Mart March 2016 by MART INFOMEDIA PRIVATE LIMITED

Volume 12 Issue 9 March 2016 ` 100

KNOW SAFETY NO PAIN NO SAFETY KNOW PAIN

- TAKE CARE OF SAFETY IN THE INDUSTRY - INDUSTRIAL SAFETY @SMART AUTOMATION - TOTAL WELDING MANAGEMENT

BUDGET REIGNITES THE INVESTMENT CYCLE March 2016

UNION BUDGET: A WELCOME MOVE

BUDGET REIGNITES THE INVESTMENT CYCLE

MAKE IN INDIA GETS A FILLIP www.martupdate.com

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March 2016

foreword Safe, Business! Hi Readers, “More business is lost every year through neglect than through any other cause.” 5th of this month is “Safety Day”, and this quote by Rose Kennedy reminds us how we are losing lives, working hours, business etc by neglecting the basic requirements needed in our facilities. If you look into minor or major man made accidents at work, you can realize the spark for the same was ignited days before because of the negligible neglects made. Safety always got the prime concern in doing business, but break-down or accidents are still plenty around us. In one of the recent news from Howrah, West Bengal two children of labors working at a Brick factory was burned to death. While playing around the premises both the kids fell down into the burning furnace which was closed by a temporary lid. When rules of the land requires strict safety conditions to start a business and at a time when the world as well as we as a manufacturing economy discuss about the implementation of smart automation, these kinds of incidents shows the ground reality in our Manufacturing. Rules and conditions can be laid down by the authorities but the effective implementation can only happen with proper awareness and willfulness of entrepreneurs as well as each and every person involved in business. We urge each one of us to ensure proper care are taken towards safety at work, a bit extra care will sure produce extraordinary results. In this edition of MART, our cover feature is on industrial safety and the lead article is by our EAB member and leading industrial consultant Mr. P S Satish, in continuation of his regular column on SME Manufacturing Excellence, and another one by Mr. Rajesh Angadi on Smart Automation of Industrial Safety. The economic conditions across the globe is not encouraging for couple of years, and presenting his union budget for year 2016-17 was sure a challenging task for our Finance Minister Shri. Arun Jaitley. India is better placed considering other major economies, and industry in general welcomed FM’s initiatives which are considered simple and workable. The reduction of corporate tax, enhancement of CENVAT credit, infrastructure spends, ultra mega power projects, MUDRA Bank,10% additional depreciation on new plant and machineries, FDI in Defence etc are some of the initiatives in this budget which will help us achieve our growth targets. Timely implementation of much delayed GST as well as more steps towards the success of Make In India needs to be looked into by the government. We included couple of articles/ views from our manufacturing industry which will give our readers a better understanding about this year budget. Along with our regular contents, in our industry feature we are including a technical paper on “Total Welding Management” by Mr. Rashmi Ranjan Mohapatra and Mr. Sritharanandh G of Kemppi India. In our On Face we are featuring Dr. Swapneshu Baser, founder of Mumbai based Deven Supercriticals Pvt Ltd. He played a major role in design, development and implementation of ‘Supercritical Fluid Processing technology’ through his association with IIT- Bombay and subsequently with DSPL. We are sure our effort of bringing MART as an utility to you is successful with this edition. We look forward your suggestions to make MART, SMART!

Hari Shanker hari@martinfotech.in

March 2016

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26 MAIN FEATURE

10 INNOVATIONS

Industrial Safety through Smart Automation System

28 Take care of safety in the Industry 30 Inventory Management: Tackling the Challenge!

34 Total Welding Management 38 Union Budget 2016 Volume 12 Issue 9 March 2016 Annual Subscription `1200 Member INS Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre S M Dangi Sandeep Hingne

MediaMart Infotech

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C-507, Wisteria Fortune Survey No: 95/2, Near New Poona Bakery Wakad, Pune - 411057

Mob: +91 9038000711 Email: info@martinfotech.in

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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. ÂŠ All Rights Reserved March 2016

CONTENTS 52

Swapneshu Baser Founder, Director, Deven Supercriticals Pvt. Ltd

ON FACE

Columns

56 Overcoming Procrastination –

Why Leaders should get Proactive

C2C: Its Importance

48 SUCCEESS STORY

60 CORPORATE MART

66 CASE STUDY

84 97

MART UPDATE THE LAST LEAF

Managing Editor

Hari Shanker

Associate Editor Hiya Chakrabarti Executive Director Siji Nair General Manager

Priya Kundu

HR & Admin

Sonalisa Dey

Creative Assistant

Sayan Chaudhuri

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Sales Team

• Five years (60 issues) at `4800 You save `1200

Adrita Baidya Subramaniam V C R Sathyanunni K Ravindranath

Send your subscriptions to: The Circulation Manager - MART Mediamart Infotech, C-507, Wisteria Fortune Survey No: 95/2, Near New Poona Bakery Wakad, Pune - 411057 Mobile: +91 9038 000711 Email: mart@martinfotech.in Web: www.martupdate.com & www.martonline.in

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

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INNO I NVAT N OIVAT ONION

Delcam enhances section measurementsin PowerINSPECT inspection software

Inspection of sections has been improved in PowerINSPECT 2016

Delcam has released the 2016 version of its PowerINSPECT inspection software, the world’s leading hardware-independent 3D inspection solution. The new release includes greatly enhanced options for section measurement, more comprehensive collision avoidance, improved point cloud inspection, the ability to add notes to reports, and improved user control of CNC surface inspection routines.

Alternatively, the near side can be hidden completely, or the complete CAD model can be shown in a solid colour as before.

Section inspection has been improved with easier creation of sections, better visualisation and enhanced reporting. The enhanced options for section editing in PowerINSPECT 2016 include a slider that can be used to move the section through the part with real-time updating of the CAD view. A specific value for the section intersection can still be entered if required.

As with other PowerINSPECT measurements, the results of the section inspection can be viewed as spot confetti, deviation lines or vector lines. The results can be displayed either on their own or as part of a larger inspection sequence.

New graphics options help with visualisation and reporting. In the CAD view, the default option highlights the section cut and displays a semi-transparent representation of the material in the foreground, providing an accurate 3D visualisation of the section in place on the part. During section creation the shading is updated dynamically as the section moves through the model.

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Once the desired section has been chosen, the inspection path can be generated automatically. The points generated can be edited if necessary. The section can also be viewed and reported as a 2D true view of the section profilethat is currently selected.

Automatic collision detection was introduced in PowerINSPECT 2015, withprobe paths adjusted automatically when a direct move between inspection features would result in a collision. A new collision-free mode extends this capability by automatically creating links between inspection features as necessary. If a potential collision is detected, the software automatically creates and calculates a new linking path that avoids the obstacle. Collision avoidance is recalculated when the order of the inspection sequences is adjusted in the

sequence tree. Intermediate paths can still be created or updated manually. This is required when the CAD model does not includecomplete information about the physical reality, for exampleif clamps or fixtures used to hold the part are not included in the CAD data. PowerINSPECT 2016 has improved reporting with the ability to include additional user-defined information. New ‘Report Note’ items allow the user to insert additional observations, including text and pictures. As with all other items in the report, the notes can be shown, hidden and re-ordered within the report. The formatting of labels has also been enhanced, particularly for GD&T items. New options have been added to the dialog for session settings to enable further control of the label display. Furthermore, the label sizes can be edited in the session settings and grid lines can be displayed for clearer reporting. A number of enhancements have been added forinspections based on point clouds. Firstly, point clouds can be imported from DMT and STL triangle files. Scanning acquisition

performance is improved and points can be saved from a pointcloud scan each time there is a pause during the scan. Several point-cloud items can also now be created in a single point-cloud session without having to leave the full-screen acquisition view. CNC surface inspection has been improved, making it easier to produce consistent results across a batch of components. New surface inspection groups provide better user control of point naming, and the positioning, contents and formatting of report images. It is also possible to reference CNC surface inspection groups directly in RPS alignments. Finally, there are significant usability improvements for the CAD File Manager. It is now possible to import one or more CAD files by dragging and droppingthem into the main graphics window. The highlighting and visualisation of individual objects in CAD models is further improved, making it easier to identify named objects and levels. For video demonstrations of the new options, visit www.delcam. tv/pi2016/lz/en/index.asp

March 2016

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INNO I NVAT N OIVAT ONION

Intelligent Earth Leakage Relay(iELR)

One more milestone ElMeasure proves that to be in the controlling segment is “Intelligent Earth leakage Relay” (ELR).

Conventional ELR works with the settings through the potentiometers / DIP switches and whenever it crosses the limit it trips. Problem with this kind of relays are accuracy and malfunctioning. ElMeasure committed to have good products and first time Microcontroller based IELR with 4digit 7 segments RED bright Digital display, which is very unique as compared to conventional ELRs. Unique features 1. Inverse curve - Trip time is inversely proportional to leakage current. This IELR isIntelligent, when the

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Leakage current is 10 times higher than the set current it trips 10 times faster.

4. Continuous scrolling display for set current and set Time.

2. Continues leakage current display (Programmable) –Leakage current displays to enhance the user to understand the quality of Electrical network / Machine online. This can be disabled through setup.

5. Field Programmable through front panel keys with password protection – No limitations on the Leakage Current settings.

96 x 45

3. Continuous Display of Trip Leakage current (Programmable) - In case of tripping IELR captures and Displays the tripped Current with the resolution of 4 digit helps the user to analyze and correct the problem. This can be disabled through setup.

6. Wide input range 60mA to 12A and the trip time programmable from 300ms to 30 seconds. 7. Manual test and Reset Keys

4 Digit 7 segment RED

bright display 4.

Panel mountable 96 x

Accuracy : Class 1.0 FS

Relay contacts – One

pair of potential free NO & NC, 2A at 250VAC or 24VDC 7.

CBCT standard size –

40, 65, 100, 150, 200, 250, 300mm Tape wound. 8.

Weight (Approx):

Specification:

Unpacked – 250 Grams

1. 1 Second update.

Shipping – 350 Grams

2. Auxiliary supply 80 to 300 VAC. Burden 4VA max.

For more details visit www.elmeasure.com

March 2016

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Renishaw launches new CARTO software solution for calibration systems

Renishaw is launching a new free software suite for Renishaw calibration systems at EMO 2015.

The suite includes Capture and Explore, which provide data capture and analysis for the XL80 laser interferometer system. CARTO release 1.1 supports linear, angular and straightness measurement with a choice of keypress, position and remote (TPin) triggering. CARTO features a new database system which automatically stores and organises data for the user, simplifying operation and allowing users to quickly and easily compare data with historical results. Capture has been introduced to the CARTO suite as an improved and updated data capture application with the following features:

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• The orientation of machine movement is detected automatically, reducing the chance for human error in the process. • The intuitive user interface allows new users to begin capturing data quickly with less requirement for training. • All the core functions are available on one screen for efficient navigation. • ISO-10360 target sequences can be automatically created, simplifying a challenging test set-up. Explore brings the advances of XCal-View data analysis software to the CARTO suite with the following features:

• Tests in the database can be searched by different criteria (such as machine name, operator, and date etc.). This enables users to review historical test data conveniently. • Multiple data sets can be overlaid on the same screen for visual comparison. • Linear error compensation files can be created from test results. • Customisable test reports can be created with choices such as graph line thickness and adding company logos. User-friendly interface The intuitive CARTO user interface allows new users to

begin capturing and analysing data quickly, without the need for training or reading lengthy manuals. The capacity for customisation throughout the suite means that both Capture and Explore can be tailored to suit an individual user’s requirements. Further development on CARTO will follow to add more features, including rotary, flatness and dynamic measurement. CARTO release 1.1 will be available to download free of charge from www.renishaw.com/carto. For further information on Renishaw’s calibration and performance monitoring products, visit www.renishaw. com/calibration.

March 2016

Quick-adjustment module and clamping unit for assembly systems

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Modular high-performance assembly

The SCHUNK VEH adjusting unit (below) allows fast and precise fine adjustment of handling systems in two linear and one rota-tive compensating direction. The APDA mounting plate (above) makes it possible to mount two components directly above exist-ing supports.

With more than 10,000 possible combinations SCHUNK offers the world’s most comprehen-sive line of modules for highperformance assembly. At the core of the design is a unique support column system consisting of numerous standardized pillar profiles, adapter plates, centering and connecting elements, offering maximum flexibility of the system design. To further expand the application possibilities, the competence leader for clamping technology and gripping systems now presents two new components: Fast and precise positioning The SCHUNK VEH adjusting unit enables especially easy and precise fine adjustment of han-dling systems. The flat and compact quickadjustment module can be

March 2016

directly positioned under the bases of Pick & Place units or other handling modules. An Allen key is used to adjust the pick and place positions of the handling system in seconds, both in the linear and the rotative axis. The SCHUNK VEH is ideal for both the SCHUNK SOE single base and the SCHUNK SOD double base, and is available for pillar diameters of 55 mm and 35 mm. Mounting plate for compact assemblies The SCHUNK APDA mounting plate expands the already very diverse combination options of the modular system. It allows mounting of components directly above existing pillars in or-der to produce especially compact solutions. The mounting plate offers diverse mounting options on all five

surfaces and is ideal for pillar diameters of 55 mm and 35 mm. The SCHUNK pillar mounting system allows the combination of diverse handling modules without mechanical adaptation by means of mounting and centering holes, for an exact fit and angular precision as well as safe, stable, and reproducible mounting of components. It can also be used for the installation of cameras, sensors or lighting elements, as well as for the construction of presses and other applications. As opposed to welded frames it offers high flexibility and variability, and compared with aluminum profiles it offers high precision of form and position as well as precise reproducibility when systems are dismantled for maintenance, for example.

To ensure high stability and minimal form and position toleranc-es of 0.02 mm as well as vibration-free movement also in the case of long support columns, all columns are hard chromiumplated and ground. Three pillar diameters are available: 55 mm for robust assembly systems, 35 mm for compact solutions, and 20 mm for reduced-space miniature applications. The lengths are available in 10 mm steps and extend from 100 mm (ø 20 and 35) or 150 mm (ø 55) to 500 mm (ø 20) or up to 1,000 mm (ø 35 and 55). All diameters are in stock at SCHUNK and are only adapted to the required length at the time of ordering. For further details visit www.in.schunk.com

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New T-style sialon ceramic inserts from Seco excel in unstable conditions

Ceramic Toolholder CS100

Well suited for turning applications that require tight tolerances and low cutting forces, the T-style (chamfered) CS100 inserts are available in 20-degree chamfers that range from 0.05 mm to 0.1 mm in width. The sharp, negative reinforced cutting edges on these inserts help absorb some of the high cutting force and pressure that would otherwise be placed on the machine setups and workpieces. As a result, these inserts eliminate the risk of workpiece deformation, especially in thin-walled components, as well as reduce excessive vibrations that shorten tool life and negatively impact surface finish. The characteristics of the T-style inserts also

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complement the existing S-style (chamfered and honed) CS100 products designed to handle high cutting forces in rigid, stable machining conditions. Collectively, the T-style and S-style inserts in the CS100 line have high abrasion resistance and superior toughness that extends tool life and allows for high cutting speeds when processing challenging materials such as Inconel, MAR, RENE and Waspaloy. In other words, manufacturers, especially those in aerospace and power generation, using these inserts benefit from high productivity, consistent quality and a low cost per part. Furthermore, Seco has added new ceramic insert

holders to its comprehensive product portfolio. Available in standard shaft and SecoCaptoâ&#x201E;˘ styles, these holders have special pocket designs and clamping systems that easily accommodate the different thicknesses and missing centre-mounting holes that are common with these types of inserts. For more information on CS100 inserts and the role different edge preparations play in machining operations, please visit http://www. secotools.com/en-IN/Global/ Products/Advanced-cuttingmaterials/CS100/SecomaxCBN600/ or contact a local Seco representative. Seco Tools is a leading manufacturer of high performance metal cutting tools. Secoâ&#x20AC;&#x2122;s product

range includes a complete programme of tools and inserts for turning, milling, drilling, reaming and boring as well as complementary tool holding systems. With more than 25,000 standard products, Seco is a complete solutions provider for the metal cutting industry and equips machine tools from the spindle down to the cutting edge. The company is headquartered in Fagersta, Sweden and represented in more than 50 countries worldwide with 40 subsidiaries, distributors and channel partners. For more information you may send your enquiry to: Seco Tools India (P) Ltd. Tel: 02137-667300 Email: seco.india@secotools.com Website:www.secotools.com/in

March 2016

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EXLUX linear luminaires from R. STAHL: Latest lighting technology in tried-and-tested fitting

Energy-efficient general lighting retrofits in any climate are straightforward with R. STAHL EXLUX 6002/6402 series linear luminaires

Despite a familiar appearance due to their tried-and-tested fitting design, R. STAHL 6002 and 6402 series linear luminaires use the latest LED technology inside. Suitable for ceiling installation, use as pendant lights, or pole mounting, these explosion-proof devices enable particularly energyefficient general lighting in zones 1, 21, 2 and 22. Their familiar form factor ensures that changing over from traditional linear luminaires with fluorescent tubes to LED light sources is an especially straightforward process. In photometric terms, one 52 W luminaire is fully equivalent to two conventional 36 W fluorescent lamps. However, up to 100,000 hours of operation mean they achieve a far superior service life,

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as well as a high luminous flux of up to 5800 lm and excellent luminaire efficiency of well over 100 lm per W. In addition, thanks to their slim, low-profile GRP housing, the lights weigh at least one third less than widely available competing products in the same class. Series 6002 models feature “increased safety” (Ex e) type of protection, while 6402 series luminaires are “non-sparking” (Ex nA). Notable for their very robust IP66/IP67 design, the products can be used at environmental temperatures ranging from -30 °C to +55 °C. Both series feature very economical 28 W or 52 W standard versions. They are available with or without diffusers in lengths of 700

mm and 1310 mm. The current R. STAHL lighting solutions campaign provides instructive information on all crucial benefits of LED lighting compared with conventional light. The campaign website, www. stahl-explorers.com, not only features background information on LED technology and the latest news on lighting solutions, but also a series of actionpacked short clips showing luminaire operation in truly extreme conditions. For more than 80 years, R. STAHL has been a trendsetting manufacturer of safety technology for hazardous areas. Based in Waldenburg, Germany, the company is one of the world’s leading suppliers

of explosion-protected automation, control and distribution, installation, operating and monitoring, lighting, signaling and alarm components and systems. Key products include customerspecific systems solutions for hazardous areas. R. STAHL’s individual packages containing tailored product combinations and a wide range of services such as consulting, project planning, engineering and training courses for customers are designed to fully meet application requirements and customer needs. International certifications, approvals and patents demonstrate the company’s expertise and allow for R. STAHL’s products to be used throughout the world. For more details visit www.stahl.de

March 2016

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New IIoT gateways from HMS allow industrial equipment to communicate with power grids

HMS Industrial Networks now introduces a new family of Industrial IoT gateways for Smart Grid applications. The Anybus SG-gateways enable communication between industrial applications and energy protocols. This communication is the very basis for the so called “Smart Grid” where power plants and energy equipment are interacting with industrial applications. The SG-gateways are yet another example of how HMS realizes the Industrial Internet of Things.

Anybus SG-gateways make the Smart Grid possible The new SG-gateways enable communication between industrial devices running Modbus, PROFIBUS, PROFINET, EtherNet/IP, or M-Bus and energy protocols (IEC61850 and IEC60870-5104). This means that a power plant control room which is using the IEC protocols, can connect to industrial devices such as generators, drives, filters and protection equipment. Since the SG-gateways can act both as a master and slave, it is also possible to connect Intelligent

March 2016

Electronic Devices (IEDs) which communicate over IEC-standards, to industrial networks, allowing them to be controlled by PLCs from e.g. Siemens, Rockwell or Mitsubishi. The Anybus SG-gateways can also be used to enable remote control and management of electrical equipment in power grids. Data is sent over Ethernet or the 3G cellular network using the telecontrol protocols, after which the data can be presented by a software application in the power plant control room. Different versions – same

The Anybus SG-gateways are available in different versions for handling various industrial networks and communication standards. These include I/O, Modbus, PROFIBUS, PROFINET, EtherNet/IP, or M-Bus. All versions use the same web-based configuration tool where commands are dragged and dropped, allowing for a quick and easy installation. No additional engineering tools are needed, only a standard browser.

for handling the conversion between energy and industry standards, “says Niklas Selander, Product Manager at HMS Industrial Networks. “The Smart Grid can offer substantial energy savings and optimizations and there is a great demand in the market to create smarter energy solutions. But to make the Smart Grid come true, you need communication between the complex IEC protocols and the industrial world. Our new SGgateways solve that problem. We already have a number of big industrial customers using the solution.”

“The Anybus SG-gateways are very powerful tools

For more details write to in-sales@hms.se

configuration

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Ametek Rotron High Output Electronic Cooling Fan Optimized For Heat Sink And Heat Exchanger Applications

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Compact MIL-XTM fans deliver best-in-class airflow capacity

High output MIL-XTM vaneaxial fans provide dependable electronic cooling for mission and personnel critical applications.

AMETEK Rotron has introduced a high output version of its MIL-XTM Tubeaxial Fan that is optimized for heat sink and heat exchanger electronic cooling applications. This addition to the Extreme Performance Series delivers best-in-class capacity of 450 cfm @ 1â&#x20AC;? iwg or 350 cfm @ 2â&#x20AC;? iwg. It is designed for long life in harsh military, aerospace and industrial environments.

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The new fans can be used to cool electronic devices and equipment racks in mission and personnel critical airborne, landbased and sea-borne applications. Multiple fans can be stacked to meet high-flow requirements. Standard efficiency and reliability features include advanced composite propeller material, shock-proof construction (meeting Mil-S-901), reverse

polarity protection and over-voltage protection. Optional features allow the fans to be used in a wide range of situations and configurations. These include round or flat case, mounting options, EMI filter, immersion protection, fan performance sensor, analog speed control, custom finishes and more. The applications are Military and commercial electronics cooling,

Satellite/aviation communications, Rack cooling, Telecom, Heat exchangers, Heat sink, Chemical processing and Fuel cells. AMETEK Rotron is a division of AMETEK, Inc., a leading global manufacturer of electronic instruments and electromechanical devices with annual sales of US$4.0 billion. For more details write to ananth.h@ ametek.com

March 2016

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A game changer for CBRN decontamination from Scott Safety

The Light Decontamination System (LDS) can decontaminate environments as large as 500m³. At only 22 kg, LDS is the lightest portable decontamination system in its class, enabling instant decontamination of equipment, personnel, infrastructure and terrain.

A new portable airborne and surface decontamination solution from Scott Safety is achieving a military first – decontamination of chemical, biological and radiological vapours, liquids and particles simultaneously in as little as five minutes. A manufacturer of respiratory protection for the UK MoD, Scott Safety has been at the forefront of CBRN defence and civil protection for over 80 years. “LDS will revolutionise the armed forces” says Dr David Crouch, Global Product Manager for Military & Civil Defence at Scott Safety. “It’s lightweight, portable yet extremely powerful. In independent validation trials, the system decontaminated anthrax by 99.9999999 percent from a 100m³ space, in less than five minutes.” The LDS utilises new Scott Safety atomisation technology to create a fine mist to ensure

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even and consistent coverage and haptic dry surfaces. Rapidly projecting these droplets in the form of a dense and turbulent mist that reaches all airborne and surface threats simultaneously the system is capable of delivering CBRN decontaminants to all nonline of sight surfaces. This process drastically reduces both the chemical footprint and time required for effective decontamination. Unlike many traditional decontamination systems that utilise liquids, this new process forces powders to behave like a gas, ensuring that sensitive and electronic equipment is not damaged.

a lance, the system achieves a projection distance of up to 30 metres and is compatible with a range of chemistries.

Environmentally friendly and cost-efficient, LDS typically requires only five percent of decontaminant compared to traditional systems due to the gas-like behaviour of the small droplet mist. Easily directed and controlled with

Compatible with a range of facemasks, including the General Service Respirator (GSR) developed for the UK MoD, the LDS can be used in a wide range of hazard management situations. e.g. critical and

For chemical and biological decontamination, the LDS is chemically agnostic so can use a diverse range of decontaminants including delivery of Alkoxides, Hydrogen Peroxide, Hypochlorous Acid, Peracetic Acid esters, Chlorine Dioxide, Sodium Hypochlorite and Potassium Peroxymonosulfate. Radiological and nuclear decontamination includes delivery of trippable coatings, fixatives and other sequestering liquids.

iconic infrastructure, airport buildings, hospitals, portable isolation units, underground facilities, buildings and rooms in general, containers, storage facilities, aircraft and ships holds, vehicles and so on. Flexible and scalable, Scott Safety’s decontamination solution can be adapted for large scale infrastructure whereby longer duration or wider area capability of up to 2000m³ is required. The Remote Decontamination System (RDS) operates using a remotely operated 360° collapsible tripod to provide increased levels of decontamination efficacy and performance. The solution is highly portable and is suitable for internal and external decontamination of larger military equipment including armoured vehicles, aircraft and other transport systems. For further details visit www.scottsafety.com/emea

March 2016

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Schmalz introduces new SBPL basic ejector for short cycle times

The new SBPL 25 basic ejector is available in the sizes 50, 100 and 150 with higher suction rates.

The vacuum specialist Schmalz is extending its range of vacuum generators with very high suction rates with the launch of the new basic ejector SBPL (Schmalz Basic Pump Large). It is particularly well suited for safe handling of various workpieces and enables short cycle times. Schmalz has greatly increased the efficiency of the ejector over its predecessor. The new eco nozzle technology is based on a multi-stage venturi concept and ensures

an optimum combination of suction capacity and energy efficiency: Thanks to the eco nozzle, the suction rate in the range from -200 to -600 mbar is, in some cases, twice as high as before. Evacuation and cycle times have been reduced considerably. When constructing the new basic ejector, the Schmalz experts also attributed great importance to the product design. The main body and

nozzle system are made of extremely robust plastic. This makes the ejector highly resilient and 50 percent lighter than its predecessor, which was made from aluminum. The modular design also presents practical advantages to the user: The SBPL can be cleaned very quickly and is also very easy to maintain. The new Schmalz product is available in two varieties: The HF high-flow version (for the range up to -500 mbar) is ideal for

handling porous workpieces such as cardboard, packaging and insulating material. The HV high-vacuum model (for the range from -500 mbar) is the perfect solution for transporting airtight workpieces such as glass or wood. The following optional accessories are available for the SBPL basic ejector: vacuum switch, vacuum gauge, quick exhaust valves, solenoid valves, filter and exhaust duct.

â&#x20AC;&#x153;Schmalz is a leader in Innovations when it comes to Vacuum Technology, this unique Vacuum Generator has been developed keeping in mind of the robust Indian Industry conditions. Hence it is user friendly and easy to maintain and can be dismantled/assembled by a layman thus reduces downtime of a machine drasticallyâ&#x20AC;? Philip J Mani Managing Director-Sales & Marketing, Schmalz India

March 2016

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MAIN FEATURE

Industrial Safety through Smart Automation System An industrial safety system is a countermeasure crucial in any hazardous plants such as oil and gas plants and nuclear plants. They are used to protect human, plant, and environment in case the process goes beyond the control margins. These systems are not intended for controlling the process itself but rather protection.

Rajesh Angadi rajesh_angadi@hotmail.com

We have Process control which is performed by means of process control systems (PCS) and is interlocked by the safety systems so that immediate actions are taken should the process control systems fail. Process control and safety systems are usually merged under one system, called Integrated Control and Safety System (ICSS). Employers are to make sure that these are strictly adhered to have maximum safety. Industrial safety covers a number of issues and topics affecting safety of personnel and equipment in a particular industry. It covers the following: General Safety - General aspects of safety which are common to all. Occupational Safety and Health - Particularly associated with the occupation. Process and Production Safety - Safety in the process and

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production etc. Material Safety - Safety of the materials used in the production. Workplace Safety - Safety issues directly related to the workplace. Fire Safety - Fire safety, in particular the risks associated to the industry. Electrical Safety - In general and in particular, arising from the equipment used. Building and Structural Safety - Safety in general including installations as per existing building code. Environmental Safety - Issues of environmental safety (direct or indirect impact of the industry). Improving Industrial Safety Improving safety procedures after breakdowns, nearmisses and accidents may help prevent future accidents, but this involves the risk of serious

injuries occurring, complete with costly shutdowns and mountains of paperwork that follow. Being able to predict when assets need maintenance rather than waiting until they break down, allows you to avoid the dangers of working with unsound machinery. Furthermore, maintaining an auditable record of when machinery requires service allows you to fix assets before they contribute to accidents, and ensures you are complying with all health and safety requirements in your industry.

electrical wiring, there are many potential hazards in the workplace that are preventable with proactive repair. Proactive maintenance means maintaining the equipment or safe work environment before a problem or breakdown occurs. Knowing how long a generator can run without an oil change, or how many hours a drill can be used in the field without being recharged will enable your team to take action before the tools they are using become hazardous. Proactive maintenance is preventative maintenance. It anticipates possible problems Reactive maintenance is before they happen and takes maintenance done on equipment action to prevent hazards. after something occurs that Many businesses already reveals maintenance is required. utilize elements of proactive If something breaks, you know maintenance, from keeping it needs to be fixed. While machines well-oiled to keeping this is not always dangerous tools charged. Generally, to workers, it becomes a proactive maintenance is done hazard when the broken based on experience and by assets are dangerous assets. using the recommendations From improper ventilation of the producer of the tool or for oil vapors, to damage

March 2016

Teaching the employees to be knowledgeable about the tools they use every day is one way to be proactive when it comes to the teamsâ&#x20AC;&#x2122; safety. It is essential to train workers to be aware of their surroundings, and what to look for when a machine is getting near its maintenance date

machinery. It is important, though, to take into account the different uses a team may have for a piece of equipment, and every team is different, so every team needs to maintain their equipment at different frequencies. When you are able to track maintenance dates, breakdown dates, usage statistics, and in a way that is easily auditable, you will be able to more accurately predict when machinery and tools will be in need of upkeep. Broken machinery or unusable tools can be both expensive and dangerous. Teaching the employees to be knowledgeable about the tools they use every day is one way to be proactive when it comes to the teamsâ&#x20AC;&#x2122; safety. It is essential to train workers to be aware of their surroundings, and what to look for when a machine is getting near its maintenance date. This way, front line workers can spot hazards or problems before they become accidents, and empower them to assist in minimizing shutdowns due to injuries caused by broken assets. Similarly, team members are the first line of visibility in the field because they know best how often they

March 2016

use an asset, and how much abuse it takes. If management in charge of maintenance is not given this essential information, theyâ&#x20AC;&#x2122;ll be unable to plan for upkeep on those materials. Preventative maintenance, then, necessitates visibility in the field, and a team that is aware of their surroundings and educated on the tools they use. Being able to reliably track maintenance actions, and view the correlation between maintenance and accidents gives teams more active involvement in their safety efforts. Teaching employees about proactive maintenance on any tools they interact with, empowers them to be more involved in their safety, and enables management to be able to perform proactive maintenance on assets in the field. A knowledgeable team can also act as a line of defense to be sure equipment is kept in good working condition, which minimizes the risk of shutdowns, near misses and accidents in the future. Industrial Software solution that enables teams to perform proactive maintenance by providing them with easyto-use and reliable tools for

collecting rich data in the field, and reviewing and analyzing this data in whatever way the team is used to will set the organization up for success. Once this data is collected and stored in the locations of the choice, making it easily auditable so that we can view patterns related to accidents, tool maintenance, etc., shed light on how often the assets need to be serviced. Collecting data with mobile forms can be integrated easily into your team with minimal training, and dramatically increases visibility in the field. Empowering employees to report when machinery is performing poorly without interrupting their daily routine provides a valuable opportunity for team members to not only be involved in site safety, but allows for accurate tracking and scheduling of equipment maintenance. With addition of proactive maintenance to routine will vastly decrease the frequency and severity of accidents and breakdowns in the workplace. By enabling the team to reliably track and review maintenance schedules, we are enabling them to create and maintain a safe environment.

Creating educated field workers who will be able to identify problems means creating safer, more productive employees who can be confident that the tools they rely on are in good working order. Smart Automation SMART Automation provides industrial facilities with an open, intelligent building automation and control solution that meets all of the challenges of environmentally smart integration and enterprise connectivity. This ensures complete interoperability among the diverse industrial facility systems. Smart Automation solutions integrate proprietary and otherwise incompatible products into a unified enterprise solution. It utilizes the synchronization, management and control of the major industrial system functions vital to the organization. These functions include manufacturing machines, shop floor, heating, ventilating and air conditioning (HVAC), energy, lighting, video security, fire, data center management, life safety and more. Smart automation are systems

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which are fully-integrated, collaborative systems that respond in time to meet changing conditions. It has the ability to solve existing problems by using open infrastructure that allows solutions to be implemented at the industry while creating advantaged value. Main objective is to enhance convenience, facilitating security, creating green buildings cost effectively, and improve the overall business efficiency. With the Smart automation solutions, we get true value for the money. The lighting solutions, sensor based lighting, blinds control, access control, alarm systems, surveillance systems, and other products offered etc. Along with industrial safety, Organizations are looking for operational excellence, increased productivity and regulatory compliance, optimal asset utilization, reduction in downtime and safety-

related incidents. Analysis of data collected and insights from these field devices when displayed across multi screens help businesses get a competitive edge. Smart automation solution provides ever-increasing demand for functional safety in machines and plants. It provides comprehensive and integrated solutions for the manufacturing and process industry, and it reliably protects people, machines and the environment, while fulfilling current and future efficiency and flexibility requirements. The comprehensive safety portfolio meets all the requirements for functional safety of machines as well as plants which permits simpler, faster, and more economical implementation of safe and productive machines. It leads for the following: 1) Improved engineering

efficiency â&#x20AC;&#x201C; By integration of safety technology into the standard automation with the Engineering Framework. 2) Maximum process safety â&#x20AC;&#x201C; By using Fault-tolerant applications and infrastructures set ups. 3) Simple implementation of safe communication â&#x20AC;&#x201C; due to use of proven standard buses/ connections for transmission of safety-related data. Smart automation system will enable to Smart Manufacturing system which will transform traditional factories from cost centers into profit centers that progressive businesses will strategically invest in to increase sales. This will improve worker safety and protect the environment by making zero emissions, zero-incident manufacturing possible. Smart automation involves information, technology and

human ingenuity to bring automation in the industry; this will eventually lead to Smart Manufacturing. Together smart automation and Smart manufacturing brings Manufacturing intelligence which enables factory to become a profitable systematic innovation research center. 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.

SMART Automation provides industrial facilities with an open, intelligent building automation and control solution that meets all of the challenges of environmentally smart integration and enterprise connectivity

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March 2016

T&D

March 2016

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MAIN FEATURE

Take care of safety in the Industry ‘KNOW SAFETY NO PAIN; NO SAFETY KNOW PAIN’ is seen by us in many posters or as a slogan especially in the month of March of the year. 4th of march every year is considered as ‘Safety day’ to remind all of us on importance of safety and for us to commit to follow safe practices in the company for the whole year. Benefits of safe practices will come only if followed every minute of our work. Murphy’s Law works for sure in safety. ‘If something can go wrong, it will’. In this article, we will focus on importance of safety and how safe practices can be inculcated in the companies.

P S Satish gotopssatish@gmail.com

51.Take care of safety in the Industry – Part 1

b. What is safety and accident?

a. Safety and us

All work can be performed safely.Safety is prevention of accidents which may result in personal injury and or property damage. Accident is an unplanned, unforeseen, undesired, interrupting and non-value added activity. Accident is caused by unsafe actions or unsafe conditions. Accidents actually do not happen but are caused. Major cause in this is unsafe acts and unsafe conditions. Small portion of accidents are caused by natural calamities which is beyond our control. It can be said that accidents may not cause injuries but injuries are caused only by accidents. As per Frank Bird’s theory of accidents close to 98% of accidents happen because of unsafe acts and conditions. That means 98% of accidents are preventable.

Safety starts with self. It is not something that can be delegated and expect someone else to follow without me practicing. The word SAFETY can be expanded as Set AccidentFree Example Through You. Practising safety is a habit which has to be practiced for long and should be taught to children in the family first. One of the company I know made an attempt to educate members of family of the employees on safe practices at home in local language. The logic was that the Employee learns about safety better when he practices at home and he follows same at work in factory or offices. I consider this as good practice and I had an opportunity to educate a group of employees along with family members in the company.

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HW Heinrich, a safety Engineer

from USA, propagated a theory in 1950s linking relationship between minor or nearmiss accidents and severe/ fatal accidents.He found this relationship from the Data of insurance claims when he was working in an Insurance company. This theory came to be known as ‘The Heinrich 30029-1 Model’. As per this, for 300 near miss or no injury accidents will cause 29 minor accidents (requiring first aid) which in turn results in major injury or fatal accidents. So to prevent a major accident, we need to work on first on cases of near miss or no-injury incidences. Effective supervision and creating awareness can prevent this happening.

duty immediately or soon.

c. Types of Accidents

d. Unsafe conditions

o Minor accidents are types of accidents where there is an illness or injury to the operator. This may or may not result in loss to property or production. The operator returns to the

As explained, unsafe conditions can lead to accidents. We should identify unsafe conditions and take corrective actions to prevent happening of accidents. Some of unsafe

o Major accidents are those where there is a serious injury to the operator and may involve loss to property or production. The operator takes more than 48 hours of leave. o Fatal accidents where there is death of operator. Normally results in loss of Production and property. For example, death due to electrical short circuit. o Dangerous occurrence are those accidents which does not result in injury to operator or death but ends with loss of property. For example, collapse of a building, explosion of tank etc.

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Major Injury

Minor Injuries

Near Misses The Heinrich 300-29-1 Model

conditions are: o Improper lighting - Poor lighting arrangements, darkness and glare o Improper guard - No guard, improper guard and not enough protection o Lack of personal protection – Not using goggles, helmets, gloves, safety shows, masks, aprons and respirators o Hazardous arrangements – Improper storage of materials and tools, gangways blocked, staircases congested, haphazard arrangement of goods, overloaded racks, no identification, chemicals not marked, Inflammable chemicals kept close to inflammable material etc. o Improper ventilation – Poor circulation of air, suffocation, contamination of air, too hot or cold, lack of oxygen, poor exhaust arrangements, dusts….. o Defective Equipment – Not suited for purpose, poorly maintained, wear and tear, poor design, not robust enough etc. o Others – slippery floor, no proper boards, leaky

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machines, no proper earthing for electrical connections,sharp edges, loose wires, faulty steps, improper furniture etc. e. Unsafe acts Accidents can also happen because of the acts by the operator or user. Reasons could be because of over confidence, lack of knowledge, lack of training, lack of proper instructions for the usage, negligence, reluctance to follow instructions, inability to learn, health issues, carelessness, disregard for safety rules, inability to recognise hazards or no experience. Some of unsafe acts are: - Rash driving of forklifts - Failing to shutoff machines - Welding without using any personal protection - Working on electrical equipment when it is on - Adjusting machine when in operation - Lifting heavy material - Overloading - Not storing properly - Using wrong or defective tools - Removing protection guards - Standing or walking under suspended material - Jumping off from elevators

- Not following instructions - Using hands without gloves - Not wearing personal protectors f. Effects of Accidents at different levels f.1 At operator level o Medical expenses and loss of leave and Pay o Strain to family members o Effect on morale o Opportunity loss at company o Loss of health and could be loss of body part o Reputation loss f.2 At Management level Loss of time, efforts and money by interaction/investigation/ inspection by • Pollution control board • PF/ESI/Insurance agencies • Police Department • Fire Department • Inspector of factories • Labour department • Local panchayat • Politicians f.3 At Company level

Loss of reputation, finance, production, image with customer, public rumours and efforts of interaction with agencieso General public o Trade unions o Press o Court proceedings The intangible portion of losses because of accidents constitute a higher portion than tangible ones. Tangible loss is only tip of iceberg. By proper awareness and care, these potential losses can be avoided. We will continue the article next month with measures on preventing accidents. Have a safe day. Please send your inputs,remarks,opinionsand suggestions toP.S. Satish,Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103, Mant riParadiseApartments,Bannerg hatta Road, Bangalore-560076. Email:gotopssatish@gmail. com;www.linkedin.com/pub/ satish-cp-pii/35/153/85b;Mob: 9845043202. Have a nice day

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MAIN FEATURE

Inventory Management: Tackling the Challenge! A week before while having coffee with one of my entrepreneur friend who is into the business of industrial automation, I asked “what are the challenges in your business today”? He immediately said, “Inventory management”. For a small-scale unit with sales turnover of 40 Crores, his slow moving inventory was whopping 4 Crores, 10% of sales which sooner or later would have become dead/obsolete inventory. He had to station himself at the factory for months, to salvage the situation & reduce the losses. Many SME machine tool industrialists like him are stuck into myriads of issues; inventory management being a small part of it.

Shirish Joshi shirish.joshi@cygds.com

Leaders in SME businesses have to deal with challenges most of the time. Without access to best practices in marketing, inventory control, employee management, project management & plant efficiencies, they operate more by gut feel than information. The source of this pain stems from problems such as growth, profitability, cash flow, customer service, attrition, productivity & compliance. A week before while having coffee with one of my entrepreneur friend who is into the business of industrial automation, I asked “what are the challenges in your business today”? He immediately said, “Inventory management”. For a small-scale unit with sales turnover of 40 Crores,

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his slow moving inventory was whopping 4 Crores, 10% of sales which sooner or later would have become dead/ obsolete inventory. He had to station himself at the factory for months, to salvage the situation & reduce the losses. Many SME machine tool industrialists like him are stuck into myriads of issues; inventory management being a small part of it. Falling levels of profitability by far remains the most significant worry for the SME sector. Besides high cost of credit, power and cost of labor, input prices have escalated as well. Since most inputs are sourced from large companies, small companies enjoy very little bargaining power. Also these companies are usually not the market

leaders in their segments and, hence, cannot dictate prices in the market. The only way to survive is to keep a strict control on costs while maintaining product quality to meet their sales targets. Let’s focus on the issues of Inventory management, which is ONE task in the entire supply, chain cycle. Every stage in supply chain works independently with a common objective, make the company profitable. Thus it is important that every stage of the supply chain co-ordinates and together form the much desired inventory policy. It has to work like the synchronous activity that generates melody from a large musical band where large numbers of musicians are playing different instruments at the same time.

In an SME, generally the owner ends up taking all decisions. It is observed that in few cases, it turns up to the advantage, as he has complete control over the situation of each aspect of supply chain. However, most of them get into trouble due to scattered focus on various links in the supply chain. No matter what size, every organization undergoes thru the demand and supply cycle. Gone are those days of doing the work on Excel or home grown software or other basic accounting system. It does not provide a 360 deg view. SME’s lack visibility on their TRUE financial position. Visibility to Inventory (stock) levels is insufficient. This results in the business carrying excess stock of items and sometimes keeping slow

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moving items for too long or sometime not enough stock when there is demand. Case Study: One of our manufacturing client a 180 Crores turnover company was struggling to improve their PAT for long. We learnt that, they addressed both domestic & exports market from the same plant with fixed production capacity. Their inventory turns ratio was very poor at 6, means average inventory was at 30 Crores at any point of time which was very alarming. There were over 200 SKU’s (stock keeping units) for direct material with minimal standardization. They had a long list of 1200 vendors that were active in their ERP system. Material was procured on LC terms with only 7 days credit to enjoy discounted rates. On the other hand, due to the thirst of garnering more business higher credit period was given to many customers thereby further widening the cash to cash cycle period. Then there were business & plant operating expenses with a very high fixed cost component. This had put an enormous strain on the cash flow management. In short, a perfect recipe of minimal or no profits. We teamed up with them and did following: • Set up a new plant to address exports market. This eliminated the priority clashes with the domestic market. Customers were happy due to

timely deliveries. • Worked with the customers & RM suppliers to standardize the SKU’s and reduced it to less than 75. This eased out the procurement cycle.

- one gauge, many applications

• Decision on RM ordering is taken only after strict discussions with Sales & operations after lot of iterations. • Took quick decisions on salvaging the obsolete inventory and freed the working capital. • Inventory turns jumped from 6 to 12. This helped to eliminate fear of obsolescence and improved working capital. • Made the ERP system more robust by working on various policies and procedures in the entire order to pay cycle. • Most important, we communicated to the team members across levels and departments to make them understand the importance of their part of work and the intensity of impact on company’s profitability. As a result there was a significant improvement in the PAT of the organization. Key Learning’s: • Companies that don’t frequently update SKU forecasts, policies & parameters always suffer from systemic over & under stocking. • There is no single solution for improving inventory management... companies continue to chase increasing forecast accuracy as a key weapon.

Nothing compares to Equator™, Nothing compares like Equator™ The unique new Equator™ is a versatile alternative to traditional gauging, offering inspection of an unprecedented variety of manufactured parts. It has been developed and proven on the shop-floor with industry-leading gauging users in multiple industries and applications. Benefits which can be gained by using Equator™ include: • Reduced gauging costs • Robust shop floor measurement process • Reduced production bottlenecks

To see Equator in action visit www.renishaw.com/gaugingapps

Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com

March 2016

www.renishaw.com

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• There is a direct link between inventory management effectiveness and company’s cash flow generation. • Establish metrics that allow you to measure productivity and profitability. • Constantly evaluate cash flow vs. plan • Install ERP backbone that givesyou business analytics as and when needed. • Constantly communicate the need to the team below. • Benchmarking, implementing best practices. • Keep an eye on service levels.

• Robust Procurement Strategy & Sourcing Contracts There is an ocean of theory, I.T tools and complex mathematical models built around supply chain practices by the experts in the western world. However, the biggest problem is practical implementation and customization to the Indian context. There are no fixed formulas. Each method may differ from other depending on the case. Result oriented & experienced professionals who can provide their expertise in time bound manner can be hired by the SME leaders. There are lean manufacturing consultants appointed by the GOI for various industrial clusters. Their services can be used to the benefit of SME’s. All the best!!!

The author Shirish Joshi is founder of Cygnus Design Solutions (www.cygds.com) based in Mumbai. They offer a basket of consulting services across multiple verticals to the industry. He is a Production Engineer with PG Diploma in Production Management with 25 years of industry experience. In the past he has worked with renowned organizations such as Bajaj Auto, Tata Cummins, Cummins India, DHL Express and Classic Stripes & Repro India. He has major contribution in setting up multiple green field projects such as diesel engines plant, aluminum composite panel plant & high volume book manufacturing & corrugation packaging plant, setting up Tool room, Cutter grinding cell, tool engineer-

ing for machining lines. He also have rich experience in setting up shared procurement services for various Cummins entities in India & also for 4 businesses of DHL Express in India. He has an expertise in development & execution of supply chain strategies for organizations with multiple plants & warehouses in India. He played an active role in two business acquisitions and brought them into main streams of respective organizations. During his tenure, he has successfully done multiple operating margins improvement projects. Endorsements from other professionals, former colleagues and superiors can also be seen in his LinkedIn profile. http:// in.linkedin.com/pub/shirishjoshi/1/b85/4b0

Inventory Management - The Benefits of being the Minimalists

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March 2016

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INDUSTRY FOCUS

Total Welding Management

Kemppi has developed the software based solution called “Kemppi Arc System -3 (KAS-3)” that provides accurate and formal solution and for the first time in the history, one gets all necessary data for whole welding process, all monitored, all documented and all controlled.

Rashmi Ranjan Mohapatra Rashmi.Mohapatra@Kemppi.com

Abstract: Welding procedure specification (WPS) is a Qualified & approved written welding procedure followed in every welding industry that gives guidelines to the welders or welding operators to produce sound and quality production welds as per their customer requirements. Today the business environment in all industries and monitoring of multiple site work activities and welding of difficult materials becomes more challenging. The customer quality requirements are demanding more than the standards/codes followed by them. How much do we really know the quality of welded objects produced by us? There has been no automated quantitative information systems that can find out the quality of the welded parts. To meet all these expectations, Kemppi has developed the software based solution called “Kemppi Arc System -3 (KAS-3)” that

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provides accurate and formal solution. This system traces the each individual welds, the qualified welding personnel for respective WPS and reports non-conformances automatically in real time. Generally the result or quality of welded object information will get after completion of NDT or DT. But now with the system we can get the online feedback during welding itself. So the productivity benefit also comes from the effectiveness of the welding work, automated monitoring and easier way to maintain, store and retrieval of the quality documents. Key words: Non Destructive Testing (NDT), Destructive Testing (DT) & Kemppi Arc System-3 Introduction: Welding – A joining process of two materials, metals/

Sritharanandh.G Sritharanandh.Govindraj@Kemppi.com

non-metals, that coalesced by the application of pressure and/or temperature. For example, power plants, Oil & Gas Industry, Aerospace, Ship building each of these industries contain thousands of thousands critical joints. In these high welding quality demanding industries, even a failure of single joint can leads to catastrophe. But how much we really know the quality of the welded objects produced by us? Welding procedure specification (WPS) is a Qualified & approved written welding procedure followed in every welding industry that gives guidelines to the welders or welding operators to produce sound and quality production welds as per their customer requirements. How do we know the welders are really following the approved WPS given by us?. Today Most of the welded

objects produced by us carry little qualitative proof that the welding was completed using approved parameters, filler metals/Electrodes and qualified welding personnel. Even to find out this much amount qualitative information, the company has to invest lot of manpower like production, Welding & quality engineer to do these tasks and of course it will be of time consuming process. But Until now there has been no system that can support these quality needs. But now Kemppi has developed the software based solution called “Kemppi Arc System -3 (KAS-3)” that provides accurate and formal solution. For the first time in the history we can get all necessary data for whole welding process, all monitored, all documented and all controlled. Functional Software modules: The Total Welding management consists of four modules.

March 2016

Internet In Welding World In 1993 when KEMPPI became the first company in the world to bring in DIGITAL INVERTER machine no one would have imagined what the welding world was up to!! Today we are talking about “digital welding machines” with nonchalance. Let us look at some statistics:

The demand for productive and sustainable welding solutions is universal. As our customer, you experience every day what proven technologies, expertise and fast reaction truly mean. You can win in welding results, documentation and learning time, material use, and manpower. Together, we always find new value to share just by knowing better.

Getting all the stake holders of Welding in to a single platform

As the pioneering company within the welding industry, it is our role to develop solutions that make you win business. Welding solutions on which you can trust your future. In this we don’t compromise, but instead continue challenging the conventional. And this is just the start.

Our technology levels support you whether you are planning an affordable welding start-up or searching for an industry-proven and smart welding solution. In case you want the highest return on your investment, we provide you with advanced and welding management software. That way, you get a 360-degree-view of your profit, project and results across multiple sites.

March 2016

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Namely Coordinator, Controller, Documenter and Manager. Coordinator module: We can develop & manage the Welding Procedure Specifications (WPS), Procedure Qualification Record (PQR) and Welder Performance Qualification (WPQ) and welding coordination. Controller module: Along with coordinator module, the controller module can collect the actual welding data to the control welding and collect data for documentation. Documenter module: All the necessary collected welding data are documented automatically according to customer requirement format to manage for Quality inspection and documentation. Manager Module: In this module starting from Engineering , Welding Production , Quality inspection, WPS’s, Qualifications and all the

welding data’s are collected and documented This module comprises of the complete control of the total welding management. Depends upon the type of industry and its welding quality demanding requirement, customer can select the above modules to implement and get the total control of welding. How it works? Kemppi Arc System-3 is very simple and easy to learn and adopt it according to customer requirement. The Welding management system is applicable for Manual Metal arc Welding (MMAW), Tungsten Inert Gas Welding (TIG) and Metal Inert Gas welding (MIG) /Metal Active Gas Welding (MAG). This system works with both Kemppi branded Power sources as well as other branded power sources. The system consists of smart reader, Internet connection (Wired or Wi-Fi), KAS-3 web based software solution & Universal adapter (In case of

Other branded machines, to connect the smart reader and the power source). We need to give the following inputs to the software 1. Base Material specification details like Grade, supplier, Heat Number , batch Number, condition & strength etc., 2. Electrode / Filler Material specification trade name, Supplier, Mechanical & Chemical properties details, diameter etc., 3. Shielding Gas (In case of MIG & TIG): Supplier, Composition, Active/ Inert Type etc., After that We need to create the welder personnel details and his qualification information with respect to different standards (like ASME, EN etc.,). Then we need to give the input to the system about the approved parameter details of welding procedures (WPS & PQR). The system automatically calculates the qualification ranges based on the input actual values. After completion all the above

steps, the system generates barcodes. Then we need to create the Project using project administration tools. Generally, The welding fabrication includes various stages like Engineering (Design), Welding procedure development and qualification and create the work order for production, actual production, Post weld heat treatment, work order for quality inspection, Then quality inspection and documentation. Similar to that KAS-3 also have the various stages of fabrication. Unless until if we could not complete the particular stage, the system will not allow you to move for further stages. Using this tool, We can create and give the particular access to respective department in charge. Others can’t have the control of project progress/stage. But the Project manager can have the complete project area access. In case of any delay/ problem in particular department/ area, So the project manager can able to find easily and can take corrective action immediately. Before welding commences, The

In the KEMPPI ARC SYSTEM 3, welding production performance has been taken to the next level by adding on new welding management expertise for documentation and quality

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March 2016

welder/Welding operatorâ&#x20AC;&#x2122;s first task is to scan their personnel identification tag, so welderâ&#x20AC;&#x2122;s qualification details are identified. Next scanning the WPS barcode ensures such variables as qualifications are suitable and in date. Filler material/Electrodes, Shielding gas, work order for production barcodes also scanned and compared with WPS and verified. In case of any mismatch/ any deviation the reader will give the red screen alert. To alert the welder, to take suitable corrective action if required before welding. This will avoid the wasted time and costly rework. Once everything is correct & ready, the smart reader gives the green colour alert message to start the welding. After completion of welding, we need to complete the weld, with using smart reader. So immediately the welding parameters details are shared to the web based software (KAS-3). The system immediately compares the value used by the welder and the value given in the WPS. The software immediately reports a non-conformance, if the voltage, Current, heat input does not stay within the allowable limits. The quality/ welding officer can take an immediate corrective action. Benefits: The system provides cost savings by automating a considerable part of manual work involved in the data collection, interpretation, storing and retrieval of information for statutory requirements is very simple and becomes easier. Also weld traceability will be attained when the barcodes are scanned. So all the different actions like production , data

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collection, review, approval, acceptance are date & time stamped. So the welding department will have complete online control over welding production. The right welding procedure is used every time. So the risks for welding defects are minimal. Efficiency and productivity are also improved by the fleet management. So the manufacturing company can meet all the clientâ&#x20AC;&#x2122;s quality requirements. Managing of Multi site operation becomes easy and cost effective. Codes & Standards are always being followed in entire project and of course all the welders qualifications have correct and up-to date. Summary: Kemppi Arc System-3 is the first total welding management system in the world that provides all the necessary data for whole welding processes, all monitored, all documented and all controlled. This system traces the each individual welds, the qualified welding personnel for respective WPS and reports non-conformances automatically in real time. The productivity & quality benefit also comes from the effectiveness of the welding work, automated monitoring and easier way to maintain, store and retrieval of the quality documents. The article is written by Rashmi Ranjan Mohapatra and Sritharanandh G of Kemppi India. Rashmi Ranjan Mohapatra, BE, MBA in Marketing, having 21 years of experience in Industrial consumables and equipment in the Indian, European and South East Asian Market, has worked for Linde, earlier known as BOC India, ADOR Welding and currently works as the Managing Director of KEMPPI INDIA based at Chennai since April 2011.

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SPECIAL FEATURE

Budget Reignites the Investment Cycle Union Budget 2016-17: Impact on the manufacturing sector

The Hon’ble Finance Minister of India, Mr. Arun Jaitley presented the Union Budget of India to the Parliament on February 29, 2016. Despite the global economy in a serious crisis and a shortfall in India’s monsoon for two consecutive years, the Indian economy has been robust and has grown 7.6% in 2015-16. The foreign exchange reserves have reached a highest ever level of about USD 350 billion. The fiscal deficit in 2015-16 and 2016-17 has been retained at 3.9% and 3.5% of GDP respectively. The current account deficit is projected to be 1.4% of GDP in 2016.

Rajesh Nath info@vdmaindia.org

The Union Budget 2016-17 has proposals with a plethora of initiatives to boost economic growth, with promises for further benefits in the future. The budget focuses on ensuring macro-economic stability and prudent fiscal, boosting domestic demand, continuing the pace of economic reforms and policy initiatives. There is focus on enhancing expenditure in priority areas of - farm and rural sector, social sector, infrastructure sector employment generation and recapitalization of the banks. The government also ensures early passage of the most awaited Goods and Service Tax bill. Finance Minister has introduced several measures with respect to the manufacturing sector and industrial growth. In the earlier budget, Government had mooted proposal to reduce Corporate Tax from 30% to 25% over a period of four years, accompanied by rationalization and removal of various tax exemptions and incentives. Final plan of phasing out

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exemptions is proposed in the current budget. New manufacturing companies which are incorporated on or after 1st March 2016 are proposed to be given an option to be taxed at 25% + surcharge and cess provided they do not claim profit linked or investment linked deductions and do not avail of investment allowance and accelerated depreciation. The government proposed to lower the corporate income tax rate for the next financial year for small enterprises i.e companies with turnover not exceeding Rs. 5 crore (in the financial year ending March 2015), to 29% plus surcharge and cess. For further promoting start-ups, the Government intends to assist their propagation through 100% deduction of profits for 3 out of 5 years for startups set up during April 2016 to March 2019.

technology hardware, capital goods, defence

In line with the Make in India campaign, the Government proposes to make changes in customs and excise duty rates on certain inputs to reduce costs and improve competitiveness of domestic industry in sectors like Information

unserved and underserved airports at an

production, textiles, mineral fuels & mineral oils, chemicals & petrochemicals, paper, paperboard & newsprint, Maintenance repair and overhauling [MRO] of aircrafts and ship repair. As part of the “Skill India” mission, Government is to set up 1500 Multi Skill Training Institutes across the country with a fund of Rs. 1700 crore and skill 10 million youth over the next three years. The finance minister laid out plans to boost infrastructure. The total outlay for infrastructure is Rs. 2,21,246 crore with speeding up of road construction. The government proposed to approve nearly 10,000 kms of National Highways in 2016-17. In the civil aviation sector, the Government is to draw up an action plan for revival of indicative cost of Rs. 50 to 100 crore each. Further, to modernise ports and increase their efficiency, Rs. 8000 crore has been allocated for Sagarmala project. To develop new Greenfield ports in eastern and western

March 2016

Samir Gandhi

Director, Gandhi Automations Pvt Ltd

coasts of the country. Work on National Waterways is being expedited. Rs. 800 crore provided for these initiatives. The Budget has done much to reignite the investment cycle by enhancing allocations for the infrastructure sector. Reducing the infrastructure gap is critical to accelerate manufacturing growth and attract foreign investment. While augmenting the allocation on roads, railways, ports and airports is significant, the Budget has rightly announced measures to revitalise public-private partnership (PPP) through the introduction of Public Utility (Resolution of Disputes) Bill, formulating guidelines for renegotiation of PPP Concession Agreements and introducing a new credit rating system for infrastructure projects. To give impetus to food processing industry, the Government intends to allow 100% FDI through FIPB route in marketing of food products produced and manufactured in India. With a view to promote Make in India, foreign investors will be accorded Residency Status subject to certain conditions, unlike currently where the investors are granted business visa only up to 5 years at a time. In order to ensure effective implementation of Bilateral Investment Treaties signed by India with other countries, the

March 2016

Government proposes to introduce a Centre-State Investment Agreement and states which opt to sign these Agreements will be seen as more attractive destinations by foreign investors. The Government also proposed to introduce a bill to amend the Companies Act, 2013 in the current Budget Session of the Parliament, which would also improve the enabling environment for start-ups. All these decisions will facilitate ease of doing business for foreign investors and their domestic recipients. The author Rajesh Nath heads the Indian office of The German Engineering Federation (VDMA) as Managing Director. With 3000 member companies divided into 38 specialized Industrial Sectors VDMA is the largest Industrial Association not only in Germany but whole of Europe. Founded in 1892, it now looks back on a 118 years history. This industrial Association with a work force of 400 employees reflects the Production Process from Components to Plants, from System Suppliers or Integrators to Service Providers. With offices in Kolkata, Noida and Mumbai, VDMA supports it member companies by their activities in India and helps to foster Indo-German Trade in the engineering sector.

â&#x20AC;&#x153;With a great emphasis on growth of economy in the Union Budget, the Finance Minister has made a commendable effort towards creating a robust path for the future. I am happy that the budget has walked the talk for Make in India. The skill development push is another positive as the market demanded and industries have been desperately searching for. The predicted 8-10% growth rate of the Indian economy signals a great run for the country in time to come with its own set of challenges. While factors like inflation, oil prices, and rupee valuations will continue to have a major play in the way India maneuvers itself in these difficult global times, we request the government to provide the requisite impetus to infrastructure and position India as great investment hub. We urge the government to adopt a pragmatic approach to strengthen the Indian economy and take India to glorious heights of progress.â&#x20AC;?

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SPECIAL FEATURE

Union Budget: A Welcome Move Union Budget 2016-17: Impact on the manufacturing sector

The union budget for 2016 has genuinely appreciated the need for greater impetus in certain areas such as education, skills and job creation, infrastructure and investment, governance and ease of doing business. However, there is not much cheer for the PM’s pet project — Make in India — where the tax incentives offered have been negligible.

Kishor Jagirdar kishorjagirdar@gmail.com

With an intention to provide impetus to Make in India, new manufacturing companies have been offered a concessional tax rate of 25% on their profits. However, they would not be eligible to claim profit-linked, investment-linked deductions, investment allowances and accelerated depreciation.

recorders and lithium-ion batteries also

The erstwhile tax regime permitted

will not face any duty, compared with as

a 30% deduction for new workmen in

much as 12.5% earlier. Last year, a similar

factories which could be availed of

measure was taken for mobile handsets

only by a manufacturing company. The

to boost local manufacturing of phones.

same benefit has been extended to all

It drew a number of companies to

sectors with the objective to match the

assemble in India and the government is

growing need for skilled labour since

hoping the latest move to complement

employment generation should increase

that.

consumption and provide an indirect

The duty changes have been made on inputs to make manufacturing competitive for sectors such as IT, capital goods and defence.

The rejig in indirect taxes framework

Carrying forward the process initiated in the last Budget, the government has scrapped excise duty on inputs, parts and components, and subparts for the manufacture of charger or adapter, battery and wired headsets or speakers of mobile phones. Besides, parts and components, and subparts for the manufacture of routers, broadband modems, set-top boxes for Internet and TV access, digital video

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boost to the manufacturing sector.

has focused on nuts and bolts changes,

While investors and industry experts,

including liberalising the cenvat credit

alike, expected and professed the need

mechanism, which rendered the

for enhancing tax sops in the R&D

country’s manufacturing uncompetitive.

arena, which is vital for manufacturing,

Restrictive credit policy had fuelled large-scale litigation in indirect taxes. For example, telecom companies found it difficult to claim tax credit on towers that sat on their books as

the deduction of two times of the expenditure has been reduced to 1.5 times and a sunset clause of 31 March 2020 has been proposed for such deduction.

cost. Moreover, in a boost to FMCG

In order to encourage local start-ups and

companies, such as Unilever, credit will

in line with the Start-up India campaign,

be allowed even if production activity

the Budget provides for profit-linked

is outsourced to a job worker or small

tax deduction of 100% of the profits

manufacturer.

of a start up which has commenced

March 2016

Sunil Khanna

President and Managing Director of Emerson Network Power India

operations, upto 31 March 2019 for a period of 3 years in any period of 5 years from such commencement. However, the real benefit could get diluted as start-ups which generally are in need for cash to meet their growth objective will be subject to MAT which will restrict liquidity and funds available for growth. Taking into account the fact that the global down turn and the slow down of the start up scenario across in the global scenario this comes as a relief to the Indian entrepreneurship which appears to be rising and will boost the “Make in India” initiative. On the indirect tax front, significant changes have been proposed to make India attractive for manufacturing vis-avis importing finished products for sale to Indian customers. Custom duties on components used in the semi-conductor industry have been reduced whereas duties on finished electronic goods have been increased to make manufacturing in India viable. Further, in order to facilitate building of manufacturing capacities, import duties on capital goods have been reduced. Similarly, the provisions relating to reversal of CENVAT credit are simplified

March 2016

and rationalised. Provisions have been made to enable transfer of input services credit to outsourced manufacturers which is a welcome move. Further, refund of service tax paid on services used beyond the factory or any other place or premises of production or manufacture of the goods which are exported outside India has been allowed with retrospective effect. Companies will now be able to claim cenvat credit on goods purchased in the first year itself. The cenvat credit policy has been restrictive as it allowed companies to claim credit only for tax paid on services used in the output or on capital goods used in the process of manufacturing. The newly set up manufacturing companies which are incorporated on or after 1 March 2016 would be given an option to be taxed at 25 % (plus surcharge and cess) provided they do not claim profit-linked or investmentlinked incentives.Additionally, the FM has proposed to reduce the corporate tax rate for small scale companies (with turnover not exceeding Rs 5 crore in financial year ending March 2015) to 29% (plus surcharge and cess). It is worthwhile to note that the above incentives are not applicable to Limited Liability Partnerships. Separately,

“The Government has tried to keep a healthy balance between inclusive growth and fiscal consolidation amidst global volatility and additional burden on account of the 7th pay commission, OROP. With an important focus on digitation, the government has shown good intent in keeping up the momentum of the Make In India and Digital India Mission. The government has shifted its focus from large cities to rural areas showing a clear intent to uplift those who belong to the bottom of the pyramid, especially the agricultural sector and focus on creating skilled labor. The effort to incentivize the Make In India program by way of domestic value adding in the Electronics Manufacturing Systems segment is a step in the positive direction as is the removing of custom duties. This augurs well for us as majority of the spending in our industry is on imported ESDM Electronic System Design & Manufacturing items. From a taxation standpoint, lowering of Corporate IT Tax for companies not exceeding Rs. 5 crore turnover to 25% plus surcharge is a positive move as it offers incentives to SMEs and SMBs in the country to focus on their growth. Another proposal that will benefit the country and stimulate start-ups on the growth trajectory is the amendments to the taxation for new manufacturing companies incorporated after is 1ST March 2016 as they will now have the option to be taxed at 25% plus surcharge and cess provided they do not claim profit linked to investment.”

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Mahathi Parashuram Head â&#x20AC;&#x201C; Public Affairs & Marketing, Grundfos India

The Budget has taken a realistic approach to encourage growth in the country. For the manufacturing industry there is no direct incentive, however, there is adequate scope to generate demand and boost the industry. To encourage domestic manufacturing, the governmentâ&#x20AC;&#x2122;s move to give tax benefits to new manufacturing units is a well-intentionedeffort. This will spur the manufacturing set up in India and will help increase job opportunities as well. The focus on the strengthening of small scale industries by offering tax benefits and other changes in indirect taxes, particularly customs and excise duty, will boost indigenous manufacturing. Overall the budget encompasses the need of diverse sectors and highlights the Governments concentrated efforts to make initiatives like Make in India and Start up campaign successful. The budget has alsogiven a high priority to water resource management and urban infrastructure which arecritical elementsfor development. This will definitely have a positive impact on the manufacturing industry. The one element that I feel that the budget should have focused on is a provision for special tax allowance to manufacture energy efficient products and offer tax benefits on using energy efficient products. This would have helped increase the demand for energy efficient products and ultimate will help make India more secure on the energy front. Overall, the budget looks to be a progressive one. We however need to see the timely implementation of the Smart City and Make in India campaigns to ensure steady growth of the Indian economy.

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tax incentives have been liberalised for employment generation.The anamoly of satisfying the twin conditions of acquisition and installation of plant and machinery in the same year for claiming investment linked allowance (which is practically not feasible in all cases) has been removed. On the other hand, in line with its plan to reduce the corporate tax rate from 30% to 25% in the next four years, it is proposed to phaseout incentives, like accelerated depreciation limited to maximum 40%,limitation in deduction of expenditure on scientific research etc, sunset clause for income exemption for SEZ units etc. Overall, the FM has attempted to put on table a balanced Budget in midst of the turbulent global economy and high expectation of the investors. While the roadmap for the Make in India initiative is out with the Budget, it needs to be seen how it positively impacts the domestic value addition. The author Kishor Jagirdar is the Chairman and Managing Director of Infopace Management Pvt Ltd a Strategic Change Management and Innovation Company. The company promotes incubation and Start up across India and works

closely with APEX trade associations and the Government. A Strategic Change Managment Specialist, Serial Entrepreneur and Innovator Kishor Jagirdar has over 24 yrs of rich management experience in international business. Master of Arts in Economics, MBA (Mktg) and a PGDHRMin his credit, Kishor co-founded Infopace Management Pvt Ltd in 1999 to cater to SMEs with holistic support in Management consulting. In the last 15 years he has been assisting and working on various aspects of enterprise development strategies for the industry and initiated various programmes on transformational Change. He is currently an acting consultant to several mid sized companies in India .He was also on the board of COMILE ENT LTD (NZ) and GVLab LLC (USA) in 2007. His focus is on Start -ups, SMEs, mid sized companies as well as micro units. He has led change mgmt on business models, innovation and org climate in mergers, acquisition and also for the Govt in Energy sector. Has delivered numerous workshops in India and internationally especially in ASEAN region reaching out to over 2 crore people and promoted numerous Start ups and social micro enterprises in India. (Views expressed are personal and is not in representation of any official forum).

March 2016

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SPECIAL FEATURE

MAKE IN INDIA gets a Fillip

Union Budget 2016-17: Impact on the manufacturing sector

Amidst high expectations from the public on one hand and global slowdown on the other, the Union Budget 2016 was announced by the Finance Minister (‘FM’). Apart from addressing areas like rural distress, agriculture, infrastructure, economic reforms, affordable housing,etc., there are some noteworthy proposals made for manufacturing sector in order to incentivize domestic value addition in line with Government’s Make in India initiatives. Few of them are highlighted below.

Vishal Shah vishal.j.shah@in.pwc.com

The newly set up manufacturing companies incorporated on or after March 1, 2016 can opt to be taxed at 25 % (plus surcharge and cess) provided they do not claim any incentives (like SEZ benefit, investment allowance etc.) except the new employment deduction. This option can be exercised at the time of filing of return of the company for the relevant financial year. While there is a tax rate advantage for the new manufacturing companies, the decision to set up such company would have to be made having regard to the

Particulars

Khyati Shah khyati.shah@in.pwc.com

overall business, financing and supply chain plans. Additionally, the FM has proposed to reduce the corporate tax rate for small companies (with turnover not exceeding Rs. 5 crore in FY 2015) to 29% (plus surcharge and cess). Interestingly, it is worthwhile to note that the above incentives are not applicable to Limited Liability Partnerships. Separately, tax incentives have been liberalised for employment generation. The anamoly of satisfying the dual

Phase out Plan

SEZ units

Grandfathered if operations started by March 2020; not eligible thereafter

Depreciation

Highest rate capped at 40% from FY 2017-18 onwards

R&D allowance

Gradually reduce to 100% from FY 2020-21 onwards (from 150%-200% currently)

Investment allowance

Available till FY 2017

Additional Investment allowance

Available till FY 2020 for Andhra Pradesh, Bihar, Telangana, West-Bengal

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conditions of acquisition and installation of plant and machinery in the same year for claiming investment allowance (which is practically not feasible in all cases) has been removed. Interestingly, the Budget Memorandum mentions that the amendment will apply with retrospective effect from April 1, 2016 i.e. for assets acquired /installed in FY 2015-16 also. As promised, the FM has proposed 100% tax holiday(subject to MAT levy) for specified startup companies engaged in business involving new innovation and technology (not applicable to LLPs). The startups need to be certified by Inter-Ministerial Board of Certification notified by Government. In addition, income from exploitation of new patents developed and registered In India will be taxed @ lower rate of 10% on gross basis. This will boost research and development in the country and consequent skill development and employment generation. On the other hand, in line with its plan to reduce the corporate tax rate from 30% to 25% by 2020, it is proposed to phase out incentives. The phase out plan is given in Figure 1: The phasing out of incentives gives a positive indication and sets in motion the plan of the Government to reduce the corporate tax rate to 25%. Also, the incentive phase out plan is only gradual so that new investment decisions in the near future are grandfathered.

March 2016

Bhavin Turakhia

CEO and co-founder, Directi

Another critical component to attract any business in India is simplification of law, certainty in taxation and reduction of litigation. The FM has taken a series of steps in connection with the above. The FM’s assurance of not introducing any retrospective amendment (which results in tax liability) is a welcome move. This would be taken well especially by the foreign investors which will help in inflow of foreign investment in India to aid the Make in India initiatives. The new Dispute Resolution Mechanism would reduce the huge backlog of pending direct tax cases, etc. In addition, the recent Circulars issued by CBDT clarifying tax issues clearly showcases the Government intention to bring certainty and reduce litigation. These are steps in the right direction and aims towards rationalizing the long drawn litigation. In terms of indirect tax, there is a welcome clarification for the cement and aggregates sector where ready mix concrete is exempted from excise duty. The industry faced litigation on this aspect earlier. The basic customs duty on import of articles like parts, components and accessories for use in manufacture of routers, broadband modems, set-top boxes and on machinery, electrical equipment, other instruments and their parts for use in the fabrication of semiconductor wafers has been reduced to Nil. Further, excise duty on articles like rubber sheets, micronutrients for manufacture of fertilizers etc., has been reduced. In addition, compliance has been made easy under the excise rules by reducing the number of returns to be filed by a central excise assessee. Further, facility for revision of returns has been extended to manufacturers also, which was only available to service tax assessees so far. Overall, the FM has attempted to put on table

March 2016

a balanced Budget considering the social reforms as well as equally addressing the infrastructure and economic aspects. While the Make in India initiative has got a Budget fillip, it needs to be seen how it positively influences the kick starting of the capex cycle and boost the overall demand in the economy. The authors Vishal Shah and Khyati Shah are with PricewaterhouseCoopers Pvt. Ltd. Vishal Shah is a Partner and Khyati Shah is a Director in Tax and Regulatory Services Group based in Mumbai. Both are Members of the Institute of Chartered Accountants of India. Earlier, Vishal was associated with firms like Bansi S Mehta & Co and RSM & Co (prior to its merger with PwC). Vishal has versatile consulting experience across industries and across a spectrum of direct tax and regulatory areas including Foreign Investment, Exchange Control and Corporate laws. Both have advised several large Indian and multinational corporate groups on various aspects of domestic and cross border taxation, Tax Treaty interpretation and Exchange Control Regulations. Vishal specializes in structuring cross border investments for multinational and Indian companies, particularly, structuring group investments of large Indian promoter groups. Vishal also regularly contributes articles and speaks on the subject. Khyati’s areas of experience include Structuring Inbound and Outbound investments, Evaluating Permanent Establishment issues for MNCs setting up presence in India, Assistance in obtaining approvals / clearances from regulatory agencies including FIPB and RBI, Representation before Revenue authorities in case of tax audits.

“This budget signifies correcting and working towards some basic priorities in terms of providing more power and support to our internal growth engine. The government has shown a clear intent on revitalizing agriculture, infrastructure, skill development and higher education sectors. This bodes well for creating a highly skilled labour force to drive the ‘Make in India’ mission in the country. The deployment of Massive Open Online Courses to promote Entrepreneurship Education and Training will help Indian youth connect with mentors and credit markets. It is an encouraging move aimed at promoting entrepreneurial spirit, especially among youth from rural areas. Amendments in the Companies Act and the ‘Stand up India’ scheme will boost the entrepreneurial ecosystem. Most importantly, the government has indeed offered unique opportunities to Start-ups, categorizing them as critical partners to the ‘Make in India’ programme. The proposed 100% tax deduction for new startups for the first 3 years, along with the speedy registration mechanism is quite noteworthy.”

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SPECIAL FEATURE

Long-term Structural Changes Envisaged Union Budget 2016-17: Impact on the manufacturing sector

The challenging macroeconomic environment coupled with the global slowdown has pushed the manufacturing sector to the brink. The softening of prices globally, the Bank NPAs the China crises, and lack of demand all show a fairly grim picture. Amidst this turmoil, their lies an opportunity for India to capitalize on this situation with due prudence and adequate caution.

Banudas banudas@moneygurukul.com

Amongst the disappointment and

March 2016 would be given an option to

skepticism shown by many analysts with

be taxed at 25 % (plus surcharge and cess)

the budget, it is important to understand

provided they do not claim profit-linked or

not only to understand the immediate

investment-linked incentives.

implications of the budget but also the long-term structural changes that are being envisaged. 1. Investment in Infrastructure The budgetary allocation for state and national highways is a whopping Rs 97,000 crores. In addition to providing

Growth in the Manufacturing Industry has been stunted due to the non availability of skilled workers. The government proposes

Further the taxes Additionally, the FM has

to built 1500 units centers of multi-skill

proposed to reduce the corporate tax rate

Training institutes. If successful this

for small scale companies (with turnover

programme could help the solve the issue

not exceeding Rs 5 crore in financial year

of unskilled workers.

ending March 2015) to 29% (plus surcharge and cess) with a vision to gradually get it down to 25%.

Other than the above there have been a number of tactical changes proposed in the budget like providing a cap on accelerated

the necessary infrastructure for coming

This move enables a significant change

Depreciation (40%), Tax holiday for 3 out

with new units in remote areas, this is also

whereby for the first time we have

of 5 years, reduction of penal interest etc

expected to kickstart to sagging demand

corporates having a lower tax than the

which does not warrant much attention.

in Construction sector. Hence structurally

maximum marginal rate in the personal

we get better infrastructure for the

income tax. The message is clear. It is no

manufacturing facilities and tactically we

more that businesses and companies will

have a demand kick started in the iron,

be charged to a higher rate of tax. This is a

steel and cement industry

significant move to the capitalistic mindset

2. Direct Taxation at 25% for new units and 29% for Small Scale units The New Startup manufacturing companies which are incorporated on or after 1

3. Pradhanmantri Kaushal Vikas Yojna

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where businesses are treated on par with personal tax.

The government had launched a massive Make in India Campaign to create jobs and make India a manufacturing hub. Further these were seconded by a number of other campaigns like Skill India, startup India and smart cities etc. However the budget falls short of addressing a number of issues,

Notably this benefit is for the new

which are critical to the success of these

manufacturing companies only.

schemes

March 2016

Rashmi Ranjan Mohapatra Managing Director, Kemppi India

- GST roadmap – GST is a must for a

without the need for RBI approvals

vibrant manufacturing sector. With

and simpler rules.

the government and opposition dragging the feet on this all-important legislation all these initiatives are in a

Inspite of the fact that ,India has moved from a largely agrarian

sorry state.

economy and now the percentage

- Customs and Excise – There is no

15% of GDP. However we still

structural change made in both these

have over 50% of the population

departments from both structural and

still dependent on agriculture

tactical perspective. Customs are a

for their livelihood. This anomaly

major bottleneck in the inbound and outbound logistics. We needed to quickly make some changes around customs. The excise department needs to completely restructured with the onset of GST to ensure a proper administrations. Now Excise rules and formalities are archaic and needs to be made in tune with the international standards. - Investments – there are no announcements and incentives to invest in the manufacturing sector. Further there are no simplification or rules for FDI in this sector. The procedures for FDI are the same for both startups and large organizations and needs immediate attention. We need investment for up to $2Mn

March 2016

of agriculture income is less that

can be changed only by the manufacturing sectors whichhas the ability to provide jobs across skills. The structural changes made in the budget and the ambitious programmes of the government are a step in this direction, but we have a long way to go. The author Banudas Athreya is an expert in the field of Startups. He has worked in several startups across the globe and is now focused on Startups in India. He has mentored and consulted several startups and also serves on Boards of Companies. Banudas is available at Twitter - @ banudas and Facebook page - https:// www.facebook.com/MoneyGurukul

“The reduction of Corporate tax from 30 to 25 percent over the next four years is a good move. This puts Indian firms’ tax liability at par with ASEAN economies. The proposed spend of INR 70000 crore in road/rail infrastructure will certainly stimulate the demand for manufacturing down the value chain. To promote investment in manufacturing in Defence sector the government has eased the FDI. In the defence sector the budget allocation has been increased by 12 percent to 246000 crore. This will help in higher manufacturing in this sector. The deferment of GAAR provisions by two years and discarding DTC would provide more certainty in the tax regime. This will alleviate the fear factor in western companies and they will be more eager to look at India in a positive note. Increase in service tax from 12 to 14 percent is a step towards the implementation of GST regime in the country. This is important to streamline the tax system and provide ease of business. The announcement of five new UMPP ( ultra mega power project ) is a huge step forward and will impact the whole value chain. An annual flow of Rs.20000 crore is a major move forward in this direction. Power still remains the major focus area for India and the whole chain of suppliers. Electrification of the remaining 20000 villages by 2020, including the off grid solar power generation is a strong initiative. The new budget has allowed 20 percent additional depreciation on new plant and machinery as against 10 percent. Enhancement of CENVAT credit on inputs and services has been made from six months to one year. This budget score very high on direction. The implementation of these along with ease of doing business and land and labour reform should accelerate the growth and stimulate the manufacturing sector.”

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SUCCESS STORY

igus: The world leader in cables for energy chains after 25 years In India, the motion plastics specialist generates 250 million INR in revenue from cables and invests in innovation, reliability and worldwide supply

Bangalore/Cologne, 13 February 2016 – With 100 million euros of revenue from cable sales over the last year, igus is maintaining its status as a world leader among cable manufacturers for moving applications in energy chains. Thanks to the industry’s largest test laboratory in Cologne, Germany, now expanded to 2,750 square metres, the motion plastics specialist is the only supplier on the market able to offer a 36-month guarantee on all chainflex cables. Increasing industrial automation is prompting igus to make significant investments in innovation, reliability and fast delivery worldwide.

The motion plastics specialist igus revolutionised the cable design for moving applications in e-chains 25 years ago and has been offering motor, control and data cables for specialised moving applications in energy chains through the chainflex brand ever since. The use in energy chains requires specific cable designs to increase the cable’s service life and, as a result, the service life of the application. In this area in particular, igus can draw on its

experience as market leader for e-chains and on its expertise of more than 50 years with all things plastics-related. “As market leader for e-chains, the advantage at igus is that we develop both energy chains as well as cables. For this reason, we can test and offer both as a system,” emphasises Frank Blase, CEO at igus GmbH. igus is having plenty of success in this area. The chainflex business area exceeded 100 million euros in revenue last year, which made

up more than 20% of the total revenue at igus. In the Indian market alone, igus generated 250 million INR (3.5 million euros), which is an increase of approximately 25 percent over the revenue from cables in the previous year. The Colognebased company has 1,040 cables to make up the widest product range on offer with respect to energy chain applications. Of these, no less than 3,200 drive cables at seven price points can be fabricated according

to 22 manufacturer standards. Components such as energy chains and cables are fabricated at the Indian office in Bangalore. This ensures that local customers receive their orders more quickly. “The degree of automation in companies is continuously increasing, particularly due to Industry 4.0. At the same time, it is necessary to guarantee an interruption-free flow of data, media and energy,” says Blase. “This really motivates us to invest significant resources

With 100 million euros in revenue from cables, the largest cable selection for the e-chain and the industry’s biggest test laboratory, igus is a leader among the field of cable manufacturers for moving applications. (Source: igus GmbH)

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March 2016

in innovation, product reliability and fast, worldwide availability, to ensure that our customers receive the best possible ratio of price to reliability.” 2,750 square metres of movement for innovation and reliability Considerable investments are being made in the industry’s largest test laboratory. Here, more than 70 cable test machines perform over two billion test cycles per year. On average, 650 cable tests are conducted simultaneously. New test rigs enable fast acceleration speeds of 15 m/s2 over 50 metres; a new cryochamber now allows tests in temperatures as low as -40 °C. Thanks to new torsion attachments and the expansion of the outdoor installation for long travel paths, cable use can be simulated under real conditions. The overall area of the test laboratory increased by 1,000 square metres to a current total area of 2,750 square metres. Thanks to a multitude of tests, igus is the only manufacturer able to offer a 36-month guarantee for all chainflex cables, including torsion cables such as the world’s first CAT7 cable for robotics. These tests also allow igus to provide exact specifications in its catalogue regarding bend radii, temperature ranges and service life for special use in the e-chain, in addition to the standard norms. The results from the test laboratory are also used for the five online tools for chainflex and three online tools for readycable. igus has invested significantly in the online area to allow customers to quickly determine the service life in moving applications and find, configure and order the most suitable cables for their particular application. Worldwide local delivery

March 2016

according to the customer’s needs igus has considerably expanded its production and storage capacity in North America, Asia and Europe to ensure even faster delivery to its customers in local markets. A warehouse expansion is also in the works for the Indian market. With cable production on three continents and 14 storage and assembly centres worldwide, customers receive the exact cable needed for their production system from stock: single, individually cut cables, reeled piece goods, fabricated cables or ready-to-install energy chain systems. igus also offers on-site system installation service. With increasing automation, quality becomes ever more important

Applications Riveting Punching

Marking Staking

Embossing Assembly Riveting etc

Revolvi Riveting machine

Rack and Pinion Press

Hand Operated Impact Press

Gala No 6, Punjani Industrial Estate, Khopat, Pokhrann Road No.1, Thane - 400601 Tel:- 022 32444073/ 25479447 Mob: +91 9029023231 Email: sales@hammerknock.com Web: www.hammerknock.com

The best possible reliability for the customer is also the goal of igus’ unique quality assurance in the production area: 20% of any chainflex batch is always removed and checked for proper function at the test laboratory following an initial visual inspection. igus wants to offer the most affordable cable worldwide that is guaranteed to work every time. But, as Frank Blase emphasises, an affordable price is not everything. “Now and in future, affordable pricing will not be the sole concern of customers. Their primary concern is the quality and reliability of a cable, particularly as it relates to special movements in the energy chain. We consider ourselves the first point of contact for finding a solution for our customers and our 36-month guarantee makes it clear that chainflex lasts.” For further details visit www.igus.de/presse

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Local Manus India: Awards for Exciting Bearing Applications Three out of 73 submissions awarded at Auto Expo 2016 The global manus award ceremony was held for the seventh time at the Hannover Messe 2015. Developers from all over the world submitted 467 applications, demonstrating the creative potential when it comes to using polymer bearings. With 73 enteries India was the leading country with the highest number of participants. The three most exciting applications out of 73 Indian submissions received the “local manus India” award at the occasion of Auto Expo 2016. The golden manus with prize amount ₹1,00,000 was given to ATS ELGI. This company relies on lubrication-free polymer plain bearings from igus at its carwash underbody sprayer. A diagnostis screening device for breast cancer from Tuscano Equipments private Ltd won the silver manus (₹75,000). The bronze manus

award (₹50,000) went to SRG Machines Pvt Ltd for egg sorting machines. Every two years, interesting applications using polymer plain bearings are chosen for the manus awards. These applications stand out due to their technical and economical efficiency as well as the creativity and boldness of the developer. The entries from all over the world demonstrate the diverse range of application possibilities for polymer plain bearings, from prototype to serial application. Most of the applications for the manus 2015 competition came from India. From these, the three most innovative applications were chosen in a local manus competition and the prizes were awarded during Auto Expo 2016 in New Delhi. From carwash to medical device – the winners of the

The golden manus went to ATS ELGI from the Indian state of Tamil Nadu. The company reduces downtimes in its carwash by using robust iglidur P plain bearings in the underbody washing system (Source: igus GmbH)

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The award winners of the local manus India. From left to right: Mr. Mihir Garware (3rd from left), Mr. V. Mahesh Kumar (4th from left) and Mr. Sudhan Chandrasekaran (5th from left). local manus India The manufacturer ATS ELGI received the golden manus award. The company relies on robust iglidur bearings for the underbody washing system at its carwash. Since these polymer plain bearings do not corrode, downtimes at the carwash are reduced. Besides the self lubricating bearings eliminates the need to grease or maintain continually. A screening device from Tuscano Equipment for diaganosing breast cancer secured a second place. In this application, the thermal radiation of the breast is recorded and a thermal map is created. Thanks to the installed iglidur PRT slewing ring bearings, linear slides SLW & ZLW, the machine runs smoothly with low noise. The bronze manus went to SRG Machines Pvt. Ltd. for egg sorting machines. These machnices segregate eggs into four different weight classes.

A lubrication-free and dirtresistant drylin N system from igus was installed here, which is resistant to corrosion and thus perfect for use in the machines. With this application, that ensured high hygiene standards by eliminating lubrication SRG Machines Pvt. Ltd. won the third place. At www.manus-award.com, you can find all information on the winners and all other applications from previous years. For further details contact Shery George Marketing manager shery@igus.in igus® (India) Private Limited 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post, Bangalore - 560048 Phone:- +91-80-45127807 Fax:- +91-80-45127802

March 2016

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ON FACE

SCFE Process is Environment Friendly, Green Technology Swapneshu Baser Founder, Director, Deven Supercriticals Pvt. Ltd

Dr Swapneshu A. Baser, founder Director of ‘Deven Supercriticals Pvt. Ltd.’ (DSPL) has played major role in design, development & implementation of ‘Supercritical Fluid Processing technology’ through his initial association with IIT- Bombay & subsequently with DSPL. Dr. Baser is recipient of many awards/ recognitions for his contribution in SCFE technology development and successful commercialization through DSPL. Presently working on Proto-type development for ‘Green’ ‘Environment friendly’ process for Dyeing of Textiles (Fibres, Fabrics) using Supercritical Fluids in place of water (which is main reason for heavy pollution and shutting of dying industry at many places in India and abroad).

What is Supercritical Fluid Processing Technology and how Deven is helping the manufacturing industry through their innovation? SCFE process is environment friendly, green technology. SCFE uses a dense gas e.g. Carbon dioxide (CO2) above its critical temperature (31 C) and critical pressure (74 bar), as the solvent for extraction. The density of the solvent is an important determinant of its solublizing capacity. Thus the solvent power of the supercritical fluid increases with increase in operating pressure as the solvent density increases with pressure. Also due to unique gas like properties such as higher diffusivity and lower viscosity, SCF penetrate better into the pores and matrices of the solid raw material and hence allow more effective

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extraction as compared to liquid solvents. By control of operating pressure, a range of selectivities and solublizing capacity can be obtained. The critical temperature of CO2 is near ambient; hence this helps in minimizing thermal degradation of the product and improves the quality of extracts by: retaining the natural freshness, delicacy and more importantly the synergistic bio-activity of natural molecules. Thus the concentrated extracts obtained from SCFE truly preserve and represent the desired goodness present in natural raw materials. This aspect also vastly increases the application potential of natural molecules in processed foods, medicines, fragrances, cosmetics etc. Worldwide, over the last few decades, SCFE Technology has emerged as a superior alternative to the

conventional techniques for extraction of natural products in food, pharmaceutical and chemical industries. ‘Deven Supercriticals Pvt. Ltd.’ offer tailor made Pilot and Commercial scale SCFE plants. We undertake turnkey assignment in field of Supercritical Fluid Extraction. Optimisation of capital investment through innovative, custom made hardware and process designs as well as total technology support from ‘Concept to Commissioning’. Our additional advantage is that we genuinely provide complete technical backup for product development and optimisation. Thus user industry can concentrate on commercial production of extracts while using the plant to its optimum capacity, with out total technical support.

Tell us about the inception and the journey till today in Indian SME sector? I was associated with SCFE technology development activity at IIT-Bombay since its inception in 1993 and shared major responsibility for SCFE technology development under the ‘Technology Development Mission Project’ from Government of India. Presently, am a full time Director with DSPL with a dedicated effort to offer wide range of world-class technologies / equipment in the field of Supercritical Fluid processing. DSPL has been able to successfully compete in the international market with established SCFE equipment suppliers from Europe, USA, Japan etc. In last fifteen years, ‘Nineteen’ SCFE plants (from Pilot to Commercial scale) have been manufactured,

March 2016

Supercritical Fluid Extraction (SCFE) plant installed at Sami Labs Ltd

including export orders from Sri Lanka, Pakistan, Malaysia and commercial scale SCFE plants, 4 x 200 Liter extractor capacity for M/S. Sami Labs Ltd., 3 x 200 Liter extractor capacity for Aceagro Biosciences Ltd. and 3 x 225 Liter extractor capacity for Vidya Herbs Pvt. Ltd. in India. Now eco-friendly technology has been gaining importance all through the world. How ecofriendly are Devenâ&#x20AC;&#x2122;s products? SCFE process has inbuilt features that genuinely qualifies it as environment friendly, green technology. There are practical problems that are associated with extracts produced by conventional solvent (such as Hexane) extraction, in present and future times: - The demand and acceptability of hexane and other organic solvent extracted products is limited and expected to go down further with stringent regulations and consumer awareness regarding suspected carcinogenic effect of the organic solvents as well as their impact on environment. - Till recently, majority of spice oil and oleoresins were produced by chlorinated solvents, the use

March 2016

of which is now banned. The solvent, most commonly used today is Hexane. However, in USA market, the residual hexane content in the products has to be less than 25 PPM and the limit is expected to go down further. In Japan even 25 PPM hexane in extracts is to be banned, so also in Europe. SCFE has successfully and totally replaced chlorinated solvents in applications like decaffeination of tea and coffee, Hops extraction etc. Similar trend is observed in other applications using organic solvents as well. The trend is gaining momentum and thus solvent extraction process may be phased out in near future. - The public opinion has become sensitive to use of Eco-friendly technology. ISO 14000 certificate is becoming important for exports especially of food products. It ensures that the process used is free of undesirable effluents that are produced at every step, right from raw material to finished product going to the consumer. Thus solvent extraction process is finding it increasingly difficult and costly to satisfy these regulations. - The traditional natural extracts undergo degradation during

conventional processing due to involvement of high temperature operations, severely affecting the overall quality, efficacy and application potential of the value added natural product. Thus the industry needs to change over to modern technologies which can improve the quality and reputation of natural products. Supercritical Fluid Extraction not only takes care of the said difficulties but also offers some additional benefits. Can you brief the uniqueness of SCFE? Superior Product : - No degradation of thermally labile components due to nearambient operating temperatures in the process, resulting in undegraded extracts with delicacy and freshness close to natural. - High concentration of desired active components. - Preserving the synergistic bio-activity of molecules in the extract. - SCFE leaves no residual solvent in the product. - Free of biological (microbial) contaminants. - Longer shelf life.

Ă&#x2DC; Superior Process : - Selective extraction andsimultaneous fractionation of extract possible to get spice oil and oleoresin in a single step. Further this results in products with high active ingredient concentration. - Flexible operating conditions for multiple product extraction.A wide range of supercritical solvent properties areachievable and the use of co-solvents enhances their solublising power. - Unique diffusivity and viscosity behaviour of the SCFs allows better penetration of the solvent into the pores and effective extraction. - Carbon Dioxide (CO2) is used as solvent that is: Generally Regarded as Safe (GRAS)and is favoured for natural product extraction. - The extracted residue (cake) from the SCFE process does not undergo any degradation, unlike in solvent extraction and steam distillation. Thus it retains all the useful natural substances such as edible proteins etc. This can be sold as a high value by-product to give additional revenue to the project. This will also eliminate problem of residue disposal as in case of solvent extraction or steam distillation

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Tell us about your recent innovations and the market reactions? We are working on number of innovative developments that include applications like Water less Textile Dying, by using Supercritical Carbon Dioxide in place of water to have environment friendly textile dying process. Second project which is in pipeline is regarding processing of leather using Supercritical Carbon Dioxide to reduce pollution. We are also working on technology development for making the SCFE process to run in continuous mode, rather than the current Batch mode operation. The Prime Minister of India announced Make In India last year. What do you think the impact of this mission? The Make in India mission is very important step. It would expose Indian engineers, skilled staff to best manufacturing practices, work culture that would be applied by the market leaders who are being encouraged to

start manufacturing base in India. In the long run, it would encourage Indian Industry to become world class, gain confidence, learn global standards to be able to compete with the established foreign suppliers. Economically, it would save huge foreign exchange and get the part of profits reinvested in India as a continuing process. You are doing business internationally for a long time. Any impacts Make In India done in the global market? In last few years, even before the make in India initiative, the recognition for Engineering skills and expertise from India have been improving in the world. The technology leaders now realise that India is capable of developing competitive products on its own, if it is starved of technology. The classic example is: In the era of Fiat 118NE, Contesa, Maruti1000 or even Qualisetc , foreign car manufacturers always introduced outdated models in India. Once Tata introduced Indica, that was designed and developed in India, we now get

the most recent designs from all manufacturers as necessity to retain the market share. On global perspective, Indian companies have now gained confidence to take over foreign companies, setup facilities in developed countries. Thus when world is looking at India as their market, we are looking at the world for marketing our products in a big way. World acceptance for Indian products has been steadily increasing. What are the steps that the government should take to promote manufacturing in India?

source of wealth accumulated by Politicians, top bureaucrats, officers etc., source of so called foreign investment coming from tax heavens in the world. The methods followed in sanctioning of huge loans by public sector banks to corporates, restructuring of loan as a standard norm and then no stringent action taken on sanctioning authorities or industry, when the loan becomes NPA. It is obvious that unless Government genuinely intends to clean our own house first, we cannot expect major change in the system.

The schemes should translate in to ease of running business in India. Today the schemes are on paper and small or medium scale entrepreneur face problems starting with acquiring of land, get bank finance, labour laws, tax structure, legal compliances etc. The corruption at every stage is complete demotivator and far from any actual improvement on the ground. Government should start the clean-up process from the top by genuinely questioning the

‘Deven Supercriticals Pvt. Ltd.’ offer tailor made Pilot and Commercial scale SCFE plants. We undertake turnkey assignment in field of Supercritical Fluid Extraction. Optimisation of capital investment through innovative, custom made hardware and process designs as well as total technology support from ‘Concept to Commissioning’ and beyond, has been our speciality and advantage. For more details visit www.scfe.in

World class SCFE plant from Deven Supercriticals, with state of the art PLC based Human Machine Interface and interlocks, installed at Vidya Herbs Ltd.

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March 2016

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TALENT MANAGEMENT

Overcoming Procrastination â&#x20AC;&#x201C; Why Leaders should get Proactive Leadership is supposed to transform companies in ways so that they are better able to meet future challenges. Too often, however, leaders fail in making the right decisions when it matters, as they lack a pro-active attitude.

Pavan Sriram pavan@ittige.com

Do you ever wonder what kind of an efficient leader you could be if you could stop procrastinating? Faster decision making? Better work/life balance? Completed deadlines? These are all distinct possibilities, if you are able to dive into tasks without hesitation.

Procrastination stands for leaderâ&#x20AC;&#x2122;s tendency to delay making important decisions while executing the less important ones. Procrastination is irrational in nature as it does not help

actions that need to be taken

promote a kind of status-

are generally less successful.

quo thinking among their

in facilitating leadership to

organisation and install

take place. In fact, leaders

status-quo thinking among

who delay decisions or put off

everyone involved. They

From an organisational point of view, procrastinating leaders will negatively influence all levels of the

team members and other employees. So what causes leaders to fall prey to procrastination tendencies? a) Care Too Much About What Others Think - It

Procrastination Is A Thief Of Time

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March 2016

Overcome Procrastination And Be A Bold Decision-Maker.

happens that sometimes they want to impress others so much that when given a task they feel so much pressure that it delays their work. b) Striving For The Perfect - It sounds weird, but perfectionism can be what causes procrastination. Most leaders may want to strive for perfectionism so much that they feel disheartened even before they begin. This is because a goal that seems unachievable can be demoralizing. c) Doing Things Totally New To Them - You need to embark on a totally new project and you have no idea at all on how to tackle it. The first reaction is to procrastinate. The uncertainty of the result

of this task causes leaders to delay commencing the project. d) The Lack Of Confidence Another common cause of procrastination is the lack of confidence in completing a task. It can be real that leaders lack the skills but sometimes it may be a perception. Because of this leaders may totally avoid completing the task. In order to develop a proactive leadership style that is not hindered by the process of procrastination, it is imperative that leaders develop strategies to encounter both forces from within and outside themselves, to practice these strategies and finally act upon them. It is this kind of

Sheryl Sandberg in her role as COO of Facebook represents a kind of leader who is able to overcome uncertainties and turn it into a goal-oriented leadership style. Her leadership style is characterised by a high level of energy and passion. Due to her relentless optimism and looking forward attitude she is able to see opportunities in every challenge

March 2016

execution that will make you authentic in the things you do. Being recognised as an authentic decision maker in turn will create conditions facilitating proactivity. Knowing how badly procrastination can hurt your leadership, these three simple steps can help you rid yourself of procrastination.

we could clear out a task immediately after receiving it? Jumping right into the work takes away any excuses you may be able to create later. Especially if it’s an easy task to forget 3. Decide if it’s something you can delegate: Sometimes we think delegation is part of procrastination. But it’s not. Delegation allows you to assign a task to another, competent team member who may be able to act on it faster than you are able to. This clears your smaller tasks and gets the job done.

1. Keep a checklist of what needs to be done: Procrastination is easy. It will find any way it can to slip into your life. One of the easiest ways to kill it is to keep a list of tasks that need to be completed. Having a visual reminder of your daily tasks and long-term goals keeps them fresh in your mind. You’re also able to see the progress you’ve made as you check them off of the list.

I look forward to hear from you at pavan@ittige.com on how you are making proactive decisions that shape the future of your business in better ways than before and in this process creating trustworthy and sustainable relationships with team-members and clients.

2. Whenever possible, take action immediately: We procrastinate because we know there’s time to do the work later. But what would happen if we decided that

Pavan Sriram is the CEO of ITTIGE Learning, a performancebased training company that works with organisations to improve learning outcomes. www.ittige.com

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CUSTOMER MANAGMENT

C2C: Its Importance C2C is normally Customer to Customer or Consumer to Consumer, or Citizen to Citizen. Contextually, it has meant one citizen selling to another, and a company or a portal like eBay supporting this service. In my article today, I want to go beyond one customer selling to another. I want to talk about the portals that allow interaction between customers.

Gautam Mahajan w

Self-help or help: These are apps or bogs that allow people to solve the problems created by products or services, which the company does not solve. Such C2C sites are a great help whether you want to learn about an excel issue, or whether your dialer is hanging on your cell phone, or your computer is getting a blue screen problem. Very often, if it weren’t for these sites allowing C2C interaction, we (and our suppliers) would be in deep s----. Advice: This is similar to selfhelp, but goes beyond problem solving to getting advice. Is it a good idea to be in Macedonia in December? Is it good to load SideSync? What is the best treatment for this ailment? The company does not have to field such questions from

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Customers. Citizen2Citizen: Citizens can help each other through such portals: What is the best time to transact with the government office, whom

even unknown companies can

These C2C sites are places to

become extremely important

understand how to minimise

or as known as “brand-known

the Customer Journey, and

companies” almost overnight,

make it a happier experience in

if they get good scores or they

the future.

get noticed.

The C2C interaction takes

to go to for help, where to

The company’s ability to find

place also in social sites, and

complain, what is the right rate

and understand the Customer’s

generally with your extended

for land etc.?

ratings on sites like TripAdvisor,

friend circle.

Customer Ratings: Customers tend to give ratings on the net. Basically, the importance of a net based customer rating of a product, place, service or portal is not properly understood, or is underplayed, the primary focus being on traditional methods of getting ratings. Thus often the C2C portal

Amazon etc. is important. Such ratings help other customers understand various options, and help them buy. One can argue that these ratings are becoming more important than the brand. Dave Aaaker, the brand guru just bought his wife an unbranded laptop based on the ratings!

Companies have to work on getting better C2C ratings. First they have to analyse why people are saying what they are saying. If someone says he got used or unclean bedsheets in a hotel, the hotel manager cannot just say, no way we always have clean sheets. Should he not check why the

rating takes second place in

Customer Journey: Comments,

Customer said that? Better

importance to the traditional

ratings made by the Customer

for him to check on made up

brand rating of a company.

often show the extra Customer

rooms to see if all have fresh

On the other hand, companies

Journey that was (hopefully)

sheets than to say to the

with poorer brand ratings or

never intended by the supplier.

Customer, this isn’t possible,

March 2016

not in my hotel. They have

issues, and ensuring

Community

Would love your comments

to get to think of eliminating

Customer problems do not

- Customer interaction and

and help. We are happy to help

complaints or negative

re-occur. Customer journeys

relationship

others in education and executive

comments. Not by bumping

can become shorter and more

- Customer self-service taking

education on courses in Value

off the guestsâ&#x20AC;&#x2122; complaints but

pleasant. Lastly, by working

pressure off you

Creation.

by actually bumping up their

with these sites, companies

- Causing Customers to offer

systems and processes

can identify Customer

ideas and new ways or new

advocates who can promote

things to do with your offerings

companies through their

- Getting to know and

networks.

understand Customers, their

Even branded products need good C2C interaction and scores, or the unbranded people will overtake them. C2C helps companies, because there is feedback, Customer scores, Customer chats. C2C is a source of communication for companies to Customers, and a way to solve Customersâ&#x20AC;&#x2122;

C2C and what it means to your company: You could be on an informal C2C interaction, through the social media. Or, you could

brand, by using the Customer score

(including Customer Value) and globalization. He is President of Customer Value Foundation and Inter-Link an International Consulting Firm in operation since 1987, working with clients from America, Europe, Asia, Australia

Therefore, you should organise

and India. Gautam is also the

the C2C interaction and build

Founder Editor of the Journal of

your strategy for giving the

Creating Value, an international

most to the Customer and

journal focused on Customer and

getting the most from it.

Value Creation (see jcv.sagepub.

Let C@C (Customer at your

com). He has also taught at IITs in

Customer Portal) work for you.

India and abroad.

effort. Companies can find

could be very valuable to

out future trends, and can

you in:

March 2016

- Going beyond building a

in strategy, general management

you could have none. Given that the C2C interaction

by understanding Customer

on the pulse

internationally acclaimed expert

have a C2C system in place. Or

problems through a community

work towards zero complaints

needs and in keeping a finger

The author Gautam Mahajan is an

- Building a Customer

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CORPORATE MART

Profitable growth for the Lapp Group

Higher turnover, more employees, more profit

The Stuttgart-based Lapp Group reported significant growth in turnover in the last financial year 2014/2015 (1 October to 30 September). After two years of low turnover development, turnover in the last financial year increased by 8.1 per cent to € 886 million. Profit before tax increased by 11.3 per cent to € 41.3 million. The number of employees rose to around 3,300. The Lapp Group has managed to clearly separate itself from the mixed development and deteriorating economic situation in important markets.

Andreas Lapp, Chairman of the Stuttgart-based Lapp Holding AG, said: “We have essentially achieved our objectives and further expanded our market position. Although the German engineering association VDMA had predicted zero growth for machinery and plant engineering - Lapp Group’s most important market - in 2015, we were successfully able to clearly set ourselves apart from the general trend.We are better than the industry average.” The Lapp Group has managed to clearly separate itself from the mixed development and deteriorating economic situation in important markets.

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Initiatives in the sales area, activities in the infrastructure segment, the system business and the consistent acquisition of new market segments particularly contributed to this. The increased turnover was also positively affected by the currency development outside of the Euro area. The annual average price of copper, important for the company, only increased marginally (from € 525/100 kg to € 527/100 kg).

important market for the Lapp Group with a 66.5 per cent share in the total turnover. Turnover rose by 2.8% to € 589.6 million (previous year: € 573.7 million). The most important single market here is Germany with a turnover share of over 30 per cent. Turnover here was € 268.5 million (previous year: € 264.8 million). Turnover development was also positive in Benelux, Austria, Romania, Poland and Italy.

Positive development in all regions

America (USA, Canada, Central and South America) even managed to increase its turnover by 26.1 per cent to € 107.7 million (previous year € 85.4 million). As a result, its turnover share

Turnover development has been positive in all three Lapp Group regions. Europe is the most

increased from 10.4 to 12.2 per cent. The high average exchange rate of the dollar and the initial consolidation of Cabos Lapp Brasil where Lapp has opened a new production plant had a considerable impact on this significant growth. Asia (with Africa, Australia and New Zealand)also achieved strong turnover growth of 17.4 per cent to € 188.9 million (previous year: € 160.9 million). The turnover share increased to 21.3 per cent. In addition to currency-related effects, Lapp Korea in particular was able to considerably increase its turnover.

March 2016

Andreas Lapp

Chairman, Lapp Holding AG

Healthy earnings and financial situation The earnings and financial situation at the Lapp Group is very healthy. The number of employees increased by 3.1 per cent to 3,300. Material costs (consisting of personnel costs, depreciation and other operating expenditures minus other operating proceeds) increased from € 285.9 to 305.5 million. At the same time, the company managed to increase profit before tax by 11.3 per cent to 41.3 million. The equity ratio improved slightly to 57 per cent. Financial Director Andreas

Georg Stawowy

Chief Technical Officer, Lapp Holding AG

Hermann: “The Lapp Group has asserted itself very well and is in a very healthy position. We have set a course for long-term stable growth.” Investments for continued growth The Lapp Group invested € 20.4 million in the 2014/2015 financial year. The biggest projects included the continued roll-out of the new SAP software ECC 6.0 and addition to capacity in important plants. For example, the production plant in Bangalore, India was almost doubled by an extension. In

Andreas Hermann

Financial Director, Lapp Holding AG

the French plant in Forbach, a new wire drawing machine was commissioned. The new machine will enable them to double production of copper wires. This makes Lapp a technological leader. The construction of a new administration and logistics centre was started in Russia. The construction of the new Lapp Europe headquarters in Stuttgart-Vaihingen was started in spring 2015. The new construction provides new opportunities to bundle Lapp’s strengths even more effectively and to provide even better support for customers

throughout Europe. The investment sum borne by Lapp Immobilien GmbH & Co. is approximately € 28 million. Outstanding innovations & examples of application - The Lapp Group group presented the new ÖLFLEX® CONNECT SERVO at the last Hanover Fair. This is a new generation of servo products with which the connection solutions for electrical drives are improved, made more efficient and available worldwide. Lapp has revived its portfolio of ÖLFLEX® servo cables and

The new generation of ÖLFLEX® servo products processed in an automated production process designed specifically for this purpose

The SKINTOP® HYGIENIC has no corners or edges and is easy to clean

March 2016

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The modular battery storage system ‘Energy Neighbor’ from Varta Storage and the Technical University of Munich is intended to help generate power from wind and solar units

Cables from the ÖLFLEX® HEAT series were used in the Arctic. Not only do these cables cope well with heat, they are real all-rounders when it comes to extreme temperature ranges.

developed a new generation of connection systems together with the global market leader Intercontec. The cables and connection systems are processed in an automated production process developed specifically for this purpose. The Lapp Group is now constructing special production facilities in Europe, North America and Asia where new solutions are produced in consistently high quality.

- Lapp has developed a portfolio of tailored connection technology especially for the food industry. These include especially resistant cables and conduits, cable glands, connectors and accessories such as cable ties. The components meet strict international requirements, such as EHEDG design specifications or compatibility with ECOLAB® cleaning agents (see also special topic).

At the world exhibition in Milan, Expo Milano 2015, the German pavilion grabbed the visitors’ attention with its energy-generating solar trees. They integrated organic photovoltaics (OPV) technology and, unlike conventional solar modules, are made from flexible, film-integrated OPV modules. The revolutionary connection technology in this installation came from Lapp. The classic photovoltaic connection technology was especially in

demand in the Asia-Pacific region. An ambitious project to store current for renewable power has been started by VARTA Storage GmbH together with the Technical University of Munich in Moosham, Upper Bavaria. Since October 2015, this has been home to a battery storage system boasting 200 kilowatt hours. ÖLFLEX® cables from Lapp help protect against short circuits. The Russian company

The energy-generating solar trees at the Expo with Lapp connection technology

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March 2016

Technomarin, based in St Petersburg and specialised in the development and production of radio navigation equipment for the maritime and aviation sector, uses Lapp products for cabling its beacons and navigation systems in the Arctic. Cables from the ÖLFLEX® HEAT series that still function reliably at cold temperatures down minus 100 degrees Celsius were used for these extreme locations.

People are the most important resource “It is our dedicated employees that make Lapp a successful company”, says Andreas Lapp. For this reason, a human resource development concept has been developed for all Lapp Group companies. Employees can obtain further qualification in various programmes. The aim is to further increase the number of managers from within the

March 2016

3 company.

Currently, 60 trainees at Lapp in Germany are learning a trade in eleven skilled trades and study courses at the cooperative university. They include for the first time a refugee from Eritrea. As a result of positive experiences, Lapp will facilitate training as a machinery and plant operator for nine recognised refugees within three years. The refugees obtain a 6-12 month IHK (Chamber of Industry and Commerce) entry qualification before the training starts. Thanks to its family-concious business culture, three years ago the U.I. Lapp GmbH was awarded the “berufundfamilie” (work&family) certificate which is awarded under the patronage of the German Federal Ministry for Family Affairs. This certificate is currently being renewed and the U.I. Lapp GmbH is in the

final round of award-winning companies again in 2016.

system solutions, automation technology and robotics solutions for the intelligent Positive outlook for the current factory of the future, as well as financial year technical accessories. The Lapp Group’s core market is in the The Lapp Group has had a good SMPS DC/DC Converter Water Proof SMPS industrial machinery and plant start. The company also expects engineering sector. Other key moderate turnover growth in markets are in the food industry this financial year. Andreas Lapp: as well as the energy and the “We are expecting important mobility sector. impulses from Asia and America in particular, as well as from The Lapp Group has remained Central Europe. However, 3 Phase Transformer in continuous family Adaptor LEDownership Drivers volatility in currency exchange since it was founded in 1959. rates and the price of copper In the 2014/15 business year, it could affect growth.” generated consolidated revenue of 886 million euros. Lapp Headquartered in Stuttgart, currently employs approximately Germany, the Lapp Group is a 3,300 people across the world, leading supplier of integrated 17 productionSolar sitesLartern and 39 1 Phase Transformer Batteryhas Charger solutions and branded sales companies. It also works products in the field of cable in cooperation with around 100 Laxmi Vihar,technology. Jandli, Ambala City (Haryana) India. Tel: +91-171-2801711/3291897 and65,connection foreign representatives. : +91-171-2801289 The Group’s Fax portfolio includes Mobile : +91-9416020078/9215720078 standard highly flexible / naceiamb@gmail.com Email :and nacei@rediffmail.com Websitevisit : www.nacei.com For further details cables, industrial connectors and www.lappkabel.com/press screw technology, customized

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CORPORATE MART

Delta Highlights its R&D and Manufacturing Operations Expansion in India Delta India Electronics, a leading provider of power and thermal management solutions, announced at Elecrama 2016, the expansion of its R&D and manufacturing operations with new facilities in Bangalore and Hosur respectively, in line with its long-term plans to harness the country’s significant long-term growth potential. Delta India plans to develop smart energy management solutions with industry-leading energy efficiency at its new R&D centre which is expected to create up to 500 engineering jobs within the next 3 years. Within the next 10 years, Delta’s new factory in Hosur will create up to 20,000 jobs for the manufacturing of power electronics, renewable energy and automation solutions.

Delta selected Bangalore for its new R&D centre due to the high quality and abundancy of its engineering talent pool for software and hardware development. This new R&D centre is expected to create up to 500 high-tech jobs within the next three years and focus on technologies such as mega-watt scale power conversion and power quality. The new plant in Hosur is expected to start operations in early 2017 and will supply the local marketplace with smart, high-efficiency telecom power systems, industrial automation solutions, UPS, renewable energy inverters and converters as

well as solutions for display and monitoring.

of Delta’s contributions for a better tomorrow”.

Mr. Dalip Sharma, managing director of Delta India Electronics, remarked, “Delta is recognized as a sustainable enterprise by world-class institutions such as the Carbon Disclosure Project (CDP) and the Dow Jones Sustainability Indices (DJSI) given its commitment to the development of solutions that truly help customers save energy. Providing telecom networks with green power, enabling energy-efficient and smart manufacturing processes and data centres and even realizing green buildings are part

Delta’s industrial automation showcase will feature advanced solutions for the growing smart manufacturing sector in India. Among these, the SCARA DRS40L series robot arm solution, which can be smoothly implemented in production lines for electronics manufacturing, packaging, rubber and plastic in applications such as assembly, soldering, inspection, insertion, screw locking, etc. with increased productivity by nearly 3 times in certain cases. Another highlight of Delta’s

offering at Elecrama, is the battery energy storage system, a modular cabinet with 41 kWh of energy backup capacity that leverages Delta’s proprietary lithium-ion battery technology and power conditioning system (PCS). With the use of an energy management system (EMS), this storage platform is suitable for a variety of applications, such as community, commercial energy storage and utility-scale ancillary services. Functions such as output power stabilization for renewable power systems, peak demand shifting to reduce exposure to elevated electricity prices and power backup are key elements of this solution.

“Delta recognizes the potential of India to become a powerhouse in manufacturing and its need for high energy efficiency which is one of Delta’s core competences. We believe our new R&D centre in Bangalore will be instrumental in the creation of innovative and energy-efficient technologies that will support the realization of national initiatives such as “Make in India” and “Digital India”. Delta was one of the multinational companies invited by the Prime Minister of India, the Honourable Narendra Modi, to the opening event of “Digital India” in July 2015. We expect the Hosur factory to eventually become Delta’s biggest manufacturing base in India.”

Kong Meng Ng Chairman, Delta Electronics (Thailand)

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March 2016

At some of Delta’s production lines, SCARA DRS40L series robot arm solutions are applied to conduct tracking, positioning and glue pasting for power supply boards and produce around 24.8 million pieces per year.

In order to support India’s growing economy and manufacturing sector, Delta also offers its renewable energy solutions, such as a full range of string and centralized solar PV inverters that feature industryleading energy conversion efficiency of up to 98.7% in certain models and power range from 3kW to 1MW for residential, commercial and utility segments. In addition, our solar tracking technology delivers approximately 30% higher output versus fixed-mount structures. The system combines Delta’s automation devices such as servo drives and motor drives, programmable logic controllers (PLC) and human-machine interfaces (HMI) and can realize both single axis and dual axis rotation depending on actual customer requirements. Delta will also offer, at Elecrama,

technology to support the creation of green data centres in India. Thus, the InfraSuite Datacenter Infrastructure Solutions combines power distribution cabinets, modular UPS technology (with AC-AC efficiency of up to 96% as well as vertical expansion from 25 kW to 200 kW), precision cooling and racks & accessories and a Environment Management System for real-time monitoring and ease-of-maintenance. A virtual tour of Delta’s green data centre in Thailand will be featured at the booth. Another remarkable section of Delta’s booth at Elecrama 2016 is Display & Monitoring Solutions which feature: - The smart monitoring system implemented in the banking industry in India to protect ATM customers while preventing and

tackling thefts and attacks on ATM sites across India through advanced image analysis technology and a remote monitoring platform. - The ultra-narrow bezel LCD video walls, which offer up to 20x15 display arrays for largescale applications, brightness of 700 nits (55-inch cubes), pixel pitch of 0.63mm, 4,000:1 contrast ratio, 3.5mm combined bezel width and the integration of Delta’s Icon Pro display controller these video walls become total solutions for realtime monitoring of surveillance, transportation management and other mission-critical applications. As India expands the digitalization of the country, Delta supports the telecom industry with its energysaving power solutions. These

include hybrid-power systems for outdoor installations that integrate solar PV energy to reduce reliance on unstable grids and on fossil fuels. The underlying energy management technologies integrate rectifiers with energy efficiency of up to 97.5% that help deliver significant opex savings for our customers as well as controllers that monitor and control the entire system and site power infrastructure, enhance battery life, enable energy savings, and inform the operator of maintenance needs. Delta’s new small cell for 4G applications, Golden Eagle, winner of the 2015 Reddot Product Design Award and featuring energy conversion efficiency of 96% is also a highlight of the showcase and a new solution for the Indian telecom market.

“At Elecrama 2016, we exhibit for the first time in India, our entire portfolio of smart solutions with industry-leading energy efficiency for a wide range of sectors such as green energy generation, industrial automation, telecom and even agriculture. Our track record includes the implementation of a smart monitoring solution for ATMs that provides a safe environment for banking customers across India while protecting the banks’ infrastructure. Also, our PV inverters, featuring the world’s highest energy efficiency of up to 98.7%, support residential, commercial and megawatt-scale projects; our innovative solar trackers increase output by up to 30% versus fixed-mount structures; and our VFD controllers combine with solar power to provide Indian farmers with a clean and energy-saving water pumping solution for irrigation”.

Dalip Sharma Managing Director, Delta India Electronics

March 2016

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CASE STUDY

Using machine tool probes for precision metrology in the manufacturing of forged wheel and car chassis The automotive industry is fiercely competitive. Tier-one car manufacturers are constantly looking for breakthroughs in areas such as performance, safety and innovative design, all of which places ever stricter requirements on the processing of metal components. SuperAlloy Industrial Company Ltd. (SAI) is a supplier of highquality lightweight forged metal products. The forged wheel and car chassis components SAI produce are used by the world’s top car manufacturers, thanks to the company’s insistence on premium quality and precision manufacturing. Renishaw machine tool probe systems, including the OLP40, RMP60, OMP60, and the NC4, are a perfect match for SAI, allowing SAI, assisted by Renishaw, to make great progress on the route to high end precision manufacturing.

Samina Khalid Samina.Khalid@renishaw.com

SAI’s relationship with Renishaw began with CMM measurement. Dr Henry Shih, CEO of SAI, explains: “When we entered the European market in 2008, we realised that our high‑end car manufacturer clients’ quality,

dimensional stability and precision requirements for metal products were extremely high. While our equipment at the time was able to meet their volume requirements, we needed to enhance product quality and reduce

the amount of rework and corrections during processing so as to achieve high quality levels. Through Renishaw, we discovered machine tool probe measurement solutions that could deliver in‑ process measurement control and

real‑time data feedback on our existing CNC machines, thereby providing effective precision manufacturing control. This was a massive help in terms of increasing production efficiency and precision.”

Wheel mounting surface

Dr Henry Shih, CEO of SAI

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March 2016

OLP40 performing in-process control of wheel production modelling

RMP60 performing in-line measurement for wheel rim production

SAI is currently focused on supplying high‑quality forged metal products. SAI’s customers are all high‑end automobile manufacturers that demand specialised technologies and services, including some of the world’s top‑tier car makers such as BMW, Mercedes‑Benz, VW, Porsche, Ferrari, Ducati, Bentley, Audi, Rolls Royce, Jaguar, Land Rover, Ford, Chrysler, Toyota, GM and Honda. The production of aluminium forged wheel rims The forged wheel production process is complex, particularly for low‑volume, high‑diversity production. SAI produces more than 200 types of wheel which requires the utmost production flexibility. Strict standards are applied to workpiece setting, reference measurements and key dimension detection during metal processing, as the precision requirements for machining wheel mounting surfaces exceed the requirements of even the aerospace industry. SAI currently has 600 CNC machine tools working on wheel rim production, including 150 Victor Taichung lathes and 450 YCM milling machines. All these

March 2016

machine tools are engaged in production on a three shift process five days per week. So how does SAI ensure that the precision and stability of 600 machine tools remains consistent? In order to increase production precision and reduce scrap, SAI equipped the relevant lathes with Renishaw OLP40 touch probes, which use optical signal transmission and are adapted for turning processes. The CNC milling machines were equipped with RMP60 machine tool probes which use wireless radio transmission to measure workpiece position and reference height, as well as providing in‑line key dimension detection, thereby increasing production performance. Mr. Y. C. Kao, Senior Manager of SAI’s Wheel Production Department, explains: “The automated workpiece setup enabled by Renishaw machine tool probes allows us to ensure that the cutting dimensions remain stable and consistent when we are producing wheel rims, as well as effectively reducing human error. For example, the air valve hole cutting thickness Process

Capability Index (CPK) rose from 0.71‑1.13 to 1.35‑1.43 when using Renishaw machine tool probes.” 3D appearance modelling for forged wheel Wheel styling design has moved from flatter surfaces towards more 3D effects in recent years, causing wheel rims to become ever larger, and placing increasingly stringent demands on processing precision. Until 2011, SAI’s acceptable tolerances for wheel rim production (with the flatter designs used at the time) were 0.05‑0.10mm. However, the tighter tolerance requirements of the current 3D designs has gradually increased cutting times and processing; wheel rim appearance processing takes as long as 180 to 240 minutes, with the result that any rework imposes considerable pressures in terms of both production time and cost. OLP40 probes allow SAI to carry out in‑process measurement control to achieve tolerance of less than 0.02 mm, and can replace human measurements and updates to workpiece coordinates. This greatly improves cutting and

efficiency for surface precision processing after coating. Even more importantly, it reduces rework by 80%, as before the introduction of in‑line measurement systems wheel production generally had to be processed twice to achieve the necessary precision. When combined with Renishaw software, the probes not only play a role in guidance during production, but also provide in‑process control and real‑time feedback, immediately updating and correcting data during metal cutting, and efficiently monitoring and controlling dimensions and deformations. Renishaw machine tool probe systems have allowed SAI to increase production precision and product quality, while also reducing scrap from 2‑3% to 0%, and improving production efficiency. Precision processing for car chassis The automotive industry has already evolved from focusing on basic safety requirements and performance towards enhanced driving comfort, improved fuel efficiency

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and reduced emissions. The safety and stability of lighter vehicles moving at high speed is closely connected to the manufacturing of the car chassis. The higher the precision of chassis produced with aluminium alloys, the safer and more stable the car is when travelling at speeds as high as 200 km/h, and the more comfortable the driving experience. The lighter the chassis, the lower the fuel consumption, and thus the easier it is for the vehicle to meet environmental requirements. SAI has continually improved its forging and mechanical processing technology. The company moved into the processing and production of precision car chassis in 2011. SAI now has 38 Tongtai high end five-axis CNC machine tools, all of which are equipped with Renishaw OMP60 optical machine tool probes and NC4 non-contact laser tool setters. Unlike wheel rim production, chassis production tends to involve high volume and lower diversity, but nevertheless still requires high-precision

metal cutting and processing. Renishaw OMP60 optical machine tool touch probes use advanced modulated optical transmission to provide 360° signal transmission. The probe simplifies measurement and calibration processes, thereby achieving high-precision measurement for workpieces with complex profiles. The NC4 uses innovative laser technology to perform high-speed, high-precision measurement of cutting tools as small as 0.2 mm, and to perform tool breakage detection on cutting tools as small as 0.1 mm. Its non-contact method avoids the potential for causing wear or damage of cutting tools. Production times for car chassis are relatively short, and can generally be kept within 20-25 minutes. Renishaw machine tool probe systems provide the operator with turnkey solutions for real-time positioning and measurement, and inprocess control measurement, helping to further automate production processes. Trusted brand, thoughtful service

SAI chose Renishaw because of the company’s trust in the Renishaw brand. Mr Shih explains: “When we choose suppliers, we don’t just look at the price of the product; we also attach a great deal of value to their R&D capabilities and service. Renishaw has an excellent reputation in manufacturing industries, and also provides service for different industries, so it doesn’t just offer a product or a solution, but also shares with us its experience, expertise and the industry’s best practices. Renishaw is also meticulous in terms of its technical support, and the Renishaw team reacts quickly to solve problems; this is particularly impressive to us.” SAI’s trust in Renishaw began with the use of CMM probes. The company now has 10 CMMs fitted with Renishaw probes. For machine tool performance checks, SAI has also fitted its machining centres with Renishaw QC20‑W telescopic ballbar measuring instruments for the most

comprehensive diagnostic testing and verification functions. About SAI Founded in 1994, SAI is a leading metal processing technology manufacturer focused on high‑tech forging technologies. The company moved into the automotive component industry in 2000 with the development and production of aluminium forged wheels. SAI has expanded from the North American market into Europe and Japan and is now a top tier supplier of automotive parts, with a client base including many of the world’s top car makers. SAI continued to grow over the last decade, and in 2011 expanded its product portfolio by creating a new department specializing in engineering and manufacturing automobile chassis components. In 2013, SAI began manufacturing a range of aircraft seat components. SAI has approximately 1,300 employees and generated annual revenues of US$163 million in 2014. For further details visit www.renishaw.com

Production process for car chassis processing

SuperAlloy Industrial Company Ltd. (SAI)

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March 2016

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CASE STUDY

Dürkopp Adler Based near Hannover is Haas Automation customer, Dürkopp Adler AG, well known manufacturer of industrial sewing machines. As well as its facility in Germany, the company has another two manufacturing plants: there’s one in Minerva, in the Czech Republic, and one in Romania. Under increasing competitive pressure from the Far East, Dürkopp Adler is undergoing a long-term restructuring and retooling programme, including standardizing most its CNC machine tools and machining operations.

Based near Hannover is

facility in Germany, the

increasing competitive

its CNC machine tools and

Haas Automation customer,

company has another two

pressure from the Far East,

machining operations.

Dürkopp Adler AG, well

manufacturing plants:

Dürkopp Adler is undergoing

known manufacturer

there’s one in Minerva, in

a long-term restructuring

of industrial sewing

the Czech Republic, and

and retooling programme,

machines. As well as its

one in Romania. Under

including standardizing most

Frank-Michael Kuhnt – Group Head of Production, Sales and Logistics: We

Frank-Michael Kuhnt – Group Head of Production, Sales and Logistics at Dürkopp Adler

Dürkopp Adler’s business in Minerva employs seventeen Haas CNC machines and the factory in Biefel has four Haas CNC machine tools

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March 2016

Dürkopp Adler AG is a well-known Germany industrial sewing machine manufacturer, with facilities in Germany, the Czech Republic and Romania.

The company have a very thorough strategy for the next 4 years to standardize machine types as much as possible – to focus on Haas

are competing with

Haas vertical machining

Many of our Haas

live tooling. On all Haas

manufacturers based in

centres at this plant. We

machines are considerably

machines, stability is

China and the Far East, but

have a Haas EC-400, for

more than 10-years old.

excellent. This matters a

we want to keep as much of

when we need to use

However, the older

lot for the parts we make,

our production as possible

more tools – the machine

machines are still going

as they’re so small and

in Germany. So, our aim is

has 72, and when we

strong and have served

tolerances are tight.

to ensure all manufacturing

need to reduce set-up

us very well. Of course,

operations can be controlled

times for a part. We have

we get much better

and monitored closely

a similar machine doing

production with the newer

from here, in Bielefeld. For

similar jobs at our Romania

Haas machines – probably

example, one centralized

factory. Batch sizes can be

20-30% better, so our aim

server will share all

anything from 10 – 1000

is to replace them all,

programmes and CAD

off. But, there are 15,000

eventually.

drawings, etc., and all

different parts, most of

machining and production

which need 4-axes to

data will be presented in

machine, so we also use

real-time.

Haas CNC rotary tables.

The business in Minerva employs seventeen Haas

We group parts in families, so it’s quick and easy to assign parts to machines.

Our intention is to machine all the critical steel parts here in Germany; probably 60-70,000 parts a year. However, where we used to employ 3000 people, locally, we now only have

We have a very thorough

250, so productivity is the

strategy for the next 4

issue. Investing in Haas

years, taking the company

means we can move away

to 2020. Part of the plan

from complex, expensive

is to standardize machine

machines, which are no

types as much as possible

longer cost-effective. When

– to focus on Haas. They’re

we make healthy profits, we

by local Haas Factory Outlet,

The standard table on

such good value we easily

can continue to invest.

Teximp. The factory in

our Haas VF-6 vertical

earn back in time savings

Biefel, which also houses

machining centre is big

what we invest.

the company’s business and

enough that we can easily

marketing teams, has four

mount three fixtures. We

Haas CNC machine tools,

use it mostly for small

supported by HFO ARO-tec.

quantities of a part – it’s

CNC machines, supported

Currently there are only

March 2016

quick to set-up.

We’re particularly interested in the latest Haas turning centres, as they can provide affordable Y-axis and

For further information please contact: MBMC – International Press and Publicity +44 (0) 1603 283 601 press@mbmc-uk.com

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CASE STUDY

National Library Of France Chooses Emerson To Optimise Air Conditioning System France’s biggest library – and one of the most important in the world – has chosen drive and motor solutions from Emerson to maximise the reliability of its air conditioning units.

The National Library of France (BnF) looked to source the drive systems from a single supplier capable of offering expertise and value-added service. The BnF’s collections are unique throughout the world, comprising fourteen million books and periodicals, but also manuscripts, prints, photographs, maps and charts, musical scores, coins,

medals, sound archives, videos, multimedia, stage sets, costumes and much more. And they’re growing constantly. The library is home to a vast documentary heritage encompassing all disciplines, whether intellectual, artistic or scientific. Its physical spaces are frequented each year by more than one million visitors, and its digital library,

Gallica, provides free access to more than three million documents. To protect these treasures and welcome its many visitors, the BnF was acutely aware of the need to maintain an extremely reliable air conditioning system. With this in mind, an initial project was defined: to replace an asynchronous variable speed drive assembly

with a new drive system that would be used to power an air conditioning pump, itself responsible for half of the library’s reading rooms. “The results of an energy optimisation study revealed in particular that the application’s operating efficiency fell to just 50% in the winter. The ROI calculation showed that it would make far more sense

The library is home to a vast documentary heritage encompassing all disciplines, whether intellectual, artistic or scientific. Its physical spaces are frequented each year by more than one million visitors, and its digital library, Gallica, provides free access to more than three million documents.

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March 2016

to swap the asynchronous drive system for the Dyneo® high-performance synchronous technology from LeroySomer”, explains Jérôme Hardy from GED ADREM, a partner company of the Leroy-Somer service network. To handle the variable torque load (also referred to as the quadratic torque) of the pump and ventilation applications, Emerson implemented a solution comprising a LeroySomer Dyneo LSRPM 250 (85 kW) motor and a Control Techniques Unidrive M600 variable speed drive unit. The permanent magnet synchronous motor is perfectly suited to applications of this kind, offering enhanced efficiency of up to 96% over the whole operating speed range. Another advantage, in terms of cost, comes from the sensorless control. This function, integrated into the Unidrive M drive unit, simulates an encoder input with a high degree of precision. “With this solution, not only do we eliminate the cost of the encoder, but we also reduce the number of components and thus the probability of a breakdown”, added Jérôme Hardy. The BnF gave top priority to the service life and availability of the equipment. It commissioned Leroy-Somer as the sole supplier on the strength of its ability to guarantee operational reliability, including a performance

March 2016

warranty and the full interoperational compatibility of the components. A global approach was adopted with the consistent aim of maximising reliability: “We applied Leroy-Somer’s premium service centre procedure. This extremely rigorous method uses multiple control points during installation and start-up. Operations such as alignment control, dielectric measurements and phase balancing offer real benefits in terms of both reliability and power consumption”, adds Jérôme Hardy. Since then, the equipment has been monitored, particularly by means of vibratory analysis, and the resulting data compared with the data collected during commissioning. This makes it easier to detect drift, premature wear and overconsumption. The original motors, also from Leroy-Somer, were overhauled and kept as backup. The assembly is connected to the BMS (building management system), an automated, centralised supervision system that gives the speed setpoint. The next phase will involve conducting an energy efficiency study on the central air treatment systems and replacing the drive solution. Further system modernisation measures are also envisaged over the coming years. For more details visit www.emerson.com

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CASE STUDY

Aerospace toolmaker moves to PowerMILL to remove programming bottleneck G. Parker Aero Tooling Solutions, a rapidly expanding aerospace toolmaker, has changed to Delcam’s PowerMILL CAM software to remove a programming bottleneck that was limiting the company’s productivity.

The company, which has been based in Accrington in the North-West of England for over forty years and is now in its second generation of family ownership, produces a wide range of tooling, including jigs and fixtures, exclusively for the aerospace industry. It has been closely involved in designing and manufacturing tooling for many of the world’s most prestigious aircraft programmes, including all Airbus platforms, plus the Eclipse and Honda VLJ

programmes. Virtually all of the tooling is made as a ‘oneoff’ so developing the most efficient machining approach for each project involves a steep learning curve. Most of the staff are timeserved toolmakers with a wealth of aerospace knowledge, and their skills and expertise are needed on almost every job. In addition, Managing Director, Mike Parker, puts a strong emphasis on encouraging direct interaction between his staff

and his customers. “We have built up a detailed knowledge of our customers’ equipment so we can make tooling that will be easy for them to install and efficient for them to use,” he claimed. “We have always designed our tooling with the same CADCAM system that is used by most of our customers, and have been happy with that aspect of the software,” said Mr. Parker. “However, we have ten machines, including several five-axis machining centres,

all demanding programs. We were experiencing a serious bottleneck with our two seats of the machining software as we couldn’t supply toolpaths quickly enough.” Mr. Parker investigated a number of alternative CAM programs before deciding on PowerMILL. The software provided a complete machining package that covers all the bases for the range of projects at G. Parker Aero Tooling Solutions, plus the price was very competitive. In addition,

All machines at G. Parker Aero Tooling Solutions are now programmed with Delcam’s PowerMILL CAM software

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March 2016

the company was already using Delcam’s PowerINSPECT inspection software and had been impressed with both the software and the support provided. Even though the staff have only been using PowerMILL for a few months, the effects have been dramatic. “We have effectively doubled our programming capacity with the three seats of PowerMILL because the software is so much easier to use,” reported Mr. Parker. Craig Cooke, Production Manager, had used an alternative CAM systemfor all his working life but hasn’t found anything that PowerMILL can’t do. “All four people that we have trained in PowerMILL have been very motivated. Of course, introducing new software has seen some difficulties but nothing insurmountable,” he said. A key benefit of PowerMILL for G. Parker Aero Tooling Solutionsis that it is purely a machining package so it is much easier to introduce onto the shop floor. “It is much simpler to exchange knowledge between the different users because it is so much easier to use,” said Mr. Cooke. “The calculation times are around 25% faster, which, along with the ease of use, means we can generate programs more quickly,” he continued. “Stock models are much easier to use in PowerMILL so we are able to reduce air cutting and shorten machining times with rest machining. We had always struggled with creating undercuts but programming for disc cutters is extremely quick in PowerMILL. The surface

March 2016

finish we get now is very good; it is extremely smooth with no faceting. This has reduced polishing time by an average of 20%.” Operator Robbie Cooke has also been impressed with the Delcam software. “PowerMILL is very graphical with pictures to tell you what the system is going to do,” he explained. “The measuring tools for angles and undercuts help me to choose the best strategy and cutting tools to use, while the automation in the software means that I can complete programs more quickly. I’ve only been using the software for a few months so the simulation tools are really valuable. They make it easy to see if you are going wrong and to put it right. They also give me the confidence to put jobs onto the machine straight away. I’ve already programmed all sorts of jobs – press tools, jigs, fixtures and so on. PowerMILL handles it all.” The productivity boost from introducing PowerMILL has come at an important time for G. Parker Aero Tooling Solutions. “Business is pretty good,” claimed Mr. Parker. “We already have enough projects lined up to make 2016 a better year than 2015. We have plans to add more five-axis machines as they always seem to be fully booked and we will be recruiting two more apprentices. Extra training, including more PowerMILL courses, is also planned for the existing staffto make them more flexible so we are able to take on more projects.” For more details visit www.delcam.com

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FEATURE ARTICLE

An Old Invention Making New Impressions Stainless steel is a vitally important material for many industries around the world. Even though it was created more than 100 years ago, use of the material has increased significantly since the turn of the 21st century. Ricky Payling, application specialist at Dormer Pramet, outlines the growth of stainless steel, how the cutting tool industry has evolved to machine the material, as well as providing a summary of some of its most common grades.

According to the International Stainless Steel Forum (ISSF) the global demand for stainless steel products has nearly doubled in the last 20 years, and continues to grow five per cent each year. In 2014, almost 42 million metric tons of stainless steel was produced worldwide - a 70 per cent increase from 2005 (24 million metric tons). This growth is predominantly achieved by an increase in China, where production has grown from a 13 per cent share of global output

in 2005 to more than 52 per cent in 2014.

consumer, oil and gas, medical and marine industries.

This rapid development is not only to meet worldwide demand, but also to support increased use within China, where stainless steel is consumed in household metal products, building materials and machinery.

Its versatility is reflected by the fact that there are more than 150 different grades. Common stainless steels include ferritic, martensitic, austenitic, superaustenitic and duplex. More details of which are covered below.

Stainless steelsâ&#x20AC;&#x2122; anti-corrosive qualities make it perfect for use in a huge range of environments and components, such as aerospace, general engineering,

The main alloying element is Chromium, which forms an ultra-thin oxide film on the surface. As a general rule,

resistance to corrosion and oxidation increases in line with Chromium content. Other alloying elements, such as Nickel and Molybdenum, can be added to change the structure, increase corrosion resistance and improve strength. This increase in production and consumption has coincided with advancements and new developments within the cutting tool industry. Due to the difficult process of machining stainless steel, manufacturers

Pramet OEHT octagonal inserts for milling stainless steel.

Dormerâ&#x20AC;&#x2122;s R459 drill is suited to machining a variety of materials, including stainless steel.

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March 2016

have invested a huge amount of time and resources in finding new ways to try to combat the numerous application challenges.

aluminium oxide, helping to transfer the heat away from the cutting tool.

Recent introductions include changes to the cutting tool design, new geometries, improved coolant and developing stronger coatings to improve performance and tool life.

The high strength of stainless steels combined with their high ductility makes chip breaking more difficult. This increases the risk of vibration, which can affect surface finish quality and reduce the service life of the tool or insert.

Drills with thin margins for example, reduces the contact with the hole surface, minimising friction between the cylindrical land and the hole walls, decreasing work hardening and temperatures generated. Positive point geometries ensure excellent chip breaking and evacuation, while a specially designed web combines the benefits of maximum rigidity with space for efficient chip removal, reducing machine downtime. Coatings and coolant Significant heat is generated during machining of stainless steel, resulting in plastic deformation and severe crater wear. Therefore, a generous flow of cutting fluid removes heat from the cutting edge, helps chip breaking and improves dimensional stability of the component. When using flood coolant, it is important to ensure a plentiful supply as any period of coolant starvation can cause temperature fluctuations. This can cause thermal cracking, resulting in reduced tool life. Cutting tools with through coolant also provide an instant reduction in temperature and supports chip evacuation. Meanwhile, a Titanium Aluminium Nitride (TiAlN) coating is ideally suited for machining stainless steel as it holds its hardness at higher temperatures due to a layer of

March 2016

To address this, always make sure tooling and work pieces are stable and well clamped. Always keep tool overhang to a minimum, especially when drilling or internal turning. To help reduce vibration, use sharp tools or inserts with a small nose or corner radius. Ferritic & Martensitic The machinability of ferritic and martensitic stainless steels shows a resemblance to that of ISO P: Steel. Normal chromium content is 12-18 per cent, with only small additions of other alloying elements. Ferritic materials are used in shafts for pumps, steam and water turbines, nuts, bolts, hot water heaters, and in the pulp and food processing industries. Martensitic steels can be hardened and are, as a result, used for edges in cutlery steel, razor blades and surgical instruments. Machinability of ferritic and matensitic stainless steels is good and very similar to low alloyed steels. Austenitic & Super-Austenitic Austenitic stainless steels are the most commonly used ISO M material, accounting for 70 per cent of all stainless steel machined. This is due primarily to their very good resistance to corrosion. The most common composition

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is 18 per cent chromium and 8 per cent nickel. Steel with greater corrosion resistance is created by adding two to three per cent molybdenum, often called “acid-proof steel” or type 316. Super-austenitic stainless steels have a nickel content of more than 20 per cent. Austenitic and super-austenitic stainless steels are used where good resistance against corrosion is required. Typical industry sectors include the chemical, pulp and food processing industries. It is also used in aircraft exhaust manifolds. Austenite stainless steel produces tough, long, continuous chips that are difficult to break. It is prone to work hardening during machining, producing hard surfaces and chips which lead to notch wear. It also creates adhesion and produces built-up edge, resulting in poor surface

finish and reducing tool life. To minimize this, avoid using tools with worn edges which could accelerate tool wear and cause breakage. Make regular checks for signs of wear and change tools or inserts regularly. Also, try to avoid any dwells or pauses in the cutting process as this will cause heat build-up and increase work hardening.

alloying elements and even higher corrosion resistance. Chromium content between 18-24 per cent and nickel content between 4-7 per cent are common in duplex steels, producing a ferritic share of 25-80 per cent.

Duplex

Duplex stainless steels are used in the chemical, food, construction, medical, cellulose and paper making industries, and in processes that include acids or chlorine. They are often used in equipment related to off-shore oil and gas applications.

Adding nickel to a ferritic chromium based steel will form a mixed base structure containing both ferrite and austenite. This is known as a duplex stainless steel.

Machinability of Duplex is generally poor due to high yield point and high tensile strength. Higher content of ferrite – above 60 per cent - improves machinability.

Duplex materials have a high tensile strength and maintain very high corrosion resistance. Super-duplex and hyper-duplex indicate higher content of

Dormer Pramet has developed a comprehensive assortment of indexable and rotary cutting tools to support machining of stainless steel.

A high rake angle reduces heat generated during milling, minimising work hardening.

Its solid carbide drill for applications up to 8xD has been specifically developed to overcome problems typically associated with deep-hole drilling of stainless steel. Created within the Dormer product portfolio, the R459 broadens the existing MP-X range which already consists of 3xD and 5xD solid carbide multi-material drills. Meanwhile, a versatile range of OEHT octagonal inserts for cutting depths 4 – 10 mm, alongside REHT (round) and XEHT (wiper) inserts, is suitable for stainless steel. By utilising eight cutting edges – the highest number available for positive inserts – the new range provides an economical offer for customers, while the wiper insert option boosts feed rate capabilities and surface finish quality. For more details visit www.dormerpramet.com

Ricky Payling, application specialist at Dormer Pramet.

Pramet OEHT octagonal inserts for milling stainless steel.

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March 2016

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TECHNICAL FEATURE

Decentralized servo technology without language barriers KOLLMORGEN develops a multi-language interface for Profinet, Ethernet/IP, EtherCAT & Co. Although machinery and plant engineering certainly has international characteristics, there are still some continental- specific features that need to be accounted for with technical equipment. These include in particular the selection of control systems, as well as the language spoken in the bus. The prevalence of Rockwell with Ethernet/IP in America and of Siemens with Profinet in Europe is a good example of this. These regional practices mean that manufacturers supplying both regions need to equip their machinery with the relevant control systems as required.

Alexander Hack Kollmorgen Europe

in a more compact manner

Since the issue of

AKD-N series using a multi-

technology in mechanical

communication automatically

language interface.

engineering. First of all, the

in machine racks. Aside from

positioning of the control

a more efficient operating

engineering in the immediate

surface, the AKD-N devices

vicinity of the actual drive task

also provide greater freedom

creates space in the control

to development departments

cabinet. These can be smaller

for constructing new machines

as a result, allowing them to

with less spatial restrictions

be integrated more easily and

through their robust design

arises with selection of the relevant automation, KOLLMORGEN has now made it easier to connect the relevant control system to the decentralized servo technology in the form of the decentralized

Benefits of Modularization Space savings, increased energy efficiency and lower installation and assembly costs are just three of the benefits of using decentralized servo

Thanks to the multi-language interface, decentralized servo axes with stainless-steel motors can be incorporated very easily into different control systems.

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March 2016

No loss of power through derating: KOLLMORGEN’s decentralized servo technology is positioned directly at the motor as an offset controller.

ultimately reduces storage,

or their customers’ special

documentation and purchasing

plant regulations. It is also

costs.

much easier to modularize the

and IP 65 degree of protection.

Freedom

Another effect of moving the

Standardized synchronous

servo drive technology to the

motors, customer-specific

machine: the thermal losses

special motors, hygienic

The features of the

are no longer concentrated at

premium steel motors in

decentralized servo technology

one spot in the control cabinet,

protection class IP69K, linear

outlined briefly can be used

which in turn saves money by

and rotating direct drives

independently of the higher-

eliminating air conditioning

and asynchronous machines:

level control system thanks

and thereby reducing

decentralized AKD servo

to further developments in

Parameterize using a few

operating costs over the long

controllers can cope with

communication. Profinet,

movements

term. As a result of derating,

whichever motor you are

Ethercat, Ethernet/IP: machine

KOLLMORGEN has made a

controlling! This makes it so

and plant manufacturers

For Silvester Tribus, CEO

conscious decision to develop

easy in practice to use the best

no longer need to worry

of TBM Automation AG in

the AKD-N decentralized

system for the relevant drive

about the language of their

Switzerland, this independence

servo controllersas an offset

task, without having to get

control system thanks to the

forms the basis for integrating

solution. This way the devices

bogged down in the multiple

multi-language interface.

machines into an existing

provide full power. With the

versions available. Since the

As communication in

plant network more easily

hybrid “piggyback” solution

decentralized controllers also

KOLLMORGEN’s AKD-N

and quickly. “We deal with

the thermal discharge from

use the same functional AKD

system is ultimately now just

very special requirements and

the motors can result in more

platform, mixed forms of

a question of the software

needs related to functions

than 30 percent power loss.

centralized and decentralized

settings, the actuators can

or data logging on a daily

The “next door” approach

controllers can also be easily

be adapted “at the touch of

basis. If we are open in terms

also creates more freedom in

implemented within the

a button” if the PLC changes

of the protocols, we are

selecting a motor compared

same application. All in all,

based on market differences.

able to meet these requests

with having everything in the

KOLLMORGEN supports

This way manufacturers have

with every control system.”

center.

designs for perfect-fitting

the benefit of being able to

What is specified and in what

solutions with a high degree

design their machines free

format differs greatly in the

of standardization, which

from country-specific features

experience of the Swiss CEO.

Motors Selection: Maximum

March 2016

whole ensemble – an aspect for which decentralized servo technology, in particular, is able to demonstrate its full performance capacity.

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“Some customers specify

in a library that reproduces at

the decentralized AKD-N drives,

thereby opens up closed

the control system, some the

least 80 percent of the basic

provides the 24V supply, the

systems, enabling completely

entire technology, and for

functions. “The remainder

bus communication, transmits

new and open designs.

others it doesn’t matter. They

can be adjusted in just a few

signals and brake management.

want their machine fitted out

parameterization steps”, says

in such a way that they achieve

Tribus.

the required performance and quality – the exact way that this is done is left to us.” In terms of communication the full-service partner for industrial automation from Widnau, south of Lake Constance, always states that machinery and plant engineering is in great shape when programming a control system, but regarding the field bus the matter “is becoming more difficult”. As a result KOLLMORGEN has written the finished software modules for the multi-language interface and collated these

The multi-language interface is integrated into the enclosure for the central AKD-C supply unit. The decentralized servo controllers are connected to the control cabinet unit with just one cable – arranged in a line rather than in awkward star wiring. The AKD-C feed-in module can be used to connect up to 16 decentralized AKD-N servo axes via the grid-bound DC supply. The system cables are just 11 millimeters thick and therefore require less space. The eight-pin structure on the inside draws the DC supply of

The author Alexander Hack is with KOLLMORGEN Europe,

The Bottom Line With the new multi-functional communication interface which is unique in the drive technology market, KOLLMORGEN provides an option for switching between control systems with just one “click” with decentralized drive architectures. This makes it possible to design machines free from restrictions on the PLC side. The multi-language communication module supports the entire ensemble with local logic for extremely rapid reactions at the servo axis in micro seconds. The new communication module

Ratingen. Kollmorgen is a leading provider of integrated automation and drive systems along with corresponding components for machine builders all over the world. With more than 70 years of Motion Control Design and application experience and profound knowledge of constructing standard and special solutions, Kollmorgen supplies solutions time and again that stand out in terms of performance, quality, reliability, and ease of use. As a result customers can achieve a market advantage which is beyond question. For more details visit www.kollmorgen.in

Structure of KOLLMORGEN’s decentralized servo system with the AKD-C feed-in module and the decentralized AKD-N servo controller.

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March 2016

The new control system PNOZmulti 2 with up to 80% less energy consumption â&#x20AC;Ś

â&#x20AC;Ś than comparable products. The power consumption of the new base unit PNOZ m B0 is a minimal 0.8 W with 20 safe inputs and 4 safe semiconductor outputs (PL e, SIL CL 3) and a width of just 45 mm. Rely on 10 years of innovation from the market leader in safe control technology! Count on the configurable control systems, the worldwide safety standard for all machine types. The simple, graphics configuration tool saves engineering costs because you can create your safety circuit simply and intuitively on the PC. Visit us at the Hannover Messe, Hall 9, Stand D17.

Further information about the PNOZmulti Configurator: www.pilz.com + Web code: web10522 Pilz India Pvt. Ltd Office NO 102 & 202, Delite Square, Near Aranyeshwar Temple, Sahakar Nagar NO 1, Pune - 411009 Telephone: +91 (0) 20 24213994/95, Fax +91 (0) 20 24213996, Web: www.pilz.in, Email: info@pilz.in

March 2016 1AD_PNOZmulti_2_222x285_EN_IND_2015_03.indd 1

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23.03.15 12:07

MART UPDATE

Omron reaffirms its position as enablers of Smart, Scalable & Sustainable Manufacturing Reaffirming its contribution towards manufacturing sector, Omron Automation, the world leader in factory and industrial automation, shared its focus areas towards enabling smart, scalable and sustainable industries today. The company imparted this information as a part of its participation in the renowned exhibition Elecrama-2016 held at BIEC, Bengaluru, Feb 13-17, 2016. Describing Omron Automation as ‘Enablers of Make in India’, Mr. Sameer Gandhi, MD, Omron Automation India said, “Our efforts to position Omron as an ‘automation partner providing end-to-end solutions’ have been yielding significant results owing to which we have been able to strengthen our share in many segments such as Packaging, Textile, Automotive, FMCG, Material handling, Pharmaceuticals to name just a few. Moving ahead, we aim to progress in the Digital segment too.” Mr. Gandhi’s words were well substantiated at the Omron booth put up at Elecrama. Themed “Pure Possibility”, the booth depicted Omron’s forte in automation industry by providing solutions which not only detects, comprehends, and act on information as humans do, but are also able to intelligently adapt to their environments and to the needs

of humans. One of the most notable displays at the booth was FORPHEUS- the Ping Pong Robot created by Omron. Adding one more dimension to the theme of Pure Possibility, the robot is a practical manifestation of the concept of “harmony between humans and machines”. Designed on Omron’s core technology of “Sensing & Control + Think”, the world-renowned robot plays ping-pong not only with greater accuracy but also returns the ball to allow its partner a longer rally that is setting in place a harmony and not competition. Talking about the future prospects Mr. Takehito Maeda, MD, OMRON Asia Pacific, Pte Ltd., Industrial Automation Business, said, “India is occupying a much more prominent position in the global manufacturing setup. The rising levels of disposable incomes, urbanization, rural demand, and financial inclusion are some of the other key factors expected to have a positive effect on the manufacturing sector in the country. And as manufacturing grows in India, so will the demand for factory automation which creates an opportunity for us playing a much bigger role in the lives of people of India, making it an important growth region for Omron in Asia Pacific.”

all the key offerings of Omron Industrial Automation business such as live demos showing the real time applications in varied fields, robots depicting the solutions for better efficiency, total automation as the one stop solution provider and IoT depicting that Omron solutions are future ready and are aligned with the emerging concept of Industry 4.0.

The visitors once inside the booth got to orient themselves with

Not only industrial automation, the booth is an interface to

“Omron’s extensive range of sensing & control technology based solutionsmore than 30,000 variants- spread across Industrial components, Automation Systems, Sensing & Safety, Motion & Drives, Robots and Software have been helping manufacturers in the form of efficiency, productivity, flexibility, accuracy andsafety as they scale up the value chain. We have recently introduced the futuristic concept of IoT (Internet of Things) to expand their horizon and help them develop smarter machines based on the concept of ‘i 3’- ‘Integrated, Intelligent and Interactive’”

Sameer Gandhi Managing Director, Omron Automation 84

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other key offerings of OMRON business verticals in India also, namely, Electronic & Mechanical Components, Automotive Electronic Components, and Healthcare. The Electronic & Mechanical components display depicted Omron as a value creating partner for designing equipment in varied industries such as automotive, building automation, home appliances, medical and power industry through a niche display of relays, switches, illumination technology. The Automotive Electronics section emphasized on Omron’s contribution in designing safer and reliable cars. The Omron Healthcare zone attracted many visitors keen to check their blood pressure by using Omron digital BP Monitors and getting acquainted with other home health monitoring devices manufactured by Omron.

March 2016

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CNCSSIPL to host HAAS DEMO DAY in Mumbai Haas Factory Outlet – A Division of CNC Servicing & Solutions has announced the MUMBAI DEMO DAY, the first for the year 2016. With live demos & tours, the event will be conducted at KoparKhairne, Navi Mumbai from April 28th to 30th 2016. Visitors at the Demo Day will see the company’s latest generation CNC machines,

VF-2 & ST-35. The Haas VF-2 CNC vertical machining centre has travels of 762 x 406 x 508 mm in the X, Y and Z axes. The machine uses a 40 taper spindle driven by a 22.4 kW vector drive motor delivering high torque through to a maximum speed of 8100 rpm. The VF-2 boasts a 20-station carousel tool changer and 25.4 m/ min rapids on the three main axes. The Haas ST-35 big bore CNC lathe can accommodate bars up to 102 mm in diameter and offers a capacity of 533 (dia) x 660 mm (length) with 806 mm of swing. The 29.8 kW, 2400 rpm spindle is served by a two-speed gearbox, while additional features include a 381 mm chuck, 12-station bolton turret and rigid tapping capability.

Visitors are invited to bring along components or drawings for a full evaluation of optimized machining solutions. The Demo Day will also feature a number of the company’s industrial partners like: Prime Industries - based in Nashik is India’s Largest & oldest Imported Graphite Machine shop. Regarded as the premium quality Graphite Supplier offering highest quality products in India. They exclusively represent Tokai Carbon Co. Ltd, Japan since 1998 in the Indian Market. SECO Tools - Seco will showcase a comprehensive portfolio of advanced metal cutting solutions at Mumbai Demo Day. The company will have its practical experts available

to assist manufacturers in redefining their productivity and profitability. Also present would be Zeiss, Mitsubishi & Delcam all able to offer complementary technologies and advice.

Grundfos India at ACREX 2016 Grundfos India, one of the leading pump manufacturers in India, participated in the 17th edition of ACREX 2016 in Mumbai. The three day expo from February 25 to 27 focused on the ‘Infinite Opportunities for HVAC&R and the Building Services Industry’. As per the Indian Society of Heating, Refrigerating and Air Conditioning

Engineers (ISHRAE), the HVAC industry is expected to reach Rs.20,000 crore by 2016, and the sector is expected to witness nearly 15-20 per cent growth y-o-y.The growth is anticipated due to increase in construction activity in infrastructure and real estate sectors. The industry is set to witness immense competition as customers are price sensitive and looking for affordable energy-efficient systems due to the rising energy costs and environmental awareness Grundfos India has a wide range of intelligent and efficient pumps and solutions for air conditioning, refrigeration and building services. The company exhibited its intelligent in-line pump TPE3, designed specifically for use in heating and cooling systems for commercial buildings. With its built-in heat

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energy meter and flow limiting function, the pump totally eliminates the need for a pump throttling valve. This pump is exceptionally energy efficient In-line pump choice, exceeding industry standards. Along with TPE3, Grundfos showcased MAGNA3, the most proficient circulator available in the market today. The MAGNA3 is designed to offer a complete range of control mode options expected from a state-of-the-art circulator pump. AUTOADAPT and FLOWADAPT, the two intelligent modes set MAGNA3 apart from thecompetition. Commenting on the occasion, Gangaprasad G, Vice PresidentSales (Building Services) Grundfos India, said, “We are witnessing an increasing demand for an effective pumping

solution to reduce energy costs and environmental impact. Our pumps are designed and developed to highlight Grundfos’s commitment to our customers’ and the industry’s need for intelligent automatic solutions that minimizes the lifecycle cost of the pump, reduces operational cost and enhances sustainability efforts.”

March 2016

NI Automated Test Outlook: Reinforces the Need for Smarter Test Systems NI identifies top business and technology trends to help lower the cost of test NI (Nasdaq: NATI), the provider of platform-based systems that enable engineers and scientists to solve the world’s greatest engineering challenges, announced the release of its Automated Test Outlook2016. The annual test and measurement report delivers a comprehensive view of the key trends expected to impact automated test environments with the proliferation of connected devices, from preparing to test mmWave communication to effectively using manufacturing test data to propel business

results. Automated Test Outlook 2016explores the following topics:

and compatibility challenge long lifecycle projects—an age-old problem warrants revisiting.

COMPUTING: Harvesting Production Test Data

ARCHITECTURE: The Rise of Test Management Semiconductor organizations pioneer real-time data analytics to Software reduce manufacturing test cost. Off-the-shelf test executives are effective SOFTWARE: Life-Cycle solutions for the influx of new Management Is All About programming languages. Software Obsolescence, OS churn,

I/O: Standardizing Platforms from Characterization to

“As strong advocates for excellence in automated test, we work closely with customers and suppliers to understand the top issues facing manufacturing and test departments. Whether your challenge is testing millions of Internet of Things devices or managing a 20-year-old test system, our goal is to spark dialogue within your organization to help you lower the cost of test and stay ahead of your competition.”

Jayaram Pillai Managing Director, National Instruments India

Production RFIC companies employ IP reuse and hardware standardization across the product design cycle to reduce cost and shorten time to market. Business Strategy: Making (mm) Waves in Test Strategy Test managers are adopting modular solutions to economically validate high-frequency components. Download the complete report at www.ni.com/ato.

R100 and R101 from Pepperl+Fuchs The R100 and R101 are available in standard, assemblycompatible housing designs and offer photoelectric sensors for both detection and measurement. They include thru-beam sensors, retroreflective sensors, including those with polarization filter, foreground suppression or for detection of transparent objects, energetic reflection light scanners and those with background suppression, as well as light barriers and distance sensors for measurement tasks. Innovations in Intelligent Combinations and Compact Design

March 2016

All sensors are available with a PowerBeam LED or innovative laser technology depending on the task at hand. The latter combines the benefits of LED emitters with the strengths of conventional laser diodes. This results in optimized operating distances, high-precision detection, and distance measurement of small objects. The multipixel technology (MPT) developed by Pepperl+Fuchs and the innovative Opto-ASIC enable reliable, high-precision distance measurement to be integrated in a standardized compact housing for close-range applications. The R101 series

offers the world’s smallest distance sensor of its type. The innovative combination of multiturn potentiometer and pushbutton allows users to adjust all functions intuitively regardless of the series. Two LEDs show that the sensors are ready for operation and indicate their status. Sensor Technology 4.0 Portfolio Expanded The R100 and R101 series feature IO-Link compatibility. They are an enhancement of the Sensor Technology 4.0

portfolio from Pepperl+Fuchs, enabling Industry 4.0 production processes to be networked and availability of machines and systems to be optimized.

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Rhino Machines features at FOIN 2016 Rhino Machines features at FOIN 2016 In the week long Festival of Innnovations (FOIN) hosted by President of India from 12-19 March, Gujarat based Rhino Machines is one of the 4 SME’s from the Cleanovator Accelerator Program of MSME selected to showcase their innovation on 17th March 2016 at Rashtrapati Bhawan. A total of 65 grassroots innovations will be part of this Exhibition which will kick-off the week-long Festival of Innovations in Rashtrapati Bhavan from March 12-19, 2016. The Festival is being organised by Rashtrapati Bhavan in collaboration with the National Innovation Foundation. President Mukherjee has extended tremendous support to the innovation movement in the country ever since assumption of office, especially by encouraging setting up of innovation clubs in all institutions of higher learning and introducing annual residency programmes for grassroots innovators in Rashtrapati Bhavan. ECOFLEX® from Rhino

Machines Team for Foundry Industry is an innovation with potential to reduce energy consumption from 30-50%, have a clean & safe working environment, amounting to a potential of 7000 MW / year for another 5 years as per the growth potential of the foundry. MSME recognised Rhino’s innovation, and selected it as one of the participants in the GCIP 2015. Rhino ended up in the top 6 innovations, and the only one from the Foundry Space – the mother industry, but long termed as dark, dusty, unsafe, high energy consumer. Rhino’s innovations have a direct impact on the Industry Economics, Work Environment, Energy Efficiency and Global Competitiveness. It impacts the contribution of the foundry by 6-8% directly. MSME once again shortlisted Rhino as one of the 4 Innovations from the 160+ to be showcased at the President of India’s Festival of Innovation FOIN 2016 on 17th March at MSME Booth. Supported by UNIDO, MSME, FICCI, GEF, Cleantech and mentored by this team, Rhino continues to bring more innovations to the Foundry domain continuously.

The week-long ‘Festival of Innovations’ will witness a number of exhibitions; roundtable discussions on different topics related to innovations with national and international participation; a talk by Nobel Laureate Kailash Satyarthi; an award for Gandhian Young Technological Innovation; Visitor’s Awards to Central Universities, including in the field of innovation; a meeting of Innovation Clubs set up in institutions of higher education across the country; a workshop for children and a hackathon to develop applications useful to society etc. The Exhibition of Innovations will remain open between 1000

to 1700 hrs from March 12-19, 2016 for the public. All visitors to the Mughal Gardens will be able to visit the Exhibition. Established in 1983 by Mr R C Kothari, Rhino evolved into a full fledged manufacturing firm producing Foundry Projects and Machines specialised over years in Green Sand Process – Moulding, Sand Systems and Reclamation. Rhino now offers Turnkey solutions for setting up foundries in India and overseas. Rhino has developed technologies, and adapted modern systems from French, Italian & American partners producing the machines in India. Rhino has also ventured into Swiss tie up for Skill Development to bridge the Industry Skill Gap.

“Rhino Machines Team is proud to share its recognition at National Level as an Innovator. It is first time an SME supplier from Foundry Fraternity will be honoured and recognised at this level. Rhino shall be displaying the ECOFLEX Model @ the event on 17th March and invite one and all to the the Rashtrapati Bhawan.” Manish Kothari Managing Director, Rhino Machines

Pramets expands shoulder milling range Pramet’s popular shoulder milling range has been expanded with a new program of cutters, geometries and inserts. This includes a program of helical cutters for roughing applications. Offering a depth of cut up to 108mm, the cutters are suitable for

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use with Pramet’s versatile ADMX 16 inserts and support medium machining of most engineering materials including cast iron, stainless steel and aluminium alloys.

delivery, promotes efficient chip evacuation. The axial clamping of inserts on the end teeth increases milling stability. This creates less noise and vibration, which, in turn, also reduces tool wear.

The large clearance between the cutting teeth, combined with internal coolant

New radii and geometries have been added to the LNGU/LNMU16 assortment to

provide greater choice. A further four radii options are available with range of sizes from 0.8mm to 4.0mm. New geometries include F, M and R for machining stainless steel, steel and cast iron. A highly positive geometry FA is for copper and aluminium.

March 2016

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“Majhi City Takatak” Grind Master Partners Initiative to make Swachh Bharat in Aurangabad

Grind Master is the proud partner of the Majhi City Taka-Tak campaign with the Aurangabad Municipal Corporation (AMC) and Confederation of Indian Industry (CII). This unique and path breaking initiative aims to bring Aurangabad to number 1 position under the Swachh Bharat Ranking in India. The focus of this initiative is to maximize resource recovery from waste and inject dignity of labour into the SWM processes. Says GauriMirashi of Civic Response Team, the executing agency of this project, “Grind Master has been our first and solid partner right from when we began our journey towards zero-waste at Sindhi Colony, through our learning phase

with Ward 84 and 72, and now, they have been the first to drive the Majhi City Takatak Campaign, by funding the training & leadership programs for all 100 Jawans and 300 SafaiKarmcharis. Indeed, Grind Master has been the pioneer of the Solid Waste Management movement in Aurangabad that has now taken such a strong and solid shape.” The aim of the campaign is to demonstrate best SWM practices in compliance with the Municipal Solid Waste Rules, 2000, with the wilful participation of all stakeholders to achieve: 1. 100% segregation at source 2. Provide door-to-door collection of segregated waste through efficient route mapping and optimization 3. Decentralised treatment of organic waste 4. Resource recovery of

“I’m very proud to say that the Grind Master family whole-heartedly supported the campaign at the Bibi – ka – Maqbara, volunteering to organize the event as well as to participate in the clean-up drive. Over 150 bags full of plastic and paper were recovered from the city. This material is being recycled with the help of the informal sector.”

Sameer Kelkar

Executive Director, Grind Master

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School kids Striking the Takatak Pose

Schools Participating in Campaign recyclables. 5. Eliminating dumping of waste at open spaces like Naregaon 6. Changing systems to include dignity of labour at each stage In Phase 1 of the campaign, CRT, with the support of Grind Master Machines Pvt. Ltd. designed and conducted a comprehensive capacity building program on Solid Waste Management (SWM) for the Sanitation Department of Aurangabad Municipal

Corporation (AMC). Along with this orientation and planning sessions have also been conducted with the ward officers and sanitation inspectors to make the first 12 wards waste free. The Majhi City Taka-tak campaign was launched across the city on the 24th January with a resource recovery drive. This campaign will change the face of Aurangabad and set an example for other cities to adapt the best SWM practices and Grind Master Machines Pvt. Ltd. is proud to be a solid partner in this historic endeavour.

March 2016

Red Lion names Daniel Gao Vice President of Sales for AsiaPacific Experienced Executive to Lead APAC Sales and Help Customers Leverage IIoT-Ready Solutions

“It is an honor to join an industry leader like Red Lion, who follows a customer-first philosophy and has been serving industrial customers and partners for over 40 years. The IIoT presents a unique opportunity for Red Lion and for our customers, and I look forward to growing the business in Asia and enhancing our leadership position in the automation and networking markets.”

Daniel Gao Vice President, Red Lion Asia Pacific Sales

STATEMENT ABOUT OWNERSHIP AND HIS PARTICULARS ABOUT THE NEWSPAPER INDUSTRIAL BUSINESS MART (Form IV – See Rule – 8) 1. Place of Publication

2. Periodicity of its Publication : Monthly 3. Printer’s Name Whether Citizen of India Address Thiruvananthapuram - 695013

: Hari Shanker A G : Yes : Tharangam, Kodunganoor Post

4. Publisher’s Name Whether Citizen of India Address Thiruvananthapuram - 695013

: Hari Shanker A G : Yes : Tharangam, Kodunganoor Post

5. Printer’s Name Whether Citizen of India Address Thiruvananthapuram - 695013

: Hari Shanker A G : Yes : Tharangam, Kodunganoor Post,

6. Names and addresses of individual who own the newspaper & partners or shareholders holding more than one percent of total capital:- Hari Shanker A G, Tharangam, Kodunganoor Post, Thiruvananthapuram - 695013 I Hari Shanker A G, hereby declare that the particulars given above are true to the best of my Knowledge and belief.

Dated : 1st March 2015 Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking,announced the appointment of Daniel Gao as Vice President of Sales for AsiaPacific (APAC). Based in Shanghai, Daniel reports directly to Red Lion President Mike Granby and serves on the executive team. Prior to Red Lion, Daniel served as a Sales and Marketing Director for TE Connectivity Shanghai. Earlier in his career, he also held executive sales positions at Honeywell Sensing and Controls, Vishay Transducer, Rohde and Schwartz, Compuwave Technologies and Spirax

March 2016

Sarco Engineering.

: Thiruvananthapuram

Sd/- (Publisher)

“Daniel is an experienced international executive with a strong track record of sales in China and throughout Asia,” said Granby. “As the Industrial Internet of Things continues to grow in Asia, Daniel will play an important role in driving sales of Red Lion’s industrial automation and networking products in the region and helping establish our position as a global IIoT provider.” Daniel has a Bachelor Degree in Mathematics and Statistics from Zhongshan University and a Master Degree in Computing from the University of Bradford. For additional information about Red Lion and the IIoT, please visit www.redlion.net/ IIoT.

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Red Lion Launches First Rugged Crimson-Enabled E3 I/O Platform High-Density I/O Modules Integrate Powerful Networking into Industrial Applications Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, today announced the availability of its new rugged E3 I/O™ module platform, a set of 17 high-density I/O modules with hardened metal enclosures and powerful communication options. This versatile platform marks Red Lion’s first rugged I/O modules configurable using Crimson® 3.0 software. Designed to withstand the critical demands of localized and distributed I/O applications, Red Lion’s Crimson-enabled E3 I/O modules feature robust networking capabilities with redundant Ethernet ports and built-in serial communication.

With one RS-485 terminal block and dual Ethernet ports that include user-selectable Ethernet modes for ring, pass through and two network, the easy-to-deploy E3 I/O modules can eliminate the need for additional switching devices. In addition, these modules offer up to 34 mixed I/O points including input/output, analog/ discrete and temperature I/O for complex industrial applications. “Customers today are demanding both more I/O connectivity and mixed I/O types – digital, analog or temperature – because of the variety of sensors and inputs needed to monitor complex systems,” said Paul Bunnell, director of automation product management at Red Lion Controls. “To keep industrial operations running smoothly,

organizations require easyto-configure equipment with multiple connectivity options and rugged enclosures that enable reliable performance in harsh environments.” Available in DIN-rail and panel-mount form factors, Red Lion’s E3 I/O modules feature rugged metal enclosures to support wide environmental tolerances and enable seamless integration into any industrial environment. Wide -40° to 75°C operating temperature, high shock and vibration ratings coupled with industry certifications that include UL Class I, Division 2 listing, ATEX* and IECEx* approvals make each E3 I/O module safe for use with industrial control equipment in hazardous locations around the world. Developed for industries

including oil and gas, water, utilities, marine, transportation and mining, the E3 I/O module platform is ideal for criticaluptime applications where customers need to expand I/O for devices such as Human Machine Interfaces (HMIs) or standalone deployments. For more information and specifications, visit www. redlion.net/E3.

New ANG Active Next Generation Servo Inverter Series Expands and Enhances Bonfiglioli DrivePortfolio Bonfiglioli Riduttori S.p.A., a global designer and manufacturer of gearmotors, drive systems and planetary gearboxes, announces the addition of a servo inverter series, ANG Active Next Generation, which provides higher performance for machine builders. With this new servo inverter series, Bonfiglioli offers the broadest connectivity with the most advanced control technology and the highest power density. Bonfiglioli has developed the ANG Active Next Generation series to meet the requirements of special machinery in a large range of industries. One feature, in

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particular, is a new positioning configuration, which is dedicated for travelling drives in crane applications. With a new micro controller, several enhanced functionalities are embedded in the ANG Active Next Generation including Cyclic Synchronous Positioning mode with cubic interpolation, brake control, and evaluation of feedback contact. Moreover, the new single axis for the control of servo motors, induction motors and synchronous reluctance motors, delivers high dynamic response, high performance and application versatility.

The ANG series supports many Ethernet fieldbuses like EtherCat, Ethernet IP and Profinet. Key Features are Power ratings: 0.25 KW to 400 kW, Voltage Ratings: 400V, 525 V, 690V, Safety: STO ( safe torque off, SIL2), Communication Protocols: CanOpen, RS232, EtherCat, Ethernet IP, Profinet, Feedback Sensors: Resolver, Absolut Encoder, PLC functions and Motion tasks. Customer Benefits: PLC functions with graphical

Bonfiglioli New Servo Inverters Series ANG Active Next Generation

software tool, Cubic interpolation for high dynamic interpolated axis, 525V and 690V supply voltages for heavy industries and the steel industry, High precision closed loop configuration.

March 2016

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Geneva Motor Show: HARTING’s rapid charging technology celebrates premiere Increasing demand for e-mobility solutions / Boost from plug-in hybrid vehicles HARTING’s rapid charging technology is celebrating its premiere at the Geneva Motor Show (3 to 13 March 2016)

on Rinspeed AG’s exhibition stand (hall 6.240). Rinspeed’s latest “Etos” concept car is a spectacular application.

HARTING is displaying the DC rapid charging plug combo type 2 at the Geneva Motor Show amongst other solutions.

HARTING is also exhibiting the mode 2 charging cable.

The industrial connectivity specialist HARTING has been manufacturing innovative products and solutions for e-mobility for several years based on decades of experience in connection and transmission technology for data, signal and power. HARTING Automotive is developing and producing charging equipment for electric and plug-in hybrid vehicles. These include mode 2 charging cables, mode 3 charging cables and DC rapid charging plugs with approval and certification for all specific markets

and which meet legal requirements worldwide. Customers can deploy the equipment in line with their own individual requirements as the HARTING vehicle charging HARTING will be presenting products such as cables are available Type 2 AC plug. in all three plug system versions used HARTING Automotive. The worldwide (with the field of e-mobility is therefore corresponding approvals) becoming ever more important for the common AC charging to HARTING as Grinblats interfaces. The type 1 plug is predicts that automotive certified for AC in accordance manufacturers will increasingly with UL, CE and JET/PSE, roll out plug-in hybrid vehicles and the type 2 plug for AC on the market over the in accordance with UL/VDE. coming years. “To achieve The HARTING GB China their CO2 balance alone, plug complies with the CQC automotive manufacturers standard. will be launching many more HARTING Automotive is such cars,” Grinblats firmly currently reporting growing believes. In order to meet the demand worldwide for rising demand, the HARTING e-mobility solutions. Technology Group is currently “Demand for such solutions investing in the expansion of remains high,” confirmed production in Sibiu in Romania, Marco Grinblats, Business Silao in Mexico and Zhuhai in Unit Manager E-Mobility at China.

Westermo Gigabit switches & media converter support higher bandwidth networks Westermo has launched three new Ethernet devices that support the growing need for higher bandwidth networks with industrial applications. Two new Gigabit switches and a media converter offer outstanding reliability, robustness and ease of

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installation, making them suitable for heavy industrial, maritime and rail trackside data communication networks. The MCW-211-F1G-T1G is an unmanaged industrial Ethernet media converter with one SFP fibre port and one copper port

that enables the connection of legacy serial devices to new Gigabit Ethernet networks. The SDW-541-F1G-T4G and SDW-550-T5G are unmanaged Ethernet switches that offer a choice of five copper or one fibre and four copper ports. The units support 100

Mbit/s or Gbit Ethernet, with the SDW-550-T5G also supporting 10 Mbit/s communications. Using Westermo’s range of pluggable 100Mbit or Gbit SFP transceivers, different types of fibre can be easily converted and distances of up to 120km can be achieved.

March 2016

DMG MORI World première:DMU 160 P duoBLOCK®4th Generation

The world premièreof the

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March 2016

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Send your subscriptions to: The Circulation Manager Mediamart Infotech C-507, Wisteria Fortune, Survey No: 95/2, Near New Poona Bakery Wakad, Pune - 411057 Mobile: +91 9038 000711/ 9038888277 Email: mart@martinfotech.in Web: www.martupdate.com

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February 2015 November March 2016 2014

THE LAST LEAF Dear Readers, India is glowing and beaming with renewed spirit. We focus on some of the facts and highlights here in this edition of Last Leaf. India is set to soon offer a locally made combat version of the Hawk aircraft for exports with licence producer Hindustan Aeronautics Limited set to roll out the first of the highly weaponised light attack planes by February 2017. The Combat Hawk has generated interest for its potential in unconventional operations. Meanwhile, India struck a unique oil deal with UAE, which will land it 4 Million barrels of oil almost free after 5 years. It is not often that an Indian project is greeted with joy all over the world. But this is precisely what happened, when the Indian Union Cabinet cleared the proposal to build an Advanced Laser Interferometer Gravitational Wave Observatory (Advanced Ligo) in India. The observatory, whose location is yet to be decided, will have to be sealed from all noise and vibrations from around it. Shielding even a meter of equipment is hard, but the detector will have two arms perpendicular to each other, each four kilometers long. Building the laser for the detector is also difficult. The detector works by splitting a laser beam into two, sending them off in perpendicular directions and then combining them to get a precise pattern of waves. The laser required for this purpose was developed by Max Plank Institute in Germany, along with a consortium of companies around it. It is the most technologically advanced laser on earth. The detector will also have the largest vacuum in the world. Building such a vacuum - two arms four kilometers long and 1.5 metre wide - is hard. The vacuum has to be maintained without using noisy pumps. Talking about logistics and transportation, the first batch of 800 cars have been shipped from Chennai port to Kandla. Seaway movement of cargo within the country was not permitted under law. The present government changed that law. This would result in transportation costs dropping to almost 1/3rd from Rs. 1.50 per kg per km to Rs.0.50 per kg per km. Bangalore’s Kempegowda International Airport received a GreenCo platinum certification by Green Building Council of CII – it is India’s first airport to receive this rating, which is owing to its water conservation, biofuel adoption, & use of solar energy. The World Bank has recently approved a US$1.5 billion loan for the Swachh Bharat Mission (SBM) Support Operation Project to support the Government of India in its efforts to ensure all citizens in rural areas have access to improved sanitation – such as a toilet or latrine with a focus on changing behaviors – in ending the practice of open defecation by 2019. Specifically, this project will support the rural component, known as SBM – Gramin (SBM-G), over a five-year period using a new performance-based program which links funds directly to results, ensuring that benefits are delivered to the people in need – more than 60 percent of India’s rural population. The Ministry of Drinking Water and Sanitation (MDWS) will play the overseeing and coordinating role for the Program and support the participating states. Funds will also be used to develop the capacity of MDWS in program management, advocacy, monitoring and evaluation. (Courtesy : worldbank.org) We are making an attempt to create a positive outlook around us that we feel, would 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 March 2016

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March 2016

Pressure Range

Capacity

Discription

Sr No

M3/Min

CFM

Bar

Lubricated SCREW Compressor

0.23 to 43.70

8 to 1545

8 to 13

Oil Free SCREW Compressor

5.30 to 51.40

187 to 1815

8 to 10

Lubricated PISTON Compressor

.125 to 6.20

4.5 to 219

8 to 40

Oil Free PISTON Compressor

.156 to 1.30

6 to 45

8 to 40

BOGE FLEXPET

1.55 to 17.9

54 to 634

BOGE AIR. THE AIR TO WORK.

BOGE India , No. 216, Third Link Street, Industrial Estate, Nehru Nagar, Kottivakkam, Chennai - 600 096, india@boge.com* www.boge.in Chennai Mr. F C Jayakaran

: +91 9600041656 : fc .jayakaran@boge .com

/ Chennai Mr. Muthu Ganesan : +91 9003172111 : muthu.ganesan@boge.com

Hyderabad Mr.W.Narendra

: +91 9704770930 : w. narendra@boge.com

/ Mumbai Mr. Hasan Hasware : +91 9840956161 : h.hasware@boge.com

Delhi Mr. Deepesh Upadhyay

: +91 9818556732 : d.upadhyay@boge.com

March 2016

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100

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March 2016