness are so deep, it is a humungous task. Last two years I have been very closely involved with Ministry of MSME officials and technology development centres. Decision making process in the govt is very tedious, and due to the poor practices of few officers, those who wish to perform are pulled down. However, one positive aspect is that industry and govt have started engaging. We went through this engagement exercise, and suddenly we were uplifted due to recognition of our innovation, which till date went unnoticed. So were many of our colleagues, the acceptance of Indian product has increased, corporates have started adapting the Indian products and are working together to support each

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other. Indirectly the Govt has supported the SME by elevating its brand across the country. MSME has also provided change in procurement policies in PSU’s to enable Indian produce get a preference. Tenders have shifted from global to domestic…lot of small steps, but surely in the right direction are happening. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? There has to be even stronger alignment between government and industry. While govt has authority, industry has competitiveness. Instead of promoting cluster funding from the government, schemes should be put out to allow industries to work in the cluster approach with the government authenticity. Rhino Machines has already worked on this approach though it is not a policy of the govt and opened Centre of Excellence for Smart Manufacturing on revenue

sharing basis with govt, where the Industry is delivering the training, and govt is the authorisation and certification partner. Similarly in cluster production sand reclamation has got the nod from the govt, where they will be monitoring the facility and getting industries to adapt and use the same, while the industry invests in the technology upgradation. Investment in modern technologies must be taken on hand, with a common facility approach to improve the machine utilisation, thereby improving the cost competitiveness and yet equipped with latest technology. The set up of such marquee centres across the country, will bring the industry closer to adapt modern manufacturing practices faster. Change in the education ecosystem also requires a sea change. We are generating more of “white collar” engineers, without any working skills, and have an acute shortage of skilled technicians with international

skills. When Rhino embraced Swiss pedagogy, after one year, it realised that the skill set available in the present ITI’s is very poor, and if the industry wishes to embrace new technology, they do not have the requisite people on the shop floor to implement. The need is to focus on increasing the quality of technical training, encourage 16+ students to embrace these skill based courses instead of the standard courses which have limited avenues and does not service the industry need. Do you think the new age startups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? As the saying goes “what cannot be measured cannot be controlled”, data acquisition, analytics and preventive are missing from the Indian paradigm. If we talk of the foundry industry less than 1% of the industry actually measure what they do, and that too is on a 24 hour or week or monthly basis. Rhino Machines with

Ecolibrium (two GCIP 2015 innovators) have come together to work together in the foundry domain and extend the energy monitoring to comprehensive data acquisition, analytics and use for corrective, preventive and predictive management of operations and maintenance of the foundry industry. Such platforms need to be built across the industries. What are your views / comments with regard to Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness? The campaign itself has moved a lot of people, and increased the nationalistic fervour. The brand of India in the minds of Indians has started changing, and the pride of using an Indian product is increasing. Industries irrespective of size are giving first priority to ‘Made in India’ products. We have seen certain government policy decisions in the govt procurement also favouring Made in India. Probably if some data exists, a comparison of the percentage

S3 - Green Sand Reclamation for Cores Bringing proven process from Italy to India to reclaim 7 Million MT of sand/year in India and conserve resources, fuel and reduce carbon footprint

Ecoflex – Energy efficient sand handling & moulding solution Improving the way Foundry operates – changing from dark, dusty & dirty to Clean, lighted and dustfree. Displayed at Rashtrapati Bhawan @ Festival of Innovation

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July 2016

of change in procurement of products/components/projects after this campaign would come up with interesting figures. As Indian manufacturer ourselves, our products have been leveraged and our branding has improved. Indirectly, there is a direct effect on the economy, employment opportunities and business opportunities. The opening of defence localisation for one is a very major shift and will go a long way in overall growth. The only suggestion would be to bring validation and recognition to those companies who have strived to build brand ‘Made in India’, and give them leverage in business which will excite and encourage more players to push for the ‘Made in India’. Please give a brief about your industry, services and offerings? Rhino Machines operates in the

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Foundry – Casting Industry Domain as a supplier of turnkey projects and machines for green sand moulding, sand handling systems, sand reclamation, liquid metal handling. Innovation is one of the USP of Rhino and it was recognised for Ecoflex® Sand Handling Plant @ GCIP 2015 and Rashtrapati Bhawan FOIN 2016 with an impact of 7000 MW saving per annum. In the same continuation its high pressure moulding machine MULTIFLEX has been selected in GCIP 2016 for a 31,000 MW energy saving potential. Rhino has taken the lead of embracing and commercialising of green sand reclamation in India – the first one to do so, and has engaged with MSME to support even the smallest foundry with quality sand. The impact of reclamation is more than 25 Million kgs reduction in

CO2 emission. Rhino has funded and promoted Meemansa – women’s ethnic wear brand led by Priyanka Bapna and growing in the 20,000 Cr market segment in India. Our design has been showcased on Femina front page worn by Kangana Ranaut recently. Rhino has joined hands with Ecolibrium for Data acquisition, analytics, reporting and monitoring for Foundry as a whole, a unique relationship between 2 GCIP innovators. A third innovator in weighing solutions is joining hands for a comprehensive solution. Rhino is bringing on one platform likeminded innovators and business owners to leverage each other’s businesses. Forming of COESM (Centre of Excellence for Smart Manufacturing) – a partnership

of Rhino and MSME, TDC Agra is another important step in fulfilling the training and skilling requirements of the industry. Rhino has partnered Swiss Pedagogy knowledge partners SkillSonics® along with ACE Foundation to deliver industry requirement of trained and highly skilled technicians. It commences its first 22 month program for 10+ students at its premises on 16th Aug 2016. Lean manufacturing and management consultancy & solutions together with Composite Solutions where Manish Kothari is a director, is the next offering Rhino has put on the table for the foundry industry and also other allied industry – bringing together commercial and technical expertise on one platform.

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Metal Injection Molding Technology for Complex and Intricate Parts Manufacturing Metal Injection Molding (MIM) is an emerging technology in the manufacturing world across the globe. Indo-MIM Pvt. Ltd., based out of Bangalore, has been a pioneer in developing the MIM process and its application to a very wide variety of parts spread across all market segments, earning the distinction of being the largest MIM Company in the World.

Sujith V Sukumaran sujith.s@indo-mim.com

Metal Injection Molding (MIM), though has its origins from early 1920’s and WWII times, when the first parts were made, came to the industrial forefront only during 1970’s. Even after 45 years, it is still considered a relatively unknown, exotic and specialized manufacturing process. One of the main reasons being the

COMPOUNDING

- Powders - Binders

emergence of only a handful of companies in the world, who have mastered this technology and invested enough time and resources to transform the science behind the process into an almost art-like form. MIM, as the name suggests, is the process of injecting fine

2 MOLDING - Binders melt - Carries powder into mold

metal powders mixed with appropriate thermoplastic and wax binders at high pressures and elevated temperatures into an engineered mold, to form the desired component shape. The temperatures are high enough to only melt the binders, which form a viscous slurry with the metal powders and upon cooling, are

3 DE-BINDING - Solvent - Thermal

ejected from the mold as a solid part. Subsequently, a controlled process of ‘Debinding’ is carried out to remove the binders using a chemical solvent. The still fragile parts are then subjected to ‘Sintering’ – a metal densification process, where they are heated to high temperatures close to

4 SINTERING - Inter particular fusion

MIM: The Process

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July 2016

Feedstock

Binder

Molded Part

Sintered Part

Metal powder

From Powders to Net Shape

the melting point of the metal alloy in a controlled atmosphere, resulting in a fusion of the metal powders together and forming a near net shape with densities ≥ 96% of theoretical density. Although the described process is simplistic in nature, the real-world complexities are manifold. These

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are interlinked and can broadly be classified into the following categories:

beforehand but also readily altered to suit the requirement.

• Material: The proportion of metal powders to binders in the mixture drives the flow characteristics and part shrinkage during sintering. This not only needs to be determined exactly

• Tool design: Tool design is invariably complex and intricate due to the nature of parts made by MIM. In addition to accommodating the part design, the tool has to provide necessary provisions for uninterrupted

material flow and uniform cooling. Add to it, the various slides for part features that need to perfectly match and act as a single unit in the closed condition, it is not difficult to imagine the complexity involved. • Machine parameters: Sophisticated molding machines

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with a horde of parameters and options, require a thorough understanding of the physics of mold filling. It is essential to be equipped with this knowledge to avoid common molding related defects of sink, incomplete filling, weld lines or flow lines. • Shrinkage: The shrinkage characteristics of a part are a function of both the initial material mixture and ‘staging’ during the sintering process. Staging refers to orientation and placement of the parts in specifically designed ceramic holders called stagers. The material mixture determines the percentage of shrinkage whereas the staging method controls the distortion, since the part would naturally tend to shrink towards its Centre of Gravity (CG). Even with other things being done correctly, an incorrect staging method would seriously hinder achieving the required net shape and dimension. Then, there is the sintering cycle itself with its carefully determined temperature range and ramp rates. A bit too much and the parts might melt; a bit less and insufficient shrinkage might take place. It is a balancing

act and learnt from a history of trials and analysis. MIM process has no parallels when it comes to manufacturing small, highly complex and intricate parts with profiles that are either impossible or cost prohibitive with conventional techniques. The process also provides a natural flexibility to adapt to varying production demands in terms of quantities. Volume requirements driven by changing market conditions can be easily accommodated at minimal risk. With the raw material in a powder form, it is also easier to meet the strength requirements of the part by simply altering the chemistry and addition of required alloying elements. The range of materials currently used cover various grades of ferrous alloys, Stainless steels and exotic metal alloys of Tungsten, Titanium and Inconel. MIM material can be ‘engineered’ in the true sense of the word without any change in the overall process and still produce a reliable and high performance part. The parts produced by MIM have mechanical properties approaching those of wrought

Machining Calibration

Welding

metals and can be practically treated as such. They can be subjected to any kind of machining operation, Heat Treatment, surface finishing operations of Glass Bead blasting, Sand blasting, Barrelling and all kinds of plating and passivation processes without extensive surface preparation. MIM, for all its capabilities has its share of limitations too. The illustrated image lists the general guidelines that are applicable to MIM process. Working economics generally limit the part weight to around 50 gms and size to under 60 mm. Thinner or thicker wall thicknesses other than those specified might also pose a problem. In terms of the tolerances directly achievable from the MIM process, a thumb rule of ±0.5% of nominal dimension is usually employed. MIM is preferable for high production volumes and small quantities may not yield the perceived cost advantage.

The future of this branch of manufacturing is bright and has great potential for development. MIM has experienced a rapid growth in the last decade with annual sales exceeding $1 billion per year by some estimates and a compound growth rate of as high as 20%. However, the engineering

MIM fits everywhere! It is not limited by any market segment or application. Everywhere and anywhere, if there is a requirement for small and

Versatility of MIM

Grinding

MIM

Length Limit <200 mm. - Ideal < 60 mm.

Heat Treatment

Tumbling

Ideal MIM Part

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Wall thickness 0.5 mm. to 5 mm. - >5mm. , coring is essential Tolerances as per ISO 2768 (M) and thumb rule of +0.5 % of nominal dimension

Annual requirement from 50,000 to to 50 Mil. is possible

Surface treatments

Plating

complex parts with intricate geometries and, conventional methods are not cost effective, MIM would come out triumphant. Today, MIM has its presence in all the broad market segments and well known applications. However, Automotive, Industrial, and Medical applications are the main segments of MIM application. Majority of applications using MIM have sophisticated design involving multiple interlocking parts and are driven by the need to combine several parts into one. The automotive industry uses various parts with irregular profiles and holes that are at an angle to each other. MIM process has been able to introduce Value Engineering/Value Addition (VE/ VA) in such cases and eliminate multiple intermediate machining/ joining processes.

Weight limit <200 gms. - Ideal 0.1 to 50 gms

MIM

All the high melting point alloys are possible

July 2016

Power tools

Sanitary Aerospace

MIM Applications

Medical

Locks Computer hardware

Electronic connecter

industry is still largely unfamiliar about MIM process and its capabilities and applications. With an increased awareness and acceptance of the technology from high volume manufacturers of metal components, an explosive growth rate can be

July 2016

expected in the future. There are still numerous possibilities in material choices and process parameter optimization that are waiting to be explored and integrated into industrial production. Another important aspect is the integration of the

technology and its potential at the preliminary concept or design stage itself, which would open a whole new world of possibilities and even widerspread of MIM in the relevant branches of engineering.

Automotive

Mobile phone

Indo-MIM extends a service to the OE industry of co-working in the space of value engineering and can give support for any initial stage concepts/ designs. Enquiries could be forwarded to innovation@indo-mim.com for a reply within 24 hours.

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Quality Is the Key for Global Footprint

Surendranath Reddy CEO, 3Ding

3Ding is a dedicated Indian research firm pioneering in Rapid Prototyping technologies and manufacturer and distributor of world class 3D printers along with its accessories. Itâ&#x20AC;&#x2122;s also the hub of fine services that includes printing, designing, scanning, reverse engineering. In conversation with MART, Surendranath Reddy, CEO, 3Ding highlights different aspects of this emerging technology. He started his career as a Robotics Engineer in Simple Labs. Later, he came up with an idea to start REDD Robotics, a Consumer Electronics Start Up which concentrates on Robotics, Embedded Systems, Internet of Things, Home Automation, and 3D printing. Currently, he heads the company which manufactures industrial grade 3D Printer FabX and Hydra. He also concentrates in educating the Indian Youth by conducting workshops and webinars.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? Conventional methods are a guaranteed buzzkill after the birth of rapid prototyping, but precisely after the emergence of its successful proofs and itâ&#x20AC;&#x2122;s dire outreach. Injection Molding and Automation are currently

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dominating the manufacturing sector. In Injection Molding, it is observed that once a mold is prepared, the time taken to get the finished product lies between a mere 30 - 60 seconds. Furthermore, the finish is smooth and the process is pocket-friendly. What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this?

Additive Manufacturing and Distributive Manufacturing are few of the most influential technologies which are bound to thrive for years to come. Over the years, injection molding has gained popularity regarding its easy accessibility, but since few of the aerial parts are not completely possible through molding, rapid prototyping solves this problem in style. Unlike injection molding, 3D printing skips the step of preparing molds for the

article. Hence the design can be modified at ease and is cost effective. How is your company adapting the upcoming technologies? We, in 3Ding, keep a constant tab on the scientific and technological breakthroughs happening around the globe. Hence, we work on bettering our standards by implementing the latest novice techniques after an intense round of research and necessary groundwork for every

July 2016

Boat

Colosseum

change we foretake. How much an engineer graduated from India is skilled in implementing the latest trends in manufacturing? How can gaps be filled? Engineering seems to have lost its edge since it has become a business bargain at homes where the letters BE carries more weight in matrimonial websites than real passion and knowledge. Engineers these days are not adequately skilled to take

on challenges in the tech world. But this doesn’t cover the entire circle. Passionate engineers with a thirst to learn and innovate find ways to challenge themselves and learn from the same. Practical implementation of studies must be effectively sown into the minds of today’s engineers. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing?

When adopting or embracing new technologies, it is important to have a good understanding of its functionality in terms of what could work and what cannot. These are the steps needed to be on the safer side of the tech-man (technological manufacturing) boat. 1. Understand the need to switch or update to the desired technology. 2. Find out the pros and cons of the technology (Visit websites and research the styles of working with this by going

through the already existing sites) 3. If the cons outweigh the pros, find out ways in which they can be minimized or removed. 4. Test the technology several times before you’re satisfied. 5. Generate case studies depending on the tests 6. Once you’re pleased with how far you’ve come, take a leap of faith and trust in your instincts no matter what. Indian SMEs are the most prominent part of

Iron Throne

Pokemon Go

July 2016

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manufacturing. Are they ready with the latest technologies to deliver competent global products? What are the challenges SMEs face in implementing these technologies? Global recognition and sustenance are the two most important goals when establishing a company or a product. India is definitely in the race, and we have come a long way from a few years back. But there is a lack of essential knowledge in certain industries which hinders their chances of taking needed risks and adapting to big and expensive trends in the market. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? Though the government of India has taken steps to aid these SME’s, the workflow is cut back or slowed down due to certain methods adopted.

What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? Quality is the key for any product to reach a global target. Apart from this, accessibility to the ones with a weaker knowledge of social media is something that needs to be worked on. Risks must be encouraged while implementing new methods. A little focus on ergonomics can change the game. Do you think the new age startups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? With respect to the highly influential trends in startups, its productivity and functionality is an ongoing process where a conclusion cannot be reached at this instant. Predictive Analysis and Big Data requires years of experience and

constant supervision. But every growing startup is putting its best feet forward to achieve the same. What are your views / comments concerning Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness? Modi’s campaign of Make in India is a plausible effort and hats off to his initiation to help these SME’s. Though we work towards making Indian products accessible with a promise of quality, the western fever seems to be rooted in the minds of every Indian. Changing this seems unlikely and impossible, but the need to do so is a throbbing desire in every Indian startup to make the grass greener on their side. Please give a brief about your industry, services, and offerings? We are the proud brains behind the face of India’s most affordable 3D printer, the

FabX 1. FabX 1 was created for a purpose that every Indian should be able to be a part of this technology and grow with this. The other printers in the series do justice to the price it comes with, covering all aspects of the produce. FabX 2, FabX 3 and the latest addition to the family, FabX Pro are just as special and amazing as its predecessor. Apart from the brilliance of housing the domestic FabX series, 3Ding’s industrial series, Hydra comes with a unique feature of customisation from customer-to-customer. That is, its build volume and extruder can be altered as per the specifications given by the customers. That’s a total hoot and you can’t deny that. Apart from manufacturing and distributing 3D superior printers (a product of Make in India), we offer upmarket design, printing, and reverse engineering services.

King of the Jungle - Printed on FabX

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July 2016

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Keep your mould running well FIBRO Mould Line Gas Springs

If additional movements are needed in a mould, designers often rely on cam pins, compression springs or latch locks. Now there is an alternative from FIBRO: Mould Line, the gas spring for mould making.

Ramkrishna Edara

Gas springs are always the right choice whenever, for instance, another intermediate plate or a slide unit is to be moved parallel to the mould opening at the parting line. Benefits include, above all, pressure monitoring and simple force control. An additional aspect

is the overload protection. Should a component, which is to be moved, be jammed â&#x20AC;&#x201C; for example, a stripper or an intermediate plate in a 3-plate tool â&#x20AC;&#x201C; latch locks can often pull until a component breaks. Not so with the FML Mould

Line gas springs from the standard parts manufacturer FIBRO GmbH, Hassmersheim: Once it reaches the set force, it remains in position. Better yet: it can be used to diagnose a pending failure and replacement can be planned without having to interrupt production.

A replacement can be installed whenever a break in production occurs. Used in conjunction with standardised elements for mould making, gas springs provide basically the same functions as a latch lock. They are placed, for example,

FML Mould Line gas springs from FIBRO in a practical application behind an intermediate plate: The space-saving pressure connection on the back can be seen in the detail.

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July 2016

Gas springs are now available for mould making: FIBRO has developed the well-known elements used in tool and die making further and made them suitable for use by mould makers.

behind the intermediate plate to be moved so that this plate is shifted by a certain distance during opening. Mould Line gas springs are characterised by their high force, their small size, a long service life of at least 1,000,000 strokes and a continuous operating temperature of 120Â°C. They are approved as per the European Pressure Equipment Directive 97/23/EG (14th GSGV ordinance on pressure vessels). In addition to technical advantages, there are also practical cost benefits: Various

mounting possibilities ensure simple installation and the elimination of the lateral machining for the fastening of latch locks on the mould. This saves about two-thirds of the costs, according to the manufacturer. Advantages of Mould Line gas springs. Minimal adjustment required No lubrication required No maintenance required for up to 500,000 strokes

Variably adjustable forces Mould temperatures up to 120Â°C Approved as per the European Pressure Equipment Directive 97/23/EG A pressure monitoring system makes it possible to recognise an impending failure at an early point (prevention) No tool breakage, should the 2nd parting line lock (the plate comes to a standstill; after the removal of the jam, production can be resumed)

In all cost savings of 60 -70% versus a latch lock

Additional information on Mould Line gas springs as well as technical data and mounting examples can be found in the new FIBRO Standard Parts catalogue for mould making. The author Ramkrishna Edara is the AGM, Business Development of FIBRO India. With extensive experience in the field of Tool &amp; Die making, he is leading standard parts business development at FIBRO India.

Mounting example of Mould Line gas springs.

July 2016

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Robotic Automation & Machining Will Transform Modern Manufacturing

Sameer Kelkar CEO, Grindmaster Sameer Kelkar, the CEO of Grind Master Machines Pvt. Ltd, loves to venture into new horizons of Robotic Applications such as Grinding, Deflashing, Fettling, Machining and many others. With his leadership Grind Master, a pioneer and leader in special purpose machines for Metal Finishing, Deburring, NanoFinish and solutions including Robotic automation and Abrasives, has also several registered designs and technology patents (pending) in the field of microfinishing and superfinishing. An explorer at heart, Sameer Kelkar, is a Silver Medallist and Graduate of IIT Bombay, and MS in Robotics from University of California, Berkelet. In an interview with MART, he opines how robotic automation and machining could be game changer of the modern manufacturing processes...

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing currently? Modern manufacturing demands more flexible and faster manufacturing technologies using Robotics & Automation. Majority of industries are upgrading their manufacturing setup from traditional setup consisting manual processes or semiautomatic processes to robotic automation.

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Various processes like Fettling, Deflashing & Grinding which were traditionally done manually or using semiautomatic tools are now successfully shifting towards robotic automation. Processes like Robotic Machining are next step of Rapid Prototyping or 3D Printing where user can work with large variety of materials. Developed countries like Japan, China, USA and many European countries have

successfully implemented Robotic Automation among various industries. India is moving swiftly towards use of such technologies, still long way to go . . . What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this? Industrie 4.0 or the fourth industrial revolution is the current trend of automation and data exchange in

manufacturing technologies. It uses cyber-physical systems and cloud computing. Machines are meant to improve quality productivity and cost efficiency. With Industrie 4.0, machines are becoming smarter and users are able to interact with these smart machines in similar way we interact with smart phones. There machines communicate and cooperate with each other and humans in real time which helps in making decentralized decisions. Industries with

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Today Grind Master manufactures over 50 products ranges including manual, semiautomatic as well as CNC machines along with Robotic Automation.

scattered manufacturing plants can now coordinate in much better way due to this. Self-diagnostics is another feature which helps in preventive maintenance which eventually helps in increasing productivity and quality. Indian MNCs are working on adopting Industrie 4.0. Even it is helpful from smaller companies where plant manager/ owner is able to track the production and maintenance data on single click over his smartphone or PC. How is your company adapting the upcoming technologies? Since its inception in 1984, Grind Master has continuously kept innovating according to need of industry. Grind Master entered in Robotic Automation for Fettling, Grinding, Deburring and Machining applications. We stand apart from rest of the Robotic system integrators due to our machine tools manufacturing experience, process know how and Engineering

July 2016

capabilities. Today Grind Master manufactures over 50 products ranges including manual, semiautomatic as well as CNC machines along with Robotic Automation. Grind Master gives specialised solutions for NANOFINISH, Metal Finish, Deburr and Robotic Automation. Over the period, we have indigenously developed our own control system NANOFINISH specifically meant for Metal Finishing Machines. Now we are replacing it with Industrie 4.0 compliant control system â&#x20AC;&#x201C; NANOSmart. NANOSmart control system has lot of advanced features for users for remote monitoring and operating the machine. How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled? The major concern in our academics is lack of hands on experience on machines. We find most of the Engineering students shy away from

working on machines while they put more emphasis on soft skills. Grind Master has taken up the task to contribute to Skill India initiative by arranging Metal Finishing Training for Engineering Institutes. We have also specifically prepared the Metal Finishing as well as Robotic Machining Centre package for engineering colleges which will help students to understand various aspects of metal finish, robotics. I think it is industry has to come forward and extend the hand to help the educational institutes improve skills of future engineers. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? Manufacturing in India needs to leapfrog technologies in order to â&#x20AC;&#x153;MAKE IN INDIAâ&#x20AC;?. Technologies are moving very fast. Paradigms are shifting very fast. Highly Innovative companies from IT background are entering

into Product Design and Manufacturing space. This is very heartening and will bring in a much needed Innovation culture and ideas that will drive advancements. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? The challenges SMEs face in implementing these technologies? The major issue with most of the SMEs is that they are not able to organise the work and responsibilities in neat manner. Unorganised planning and supply chain management eventually results in delayed deliveries with substandard quality. To deliver world class product, it is essential to follow right process flow. It we stick to the process, it is very well possible for Indian Manufacturing sector to grow multifold How much the Government of India is helping the

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Indian SMEs to work in a progressive and competitive environment? Government of India is proactively promoting manufacturing sector. Many incentives and subsidies schemes like CLSS, CGTMSE are offered for SMEs and Startups are launched. EEPC is actively participating and promoting SMEs to participate in Engineering Shows worldwide. Offset clause will play vital role in bringing manufacturing of defence and aerospace sectors in India. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? Over 60% of turnover of

Grind Master comes from Exports and we stands as maximum exporter of Machine Tools from India as per IMTMA. With our experience with Global companies, I can say that rather than going for delivering cost competitive products, we should go with ‘Quality First’ approach. We have cheap resources available; if we improve on front of better workmanship and do detailed inspection we can definitely deliver world class products with competitive pricing. Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? Manufacturing sector is not yet ready for IoT or Big Data. This is why leapfrogging of technologies is required.

Traditionally organized manufacturing units have a real challenge to transform working cultures and philosophy to adopt this VUCA world. This is where new age startups with a highly innovative culture can challenge established players. What are your views / comments with regard to Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness? Make in India has had a very positive branding impact. This impact needs to be backed up with delivery of Infrastructure and solution to Ease of Doing Business related issues. Considering the speed with which actions have been taken in the above respects I believe the results of Make in India will be clearly visible on the ground

in the next 3-4 years. In order to help Indian manufacturing leapfrog into competitiveness the government needs to take more efforts in spurring Innovation. Please give a brief about your industry, services and offerings? Grind Master is a pioneer & leader in special purpose machines for Metal Finishing, Deburring, NanoFinish and solutions including Robotic automation and Abrasives. We provide total solutions for surface finishing requirements With over 4000 machines across 6 continents, serving a wide range of industries, we bring a world of experience of over 30 years in machine technology and process knowledge.

Grind Master gives specialised solutions for NANOFINISH, Metal Finish, Deburr and Robotic Automation.

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July 2016

EXHIBITION & CONFERENCE – ALUMINIUM DIE CASTING 1 - 3 DECEMBER 2016 | BIEC, BENGALURU, INDIA www.alucast2016.com

For more information & space booking, please contact: NürnbergMesse India Pvt. Ltd.

Aluminium Casters' Association of India

Ms. Rucheeka Chhugani

Ms. Veena Upadhye

Tel +91 11 4716 8828

Tel + 91 20 2729 0014

rucheeka.chhugani@nm-india.com

alucastindia@gmail.com

July 2016

Organizer:

Event Producer:

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ElectroMech Cranes for Valmontâ&#x20AC;&#x2122;s Long Poles Handling Needs ElectroMech cranes for the Valmont plant in Maharastra offers optimum support to the linear material handling lines from raw material entry point to dispatch bay. Installation of these ingeniously designed cranes for different applications at different bays ensures safety, sooth material flow and resulted in a tremendous amount of saving in labour, time and enhanced productivity at Valmont.

Valmont is a world-renowned company that manufactures street lighting poles, traffic signal poles, utility poles, communication poles and poles to light up large sports complexes and stadiums, with manufacturing locations spread around the world. In India, Valmont has a large manufacturing plant at Indapur Maharashtra.

the entrance of the fabrication shed/bay. This necessitated lifting and then rotating of poles by 90 degrees. Conventional cranes pose a limitation in rotating the poles automatically and placing them precisely on the conveyors. This made the handling requirement from the EOT crane in this area most challenging.

The handling challenges at Valmont.

Solutions from ElectroMech

Valmont needed cranes to integrate handling right from the entry of raw material to the final stage of processing and despatch. At the beginning of the manufacturing process, in the steel yard the pole stacks are required to be lifted and placed onto the conveyors at

At Valmont, ElectroMech installed a total of 22 cranes throughout their manufacturing plant at several locations performing different applications. These cranes are being used at various stages in manufacturing, right from the unloading and carriage of steel poles from the steel yard to

placing the poles on the conveyor for fabrication followed by a galvanisation process and then to the final despatch yard. The cranes used in the main manufacturing bays are of standard configurations and are used for performing rigorous applications. There are cranes installed in 5 different bays at Valmont which include the steel yard, fabrication bays, stores, galvanising bay and despatch area. 20 cranes are installed in the indoor area while two cranes are operated in the outdoor which consist of one 10/10MT single girder crane at the despatch area while the other 10/10MT double girder crane with a rotating crab between the steel yard and the

fabrication bays. The fabrication shed consists of a combination of 13 cranes of different types and capacities altogether, ranging from 5/5MT to 8/8MT with the span of 17.6m to 23.46m of double girder and jib cranes. One single girder crane of 5MT capacity with a span of 10.5m is operated in the stores area, while six double girder cranes of 16MT capacity with 24m span are installed in the galvanising plant, where the steel poles undergo Seven Tank Galvanising process. ElectroMech designs a special crane for Valmontâ&#x20AC;&#x2122;s distinctive application The engineering team at

The plant is designed to facilitate a linear flow of material right from the entry of the raw material to the finished product at the despatch bay.

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July 2016

ElectroMech analysed the conditions and designed an innovative and cost-effective material handling equipment for the steel yard. Using a conventional EOT crane was ruled out because rotating the poles would have been a very cumbersome process, involving manual intervention to do the job. Considering this aspect, ElectroMech’s engineers designed a special crane with a rotating crab. This innovative design permitted extreme flexibility and ease of work. This one of its kind rotating crab is capable of rotating the object by 360 degrees in clockwise or anticlockwise motion. The special design consists of two hoists of 10MT capacity each, mounted on a rotating crab of a double girder crane. The span of the crane is 17.6m and the height of lift is 7.6m. It can lift a load up to 20MT. The steel poles from the steel yard are lifted using this special purpose crane, turned by 90 degrees to bring them in line with the conveyor in the fabrication bay and then carefully placed on the conveyor. Here, the steel poles are bifurcated into large poles and small poles according to their diameter sizes and then transferred to the respective fabrication bays. This indigenously designed system resulted in a tremendous amount of saving in labour, time and enhanced productivity at Valmont. Challenges • Integration of handling in the entire plant • Rotation of 15m to 18m long poles through 90 degrees for placing onto the fabrication conveyors • Ensure safety while handling long poles • Achieve economy through optimum design of cranes

material flow • Specially designed rotating crab allows rotation of poles through 360 degrees • Cranes which ensure high levels of safety • Reduced project cost and time due to indigenous development Other similar applications of Rotating Crab • Cranes of similar design with

newer concepts are being used at a leading steel plant. There, the slewing bearings and slewing wheels are used to achieve rotation of the crab. • The application can be extended to various industries handling a wide spectrum of products such as TMT bars, billets, pipes, etc. • A similar concept is used in Stacker Cranes designed and developed by ElectroMech. A

Stacker Crane is a combination of a Reach Truck and an EOT crane used in warehouses. How Valmont benefitted from ElectroMech solution • Swift, precise and easy placements onto the conveyors • High level of safety is ensured • Reduced project cost due to indigenous solution

Connect

Protocols. Devices. Locations.

IIoT Advantage: Protocol Conversion for Extended Lifespan Red Lion’s Graphite® HMIs and Data Station Plus data acquisition devices seamlessly connect disparate equipment across multi-vendor environments to extend equipment lifespan. • Enable communication between 300+ industrial protocols • Support a variety of physical interface media from serial to Ethernet and USB • Use powerful Crimson® 3.0 software for easy point-and-click programming Learn more today at www.redlion.net/ProtocolConversion

Solutions • Recommended use of 22 cranes while taking into consideration the Connect. Monitor. Control. I www.redlion.net

July 2016

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Automation, Waste Reduction & Energy Efficiency Dominating Technological Trends in Manufacturing

Utsav Doshi Technical Director, Rajoo Engineers

Starting as a small entity in 1986 in the small town of Manavadar in Gujarat, Rajoo Engineers has grown into one of the leading company in plastic extrusion machinery segment with footprints both in India and overseas. Run with a motto, ‘Excellence in Extrusion’ the company offers solutions for widest range in blown film lines, sheet lines and thermoformers. In conversation with Utsav Doshi, Technical Director, he shares his views on the latest technologies entering overall manufacturing industry as well as extrusion industry in particular. Utsav joined Rajoo Engineers in 2011 as Engineer – Vender Development and is currently an integral part of the senior management and responsible for entire manufacturing activity at REL. He holds a Bachelor’s Degree in Mechanical Engineering with a Masters in Polymer technology from HTW Aalen University, Germany.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? While it is true that manufacturing has grown exponentially, the fact also remains that a slowdown has been experienced in the last couple of quarters. The latest technologies that will continue to dominate manufacturing are – automation, waste reduction

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and energy optimisation. Compared to the technological trends in manufacturing across the globe, how Indian companies are catching with this? Indian companies are forging ahead and investing in such technologies with great vigour. Indian companies are imbibing advanced technologies either through technical collaborations or

joint ventures. Further, Indian companies are focusing on exports to be able to get an exposure to the global competition which in turn is also pushing technology development. How is your company adapting the upcoming technologies? We are one of the leaders in our industry segment. And as I mentioned, the Indian companies are fast catching

up with their global counterparts, and our company is also following the trend. How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled? It is indeed an irony, while engineers continue to be churned out by

July 2016

With no regional bounds, the company is a market leader in blown film lines, sheet lines and thermoformers in the Indian sub-continentIs in a position of leadership amongst Asian manufacturers of similar equipment.

While installations are spread across 60 countries, installations in Germany, Spain and U.K stand out as acceptance by the most stringent and developed markets of the world.

the education factories, most of the engineers are unemployable. Engineers from reputed institutes are either veering away from engineering and embracing management or opting for lucrative services sector, away from manufacturing. This dichotomy needs to be addressed seriously, firstly by bridging the gap between what the industry needs in terms of skillset and education and the education that is imparted. Formal platforms needs be created to bring the academia and industry on board to identify the skill gaps and impart education which is relevant and contemporary. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? As I mentioned automation, waste reduction and energy optimisation are the prime focus for industries across segments. In the globally competitive market, every industry focuses

July 2016

on these three areas for efficiency in cost, process and output. So, technologies related to these three areas are the dominant paradigms for adopting in the manufacturing industry. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? The challenges SMEs face in implementing these technologies? Yes, SMEs in India need to wake up and get global exposure on how to do business where a gap continues. After-sales-service, promptness in responding are some of them. SMEs are also facing a crunch in terms of relevant skilled manpower to implement contemporary technologies which is indeed a challenge. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment?

A lot yet needs to be done by the GOI to help and support SMEs. Several initiatives have been launched – Make in India, Skill Development and the recent Capital Goods policy. However, SMEs need further handholding in terms of Technology Upgradation Funds, Export Promotion support and Cluster Development approach. Do you think the new age startups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? Yes, we think they are equipped but they need a lot of handholding and support. What are your views / comments with regard to Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness? In principle, it is a step in the right direction to increase India’s share in global manufacturing but its effects still needs to percolate to the industry in

real terms. In addition to the Central Government adapting it, the State Governments also need to fall in line, irrespective of political affiliations. GST is a long pending reform which needs to be pushed. Please give a brief about your industry, services and offerings? Rajoo Engineers is in the business of designing and manufacturing plastic processing machines. With no regional bounds, the company is a market leader in blown film lines, sheet lines and thermoformers in the Indian sub-continent with a position of leadership amongst Asian manufacturers of similar equipment. A sought-after name in global markets – exports accounting for over 50% of sales is indicative. While installations are spread across 60 countries, installations in Germany, Spain and U.K stand out as acceptance by the most stringent and developed markets of the world.

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New Plastic Strain Wave Gearing enables low priced 6-axis Robot igus expands the robolink modular kit for industrial low-cost automation Simple, modular, light and cost-effective â&#x20AC;&#x201C; that is robolink. igus has expanded this modular kit of plastic components for low-cost robotics and displays many new products at the Hannover Messe: from a new gearbox design and a complete robot arm up to a simple robolink online configurator. Therefore robot manufacturers can build inexpensive robots and users are able to automate simple tasks.

Santosh Jacob santhosh@igus.in

The robolink D modular kit

robotic systems. The

sizes. Now igus has further

This gives the ability to

from the motion plastics

separate joints, which are

expanded its range and

combine motors and joints

specialist igus offers users

driven by a motor directly

presents at Hannover more

in several sizes with the

the ability to assemble

on the axis, are available

components that offer still

standard controls to make

cost-effective custom

in various installation

more scope for design.

a complete 6-axis low-cost

With the new plastic strain wave gearing, a complete robot arm having six axes can be assembled at a very low price â&#x20AC;&#x201C; from 243 euros for a robolink joint without motor. (Source: igus GmbH)

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July 2016

robot made of plastic and

with strain wave gearing.

aluminium. In Hall 17 igus

The worm wheels for

exemplarily displayed

the new transmission

an application that can

ratios 1:30 and 1:70 of the

move up to 3 kg load, with

robolink D worm gear also

Beckhoff control.

utilise iglidur materials.

New strain wave gearing for lighter arms

For these, igus now also offers a decoupled option of motor and joint. The

A special feature is the

two components are

new robolink strain wave

connected to each other

gearing, which can be,

by an aluminium profile

for example, very easy

– the result is a better

to use as the sixth axis of

weight distribution on the

the robot arm, that is, as a

axis, whereby more load

radial connection between

can be lifted. The new

arm and gripper. It is very

universal gripper adapter

lightweight and efficient

allows the attachment

and is offered by igus in

of different grippers on

two installaiton sizes as

the robolink D joints. The

a single component, or

robolink D modular kit is

with a Nema17 or NEMA23

rounded off with a new

stepper motor. “The

online configurator, by

strain wave gearing has

which users can assemble

the advantage that it has

their robolink D joints

minimal backlash and

from the start of the

thus ensures a precise

Hannover Messe and thus

adjustment with incredible

can configure their low

smoothness,” explains

priced robotic arms.

Martin Raak, robolink product manager at igus.

From € 243 per axis

“It is very compact and

The system is modular and

has a high transmission

therefore cost effective

ratio.” The gearbox

through the use of iglidur

consists of an outer ring

plastics. A robolink joint

gear and a flexible wear-

without a motor is already

resistant inner ring gear

available from Euro 243,

made of iglidur high-

when ordering one piece.

performance plastic.

Motors, encoders, cablings

Quick and easy to configure with new online tool

and other accessories are available as options. igus also supplies mounted arms; all gears are offered

In Hannover, igus displays

to robot manufacturers in

a complete 6-axis arm

series production.

July 2016

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Adopting New Technology Inevitable for Global Footprint

Avinash Chabukswar

Director, C-Tech Engineers Pvt. Ltd.

In an illustrious career, spanning three decades, Avinash Chabukswar, served Merchant Navy and Shipping Corporation of India, worked for private technology players and headed many projects. With years of experience in the engineering and machining, he established C-Tech Engineers Pvt. Ltd. with Mr. Satish Mutha and Bhaskar Kulkarni in Pune in 2001 and continues working as a Director. He studied BE Mech from COEP Pune in 1976. Talking to MART, he says why he feels Indian SMEs should be more aggressive for global business, Indian universities should be pro-active for better collaboration between engineering colleges and industry, structural issues should be obviated to render â&#x20AC;&#x2DC;Make in Indiaâ&#x20AC;&#x2122; successful.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? No doubt it is growing. Mainly, I feel there should be a change in attitude. As more and more new companies are entering Indian market, we should be ready to take them by: 1) Adoption to new technology. 2) Best IT practices to remain

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connected 3) Training people for taking all these things to increase accountability and responsiveness. 4) Re engineering core process to increase efficiency. 5) Defining product mix policy to develop export market. What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this?

In mass production Robotics will play an important role. Indian companies are in double mindedness with huge investment associated with adoption of new technology like this and the proposed RoI for that on one hand and the need to keep abreast with advanced technology adoption to remain in competitive market on the other. People are bit cautious about all this. There is lot of hope, but

still results are having few question marks. How is your company adapting the upcoming technologies? Mainly, we look for replacement of old machines with new technologically advanced machines, developing machines with more speed and accuracy to serve good customers, training people to adjust

July 2016

Present turnover of the company comes from 30% domestic and 70% export sales.

with that. So, we are in sync with the latest trends in technology.

this and people from different industries should be called and interaction should be made.

How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled, if there are any?

Also one visit to be made compulsory to one industry and students should be asked to submit report on it.

I feel there is a very poor understanding among fresh graduates if you consider most engineering colleges. A handful of colleges are exemption to this and students of those colleges are also far ahead. Industry/Academics collaboration should be very strong and there should be proper guidelines from universities so that staff will take active interest. Many staff members are seen to be interested in such collaboration but when I talk to them they express that they are not given enough time and scope to do this. I feel there should be a weekly 2/3 hours to be allotted to students in their curriculum for

July 2016

What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? 1) One should adopt to change in technology as a must and make preparation to it 2) Train of own people to adopt this. 3) Attend international exhibitions to understand global trends. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver globally competent products? What are the challenges that SMEs face in implementing these technologies? Indeed, Indian SMEs are

most prominent part of manufacturing. According to me, it is the biggest R&D centre as everyday people are doing R&D for reduction in cost without hampering quality. This is the only reason people are surviving in tough competition. Major challenges are structural. They should overcome these challenges by: 1) Changing self attitude and people working with them 2) Investing funds to this without any doubt. 3) Not thinking of short term gains. No doubt this is going to affect their profit margin initially. How much is the Government of India helping the Indian SMEs to work in a progressive and competitive environment? Indian government is trying to help by giving various incentives but one has to ascertain that whether it is reaching to the bottom level

and, if yes, at what cost, which is my concern. All schemes are designed by very intelligent people after giving all thoughts about constraints faced by SMEs .Our problem is at implementation level. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? Majority of SMEs, in spite having expertise, are afraid of doing global business after thinking of risk factors. And unless this fear is gone they cannot do global business. All customers, domestic and overseas, are same. On the contrary overseas OEM companies are more careful about not doing any default as it can spoil their all international business. One complaint against them

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can be flashed all over the world and their credibility can be at stake. They will not get good supplier globally. So, only thing is one has to be very stringent about quality. Poor quality can throw them out of business. There is no challenge to poor quality in any court of law. Otherwise all things are same for them in domestic and export business. Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? I am not an expert in this field but it will be a great challenge to IT companies

and service industry, surfaced during these two years.

There will be huge challenges in terms of investment, infra structure, labour laws in India, skilled manpower, R&D expenditure, raising our standards to match with global standard etc.

What are your views/ comments with regard to Mr. Modi’s campaign of ‘Make in India’? Do you have any suggestions to increase its effectiveness? As far as Mr. Modi’s ‘Make in India’ campaign is concerned, I feel it is the biggest concentrated decision made by India in the last 69 years after independence. It is well planned at all levels. It has started with a bang and will continue. Now the biggest test is how it is implemented by government authority so that people who are coming to India are comfortable with it.

Any shortcomings in this can make these projects uneconomical. So, change in attitude at government level is also a key factor for success of this. There should be minimum political disturbance. Unless all these factors are controlled its potential will get diluted. Please give a brief about your industry, services and offerings? C-Tech Engineers Pvt. Ltd.

is a manufacturer and exporter of precision machined components and parts of excavator. The company was established in 2001 by technocrats with two customers with 10 lacs turnover for export only. Currently, the company has grown with export to 15 countries with 14 crore turnover. Present turnover of the company comes from 30% domestic and 70% export sales. We have good machining expertise with state of the art machinery for turned, milled and ground components. C-Tech Engineers Pvt. Ltd. has received consecutive 8 export awards from Engineering Export Promotion Council as a “Star Performer in “small scale category”.

Hard Bush

Hard Pins

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July 2016

CNC Machine Tools

ITL Industries Ltd.

SEC

Hurry ! Book Your Space NOW

SUNITA ENGINEERING CORPORATION

[ Diamond Participants ]

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CNC Machine Tools

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July 2016

[ Jointly Organised By ]

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Dormerâ&#x20AC;&#x2122;s PFX Range for Deep-hole Drilling Needs Dormerâ&#x20AC;&#x2122;s PFX range offers the versatility and productivity to meet most deep-hole drilling needs. Providing a cost-effective option for a wide range of applications, all PFX drills are manufactured from high speed cobalt steel and suitable for use in a variety of materials for drilling depths from3xD to 25xD.

This includes 3xD stub (A920, A921), 6xD jobber (A900, A901), 10xD long series (A940, A941) and 15xD to 25xD extra length (A976, A977, A978). All feature a straight shank and parabolic flute design for increased chip space and improved evacuation. This design allows greater hole-depths to be achieved in

some cases without the need for pecking.

the cycle time of the application.

A thick web increases the structural strength of the drill for greater rigidity and minimizes the risk of tool breakage. In addition, a special point geometry provides additional benefits including excellent centering - eliminating the requirement for a pilot hole and reducing

Also, it reduces thrust force and power requirements, ensuring accuracy is maintained throughout the depth of the hole. Available in bright finish across the full range, a smooth-low coating option is available on stub, jobber and long series drills. This AlCrN-

top coating reduces friction; increases wear resistance and in combination with the parabolic flute, eliminates chip packing at greater depths. To find out more about the Dormer PFX range or watch the A940 in action visit www.dormerpramet.com or contact your local Dormer Pramet sales office.

Dormer PFX drills come in wide range for most precision drilling in various applications

The design with straight shank and parabolic flute shank and ensures less friction and high accuracy in deep drilling needs

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July 2016

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Conducive Atmosphere created by the Government for the Growth of SMEs Vivek Nanivadekar Executive Director, FIBRO India

In conversation with MART, Vivek Nanivadekar, Executive Director, FIBRO India Precision Products Pvt. Ltd., considers infrastructure, investment and smooth licensing as important as adoption to new manufacturing technology for global competitiveness and commends Governmentâ&#x20AC;&#x2122;s initiative for the growth of SMEs. Vivek Nanivadekar is Mechanical engineer with the Business Management Diploma having more than 30 years experience in Machine Tool industry for Die & Mould sector. He headed he international marketing for more than 10 years and took over as the Executive Director of FIBO india since April 2013.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? I believe Aerospace engineering, Die & Mould, Railways, Robotics & Automation are some of the sectors which are growing rapidly in India. What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this? The upcoming technological trend in manufacturing in developed countries probably is â&#x20AC;&#x2DC;New composite materialâ&#x20AC;&#x2122; replacing the steel to reduce the weight of the components

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without scarifying the strength of the steel. This would change the entire manufacturing concept. But India is far away from such new technology as globally it is just a beginning of this new technology.

education system particularly in engineering. There is a wide gap between what is taught in university and what is practised in the industry. They learn practically hands on when they join the industry.

How is your company adapting the upcoming technologies?

Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? What are the challenges SMEs face in implementing these technologies?

As of now, we are in a process of indigenising those components / parts which have large demand globally including India so as to be competitive. How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled, if here are any? We need to change the entire

The new manufacturing technologies do not replace entirely the traditional manufacturing technologies. We still need the traditional technologies and most of

the Indian SMEs fall in to this category. They can still deliver the products globally competitive. Many of these SMEs manufacture the intermediary products to the OEMs and the final finishing is done by the OEMs. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? The manufacturing technology is not the only element to be competitive. There are many other aspects such as the cost of finance, availability of raw material, infrastructure etc. I do believe the government has recognised these facts and trying to create conducive atmosphere for SMEs. Of course, it is a long

July 2016

Source: Company website Aerospace engineering, Die & Mould, Railways, Robotics & Automation are some of the sectors which are growing rapidly in India.

term plan and cannot be done overnight. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? The license and inspector raj was the main hurdle for the growth of SMEs. But the government has made certain changes to remove this hurdle to the great extent and I am sure it will

continue to do so. Do you think the new age startups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? As of now they are not well equipped but it will happen in next couple of years as the direction has been set. As I understand, these technologies are at primitive stage in the developed markets as well.

What are your views / comments with regard to Mr. Modiâ&#x20AC;&#x2122;s campaign of Make in India? Do you have any suggestions to increase its effectiveness? This is the first time that Indian government is aggressively asking the world to come and make in India. The response has been also very good as India received the largest FDI than any other country in the last financial year. So, I look at

it very positively. Please give a brief about your industry, services and offerings? FIBRO India is the 100% subsidiary of FIBRO GmbH. FIBRO is the pioneers in standard parts for Die & Mould and Rotary/ Indexing tables since 1960 in the Europe. FIBRO India is the only manufacturing set up out of Europe having marketing subsidiaries all over the world.

India received the largest FDI than any other country in the last financial year.

Standard Parts for Die & Mould

July 2016

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New Schmalz Bag Suction Cup for High Speed Packaging Processes

The vacuum specialist Schmalz has developed a new series of SPOB1f-type oval tubular bag suction cups especially for flow-wrap packaging processes. With up to 600 parts processed per minute, flow-wrapping is an extremely dynamic application – which involves special requirements for the handling of workpieces.

The bag suction cup from Schmalz is used in flow-wrap processes in tubular bag packaging. “Flow wrapping” refers to a process in which products are packed into a thin film on the packaging machine. The new SPOB1f allows the operator to further package the products in cardboard boxes with maximum reliability directly

after the flow wrapping stage. It comes equipped with a thin and flexible sealing lip. That allows it to handle the film-packaged products with special care – even when there is damp or frost on the surface. Thanks to the FDAcompliant silicon material, the suction cup can also be used when there is direct contact with food products. It is

therefore especially suitable for use on small and mediumsize narrow products like ice creams and chocolate and muesli bars in the consumer goods sector. The 1.5 bellows suction cup is available in three different sizes: with dimensions of 35 x 15 mm, 60 x 25 mm and 80 x 35 mm. The suction cup has

impressively high rigidity. It is currently the only oval bag suction cup on the market for tubular bag packaging. The SPOB1f features an extremely high holding force: The force is between 30 and 50 percent higher than the holding force of two round suction cups. It is designed with an antirotation connection element for especially high stability

SPOB1f is especially suitable for use on small and mediumsize narrow products like ice creams and chocolate and muesli bars in the consumer goods sector.

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July 2016

for manufacturers of casepacking plants. The company

The new oval tubular bag suction cups from Schmalz feature an extremely high holding force.

and positioning accuracy. The SPOB1f is recommended for all operators that

July 2016

manufacture and handle small and narrow filmpackaged goods, for delta robot system integrators and

Schmalz is the worldwide leading provider of automation, handling and clamping systems, providing customers in numerous industries with innovative, efficient solutions based on vacuum technology. Schmalz products are used in a wide variety of production processes â&#x20AC;&#x201C; for example, as grippers on robot arms in the production of car bodies, in CNC machining centers as clamping solutions for furniture pieces, or used by an operator to lift items

ranging from boxes to solar modules. Schmalz customers can either choose from a diverse line of components or they can benefit from a complete solution that is custom-tailored to their requirements. Schmalz is dedicated to its customers, providing groundbreaking innovation, exceptional quality and comprehensive consultancy. The company is headquartered in Glatten (Black Forest region of Germany) and is active in 16 additional countries with their own subsidiaries. Schmalz employs a total of more than 1.000 persons worldwide.

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Manufacturers Upbeat on Sophisticated Interlinking of Whole Process with Advanced Technologies

Andreas Zieger Managing Director, EMAG India

With decades of experience in machining, gear cutting, laser welding, electro-chemical machining and induction hardening EMAG offers cutting-edge manufacturing solutions for a multitude of applications in the aerospace, automotive, off-highway and energy sectors. Andreas Zieger, Managing Director, EMAG India, shares insights, while talking to MART, on how India is fast becoming a preferred technology development partner for the global automobile industry, how manufacturers are focusing on reducing ideal production times by smart interlinking of processes and why dual training by institute and industry, which is at the end of the value system right now, should be the priority. Mr. Zieger obtained technical commercial education. He has spent 12 years in India prior to taking up the role of CEO of EMAG since 2014.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? If I consider our EMAG products and technologies, I see an increased interest of the customer in

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upgrading the used common technologies. Earlier, I saw more raw part manufacturing like casting or forging and in my content demand on turning machines and grinding was common. But now on the way to create more business, I see the Indian industry targeting

on finished products or assemblies and here our more advanced technologies like induction hardening, laser welding or even electro chemical machining are added and integrated in lines. What are the upcoming technological trends in

manufacturing across the globe? How are Indian companies catching with this? India is playing more and more on the international level as recognised supplier in the automotive circus, even as a lead supplier and

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India is playing more and more on the international level as recognized supplier in the automotive circus, even as a lead supplier and by that, responsible partner to execute technology development.

by that, responsible partner to execute technology development. To achieve that, we work as machine tool partner with the wide technology portfolio in close cooperation with the manufacturers. Trends we see are beside the need to have flexible solutions because the life time of parts is changing fast nowadays also an increasing centralisation and by that clear automated mass production, but most important is that the parts become smaller, harder and more sophisticated with the clear demand to have high end machines to serve that direction. Finally, we see in the daily search for price reduction in the cost per piece the trend to replace old technologies and add more exotic technologies or the fight to reduce the ideal times by sophisticated interlinking of the whole process. How is your company adapting the upcoming technologies?

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We provide a wide range of machine tool technologies and our future development is to interlink them and integrate these technologies to our standard machine concept. Thus all our machines consist of a base machine concept with a mineralite column to have optimal stability and damping features for best tool life. Each machine has an integrated automation, which allows an easy linkage and if you use that concept you can create process lines with turning, grinding, hobing, induction hardening, laser and so on and all its variations. Take for instance a balancing shaft for a gear in a truck and here we have smaller batches and lot of variances. Using a shaft line and various gear line and finally use a heat shrink machine to build all the variances can help to managed to have a mass production and lot of varieties.

How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps between institutional training and practical required skill can be filled? Yes, that is still a challenge we face. From operator up to maintenance these increased technologies need to be handled. And I still see that many simple machines are the preferred choice instead of a single high end machine even if the total economic consideration is better for the high end machine. A short solution I do not have either, I see here that the education system has to put focus on practical experience, a dual training between school and industry is a topic I see often on the political agenda and at the end the value system in the society. India needs high recognized skilled workers and not only managers and that recognition has to go down till to the marriage

market. I have that lucky situation that our team is many years with us and experience is what counts. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? Often I see that money and quality is delinked because, at the end, technology has its price. Everyone knows that phenomena out of his private life, if an electrician for your home is coming with an old screwdriver it is not possible to get world class service, same with machine tools. On the other side we need to get access and more information about new technology to all levels of operation from management till to the operator level. Thus everyone can contribute to the improvements and development of new processes. Indian SMEs are the most prominent part of

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manufacturing. Are they ready with the latest technologies to deliver global competent products? What are the challenges SMEs face in implementing these technologies? I still see a gap between the average SME and the international players in India. Beside the technology, the documentation, connection and understanding of the international rules are minimizing the access to that sector. On the other side I see SME with visionary, fast decision processes and at the end, money is sometimes only one factor project. How much is the Government of India helping the Indian SMEs to work in a progressive and competitive environment? I hear a lot of handy slogans at the moment which for sure will boost the confidence, but carries a danger of

nationalism. I think a smart use of local and international possibilities is good base for a good progress. Some of the initiatives like start up support or SME support will help and I hope not only the IT sector. A more simple tax system and company act necessary to ease is for me not yet that visible. I still spend too much of my time in that support function of the operation. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? I see some very successful international operating Indian companies that shows success is possible. And while discussing with them, I hear that the mentioned topic, like education system, administrative effort, labour and tax issues could be streamlined or simplified.

Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? I see a lot of activities of the startups in e-commerce, app development for the consumer, not too much in the industry or manufacturing segment. But for sure at the moment the IT and the production are coming closer and partly merge, and that could be the chance for the young IT people. What is clearly visible is the different value system, structure and work spirit in that sector, which is modern and creates an optimistic dynamic. What are your views / comments with regard to Mr. Modiâ&#x20AC;&#x2122;s campaign of Make in India? Do you have any suggestions to increase its effectiveness? I appreciate Mr. Modiâ&#x20AC;&#x2122;s plan, India needs a

stronger industry and more industrialized agricultural sector plus a push in the infrastructure. The focus is clear but, now we need to deliver at ground level and that together each on its place. Please give a brief about your industry, services and offerings? Finally everyone has to think how he can contribute to the development of India. I, for my side, want to create a self-responsible, open and less hierarchical work environment, where each individual is valued equal and ideas from all parts of organisation are appreciated. Furthermore a responsibility for the whole country and the environment and the limited resources or topics of importance and finally with our products we hope to increase the power of Indian manufacturing industry.

Smart use of local and international possibilities is good base for a good progress.

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Magnesia Drywalls for a Greener India An emerging technology for construction material engineering Given the thrust in housing development both for residential and official purposes in the country, adoption of emerging trend in civil engineering is a necessity today. Magnesia drywall is one such technology which is light weight, fire and water resistant, abuse proof and fixtures compliant. Most importantly, being minimalist in energy consumption and recyclable right from its manufacturing to installation process, it is the environment friendly technology. Anutone Acoustics Limited, has been pioneering the manufacturing of drywall technology with setting up the first manufacturing plant in India for magnesia drywall at Malur, Karnataka.

Sandeep Mittal sandeep@anutone.com

Traditionally in India partition walls for buildings are constructed with brick masonry. This is time consuming and labour intensive apart from rendering a building very heavy. More importantly it consumes water and sand, both of which are scarce natural resources. The answer is drywalls for internal partitions of buildings but this has been adopted mainly in major cities for commercial high rises due to limitations of gypsum plasterboard that dominate the industry. Non-adoption of paper-lined gypsum drywalls in residential high-rises and other construction is due to susceptibility to water damage, fragile to pedestrian abuse and inability to uphold heavy objects like televisions and airconditioners. This is where magnesia

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drywalls come in and can replace brick masonry at a faster pace in constructions that have hitherto shied away. Magnesia drywalls consist of monolithic boards and hence no limitations associated with paper exist. Their resistance to fire, water and abuse is much higher as is their ability to hold heavy wall fixtures. Hence they can get into wet areas like kitchens and toilets, high security areas like data centres, pedestrian-abuse areas like public lobbies and wall-fixture featured-spaces like hotel and hospital rooms. Magnesia drywalls leave no wastage at site as end cuttings and trimmings can be recycled back at the manufacturing plant. Similarly the wastes generated at the plant during the manufacturing process are all recycled. Hence the recycled content in each magnesia board is significantly high and

any wastes are recyclable making it an eminently green product. and hence no limitations associated with paper exist. Their resistance to fire, water and abuse is much higher as is their ability to hold heavy wall fixtures. Hence they can get into wet areas like kitchens and toilets, high security areas like data centres, pedestrian-abuse areas like public lobbies and wall-fixture featured-spaces like hotel and hospital rooms. Magnesia drywalls leave no wastage at site as end cuttings and trimmings can be recycled back at the manufacturing plant. Similarly the wastes generated at the plant during the manufacturing process are all recycled. Hence the recycled content in each magnesia board is significantly high and any wastes are recyclable making it an eminently green product.

Then again it is not only about magnesia drywalls as an end product that is greener for buildings and the environment. Consider this. The manufacture of magnesia boards requires no heat either during the manufacture or curing. This is a major boon to energy-starved India as every other building board requires plenty of external heat either in its manufacture or curing (called autoclaving in industry parlance) or both. Emerging technologies need not be only in the tech sector of robotics or 3D printing or precision engineering or internet of things. Emerging technologies is a way of life to be adopted in every facet of the manufacturing and engineering industry. Construction industry and the building sector are one of the biggest consumers of energy alongside the automotive/ aviation sector. If we can

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Magnesia drywalls leave no wastage at site as end cuttings and trimmings can be recycled back at the manufacturing plant

Bengaluru Metro Rail Corp Ltd Bengaluru

lower the embedded energy of a building when it ready for occupancy and the consumed energy during its use, then a major battle in the war against global warming is won. Here is a product and a system that is energy minimalist right from the manufacturing stage to its installation in buildings that makes it highly environment friendly. The raw materials are indigenous and proximally available with finished products delivered to sites across the nation. Wherefore is the need to import building boards and spend carbon credits in their transportation across the seas? Should we export raw materials and import the finished products as we did for iron-ore and steel sheets? Or shall we harness emerging technologies for the engineering superiority of Indian industry for the benefit of domestic consumption if not international markets. Time we made India proud and pitchfork it as the factory to the world. If software has got the world to sit up and notice India then hardware will place us at the

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comity of nations.

jointing methodologies.

China has an estimated 300 units that manufacture magnesia boards and export across the world whereas India with rich magnesia deposits at Salem, Tamil Nadu had none till Anutone established Indiaâ&#x20AC;&#x2122;s first such plant at Malur outside Bengaluru in neighbouring Karnataka in 2014. Only countries that are blessed with rich deposits of magnesia can afford to boast a plant and include Russia, Nigeria, Turkey etc. Why does China alone have to be the factory to the world and not India too?

Since 2014 Anutone has taken the first steps to supply Tufbloc magnesia boards to a number of projects across India and hence slowly but surely the industry is embracing the concept and giving it a thumbs up for the many inherent advantages. Apart from the features listed above about fire and water resistance, abuse proof and fixtures compliant, one of the biggest advantages is lightweight, fast construction that allows buildings to rise higher and faster, a boon in land scarce India with a growing demand for housing and office space.

Since Anutoneâ&#x20AC;&#x2122;s plant at Malur is Indiaâ&#x20AC;&#x2122;s first, there were teething issues both in setting up of the plant since major equipment had to be imported and also in marketing the concept to the civil industry which is traditionally conservative and hence change resistant. Installation of the product at distant project sites was also an initial issue since the drywall job crews are used to the softer gypsum plasterboard and different

Some of landmark spaces that have benefited with Tufbloc magnesia drywalls from Anutone are Yahoo-Bengaluru, ZohoChennai, IIT-Guwahati, Victoria Biscuits-Kharagpur, CISCE-Noida etc. Given the thrust in housing development both for residential and official purposes in the country, adoption of emerging trend in civil engineering is a necessity today.

Magnesia drywall is one such technology which is light weight, fire and water resistant, abuse proof and fixtures compliant. Most importantly, being minimalist in energy consumption and recyclable right from its manufacturing to installation process, it is the environment friendly technology. Anutone Acoustics Limited, has been pioneering the manufacturing of drywall technology with setting up the first manufacturing plant in India for magnesia drywall at Malur, Karnataka. The author Sandeep Mittal is the Managing Director and Chief Technology Officer at Anutone Acoustics Limited, a drywalls, ceilings, panelling and acoustics company. His mission at Anutone is to transform the internal partition industry by wider and faster adoption of emerging technologies like magnesia drywalls that result in greener buildings with lower carbon footprint for a safer planet that benefit future generations.

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Push for FDI Will Push Local Manufacutrers’s Competitiveness Harish Pant Managing Director, Hampson Industries

Hampson Industries Pvt. Ltd. has built its reputation as a manufacturer of machined components for defence, aerospace and civil avitation. The company plans for more investment into adoption of new technologies to enhance its capabilities in machining medium and complex components and sub assemblies in its segment. While talking to, Mr. Harish Pant, Managing Director, Hampson Industries Pvt. Ltd., opines that manufacturing is set to grow rapidly as the country is slated to become the global manufacturing hub by the year 2020 and the relaxation on FDI norms will push local manufacturers for attaining competitiveness with global OEMs. Mr. Harish Pant, a Mechanical Engineer with multi-faceted global exposure and experience of 30 years across Steel, Automotive, Aerospace and Engineering sectors. Prior to joining Hampson, he worked with HAL, Maruti Udyog Ltd, General Motors and Jindal Group.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? “India is projected to dominate the growth in the working-age population in Asia Pacific by 2050, becoming home to over a billion people eligible to enter the job market, a UN report has said.” India is already slated to become the next manufacturing hub by 2020. However, technology

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upgradation and various other aspects need looking into, if the country has to make a further impact on the global front. This necessitates creation of highest number of jobs in the world by a country. Now the task is set out to become a multi trillion economy and grow across all the secotrs multifolds. Manufacturing has to lead with prodct design led growth for a sizable global market. Stage is being set with the expected FDI inflows of $60 billion in the financial year 2016.

India’s manufacturing sector needs to reach at least 25% of country’s GDP from 16% at present which means about doubling manufacturing in coming five years. The recent announcement by government on allowing 100% FDI in defense for modern technology, civil avaiation, pharma and others will spurt further interest in latest technologies. Global OEMs are expected to establish substantial local manufacturing in India with

high level of technology transfer and capabilities. According to the Global Innovation Index (WIPO, 2014), India ranks 76th among the 143 countries. This necessitates nation wide policy decisions and efforts to establish structures, knowledge, skill sets and processes to leapfrog India to the top 5 innovative countries in the world. Most of the present manufacturing growth is happening due to internal consumption as export growth

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MAHR Form Tester

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Inspection quipment

Profile Projector CMM

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has tapered. Now local companies have to aggressively compete with MNCs due to increasing relxation of FDI norms. All Indian companies are huslting to pursue research and development and adapting technologies which can fast churn out prodcuts from concept to final product through rapid product prototyping. There is a deep interest now in 3D Printing. Extensive usage of Engineering softwares directly connected to machines with Flexible manufacturing is gaining momentum. There is increasing awareness for Machine Learning, Cognitive Automation, Internet of things, Augmented Reality, Virtual Reality and Bots. A hybrid of Frugal Engineering with these emerging

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technologies has potential to make India global competitive. What are the upcoming technological trends in manufacturing across the globe? Developed economies have population which is not growing and aging where as developing economies like India is seeing explosion of working age population, hence both differ in the need and motive for technology evolution. Industry 4.0 heralds the convergence of cloud computing, 3D Printing, Augmented Reality, Big Data Analytics, Robotics, simulation, horizontal and vertical integration, IOT and cyber security. All developed economies are aggressively pursuing Machine Learning and Cognitive

Automation as well.

wide momentum.

Manufacturing will be increasingly supported by various Digital services where only experts intervention will be required, in case as all repetitive jobs get automated.

Indian manufacturing and supply chain had been mired with various bottlenecks and perneial issues of controls and restrcitions. However, as present government is aggressively working towards facilitating business, Indian businesses need to switch gears and start working on excellence in the entirety of manufacturing from Concept to Consumer. Indiaâ&#x20AC;&#x2122;s journey from pockets of technology adoption to every sector of economy will be unprecedented as the present way of manufacturing in the world is non sustainable at global scale.

When it comes to adopting latest technologies, where does India stand compared to its global counterparts? We need to envision global aspirations; identify products and services where we need to lead; carry out research and development and idenfiy capabilities and capacities required. This process will help us in articulating future technolgies required and identify best ways to go about it. We have pockets of technology adoption and now need compelling reasoning; resources and scale for country

How is your company adapting the upcoming technologies? We are building critical and niche capabilities for defence, aerospace and automotive

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sectors primarily in machined components. Our continued investment in the latest machine tools will help us in enhancing capabilities for machining medium and complex parts and sub assemplies. Flexible set up with rapid changeovers will help us to meet varied customer requirements. Integrated NDT and inspection facilities helps in smooth value flow across manufacturing. We are expanding our capabilities in Engineering services to spearhead adaption of new technologies. We will further invest in technologies, hardwares and softwares to provide end to end solution to customer at a price desired. How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? Most of the engineering graduates have more of a theoretical knowledge as

industrial enagaement and project work has remained poorly structured due to lookwarm industrial response. Also, most of the institutes lack latest machine tools and set up to give first hand experience and skills to graduates. There is an increasing realisation by industries that they have to hand hold educational institutes and work together to develop right skills and capabilities in graduate engineers. In addition to technical knowledge, now students also need to collaborate and work on innovations and various projects; embrace diversity and thus need to upgrade their communication, problem-solving skills, attitude, work ethic, critical thinking, resilience, adaptability and creativity at world level. Cross skilling is future mantra for career growth. Defence, design and new product development,

machineries and transportation solutions and infrastrcutre are the new areas with potential for massive growth requiring specialized skills. Investment in Electronic sector with an aim to import to be zero by 2020 offers equally attractive avenues for skill development. National Policy on Electronics envisages investment of $100b and creation of 28 million new jobs and 200 elctronic clusters by 2020. Introdcution of vocational training in the curriculum will be of further help. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? All economies are becoming service oriented where manufacturing has to support a predictive supply chain in the VUCA (Volatile, Uncertain, Complex and Ambiguous)

world to provide a higher value to a specific customer. Now each economic expansion and movement needs to address complex political, global and local factors and answer a lot â&#x20AC;&#x153;New whyâ&#x20AC;&#x2122;sâ&#x20AC;?. Incremental approach has to give way to innovative mind set for multi times growth trajectory. At a very low level of manufacturing set ups with limited capacities, Return on Investment on new technologies, new product development and experimentation with innovation are difficult to justify unless a company thinks to a larger ecosystem for business scale up and develops newer capabilities as being essentials for business growth. Sustainable business in high technology industries like defence and aerospace requires multi agency

Aerospace Cell

Shaft Cell

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commitment including goverments through policy interventions and financial incentives and investments.

and collaboration with business partners, facilitation by government agencies and long term policy support.

Climate change challenges are also driving newer industries to adopt advance technologies for the next billion customers.

Indian SMEs are the most prominent part of manufacturing. How many of them do you think are ready to keep up with the demand? And, what factors pull them down?

Safety and security have higher visibilities and implications for industries in the digital world. Inculcating a culture of innovation and encouraging new ideas, collaborative mind set are essential to step change for massive growth in manufacturing sector. Rapid cycle of delearnign and learning also necessitates flexibility across organization

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Newer products and technologies are reshaping the entire supply chain pyramid. Tiered supply chain will see massive disruptions. These disruptions are likely to open avenues for new start ups in one hand and closures for many inefficient ones. We need global and country

wide data and analyitics as the confluence of various sectors emerge e.g Mobility and understand their impact on SMEs. This convergence necessitates development of new platforms of enagagement. Itâ&#x20AC;&#x2122;s no more simply about better processes and systems. There is also a need to come out of the definition of SME by investment but to have a sector specific insight into what strcutre and investment grouping will help various size of players and where and what support is needed in the economy. How much is the Government of India helping the Indian

SMEs to work in a progressive and competitive environment? Government has a definitive role in policy formaulations and financial interventions. Recently, it has started working on many fronts like labour, skills, stratups and also has come out with varuous initiatives. This task is humnageous and requires huge mind set change at political, economic and industrial levels. Various constituents of the economy like management, commercial and industrial associations have to collaborate with Government to create sector specific think tanks to steer the country and SMEs to the future. We need to structure and align various

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disparate constituents to create a competitive India. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? Mass movement for creation through manufacturing – we have seen success in White revolution of a global scale in India and now it’s time to move with manufacturing. A culture of performance and not entitlement and priveleges will go a long way to divert attention from shoddy managing to chenalising capabilities for excellence – we have in plenty! Attract massive investments in all spheres of manufacturing.

Nation wide data collection and analytics for skill development and other nationwide policy decisions. Facilitate and incentivise all economic activities under organised sectors and discourage unorganised sectors. Government’s role as facilitator rather than controller and regulator. A list can be prepared where Government does not have a business to be in business. Each government servent needs to be accountable for the impact they are being paid for. Help create various platforms and structure for a global scale. Creation of think tanks with policy makers who are responsible to prepare

actionable plans for medium and long terms. Live Start up and SME echo system where there is a play of competition and way to transition to global competitive level. Strcutred planning for FDIs, foreign players and local players and how this mix will pane out in future.

Young generation is very highly adaptive with new technologies applications but we lack depth which will come with experience and usage. How is your company adapting the upcoming technologies into manufacturing?

Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics?

Basics of business excellence has been in our DNA and now we are moving to integrated manufacturing and remain open to adapt various technologies as we take bigger projects requiring high integration of 5M’s and digital connect.

We need to graduate from minimalistic thinking to global level and create an echo system wherein the moment we have players emerging, these can be supported for massive growth.

We are gradually moving to high value engineering and manufacturing in aerospace. We will further integrate flexible cell manufacturing with ERP and measurement system for end to end solutions.

Journal Bearings

Flingers

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Heavy Duty Machining - but safe

The importance of the tool holder is still understated, especially when it comes to roughing and heavy dutymachining. Metal removal rates in these types of processes are absolutely crucial for the productivity of the machining operation. By using special shrink fit chucks with drive pins and spiral grooves in the tool shank it is now possible to performhigh-feed full slotting of up to 2 x D (50 mm) or more indifficult to machine materials. Application studies conducted by the machine tool manufacturer Heller have proven the effect of the HAIMER Safe-Lock™ system.

Especially within the aerospace, energy and mechanical engineering sector, production managers have to bridge the gap between economic efficiency and high process reliability when working with materials that are difficult to machine. Fortunately there is peace of mind in knowing that the machine technology innovations continue to develop to meet the ongoing demands of manufacturing. Heller machine tools is known as a source of inspiration for these kinds of innovations. The company, located in Nuertingen, Germany, is known for its high quality 4 and 5-axis CNC machining centres, CNC mill/turning centres, CNC machines for crankshaft and camshaft machining as well as flexible

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manufacturing systems. Customers value their availability of products and their competency in managing special processing demands. Both qualities stem from Heller’s in-house manufacturing, which relies on closer collaboration with customers, suppliers and research institutes to remain on the forefront of innovation. Roughing is a highly promising process Werner Kirsten, who is working in the Technology Development Department at Heller and is responsible for the area of “difficult to machine materials“, explains: “our service includes optimizing the machining processes together with our customers and suppliers.

To support such services with practical trials, our Technology Center is equipped with a variety of machines”. In most cases the aim is to increase the productivity without compromising the process reliability. Technologist Kirsten adds, “We often achieve this aim with an optimized roughing operation which ultimately results in a reduced finishing process. By maintaining the same technological values, but shortening the finishing depth of cut by 50%, the overall machining time is reduced to half. However, this requires process reliable and controllable systems during roughing.” In this regard,all machining components in the process

chain have to be considered in order to improve productivity. The machine tool is the most evident component of the machining process, however the tool, the tool holding system, the coolant supply and other elements are also essential for a successful operation. “In the end the weakest link of the process chain limits the success,” Werner Kirsten emphasizes. In his opinion most machine shops don’t pay attention to the tool holder even though it is especially significant for high performance cutting. “Many of the trials which we carried out during the last few years have proven this point”, Werner Kirsten explains. We realized that the tool holder hasan incredible influence on the machining process. In

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Heller Fraesen TiAl6V4

“Therefore I consider the Safe-Lock™ systsem a practical, easy to handle and process reliable addition to the shrinking technology which we already utilize, especially in connection with standardized tools of other manufacturers”

Werner Kirsten Technology Developer, Heller

the case of reinforced shrink fit chucks, for example, the vibration node is closer to the bearing point (due to the larger mass). The result is a smoother machining process with less vibration and a better surface finish quality while using the same tool, machine, process parameters and fixturing technology.” Tool holding - an important factorfor productivity

By selecting the right tool holder you can even achieve good productivity and surface quality results using basic standard cutting tools. Werner Kirsten refers to comparative tests with basic four-edge cutting tools without an inner coolant supply. As an alternative to a standard shrink fit chuck he selected a HAIMER Power Shrink Chuck with Cool Flash which ensures that

the coolant is transported directly to the cutting edges. “Compared to using a normal shrink fit chuck and external coolant, we were able to achieve significantly better results.”

Harburg visited Heller,an especially extensive milling application study was conducted in Titanium Ti-6AI-4V.

When a group of representatives from the aerospace industry, the Technical University of Dortmund and Technical University of Hamburg-

The available machining center was a four axis Heller H 5000 with a gear unit and HSK-A100 spindle, which yields torques up to 2.290 Nm. In order to demonstrate

Gaining new insights from difficult cases

HAIMER Heavy Duty Shrink Chuck (middle) and Power Shrink Chuck (on theright) next to a shrink fit chuck with a standard geometry.

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the machining potential, different 25mm diameter end mills were used to mill full slots into a titanium plate. To simulate holder conditions used in the aerospace industry, the tools were clamped into reinforced shrink fit chucks. At an axial cutting depth of0.5 to 1.0x D the machining process was found to be very reliable. Since the spindle was not running at full capacity, the trial participants agreed to increase full slottingdepth to 2 x D. Werner Kirsten explains: “Under these conditions the tool pulled out of the shrink fit chuck during the machining operation, creating a slot closer to 2.5xD as it progressed through the part. Towards the end of the slot the tool finally broke as a result of increased cutting forces.”

The milling specialists all agreed that the clamping force of the chuck was the limiting factor in this process. As soon as the axial pressure and process related vibrations are too high the tool moves out of the chuck and further into the workpiece. At the same time the cutting pressure increases such thatin the end the tool breaks and the workpiece is irreversibly damaged. Reasons and possible countermeasures were discussed intensively. In the end, Werner Kirsten developed the idea that the tools are forced to navigate towards the spindle when the holding forces are exceeded. This is how he ultimately noticed the patented HAIMER Safe-Lock™ system which in addition to frictional clamping forces, has

the same helix pattern as the tool. Theoretically, he realized that even if the tool got loose while using Safe Lock™, it would be pulled into the holder through the helical drive keys and not into the part. A movement that can be easily prevented through the use of length presetting screws. Prevent tool pull-out Werner Kirsten got in contact with HAIMER, the European market leader for tool holding technology, in order to test the Safe-Lock™system: “we wanted to know if our ideas could be put into practice using the HAIMER system in an even less forgiving environment.” The Heller technology developer repeated the described trial,with a few major changes. HAIMER Safe-Lock™ grooves were subsequently

added on similar solid carbide tools, but the application would be run again with a reduced spindle taper interface (HSK 63 instead of HSK 100), with a less rigid 5-axis gear driven spindle and a less stable diagonally fixtured workpiece. The result: Despite these additional limiting factors, the tool was able to process a full slot of 2 x D = 50mm with complete process reliability. Werner Kirsten says: “this way we were able to indirectly prove that Safe-Lock™ works and that the shrinking technology has even more potential with HSK-A100, especially on 5-axis machining centers withgear spindles.” Afterwards this sample machining on Ti-6AI-4V was carried out various times, including during the Airshow in

Haimer Safe-Lock™ : In order to equip tool holders with the HAIMER Safe Lock™ system, spiral grooves are ground into the tool shank. In combination with special drive keys within the chuck,the system prevents milling cutters from getting pulled out of the chuck during extreme machining.

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Plot No. 347A, 2nd Phase, KIADB Industrial Area, Harohalli, BENGALURU-562112 Kanakapura Taluk. Ph: 080-26396461 / 41632962 / 99456 95322 Manfred Maier Email: fenmet@gmail.com , www.fenfemetallurgicals.com Managing Director & COO, HELLER July 2016

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Farnborough, whereby it was proven that the previous limit of 1 x D = 25 mm full slotting in titanium could be doubled with the use of Safe-Lock™. Kirsten summarizes the results as follows: “For roughing operations this is a reliable process. Therefore I consider the HAIMER Safe-Lock™ system a practical, easy to handle and process reliable addition to the shrinking technology which we already utilize, especially in connection with standardized tools of other manufactures.” A number of tool manufacturers are offering Safe-Lock™ products From the onset of its creation, HAIMER recognized the incredible potential of the SafeLock™ system, which is why the company created a licensing program to give innovative tool manufacturers the ability

to integrate the patented pull-out protection system into their tools. The result of their vision to create a more open system has been a tremendous success, with leading cutting tool manufacturers having now signed licensing agreements, including Walter, Widia, Sandvik Coromant, Seco Tools, Sumitomo, Kennametal, Helical, Emuge Franken, Data Flute, Niagara, OSG,SGS Tools and recently Mapal. Through the steady increase of Safe-Lock™ tooling in the market via Haimer and its licensed partners, the system has become the new standard for heavy machining and roughing. In fact, the popularity and simplicity of Safe-Lock™ is such that it is also replacing the old Weldon clamping system, particularly when new milling strate-gies such as trochoidal (dynamic) milling are involved. President

of HAIMER Group Andreas Haimer explains: “With our Safe-Lock™ system we found a solution that combines a high run out accuracy with 100% pullout protection. The system has established itself successfully as a standard in the aerospace industry and generally speaking for roughing and heavy duty machining. And now more and more companies that make use of the trochoidal (dynamic) milling strategy are also making the switch to Safe-Lock™, and for a good reason.” During trochoidal milling operations, where the cutting speed and axial depth of cut can be increased through software support, productivity is significantly improved. However, the increased cutter engagement and cutting forces that

result from the higher cutting performance create a situation where tool-pullout can occur very easily. Prior to Safe-Lock, this problem was prevented with Weldon shanks and chucks.However customer had to sacrifice speed and accuracy due to the nature of this clamping system. A shrink fit chuck with Safe-Lock™ offers the same safety as the Weldon system, but provides the additional advantage of accuracy and balance. The ideal balancing and runout characteristics of the shrinking technology in combination with the clamping safety of the Safe-Lock™ system permit greater productivity achieve through faster permissible speeds and increased tool life all with complete tool security assurance. For more details visit www.haimer.in

Haimer Heller CoolFlash: The vibration resistant shrink fit chuck HAIMER Power Shrink Chuck is also available with Cool Flash. Tools without inner coolant supply benefit from the fact that the coolant is in direct contact with the cutting edge. This results in a smoother cutting process and longer tool life.

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Laser Replacing Continous Inkjet Technology

Dhananjay Bapat

Director Marketing, Videojet India

Mr. Dhananjay Bapat, Director of Marketing at Videojet Technologies in India, heads marketing activities in India to help drive growth, support sales efforts and value of innovative products and solutions to customers. He obtained his MBA from Welingkar Institute of Management and prior to Videojet he held marketing and sales management positions at Atlas Copco and Saint Gobain Abrasives. In conversation with MART, he discusses how laser technology is replacing CIJ technology in coding and marking process across industries for its higher precision, print quality and low running cost. He also highlights the need of strict regulations on coding and marking in India for safety as well.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? In terms of coding and marking in the Indian market, the biggest trend that we are seeing is that a lot of customers are shifting from Continuous Inkjet (CIJ) to laser. They prefer laser because itâ&#x20AC;&#x2122;s a one time, capital investment. Laser has a higher initial financial outlay compared to CIJ, however, the running cost is negligible because there

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are no consumables. Another trend we see specifically in the pharmaceutical industry is that Thermal Inkjet (TIJ) is gaining in popularity; traceability regulations for primary to tertiary packaging are driving a significant growth in demand for this technology in India. What are the upcoming technological trends in manufacturing across the globe? Similar to the trend we see here in India, global customers are also beginning to move from CIJ to laser increasingly.

The reason for this is two-fold; one is growing awareness in terms of the consistency of print quality in permanent marking with laser, the second is the financial benefits in terms of much lower running costs. These factors are driving people toward laser coders globally. The challenge with laser, however, is that it is not a very flexible technology when changing its use from one substrate to another substrate that is quite different. The configuration of a laser

machine is set based on a variety of working parameters, such as material composition, line speed etc. CIJ is a more versatile technology and therefore can code on a variety of substrate shapes and sizes. Secondly, while laser is fairly safe in terms of operations, there is fear among food, beverage and pharma manufacturers that contamination may occur as a result of product being exposed to the laser beam. Because of this Videojet is doing a lot to help educate

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Working of InkJet printers on production lines of beverage industries

customers about the safety element of laser with controlled beam penetration. There is still a lot of work to be done in the food in beverage industry to promote laser, but things are changing. Currently in India the government is working on regulations that may make it mandatory to code bottles of mineral water with lasers. In India, mineral water bottles must not be refilled and recapped as the quality of refilled water may not be high - it is estimated that 23-24% of the mineral water market in India is not genuine. Laser codes are permanent which would make the reuse of these bottles by counterfeiters difficult. The coding system that the government wants to use is something which Videojet has already used with a large manufacturer in India. In this instance, we marked a unique code on the neck of the bottle and made the same unique code on the inside of the cap, so if the two codes don’t match it is likely that the bottle is counterfeit. When it comes to adopting latest technologies, where

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does India stand compared to its global counterparts? Working across the global strategic accounts, we can see India is definitely keeping up with global trends. Customers are very knowledgeable today; they are more informed compared with 5-10 years back, and even in the food industry we can see that demand for the latest technologies is growing. For example, a major client of ours in India, a chocolate manufacturer, has started moving from CIJ to laser for coding on chocolate wrappers. This brand is famous in India for its extensive output, so it is unlikely that they have to move stock across packaging lines. The packaging material doesn’t dramatically change with modification in the dimension or the variety of product - they might produce small variants but the packaging doesn’t completely change, so they can use the same packaging line. How is your company adapting to the upcoming technologies? Videojet is the innovation leader in the coding and

marking industry, when you talk about CIJ, laser, the latest coding technology or the new variants introduced to the industry Videojet is ahead of the competition. So it’s more about other companies adapting to the technology we have launched, rather than Videojet adapting to new technology. How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? This would depend on the type of exposure graduate engineers have had to coding in their education. On a country level the understanding or the knowledge about coding technology is pretty low. Someone who has recently graduated would need a significant amount of training on products, technology and the different applications. This is likely the case worldwide, however, as coding is something which is niche and is unlikely to be a part of tertiary curriculum. However, with focus on coding regulations and counterfeiting being undertaken more

globally, there is a growing awareness across all segments of manufacturing. If you look at it from a US or European perspective there are some strong regulations, and where there are regulations in place people tend to have greater awareness. It is likely that in the not too distant future this will affect India and Asian countries in the same way. What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing? This is industry specific, so if we talk about the pharmaceutical sector coding mandates are pretty tight. If a manufacturer from India has to export to the USA or Europe, there are very clear guidelines on primary, secondary, and tertiary packaging. These are basic mandates which are required for selling into these international markets, so technology adoption is more driven by markets and regulations. When we talk about the food and beverage market, the local government here in India is in charge of new incentives and we will see www.martupdate.com

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a lot of regulations and changes coming in. As a result, a lot of customers are moving toward a more structured approach toward coding. This would mean incorporating technology which can produce a better quality of coding. We will see a lot of customers over the next five years move from older technologies, such as rubber stamps and serial coders, to more innovative technologies such as those offered by Videojet. Indian SMEs are the most prominent part of manufacturing. How many of them do you think are ready to keep up with the demand? And, what factors pull them forward? SMEs can be divided into two groups in India; firstly, manufacturers who supply to larger brands and have the confidence in terms of continuous business orders. These manufacturers would go and invest in coding technologies as they have guarantees in terms of business. The second group consists of small companies who work across a number of products

and with limited volumes. Often it is not financially viable for these types of operations to invest in advanced coding and marking technologies. In India, labour is typically inexpensive; therefore some low grade manufacturers prefer to utilize manual stamping. Coding technologies are generally suited to production facilities with automated systems. The coding machine itself is a stationary machine and for any kind of coding application, whether itâ&#x20AC;&#x2122;s CIJ, TTO or laser, there has to be some type of relative motion. Components need to be moving on a conveyor belt or some form of handling system. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? The government encourages SMEs by offering tax efficient ways of working for start-ups. It has launched a campaign that states that start-up ventures will not be taxed for the first three years of operations. These are the kind of incentives that

the government is taking to promote the expansion of Indiaâ&#x20AC;&#x2122;s SME base and grow more in terms of manufacturing. What, according to you, are the dominant changes that should be made immediately in the India manufacturing scenario to make it globally acceptable and competitive? In India we produce all grades of products, in particular in industries such as pharmaceuticals aerospace, auto and textile; these are the markets which we are most competitive in. A lot of machinery and components are also produced in India. These are high quality products. Typically, products for low end markets are supplied to more domestic markets, and to countries where the quality of products is not relevant from a country perspective. While there are low quality manufacturers in India as well, the overall aim for most is to produce better quality products and get into business

with people who value that quality. Do you think that new age startups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? Start-ups are well equipped and use the internet is very extensively in India, which helps grow the awareness of coding solutions Customers rarely used to understand coding, the different options and different technologies, but now customers on all fronts are much more informed. Before investing or buying new technologies, manufacturers are deriving a lot of information via search engines and are doing their own research, so they are better informed when searching for suppliers. Big data is relatively new in India; however that is something which is definitely drive future. In general, people are really aware and concerned with analytics, however when we talk about predictive analytics I believe itâ&#x20AC;&#x2122;s currently in very limited segments here in India.

Videojet 7510 Laser Engraving Machine, specifically engineered for high speed beverage, pharmaceutical and extrusion manufacturers, delivers advanced performance for high contrast marking on robust plastic packaging, metal containers and other industrial products even at ultra-fast line speeds up to 440m/min.

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Automation is the Latest Concept of Manufacturing

Ganesh Jivani

Managing Director, Matrix Comsec

Matrix is a global leader in telecom and security solutions for modern businesses and enterprises with 500 channel partners in more than 50 countries. Its products range of cutting-edge solutions include IP Video Surveillance, Access Control, Time-Attendance, Unified Communication, Convergence, IP-PBX, Universal Gateways, VoIP-GSM Gateways and VoIP Terminals. In conversation with MART, the visionary founder and managing director of Matrix Ganesh Jivani feels sustaining lower-tech platform industries and echo system is as much important as focusing on the growth of high-tech industries and that the Government is on the right track by promoting manufacturing in India and not manufactured by India. Mr. Jivani, graduate in Computer Science from the Faculty of Technology, The M. S. University of Baroda, has over two decades of telecom acumen and expertise with which he has driven Matrix for customer specific solutions and innovative products which has earned the company many accolades in its field.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian manufacturing? Automation and Lean Manufacturing are two dominant trends. Automation and robotic manufacturing is replacing humans from repetitive manufacturing and working

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in hazardous conditions. Lean Manufacturing is helping organizations improve quality, cost and delivery parameters by removing waste from the entire value-chain. How is your company adapting the upcoming technologies? We are in sync with modern product development and manufacturing methodologies and tools. We work with

consultants who help us absorb new methods. In addition, we also send our people for frequent training programs to upgrade our skills. How much an engineer graduated from India is skilled to implement the latest trends in manufacturing?How gaps can be filled? There is only so much you can learn in the classrooms

and from books. Moreover, manufacturing is more experiential learning. Our education system is more academic oriented. Obviously, our fresh engineers lack practical exposure to see, experience and assimilate manufacturing technologies and processes. Most people learn on the job. Fortunately, most organizations are investing time and resources in

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Matrix Telecom Solutions

training their engineers. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? The challenges SMEs face in implementing these technologies? Let us face it. Indian technology-product development and manufacturing is at nascent stage. We will need a lot of determination, efforts and resources to build this. It is one thing to talk about globally competent products and quite another to actually build such products. It is not only about SME, enterprises or government. Technology development, product design and manufacturing are important aspects of a nation’s capabilities. They need vision, determination, sustained efforts and large investments. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? The government is trying everything possible. There is serious intent and drive from the top to grow manufacturing in India. But make no mistake,

the Government is focused on manufacturing irrespective of whether it is an Indian SME or MNC enterprise. I believe this is the right way to go. We don’t have the luxury of time or resources to favour “Indian” companies. Government is ready to help whoever is ready to manufacture in India. What, according to you, are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? We need to improve all three deliverables – quality, cost and delivery. Again, it is not possible to chase one factor independently because all three are connected. For example, better manufacturing practices such as lean manufacturing improves quality and cost and reduces delivery time. Similarly, working on DFM (Design for Manufacturing) also brings benefits in all three. Overall, we need knowledge, skills, equipment and infrastructure to make Indian manufacturing globally competitive. I believe this is surely doable with the right amount of belief, intent, energy, inputs and patience.

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Matrix R&D Center

Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? Yes, one thing very good about most start-ups is that they are all focused on a specific technology and business model. In todayâ&#x20AC;&#x2122;s technology world, depth is more critical than width. Instead of doing ten things, it is more important to do one thing better. Startups have a natural advantage in keeping razor-sharp focus on their objective.

What are your views / comments with regard to Mr. Modiâ&#x20AC;&#x2122;s campaign of Make in India? Do you have any suggestions to increase its effectiveness? Make in India is all about manufacturing in India which is a necessity for many reasons including economic growth, jobs, internal consumption, foreign exchange, technology independence, etc. Electronics and telecom being high-tech industries, it is impossible to create sustainable manufacturing unless supported by lower-

tech platform industries and eco-system. Instead of spending time being attracted to very high-tech such as semiconductor boundaries, it is prudent to nurture manufacturing of basic passive components, PCBs, antennas, crystals, connectors, cables, etc. One serious and unfortunate side-effect of economic opening up in 1991 is that most such manufacturers have completely disappeared. We need to rebuild electronics manufacturing from the scratch. The right way to do is to focus on volume and not on particular technology.

Please give a brief about your industry, services and offerings? Matrix is an indigenous product design-manufacturing company active in telecom and security solutions for modern enterprises and businesses. Matrix offers cutting-edge solutions such as Centralized IP Video Surveillance, Access Control, Time-Attendance, Unified Communication, Convergence, IP-PBXs, Universal Gateways, VoIP-GSM Gateways and VoIP Terminals.

Matrix SATATYA

Matrix Time-Attendance and Access Control Solutions

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Innovation Is a Must for Growth

Sudhir Patankar

Managing Director, PAT Productivity Solutions Pvt. Ltd.

Mr. Sudhir Patankar, Managing Director, PAT Productivity Solutions Pvt. Ltd. bears 27 years of experience in serving Indian industries with various responsibilities at leadership level. Spearheaded by him, his team at PAT Productivity Solutions Pvt. Ltd. always strives for providing Key, Customised and Continuous Support (KCC) to its customers. PAT Productivity Solutions Pvt. Ltd. offers well integrated turnkey solutions in the field of Engineering, Information Technology and People Management. Stressing on need for innovation in manufacturing for growth while talking to MART, pat came his innovative thinking as well as he opines how a ‘reality show’ for showcasing technological innovations by young minds at national level can boost ‘Make in India’ campaign.

Manufacturing has grown exponentially. What are the latest technologies that are dominating Indian Manufacturing? The 1980s to 2000 was the era of moving away from the conventional dedicated manufacturing to flexible manufacturing systems. During the last 15 years, Indian industry has matured up to the ever demanding Indian customer. It has been exposed,

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trained and honed into maximising the productivity and yet remain highly flexible to the changing demand scenario. CNC and Automation still remaining the back bone of the latest technology, the new offerings are equipped with the state of art “IoTs and intelligent human interface functions” which not only make it more human friendly but also brings in a high level of operational safety for man and machine, inbuilt checks to

verify simulated path which is much advanced that virtual programming and many other intelligent functions which are making user increasingly shop for such machines and application functions. Such technologies have made the earlier highly paid programmer and machine operators redundant as the machine interface console is easy to understand and operate. Such is the movement of this

technology that from multi tasking 7 axis CNC machines are increasingly being used in Automobile manufacturing to Aero Space Parts manufacturing to remotely operated medical robots to our own home appliance like the water purifier and washing machines which have such intelligent functions including service recording, health monitoring of key functional parameters, auto registering

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Large Fixtures

Fixtures for HMC

of service calls. Ironically such new technologies are making us dependent, less skilled and slowly pushing us to boredom (polite way of lazy) without us realising this face and yet we continue to enjoy the bliss of an unlimited applications on our smart phones. What are the upcoming technological trends in manufacturing across the globe? How Indian companies are catching with this? Smart, smarter and smartest are the technologies that are making most of the devices we use, communicate with each other and optimize the way they all can be used to our advantage. Internet of Things (IoT) is not as simple as it sounds. It is no longer an IT jargon. Increasingly no of manufacturing industries have understood the power of IoT and using this simple application base to platform their utilities in order to cater to a large portfolio of their clientele. A smart phone is

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popular because it has multi tasking, tracking applications, recording applications, application for pleasure and happiness through a maze of multi user game from any part of the world, entertainment at the flick of an application. If a simple dumb phone till recently has been turned into a smart phone by the appropriate use of human interface applications, it is only a matter of imagination what every device we use whether in the factory, office or home can be turned into to change our way of living life. How is your company adapting the upcoming technologies? We, at PATSOL, help our customers to substantially improve their top and bottom line by the selective use of such new technologies by intelligent and appropriate application as per the customer need. Providing too much information to the customer becomes most of the time over whelming for the customer as

he tends to drift away to the dream world as to what all he will be able to do. We assess and calibrate what precisely is needed and help the customer to achieve the final goal. Direct use of upcoming technologies has its own lop side as on one hand it makes the system reliable with high uptime but on the other hand makes the work force very lethargic and dependent. It is a dangerous combination in companies who opt for partial introduction of such technologies. We are able to create the balance with a balanced outside in approach and deliver perfectly.

exposure is all the professor can offer as they themselves are way away and behind from access to technology. Experimenting in a lab for the sake of completing the syllabus is at one end but the reality hits hard when students feel the gap when exposed to the real work in the industrial environment. A student cannot work in isolation within the industry. He needs to be trained not only in new technologies but also the application in the industrial environment wading through all the challenges to make it a success.

How much an engineer graduated from India is skilled to implement the latest trends in manufacturing? How gaps can be filled?

What are the dominating paradigms in terms of adopting advanced technological trends into manufacturing?

Most good engineering colleges do not focus on the application part of upcoming technologies. Theoretical

Unless there are compelling reasons for a company to use latest trends which will directly increase their turnover, the idea is

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mostly left for the future. But increasing no of companies have realised that without innovation there is no growth. Innovation can be done either intrinsically or extrinsically or in a correct mix as the innovation progresses in time. Just adopting any new technology in a current environment can be counter detrimental to the success of the project. Which means a company may spend million buying new technology and yet is unable to convert it into monetary gains on the balance sheet. The gap may lie in the 4Ms â&#x20AC;&#x201C; Man, Machine, Material and Method of the existing culture. Unless the existing culture is also upgraded, trained and involved in the transition of

adopting the new technology and making a successful use of if, it will still remain within the board room till such time. Indian SMEs are the most prominent part of manufacturing. Are they ready with the latest technologies to deliver global competent products? What are the challenges SMEs face in implementing these technologies? SMEs are either on their own or have a tie up with a foreign partner to supply a limited range of products to the OEMs. The SMEs have a very less say as the prices are literally bullied by the OEMs leaving little or nil chance for the SMEs to look at putting

funds aside for innovation and new technology. SMEs are presently working on the edge of survival and are dependent on OEMs. For SMEs to grow out of this catch 22 situation, it needs separate funding for companies capable of innovating new products for the domestic and global market. Indian engineering has matured and it is time that we stop the brain drain and start harvesting the new minds into inventing new technologies for present and the future. How much the Government of India is helping the Indian SMEs to work in a progressive and competitive environment? There are several aids being provided by Ministry of

Industry for the growth of SMEs. But there is a lot of red tapeism that need to be reduced for making sure that the deserving and promising SMEs are given the platform and aid to bring out new technologies from within India. There are a lot of young and not so young minds who are eagerly looking forward to doing something worthwhile for Indian technology to compete at the global level. What, according to you are the dominant changes that should be made immediately in the Indian manufacturing scenario to make it globally acceptable and competitive? â&#x20AC;˘ Have a younger team of engineers, scientists and

aerospace parts

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managers to manage an industry forum. • Earmark the agenda on all India basis for the target development to be done. • Select and make consortium of companies which will be assigned these tasks. It should not be limited to a few companies but to all the competitive and promising companies who have been shying away due to the long selection procedures. • Real talent needs to be harnessed, consolidated and unleashed with a set of agenda. Do you think the new age start-ups are well equipped when it comes to technological trends like Big Data, IoT or Predictive Analytics? They are well equipped with ideas and the will to be successful. It is only a matter of time that they will fight their way to success through intelligent, smart and hard work through cooperative working. What are your views / comments with regard to Mr. Modi’s campaign of Make in India? Do you have any suggestions to increase its effectiveness? ‘Make in India’ is a good campaign but it seems to fizzle out at OEM levels and large tier companies. It is still just a name at the ground level where the actual action and innovation happens. ‘Make in India’ campaign should create various forms on media for budding and promising engineers to showcase their talent at national level. For example: it needs to be put on the media on a reality show on technology. We

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have comedy, dance, singing, talent shows but we lack reality shows on technology on the media. Maybe initially there will be a few sponsors but with the government backing and backing from the industry biggies, it will soon become a show stopper as the real hidden and suppressed talent from faraway places and remote villages would be witnessed. This will be the real ‘Make in India’ where everyone contributes to the national campaign. After World War II, Japan as a nation rose to the national cause which still is evident after 70 years. The primary reason for their success is the spirit of “together we will win”. Why not us? What is keeping us behind? It is our own minds that stop us from going ahead for the fear of failure. Once we Indians decide, we are second to none. Please give a brief about your industry, services and offerings PAT Productivity Solutions Pvt. Ltd. offers well integrated turnkey solutions in the field of engineering, information technology and people anagement with a primary focus to provide KCC: • Key • Customized • Continuous support to the Indian Industry for high growth path using best global practices to achieve : 1) Operational Excellence 2) To bridge the gap between the OEM expectations and tier supplier capabilities to achieve sustainable and high performance in PQCDSME 3) To make tier supplier more capable and profitable for sustenance .

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Product Development Is Important for Competitiveness in Manufacturing

Gautam Ahuja

Managing Director, Dormer

Originally founded in Sheffield, England, in 1913, Dormer is one of the world’s foremost producers of solid carbide and high-speed steel rotary cutting tools. Dormer Tools India Pvt. Ltd. operates as a subsidiary of Dormer Tools and offers products under three brands, namely, Dormer, Pramet and Carboloy. The Indian arm of the company which was initially known as Pramet Tools India with the company was rechristened as Dormer Tools India in 2013 in the wake of the amalgamation of the two companies globally. Incidentally, 2013 was also the centenary year of Dormer Tools globally. Gautam K Ahuja, Managing Director, Dormer Tools India, throws light on the need for product development for competitiveness in manufacturing and his company’s product development efforts.

What are the impact of new innovations in the Indian market? For meeting the customers’ need of deep hole drilling, Dormer’s PFX drills offer versatility and productivity. All PFX drills are manufactured from high

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speed cobalt steel and suitable for use in a variety of materials for drilling depths from 3xD to 25xD. All PFX drills have a straight shank and parabolic flute design for increased chip space and improved evacuation, which allows greater

hole-depths to be achieved in some cases without the need for pecking. Thus, we provide a cost-effective solution for a wide range of applications. What’s your take on the impact of Product Developments in the competitive manufacturing sector?

Product development has taken quantum steps to meet customer requirements of productivity improvement with enhanced tool life. The use of heat resistant materials in the industry is on the rise, and cutting tools have to meet tough

July 2016

Pramet has recently launched M6330 grade in Milling, for machining applications with unstable conditions and fragile components.

machining conditions. The challenges are to have a keen cutting edge which needs a tough core to avoid chip off, while the coating has to be highly wear resistant.

manufacturing plants in India.

Pramet has recently launched M6330 grade in Milling, for machining applications with unstable conditions and fragile components.

All emerging technologies are available in India, since all the global machine tool builders and cutting tool manufacturers are operating here.

What do you think about the adaptability of emerging technologies by Indian Manufacturers?

However, the difference is that Indian Manufacturers want value for money, though they can provide high volume. Thus, practically there is not technology gap between India and the Western world, and the industry is open to imbibe new technologies.

The Indian manufacturing industry is at par with the global standards, especially with many multi-national companies having their

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Also, many of our customers are exporting components to world class corporates globally. India has the advantage of a skilled English speaking workforce.

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TALENT MANAGEMENT

Learning On The Go Why Mobile Learning is the Future

Mobile Learning can be a great tool to embrace moments of learning for application of knowledge when needed. In the time to come, Mobile Learning will not be a ‘choice’ anymore, but a compulsive mode of learning to stay ahead.

Pavan Sriram pavan@ittige.com

As noted by Irwin Jacobs, the founding chairman of Qualcomm, Inc., “always on, always connected mobile devices in the hands of learners has the potential to dramatically improve learning outcomes.” Learning is at a critical juncture in India today. What was designed for agrarian and industrial eras, the methodology and access does not support the

learning needs of a 21st century working professional. Educating this dynamic workforce, organisations sometimes need to go beyond physical confines of the classroom and the fixed time periods of the working day. You will have to allow learners to access content 24/7, communicate with colleagues and trainers, and collaborate online.

So what it is it about flexible, online, and mobile learning that makes it an increasingly essential aspect of today’s teaching and learning practice. What is it about mobile learning that helps trainers to teach better, or learners to learn more effectively? According to the ATD 2015 State of the Industry Report, 1.5% of training hours were completed

via a mobile delivery method in 2014, up from 1.2% in 2013. A third of organizations had a mobile learning program of some sort in place by the end of 2014. Mobile is used as a reinforcement tool and placed within a blended learning curriculum rather than becoming a primary delivery method. Mobile devices, used in conjunction with near universal

Mobile Learning is an essential piece of the blended learning puzzle

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Mobile learning is not intended to be a unique learning method but rather to complement class-room training, computers and e-learning

4G/3G wireless connectivity, are becoming increasing popular to enable innovation and help learners, trainers, and organisations gain access to personalized digital content and global best practices in learning and development. It enables, empowers, and engages learning in ways that transform the learning environment for learners inside and outside of their physical work spaces.

learning remotely and outside their desk space, and recent studies claim that employees are happier when they have the opportunity to telecommute. With advances in online training (think MOOCs, which are in the spotlight today), learners want, and need, instant access to information and learning without necessarily having to wait for a trainer to show up in the training room.

At ITTIGE Learning where we have taken some modest steps with a few clients to engage their employees post the class-room training using our mobile learning app, we have seen dramatic improvement of over 30% in learner engagement and 50% increase in real-time information access between trainers and learners.

2. Encourages Learning Retention: By being able to use mobile devices to extend learning from the classroom to the real world, there are more opportunities to take learning from the theoretical to the actionable outcomes. Formal and informal learning can be blended and embedded for an enhanced learning experience and greater applicability (and therefore retention) of learning concepts.

To inspire some of you to try out mobile learning this year –these are some of the best reasons I can think of for investigating and supporting the use of mobile learning approaches in both workplace professional development and training 1. Learners Learning Everywhere: More people are

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3. Enhances Collaboration: Content that promotes learning can be rapidly shared (e.g., audio and video-aids, best practices, articles, assessments, lessons learned, forms, and checklists and more). Communication

time lags can be reduced with alerts, status updates, voting, proactively asking for help, search, and 1:1 messaging and chats. 4. Enhances Productivity: From increasing training compliance by having more employees complete modules on their own terms to saving costs via digitally-enabled learning, the ROI on training can increase by providing learners with learning experiences that are relevant to their needs as well as to business needs. As often as possible, linking employee job satisfaction requirements to bottom-line business needs - workplace productivity can improve exponentially. 5. Intrinsically Engaging: Mobile phones and tablets can make learning fun, interesting and powerful. Learning approaches can be devised to encourage learners to discover information, to create their own resources using images, audio and video, to share, to collaborate, and to interact with peer learners. Mobile learning is definitely here to stay. As smartphones and tablets become a near

constant presence in our lives, almost every type of company is considering how best to use mobile devices and applications to enrich their organizations’ talent development capabilities. However, by making the technology serve the unique environment of mobile learning and by offering compelling user interfaces and seamless user experiences, companies have the opportunity to energize the entire ecosystem of talent development, delivering compelling learning experiences for their workforce anytime, anywhere, and in support of clear business outcomes. I look forward to hear from you at pavan@ittige.com on what your plans are to deliver mobile learning and engage your employees outside the traditional classrooms? Or, how we can help you “get up” and go mobile with learning? Pavan Sriram is the CEO of ITTIGE Learning, a performance-based training company that works with organisationsto improve learning outcomes.www.ittige.com

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MANUFACTURING EXCELLENCE

Visual Boards for Performance Monitoring and Better Decision Making Managing SME in India - Part 43

As part of the visual management system, visual boards play a key role in presenting a clear idea of the performance parameters of a company (Quality, Cost, Delivery, Safety, Productivity, Morale and General). With display of continuous relevant data visual boards help in better decision making for operational improvements.

P S Satish gotopssatish@gmail.com

54. Managing visual boards in the company In the previous article on importance of visualization, we saw what visualization is, why it is important for the company and few tips on application in the company. One of the important things in visualization management in the company is visual boards. Basically these visual boards are meant to display important key performance parameters (KPIs) or measurements. All employees and even customers can understand where the company is heading to by looking at these visual boards. Having said this, let us see why measurement is important

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for the company. Importance of Measurement We know all that anything that cannot be measured cannot be managed well and improved. One of the principles of quality system standards is that decision be driven by data and not by gut feelings or assumptions. Collecting and continuous monitoring of relevant data in the company helps in better decisions. Visual boards support this activity. Without proper measurements, company would not know whether they are towards their targets or goal or vision. Any

gap here with respect to actuals will help to identify corrective actions. Visual boards act as aid to make all employees aware of the gap if any. Visual boards with measurements act like a dashboard of car. By looking at the dashboard, the driver can know the condition of the car and also how long he can go further.

behavior by linking rewards to results • Serves as rearview mirror to move further • The information on the gap between target versus actual will help to identify actions • Will identify performance of a function or department. Management can decide on the further support needed

Why Measurements are required?

Indirect Measurements

• Measurement leads to better decision making • Will result in better communication among various departments to understand mutual support needed • Motivates and influence

Sometime a parameter cannot be measured directly and it calls for indirect measurement. For example, how do we know, as a country how much India is affected by the global economy? This measurement helps to assess the impact on the

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One of the principles of quality system standards is that decision be driven by data and not by gut feelings or assumptions.

Indian economy whenever there is a fluctuation in global economy. Correct measurement of this factor may be difficult but the same can be measured indirectly by measuring ratio of total trade to GDP. The team of the company has to identify the need for indirect measurement in the company. Lag and lead Measurements Lag measurement is reactive and is measured for things done in the past. Simply, measuring new customers added to the company every month is a lag measurement. It may not indicate what actions to be taken to close the gap. On the other hand, lead measurement is pro-active. Here instead of measuring new customers added, focus would be number of interactions made with customers in terms of visits, correspondence, discussions etc. This drives action on what needs to be done further. Naturally, more the interaction and visits to

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potential customers, more is the probability of their addition to the Company. Though both the measurements are required, visual boards should focus more on lead measurements. Objectives and Key results Objectives define what we want to achieve. For example, keeping customers delighted. How do we measure whether customer is delighted or not? For this, Key results will help. In this case it could be customer satisfaction score. Based on Company Objectives Key result areas (KRAs) should be arrived which could be monitored in visual boards. Typical visual board contents Normally sheets (A4 size) are used on the board, which are easy to handle and update every month. Instead of an excel table, graphical representation is better for easy readability. The graph or chart should

show Targets for measuring parameter, Trends to show whether we are improving or deteriorating, Comparison with previous period results or bench marks and key causes in case of deviation from the target. Graph will also have scope of the measuring parameter. Typical topics in visual boards are – Quality, Cost, Delivery, Safety, Productivity, Morale and General. The key parameters in each of above areas will vary from company to company and following items are typically monitored in a manufacturing company. Quality • Week wise/Month wise internal rejections • Month wise Customer complaints• Month wise Pareto analysis and corrective actions • Defective parts or photos to indicate defects that occurred recently • Information on Internal and

3rd party audit results • Quality policy and objectives • Awards, Certifications • Quality alerts Costs and Productivity • Month wise Indirect variable costs monitoring e.g. Electricity, consumables, Tools, water, transport, contract wages etc. • Re work and scrap costs • Inventory as Finished Goods, Work in progress (WIP) and raw material • Total quality costs with cost of quality • Raw material consumption Note: All these can be as ratio of sales volume • Cost reduction efforts and results • Overall Equipment Effectiveness(OEE) Delivery • Customer schedule for the current month and next 2 months • Percentage fulfillment of Delivery -Customer wise and as total

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• Premium freights – Number of occasions and costs • Percentage fulfillment of Suppliers for critical parts • Service level of Logistic service provider Safety • Number of Accidents in the month – Minor and Major • Last accident report to know days without accidents • Guidelines on safety • Emergency numbers to contact • First aid guidelines

• Achievements of Employees – within or outside the company • CIP activities – Before and after • Number of suggestions • Major suggestion results

updated regularly. A person is to be nominated for managing boards. Ensure that too many and not relevant parameters are not monitored. The metrics should be meaningful.

General

Deciding on measurement metrics

Morale

• Vision and Mission • Company sales volume • Number of samples developed • Company progress updates • New Customers • Circulars • Holiday lists •General information

• Skill Matrix of Operators and staff • Absenteeism trend • Training plan versus fulfillment • 5S Scores

Above measuring parameters are not exhaustive and many more can be added depending on the type of business. There will be no benefits if boards are not

Visual boards are not just for monitoring some random metrics. Careful study has to be done on what metrics to be monitored and it should sensitize employees by looking at it. For example, instead of measuring number of customer complaints, customer complaint index (CCI) can be developed. CCI takes care of severity of the complaint to distinguish complaints that can come at inward inspection, at zero

kilometer, in shop floor or from field. The index will give intensity. Visual boards are very effective in communicating to all employees in the company. It gives a positive impression for the customers visiting. Let us start if not being used and improve if already being used. Please send your inputs,remarks,opinionsand suggestions toP.S. Satish,Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103, Mantri Paradise Apartments, Bannerghatta Road, Bangalore-560076. Email:gotopssatish@gmail. com; www.linkedin.com/pub/ satish-cp-pii/35/153/85b; Mob: 9845043202. Have a nice day.

Without proper measurements, company would not know whether they are towards their targets or goal or vision.

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February 2015 November July 2016 2014

THE LAST LEAF Dear Readers, India Inc’s business optimism for the July-September period touched an eight quarter high driven by initiatives like the clearance of Bankruptcy Code and reforms in Foreign Direct Investment front, says a report. According to Dun & Bradstreet (D&B), India Inc’s business optimism stood at a 8-quarter high in the July-September period, while optimism for net profit was at a 7-quarter high. It says that the focus of the Government on policy certainty, predictability and continuity has given a strong boost to business confidence in India Inc. (Courtesy:profit.ndtv.com) The Govt. announced an incubation cell at Indian Institute of Foreign Trade to offer support to export startups under the initiative KITTES (Knowledge for Innovation in Trade and Technology for Entrepreneurial Startups) – this will allow them to expand their business to foreign markets. FAME (Faster Adoption and Manufacturing of Hybrid and Electric Vehicles in India) is a part of the National Electric Mobility Mission Plan, to focus on quick and widespread adoption of hybrid/electric vehicles in India. The FAME scheme provides incentives on purchase of hybrid or electric vehicles (cars, trucks, buses, two-wheelers) in form of lower cost of purchase, like a discount. The manufacturers then claim the discounted amount from the government at the end of each month. When launched, the Ciaz SHVS was priced lower than the diesel powered variant (as a result of incentives offered by the FAME scheme). The road transport and highways ministry has also passed a notification to allow owners to convert their vehicles into electric hybrids through hybrid electric kits. All such initiatives will help to curb pollution by significant levels. The Government of India has invited Tesla Motors to make India its manufacturing hub for Asian markets. Tesla senior executives were requested to make India its Asia manufacturing hub and offered land near major Indian ports to facilitate export of their vehicles to South and South East Asian countries. Taiwan-based Foxconn, which makes iPhone, iPad and other Apple products, will commence making mobile phones starting August, at a 2 lakh square feet rented facility in Navi Mumbai and later laptops and computers. Foxconn had recently announced plans to make India a key global manufacturing hub for servicing markets across Africa and West Asia. The World Bank , last month, said it would lend India more than $1 billion for its huge solar energy programme, after Prime Minister Narendra Modi sought climate change funds from its President Jim Yong Kim. The World Bank loan is the organization’s biggest solar aid for any country and comes as India has set a goal of raising its solar capacity nearly 30 times to 100 gigawatts by 2020 and is attracting mega investment proposals from top companies and institutions. Still India reckons its renewable energy industry could generate business opportunities worth $160 billion this decade, making it a lucrative market that has already attracted big global players such as Japan’s Softbank Corp and Taiwan’s Foxconn. Consciously, we are making an attempt to create a positive outlook around us aimed at facilitating to stimulate and energise our industry atmosphere. Your feedback in this regard is welcome, to enable us improvise our channel of information and motivation to our readers for a better tomorrow. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board

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