Volume 9 Issue 6 December 2012 Pages 68 `100
Total Chip Protection for Machine Tools New energy chain for unsupported travels up to 50 m from igus
Introduction to Additive Manufacturing (Rapid Prototyping and Manufacturing Technology)
Rapid Manufacturing of Aluminium Components ON FACE
Soo Kam Tatt, Director, Hypertherm Asia The HyPerformance series of HyDefinition Plasma systems from Hypertherm
CONTENTS 20
Cover Feature
Introduction to Additive Manufacturing
24 Rapid Manufacturing of Aluminium Components COLOUMN 38
Sarvajith Singh
Quality Management Cost of Quality
42
P S Satish
Manufacturing Excellence Journey Towards Excellence
46
Vivin Agarwal
Responsible Business Greening your Responsibility
48
A S Shetty
Machine Design Fundamentals Strength of Material Aspects
32 FEATURE ARTICLE
ON FACE
12
NEWS MART
50
FAIR MART
56
TECHNO MART
58
PRODUCT MART
58
PRODUCT MART
LAPP INDIA inaugurates state-of-the-art Cable manufacturing plant in Bhopal
Hannover to visit Delhi again after |its maiden Success
Dassault Systèmes Unveils New SolidWorks Electrical Applications Aluminum Precision Drawn tubes for Teliscopic Tube Application from Siddhi Engineers
63 THE LAST LEAF Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, Bangalore – 560 043 Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed in the journal are not necessarily those of the Publishers. Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither the Publisher no any of its employees accept any responsibilities for any errors or omissions. © All Rights Reserved
Dear Readers,
Foreward
We are winding up 2012 – the ups and downs we faced during the last twelve months would make a story in itself. We look forward and are preparing ourselves to do our best in 2013. There is no doubt 2012 has been a difficult time for all across the world, as a result of the global financial slowdown going on for the last couple of years. An emerging economy like India can get back on its growth path in no time, with result-oriented reforms from the Government. Controversies apart, Foreign Direct Investment in Retail Sector was passed in both houses of parliaments in December. The whole world is watching the recent developments in India. The go-ahead given to FDI in retail sector will restore the Foreign Investors’ confidence of India as a safe, secure and promising market to invest. Recent studies by trade associations state that FDI will lead to growth in the domestic manufacturing segment especially the SME sector, employment generation, supply chain efficiency and qualitative improvement in the branding of products. Concerns are that we will not be able to establish ourselves as a low-cost manufacturing country, forcing the international retailers to source products from other low-cost economies. This would hurt our already-challenged manufacturing sector and this has to be addressed with priority. Rapid Prototyping (Additive Manufacturing) is a remarkable technology that is revolutionizing the way companies design and manufacture products. Rapid Prototyping enables quick fabrication of a physical model through additive processes. This technology employs various engineering and software techniques to produce a physical model through Layer Manufacturing in accordance with the geometrical data derived from computer generated 3D CAD designs. These processes are bridging the gap between design conceptualization and manufacturing. L Jyothish Kumar from this edition starts his regular column on Additive Manufacturing. We have also included two more articles on Rapid Prototyping. In our ON FACE segment, we have included an interview of Soo Kam Tatt, Director, Hypertherm Asia, reviewing this year’s performance and also sharing their plans for the coming year. Hypertherm designs and manufactures the world’s most advanced metal cutting products for use in a variety of industries such as shipbuilding, oil and gas, heavy equipment, structural steel, and manufacturing. We thank our readers for their reviews which help us to improve the quantity and quality of MART. With the inputs, we were able to bring a lot of changes in the magazine which resulted in substantial growth in our reach during this year. We are sure the substantial and sustained subscription growth would continue. We welcome your suggestions to improve. Signing Off, Hari Shanker Managing Editor
NEWS MART
LAPP INDIA inaugurates state-of-the-art Cable manufacturing plant in Bhopal
Completed Phase 1 of the plant, with an investment of Rs 50 crores will have the capacity to produce 1,000 kms of single core cables on a daily basis. The 4-phased plant to be completed over a period of 5 years will have a total investment of Rs 150 crores. LAPP INDIA, a 100% subsidiary of LAPP GROUP based in Germany and globally one of the leadingmanufacturers of cables and other cabling solutions, announced last month the completion of Phase 1 of its second manufacturing plant in India. A total of Rs 150-crores will be invested to set-up this 4-phased cable manufacturing plant in Pilukedi, Rajgrah District of Bhopal. With an initial investment of Rs 50 crores, Phase 1 of the plant will produce 1,000 kms of single core cables daily, catering mainly to the Building Cable Segment (BCS).
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The inauguration ceremony had presence of special invitees including Shri Kailash Vijayvargiya, Honorable Minister of Commerce Industries and Employment, Government of Madhya Pradesh, Mr. P K Dash, Additional Chief
Secretary Govt. of Madhya Pradesh, Department of Commerce Industries & Employment among others. Also, key members from the global leadership team of LAPP GROUP namely Andreas Lapp, Chairman of The Board LAPP HOLDING AG and Honorary Consul of the Republic of India for BadenWürttemberg and Rhineland-Palatinate, Siegbert Lapp, Member of The Board LAPP HOLDING AG and Richard Lee, CEO, Asia Pacific at LAPP GROUP and acting Managing Director of LAPP INDIA Pvt. Ltd had travelled to Bhopal to attend this prestigious event. The Bhopal plant is the second LAPP INDIA facility in India after Bangalore and is spread over an area of 1,17, 000 Sq m. The 4-phased plant construction is expected to be completed over a period
of 5 years and will be LAPP GROUP’s largest facility globally. In terms of the location of the plant, Bhopal provides a strategic geographic advantage. Being centrally located in the heart of India, the facility in Bhopal will be well-equipped to meet the logistical requirements of the Northern and Eastern parts of India and cater to increased demand across India. Mr. Sriram Ganapathy, Vice President, Head– Building Connectivity Solutions, said that, “Geographically, the LAPP INDIA plant in Bhopal is well-connected, making it a key factor for us to decide on the location. Further, the Government of Madhya Pradesh has been extremely supportive towards LAPP INDIA, including providing required land approvals without causing any delays as
“Expanding our operations in India has been a key focus for us at LAPP GROUP, mainly due to promising growth opportunities presented by the country. This year LAPP INDIA’s growth has increased to 23% compared to last year and the set-up of this new facility in Bhopal will help us cater efficiently to growing customer demands. The market size for single core wires (in the building segment) today stands at approximately Rs 6,000 crores which indicates a large market opportunity in this sector. With respect to LAPP range of products, the addressable cable market in India is currently being valued at Rs 1,000 crores. We, at LAPP, have identified this opportunity in India for single core cables and are strengthening our base accordingly.” Andreas Lapp Chairman, LAPP HOLDING AG & Honorary Consul of the Republic of India for Baden-Württemberg and Rhineland-Palatinate 12
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well as offering us uninterrupted power supply at the plant thus helping increase efficiency of production.” The construction of the entire factory in Bhopal has been divided into four phases with the currently operational Phase 1 focusing on production of single core cable. The latter phases will focus on producing multi-core cables, aluminium cables and HT/LT aluminium cables respectively. With the establishment of this plant, Mr. Richard Lee, CEO, Asia Pacific at LAPP GROUP and acting Managing Director of LAPP INDIA Pvt. Ltd is quite optimistic about LAPP INDIA’s future in terms of expected business growth and mentioned that, “We, at LAPP INDIA are extremely bullish on the opportunity for single core cables in the country, thus
December 2012
making India the focal point for LAPP GROUP’s activities. Hence by setting up this facility, LAPP INDIA has great potential to grow and cater innovatively to the evolving needs of the industry as well as add to the range of products that LAPP INDIA currently has to offer.” LAPP INDIA is a 100% subsidiary of the LAPP GROUP which manufactures Cables, Connectors, Cable Glands, Conduits and Accessories. They are the pioneers in introducing the concept of “Total solutions in Electrical Connectivity” in India, with an unbeatable range of products. LAPP INDIA started its India operations in 1996 with a manufacturing unit in Jigani, Bangalore. Today, our Bangalore manufacturing unit is the third largest manufacturing facility of the LAPP
GROUP, producing about 100,000 km of ÖLFLEX® connecting and control cables and insulated single cores each year. LAPP INDIA has trained regional marketing organisations in Delhi, Kolkata, Mumbai, Pune, Bangalore and Chennai along with 23 sales offices and a strong network of dealers throughout the country. Headquartered in Stuttgart, Germany, the Lapp Group is a leading supplier of integrated wire, cabling and connector products and solutions. Its offering includes electrical and fibre optic cables, industrial plug-in and screw connectors, cabling solutions, automation technology and technical accessories. Lapp Group’s core markets are in the mechanical and plant engineering and electronics manufacturing sectors, with rapid market expansion in the renewable energy, mobility and life science industries.
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NEWS MART
Fluke introduces ScopeMeter® New Fluke 190 Series II ScopeMeter® Test Tool is first handheld oscilloscope to achieve 500 MHz at 5 Giga-samples-per-second sample rate
Fluke Corp. introduces the Fluke® 190 Series II 500 MHz ScopeMeter®Test Tool, the first to achieve a 500 MHz at 5 GS/s real time sample rate in a handheld, sealed, rugged, oscilloscope, without compromising on safety rating, ruggedness or battery operating time.Now professional electronic troubleshooters have a high-performance scope with the bandwidth and resolution to capture virtually any signal while in the field. The two-channel 190-502 model is the latest in the190 Series II with bandwidth from 60, 100, 200, - and now 500 - MHz. High-tech electronics in today’s medical, communications, navigation and military devices routinely operate at high speeds
requiring higher bandwidth. Correct display of waveforms with high frequency content such as clock pulses requires a bandwidth of at least five times the clock rate of the system under test. The 5 GS/s - or 200 pico seconds - sample rate of the Fluke 190-502 provides greater accuracy and clarity of shape and amplitude of unknown waveform phenomena like transients, induced noise and ringing or reflections. The rugged 190 Series II ScopeMeter® test tools include innovative functions like ScopeRecord™, TrendPlot™, advanced triggering and automatic measurements functions you would expect to find in high performance scopes. The 190 Series II safety rating according to IEC 61010
standard is 1000 V CAT III/ 600 V CAT IV making it possible to safely measure from mV to 1000 V. The Fluke 190-502 ScopeMeter®test tool is available from November 20th 2012. For more information, visit: http://www.fluke. com/190II. For information on Fluke tools and applications, or to find the location of your nearest distributor, call 1800 209 9110, e-mail info.india@fluke.com or visit the Fluke Web site at http://www.fluke. com/india.
One day workshop on TPS by MBERG MBERG announces one day workshop on “Toyota Production System” on 19th December 2012 at Hotel Radisson, Gurgaon. With interactive sessions, presentations and case studies the workshop’s objective is to discuss Toyota Production Principles, concepts and terminology and the key elements of Toyota Production System. The fundamental reason for Toyota’s success in the global marketplace lies in its corporate philosophy - the set of rules and attitudes that govern the use of its resources. Toyotta have succesfully penetrated global markets and established a world-wide presence by virtue of tis productivity. The foundation of TPS lies on two very important factors:- Continous improvement or Kaizen, the basic approach and the respect for people.
14 industrial industrial business MART business MART 14
This workshop is designed to guide participants about TPS principles in product delivery environment. Millennium Business & Entrepreneurship Resource Group (MBERG) was formed by Late Shri K. K. Malhotra, formerly Deputy Secretary General at PHD Chamber of Commerce (PHDCCI) New Delhi and Senior Adviser at Asso¬ciated Chambers of Commerce & Industry of India (ASSOCHAM). To his credit he gave MBERG a rich experience of over 4 decades in Training, Finance, Administration etc. He was instrumental in organizing knowledge based work¬shops primarily to impart training to over 25,000 delegates with over 780 programmes involving around 3,000 training days since 1991 throughout the country. For further details visit www.mberg.org
The faculty A K Vohra is a Graduate in Electrical Engg. from Punjab Engineering College, Chandigarh with a PG in Industrial Engineering and Advanced management course in Corporate and Strategic Planning from West Germany. He was associated with National Productivity Council for more than 33 years and Retired as Director and Group Head (Process Management) after holding positions like Director (Finance), Secretary, Dir. (Admn.), Dir. (HRD), Regional Dir., at Patna & New Delhi. He has conducted numerous training programmes on TQM & Industrial Engineering subjects along with many consultancy studies / assignments in Industrial Engineering in India & abroad.
December December 20122012
December 2012
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NEWS MART
Rodeka and Rodeka 8 - The Revolutionary New Indexable Milling Inserts from Kennametal Kennametal introduces the revolutionary new Rodeka™ series of inserts for indexable milling. Based on the success of Dodeka™, Rodeka double-sided inserts have a unique design with twelve cutting edges for a more productive and cost effective cutting process.
The anti-rotation feature on the inserts provides excellent stability for higher feed rates and cutting forces with an easy-to-index insert in the pocket. The three variable topography styles of Rodeka inserts have robust cutting edges capable of covering any type of component and application. This design helps to achieve low cutting forces while consuming less power. The higher clearance of the bodies permits pocketing, profiling and 5-axis machining. Each insert is marked so the user can easily identify the insert topography and edge number for correct indexing in the tool pocket. For correct indexing, the dimple
in the edge of each number should be aligned with the groove in the cutter. To keep a fresh cutting edge and not lose performance, these inserts should be rotated counter-clockwise. The three topographies of Rodeka inserts are engineered to take on different tasks and make these inserts diverse enough to handle a wide variety of indexable milling applications: wThe LD style insert has a honed edge for light to medium machining and is the first choice for stainless steel and titanium operations. Rodeka -LD inserts can provide up to 87% higher metal removal rates
than some high-feed cutters at equal tool life but with twice the effective cutting edges. wThe GD insert style for medium to heavy machining has a 10° positive T-land and hone. This insert is the first choice for general-purpose applications and has been shown to offer increased metal removal rates when compared to similar cutters. wRodeka HD inserts are designed with a 0° T-land and hone to take on heavy machining tasks and cast iron materials. These inserts also offer higher metal removal rates and can have a considerably longer tool life than similar milling inserts. Though an insufficient negative clearance angle limits the ramping capabilities of Rodeka inserts, they are capable of taking on pocketing, profiling, face milling, and blade machining at high metal removal rates with long tool life. Rodeka is available in a range of cutter styles and diameter sizes, including a 32–42mm diameter screw-on option, a 32mm diameter Weldon® style, 32mm cylindrical shank end mills, and shell mill cutters from 40–100mm in diameter. Rodeka 8 is a variant of the double-sided Rodeka line of inserts with eight total cutting edges and specially designed tool bodies that are specifically engineered to take on turbine blade machining. Rodeka 8 inserts have the same antirotation feature as Rodeka for a higher contact area with excellent stability for higher feed rates. Also, like Rodeka inserts, the seating dimple between tool
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December 2012
faces on Rodeka 8 eases insert rotation and improves second side edge performance. These inserts are offered in the same -LD and -GD styles as Rodeka inserts, with the Rodeka 8 -GD style being preferred topography for forged blades. An advantage to the Rodeka 8 insert are the dedicated inserts developed to improve milling performance. PVD inserts have a polished rake face to generate better chip formation and increase tool life. CVD inserts have a thinner coating to avoid premature flaking on the insert and be better functioning in combination with sharper edges. All Rodeka 8 inserts are made of a KCMP30™ grade. This multilayered coated carbide with advanced post coat treatment has a wide application in general and rough steel milling that works best
December 2012
in dry conditions. KCMP30 has improved edge toughness and reduces depth of cut notching. The grade’s toughness also avoids work-piece sticking and greater integrity at elevated speeds. Rodeka 8 tool bodies are available in a shell mill cutter style with diameters from 40–80mm that are designed to improved blade machining, but also capable of pocketing, profiling, and face milling. Kennametal Inc. (NYSE: KMT) delivers productivity to customers seeking peak performance in demanding environments by providing innovative custom and standard wear-resistant solutions. This proven productivity is enabled through our advanced materials sciences and application knowledge. Our commitment to a sustainable environment provides additional value to our customers.
Companies operating in everything from airframes to coal mining, from engines to oil wells and from turbochargers to construction recognize Kennametal for extraordinary contributions to their value chains. In fiscal year 2012, customers bought approximately $3 billion of Kennametal products and services – delivered by our approximately 13,000 talented employees doing business in more than 60 countries – with more than 50 percent of these revenues coming from outside North America. For further details visit www.kennametal.com
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NEWS MART
Grundfos launches ‘NO COMPROMISE’ campaign for efficient sewage water management technology Grundfos Pumps India Pvt Ltd launched “No Compromise” yatra, an innovative mobile campaign on efficient sewage water pumping technology, introducing their new range of S-Tube embedded SE1 / SL1 range of Sewage pumps. This mobile exhibition will travel around the country to showcase, communicate and educate customers about this new range of S-Tube sewage water pumps. The yatra was flagged by Mr.Chandrasekaran, Sr. Business Director, Grundfos India on 1st of November at Pride Hotel, Gurgaon. The new SE1 / SL1 range of sewage pumps are fitted with the new ‘S-tube’ impeller technology that avoids clogging problems unlike traditional Sewage pumps available in the market, said the company sources.With the S-tube impeller, the efficiency is higher compared to other wastewater impellers, as there are no edges, dead zones, or cutting functions that get worn over time. Furthermore the S-tube impeller features an innovative and patented labyrinth and sealing system, for years of trouble-free operation. “The very name of the campaign is
derived from the benefits of using an S-tube impeller. No compromise literally means, that there is no compromise between pump efficiency and free passage inside the pump for better solids handling and greater non-clogging capabilities” said Mr. Ramanan, Head Marketing, Grundfos India. “The S-Tube impeller Pump is a trend
setting product in waste water market, and a boon to municipalities with medium and small sewage pumping stations, due to its high reliability with longer lifetime at lower maintenance cost. The S-tube impeller technology meets the challenges of Backflow, Vibrations, Abrasive wear and clogging. The unique and patented sealing system provides the highest possible reliability, as the hydraulic parts are kept clean during operation. The lowest possible
vibration level is guaranteed through the new static and dynamic balancing of S- Tube” said Mr.Chandrasekaran, Sr. Business Director, Grundfos India while launching the product. Grundfos Pumps India Pvt. Ltd., a wholly owned subsidiary of Grundfos holdings was established on March 13, 1998. Grundfos India is responsible for sales of Grundfos products in India, Bangladesh, Bhutan and Maldives. Currently, Grundfos India has manpower of over 200 and operates with about 150 Distributors and Dealers with 13 offices across India. Grundfos India provides pumps and pumping solutions for various applications – Heating and hot water service systems, cooling and air-conditioning systems, Industrial applications, Pressure is boosting and liquid transfer, Groundwater supply, Domestic water supply, Sewage and wastewater, Dosing, Chlorination systems, Disinfection systems and pumps running on renewable energy. For more information, visit http://www. grundfos.in/
Autonics launches KRN 100 Series, A brand new Hybrid Recorder
Hybrid paper type recorder, combines functions of paper recorder and paperless recorder Autonics unveiled KRN100 series, its brand new 100mm hybrid recorder following the launching of the KRN50 series in 2009, 50mm compact paper type hybrid recorder. KRN 100 series can
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both display a wide variety of industrial values on the LCD and print them on the paper. It can save data at an external USB memory and also can print it through its data backup function (data logger function) of internal memory as well. In addition, it supports parameter setting on the PC through USB communication, Max 12 channel support due to its slot type input/ output cards and a wide variety of optional cards.
Combines functions of paper recorder and paperless recorder, Enables to print the saved data of inner memory when run out of recording paper (Date logger function), Inner data backup with USB memory, Supports several communication (RS485,Etherner) to transfer real time data and High legibility and setting convenient by graph LCD. For further details visit http://www.autonics.co.in
December 2012
Godrej launches Knock N’ Lock Godrej Locking Solutions and Systems (Godrej LOCKSS), the leader and innovator in the locks category has announced the launch of Knock N’ Lock - a unique invisible lock that is designed to provide the highest degree of security available for outdoor and indoor facilities. This revolutionary locking unit is based on patented Knock Code technology that enables a concealed lock with no visible access point, thus preventing break-ins. First of its kind in India, this unconventional product is designed with sophistication, embedded with smart technology, forged for superior security and programmed for greater convenience. Knock Code Technology is a patented approach to locking that resembles no conventional system in the market. The
December 2012
locks are virtually invisible – they have no keyhole or external interface that can be tampered with. Unlike a conventional key, the KnocKey transmits a sequence of mechanical pulses to open the lock. The user simply holds the KnocKey against the locking unit or an adjacent hard surface and enters the code, which passes straight through to the lock – even through solid metal, wood or glass. The system is extremely secure and robust, because it never uses the same code twice. So it’s impossible to imitate the key — even by recording the code. The Knock N’ Lock versatile lock is ideal for securing all types of cabinets, containers and doors, defence vehicles, windmills, petroleum vehicles, commercial complexes as well as residential applications. Since the lock is fitted internally and has no exterior contact points, its presence and location
are invisible from the outside, providing maximum security. This lock is easy to install and has no wires. A mechanical unlocking button is fitted to the lock to allow quick opening from inside. The Lock can be operated by battery or adapted for an external power supply. A variety of strikes and mounting brackets makes this lock suitable for a wide variety of applications.
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COVER FEATURE
Introduction to Additive Manufacturing (Rapid Prototyping and Manufacturing Technology)
Additive Manufacturing (Rapid prototyping-RP) can be defined as the layer by-layer fabrication of three-dimensional physical models directly from a computer-aided design (CAD) data.
In today’s competitive world the evolution of rapid prototyping (additive manufacturing) technology has changed
• Rapid Prototyping
for the rapid production of models,
• Advanced Manufacturing
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parts.
• Direct Digital Manufacturing
Since its evolution additive
Applications of Additive Manufacturing
manufacturing technology has changed
Technologies:-
design, engineering and manufacturing
• Automotive
process within the aerospace, automotive, electrical and electronics, medical devices and consumer products industries. Because of its wide applications additive manufacturing technology has become a powerful and revolutionary field of
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• 3D Printing
the face of direct, digital technologies prototypes, patterns, fit and functional
L Jyothish Kumar Founder &CEO, RAPITECH Solutions Inc. www.rapitech.co.in
Known by many names such as-
manufacturing. Additive Manufacturing Technology
• Aerospace • Consumer Products • Electrical and Electronics • Dental and bio-medical • Commercial and Industrial Equipments An Important difference between AM technology and conventional machining December 2012
process is that prototype or model is obtained by layer by layer addition process as opposed to removing material from a ‘block’. There are three main Rapid Prototyping systems, depending on the form of materials involved: *Liquid-based RP systems – The initial form of material is in liquid state and, by a curing process, the liquid is converted into solid state; the system includes: 3D Systems’ Stereolithography December 2012
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CASE STUDY
Direct Metal Laser Sintering Technology in Production Mould with inserts German based company FIT focuses on rapid fabrication of prototypes and small lot production on special parts. Examples of these parts range from unique structures for space vehicles to lightweight components for racing cars as well as customized biomedical implants. Challenge:
Benefits:
• Series production tool for injection moulded plugs in PBT GF10%
• Tool availability: 6 working days
• Tool availability as „quickly as possible“
• No need of pre-series tooling due to rapid delivery of production mould • Reduction of tooling costs.
Solution: • 3-cavity mould in hybrid concept • Machined aluminium tool base with inserts in EOS Maraging Steel MS1 (1.2709)
Production mould with inserts made from MaragingSteel MS1 (courtesy of FIT). Source: EOS gmbH – www.eos.info
Benefits of Additive Manufacturing Technologies • Prototypes, fit & functional parts are generated directly using 3D CAD data • It is a cost effective and quick process for intricate parts • AM technology eliminates tooling so that the cost and time of tooling is reduced. (SLA), Objet Inkjet Printing. *Solid-based RP systems –
• This would also reduce the lead times for new product development.
The initial form of material is in solid state, except for powders (wire, roll, laminates, pellets); this system includes: Stratasys ‘Fused Deposition Modeling (FDM). *Powder-based RP systems – The initial form of material is powder; the system includes: 3D Systems’ Selective Laser Sintering (SLS) and 3D Printing, EOS Direct Metal Laser Sintering (DMLS).
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• It produces fit and functional parts • It reduces prototype/production time from months to weeks or days • AM machines are small and
environmentally friendly and can be easily operated. We will be continuing this article on Additive Manufacturing from next issue as a regular column. The author L Jyothish Kumar is the Founder and CEO of RAPITECH Solutions Inc., Bangalore. He completed his B.E., (Mechanical) from National Institute of Engineering, Mysore and M.Sc (Rapid Product Development) from De-Montfort University, UK. He is also the President of Additive Manufacturing Society of India (AMSI). He is specialized in Additive Manufacturing , Technology, Application of Additive Manufacturing TechnologyAerospace, Automotive, Electrical and Electronics and consumer goods, Advanced Materials for Additive Manufacturing Technology, Process control and optimisation of Additive Manufacturing Technology and Research and Development in Additive Manufacturing Technology. He can be contacted at jyothish@rapitech.co.in December 2012
Window to the industrial world now comes out with a “Secure Wallet”
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“industrial business MART”, popularly known as MART - the largely read international engineering manufacturing monthly, now the one year subscription comes out with a Secure Alumunium Wallet worth `1899 absolutely free!
With the last nine years of networking and publishing of MART, we were successfully made a place in the Indian Manufacturing industry. Our growth was always triggered by the changes undertaken as per the needs of the industry. The contents of MART is unique, with regular columns by industry experts in the diversified fields of engineering manufacturing, technical features, news updates, interviews, case studies, trade fair informations etc. The guidance and support of the experienced industry professionals through our Editorial Advisory Board have helped us to understand the need of the Indian Manufacturer better and produce a journal which is used by the industry as an utility.
Yes, We are interested to subscribe “industrial business MART” as per the selected option:One Year (12 Issues) with Aluminium Secure Wallet worth `1200/One Year (12 Issues) at `900/-, You save `300/Three Year (36 Issues) at `2500/-, You save `1100/- and also get Aluminium Secure Wallet worth `1200/Name: ....................................................................................... Designation: ............................................................................ Company: ......................................................................................... Address: ............................................................................. ........................................................................................................................................................................................................ City: ......................................................... Pin: ......................... Tel: ............................................................................................. Mobile: .................................................................. Email: ............................................................................................................ Enclosed find our Cheque/DD No:..................... dated:..................... for ` .................... favoring “MEDIAMART INFOTECH”
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COVER FEATURE
Rapid Manufacturing of Aluminium Components This article will describe an ideal combination of traditional RP and an innovative lost-wax investment casting process to arrive at rapidly produced low-volume aluminium castings. The casting quality from the process is equivalent to those produced by Low-pressure Die Casting.
Traditionally Rapid Prototyping (RP) processes have addressed the need for plastic parts. Most commonly used RP processes are: 1. Stereolithography (SLA), 2. Selective Laser Sintering (SLS),
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3. 3D Printing (3DP), and 4. Fused Deposition Modeling (FDM). Since early 1990s, all RP processes, including above processes, have focused on creating plastic parts from a CAD data. Even amongst plastic materials, RP processes have had limited material choice.
Dr. Mukesh Agarwal Total Prototyping Pvt Ltd Bangalore
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SLA creates models from limited number of epoxy material. FDM creates parts out of ABS and Polycarbonate (PC), SLS out of nylon based materials. Recently some efforts have been made to develop
RP processes to create parts from metals. However, the success has been limited. One such process is Direct Metal Laser Sintering (DMLS). Although DMLS can create parts from certain metallic materials, the choice of metals used in the process is limited and proprietary. One can not produce parts out of alloys of one’s choice. Another major drawback of these RP processes, whether for plastic or metal, is their inability to produce parts in larger quantities fast and economically. In summary, Direct Rapid Manufacturing (DRM) of Metal Parts by RP has been limited. DRM by RP does not offer a wide choice of materials to customers. The problem of obtaining larger quantity of metal parts from a choice of alloy is solved by combining traditional RP December 2012
Wax Pattern
Casting
Ceramic shell with Pattern
Ceramic shell
Metal pouring
Figure 1: Schematic Showing the Steps in Traditional Lost-wax Investment Casting
with traditional Such Indirect Rapid Manufacturing (IRM) of metal parts is very common in the US . In US, it is a common practice to produce a plastic or wax casting pattern or master model directly from CAD data using one of the above listed RP process. The wax or plastic model thus produced is used in conventional casting, sand casting or lost-wax investment casting, operation to produce fully functional metal components out of alloys of one’s choice. This approach is so widespread that almost 25% of all models produced from RP machines in US are used as patterns for metal casting. Compare that to almost nil such application of RP plastic models in India. Also, worth noting is that the total number RP machine installations in US is almost 30-50 times more than in India. So, total number of RP plastic models produced is that many times higher
December 2012
and of which 25% are used as casting patterns/masters. In fact, the revenues from such castings are much higher than the total revenues generated from sale of RP machines and sale of RP plastic models combined. To summarize, use of RP combined with traditional foundry operations to produce metal castings for product development has a long way to go in India. One of the reason for this lack of appreciation of RP in foundry industry maybe due to the fact that Indian metal casting producers are doing contract manufacturing doing print-to-design work. As Indian emerges as a global hub for castings, to keep pace with global demands and maintain its edge, Indian Casting Companies are moving up the value-chain. To do that, Indian Companies are engaging in New Product Development and not just remaining contract
manufacturers doing Print-to-Design. This new found zeal for value-addition will result in the need for Rapid Metal Casting. This article describes one such innovative way of combining traditional RP with traditional lost-wax investment casting process to rapidly produce low-volume high-quality aluminium castings. The same approach is used for production of ferrous castings also; however, this article focuses on production of aluminium castings.
Lost-Wax Invstement Casting: Lost-wax investment casting is a widely used foundry process for production of ferrous, especially stainless steel, components where near-net shape is required. The process begins with production of wax patterns. Figure 1 schematically demonstrates the whole process. Each wax pattern results in a casting at the end of the process. Wax patterns are produced by injecting
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molten wax into a machined steel die. One or more wax patterns are then assembled together with sprues, runners, ingates etc to create a “tree”. The tree is then coated with a ceramic slurry by repeated dipping and drying process which takes 5-7 days. This is followed by melting of the wax and firing of the resultant ceramic shell. Finally, molten metal is poured into the ceramic shell under ambient conditions. The shell is then broken manually to get the casting out. The casting is then fettled after which it undergoes machining operations to suit a particular assembly. This traditional approach has three major drawbacks which render the process unsuitable for rapid, lowvolume production during early-stage production development cycle. These drawbacks are: 1. A machined die for production of wax pattern is time consuming and costly affair, especially when low-volume components are required. 2. 5-7 days for ceramic coating a wax assembly is definitely not “Rapid”. 3. Molten metal pouring done under ambient conditions can result in poor quality.
of SLA due to its superior dimensional accuracy and surface finish. The RP Model is then used as a master pattern to produce a silicone rubber mould. The silicone rubber mould produced is similar to those produced and used in RP process called vacuum casting of urethane parts. Silicone rubber moulds from such RP Master take no more than 1-2 days.
Wax Pattern Production: Wax patterns by melting and pouring wax into the silicone rubber mould. The wax used is any conventional investment casting grade wax. The whole process of melting and pouring of wax is done in a vacuum chamber called Vacuum Casting machine. Figure 2 shows such a machine along with a silicone rubber mould and the wax pattern. This process can produce 2-10 wax patterns depending on the size and geometry of the component. One or more wax patterns are then assembled with wax based gating system to create a “tree” similar to the one produced in traditional lost-wax investment casting process.
Ceramic Shell Production: The wax tree is used to create a ceramic
This article describes an innovative approach of lost-wax casting process which overcomes the above drawbacks.
The process begins with the components’ 3D CAD Model along with 2D drawings. After thoroughly studying the model and drawing for tolerances, accuracies, and machining provisions, necessary modifications are made to the CAD model to allow for metal casting shrinkage and machining allowances.
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Figure 3: Investment Mixer
process. The wax “tree” is placed inside a steel flask which is open from both ends. The flask is then placed in a system called Investment Mixer. The investment mixer consists of two chambers – top and bottom. The flask with the wax tree is placed in the bottom chamber. The top chamber is filled with the required amount of ceramic powder and water. A rotating stirrer blade in the top chamber creates a slurry which is then poured into the flask in the bottom chamber. This entire exercise is done under vacuum. This process results in the entire wax tree being encapsulated in the ceramic slurry inside the flask. Within 2-3 hours the ceramic material hardens and then flask is then removed from the machine. Figure 3 shows the investment mixer with the flask kept in the bottom chamber.
RAPID METAL CASTING:
The modified 3D CAD model is then used to produce a RP Model, mostly out
shell just as in traditional investment casting. However, the process of repeated (3-5 times) dipping and drying of ceramic slurry is not used in this
Dewaxing and Shell Baking: The flask with the wax tree embedded in hardened ceramic is placed in an autoclave oven. The oven is heated upto 700 C with various stages of holding at different temperatures. Figure 2: Vacuum Casting Machine
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free removal of wax and also in baking of the ceramic into a hard shell. Removal of wax from the ceramic structure results in a cavity into which molten metal can be poured.
Metal Casting: The flask with the hard ceramic shell is removed from the oven and placed into the Metal Casting System. The metal casting system consists of two chambers – top and bottom. The top chamber consists of an induction furnace with a graphite crucible for melting aluminium alloys. The bottom chamber is where the flask with ceramic shell is placed. Figure 4 shows the casting unit. Both chambers are closed after placing required amount of virgin alloy material in top and the flask in the bottom chamber respectively. Both chambers are connected to a vacuum pump capable of evacuating
Figure 5a: Fuel Pump Component
the system as well as to inert gas supply. The entire system is controlled through a PLC control panel. The entire process of melting and casting is carried out under a combination of vacuum and inert gas pressure. Once the alloy has achieved molten condition and is at casting temperature, the molten material is poured into the ceramic shell by opening a valve between the two chambers. The molten material is thus filled into the ceramic shell cavity thereby completing the casting cycle.
Case Studies: The above described procedure has been used to carry out several complex aluminium castings, such as automobile cylinder head, intake/exhaust manifold, transmission housing etc. Figures 5 show many such examples of castings produced.
Conclusion: This article has described an ideal combination of traditional RP and an innovative lost-wax investment casting process to arrive at rapidly produced
Post-Casting Operations: The flask is removed from the bottom chamber of the casting system and the ceramic shell is broken by a high pressure water jet system. The metal casting is removed and taken for traditional fettling operation to remove the gating system.
Figure 4: Metal Casting System
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Finally, the casting is ready for any further operations such as pickling, sand blasting, heat treatment, and finish CNC machining.
Figure 5b: SLA Master, Wax pattern, and Casting
low-volume aluminium castings. The casting quality from the process is equivalent to those produced by LowDecember 2012
pressure Die Casting. This entire process does not require any investment of time and money into machined dies or moulds. The process can produce 1-20 castings in 10-20 days depending on size and geometry of the component. The process is ideally suited for initial prototype requirement during product development stage. Since the material
Figure 5c: Aerospace Fuel Pump Castings
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used is as per the requirement and the casting quality is comparable to LPDC components, the components from this process are also suitable for final use and not merely prototype for design validation. Hence, this process is suitable for lowvolume production during early-stage production while the production of die/ mould is yet to begin actual production. Adoption of such a process can expedite product launch giving the manufacturer tremendous advantage of first-tomarket. The author Dr. Mukesh Agarwal, is an Entrepreneur, Scientist, Consultant, Author and a speaker. He is the Managing DIrector of 3D Product Development. He has more than 50 articles and technical papers published
Figure 5d: HVAC Mounting Bracket
as well as five patents in RP Technologies and material processing. Dr. Agarwal has been a research scientist at some of the world’s most reputred universities. He has established a SixUniversity Consortium in Ohio, USA, to meet the aggressive needs of local industry and to conduct advanced R&D in RP. He can be reached at mukesh@3dpd.net
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COVER FEATURE
Rapid Prototyping – An Insight Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing technology. The first techniques for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a much wider range of applications and are even used to manufacture production-quality parts in relatively small numbers.
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Rapid prototyping processes are a relatively recent development. The first machine was released onto the market in late 1987. While rapid prototyping is the term commonly applied to these technologies the terminology is now a little dated, reflecting the purpose to which the early machines were applied. A more accurate description would be layer manufacturing processes. An alternative term is free-form fabrication processes.
E D Balasubramaniam Director Technical & Operations Pet Moulds
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These processes work by building up a component layer by layer, with one thin layer of material bonded to the previous thin layer. There are several different processes. The main ones are:
• Stereolithography; • Laser sintering; • Fused deposition modelling; • Solid ground curing; and • Laminated object manufacturing. In addition there are a number of newer processes, such as ballistic particle manufacturing and three-dimensional printing, which have appeared on the market. All these processes essentially start with nothing and end with a completed part. This is in contrast to conventional manufacturing processes such as milling machines that start from a solid block of a substance and cut material away to form the finished part. Rapid prototyping processes are driven by instructions which are derived from three-dimensional computer-aided design (CAD) models. CAD technologies are therefore an essential enabling system for rapid prototyping. The processes use different physical principles, but essentially they work either by using lasers to cut, cure or sinter material into December 2012
a layer, or involve ejecting material from a nozzle to create a layer. Many different materials are used, depending upon the particular process. Materials include thermopolymers, photopolymers, other plastics, paper, wax, metallic powder, etc. The application of these processes is not restricted to supporting new product development activities C they can also be used to create production tooling. They can therefore be used to support one-off or small batch production runs. Thus the processes can be used to create models, tooling, prototypes, and even in some cases to directly produce metal components. Many rapid prototyping technologies actually produce physical models. These models are then used to produce tooling using an indirect secondary process such as investment casting. The resulting tool
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is then used to manufacture a component. However, new processes are beginning to appear that allow the tooling to be manufactured directly from the computer model, thus eliminating the physical model production stage. In the future it is likely to be possible to manufacture components directly from the computer model, eliminating the need to produce physical models and tooling first, although these may still be required for other purposes. The important point to understand is that, while rapid prototyping started out as an expensive tool for producing physical models for design engineers to visualise their component designs, this is now no longer an accurate description of the technologies or their application potential. The potential different applications of
rapid prototyping technologies span the complete product life cycle from concept generation, through preparation of specifications and detailed design, to manufacture. Director Technical & Operations with Pet Moulds, the author E D Balasubramaniam is an Engineering graduate with specialization in Manufacturing with an overall experience of over 19 years in the Plastic Engineering industry. Right from beginning, he has experienced in the same platform of PET processing & Mould design & manufacturing. He has expertise in PET Packaging sector & Hands on experience in PET processing equipments. Apart from the vast experience in costing & Planning, he has sound knowledge in Material selection & process routing. He has also served as a Management Representative in ISO certification process. He can be reached at +91 98843 90666
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FEATURE ARTICLE
FARO Technologies announces its first Asia Pacific 3D Documentation Conference FARO Technologies, Inc. (NASDAQ: FARO), the world’s most trusted source for 3D measurement technology, announced that it will host its first ever 3D Documentation Conference in Asia Pacific from 25 – 26 April 2013 at Marina Mandarin Hotel, Singapore. This will be Asia Pacific’s largest platform for the gathering of 3D documentation professionals and practitioners from various fields across the region. In line with the event theme, “Connecting 3D Communities”, the conference will
exclusive networking opportunities. At the same time, there will also be an exhibition where 3D technology and solution providers will showcase their products and services to existing and potential customers, as well as business partners. FARO welcomes
and assemblies, production planning, inventory documentation, as well as for investigation and reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites.
participants from a variety of sectors
With FARO, 3D measurement and
such as Architecture, Civil Engineering,
documentation needs can be fulfilled
Surveying, Forestry, Forensics, Facilities
confidently. As a pioneer and market
Management, Mining and Tunneling
leader in portable computer-aided
amongst many others.
measurement, FARO consistently applies the latest advances in technology
encourage cross-vertical interactions
to make its industry-leading product
amongst 3D laser scanning communities
offerings more accurate, reliable, and
and stimulate industry integration and cooperation.
easy to use. The focus is on simplifying
“FARO Technologies envisions a
customers, thereby dramatically
platform where the terrestrial laser
reducing the on-site measuring time and
scanning community in Asia Pacific can
lowering overall costs.
workflow with tools that empower
gather to share, learn and network.
Worldwide, approximately 15,000
Currently, we have a substantial pool
customers are operating more than
of users in the region and the timing
30,000 installations of FARO’s systems.
could not be better for the conference to be held here,” said Joseph Arezone, Senior Vice President and Managing Director, FARO Asia Pacific. “Participants can expect to benefit from the sharing sessions chaired by industry experts from around the world, the enduser presentations, and the various application workshops. This conference will be an avenue where all stakeholders related to 3D documentation can come together to collaborate and expand the market.” This FARO 3D Documentation Conference 2013 will feature keynote addresses by renowned professionals, power speeches by industry experts, and
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are used for inspecting components
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The company’s global headquarters For more information about the FARO
are located in Lake Mary, Florida, with
3D Documentation Conference 2013, visit
its European head office in Stuttgart,
www.3d-documentation-conference-
Germany and its Asia-Pacific head office
2013.com. Exhibition and sponsorship
in Singapore.
opportunities are also available for this conference.
FARO has branch locations in Japan,
FARO is a global technology company
Malaysia, Vietnam, Canada, Mexico,
that develops and markets computer-
United Kingdom, France, Spain, Italy,
aided coordinate measurement devices
Poland, and The Netherlands.
and software. Portable equipment from FARO permits high-precision 3D measurement and comparison
China, India, South Korea, Thailand,
Further information: www.faroasia.com/in
of parts and compound structures within production and quality assurance processes. The devices
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ON FACE
“Sucessfull Implementation of FDI can attract investment, raise confidence in the Indian Market”
Hypertherm’s mission is to provide customers with the best cutting equipment and service in the industry. Hypertherm first entered Asia in 1991 by setting up a Singapore subsidiary. Since then, they have expanded across the region and now have a business presence in five Asian countries, namely China, India, Japan, Korea and Singapore.
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Excerpts from an interview with Soo Kam Tatt, Director, Hypertherm Asia about industry in general and Hypertherm’s plan for 2013 in the region.
What interesting or outstanding trends
mild and stainless steel. With increased
What was the biggest challenge for the
did the metal cutting industry in Asia
competition in these segments,
industry this past year, or over the past
display in 2012?
previously known applications were
few years?
Within the global thermal cutting industry, fiber laser made greater
introduced.
The greatest challenge in 2012 was, in my opinion, the slowing economy
inroads, as higher capacity systems
Manufacturers of plasma systems
in Asia, and in particular in China. In
that can cut thicker materials were
also introduced more accessories
addition, the India market showed signs
introduced. This was a continuation of
and applications-based solutions that
of lagging later in the year, and other
the trend seen in 2011, which saw the
enhanced the original equipment
Asian markets were also affected by the
technology outpace CO2 lasers.
manufacturers’ (OEMs) ability to
downturn, leading to lower economic
integrate plasma into their cutting tables
output across the region.
In the field of plasma, the industry observed continued refinement of cutting technology capability for both
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reinforced, while new ones were
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more easily. At the same time, this increased the value proposition of the final product.
On top of economic difficulties, demand evaporation and heightened investor
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cautiousness dampened the investment climate of numerous key Asian countries. Is there any silver lining for the metal cutting industry in response to a poor global economic outlook for 2013? On the global front, it is difficult to determine whether the metal cutting industry will see an improvement as the US and Europe economies are now in different stages, and continue to be exposed to various market challenges. Although the US industry performed generally well in 2012, the looming fiscal cliff is a time-sensitive factor that may throw the country and international markets into disarray. Closer to home, China hopes that its new leaders will recognize the need for continued growth. This comes alongside expectations for measures that will facilitate economic development and growth that is sustainable. In India, the government recently proposed crediteasing measures and new regulations, in order to attract foreign direct investment (FDI). These, if agreed and approved, should inject some confidence into the sagging Indian market. Apart from Asia’s two largest economies, governments of other countries in the region have also invested or plan to invest large sums to upgrade business infrastructure, in order to improve the local economic climate. These measures will be key to making 2013 a better year for companies in general. Please share with us the significant milestones that Hypertherm witnessed as a company in 2012?
Channel partners at a training session in Hypertherm’s India CTC. houses our first local cutting technology
HyPro2000 torch, meant for retrofitting
center (CTC). The CTC will serve as a
onto existing MAX200 systems.
gathering point where employees of
Compared to the standard torch, the
over 40 channel partners can train up
HyPro2000 cuts 25% faster and has
their technical skills and sales expertise
the potential to increase consumable
to enhance their capabilities when
lifespan by up to 75%.
introducing Hypertherm products to end-users.
2012? What were the factors that led to
to a larger premise to accommodate the
this?
growing associate base, and to have the CTC and office located within the same facility. This is in line with the growth that we’ve seen in the country over the years.
wasn’t a specific industry that stood out for our Asia business. The leadership transition in China complicated the slowdown of the domestic economy as the country normally doesn’t make
products in 2012, the most notable
transition and implementation measures
being the Powermax 105®. This is a
during this changeover period.
new 105-amp air plasma system used for handheld and automated cutting and gouging. The system is designed to comfortably cut 32mm-thick metals, and
Hypertherm reinforced further our
toughest, most versatile system in its
presence in two Asian markets – India
class.
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2012 was a challenging year, and there
Hypertherm launched a few new
sever metals up to 50mm-thick. It is the
new office in New Delhi, which also
attain the most significant growth in
As for our China operations, we moved
Within the span of a single year,
and China. In India, we incorporated a
In which industries did Hypertherm
Another outstanding innovation was the
Although signs of economic decline in other Asian nations became evident only after China experienced a drop, the slowdown was already felt within the industries earlier in the year. Many markets in the region witnessed decreasing GDP as we moved towards the end of 2012. In India specifically,
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this call? Sustainability is an inevitable call to ensure that the incessant industry pursuit of growth doesn’t come at the expense of environmental degradation. Many companies are aware that they can play a part, and have started pursuing efforts to reduce their impact on the environment. At Hypertherm, we have set long-term goals to reduce waste and minimize our carbon footprint. We continually hold ourselves accountable to these targets. As part of our efforts to reduce waste, we are looking into ways to make every component of our products recyclable, reusable or reclaimable. Our target is to produce zero waste by 2020. In order to reduce our carbon footprint, we hope to improve in the way we The Powermax 105® is the toughest, most versatile system in its class. inflation, government bureaucracy, the
Many organizations and governments
weak Rupee and decreased agricultural
are now pushing for companies to
output due to low rainfall have lowered
practice sustainable development. How
the country’s GDP down to about 5% for
can the manufacturing industry answer
2012.
transport our products worldwide. Energy consumption is one area we are looking at as part of our sustainability efforts – we want our products to be as electrically efficient as possible. Another area is the way we transport our products worldwide and here we
India’s government recently expressed its openness towards FDI. Does this have any impact on Hypertherm’s business in the country? New initiatives by the Indian government to attract FDI have generally been viewed positively by the business community. In order to succeed, however, these propositions have to find traction within the complex web of Indian democracy, the coalition government, and the bureaucracy that the country’s leaders plan to minimize. Successful implementation of proposed ideas is likely to attract investment in the country, and should therefore raise confidence in the local business climate.
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Hypertherm believes that business growth should not be at the expense of the environment.
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The HyPerformance series of HyDefinition plasma systems was well-received by the Korea market. will be optimizing and finding a blend
the government’s measures to attract
at Hypertherm, we view the New Year
of reducing the carbon footprint and
FDI kick in, this would bode well for the
with vigor, as we always have. As a
serving our customer efficiently.
country’s business in 2013.
company, we will focus efforts on
What are Hypertherm’s plans for its
Although these factors may bring
business in Asia come 2013?
about favorable conditions, growth is
As I mentioned earlier, 2012 has been a challenging year for Hypertherm in Asia. China’s purchasing managers’ index (PMI) in October indicate that the country’s economy may have hit rock bottom, which seems to coincide with the general view that recovery will probably only occur in 2013. For India, if
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unlikely to occur at the same pace as
pursuing technologies and applications that offer value to end-users and our partners.
it did previously as current domestic
We have expanded our capabilities
issues in both China and India will crimp
in China and India in 2012 with larger
exuberance to a certain extent. At the
offices and incorporated new cutting
same time, export prospects presented
and training facilities. These will further
by the rest of the world will not be as
raise our support levels, and allow us to
bright as before.
serve our customers more efficiently to
Notwithstanding the economic climate,
minimize potential downtime .
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QUALITY MANAGEMENT
Cost of Quality “Quality is never an accident; it is always the result of high intention, sincere effort, intelligentdirection and skillful execution; it represents the wise choice of many alternatives.” —Will A Foster
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The impact of quality on our business can be measured in terms of the Cost of Quality (CoQ). CoQ represents the total business cost in achieving quality. In other words, CoQcovers any and all costs that an organization incurs from having to repeat a process more than once in order to complete the work correctly.
Saravjit Singh CEO, www.10xQuality.org
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CoQwas introduced by Juran in 1951 as a means of providing cost and accounting based justification to management for investments in process improvements. The goal of Total Quality Management is to reduce the cost of quality through continuous improvement of methods (processes) and other means such as error elimination, building in quality at product and process design stage, and improving methods – as shown in Exhibit 1. This involves failure analysis as well as
process analysis. As seen in Exhibit 1, every activity done within a company can be categorised as either one of the following four: 1. Prevention – Activity to ensure work is carried out Right First Time (e.g. Training, developing systems standards and specifications). 2. Appraisal – Activity to check if work has been done Right First Time (e.g. Auditing, Checking, Inspecting, Supervising). Some of these can add value – e.g. audits; but most simply add cost. 3. Failure – everything that has to be done because something wasn’t Right First Time (e.g. Re-work, corrections, answering complaints, dealing with December 2012
• Costs incurred on analysis of failure • Cost of crisis management to correct quality • Re-testing costs • Downtime and work stoppages due to internal failures
Exhibit 1: Cost of Quality enquiries about problems, problem solving). 4. Base Workload – everything else, done Right First Time to meet a customer’s need. This requires continuously improving basic processes. As seen in Exhibit 1, the sum of Prevention, Appraisal and Failure is the Cost of Quality. In service businesses, this often amounts to 40% of operating costs, with Failure and Appraisal accounting for most of that. In production work, CoQ is typically 25% of Sales Revenues, again with Failure and Appraisal being the biggest contributors to this cost. In order to use the CoQtechnique, you should list all the activities in the
business thencategorizethese activities according to the four types as seen in Exhibit 1. Thenyou measure (or estimate when measuring is not possible) the amount of time and cost spent on each activity. Add up all this and calculate total time and cost spent on Failure and Appraisal. This is usually a big enough number to motivate management to want to take some improvement actions!
2. External Failure Costs:External failure is the worst of all possible situations. This includes failure of a product or service at the delivery point or when the product is being used by the customer. This is a bad situation because of two reasons. One, the product needs rectification and replacement of components or even full replacement. Second, company’s reputation is impacted. Costs associated with this are: • Customer dissatisfaction and loss of repeat business • Loss of new business • Product and service support costs
In order to better understand the CoQ we divide this into Cost of Poor Quality and Cost of Good Quality. This is shown in Exhibit 2.
• Cost of litigation and penalties
Cost of Poor Qualityhas two components. These are:
Cost of Good Quality is associated with putting systems and processes in place to reduce the likelihood of a failure. The ideal condition is achievement of zero defects. Cost of good quality includes two components:
1. Internal Failure Costs:These are those costs that are associated with recognizing and correcting a poor quality characteristic BEFORE the product leaves the factory. The most common costs in this category are: • Cost of scrap • Costs related to all rework
• Loss of reputation and erosion of brand image
1. Appraisal Costs: Appraisal mainly includes inspection costs. Any activity we do that inspects the quality of the product or service falls in this category. Typical appraisal costs include the following: • Allverification and validation costs • Product and process review costs
Exhibit 2: Bifurcating Cost of Quality into its four components December 2012
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• Costs towards product audits and compliance activities • Products and services testing costs 2. Prevention Costs: Prevention costsare associated with preventing a quality problem from occurring in the first place. Typical costs that are included in this category are: • Training costs • ISO related costs, including quality management and continuous process improvement costs • Tool evaluation and equipment automation costs
Exhibit 5: Optimal level of quality
• Hardware and software up-gradation costs • Costs towards defect prevention by incorporation of techniques such as
How this affects a manufacturing company is shown below in Exhibit 3. When a company uses Six Sigma initiatives to improve its processes there is a reduction in the Cost of Good Quality (Prevention and Appraisal costs). This is shown in Exhibit 4.
Exhibit 3: Costs vs. Defect Level
Exhibit 4: Six Sigma reduces Cost of Good quality
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good quality) and the cost of rectifying defects (cost of poor quality).
poka yoke.
This is the traditional view of quality and total cost of quality as practiced by most manufacturing companies. Exhibit 6 illustrates costs associated with poor quality. The visible costs shown in this exhibit are obvious to everyone and most companies concentrate on reducing only these costs. However, there are many more other invisible costs of quality as shown in Exhibit 6.
Lynda Byrne sees the Cost of Quality as shown in Exhibit 5. She suggests that each firm has an optimal quality level shown as ‘you want to be here’ point in Exhibit 5.
Many companies when undertaking continuous improvement projects do not consider these costs. These invisible, hidden, costs of quality represent areas of big opportunity for reducing costs.They relate to all kinds of waste whichdirectly or indirectly contribute to the increase in the cost of developing, producing, delivering and servicing a quality product.
You will notice that this quality pointcoincides with the intersection of the cost of implementing quality (cost of
The concept of zero defect was first adopted by Japanese companies, ledby Toyota. This concept was seen to workand these companies were able to produce components and products having zero defects. Now many automotive multinationals and December 2012
products at lower costs than companies in the western world. Now that we know it is possible, we too can achieve minimum CoQ level at 100 % quality level through minimizing waste and achieving zero defects. For this we have to become TQM compliant and use lean thinking methods to achieve continuous improvement of processes and productsby undertaking lean six sigma projects. The main mantra followed by Japanese companies is continuous Exhibit 6: Visible and Hidden Costs of Quality other companies have achieved zero defectmanufacturing and services. The real advantage of zero defect production and services is that the cost of quality is minimum when quality is 100%, as happens when zero defect rate is achieved. This is seen in Exhibit 7. Compare this to the traditional view as shown in Exhibit 5, where the optimal quality shown as being achievable is at a level well below the 100% quality level. It is no wonder that Japanese companies have achieved such heights and have been able to deliver better quality
Exhibit 7: Cost of quality is minimum at zero defect quality improvement, mostly through small projects at shop floor and at all operational areas. This initiative has beenled in Japanese companies by quality circles working on a large number of kaizen projects. How increased profits are achieved through continuous quality improvement is shown in Exhibit 8. The author Sarvajit Singh is the Chief Executive Officer of 10xQuality.org and he can be contacted at saravjit@10xquality.org
Exhibit 8: Increased Profits throughContinuous Quality Improvement December 2012
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MANUFACTURING EXCELLENCE
Journey Towards Excellence
Understanding expectation of Customer – Part 7
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In the last six articles under the same heading, we dealt about SWOT analysis of sourcing from India and expectation from customer related to quality,technology,cost management,managerial ability and logistics. We will continue the topic further in this issue by focusing on those expectations that are not spelt out by Customers explicitly.
8.0 Untold expectations
8.1 Understanding culture of Customer
The customer has explicit and implicit needs. It is easy to understand explicit needs like quality standards, price, delivery, specifications, defining testing requirements, contracts etc. The challenge is to understand implicit needs which are not defined and if not met customer will be unhappy.
I was heading international purchase of Robert Bosch Group in India to source from Indian Suppliers to Bosch plants worldwide. This involved close interaction between suppliers and customers and one of key task was to identify gap between customers and suppliers. These gaps were technical, commercial and typically cultural.
The chances of enhancing business is high if implicit needs like trust, relationship, satisfying ego, giving feeling of importance etc. are met. I call these implicit expectations as untold by Customer.
P S Satish Mentor and Consultant Saraswati Industrial Services
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No checklist of Customer captures these points in assessing the supplier but are assessed in mind for decision to do business with supplier.
It was observed that business developed well when supplier made an attempt to understand culture of Customer. Each country and region has their own culture and many of our behaviour have come from our culture. For example, Japanese takes time for a decision and it is done collectively. If we understand the reason for this could be that Japanese tries to a perfect job and December 2012
does not want any mistakes then we can adjust our interactions effectively. They believe in team. They will be happy if we understand this cultural aspect and respond suitably by way of a detailed and perfect job in a team. It is equally important that customer as well understands culture of country and business at supplier. I used to tell overseas customers that if you want to do business in India better understand and appreciate why cows are seen on roads. Companies dealing with foreign customers need to expose employees for proper understanding of culture of customers and link to the business. Bigger corporates are conversant with this and SMEs need to catch up. Within India itself we find different cultures. The way business is done in
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south India is different from that in north India. 8.2 Right attitude In simple words, attitude is nothing but response to the situation. Customer expects right attitude by the supplier which is very difficult to measure. Right attitude and not the aptitude decide the altitude. Many times approach to the problem solving is seen as more important than solution to the problem itself. Suppliers need to develop and demonstrate right attitude in all dealings with Customer. For example, business will not last long if the supplier demonstrates attitude of being opportunist. 8.3 Good behaviour Demonstrating good behaviour during interactions with the customer including
that in video/telecom is important. Training employees especially marketing colleagues on etiquettes helps a lot. Talking loudly on phone is accepted as normal in one culture but not in the other. 8.4 Pro-active actions Customer expects that supplier be proactive. He should be able to solve problems before they appear. Reactive approach will not help in long term relationship. Proactive actions like improvements of processes, cost reduction and improvement of products without being told goes a long way. Typically customers are communicated when they ask for something. Pro-active communications without a reminder and follow up is also part of this. Some times over communication to customer are better if done structurally.
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8.5 Building Trust and relationship
8.7 Customer orientation at all level
This is one of the foundation blocks for long term relationship. Japanese customers give lot of importance for this. Efforts needed here are high and takes time. Supplier need to develop patience.
It is a wrong concept to think that only marketing colleagues who deal directly with Customer need to be customer oriented. In lots of companies managing director or CEO has no interaction with the customer. For a sustained business, CEO should ensure that all employees in the company are oriented towards customer.
8.6 Meeting Customer regularly It is important for supplier to meet customer regularly even though there are no issues. This will build relationship. Supplier can ask pro-actively Customer about his feedback on performance and seek suggestions for improvement. I have seen suppliers who have not met their customers for years. When asked, they say that there is no issue and hence no need. Voluntary offer by Suppliers for a meeting will make Customers definitely happy. Of course, this meeting has to be structured.
8.8 Strategic thinking One of the concerns of Customer is that whether the supplier has strategic thinking to ensure that his business is sustainable in long term. Suppliers seen to be doing for survival are potential dangers. Question to look at is if company has strategic approach of business involving senior management team
maintaining good housekeeping, visualization in the company,continuous improvement thinking, ability to do business using modern media like internet, safety at work, understanding law of the country where business is done, bench marking with competitors, understanding consequences of warranty and liability etc. With these notes, I conclude this series of articles on understanding customer expectation. We will catch with some other topic in the next issue. Please send your inputs, remarks, suggestions to P.S.Satish, Mentor and Trainer, M/s Saraswati Industrial Services, Q-103,Mantri Paradise Apartments,Bannerghatta Road, Bangalore-560076. Email : gotopssatish@gmail.com . Wishing good day to you all.
Other general expectations include
The all new Ball Screw driven Electric Press Brake from Muratec Muratec, a pioneer in AC Servo Sheet Metal machines has designed and developed a fully electric Green Press Brake BB 4013. BB 4013 is built with rigidity and a special offset frame to accommodate full length bending over full ram stroke. Key Features include high speed ram movement (100mm/sec), stable high repeatability, oil-less environment and an advanced NC compatible with SDsimulation (option). Meiban Engineering Technologies Pvt Ltd is a solution provider in the field of automation and turn key projects for manufacturing Automobile and Sheet metal components. Meiban Engg. supplies and services sheet metal machines which include CNC Servo Turret Punch presses of various
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capacities, punching and shearing machines, and panel benders. Meiaban team also supplies the latest advance “CONIC� made in Japan, tools for sheet metal punching machines. Meiban Engineering Technologies is based in Bangalore, with a Sales & Service office in Chennai and a Sales representative in Mumbai. All their sales & service engineers are factory trained to support the customer with technical and application information. For further details contact Tel: 98450 88605, E-mail: office@meibanengg.com
December 2012
December 2012
industrial business MART
45
RESPONSIBLE BUSINESS
Greening your Responsibility.
Read this article online at http://issuu.com/mediamart
Turning Eco Friendly practice into competitive advantage It is a fact that if you green your offerings, you differentiate. Green product development is a process which needs to be mastered. The companies with innovative outlook can use “architect strategy”, for building green products from scratch.
ment depends upon the quality of data accumulated about eco-conscious consumers’ knowledge and preferences.
Architecting eco elements in to a product may be a slower and costly process than acquiring or accentuating, but is most beneficial in competitiveness.
Companies evaluate their assets along two dimensions: green-able attributes of their existing products and brands. Financial & organisational capabilities to handle the development process. It requires a careful analysis of greening benefits the proposed brand offers.
On a larger scale is the example of Prius the more-fuel efficient car by Toyota which dominates the fastest growing segment in car purchases. At a smaller level we have the example of Colorex developing household natural cleaner products to clean glass, bathroom ceramics & toilet bowl. Both the products categories are now the best sellers in their domain. Vivin Agarwal Product Architect & Social Entrepreneur
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The success of the product develop-
First three steps that will influence the Green Growth Initiative. Viability:-
Each product will have its own category- specific attributes, ranging from recyclability, to energy efficiency, toxic reduction, lean consumption of raw materials etc... There are about 70 such performance indicator are listed in Global Reporting Initiative. The second dimension involves appraising the company’s Green resources and December 2012
capabilities. Review of the process and priorities for innovation and new product development, supply chain management, the co-ordination of collaboratives among distributors and even partnership with environment organisations. Willingness:Managers asses the strategic fit of each options with company’s objectives and the resources they can bring in the gambit of Green Initiative. They need to consider speed to market, the investments, reputations and competencies that the initiative will require. For a progressive company green growth may be part of an enterprisewide sustainability initiative to retool options, shift of culture, ultimately repositioning the organisation. Execution:Taking action on all the points discussed above.
To develop unique competency.
Can we differentiate our brand?
To respond to new market needs.
How can we exploit the green weakness of our competitor?
To gain green credibility. 2. Your brand portfolio: How will this initiative affect the positioning and resources of existing own brands? Will the initiative provide wider abilities that can influence the other brands? What will be the relationships of the existing and new brands? 3. Your customers. What innovations and feature , consumers are expecting in greener alternative? Does you parent brand have the permission to enter Green space? Will this initiative will demand to create a new alternative, isolated brand?
Following questions may help for for analysing Green Growth options,
Will this development will need to educate develop the market and bring new customers into the category?
1. What’s our strategic Goal?
4. Your competitors.
To create a new Green solution.
Are we creating new green category?
Does the category already infested with competition? 5. Warning. Do we have environmental skeleton in our current business model? Will our initiative will be credible or we will be blamed for Green-washing? The Sustainability Road Map: The social forces have shaped the competitive landscape in past. Sustainability and greening are emerging as Megatrends, their courses are somewhat predictable. Our focus always be on the emerging business Megatrends which will lays new rules for the competition. Such transformations come from technological transformation or from new ways of doing business. So decide your own Green Responsibilty. To be constantly innovative is a mandate of Responsible Business. You can join us in the search of innovative products, by responding to me at lumeryardinc@ gmail.com.
First time in the World from Elmeasure Contact-less Prepaid Meter for Gas, Water & Electricity Most power distribution companies face major challenges in recovering electricity bills on time. ElMeasure has developed a unique Contactless Prepaid Energy Meter which acts as a direct revenue interface between power distribution companies and the consumers.
Contactless Prepaid Energy Meter Solution, Remote Display Unit allowing customer to recharge and monitor consumption, Integration of Gas and Water with the electrical parameters thereby, extending the flexibility for the user to budget expenses.
Unique featutres Include: User friendly
Tripping of EB or DG consumption at
December 2012 2012 December
pre-determined set point for protection and effective use of energy, History of consumption for analysis and Direct current measurement up to 80A for Single or three phase measurements. For further details visit www.elmeasure.com
industrial business business MART MART industrial
47 47
MACHINE DESIGN FUNDAMENTALS
Strength of Material Aspects In this thirtyfifth series of article on machine design fundamentals on strength of material aspects let us continue with what we had already discussed in the thirtyfourth series of article.
4. Light Gauge Hot Rolled Sections: In the case of pipes, channels, I sections and angle sections lower the thickness of the section, material utilisation is optimum. Hence for the same weight lesser thickness and deeper sections resist higher bending loads.
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This principle is best illustrated in Fig.1. All the sections shown from 1 to 1e have the same moment of inertia. The saving in weight in the case of 1b is about 28%, in the case of 1c 53%, in the case of 1d 68% and in the case of 1e it is 78% which is the thinnest. It is strange that in India practically all the steel plants concentrate on producing medium and heavy gauge hot rolled angles, T- sections, channels and I sections.
A S Shetty CEO, Sedvik Industries
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Light gauge hot rolled metal sections are available in technical tables only. Our steel plants should be motivated, persuaded and encouraged to produce
more of lighter gauge hot rolled sections by the concerned government and professional institutions. 5. Torsteel: Already in the case of building industries for concrete reinforcements mostly torsteel is being used instead of plain bars where there is considerable weight saving. 6. Stress Concentration: Avoid stress concentration in machine elements. Failure of machine elements is mainly due to stress fatigue and it occurs in the area of stress concentration. By analysing the flow of stresses in machine elements a lot of material saving could be achieved. In any machine assembly identify the weakest link. A machine assembly is only as strong as the weakest link and there is no point in making parts strong and heavy in several areas leaving one place the weakest
December 2012
link. The failure occurs at the weakest link only. In machine design terminology it is called the factor of ignorance and not the factor of safety. The machine design taking into consideration of stress flow through the machine elements and taking measures to reduce the stress concentration requires a deeper understanding of the strength of materials, mechanics, different manufacturing methods, kinematics etc. 7. Corrugated Tubes: Wherever possible go for corrugated tubes/pipes instead of plain tubes. It is a well known fact that corrugation imparted to a plain sheet increases its strength many folds. The idea of converting the corrugated sheets into pipes and culverts is a fairly new concept in India. We are mostly used to plain pipes and curvatures of plain sheets. Bending the corrugated sheet into a pipe form gives an enormously higher strength pipe and there is a huge material saving. Other variations of corrugated pipes having lesser thicknesses are provided with lock-seams or rivetted. 8. Gusset Plates: Another area where material can be saved is making use of gusset plates at the appropriate places where the stresses are high. Fig. 2 shows how a heavy plate for carrying load could be replaced by a thinner plate with ribbing and using gusset plates as shown in Fig. 2c. Fig. 2a & b show how material saving could be achieved by using gusset plates.
9. Sandwich Construction: Usage of sandwich construction: It consists of generally three types of materials bonded together. The outermost laminations are called skins or facings and the inner lamination is called the core. The skins or facings of a panel act very much like the flanges of an I -beam by taking the bending loads. One skin is in tension while the other skin is in compression. The core material responds like the web of the I-beam. The core material resists the shear loads and increases the stiffness of the structure by spreading the skins apart. These are used as door /prefab panels. The core
materials most frequently used in sandwich construction are honeycomb cores, foam cores and wood cores. From the above cited examples it could be seen that by proper shaping the cross sections of the components material could be conserved and consumption reduced ultimately leading to stable prices in the long run. The author A.S.Shetty is the CEO of Sedvik Industries, manufacturer of Rollforming machines, Bangalore and he can be contacted at +91 80-25452669 or E-mail: sedvik@vsnl.com
Air Borne Particle Counters Portable & Online from Marvel High Quality Portable and Online Instruments and Systems for applications and research in fluid mechanics, environment, aerosol, particles measurement, and customized systems are now available for use, at MEC Customer’s plants in India.
confirm to US FDA regulations, meeting fully international regulations and should be ideal for Pharma Units, Bulk Drug Production Houses, Drug Discovery Establishments, Electronic Components Making Facilities, Space Applications and the like.
There are four different models that
In addition, continuous on-line systems
December 2012 2012 December
are there for meeting real time measurements. For more details write to Marvel Engineering Company at marvelco@vsnl.net or call +91 44 28112297/ 28110582 or visit their website www.marvelco.in
industrial business business MART MART industrial
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FAIR MART
Hannover to visit Delhi again after its maiden Success India’s largest Industrial Trade Fairs of Hannover attracted more than 6,000 business visitors With the first ever event in the North, Industrial Trade Fairs of Hannover made a mark in the city with 6,174 Business visitors during the 4 days of their five concurrent shows held in November 2012. The number of exhibitors have exceeded to 8% in comparison with the last year. Out of the same, had a combination of 60% Indian exhibitors and 40% international companies. The fairs are expected to convert more than 400cr worth transactional business for the exhibitors. Owing to the success witnessed in Delhi NCR, the next edition will be organized from 17-20 December 2013 at Pragati Maidan, New Delhi. The shows hosted more than 4000 products on display including the latest technologies from- Germany, Italy, China, Taiwan & Korea. The Industrial Trade Fairs of Hannover was the most sought after B2B event covering the manufacturing, automation, materials handling, surface technology & laser technology.
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Gracing the occasion at the inaugural ceremony were Shri Ranajit Pratap Naraine Singh, Hon. Minister of State –
Home Affairs, Central Government, Dr. Jose B. Schulz, Minister Counsellor, Head of Economic and Commercial Division, Embassy of the Federal Republic of Germany, Mr. Deepak Sareen, Executive Director, Electronics and Computer Software Export Council (ESC). The premier edition of the International Purchase Managers’ Summit – India 2012, saw more than 150 industrial Purchase managers understanding the trends of purchasing internationally. Mr. B. Narayan, Group President, Reliance Industries Ltd., inaugurated the event and was also awarded as “Distinguished International Purchasing Professional Award”. Live demonstration of E-procurement solutions was also a part of the summit to provide the complete experience to the delegates attending the summit. On the other concurrent Seminars and conferences combined with the exhibition, the fair commenced with the CEO Conclave where the participating exhibitors interacted with each other and discussed new innovations in technology to Indian forefront. The
Laser Forum seminars with the onsite workshop and live demonstrations on Forklift Driving & Maintenance Practical Master Class were also inaugurated on the 1st day of the event. This was followed by the seminar for Surface Technology by SSPC. The day concluded with the stall awards and a high profile Exhibitor evening. The Day 1 of the event saw delegations like Chinese Surface Technology delegation and Industrial delegation from Ludhiana. The other days had important delegations from Mohali, Haryana, Chandigarh, Faridabad, Ghaziabad, Gurgaon and Manesar over and above the general Industrial Visitors. On day 2, Hannover Milano Fairs and Deutsche Messe also unveiled their upcoming HANNOVER MESSE 2013 at a press briefing. Industrial Delegations at the shows: AIM India, Chamber of Chandigarh Chambers, Derabassi Industries Association, Faridabad Chamber of Commerce and Industries, Ghaziabad Industries Federation, Haryana Chamber of Commerce and Industries, Industries Association of Chandigarh, Manesar
“As the premier meeting place for decision makers and investors from industry, business and government, HANNOVER Fairs India Pvt Ltd has shown time and again that it has the power and influence to kick off new trends and shape future developments. Our first venture in the North of India has been a resounding success. Our participants were able to create new business and new relationships in a professional trade focused setting. We look forward to coming back next year with a much larger and diverse set of innovations and new product launches. My team and I look forward to welcoming you back to WIN - World of Industry India.” Mehul Shah Managing Director, HMFI
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Industries Welfare Associations and Mohali Industries Association. Company Delegations at the shows: Maruti Suzuki India Pvt Ltd, Hindustan Aeronautics Ltd, Godrej & Boyce, Hero Moto Corp, ISRO, JCB India, Tata Motors, Titan Industries, JREW Engineering, Mahindra and Mahindra, New Holland Fiat India Pvt Ltd , Reliance Power
Surface Technology INDIA - Arcraft Plasma, Brissa Enterprise, Daksh Scientific, DST Chemicals, Helm Hellas, Keepsake Engineering, LacTec, Mec Shot Blasting, NGL Cleaning, Progalvano SRL, Raj Systems, Rosler Surfacetech, Statfield Equipments, Technical Drying Services, WALTHER Spritz LASER INDIA - Angel India Cad Cam, Coherent, Komastu NTC, Laser Science, Miyachi, Sahajanand Laser Technology, Scantech Laser, SEI Italy, SPI Lasers, World Star Technologies Hannover Milano Fairs India Pvt Ltd (HMFI), is a wholly owned subsidiary of two of the world’s leading trade fair organizers Deutsche Messe AG, Germany and Fiera Milano, Italy. HMFI have been bringing world class trade fairs into the Indian market for Indian and international enterprises since 2007.
Transmission and Moser Baer India ltd. About the Exhibitors from important Manufacturing Sectors: MDA INDIA – ARGO-HYTOS, Bucher Hydraulics, EPE Process Filters, Fenner India, Janatics Kastas, KTR Couplings, Ringspann, Rotomotive Powerdrive, SKF India, Spareage Seals, W. Hunger Hydraulics, Windsor Exports Industrial Automation INDIA - ACE Automation, BECKHOFF, Brainchild, Cognex, Daehan Sensor, Festo, ILME, Meyle, Pepperl+Fuchs, Pilz, Wago CeMAT INDIA - Armsel Kito, Exide, Gandhi Automation, Giovenzana International, Grey Orange Robotics, Hercules Hoists, Hoffmann, Hormann India, KAUP India, Nilkamal Ltd., Roots Multiclean, Speed O Controls, STAKALL, Voltas Material Handling December 2012
The strong international presence and the vast expertise and best trade fair practices of its parent companies are deployed in the fairs in India which is expected to boost trade which is the USP of fairs of HMFI. Exhibitors and visitors will gain from the professionalism of the international leaders. Deutsche Messe - based in Hannover, Germany - is the world’s foremost trade fair company. Deutsche Messe develops, plans and runs trade fairs and exhibitions in Germany and abroad as Hannover Fairs International with a Turnover – 410 Million $. Deutsche Messe was established in 1947; own the largest Fair Ground in the world with Indoor capacity of over 4.5 Lac square meters of display area. It organizes World’s Largest Engineering Trade Fair – Hannover Messe and World’s Largest IT Fair – CeBIT Italy’s largest Trade fair organizer owns the 3rd largest Trade fair venue with a Group Turnover – 150 million $.
www.vibrantgujarat.com 8-13 January 2013 Gandhinagar, Gujarat Organized by:K & D Communication Ltd The biannual event scheduled from January 8-13, 2013, at Gandhinagar, Gujarat, is jointly organised by the Government of Gujarat and K and D Communication Limited. It is a platform wherein the best of manufacturers and the best of innovations will come to showcase the latest advancements in manufacturing technology.
www.imtex.in 24-30 January 2013 BIEC, Bangalore Organized by:IMTMA IMTEX series is the largest exhibition of metal-cutting machine tools and manufacturing solutions in South and South-East Asia. Concurrent event Tooltech 2013, the 15th International Exhibition of Cutting Tools, Tooling Systems, Dies, Moulds, Forming Tools, Machine Accessories, Metrology and CAD/CAM.
www.ietfindia.in 15-17 February 2013 Pragati Maidan, New Delhi Organized by:Confederation of Indian Industry International engineering and technology fair was initiated in 1975, as a national event with participation of players from Indian Engineering Industry. Over the years, IETF enhanced its scope with presence of international players, and national pavilions of various countries showcasing their strength and capabilities. Partner Country: Korea industrial business MART industrial business MART
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The Center Stage for Metalworking Community to Drive Regional Growth! METALEX 2012, the flagship event of ASEAN metalworking community, won a great applause from over international visitors, exhibitors, supporters, speakers and delegates due to its solid contents, technology breakthroughs and outstanding business opportunities.
Yaskawa.
Taking place at an incredibly exciting time for ASEAN metalworking community, the show attracted 65,216 manufacturing industrialists from across Thailand, ASEAN and 387 persons of Business Delegations from 13 countries (Australia, Austria, China, India, Indonesia, Italy, Japan, Malaysia, Philippines, Singapore, Sri Lanka, Turkey, UK) with strong intention to source the best-of-breed machinery and technologies as they were exposed to over 2,700 global brands from 50 countries and 8 officially international pavilions (China, Germany, Japan, Korea, Singapore, Russia, Taiwan and UK). Read this article online at http://issuu.com/mediamart
Some of the highlighted brands at the show included ABB, Agie Charmilles, Amada, Brother, Carl Zeiss, Chevalier, Davi, DMTG, Durma, Emuge, Erowa, Euromac, Fanuc, Guering, Haas, Haco, Hankwang, Hexagon, Hitachi, Hwacheon, Hyundai-Kia, ISCAR, Kawasaki, Komatsu, Kyocera, Matec, Mazak, Mitsubishi, Mitutoyo, Mori Seiki / DMG, Nachi, Nikon, Noritake, Okamoto, Okuma, Olympus, OTC, Renishaw, Rollomatic, SMT, Sodick, Sumitomo, Takamaz, Taegutec, Tornos, Toshiba, Toyoda, Trumpf, Tungaloy, Walter and
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METALEX 2012 welcomed many key industrial figures visiting the show whose honorable presences underscored the show’s recognition and pivotal role for ASEAN’s metalworking community. Playing host to an unrivalled, record number of 160+ international speakers, the concurrent international conference and seminar tracks covered all aspects of metalworking, businesses and trends that matter to the industry with exclusive in-depth technical contents such as The 2nd METALEX Nano Forum (on nanotech for metalworking), Metallurgy Forum (for metal fabrication and construction), the 4th Thai-Japan Mould & Die Technology Symposium (on Japanese mould and die technology for ASEAN industries). Moreover, the development of new business partnerships and networks were constant and common with outstanding outcomes with business-inducing activities such as Business Matchmaking Program and BUILD Marketplace.
represented a high‐quality event where community members were able to meet, network, secure future business partnerships and discuss the positive results to date of those already engaged in their own moves towards the upcoming AEC in 2015. The Pride of ASEAN on the Rise Next Year Taking advantage of the growth of the industry and the event, METALEX 2013 will be even greater attractions for 68,000 international manufacturing industrialists who will discover the topnotch metalworking technologies by 2,700 brands form 50 countries along with more new contents and onsite activities will be developed to deliver more specialized, vertical presentations dedicated for the advancement of metalworking community in ASEAN. In addition, the business horizons will be expanded to get participants ready for the flourishing opportunities from the upcoming AEC in 2015. METALEX 2013 will take place from 20 – 23 November 2013 at BITEC, Bangkok, Thailand.
In summary, METALEX 2012 December 2012
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COVER STORY
Total Chip Protection for Machine Tools New energy chain for unsupported travels up to 50 m from igus
New energy chain “Guidelok” for chip areas -from igus Gmbh, Cologne. Up to 50 m long unsupported travels are now possible. So no debris and chips can settle between upper run and lower run of the chain.
Read this article online at http://issuu.com/mediamart
Metal chips are a problem for long travels and for when energy chains need to be used for gliding applications. Now the designers from igus GmbH, Cologne have developed a horizontal upper run guiding system called “Guidelok”. This new energy chain solution is ideal for longer travels up to 50 m and unsupported travel in the machining industry.
brackets first. The roller bracket then moves out again behind the radius. Afterwards the upper energy chain run is supported on the roller brackets. Due to this construction no debris can settle between the sliding surfaces of the upper run and lower run of the energy chain. With less material and energy, almost no wear.
Along with the main benefit of protecting cables and hoses against chips and debris, this design offers a number of other advantages. The enormous improvement of the freesupporting length allows users to choose a smaller energy chain for the given length, saving material and overall costs. Secondly – by using a smaller and unsupported energy chain the required
The new system carries the upper run of the energy chain on a swivelling roller bracket which moves away from the moving radius guaranteeing an unhindered ride. Guided in a lightweight aluminium trough, the The energy chain passes the swivelling roller brackets (left), moves in and behind the radius then out energy chain passes again (middle). Then the upper run sets down again, and is supported by the brackets (right). through the roller
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drive force reduces. Thirdly upper run and lower run of the new “Guidelok” are separated from each other. This minimizes friction and wear, which increases the lifetime once again. Already in service Just introduced, the new energy chain system is already used successfully in an industrial application at a German manufacturer of machine tools. A heavy steel chain has just been exchanged with “Guidelok”. Changing the existing system for a gliding energy chain solution was out of the question. Metal chips of a 1 Euro coin size would have settled in the inner radius between upper run and lower run, which could have caused damage. In contrast the new system for long unsupported
December 2012
lengths is ideal for such applications. The “Guidelok” energy guiding is designed modular and with few parts, and is optional with or without side troughs - available ex works straight away. The company from Cologne is showing the product at www.igus.eu/ guidelok; among other things, a movie illustrating the new principle of design. The manufacturer igus can deliver within 24 hrs or at the same day. The program includes more than 70,000 energy chain, cable, plug and connector components as well as other accessories. www.igus. eu/machinetools igus® operations in India started in the year 1998 with head quarters in Bangalore. Today igus® (India) Pvt Ltd, 100% owned subsidiary of igus® GmbH,
Germany has established it’s presence in the whole country with wide network of sales & service force with an aim to serve customers where ever they be. igus® widest range of products that includes, E-ChainSystems®/ Cable drag chains, High-flexible Chainflex® cables, iglidur® polymer bearings, igubal® spherical bearings, DryLin® linear bearings & guide systems enable to serve the whole industrial establishments in the country from a small work shop to huge industrial establishments. For more details write to Harish, Product Manager, E-ChainSystems® & ReadyChains® at igus (India) Private Limited, Tel : +91-80-39127809 (Direct), Email : harish@igus.in or visit them on www.igus.in
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TECHNO MART
Dassault Systèmes Unveils New SolidWorks Electrical Applications Real-time Integration of 2D Schematics and 3D Models Allows Mechanical and Electrical Teams to Better Collaborate and Deliver More Accurate Designs
Dassault Systèmes (Euronext Paris:
and allows real-time integration of
to learn and will allow both our
#13065, DSY.PA), the 3D EXPERIENCE
2D schematics and 3D models leading
mechanical and electrical departments
Company, world leader in 3D design
to increased collaboration and
to collaborate on electrical system
software, 3D Digital Mock Up and
productivity.”said Manoj Mehta, Country
and wiring design,” said Kyle Strong,
Product Lifecycle Management (PLM)
Manager, India and SAARC, SolidWorks.
project manager at Getman Corporation.
solutions, introduced new SolidWorks
“Our mining vehicles include complex
Electrical applications during last month
When it comes to electrical system
electrical wiring and need to have
at New Delhi.
design, organizations frequently look
consistent design -- the decision to
for ways to improve the overall delivery
consider SolidWorks Electrical was
These new offerings include an
performance of their departments.
easy. By integrating our electrical and
innovative, system level 2D schematic
SolidWorks Electrical applications make
mechanical design processes, we can
design tool and a powerful 3D electrical
it easy for engineers and designers to
better document electrical requirements
modeling add-in to SolidWorks design
plan electrical systems and integrate
and cable/wire paths, resulting in less
application that are linked in real time.
those electrical aspects into the overall
rework, higher product quality, and
3D mechanical models.
faster time-to-market.”
endeavor to create accurate designs
These new applications pave the way for
SolidWorks Electrical provides new
with fewer mistakes and complications,
mechanical and electrical engineering
capabilities with the following three
for faster time-to-market.Towards this
teams to collaborate during product
applications:
end, SolidWorks has introduced its new
development, streamline the design
offering- SolidWorks Electrical- a design
phase, and reduce product delays,
1. SolidWorks Electrical – a 2D schematic
application that integrates electrical
resulting in more consistent and
design tool for electrical system
and mechanical designs to speed up
standardized designs, lower costs, and
architecture and planning that:
complex design projects.This simple,
faster time-to-market.
“Design professionals worldwide
• Simplifies electrical design with
intuitive application simplifies electrical
a dynamic, context-sensitive user
tools, comprehensive parts database,
will make SolidWorks Electrical easy
interface, providing the ability to quickly
Read this article online at http://issuu.com/mediamart
system design with its intelligent design
“The full integration with SolidWorks
“Today, companies in industrial equipment, engineering services, high-tech, medical devices, and consumer goods are developing products that include more electrical content. More than half of our SolidWorks customers require a solution that streamlines collaboration between mechanical and electrical systems engineers. The addition of SolidWorks Electrical to our product portfolio moves us into this underserved market with a robust solution that upholds the SolidWorks focus on ease-of-use and makes close collaboration between mechanical and electrical design groups a reality.” Bertrand Sicot CEO, SolidWorks, Dassault Systèmes
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turn concepts into detailed designs
between 2D and 3D to synchronize
The SolidWorks Electrical applications
electro-mechanical designs so that • Identifies problems immediately with
are based on technology from Trace
consistency is maintained throughout
real-time error detection which prevents
Software, a company with more
development
than 20 years of experience in the
costly scrap and rework • The integration of the 2D schematic • Allows for easier and more accurate
with the 3D model to help standardize
creation of schematics with a library of
designs and unify BOMs to reduce
more than 500,000 standard electrical
mistakes and delays
parts • Placement of the electrical system and • Enables multiple people to work on
cables/wires in the 3D model to enable
the same project at the same time
planning of specific locations and paths
2. SolidWorks Electrical 3D -- an add-in
for consistent product manufacturing
to SolidWorks CAD application that
3. SolidWorks Electrical Professional
connects SolidWorks Electrical 2D
– includes the functionality of both
systems-level schematics to 3D models
SolidWorks Electrical and SolidWorks
designed with SolidWorks. It includes:
Electrical 3D in a single application for
• Real-time, bi-directional updates
December 2012
users working in both 2D and 3D areas of
electrical design market. As a current SolidWorks Gold Solution Partner, Trace’s elecworks™ products are integrated with SolidWorks, allowing engineers to stay within the familiar SolidWorks environment to optimize electromechanical designs. The first release of SolidWorks Electrical will be available in North America, Europe, and the Middle East in August 2012, with other regions and countries to follow. For more information about SolidWorks Electrical, please visit: http://www.solidworks.com/electrical/
electrical development.
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PRODUCT MART
Aluminum Precision Drawn tubes for Teliscopic Tube Application from Siddhi Engineers 1050, 1070, 1100, 3003, 3103, 5052, 2014, 2219, 6005,6061, 6063, 6351 as per EN standard. 3. While processing product Siddhi Engineers give the product in exact length or multiple length, which eliminate wastage, which may be to the extent of 15 to 20% in case of extrusion.
Ahmedabad based Siddhi Engineers, a TUV certified ISO 9001-2008 & ISO- 14001-2004 TUV NORD certified Company, engaged in manufacturing of Close Tolerance, Precision Aluminum Redrawn COIL tubes. Aluminum redrawn Coil tubes by its process have various advantages, over extruded tubes as mentioned below: 1. Advantages of Aluminum Precision Drawn Tubes over Extruded Tubes
Read this article online at http://issuu.com/mediamart
Very close dimensional tolerances +/-0.02, Very good surfaces finish Ra 0.4Îź, Added mechanical/physical properties, Accurate straightness 1: 1000, Very small (from 1 mm diameter) & very thin (from 0.2 mm) section is possible, Very precise quality and eccentricity. Special shapes with high accurate in dimension. 2. Siddhi Engineers are able to supply Precision Drawn Coil Tubes & Profiles in Various Types of Aluminum wrought alloy like 19500, 19700, 19000, 31000,52000, 24345, 62400, 65032, 63400, 64430 as per IS standard.
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Presently, they cater to Heat Exchanger application, Fin Tube application, Radiators, Space Application, Telecommunication, Blood Bang Rings, Aluminium foil, Defense, Pneumatic Cylinder, Refrigeration industry, Airconditioning Industry, Automobile Industry and Aluminum Rollers.
They are being supplied for various reputed brands. Please inform us about your size, OD, ID, Length, Alloy, Tolerances, with drawing so that we can supply you the best sample for your evaluation. Please also inform us about what process you would like to carry out Our product so that SUITABLE alloy and critical dimension can be supplied accordingly. Please refer website www.siddhiindia.com for more information. For further details do contact Siddhi Engineers Tel: +91 79 40244300/ 27542909 Email: scmktg@siddhiindia.com, sgmmktg@siddhiindia.com
Siddhi Engineers manufacturer of drawn close dimension precision Aluminium tubes of various shapes for traveling bags. The tubes of shapes like round, square, rectangular elliptical are produced for variety of bags. The strolly bags, heavy luggage, computer laptop bags, school bags use same. The tubes are made for single tubes as well as telescopic applications. December 2012
Planetary Geared Motors from Powertek POWERTEK offers a wide range of Planetary Geared Motors. The Precision Geared Motors ranging from 0.16HP to 500HP. Output 0.1RPM to 450RPM and torque range upto 90,000KGM. Designs, Virtually Maintenance Free operations are some of advantages associated with Planetary Geared Motors. Special Designs to meet individual drive requirement.
High operating efficiency, Space saving compactness, Easier Mounting, Wide range of Reduction Ratios, Robust
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They can also supply Geared Motors such as Variable Speed Geared Motors, Multi Speed Gear Box, Electromagnetic Brake Geared Motor,
Helibevel Geared Motors, Flameproof, Shaft Mounted Gear Box, Custom Built Geared Motors, Agitator Duty Units. The Planetary Geared Motors find applications in Plastics, Rubber Textile, Machine, Tools, Papers, Cement, Printing, Wire Drawing, Cables, Pharmaceuticals, Leather & Sugar Industries. For further details contact Powertek Equipment Company, Tel: +91 22 25905333 / 25905324, Email: info@powertekindia.com/ powertekmumbai@yahoo.co.in or visit www.powertekindia.com
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Rapid Prototyping Services from Infrotrans Designs & Engineering Mumbai based Infotrans Designs & Engineering provides end to end services for Plastics product development of which prototypes are a very important part. They not only select the right prototyping process considering the development stage , but deliver a completely finished, well assembled product proto.
Some of their prototypes have been tested in rigorous environment & passed with flying colours. Through these services we help our clients ensure that there are no bottle necks in tool development, no inadequacies left in assembly & aesthetics & in some cases even those in function. It provides them enough confidence to move ahead with investments in further development of their projects. IDE can provide exact replica of your designed 3D models parts in special polymers. The direct methods used are
StereoLithography Apparatus, Selective Laser sintering, Fused deposition modelling and Cast Polyurathane. •SLA : (StereoLithography Apparatus) This method provides prototypes with excellent finish & is suitable for parts having intricate details as well as those having excellent surface finish requirement . The Masters for vacuum casting process are made using this process. These prototypess are pricier than those made with SLS. Also are slightly brittle than SLS protos.
•SLS : (Selective Laser sintering) This method provides prototypes with slightly coarse finish but with better strength than those done with SLA. Especially suitable to check snap fitting & even live hinges with special grade resins. Though the as obtained prototypes have coarse finish, they can be post processed with sanding/ laquering & finally spray painting to get desired colours & finish. •FDM (Fused deposition modelling) This involves laying of layers of fused strand of material(ABS or PC) to get required form. It produces prototypes with coarse finish , but with much better strength & heat resistance compared to other processes. •Cast Polyurathane
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Short batch production by vacuum casting : A master made by SLA is utilized to get a rubber mould by vacuum casting & the cast protos are obtained by using special PU based polymers. Depending on intricacies / simplicity of profile one rubber mould can produce many copies of prototypes. For further details do write to Infotrans Designs And Engineering, Mumbai, C V Kushe (CEO), Email: info@infotrans-caddesign.com, chandra_kushe@yahoo.com or call him at Mobile: +91 9821246012 Tel: +91 22 42666019
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Power Operated Hydraulic Scissor Lift Table from Ferro Foundries Mysore based Ferro Foundries offers “TIGER� Hydraulic Scissor Lift Table can be smoothly taken up or down and can be stopped at any intermediate position
by operating the push button or pedal switch. This equipment brings table to the most convenient working height for panel feeding and receiving to process machines and it helps in increase of production. It is being used in wide range of applications in engineering, Paper, Textiles, Chemical, Plywood, Glass, Asbestos sheet, Industrial Laminates and other industries. Standard models are
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also available and the equipment can also be custom built. Available in different capacities and in different heights catering to the specific application the industry needs, these equipments will be ideal in improving efficiency and also takes care of safety of men and material. For further details and specifications please visit www.ferrotiger.com or contact Ferro Foundries Pvt Ltd, Tel: +91 821 2402376 / 4282101,3048000-04, Email: info@ferrotiger.com
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Panasonic PLC from Strategi Automation Panasonic of Japan brings a range of compact yet powerful PLC’s in a wide range of models to suit a diverse set of applications. These Micro to Medium range of PLCs have class leading memory capabilities and scan times. The PLCs follow industry standard IEC 61131 standards of programming and can be programmed in Ladder, FBD, IL, ST and SFC styles. The PLC software has dedicated function blocks for Motion control rendering programming of stepper and servo motors very simple and quick. The PLCs support upto 4 axes of control with linear interpolation. The PLC also supports upto 8 high speed counters simultaneously. The software also has options of creating customised function blocks giving OEM customers the option of creating their own IP and protecting the same. The new FPOR PLC has dedicated function blocks for Electronic gearing and Print mark registration control which are very useful in packaging, labelling,
bag cutting applications. The FPX PLCs have upto 8 high speed counters useful for applications such liquid filling. The FP Sigma and the FP2 series complete the range of PLCs.
in an Industry leading warranty of 3 years. Applications abound in Printing, Packaging, Pharmaceutical, SPM, Machine controls, Building Automation and Process automation.
Options exist to connect these PLCs to industry standard networks like Profibus, Devicenet, CANOpen, CCLink, Slink etc. A wide range of communication options also exist on the CPU which includes RS232, USB, RS485 and Ethernet.
For further details contact Strategi Automation Solutions Pvt Ltd, Tel: +91-80-32489798/32467879, Email:sales@strategiautomation.com, Visit www.strategiautomation.com
A wide range of high brightness and high contrast touch screens are also available to complement the range of PLCs from Panasonic. These PLCs have CE and UL certification and wide range of models are available
Servo Insert Couplings from Rotolinear Rotolinear Systems offer Servo insert
couplings . These servo insert couplings are with features like , pluggable,
Different models like stud/set screws clamping, Collet clamping, Outer conical hub, split hubs, compact version, Expanding clamps etc are available.
damp vibration,
Some of the applications include linear
compensation
slide, machine spindle, screw jack
of misalignment
units, servo drive, printing machines,
& backlash-
packaging machines ect.
free etc. Servo
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insert couplings
For further details contact Rotolinear
are available
Systems, Tel: +91 80 23572855
from 0.5Nm
Mobile: 9845196751,
upto torques of
Email: rotolinearindia@vsnl.net,
525Nm.
Visit: www.rotolinearindia.com
December December 2012 2012
THE LAST LEAF Dear Readers, Leadership is all about the vision and direction to a team of people. It is about raising the confidence and aspirations of the followers. It is about enthusing the team with a hope and desire to conquer and reach the far away. In other words, a leader is an agent of change, aimed at accomplishing progress and growth, inspite of tough times. Leaders do something, and in doing so, combat the forces of entropy and evil that can so quickly and easily take over, like weeds overcoming an untended garden. (Courtesy : Jeff Janssen, Janssen Sports Leadership Center) A name which comes to mind when we talk about leadership is Jeff Bezos founder & chief executive of a $100 billion empire built on books. Amazon. He was recently named 2012 businessperson of the year by Fortune. A person with clear thinking & a cohesive vision, Bezos is an ultimate disrupter. He has upended the book industry & displaced electronic merchants. He remains zealous about delivering a good customer experience. In fact, in absence of Steve Jobs, he has become the new undisputed role model for founders who want to keep control of their companies. The stock of his company is up 10-fold in the past six years. The one thing that I liked about Bezos is his act of innovating by starting with the customer & working backwards. Customer focus is a cultural issue, that distinguishes Amazon from other companies. Bezos uses the concept of ‘distributed innovation’ to add businesses under the Amazon roof. The three big ideas at Amazon are long-term thinking, customer obsession & a willingness to invent - all of these coincide with the skills of a leader. When you consider the greatest business minds of past 100 years, the two people who would top the list would be Steve Jobs & Sam Walton. Both created businesses that helped change the way we buy, shop & interact thereby creating a societal revolution, in a true sense. Hence, both of them are extraordinary business leaders. They were both extreme charismatics. (Courtesy : Fortune) Quietly, with little advertising, the Philippines has surpassed India as the number one call center in the world. Now, this South China Sea nation of 7,000 islands, 39 million people workforce, and 470,000 English-speaking college students graduating every year, is going to overtake India in non-voice (back office) business process outsourcing (BPO) by 2015 (Courtesy : The Epoch Times). As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board (EAB)
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