MART JANUARY 2013

Image Dimension Measurement System, Place, Press, Process

Totally New Dimension Analysis System IM-6500 Series from Keyence

Come and Experience World Class Live Technologies Shailesh R Sheth Chairman - Media, Imtex 2013

Within 5 Years, LAPP INDIA will become the biggest player in the LAPP GROUP Richard Lee CEO - Lapp Group Asia Pacific

56

38

40

58

16

An innovative illuminated Emergency Stop button and a Safety Light Curtain with integral Muting have been introduced by Banner Engineering.

Holcim, one of the largest producers of construction material worldwide, relies on drive technology from NORD

Haas DT-1 CNC drill-tap machines have replaced conventional stamping with state-of-the-art machining at FELCO

Developed in response to customer needs, Renishaw EquatorTM100 provides users with extra fixturing space below the measuring volume.

Delta Electronics, the world-leading energy saving solutions provider, announced the roll out of the new Ultron EH Series UPS

Contents 44 Saravjith Singh - Quality Management Gemba Kaizen

48 Vijay Allaham - Green IN

Kaizen for Environment

50 P S Satish - Manufacturing Excellence Column

Managing a SME in India

52 Vivin Agarwal - Responsible Business Being Responsible is a Brand

62 Hiya Chakrabarti - en Masse

Industry meeting Academia

12

NEWS MART Waaree Instruments Ltd is becoming Baumer

26

FEATURE ARTICLE Productivity one of the Critical Pillars of Industrial Competitiveness

54

CROSS WORD Fundamentals of Aluminium Metallurgy

60

TECHNO MART Mayr - New application limits for torque limiting clutches

65 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, Happy New Year 2013!

Well, here we go emerald with Mart, January edition optimizing prosperity and growth of a better business environment. Tragedy, the New Year hits with death of three workers of a forging factory at Peenya, Bangalore. On this, we mourn at and hope the utter negligence in using furnace oil will be inspected and avoided in near future. However, to begin with a positive note, the relief from the proposed sudden hike in taxes, for sure, comforts the global investors. Earlier, FM’s hints at GST road map in Budget created much hype!

Now, for the manufacturing world, IMTEX, the mega event organized by Indian Machine Tool Manufacturers’ Association is the perfect start, which is our featured story for this month. With exhibitors nearing to almost 1000, this edition of exclusive Live Cutting Exposition is the biggest of its kind in the subcontinent as well as in the South Asian region.

Foreword

IMTEX: The Emerald Joy Story

Bangalore is hosting 16th edition of IMTEX from 24th to 30th of this month, at BIEC. An exclusive chat with Mr. Shailesh R Sheth, Media Chairman of IMTEX, is featured in our cover story, bringing in details what’s waiting for you there! The road connectivity is better, which was always a worry for visitors and exhibitors to commute from the city to the expo centre.

From this edition we are starting two new columns. Green IN where we will be inviting guest writers to pen down their experience and expertise in keeping our environment green, which is key to further human existence in our universe. Vijay Allaham, Consultant with Kaizen Institute has written the first column on Kaizen for Environment.

MART always remains the front runner in bridging the gap between the industry and engineering education institutions. From this edition we will be having a regular column ‘en Masse’ on Industry Academy Synergy, and we feature “Jagruti” an endeavour by Udaan initiated by IMTMA at this IMTEX Exhibition.

We have included our regular columns on Quality, Manufacturing Excellence, Cross Words, Industry Update, Fair Mart etc. for your delight.

We have also started a page on Tenders powered by Tender Tiger from this edition.

We look forward your sincere feedback about our quality and quantity of MART. You can reach me at +91 8553012371 or email me at hiya@ martinfotech.in. Your reviews help us to make MART, SMART! Once again, Team MART wishes you all a wonderful year ahead!

Enjoy reading with our magazine!

Hiya Chakrabarti Associate Editor

Asia Pacific CEO of LAPP Group, Mr. Richard Lee was appointed as acting Managing Director of LAPP INDIA recently. With a manufacturing unit in 1996, LAPP INDIA started its operations in India, and with the completion of their second manufacturing plant at Pilukedi, Bhopal LAPP INDIA will become the biggest player within the LAPP Group. In an exclusive interview with MART in its ON FACE column, Mr. Richard Lee talks in details about the challenges, action plan and future of LAPP India and its offerings.

NEWS MART

BaumerCombiView

Alarm Management for Process Monitoring With the new CombiSeries, Baumer has developed tailor-made alarm management for the process industry. They easyto-handle measuring instruments with flexibly programmable displays provide for new practical options in process monitoring. With the CombiPress pressure gauge and CombiTemp temperature gauge, Baumer has introduced the first two products of this series which can optionally be configured with a CombiView display.

The BaumerCombiView displays provide an often helpful overview of the current status of individual processes directly on site. The measuring values do not have to be analyzed first because the display indicates at a glance whether the preset measuring values are exceeded and immediate intervention is required.

In practice the principle of the BaumerCombiView is similar to a traffic light circuit: A clear signal indicates whether there is a need for action. The background color “red” is suitable e.g. for values that call for fast intervention.

A green background could signal proper operation. One look is all you need to see

that everything is in order at a gauge.

The user can individually select and set his indication preferences himself.

The representations on the display can also be adapted as required or according to the respective company’s usage.

Digital as well as analog representation of the values is possible, e.g. as a scale with pointer, bar or column diagram.

Because the display can be rotated in two axes by up to 360°, it is visible from almost any location thanks to the housing diameter of 80 mm.

For further information contact NitinGunjal of Baumer India Private

Limited at +91 20 25286833 or email at sales.in@baumer.com or visit www. baumer.com on the internet.

Everything remains different: Waaree Instruments Ltd is becoming Baumer

Read this article online at http://issuu.com/mediamart

Following the takeover of the Indian manufacturer of process measurement instruments by the Swiss Baumer Group at the end of 2010 the integration has now been completed. The company is now part of the global Baumer family as Baumer Technologies India, headquartered in Mumbai.

The whole of the former product range known under the brand “Waaree Instruments Ltd”, which has also been extended, is now available on the Indian market under the brand name Baumer. This includes pressure, temperature and level measurement instruments for the 12

industrial business MART

process industry. The products will continue to be manufactured at the production site in Vapi. Processes and products have been continually optimized since the purchase of Waaree Instruments Ltd. by the Baumer Group. The change of name therefore goes hand in hand with a significant increase in performance, quality and availability of the products.

At the same time, customers on the Indian market will profit from a significantly wider range of products for process measurement technology, which Baumer Technologies India can offer as a result of integration into the global Baumer Group.

This includes a noticeably improved range of customized solutions. The same team of developers, engineers and managers who were already involved with Waaree Instruments Ltd. in India and are very familiar with the market and its requirements will be taking care of this.

“The change from Waaree Instruments Ltd. to Baumer is an inspiring development for us. Through the intense exchange with international colleagues and thanks to the valuable stimuli within the Baumer Group we can fulfill our promises to deliver even more reliably in the future.”

Shyam Warialani Managing Director Baumer Technologies India

January January2013 2013

“World Plasma Leader, Local Expertise” Hypertherm @ Weld India 2013 over conventional oxyfuel for cutting.

Come 7 to 9 February 2013, Hypertherm will once again reinforce its commitment to the India market at Weld India 2013. “World Plasma Leader, Local Expertise” is Hypertherm’s theme for its participation at the event. Associates will share the company’s expertise in the field of plasma cutting, and showcase its cutting edge plasma solutions. Live demonstrations will be conducted as well for visitors to learn about and appreciate the advantages of plasma

January 2013

Hypertherm has served the India market since 1999, with a steadfast mission to help end-users reduce the cost of cutting metal. Over the years, the company has introduced numerous world-class plasma solutions to the local market, allowing manufacturers to benefit from many advantages that the cutting technology offers.

At the same time, Hypertherm has steadily grown its pool of local associates, in order to effectively cater to its expanding customer base. Late in 2012, the company opened the doors to its first cutting technology center (CTC) in the country. The facility serves as a gathering point, where channel partner employees can train up their technical skills and sales expertise to enhance their capabilities.

“Hypertherm always looks for avenues that will allow us to reinforce our commitment to the countries that we serve. We look forward to meeting customers, prospects and partners at Weld India, and to sharing our knowledge about thermal cutting solutions with visitors to the show.”

Abhinav Sood Sales Leader, Hypertherm India

industrial business MART

13

NEWS MART

Badve bags IMTMA Award The Plastics division of Badve Engineering Pvt Ltd has received first Prize, Memento and Cash Prize of Rs 1 Lacs, for competition based on theme of “Productivity Improvement”. This competition was arranged by Indian Machine Tool Manufacturers Association (IMTMA) and was held at Bangalore during 7 and 8 Dec 2012. Companies participated in this national level competition are - Maruti Suzuki , Tata Motors , L and T , Bajaj Auto , Shriram Pistons , TVS , Wheels India , Laxmi Precision etc .

New Cost-effective UPS from Socomec Socomec has introduced new costeffective UPS for business critical appreciations.

The technological features consist of online double conversion mode with 0.9 output power factor.

The new UPS is having one plus one parallel redundancy with back feed protection. The internal batteries are having more than one hour run-time and EBS for exclusive battery management.

The UPS is having multilanguage display and Web SNMP interface for remote monitoring.

Socomec is a manufacturing company that has focused its expertise in power solutions since 1922. High quality of products, innovation and service are the DNA of a modern organization dedicated to satisfying customer needs. For further details, please visit : www.socomec-ups. co.in

14 industrial industrial business MART business MART 14

BSI Inclination Sensors – For Special Demands The new, liquid-based BSI inclination sensors from the sensor specialist Balluff detect deviations to the horizontal on an axis over a full 360° contact-free and absolutely. With an extremely high accuracy of 0.1°C, a resolution of 0.01° and a temperature drift of just 0.01% /10K, they are the ideal choice when, in complex applications, inclination angles need to be precisely detected or rotary movements must be constantly tracked.

BSI inclination sensors feature a compact and robust metal housing with an enclosure rating of IP 67 and can be easily installed in systems with limited space. With an expanded temperature range of -40°C to + 85°C, the sensors are virtually predestined for outdoor applications.

The highly precise, high-end sensors show their true strength, howev-er, where deviations from the horizontal or to the vertical axis are to be determined with high resolution and accuracy: e.g., in wind power stations, in solar-thermal power plants, oil and gas production

plants and in medical technology, for example, in computer tomography and irradiation facilities.

Balluff BSI inclination sensors are based on a capacitive measuring principle and are equipped with a liquid-based measuring cell. These consist of four capacitors filled with a liquid dielectric.

Depending on the inclination of the sensor, the “horizon” of this medium covers the capacitors differently, causing the capacitance – as measure for the inclination angle – to change. The analog output signal from 4 – 20mA is scaled linearly over the angular range of 360°C. For further details contact BALLUFF India, 405 Raikar Chambers, Deonar Village Road, Opp. FirexGovandi (E), Mumbai 400 088 Tel: +91-22-67551646 Email: balluff@bom5.vsnl.net.in Visit: www.balluff.co.in

Maharashtra unveils new Industrial Policy An investment of Rs.5 lakh crore, jobs for two million people, new industrial corridors and attractions for micro, small and medium industries have been proposed in Maharashtra’s New Industrial Policy 2013-18.

It was officially announced that the new policy will be implemented from April 1 and will be valid for five years. It aims to increase the state GDP to 28 percent.

The other highlights include a 1,000 MW gas-based power plant and multi-modal logistics park in the Talegaon area on the outskirts of Pune, as part of the state government’s initiatives under the DelhiMumbai Industrial Corridor (DMIC).

The Confederation of Indian Industries welcomed the new policy, especially the sections on the IIAs, and micro, small and medium enterprises which form the backbone of economic growth constituting 80 percent of the total enterprises.

The Indian Merchants Chamber also welcomed the NIP, terming it as “proactive to the industry”.

“We want proper all-round development in the state. With the special economic zones (SEZs), there have been issues like minimum alternate tax and dividend distribution tax. So, we are now offering IIAs.” Prithviraj Chavan Chief Minister, Maharashtra January 2013

January 2013

industrial business MART

15

NEWS MART

Norgren´s New IVAC Cylinder Offers Dramatic Reduction in Energy and Operating Costs Norgren, an international market leader in pneumatic motion and fluid control technologies, has announced the launch of an innovative, high-performance range of cylinders, designed to significantly reduce energy usage and operating costs for OEMs and end users in a range of processing applications.

For a machine operating at two million cycles per year, this results in enough energy savings to pay back the cost of an IVAC product within one year. In addition the IVAC presents improved machine aesthetics. A sharp, uncluttered appearance reveals a more sophisticated look and, for end users, it makes plants look cleaner and more advanced.

Conventional pneumatic control involves an arrangement of valves or valve islands, actuators, flow controls and sensors, along with connectors and accessories.

In typical applications, up to 13 different components can be required for each actuator function. This complexity presents some intrinsic disadvantages and performance constraints.

Following close collaboration with customers to offer a solution which would overcome these shortcomings and satisfy individual requirements, Norgren has developed IVAC (integrated valve and actuator control) - an integrated unit which delivers Engineering Advantage by combining the valve, flow controls, cushioning and sensors in a single actuator package.

IVAC is a weight and space optimised actuator, suitable for a range of bore sizes from 40mm to 80mm, featuring integrated valve and magnetically operated switches for complete actuator control.

Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection,

eliminating the need for multiple valve islands, components, tubing and accessories.

This integrated platform lowers costs for users in many ways. Because it is easier to install, maintain and replace a single unit, scheduled and unplanned installation, commissioning and maintenance time and costs are reduced. Less downtime for maintenance also means higher productivity.

Meanwhile, eliminating air piping between valves and actuators minimises ´dead´ volume, reducing air consumption by up to 50 per cent, significantly cutting cost per mm of stroke when compared with conventional pneumatic systems.

A number of options and varieties are available including cleanline versions for industrial cylinders, industrial slave cylinders and easy washdown, helping OEMs comply more easily and cost effectively with hygiene regulations.

OEMs can take advantage of all of these benefits without any mechanical design changes, as IVAC products conform to the latest ISO VDMA dimensions. Its single M12 connection for input and output can be hardwired or plugged into a fieldbus system no matter which protocol is being used.

For further information email to enquiry@norgren.co.in, or call at +91 120 4089500 or visit www.norgren.com/ivac

Delta Rolls Out the Ultron EH Series UPS Delta Electronics, the world-leading energy saving solutions provider, announced the roll out of the new Ultron EH Series UPS (uninterruptible power supply) in India.

“Delta India grows at CAGR of 50% on UPS business over last year and is planning to double the revenue in FY 2013 says Mr. Suhas Joshi, Director, Delta Power Solutions”.

Introduction of new products and

16 16

industrialbusiness businessMART MART industrial

technologies is helping Delta India to further strengthen its roots in Indian market. Moving towards the growth direction, Delta MCIS introduced Ultron EH in the market.

The Ultron EH Series, with power ratings of 10/15/20kVA, is a true online uninterruptible power supply device with three-phase four-line input

and single-phase output, which can provide a reliable and stable sine wave power supply to protect mission critical applications from downtime, data loss and corruption. The Ultron EH Series UPS provides clean power supply for server rooms, communication systems, computer network systems, medical treatment systems, surveillance systems, factory equipment, and more.

More information about Delta MCIS products can be found at: www.deltapowersolutions.com January2013 2013 January

SKF Machine Condition Indicator to Improve Machine Health SKF launches the SKF Machine Condition Indicator, a low-cost vibration and temperature monitoring device designed for rotating machinery with constant operating conditions.

The device can be used indoors or outdoors, in almost any industry where rotating machines are used, such as pulp and paper, power, food and beverage, hydrocarbon processing industry (HPI), oil and gas industry, machine tool, as well as heating, ventilation, and air conditioning (HVAC).

The SKF Machine Condition Indicator runs on a high energy lithium battery and has a life expectancy of more than three year (with one acknowledged alarm).

“The SKF Machine Condition Indicator is

January 2013

as simple as the ‘check engine’ warning light in a car,” said Torsten Bark, Product Line Manager at SKF Condition Monitoring Centre, San Diego. “Once LED’s are illuminated, it alerts the predictive maintenance technician to do a root cause analysis on the machine to determine what kind of problem might be affecting its performance.”

good solution for manufacturers looking for an economical way to make sure their semi-critical machine assets are kept up and running.

By utilizing the SKF Machine Condition Indicator, plant operators can save both time and money by freeing up maintenance engineers to spend less time on problem detection and more time focusing on root cause analysis and other more significant issues.

The device costs less than a standard industrial accelerometer, which makes the SKF Machine Condition Indicator a

industrial business MART

17

NEWS MART

Image Dimension Measurement System, Place, Press, Process

Totally New Dimension Analysis System The IM-6500 Series from Keyence is a new type of measurement device. It is a completely new concept to rival established measuring equipment such as profile projectors, measuring microscopes or automatic CNC measuring machines.

The dimensional measurement concept of the IM-6500 series utilizes state of the art imaging technology, thus enabling any user to perform reliable measurements in a minimum of time and with an increased accuracy.

You simply place a part on a measurement stage, push the button and up to 99 dimensions are measured in a few seconds with accuracies down to 0.7 micron. No tiresome positioning, nor risks of measurement variance or deviation between individual operators. The simplicity of use results in the IM-6500 series emerging as a massive cost saving alternative to traditional time consuming measurement processes.

The IM-6500 measurement concept combines the flexibility of a vision system with the accurate execution of a double telecentric lens. The all new double telecentric lens, with a large diameter of 100mm, captures the complete image of the target element, thus allowing the measurement of all the control points at once. With this technology it becomes possible to capture pixels without image distortion of the component that is placed around the lens circumference. Hence measurement is neither affected by distortion, nor by the distance. The lens size dictates that parts up to 100mm in diameter can be measured.

Measurement data can be stored digitally as Inspection Reports, Data Lists or Trend Graphs along with screen shot images.

These files can be exported to other sources as the IM series utilies a convenient PC based data management system.

With the IM-6500 dimensional measurement concept, you simply place the part to be measured in the measurement area. The iPASS method (Intelligent Pattern Analysis Search System) performs a shape scanning (from the already recorded targets) to determine its position and its shape. Many features can be measured, from internal diameters, circular threads and angles.

Previous difficult to measure features with traditional methods can now be performed automatically with reduced risk of operator error.

The IM-6500 series utilizes the latest technology to eliminate individual differences.

The original sub-pixel concept by Keyence makes it possible to automatically detect the position of the component edges more accurately than with traditional vision systems thanks to the sub-pixel processing with a margin of 0.01 pixels. The IM series has overcome the age old issue of measurement variations from one user to the other. The same applies for errors due to differences in operator competence.

The built in temperature sensor allows the IM-6500 series to be installed almost anywhere in a production facility. Temperature compensation ensures accurate measurement once the system is in use.

The IM-6500 series is of a compact space saving design with a footprint the size of an A3 sheet of paper. It can be easily mounted near the production lines or in a laboratory.

For IM Image Measurement specifications and applications, please visit: www.keyence.co.in/impr For further details write to KEYENCE INDIA PVT. LTD, 1st Floor, C Wing, ALEXANDER SQUARE,No.34-35, Sardar Patel Road, Guindy, Chennai 600 Tel: +9144-4963-0900 Email: info@keyence.co.in

Accelerated Manufacturing can boost up Indian Economy At the 12th Five Year Plan of the Planning Commission, it has been said that Indian economy can grow at 9-10 per cent if the coordination and collaboration of stakeholders accelerates the manufacturing sector by 2-4 per cent.

Mr Arun Maira, member of the Planning Commission, told reporters at CII’s 11th

18

industrial business MART

Manufacturing Summit that” there is a need for co-ordination and collaboration amid various stakeholders, including the government, the industry and the civil society as a whole that can help to accelerate the growth in manufacturing sector by 2-3 per cent from the current level. It will make the manufacturing become the driver of India’s economic

growth,” There is also a need to increase `depth’ in manufacturing, which involves increasing participation across the value chain in manufacturing, improving domestic value addition and stimulating innovation.

Moreover the existing labor laws need amendment, he added.

January 2013

WIDIA Victory Portfolio means Higher Turning Productivity Lower costs across wide range of materials With overwhelmingly positive feedback from pre-launch customers, new high-performance WIDIATM VictoryTM turning grades deliver increased productivity with improved surface finishes and longer tool life across steel, stainless steel, cast irons, and specialty alloys.

“These are significant new turning solutions including 10 different grades and 14 different geometries, including five new chipbreaker designs”, says John Gable, product manager, global turning

January 2013

products for WIDIA. “And in many cases, the results are not just marginal improvements, but more like double the number of parts versus other inserts.”

WIDIA´s Victory inserts employ coating technologies to improve wear resistance and allow for higher speed and / or feed capabilities. Additional post-coat treatment provides increased cuttingedge toughness to reduce the depth of cut notching and extend tool life. WIDIA Victory inserts are ground after coating to provide a secure seating surface, adding to tool reliability.

“Whether the task is light or medium turning under favorable conditions or heavy-duty roughing with heavy interrupted cuts, there is a WIDIA Victory insert that will improve your results,” Gable says. “Customers can machine more parts per insert and get higher dependability at elevated cutting speeds. The bottom line is more uptime and higher throughput to get parts out the door faster.”

To locate a WIDIA distributor, contact: WIDIA Products Group +91 80 2219 8341 or visit www.widia.com

industrial business MART

19

COVER FEATURE

IMTEX 2013 in Tech-talk Making India the Manufacturing Power Hub Any manufacturing to start with- it is the Machine Tool Industry. Now on the global economic slowdown, Indian Machine Tool Industry is transforming to become more productive, more efficient and cost effective this year – hitting the 16th IMTEX 2013 from January 24-30 at Bangalore International Exhibition Centre.

The most sought after machine tools exhibition of India, IMTEX is acclaimed internationally as India’s largest Metalcutting Machine Tool Exhibition on manufacturing technologies. The apex machine tool exhibition of South and South – East Asia promises to showcase the latest trends as well as refinements to the already successful technologies.

It will definitely spearhead a wide range of opportunities for manufacturers, users, technocrats, researchers, policymakers, academia & even budding engineers & tech graduates, all to say everyone connected to manufacturing.

Read this article online at http://issuu.com/mediamart

Countries like Australia, Canada, Japan, France, Turkey , Belgium, Russia, UK, USA etc are participating individually as well as a group participation of nine countries will be there to take the offers as much as possible from IMTEX 2013.

Aerospace, Automobiles, Defence, Capital Goods, Electrical & Electronics, Food Processing and Dairy equipment, Railways, Infrastructure, Oil & Gas, Pharma, Space& Nuclear, Telecom and other industries will be benefitted from this exhibition.

20

industrial business MART

IMTEX 2013 is being organized in the midst of a challenging economic environment. Basically the slowdown is caused due to global turmoil as well as stagnant domestic conditions.

New sectors are driving Machine Tool industry to newer heights. Opportunities are there to expand markets and reach new customers. The sole objective of IMTEX 2013 is to optimize productivity, enhance quality, and increase reliability and to rein competitiveness.

IMTEX 2013 displays the entire range ofcutting tools, tooling systems,machine tool accessories,metrology equipment, together with CAD and CAM software.

It also features recent innovations and tooling technologies to reach towards the precision.

IMTEX this year is having a gross

exhibition area of 48,000 sqm having five multilevel halls and a total number of exhibits is 1500 machines costing a value of Rs.1500 cr. Since growth is concerned, IMTEX 2013 is witnessing growth both in the national as well as the international exhibitors. Some of the major Indian participations are Bosch, Fanuc, Haas Automation, PMT Machines, Seco Tools, Siemens etc. On part of overseas, we can see Carl Zeiss, Chiron,DMG – Moriseiki to name a few.

IMTEX is also holding some academia industry synergy programme where students from technical colleges, budding engineers as well as the industry leaders can interact with each other.

They can also do some presentations for manufacturing excellence. ‘ Jagruti ‘is a an appreciated initiative by IMTMA. Morever, there are logistical support for the visitors, projects like “Map Your Show” which will eventually help both the exhibitors and the visitors at the exhibition centre.

So let’s cheers for all the manufacturers saying “veni, vidi, vici”

January 2013

January 2013

industrial business MART

21

COVER FEATURE

“Come and Experience World Class Live Technologies at IMTEX” IMTEX 2013, the 16th Indian Metal- Cutting Machine Tools Exhibition with International Participation is going to be held from 24-30 January, 2013 at Bangalore International Exhibition Centre. This is the most sought after machine tools exhibition in India having participants globally.

Read this article online at http://issuu.com/mediamart

IMTMA (Indian Machine Toolvv Manufacturers’ Association) prepare for every IMTEX in much well in advance. The association follows the 10 year schedule both nationally and internationally, plan it up and then execute it with utmost effort. As many companies outside India participate in this event it follows an informal global calendar to make it a huge success.

Excerpt from the conversation our Assistant Editor, Hiya Chakrabarti had with Mr. Shailesh R Sheth, the past President, IMTMA and the Chairman - Media, IMTEX 2013.

What special in IMTEX 2013?

IMTEX is the only international exhibition catering to this industry specific product in South East Asia. As of 2013, adding IMTEX and ToolTech, there is a total 947 exhibitors of which both foreign and Indian numbers

22

industrial business MART

of exhibitors have grown high. We have 25 countries participating from overseas and the percentage of overseas exhibitors is 49%. Over 95 % of Indian metal-cutting machine tool industry will be represented at this exhibition in 5 multilevel halls.

January 2013

What are the priorities and the objectives of IMTEX? First and foremost, IMTEX is not a B2C event; rather it is a B2B event. We prioritize the business sentiment. Our sole objective is long-term manufacturing solutions. Once manufacturing industry will grow, the revenue as well as the other industries will be definitely boosted up and India will have a good economical success. IMTEX 2013 is featuring recent innovations and tooling technologies for precision finish.

Here, we display ‘Live Technologies’ giving edge to manufacturing to enhance quality, productivity and reliability.

What are the expectations on business enquiries during IMTEX 2013?

During IMTEX 2011 we had business enquiries of Rs.7000cr. of which 1022 had been confirmed. This year we expect 8750cr of enquiries of which 1200 must have been confirmed.

What is your opinion on the current economic slowdown in India?

As everybody is saying economic recession is there. But the first half of the fiscal is not bad. There was growth. On March 2011, first two quarter witnessed good growth.

Eventually on July-Aug 2012, order booking went slow and undoubtedly that reflected on Quarter three and four.

What can be the steps taken by IMTMA or the Government to come out of the financial crisis?

There are few major steps have already been taken to come out of the dark phase of Indian economy. Amendment bills have been passed, banks are being capitalized.

Removing subsidies is one more option.

Over all, there is a cautious optimism. We do not dream of sudden change in the first quarter of this financial year, but yes, of course from April – June quarter of 2013 will see some slow improvements.

IMTEX always focuses on academiaindustry synergy. What special for this January 2013

year?

If you go to any manufacturing industry, the first thing needed is Machine Tools.

Again if you go to technical colleges in India, they are offering various degrees including civil, mechanical, electrical etc. Machine Tools products embody all engineering methods. So when an engineer goes for working in some manufacturing firm, he faces difficulties and complexes in manufacturing a product as the core of all engineering is machine tools.

We in IMTEX give the opportunity to the industry as well as the academia to interact with each other solving their queries and opening new windows towards development. This year “ Jagruti” has been held up for all engineering students who wants to make their career in manufacturing firm, entrepreneurs from small scale industries to learn and share the basic fundamentals.

‘Jagruti’, an initiative by Udaan will be held every day from Jan 24-30 during 14.00 hours to 18.00 hours. This is the time exclusively to present R & D on Machine Tool by engineering students from technical institutions from all across India The Export business of India is lacking. Tell us what the actual scenario is as well as what are the measures which can be taken up to promote export?

As per 2012, the total demand is 10,000 crore from which 3300 cr. is from Indian Manufacturing firms. But unfortunately we have to import 6700 cr from foreign countries. So the total export share is 33%.

However, through IMTEX , we determine to increase in various manner in customer base from 33% to 60% in 5-6 years.

In your Action Plan there is one recommendation on counter trade. How can it help the economy?

Countertrade means exchanging goods or services which are paid for, in whole or part, with other goods or services, rather

than with money. When we are lacking of hard currency, this will be a great help to survive. Aerospace is a must say industry which use counter trade and indeed, it is a rapidly growing industry!

What your say on FDI impact in manufacturing?

Everybody likes to access domestic market.

Import is too costly and economic price of every product is rising high day by day.

Standing at this situation, FDI is definitely a welcome mark for India. Surely it will take some time in assembly manufacturing.

But the good sign is already marked in automobile sector. Passenger car and two wheelers will be on the profit segment as FDI inflows to this industry. Eventually it will benefit the Machine Tools Industry also.

“MAP YOUR SHOW” is something IMTMA introduced for the first time in India. Tell us something how it can help the visitors?

It is a powerful online planning and networking tool which allows visitors to do exhibitors and product search and also fix meetings with exhibitors and utilize his visit to the exhibition in a most effective way.

What are the supports from the Government to uplift the manufacturing industry in India?

Government is funding for the technology development as well as the product development centers in India. More centres of excellence are being established to enhance R&D in manufacturing.

What is ‘IMTEX Forming 2014’?

IMTMA will hold IMTEX Forming 2014 – Metal and Non Metal (Plastics and composites) International Forming Technology Exhibition from 23 - 28 January 2014 at Bangalore International Exhibition Centre (BIEC), India. The previous edition of 2012 received an exhilarating success with a growth of about 40%.

industrial business MART

23

Cleaning Technologies Group, LLC introduces new cleaning solutions at IMTEX 2013 Cleaning Technologies Group a world leader in providing cleaning and waste minimization technologies will introduce a host of advanced cleaning solutions at the Indian Machine Tool Exhibition (IMTEX) in Bangalore, India January 24 – 30, 2013. Visitors to Cleaning Technologies Group Booth #A102Q will be introduced to a number of new products, technologies and services.

• New Gen 3LeanJetRB-2 Aqueous

made of all stainless steel construction.

both our aqueous and hydrocarbon

Immersion Cleaning Systemuses a

Available in various sizes and intended

machines in operation. Customers will

patented washing and rinsing process of

to sit easily on a workbench or as a

also have the opportunity to send in their

agitation, spray impingement, hydraulic

drop-in, these parts washers offer the

parts for cleanliness testing and Millipore

purging through immersion and rotation,

same cleaning capabilities as the more

validations. We are very excited about

ultrasonics, and heated blow-off

elaborate models but at a lower price.

the new facility and the opportunity to

drying. The patented “triple action”

They are great for cleaning small parts

work closely with our local customers to

batch cleaning process was developed

on an intermittent to semi-production

find the right cleaning solutions for their

specifically to process a broad range

basis but are not recommended for

application” says Chris Whittaker, VP

of challenging parts, especially those

high volume cleaning. These tanks are

Sales & Marketing.

with internal bores and passages and

available for use with single or multi-

complex geometries, making this system

frequency generators.

capable of meeting critical cleaning

At the show we will have technical experts available to explain our

• CTG Announces a New Lab

technologies in more depth and provide

Testing Facility in the Association for

suggestions to our customers to improve

The LeanJet RB-2 parts washer

Manufacturing Technology’s (AMT)

their cleaning processes. For more

also features the latest Siemens

Technology and Service Center located

information about Cleaning Technologies

programmable controller and operator

in Chennai, India. “Our Indian customers

Group, please visit: http://www.ctgclean.

interface screen. This controls platform

will be able to visit the lab and observe

com.

expectations.

boosts system flexibility for automation integration, process control and data logging while offering an intuitive user interface.

• New LeanJet RB-Hydrocarbon Read this article online at http://issuu.com/mediamart

Cleaning System guarantees near-zero atmospheric emissions. Incorporating similar part rotation dynamics and process parameters to the Aqueous LeanJet RB-2 System it also offers vapor cleaning and rinsing cycles. Air recirculation drying systems and advanced vacuum technology eliminate the need for exhaust smokestacks.

• PROHT SonicTank also known as the “Benchtop Series” is an entry-level benchtop ultrasonic cleaning system

24

industrial business MART

January 2013

January 2013

industrial business MART

25

FEATURE ARTICLE

Productivity one of the Critical Pillars of Industrial Competitiveness

Read this article online at http://issuu.com/mediamart

Where does industrial competitiveness come from? Does it come from Innovation? Sure it does! But is innovation enough to be competitive? Innovation is not the only ingredient for competitiveness, though it is a very essential or important one. There are countless cases where innovations have stayed in the cupboard and not commercialized.

Does it come from industrial design? A good design converts an innovation into a product, which can be manufactured. However if not manufactured competitively there would be few buyers.

There is a saying “Selling coal to

comes to mind is producing more

Newcastle�. Marketing people can

components or parts in the same time

sell anything to anyone. There is

or better asset utilization. One way to

also another truth; one is successful

do this is to reduce the cycle time of

and competitive if you have repeat

the process. However speeding up a

customers. One can sell a shoddy

process could lead to greater resource

product once but can one sell a

wear, for example cutting tool wear.In

shoddy or costly product to the same

turn this could lead to a quality issue or

customer again and again? Finally

a frequent change of tool and during

success comes only when you have

which the machine would be idle.

innovation, and a good industrial design competitively manufactured

Thus one has to optimize the speed

and effectively marketed.

or cycle time and strike a balance between the parameters, which

Gautham Doshi Advisor, IMTMA 26

industrial business MART

Since we all agree manufacturing

include the resource(tool) life.

competitiveness is critical to success

Continuous research in resources

and productivity is a critical pillar, let

increases their life and at the same

us look at some facets of boosting

time allows one to operate at higher

productivity. The first thing that

speeds. Needless to say the final

January 2013

limitation may come from the design of machines or the part being machined.

While optimizing the cycle time is one facet, another important aspect to resource utilization is how much time in a day or shift do we use it. We pay interest 24X7 but do we use our asset 24X7? For example if a cycle time for a part is 6 min, do we get 10 parts an hour or 240 parts in a day? If not we are not utilizing the resource fully.

The reasons for not getting 240 parts in a day are many, for example machine breakdown, set up change, tool change, adjustments of tool, lunch and tea breaks, material not available, electricity not available, operator not available and so on. All this results in poor resource utilization. Often these reasons account for 60% of 24X7 and are a very big drain on productivity.

In some organizations we produce for stock. For example we can produce 120 units of part A but we sell 100 units. 20 units are in stock to be sold in the next month. However in this period there was an order of 50 units of B and due to capacity constraints we were able to produce only 30 units of B. This is against common sense, but the reason given is we did not want to break the batch of A, because there is loss of productivity as an additional set up time is required.

Machine utilization is high but at the cost of inventory. What is forgotten is improper utilization of resource, i.e. money. Therefore this is certainly not higher productivity. Often you can observe an operator of a CNC machine standing idle during the automatic cycle. Is this good resource utilization?

Resources include energy and material. Do our forgings or castings have too much machining allowance? What do we do to reach near net shape?

Do we measure how much energy we consume per unit of our product and try to reduce it?

Larger batches are taken also because processes are not stable, rejection and rework take place. If one wants 100 to be dispatched take a batch of 105 could be the rationale. As a result there is waste in the process and poor productivity. Rejections mean January 2013

industrial business MART

27

that either the capability of the process

of material and people with shortest

cannot be far behind. If a company

does not meet specifications, or special

path. Newer and better processes can

takes up several Six Sigma projects,

causes make the process unstable.

be included, which could not only lead

team members look deep into the

to better productivity but improved

process and find hidden treasures.

quality as well. Assembly conveyors,

Their understanding of the process

wherever possible, with proper work

improves and this leads to a quantum

station balancing are an example of

jump in productivity. High quality

optimizing flow as well as minimizing

results in smooth and uninterrupted

material and man movement.

production and the best way to

One needs to deep dive into the process and understand the variables that affect the process. SPC studies certainly help in analyzing the process.

Process control and monitoring systems need to be set up. A deep

In metal working new or better

its improvement and ultimately results

companies use the quality route to

processes are continuously being

in higher productivity. No rejections or

productivity. It also leads to less

introduced. New tool coatings and

rework mean one can produce exactly

confrontation between management

materials enhance cutting parameters

as much as one sells!

and workmen as no one has any issue

as well as tool life. Hydroforming

with improving quality, especially when

allows one to manufacture parts

quality and safety are also closely

hitherto not possible or reduce the

linked.

Value stream mapping is a very effective tool to identify steps in process, which do not add value.

These activities that do not add value can then be eliminated, simplified, combined and overlapped, or reduced.

Let us look at one such activity. A fixture needs to be aligned to the axis of the machine, whenever it is changed. During this period parts are not produced.

Most engineers are aware of the several means available by which the fixture repeatedly gets aligned without loss of time. Another example; with the addition of pallet changer, cycle time permitting, machine need not be idle during lunch and tea breaks.

Also load/ unload time for the part is constant and predictable. Autonomous maintenance carried out by operators has demonstrated in many factories a significant reduction in machine breakdowns.

Workflow study often reveals excessive material and people movement. When traced in factories it often resembles a plate of spaghetti. Manufacturing system redesign results in smooth flow

28

improve productivity. Sensible

understanding of the process leads to

industrial business MART

weight of conventional parts. New and better tool holding systems allow

There are many approaches to

spindles to run at higher rpms without

improve productivity. Be it through

reducing cutting forces. Newer CAM

manufacturing system redesign, or

software using advanced cutting

better asset utilization, or optimizing

strategies allows one to remove

the process or the quality route

material faster. Optimising design of

to productivity. Often companies

machine elements using FEA tools

combine all these approaches. There

allows one to make them more rigid

are many tools that one can use. TQM

and vibration resistant, allowing the

or the Japanese approach or the Lean

use of higher cutting parameters. All

approach of the western countries

these approaches lead to optmising

both look at productivity improvement

metal working processes.

maybe from slightly different view points, but the results sought are the

Shop floor culture is a driving force

same.

behind improving productivity. It is observed companies that do not pay

Their approach is rooted in their

lip service to safety but give this aspect

culture. Maybe it is time for us

as the highest priority are also highly

to create an Indian approach

productive. A high level of safety

rooted in our culture to improving

cannot be achieved without practice

productivity resulting in manufacturing

of 5S. 5S needs complete involvement

competitiveness. IMTMA’s Productivity

of all personnel. This attitude of mind

Summit and Productivity Buzz is a

will not brook poor quality in the

platform for helping our manufacturing

workplace. One cannot have high

and production engineers to network,

productivity without high quality. They

get acknowledged, and develop an

are totally intertwined.

Indian approach to productivity and quality.

When quality improves productivity

January 2013

January 2013

industrial business MART

29

ON FACE

Within 5 Years, LAPP INDIA will become the biggest player in the LAPP GROUP 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, Lapp’s 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. Recently, LAPP INDIA completed phase 1 of its second manufacturing plant in Pilukedi, Bhopal which will produce 1,000 kms of single core cables daily, catering mainly to the Building Cable Segment (BCS). 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.

Read this article online at http://issuu.com/mediamart

MART converse with Mr. Richard Lee, CEO - Asia Pacific at LAPP GROUP, newly appointed as the acting Managing Director of LAPP INDIA about his new role, challenges and future plans.

30

industrial business MART

January 2013

January 2013

industrial business MART

31

As the newly appointed acting Managing

whole team of LAPP INDIA to ensure

Director of LAPP INDIA, how challenging

that we achieve more success from an

it is to take up the entire responsibility of

organizational point of view.

the Indian operation?

In my role as the CEO, Asia Pacific at LAPP Group, I have been already very familiar with the values and principles observed by the LAPP GROUP at large.

Hence even in my current extended role as the acting Managing Director of LAPP INDIA, the guiding principles of being customer-oriented, success-oriented, family-oriented and innovative which form the crux of our operations at LAPP, still remain the same making it easier for me to take up this responsibility.

In terms of the business operations, India is definitely a very big market for the LAPP GROUP and we have a lot of growth expectations from this market.

Accordingly, we have mapped out the industries that we will specifically focus on for this year and are working towards achieving these targets. The recent set-up of phase one of the Bhopal manufacturing facility is definitely a step in this direction and will focus on the production of single core wires targeted towards the Building Cable Segment.

What is the present market scenario of Lapp India and what is the future scope?

LAPP INDIA currently caters to a market size of approximately Rs. 5-6 billion. We primarily cater to machine tool, panel builders, automation and the general industry as we specialize in control and signal cables. Further, the building and renewable energy sectors are also key emerging sectors with increasing awareness about safe cabling and efficient use of energy.

Further, expanding our operations in India has been a key focus for us, mainly due to promising growth opportunities presented by the country. The market size for single core wires (in the building segment) today stands at approximately Rs 6,000 Cr 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 Cr. The recent set-up of LAPP INDIA’s new manufacturing plant in Bhopal

will help us strengthen our base in the single core cables segment as well as cater efficiently to growing customer demands in India.

Lapp India has recently inaugurated its second manufacturing plant in Bhopal.

Can you share about your further expansion programme?

LAPP INDIA recently announced the completion of Phase 1 of its second manufacturing plant in India. A total of Rs 150 Cr is being invested to set-up this 4-phased cable manufacturing plant in Pilukedi, Rajgrah District of Bhopal. The Bhopal plant is the second LAPP INDIA facility in India after Bangalore and is spread over an area of 117,000 sq m. The 4-phased plant construction is expected to be completed over a period of 5 years and will become LAPP GROUP’s largest facility globally. With an initial investment of Rs 50 Cr, Phase 1 of the plant will produce 1,000 kms of single core cables daily, catering mainly to the Building Cable Segment (BCS).

The construction of the entire factory in Bhopal has been divided into four phases with the currently operational Phase 1 focusing on production of

Apart from this, I understand the intricacies of Indian business operations and we are working together with the

32

industrial business MART

January 2013

January 2013

industrial business MART

33

single core cable. The latter phases will

Oscar Lapp Academy, Stuttgart. LAPP

• ÖLFLEX® – versatile connecting and

focus on producing multi-core cables,

has also supplied all the demonstration

control cables: In 1959, ÖLFLEX® was the

aluminium cables and HT/LT cables

kits, display panels, training kits and

very first control cable to be designed

respectively.

various types of tools used for handling

with colour-coded wires and was at the

cables and cable accessories required

same time the first branded cable in the

for the centre. This unique centre

world. Today, ÖLFLEX® connecting and

serves as a link between industry and

control cables are some of the most

institution as through this centre the

widely used in the world, and for good

students will get exposure to the latest

reason

Lapp Group is very particular on its Corporate Social Responsibility. Tell us something about the social initiatives taken by Lapp India?

We are very conscious about our

industrial equipment and techniques

corporate social responsibility and

and the local industry will also benefit

therefore LAPP INDIA is extending

from it. LAPP INDIA is also planning to

support to HBP Indian School, which

establish 5 more Centres of Excellence

is one of the oldest English schools

in India.

in South India, for the girl child. We have adopted a building block and the science laboratory of the historically important HBP Indian School located at Shivajinagar, Bangalore. In recognition of the significance of education and more specifically practical learning for the holistic development of children and upliftment of the society at large, Lapp India Pvt. Ltd. furnished the interiors

fast, safe and forward-thinking solutions for transferring data. The range includes data cables for all electronic

Also, to extend trade relations between

applications, from tiny cables in coffee

India & Germany, our group chairman

machines to those transferring huge

Mr. Andreas Lapp founded the Indian

amounts of data in supercomputers

Business Centre Stuttgart (IBC) that is headquarters in Stuttgart. By providing fully furnished offices, technical infrastructure and expert advice, the centre aims to make it easier for Indian companies to locate in Germany.

• HITRONIC® – superfast fibre optic cables: Our optical transfer media are unbeatably fast and secure when transferring large amounts of data in inter-office communication as well as in industry. Not even electromagnetic

From the very start, Lapp Group gave

interference can affect a HITRONIC®

and also provided for its equipments.

much emphasis on Branding. Tell us

cable

Additionally the organization supported

about the journey of Brand Lapp?

lifetime maintenance of one of the three building blocks’ which houses the laboratory among other classrooms, on the premises of which the school operates.

Read this article online at http://issuu.com/mediamart

This is the brand of choice if you want

of the school’s science laboratory

the renovation and will be undertaking

34

• UNITRONIC® – innovative data cables:

Branding policies are still rare in the

SKINTOP® cable glands ensure a secure

technical field; however, LAPP has

connection in a matter of seconds. The

encouraged them right from the

universal systems are simple, perfect

very start. To give a LAPP Global

and easy to install: simply insert the

perspective, Way back in 1959, LAPP set

cable, close and go

out a definite brand policy. Giving the

Further, to nurture young minds who

products brand names was a completely

will go on to shape the development

new idea at the time, but it allowed

of tomorrow, LAPP INDIA believe in

them to be distinguished from the

engaging engineering college students

competition more easily. Oskar Lapp

through positive interaction. As a

was again one of the front runners

result of this exercise, a Lapp Centre of

and became one of the first people to

Excellence has been established in the

offer this kind of attractive branding.

PSG Engineering College, Coimbatore

These brand names are still in use at

and RV College of Engineering,

Lapp today. The most well known

Bangalore to enhance practical

brand is ÖLFLEX®, which has secured a

understanding and technology know-

place in the history of the sector. Since

how of the students and lecturers. The

then, LAPP has carried out a consistent

entire faculty members responsible for

branding policy for each of our product

this centre have been trained at the

lines namely:

industrial business MART

• SKINTOP® – the handy cable glands:

• SILVYN® – robust cable protection and supply systems: This universal range completely protects cables against dust, moisture and technical, thermal or chemical exposure • EPIC® – robust industry connectors: EPIC® rectangular or circular connectors are found in any machine and plant engineering or drive technology application used for measuring, control, regulation or drive. It is a flexible system consisting of casings, inserts, contacts and accessories which is perfectly suited to any requirement January 2013

• ETHERLINE® – active network

they stand for the values which we and

the next five years. With the slowdown,

components: Ethernet technology-based

our customers consider paramount:

the manufacturing industry has also

networks are playing an increasingly

quality, precision, and reliability.

felt the impact. More specifically, the

important role. We therefore offer reliable system solutions for network

What is the current position of Cable

technology. The range includes

Technology worldwide?

products, software solutions and

With cables being a critical component

services for total security and availability • FLEXIMARK® – the clear marking systems: These sophisticated systems

across industries, manufacturers produce multitude of cables ranging from power cables, fire safe cables,

domestic electrical equipment industry reported a 6.6% growth in FY12, as compared to 13.7% in 2010-11. Sluggish growth in power sector and escalating imports of electrical equipment is impacting the commercial viability of domestic electrical equipment industry.

facilitate durable cable marking and

single cores, multi cores and data cables.

However, we are optimistic with

ensure everything is clear and quick

According to Global Industry Analysts,

industry will be able to recover in the

Inc the wire and cable industry is

upcoming quarters.

to identify. From simple inscriptions, to labelling and marking solutions for manual marking right through to FL SOFT software for electronic recognition, this range can meet your every need However, this is driven by more than just mere desire to establish an easily recognizable product name. Strong branding gives our customers the peace of mind that each individual component allowed to carry the brand name fulfils the same high expectations. Today,

expected to generate USD 113.9 billion by the year 2015. In India, the wire and cable industry has moved from unorganized to organized over the last 20 years. However, 35% of the industry is still in the unorganized sector. There are multiple players in the market, including Indian as well as International providers and the Indian market consists of both branded and unbranded cables. Cables and wires are also imported from other countries to meet the ever growing

the Lapp brands are some of the best-

requirement.

known in the cable technology field and

The wire and cable industry comprises

have earned an outstanding reputation as a premium brand. All over the world, January 2013

40% of the entire electrical industry, which is expected to double in size over

sustained and efficient production the

Tell us about the reinvention of brand OLFLEX by Lapp Group.

Lapp Group is using the SPS IPC Drives trade show to launch two new versions of its connection and control cables, ÖLFLEX® Classic 110 and Smart 108, both tried and trusted names for over 50 years. The new arrivals from Lapp promise greater versatility, performance and efficiency. As a medium-sized family-owned company, the Lapp Group has always focused on quality and innovation, setting itself standards that are frequently higher than those accepted as the norm. The industrial business MART

35

new ÖFLEX® products have been tested

this improved standardization, ÖLFLEX®

the BSC segment. The Bhopal plant has

and optimized in in-house research and

Smart 108 is always readily available, and

test centres. Furthermore, they have

at a highly attractive price.

been divided into four phases and will be completed over a period of 5 years, post which it will become LAPP GROUP’s largest facility globally. As a result of this, LAPP INDIA, being the second largest segment within the LAPP family, is well poised to become the biggest player in the LAPP GROUP in a few years time.

also been certified by the VDE, which regularly tests them and monitors manufacturing standards.

characterized by increasingly complex demands from its various segments, a

The wide-ranging performance

growing emphasis on instant availability

characteristics of ÖLFLEX® Classic 110

and a heightened level of cost-

connection and control cables make

consciousness, these two new products

them suitable for an exceptionally broad

mean Lapp is now able to meet the

spectrum of applications. They are

specific needs of users more accurately

oil-resistant and therefore appropriate

than ever.

for use in power chains, and even suitable for applications with torsional movements, such as those typically found in wind turbines. Furthermore, unlike its predecessor, the latest ÖLFLEX® Classic 110 has an expanded temperature range stretching from -15°C to 70°C, and can even withstand up to -40°C when permanently laid. As a result, it can be installed during the cold winter months, thereby helping to cut costs. The ÖLFEX® Classic 110 is designed to cater as closely as possible to the individual requirements of Lapp Group customers. With 145 different

Lapp Group is expanding its market in the renewable energies and life science industries. Tell us something about this?

With the Government granting licenses for lot of megawatt of solar energy and with various states across India exploring deployment of solar power plants, there is a lot of potential for LAPP INDIA in the country. Further, with attractive subsidies for solar energy from the Indian Government, we expect a significant rise in business from this sector.

dimensions and up to 100 cores, there

We expect good business this year

are variants for virtually any application.

from installations in India’s solar sector,

Efficiency and sustainability are the hallmarks of ÖLFLEX® Smart 108. In an environmentally friendly solution that also helps to keep costs down, the inner layer of the outer sheath is made of recycled PVC reclaimed from in-house manufacturing processes. In addition, ÖLFLEX® Smart 108 is geared exclusively towards use in the most well-established fields, with standardized lengths and containers – and the resulting savings in logistics and packaging are passed on to the customer. The product is available in the 29 most common sizes – with up to seven cores measuring up to 2.5 mm2 – and in fixed standard lengths and containers ranging from 50 to 1,000 metres in coils and drums. Thanks to

36

Developed in response to a market

industrial business MART

mainly since cables form a critical component of solar panels and modules.

This is mainly due to the fact that cables in the solar sector need to have a longer life span as they have to be protected from ultra-violet radiation.

Your future plans for Lapp India?

The Building Connectivity Solutions (BCS) division is currently a key focus for us at LAPP INDIA, in view of the huge market opportunity identified in this segment. Keeping this is in mind, LAPP INDIA has recently inaugurated phase one of its second cable manufacturing facility in Bhopal, Madhya Pradesh which will produce 1,000 kms of single

Also, with the state-of-the art manufacturing facility in Jigani, Bangalore nearing its full capacity we plan to invest in expansion of the Bangalore plant. This will help us gear up to meet India’s growing domestic needs.

LAPP cables are largely accepted in the machine tool industry, automobile sectors and our flagship product ÖLFLEX® is popular across the industries.

Further, we are increasing capacity to focus on verticals like renewable (solar and wind), Building Connectivity Solutions and instrumentation cables for process industries.

With cables being a key component of solar panels and modules, and huge Government thrust and subsidies for solar energy being offered, this sector has huge business potential for us. While the Government has given out licences for lot of megawatt of solar energy, only a fraction of that has been deployed.

However, now with States such as Gujarat, Karnataka, Madhya Pradesh and Rajasthan moving forward to deploy solar power plants, there is lot of scope for LAPP INDIA in the domestic market.

Further the tier-II and III cities have been developing vigorously and we have been witnessing good demand from these regions. Hence we are focusing our efforts on exploring the market potential in these regions by educating buyers about the significance of quality products as opposed to the low-priced sub-standard products.

core cables daily, catering mainly to

January 2013

January 2013

industrial business MART

37

CASE STUDY NenadMackic, facility manager in the Sumber quarry, is completely satisfied: “We value the drive technology from NORD due to its high reliability and efficiency. Service and delivery availability are also the best. For good reason, we have been operating NORD products in our quarries for more than 10 years without experiencing problems�

Holcim, one of the largest producers of construction material worldwide, relies on drive technology from NORD In its cement plants and concrete factories in Croatia, geared motors of different performance classes are used. Heavy duty is no problem for the NORD products - they are ready for any challenge. That is why both companies have now completed a three-year-contract for the exchange of older drives.

Read this article online at http://issuu.com/mediamart

HolcimLtd.,for a good ten years, the corporation has been represented in Croatia with six concrete factories, a cement plant and three quarry systems.

From the beginning, Holcim Croatia has mostly used drive solutions from NORD DRIVESYSTEMS for the belt conveyor systems used in these facilities.

Drive spectrum for heavy-weight conveyor applications NORD drive systems are ideal for all types of conveyors and suitable for

38

industrial business MART

almost all grades, lengths and speeds.

Variable speed geared motors with frequency inverters are used for small bucket elevators, whilst unregulated single speed geared motors provide the higher performance required for larger systems. With an efficiency of about 95 percent, the gear units are available in a shaft, foot or flange mounted versions to suit the application. The maximum capacity is up to 200 kW with a maximum torque of 50,000 Nm.

Drive technology in the cement plant: Ex-protection is also in demand NORD drive solutions are used for all transportation and conveyor tasks in cement production. Some of the drives are designed for operation in explosive environments according to ATEX Zone 21 or 22. Primarily mid-size geared motors are used: Helical, parallel and bevel geared motors up to 45 kW, mostly with protection class IP55, depending on the respective task. A plus point for the difficult requirements is the UNICASE January 2013

concept from NORD: All bearing seats and sealing surfaces are machined in a single stage on the latest CNC machining centres. The benefits include extremely high reliability and exceptional sealing with safe handling of even the largest torques combined with high axial and radial load bearing, quiet running, low maintenance and exceptionally long operating life.

NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 2,800 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energysaving drives or explosion-protected systems. The annual sales in the 2011 fiscal year amounted to about 412 million Euro. The company founded in 1965 now has over 35 subsidiaries worldwide.

The closely meshed sales and service network ensures optimum availability for short delivery times and customeroriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 200 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units.

For further details write to NORD DrivesystemsPvt Ltd, 282/2, 283/2, Village Mann,Tal. Mulshi, Adj. Hinjewadi MIDC II, Pune 411057, Visit www.nord.com

www.iatf.in

India Automation Technology Fair 1-3 February 2013 Bombay Exhibition Centre, Mumbai Organized by:MMI India Pvt Ltd Tel: +91 22 42554700 Email: tarun.marwah@mmi-india.in

www.acma-automechanika.in

India’s Leading International Trade Fair for the Automotive Industry 7-10 February 2013 Pragati Maidan, New Delhi Organized by:Messe Frankfurt & ACMA Messe Frankfurt Trade Fairs India Pvt. Ltd. Tel: +91-22-6144 5900 Email: sagar.nanal@india.messefrankfurt.com

www.ietfindia.in

15-17 February 2013 Pragati Maidan, New Delhi Organized by:Confederation of Indian Industry Tel: +91 124 4014060-67 Email: j.shankar@cii.in

www.timtos.com.tw

Taipei International Machine Tool Show 5-10 March 2013 TWTC Nangang Exhibition Hall, Taipei Organized by:TAITRA Tel. :+91 44 30063616 E-mail: chennai@taitra.org.tw

www.techindiaexpo.com TECHINDIA will comprise four specialized events catering to individual needs of India’s manufacturing industry 3 - 5 May 2013 Chennai Trade Centre, Chennai Organized by: ITE Group Tel: +91 22 2839 8000 E-mail:nikhil.behl@itei.in

January 2013

industrial business MART

39

CASE STUDY

FELCO Trims Part Costs

Read this article online at http://issuu.com/mediamart

FELCO is perhaps the world’s leading brand name for garden secateurs, certainly Europe’s. The company manufactures around 1 million pairs every year at its Swiss headquarters, where two, fully automated Haas DT-1 CNC drill-tap machines have replaced conventional stamping with state-of-the-art machining.

Located in the village of Les Geneveys-

The company’s early products were

transfer, FELCO has differentiated itself

sur-Coffrane, around 5km from

designed to offer comfort and

by transitioning to CNC machined blades.

Neuchâtel in the French-speaking

ergonomics, inter-changeability of parts

west region of Switzerland, FELCO

and durability – attributes which have

SA is a company with a history dating

since become common features of

back to the end of World War II, when

all FELCO products. Owners of FELCO

Félix Flisch, a trained fitter and turner,

secateurs made in the 1950s and 60s can

set himself what was at the time a

still buy replacement blades and other

very ambitious goal: to create the

components, in the unlikely event that

best pruning shears and sell them in

they should fail.

Switzerland, Europe and beyond.

40

With the exception of screws and

Mr Flisch fabricated the first pair of

springs, all of the company’s secateurs

FELCO secateurs in the garage of his

components are manufactured at its

home, alongside which the current

Swiss plant - the two blades being, of

factory still sits, today. The reliability

course, the critical parts. Traditionally

inherent in their simple design, almost

these are produced by stamping,

unchanged 70years later, caught the

a process practiced by almost all

attention of winemakers at the region’s

companies in the garden tools industry

many local vineyards; with revenue

– until now. With the aid of the latest

from early sales, he set-up his nascent

Haas DT-1 drill-tap-machining centres,

business.

integrated with robot loading and

industrial business MART

“With our previous method we required several stamping machines to produce the blades,” explains the company’s Manufacturing Manager, Mr Sébastien Nussbaum. “The initial idea was to switch to an automated machining cell to mill and bore, instead of stamp. This is when we started to look for a suitable CNC machining centre.”

January 2013

the way we make our products.”

FELCO’s two Haas DT-1s combine to form a single cell using Fanuc LR Mate 200iC vision-enabled robots, set-up to orientate, load and transfer parts between the machines. The company splits the operations on the DT-1s – one for each side of the steel blades, which are handed either left or right by

by doing so we get much higher quality compared to the stamped alternatives offered by our competitors,” says Mr Nussbaum. “Not only is milling a lot faster as a complete process, there is no grinding required to finish the blades.”

The new Haas cell runs seven days a week, 24 hours a day. FELCO has factory operatives in the plant between 05:00 to 22:00, who “keep an eye on things”, but

The company installed its first Haas, an EC500 CNC horizontal machining centre, in July 2011. A VM-2 vertical machining centre followed soon after, and thanks to their performance and reliability, Haas machines also climbed swiftly up the list of potential investments for the company’s latest project: the automated blade machining cell, where Mr Nussbaum says he wanted machines that could, amongst other things, change tools quickly. The Haas DT-1 has a high-speed, side-mount, 20-pocket tool changer, where chipto-chip times are just 1.8 seconds.

“Together with a generous working area, powerful direct drive spindle and high rapids and accelerations, the Haas DT-1 machines offered me an exceptional price-specification ratio,” he says.

“They provide the foundation for a manufacturing solution that has changed

the robots. Operations to tolerances of 0.03mm include profiling, bore production, feature milling and blade point milling. Cycle times average out at around 40 seconds and annual blade volumes top 700,000!

“Today, only FELCO is milling blades, and

during the hours 22:00 to 05:00 the cell works unmanned, lights-out – a period Mr Nussbaum refers to as the “ghost shift”.

From its earliest days FELCO has sought to bring in-house every process required to manufacture its product range. This approach has allowed the company to systematically integrate technological advances into each stage of production and to enhance them with know-how acquired over 60 years. Today, FELCO is widely acknowledged as the leading brand in its field, and has six subsidiaries distributing its products in more than 120 countries.

Cutting and pruning are seasonal, of course, by their very nature. In general there is no pruning in summer, so FELCO’s production continues for stock purposes only, with sales typically recommencing in the autumn, dropping

January 2013

industrial business MART

41

off later in the year and recommencing in spring. In total, 90% of the one million secateurs produced at the FELCO factory every year are exported: 15-20% to the United States, with Europe the next big

Reflecting on how things are done differently compared to when he joined the company, Mr Nussbaum also

machines and other conventional mills, which were not suitable or reliable enough for high-volume manufacturing.

summarises the challenges of keeping

“It was also important that we

a well-established, Europe-based

improved the perception of FELCO

FELCO has a history of developing

manufacturing firm at the forefront of

as a manufacturer, bringing it into

solutions in-house, even building its

its market, given the competition it faces

the 21st century. But, it wasn’t easy.

own machines in the past. “We did our

from companies located in lower-cost

Without affordable technology like the

homework before selecting the DT1

regions of the world.

Haas machine tool cell, it wouldn’t be

market.

machines,” recalls Mr Nussbaum. “They were supplied by Haas Factory Outlet, Urma AG, and the robots were supplied

by Robotec. We preferred not to ask for a finished solution; instead, we wanted to assemble the cell and create our own process from scratch, simply because we have always done so and we have the

Read this article online at http://issuu.com/mediamart

to remove a number of old, FELCO-built

in-house expertise.

possible. Salaries 30-40 years ago were

“There were 15 people working in component manufacturing when I started in 2005,” he says, “whereas today there are only five. We’ve pushed to use CNC wherever possible, to keep costs down and quality high. As well as replacing our 15-year-old stamping

quite low in Switzerland, and critically there was little competition. But, today you need CNC and you need automation if you want to maintain quality at highvolume and you want your products to remain affordable. It’s as simple as that!”

cell, the Haas DT-1 cell has allowed us

One-on-One Personalised Performance Coaching and Group Mentoring

Problem-Solution Workshops & Consultancy

All our coaches and Mentors have 15+ years experience at Senior Management Levels and Consultancy

Practical work based end-to-end solutions.

Out facilitators have 40+ years experience.

Our performance coaching and group mentoring helps Managers achieve their maximum potential, tackle challenges and reach goals.

1. ISO/TS 16949:2009 topics: APQP, PPAP, FMEA, SPC, MSA, VE, Concurrent Engg.

2. Lean Manufacturing: TPS, 5S, Kaizen, VSM 3. Reliability and Maintainability Engineering 4. Project and Change Management 5. Business excellence model implementation 6. Dynamic strategic management

We lead you to personal and professional development, improved productivity performance and motivation and help you achieve work/life balance.

Group Mentoring via Video@Rs.4,000 a month.

To enroll email to: saravjit@10xQuality.org

Programs@Rs.20,000 per day + expenses.

For workshops and consultancy email to: info@10xQuality.org

Please visit our quality integrator website: www.10xQuality.org

42 2012 industrial business MART December

42 2013 industrial business MARTJanuary

January 2013

industrial business MART

43

QUALITY MANAGEMENT

Gemba Kaizen Japanese Road To Competitive Success GEMBA, in Japanese, means ‘real place,’ where the real action takes place. Gemba is where the value-adding activities to satisfy the customer are carried out. In manufacturing companies, the three major activities are developing, producing and selling products.

KAIZEN is a unique Japanese concept. Kaizen literally means,“to make better”. Engineers use this term kaizen to refer to continuous improvement.Gemba kaizen means continuous improvement in the work place where value-adding activities are taking place.

MUDA means waste. Any activity that does not add value is muda. People, and other resources, in gemba either add value or do not add value.

Toyota Production System,also known as Lean Manufacturing, has two interrelated components; Muda Read this article online at http://issuu.com/mediamart

and Gemba Kaizen.Muda elimination is a cost-effective way to improve productivity and reduce operating costs.

Kaizen emphasizes the elimination of muda in gembawith minimum investment.

CEO, www.10xQuality.org

44

industrial business MART

lead to spectacular results. Gemba kaizen has contributed greatly to the competitive success of Japan’s companies and to many other companies

Each kaizen improvement is small.

worldwide who have adopted lean.

However, in a company that follows

One such company is Autoliv, a giant

the kaizen process many such small

automotive components supplier.

improvements are constantly being

Saravjit Singh

small improvements accumulate and

undertaken – mostly on the shop floor and at customer contact points. These

The kaizen process involves everyone in the organization. The Japanesebelieve that all parts of our work and personal January 2013

life should be constantly improved. The

you should standardize such a

process control and control charts in

notable characteristic of Kaizen is that it

countermeasure so that the same

gemba without making efforts to clean

requires little expenditure.

problem will not recur. When a root

house, eliminate muda, or standardize.

When a production process undergoes continuous improvement for waste eliminate it leads to cleaner production.

cause has been addressed the particular problem connected with the root cause disappears.

Effective gembakaizen requires eight steps: 1. Build the right ecosystem. First

When practicing cleaner production,

In order to solve problems through

the plant manager’s first priority should

gemba kaizenwe use commonsense

be to go to gemba often and observe.

tools, checklists, and low cost

When he goes to gemba, what hesee is

techniques. This approach achieves

the real data. The reports from gembahe

significant improvement and is an

reads sitting at his desk is merely

essential building block towardstrue

secondary information.

competitiveness.

In order to use gemba management,

We should practicegemba kaizen in the

in problem solving and then follow

you should follow five gemba principles:

following three areas:

through. The ecosystem requires solid

1. Most important principle: when an

1. Housekeeping. Housekeeping is

abnormality comes to your noticethe

necessary for good management.

2. Teach and coach basic problem-solving

best thing to do is to go to gemba at

Through good housekeeping, employees

capability. Good problem-solving skills

once and see things as they really are.

acquire and practice self-discipline.

are mandatory. Employees at all levels

Employees without self- discipline make

need practical training, practice, and

it difficult for a company to provide

coaching.

2. Check with gembutsu (machines, tools, rejects, and customer complaints.)

Gembutsu means tangible things on which you can put your hands or see. If

products or services of good quality to the customer.

ntroduce an effective lean management system. This helps drive good standardize-do-check-adjust (SDCA) and plan-do-check-adjust (PDCA) thinking. It integrates solid visual controls, andon response, standard work, and regular team reflection meetings toengage

lean leadership behaviors.

3. Keep the system simple, transparent, quick, and local. Bureaucracy is the

a customer is complaining, the customer

2. Muda elimination. People in gemba

enemy of kaizen. Make it easier for

is gembutsu. If a machine is down, the

either add value or do not add value.

employees to understand the system,

machine itself is gembutsu. When a

This also applies to all other resources,

easily know the status of their ideas,

machine is down, go to gemba and have

such as machines and materials. Muda

and get quick feedback after they first

a good look at the machine.

elimination is the most cost-effective

submit their idea – say within 24 hours.

way to improve productivity and reduce

Improvement effort and connected

operating costs. Kaizen emphasizes the

decisions should be handled at the

elimination of muda in gemba.

lowest possible level, i.e., the concerned

3. First take temporary measures on the spot. For instance, if a machine is down, get it started because the show must

work team.

go on. If a customer is angry, apologize

3. Standardization. A Standard is defined

immediately. Note that such temporary

as the best way to do the job. Standards

4. Prioritize.When kaizen idea system

measures do not address the real issue.

prevent recurrence of known problems.

gets going, we may get dozens of ideas

Thistakes us to the next point.

Certain standard must be maintained at

per person per year. Such a magnitude

each process in order to assure quality.

of ideas cannot be implemented at

4. Find the root cause of the problem.

This is done by why-why analysis –

As a general rule of thumb, good

repeating the question “why” several

housekeeping in gemba reduces

times till you get to an answer that does

the failure rate by 50 percent, and

not lead to another answer when you

standardization further reduces the

ask “why”. This is the root cause.

remaining failure rate by another 50

5. Standardize to prevent recurrence.

Once you identify the root cause and come up with a countermeasure, January 2013

percent – giving a total of 75 percent reduction in failure rate. Yet, many managers elect to introduce statistical

once. Teams should apply simple ways to prioritize which ideas to take up first (for example around ideas’ impact on the team’s performance metrics and the effort required to implement). They should work on no more than a handful of ideas at a time.

5. Do not separate finding from fixing.

industrial business MART

45

Employees are truly engaged when

extends about as far as the circle of his

they “own” the improvement; meaning

“self.” See Exhibit 1.

that they themselves discover the

to the complete value stream.

Autoliv, with headquarters in Stockholm, Sweden, is the world’s largest

problem and then personally fix, or

automotive supplier ofcar airbags

help to fix it.

and seatbelts as well as passive safety

6. Provide nimble resources for

electronics and active safety systems

implementation.Effective lean

such as radar, night vision and camera

organizations invest in modest, but

vision systems. Autoliv enjoys a global

targeted resources to help facilitate

market share of approximately 35% in

daily kaizen. These resources include

passive safety and around 20% in active

setting up the kaizen promotion

safety equipment. They have operations

office.

in 29 countries and employ 50,000 employees worldwide. They follow lean

7. Share and manage the change.

Horizontal sharing of improvement ideas (yokoten) is an excellent way to recognize those who did the kaizen. This also inspires others to “borrow” and further improve on the improvement.

At the same time, have reduced bureaucracy to manage change to

manufacturing at all their plants. Exhibit To start with,employeesmay not look

2 shows the continuous improvement

beyond the “self”. So westart by training

journey over a seven year period attheir

and involving them first in “self related”

plant in Brigham City, Ohio, USA.

creature comfort kaizen for themselves.

Recognize their improvements and their creativity and share it with others.

Exhibit 2: Progression of Kaizen in one company

ensure that practical standardization is maintained where needed.

8. Promote 3C’s – Challenge, Courage and Creativity.

• Challenge. Constantly question the status quo and look for better ways to perform activities. The challenge can be stimulated by the envisioned ideal state and/or a specific target condition. It’s about closing the gaps. Challenge should provide the “pull” for improvements.

• Courage. Be ever willing to test improvement ideas and learn from trial and error. Lean leaders must actively nurture an environment within which people fearlessly (not recklessly) apply scientific thinking.

• Creativity. Doing kaizen without creativity is a sterile exercise. We need to think and act differently in order to get results.

46

The four-fold goal of kaizen is easier, better, faster, and cheaper in that order. Start with easier improvement efforts. This develops the employees’ kaizen capability.If done effectively, this develops their appetite and eyes for

Where should we start kaizen effort?

kaizen. You must then expand extend

We feel that it is best to start with an

the line of sight beyond just the self –

average employee’s line of sight that

progressing from self to team and finally

industrial business MART

One kaizen event takes about five days. In our February, 2013 Quality Management column we will discuss in detail how lean companies do kaizen. Meanwhile, if readers have any suggestions or questions they may please send an email to saravjit@10xquality.org

January 2013

January 2013

industrial business MART

47

GREEN IN

Kaizen for Environment

Read this article online at http://issuu.com/mediamart

The advent of industrial revolution has had a very profound effect on human society and mankind has benefitted greatly as a result. Advances in manufacturing technology meant that the luxuries that a very few could afford in the past are now ubiquitous (automobile, electric bulb etc.).

Vijay Allaham Consultant, Kaizen Institute 48

industrial business MART

Development in the field of transportation – starting with the steam engine and later automobiles and aircraft – mean that vast distances can now be traversed in a matter of mere hours. Improvements in the medical field have helped prolong human lifespans (Life expectancy of an average American is now 30 years more than it was a century ago).

depended largely on burning fossil fuels and our societies have become increasingly energy hungry. The rate of greenhouse gas emissions as a result of burning these fossil fuels has increased almost exponentially over the past half a century. The corresponding increase in global temperature over the same period is not a mere coincidence (see chart).

The process of industrialisation began in the UK in late 18th century and gathered pace throughout the 19th century. The US and rest of Europe industrialised rapidly in the 19th century.

But the rate of global industrialisation intensified post second world-war, in the second half of 20th century with countries like China, India and Brazil (and many others) following suit. While this has brought undoubted economic growth and advancement, the costs of development are sometimes overlooked.

The process of industrialisation has

Scientists believe that increase in greenhouse gases in the atmosphere directly contribute to global warming.

In addition, industrial and automotive emissions have made most large cities across the world almost uninhabitable.

Deforestation is occurring at an unprecedented rate in order to fulfil our insatiable appetite for raw materials and arable land. Clean drinking water is becoming scarcer across the world.

Landfills full of non-biodegradable material are now pervasive.

Unfortunately, the pace of this energyJanuary 2013

gas, oil, nuclear etc.

2. Air Emissions – a. Emissions through product or service – Harmful emissions generated during the process of making the product or service, or emissions generated during the continual use of the product or service.

hungry and resource-wasteful “growth” shows no sign of abating.

The dangers posed by this unconstrained growth are evident enough. Global temperatures are on the rise – and are projected to continue rising – wreaking untold damage across the world. Natural resources such as oil, coal, and gas however abundant today, are ultimately finite.Deteriorating quality of air and water and scarcity of water have grave implications for human well-being. In spite of this, very little meaningful action has been taken to combat these perils.

Global summitry has focused more on apportioning blame for past emissions rather than developing solutions to avert or to mitigate the effects of global warming.

Some businesses have undertaken initiative towards “sustainable” development as a part of their corporate social responsibility and individuals are beginning to develop awareness of the consequences of their actions towards climate change or global warming.

However, these are not enough and a fundamentally different way of doing things is required to moderate the impact of our activities on the environment.

The Kaizen Way Many businesses across the globe have, over the past two decades, adopted Kaizen tools and practices to improve their operations. At a fundamental level, the Kaizen philosophy espouses the identification and relentless effort to minimise or eliminate the seven kinds of Muda(or waste) from our processes.

These seven kinds of Mudaare –

January 2013

1. Overproduction – Producing more than or earlier than customer requirement.

2. Inventory – Excess raw material, workin-process or finished goods inventory.

3. Waiting – Either a part or a person or a machine waiting.

4. Defects – Producing a defective product or service.

5. Transportation – Movement of material from one place to another.

6. Motion – Movement of a person from place to place.

7. Excess Processing – Incorporating a process customer would not be willing to pay for.

These are deemed non-value added activities (i.e. they add no value to the customer or end user) and through observation and thorough analysis (through tools such as “Value Stream Mapping”) at the Gemba (place where work is done or value is added), they are identified. Improvement activities are usually geared towards minimising or eliminating them from the process.

As any Kaizen practitioner or a Kaizen practicing business would vouch, the importance of this simple philosophy cannot be overstated.

In a similar vein, our approach to environment must be fixated towards identifying and eliminating or minimising “environmental hazards”. We have classified them into five kinds and they are – 1. Use of non-renewable energy – Energy generated though sources such coal,

b. Transportation emissions – Harmful emissions generated through transportation (air, sea or road).

3. Water – a. Usage – Excess usage or wastage of water. b. Pollution – Chemicals or harmful contaminants dumped into water sources.

4. Use of non-biodegradable material – a. Direct material – Content of nonbiodegradable material in the product. b. Garbage – Content of nonbiodegradable material in disposed waste or garbage.

5. Ecological Damage – Damage wrought to ecological balance by activates such as deforestation or cutting trees or harming the habitat of certain species.

A thorough analysis of all business processes (through tools such as “Green Value Stream Mapping”) must be conducted to identify and quantify these five “environmental hazards”.

Once known, a relentless effort to minimise and eliminate these hazards from the processes must be undertaken.

Ultimately, businesses must aim to be “Carbon-Neutral”, “Water-Positive” with zero contribution to landfills and with zero ecological damage.

In the long run, if this way of thinking is adopted en masse, businesses and individuals can contribute towards arresting the negative impact of our actions on the environment. Doing nothing or carrying on in the same way that we have over the last century is simply not an option. We may not be left with an inhabitable planet within the next two generations if we do not change our ways. industrial business MART

49

MANUFACTURING EXCELLENCE

Managing a SME in India - Part 1 Journey Towards Excellence SMEs in India are backbone for industrial growth. Having recognized this, government is trying to offer many opportunities to them. Compared to big corporates, SMEs have unique strength of flexibility. Like catamaran, they can enter small lanes of water flow where big ships cannot enter. In one of earlier articles, I dwelled upon challenges of SMEs.

This series of article focuses on tips to owners or CEOs of SMEs on managing their company better when competition is catching up very high and when big corporates are trying to take share Read this article online at http://issuu.com/mediamart

of business of SMEs. Many SMEs are focusing on survival strategy than long term sustenance strategy. With thinking of survival alone, focus will be on that day and somehow do something to survive without any long term thinking on the implications of actions. SMEs need to act for long term sustenance.

P S Satish Mentor and Consultant Saraswati Industrial Services

50

industrial business MART

Gautama Buddha said, “You are able because you think you are able “. If the companies start visualizing as big corporates and start acting like them, they will catch up to grow faster. I started mentoring a company who has achieved a turnover of close to 7 crores per year after 20+ years.

Knowing well the potential of the product they are manufacturing in the market, I asked the owner why the growth is so slow when it could have been at least 30 crore Rs per year. I

1.0 Think big

was surprised by his answer when

In my observations, many of SMEs

scale industries, how can we grow so

remain small because they think small.

fast?” Problem lies here in that, many

he said, “Sir, we are running small

January 2013

companies have concluded that they

cheated them. With this one or two

Long back, one of my bosses in a

cannot grow. Think differently and big. It

experience, the owner many times do

company told me, “ As a Manager, your

will happen.

not believe any employees and start

job is to allow your subordinates to run

doing everything themselves. This

and to remove obstacles on the way”.

limits company growth. He will be

What are we doing? Many times in the

instrumental to develop a bad culture

name of guidance or non-trusting, we

in the company. In a company I visited

become or create obstacles. It is but

recently in Chennai, all cutting tools

natural for people to make mistakes.

and inserts were in a locker in owner’s

Who has learnt or mastered without a

cabin. Any operator who wants this has

mistake?

2.0 Problem is at top One of SME asked me to study their company to find out what is the problem for their growth. Before that he started telling about problems of small scale industries, not competent employees, operations, government policies etc.

For few days, I observed closely what is happening in the company.

I visited few of their key customers along with the owner to get a feel of how customer thinks of the company.

I closely interacted with the employees and studied their operations, systems and processes. The owner was curious to know about my findings after few weeks. I complemented him for his realization to study the gap and told him the root cause of problem was found.

He was shocked when he was told that the problem is not with employees, operations, systems or customers but himself. It took some time for him to digest till I explained him how his style of functioning, his thinking, indiscipline approach,not trusting employees, lack of customer orientation is affecting the company.

I saw a board in one of conference room of a corporate,” Decide whether you are the part of the problem or solution”.

Introspect yourself, start thinking with open mind and take support to change.

It may be difficult to change overnight but it is possible. Start and you can.

3.0 Trust employees

to ask the owner. His argument was that we should not believe operators

Every mistake is an opportunity for

and cutters are very expensive. I agreed

learning next step. I was talking recently

with his view but asked him to think how

to my counterpart in Chennai and

the operator feels about the company.

he narrated an incident in his career

How do we feel if mother locks all food

when he started. He was working in

in the house and we have to ask her

motorcycle company Jawa as testing

to take what we want? Employee will

engineer. He had to test motorcycle

not develop the ownership if he is not

by riding 1-2 kilo-meters at the end of

trusted. I saw ina company that CEO had

line,which he was afraid lest he will

allowed only one e-mail for the company

damage the bike, though he knew how

where about 100 employees were

to ride. His boss came to know about it

working. He wanted to look at every

and also the reason.

mail that comes to company and answer should go with his consent.

January 2013

you are going to ride for testing and

The logic was that his managers do

I want you to damage at-least 2 bikes

not know how to write and by writing

“. My friend started and there were no

something wrong may bring a bad name

accidents. His confidence increased. In

to the company. Good control but the

companies, we ask employees to run

question is will it work when you want

with too many restrictions and obstacles.

to grow? What do you do? Should you

Toyota culture encourages employees to

trust everybody and everything blindly?

make mistakes so that they learn better.

Answer is no.

Do not be an obstacle but a remover of it. Employees are capable of running and

I came across a German proverb which

allow them. Ask them to make mistakes.

says “ Vertrauen ist gut aber Kontrolle ist

It is rewarding.

besser “ meaning that trusting is good but control is better. The cost of trust in

I will continue the article in the next

the long range is lower than not trusting.

issue. Please send your inputs, remarks,

Develop a mechanism of control or

suggestions to P.S. Satish, Mentor

check to ensure person is trustworthy.

and Trainer, M/s Saraswati Industrial

Trust your employees. They are good

Services, Q-103, Mantri Paradise

and capable. If not,they will be when you

Apartments, Bannerghatta Road,

trust them.

Bangalore-560076. Mobile: 9845043202 Email :gotopssatish@gmail.com Wishing

If we go to any SME, we hear a typical story that someone trusted very high

He said to my friend one day, “ Today

4.0 Allow employees to run

good day to you all.

industrial business MART

51

RESPONSIBLE FAIR BUSINESS MART

Being Responsible is a Brand The brand has traditionally been a focus of company’s communication with the customers. Companies especially with a large consumer base - communicate a bundle of benefits through their Brand positioning.

In the battle for market share, products and brand differentiation is carefully designed towards different segments in the product space. The entire advertising Industry is created to persuade predetermined groups of consumers by using controlled communications to Readthis thisarticle articleonline onlineatat http://issuu.com/mediamart http://issuu.com/mediamart Read

push an image or benefit of the offer.

industrial business MART

intercepted by the opinions of co consumers. They discuss, evaluate, and make independent judgment. Most influencing factor in this judgmental process is the Companies Responsibility status in terms of promises, deliverables, services & value co- creation with them.

Earlier the brands were created by advertising and communication. No

The rise of Active Consumer has

more, now it evolves from the quality

shattered the old company centric

of experience. The consumer can very

model of Brand Creation. Advertising is

easily assign RESPONSIBLE OR NON

been substituted by word of mouth.

RESPONSIBLE tag to each company they

Web-linked consumer communities

52

from Company to consumer is now

the Internet & dot-com., advertisers techniques are losing their effectiveness.

Vivin Agarwal

Communication which once flowed

The first dent in this system came from discovered that traditional persuasive

Product Architect & Social Entrepreneur

assessment.

deal with.

have access to the information to

Now a company’s transition to capture

make decision and declare their own

this new opportunity is embedded January 2013

with an image which is rated on a

goes to the heart of creating trust and

address the customers’ expectations,

Responsibility scale. The fact that the

graduate to be “Responsible”

this is no focus stage.

The company can push products and

This is followed by the reactive stage.

services to the consumer in many

Company graduates to understand the

ways, if it does, the result is likely to

expressed desires of the customers

be a set of fragmented and vastly

and identify their problems and start

an advertiser.

varying experiences for customers. The

attending to them as and how they arise.

“Being Responsible” becomes major

a consistent quality of experience across

image makeover in the company’s brand

multiple channels, which qualifies them

management exercise. The new focus

to be recognised as being Responsible.

Brand is now rooted in an individual’s experience has demolishes the myths of traditional advertising. The experience is the outcome of one’s interaction, which cannot be predetermined or pushed by

must be fostering consistent feelers in this domain. A collective experience of the customers that creates the trust and in turn defines the Brand. Creating a unified experience across multiple domains such as banking, engineering, travel, hospitality, healthcare etc. represent a new challenge to firms that

January 2013

challenge to managers is one of ensuring

In the third stage it is responsive. A responsive company doesn’t merely react to customer’s complaints; it performs consistently and without

Different stages of establishing the

complaint, demonstrating through

Responsible tag.

voluntarily actions its concern for

Companies have evolved through several stages in their practice of managing customers and their reactions.

Let us assume the company cannot

customer satisfaction. A responsive company might call back a defective product and replace it for free.

In both the reactive and responsive

industrial business MART

53

CROSS WORD

Fundamentals of Aluminium Metallurgy Production, Processing and Applications

Edited by: R Lumley, CSIRO Light Metal Flagship, Australia Year of Publication: November 2010 Price: 19750/Aluminium is an important metal in manufacturing, due to its versatile properties and the many applications of both the processed metal and its alloys in different industries. ‘Fundamentals of Aluminium Metallurgy’ provides a comprehensive overview of the production, properties and processing of aluminium, and its applications in manufacturing industries.

Read this article online at http://issuu.com/mediamart

The book is divided into three parts. Part 1 provides a comprehensive overview of production and casting of alluminium and its alloys. Readers can have a brief

The Second Part considers metallurgical properties of aluminium, fundamentals and models of work hardening and its application to industrial alloys, the commercial trends and the future.

Part 3 shows us the processing and application of aluminium and its alloys to specific industry areas such as Aerospace. Here, one can find out the

mechanical joining, fusion welding, solid state welding, aluminium sheet fabrication and the Rapid Prototyping of aluminium.

The book has been dealt with a wide range of data , facts, figures, case studies and designs as per the industry basis. With its distinguished editor and team of expert contributors, ‘Fundamentals of Aluminium Metallurgy’ is a standard reference for researchers in metallurgy, as well as all those involved in the manufacture and use of aluminium products.

stage the company is still concerned

technologies, products, services and

the customers but to being educated

entirely with the current products and

opportunities of the future has already

by them as well. The customers do not

services. In fourth Anticipatory stage,

cost the business dearly.

become loyal instead become passionate

the company moves beyond these limitations.

Traditional one-way format of

advocates and activist for the company.

business promotion- press release,

It is believed that in time, new

Anticipating is shaping expectations-

advertisements, publicity stunts-- can

approaches and tools consistent with

educating current and potential

not engage the customer in a dialogue

a new responsive based assessment of

consumers as to what the world could

that they are part of the business, the

a company will emerge that will offset

be like. If only a few companies are doing

company is responsive to them.

the current practices of influencing the

the job of anticipating, even a few have reached the shaping stage. Failure to educate consumers about the emerging

54

idea of how the raw materials used in the aluminium production process, energy efficiency in the utilization of carbon anodes and the past, present and future of primary aluminium production.

industrial business MART

Inviting them in a purposeful dialogue

customers.

means being open not only to educating January 2013

January 2013

industrial business MART

55

TECHNO MART

Emergency Stop Button with Illuminated Base and Safety Light Curtain with Integral Muting New safety products from Banner Engineering also increase productivity. An innovative illuminated Emergency Stop button and a Safety Light Curtain with integral Muting have been introduced by Banner Engineering.

are available with 30 mm mounting base or in surface flush-mount configuration.

They are CE compliant to ISO 13850 and IEC 60204-1.

Integral Muting eliminates need for external module or controller Banner’s new EZ-SCREEN Low-Profile Safety Light Curtain has a built-in muting function that reduces installation and wiring costs. Seven predefined muting configuration options are available, including Bypass, Mute-Dependent Override, Mute Enable, and Mute-cycle time extensions for “L”-style cell exit applications. Setup can be performed

New illuminated Emergency Stop button from Banner Engineering glows yellow when armed, changing to flashing red when alarm button is pressed.

First stop button to combine action and

button to reduce downtime. Multiple

status indication

buttons can be connected with CSS

The new U.S. patent-pending 30 mm mount Emergency Stop pushbutton Read this article online at http://issuu.com/mediamart

combines safety operation and high visibility status indication in one

Series Hookup Cordsets, and some models are compatible with popular safety bus I/O gateways.

The illuminated Emergency Stop buttons

housing for the first time. With no assembly, individual wiring or additional enclosure required, the E-Stop enhances

Illuminated Emergency Stop button is available with 30 mm mounting base (shown) or flush mount enclosures.

productivity as well as safety.

The button base is illuminated in yellow when the button is armed and the

without a PC or other device; DIP switch

machine is running or enabled to run.

configuration features many of the same

When the button is pushed, the steady

functions as a standard EZ-SCREEN.

yellow turns to flashing red, allowing quick identification of the actuated

56

industrial business MART

Multiple illuminated E-Stop buttons can be connected with CSS Series Hookup Cordsets.

With a variety of sizes up to 1.8m, end-

January 2013

to-end sensing and compact design, the

and wireless network products. The

two-piece optoelectronic device creates

company provides local application

a “screen� of synchronized infrared

support worldwide.

sensing beams to guard machine hazards.

For further details write to Banner Engineering India Pvt. Ltd. Tel:

The low-profile, low power consumption

+91-(0)20-6640-5624 Email: salesindia@

screen is designed for use on smaller

bannerengineering.com

production machines but is robust enough for large power presses. It is FMEA tested to ensure control reliability and third party CE certified to Type 4 (IEC61496), Category 4 PLe (EN/ISO 13849-1), SIL3 (IEC61508).

Banner Engineering is a leading manufacturer of vision, photoelectric With integral muting function, the new EZ-SCREEN Low-Profile Safety Light curtain facilitates setup, reduces wiring requirements and cuts installation costs.

January 2013

and ultrasonic sensors, fiber optic assemblies, machine guarding systems, measurement and inspection systems

Muting allows entry and exit of materials but keeps personnel safeguarded from machine hazards

industrial business MART

57

TECHNO MART

Renishaw Equator™ 300 Versatile gauging takes a step up Following the widespread success of the Equator™ 300 gauging system launched in 2011, supported by a turnkey installation service and global support network, Renishaw has expanded the range with the new Equator 300 Extended Height system. Developed in response to customer needs, it provides users with extra fixturing space below the measuring volume.

This new variant allows components to be transferred onto the machine on their machining fixtures and also allows the use of automated systems such as robots and conveyors. The system can inspect features on parts up to 300 mm tall, with rapid changeover to smaller parts using an extended fixture plate spacer.

Since its launch Equator systems have been installed in multiple automotive, aerospace, medical and electronic companies across the world. Users have been attracted by the reduced purchase, maintenance and fixture costs compared to traditional gauges, plus the ability to gauge multiple parts and to re-program for design changes. Equator 300 Extended Height systems have already been supplied to customers looking for the flexibility allowed by an extra 150 mm height below the measuring volume.

Read this article online at http://issuu.com/mediamart

In seconds, users can load parts that are still attached to the fixtures used during machining operations. The Equator fixture plate can be easily exchanged for other plates, each mounted to the Equator base using highly repeatable three-point kinematic seats. The plates can also be exchanged for fixture plate spacers, allowing smaller parts on their own fixture plates to be gauged in the same measuring volume.

Turnkey installations Since the launch of the Equator gauging system in 2011, many customers have also taken advantage of the turnkey programming service offered by Renishaw and its partners. Using

58

industrial business MART

Renishaw’s comprehensive MODUS™ software, experienced engineers work closely with a customer to generate programs that allow a wide range of parts to be gauged on a single Equator system.

A customer’s shop-floor staff then simply select and run programs using the intuitive Modus™ Organiser operator front-end software, requiring little or no training. The Organiser software can report gauging results with a simple ‘pass’ or ‘fail’ message, while also allowing a full inspection report to be viewed.

Global support Reflecting the international nature of many modern manufacturing organisations, Equator customers have been able to take advantage of Renishaw’s extensive network of Equator support engineers. Projects initiated in one country or region can be easily transferred and locally supported in multiple locations.

Renishaw now has approaching 70 regional support offices and multiple approved partners, covering every industrialised area of the world.

traditional dedicated gauging, filling a gap in the market never before addressed. The patented low-cost design, unique in construction and method of operation, is capable of high-speed comparative gauging for inspection of high-volume manufactured parts. Equator is a lightweight, fast and highly repeatable gauge that operators can use with ‘push-button’ simplicity. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines.

Thermal stability Equator’s innovative and highly repeatable gauging technology is based on the traditional comparison of production parts to a reference master part. Re-mastering is as swift as measuring a production part and immediately compensates for any change in the thermal conditions of a shop-floor environment. Equator

Equator principle of operation Equator is a radical alternative to January 2013

can be used in factories with wide temperature variation – simply re-master and the system is ‘re-zeroed’, ready for repeatable comparison to the master.

With the calibration file loaded into the Equator software, measurements made in the Equator system can be referred back to the CAD or drawing nominals.

Traceability to calibrated CMMs

Low-cost fixturing

Master parts do not need to be expensive custom parts like those used on a traditional gauge; users simply take a production part and measure it on a co-ordinate measuring machine (CMM) to establish the variation from CAD or drawing nominals. The results from CMMs can be configured to be used directly within the Equator software.

Compared to dedicated gauging, Equator cuts fixture costs considerably.

By using fixturing that positions parts to within 1 mm of where the master was measured, there is no significant effect on system repeatability and the need for expensive precision fixtures is removed.

Effectively, the calibrated absolute accuracy of the CMM (often located in remote temperature controlled rooms to ensure accuracy) can be ‘extended’ onto the shop floor to provide calibrated traceability to Equator measurements.

January 2013

Integrated stylus changing Further versatility is offered by the Equator-specific stylus changing rack, included in the purchase price of an Equator system, which allows automated in-cycle changing of SH25 stylus holders. The SH25 holders couple

to the industry-standard Renishaw SP25 probe, allowing Equator users to swap the stylus configurations without re-qualifying each time. Up to six stylus combinations can be loaded into the rack at any time and they can be used on a single complex part or with multiple parts of varying geometries.

The versatile gauge Equator is unique in its design and method of operation, and has already changed the thinking of hundreds of production engineers, making Equator the new gauge of choice. The versatility and repeatability Equator offers is redefining the world of gauging.

For further information on our gauging range visit www.renishaw.com/gauging

industrial business MART

59

TECHNO MART

Mayr - New application limits for torque limiting clutches Perfect torque limiting clutches for test stands Test stand applications place highest demands on torque limiting clutches, which quickly overstrain the standard designs available on the market. Therefore, mayr® power transmission has developed new torque limiting clutches, which meet the demands and which are suitable for speed values of up to 16,000 revolutions per minute.

Read this article online at http://issuu.com/mediamart

As worldwide market leaders, mayr® power transmission has offered the widest range of products in load-holding, load-separating, torque and forcelimiting, frictionally locking, positive locking, magnetic, controllable and switchable torque limiting clutches for decades. Despite this extensive selection, the company permanently records demands from all different branches for new, application-optimised torque limiting clutches, as the standard type series available on the market are

they must be able to transmit the torque in a backlash-free and torsionally rigid manner. In case of malfunctions, protection of the high-quality systems must be guaranteed. When dealing with high speeds, the only expedient option is a residual torque-free separating (disengaging) torque limiting clutch, so that in case of overload, the rotational energy stored in the uncoupled masses can slow down freely.

With the type series EAS®-HSC and EAS®-HSE, mayr® power transmission has developed new torque limiting clutches tailored for the extreme demands of test stand technology.

Both construction series are based on tried and tested design principles, which have proven their worth for decades.

The basic prerequisite for the application of a torque limiting clutch in high-speed applications is, among other things, a On the test stand clutch EAS®-HSE, individual overload elements high balance quality in each transmit and limit the torque. The torque can be varied greatly via the number of elements and the layering of the installed cup individual component, in springs. order to reach optimum running smoothness of the drive line unable to fulfil the increased demands on combination of the components. optimally.

When speeds increase, imbalances cause substantial centrifugal forces Test stand technology is one of these and vibrations. This puts a strain on application areas. Here, torque limiting the entire test stand construction, clutches must primarily be suitable for leads to uneven running and falsifies extremely high speeds. Furthermore, the test results of the measurement

60

industrial business MART

devices. Therefore, optimising the mass imbalance was a top priority in the development of the new high-speed clutches.

In comparison to the standard torque limiting clutches available on the market, the new test stand clutches EAS®-HSC and EAS®-HSE provide numerous technical features. At first glance, the extremely compact design of the clutches is noticeable. The high performance density reduces the rotating masses and has a positive effect on the running smoothness and the machine dynamics.

Torque limiting clutches consist of many individual components, which must not change their positions within the clutch in mounted condition and also in case of overload. This is guaranteed through certain design features. Furthermore, the clutch is balanced in completely installed condition to a balance quality of G2,5, reference speed 3000 rpm.

In order to guarantee that the completely installed torque limiting clutch, which is set to the respective torque and balanced, also provides the required balance quality after integration into the customer system, the joint clearance between the customer shaft and the clutch bore is minimised. The clutch bores are designed in quality 6 in the standard series. Furthermore, the frictionally locking shaft-hub connection guarantees backlash-free torque transmission.

January 2013

positive locking. In case of overload, these overload elements disengage and separate the input and output almost residual torque-free with high switch-off and repetitive accuracies. The kinetic energy of the rotating masses, which is stored in the system, can slow down freely. The elements do not re-engage automatically. They remain separated until they are re-engaged manually or via a device. The position for synchronous re-engagement to maintain the balance quality is clearly marked on the clutch.

Disengaging, backlash-free EAS®-torque limiting clutch in combination with a backlash-free ROBA®DS all-steel disk pack coupling, installed into a test stand at ThyssenKrupp EGM, Langenhagen.

External reaction forces which have an effect on the output flange of the high-speed clutches are absorbed by a high-quality clutch bearing, and therefore do not influence the disengagement mechanism. The precise torque limitation remains intact. In case of blockage of the drive line, the torque limiting clutch disengages instantly. The input side to output side of the EASHigh Speed is accelerated extremely quickly. The high-quality clutch bearing is designed to absorb these accelerations.

After overload occurrence, too, the position of the individual components to each other must not change. On clutch disengagement, the input and output are rotated in relation to one another.

Therefore, it must be guaranteed that the initial position is re-established after re-engagement. That is why the new test stand clutches are disengaging, with synchronous re-engagement.

On the EAS®-HSC, the torque in normal operation is transferred via balls which engage simultaneously into the grooves of the hub and the output flange.

Cup springs pre-tension the balls via a ring. The amount of spring force is proportional to the transmittable torque.

January 2013

This principle also remains backlash-free in case of wear on the grooves. mayr® power transmission uses cup springs with falling characteristic curve in their torque limiting clutches. This means that the torque is transmitted torsionally rigidly until the pre-set disengagement value is reached. In case of overload, the spring pre-tension force is reduced, and the clutch disengages precisely.

After disengagement, a special disengagement mechanism ensures that the clutch remains disengaged. The drive line can slow down freely. During the stopping time, there are no engagement impacts, which might have a negative effect on the drive line, in particular on the torque measurement device. The torque transmission unit is designed so that re-engagement is only possible at the disengagement position. This means that the individual components of the clutch always have the same angular position to each other during operation, and the balance quality is maintained.

The special disengagement mechanism enables easy, fast re-engagement without major expenditure of force.

The new test stand clutches are supplied in flange design for the attachment of customer-side elements or with torsionally rigid single-jointed or double-jointed disk pack couplings. In addition to the classic connection of 2 shafts, mayr® power transmission offers adaptor flanges for the direct integration of standard measurement flanges. This enables extremely compact overall designs.

The EAS®-HSC type series covers a nominal torque range of 5 to 1,000 Nm with 5 construction sizes. Depending on the size, speeds of 6,000 to 12,000 rpm are permitted. For the EAS®-HSE type series, 3 sizes for torque values of 500 to 5,700 Nm have been realised up to now.

Plans have been made for four additional sizes. The complete type series will be able to cover torque values of 300 to 25,000 Nm and speeds of up to 16,000 rpm.

Due to their characteristics, the new torque limiting clutches EAS®-HSC and EAS®-HSE are not only suitable for test stands, but are also the perfect solution for all other high-speed drive axes.

For further details write to National Engineering Company (NENCO), J-225, MIDC Bhosari, Pune 411026 Tel: +91/2027474529 Email: nenco@nenco.org

On the EAS®-HSE, individual overload elements transmit the torque via industrial business MART

61

en Messe

Industry meeting Academia to cultivate future ‘think-tanks’ Development will only follow in our country when the industry will meet the academia and this year, Indian Machine Tool Manufacturers’ Association is going to spot the light again on this issue at IMTEX by arranging “Academia- Industry Synergy” which is the need of the hour. During IMTEX, IMTMA has held a special interaction space for the students of various engineering colleges and the leaders of different manufacturing association, technocrats, and entrepreneurs from SMEs as well as the researchers from high-end technical institutions.

The whole initiative named “Jagruti”,

note to involve the second-generation

the industry in large. The ‘action plans’

which is an endeavour of “Udaan” was

entrepreneurs, emerging leaders and

are segmented under four categories:

highly paid attention during previous

young professionals of the machine tool

Leadership, Management, Vision and

IMTEX and this year also the organizers

industry into the mainstream activities

People.

expect a massive attendance from the

of the industry. Thus, the tagline is

enthusiastic engineering students.

very tuned to the objectives: Emerging

“We in IMTEX give the opportunity to

Leaders Expanding Horizons.

After developing self-identity, an entrepreneur can focus on leadership development and through self-

the industry as well as the academia to

Udaan members consist of the young

empowerment and setting high goals

interact with each other solving their

entrepreneurs, young professionals

and values; family and professional

queries and opening new windows

being nurtured with CEOs/COOs as well

management can be combined up.

towards development. This year

as the second generation of the family-

Academia – Industry synergy should

“ Jagruti” has been held up for all

owned enterprises. Its key objectives

be addressed in a larger perspective to

engineering students who wants to

are to nurture, develop and foster

share and learn best business practices.

make their career in manufacturing

leadership development, to groom

Udaan, doing this, is actually selling

firm, entrepreneurs from small

fresh talent giving them the confidence

exciting future of Machine Tools to

scale industries to learn and share

to think creatively and individually and

young engineers.

the basic fundamentals.”, said Mr.

to encourage and enlist their active

Shailesh.R.Sheth, the past President and

participation in all initiative of Industry

the Chairman, Media of IMTEX 2013.

and Association.

Indian Machine Tools Manufacturers’

Udaan has framed its own charter and

synergies. Colleges should come out with

Association has formed this club named

to execute this, all Udaan members have

projects like special visit to industries,

“Udaan” much earlier with a positive

set up ‘Action Plans’ for the group and

plant visit, seminars where the students

As Machine Tool is the basic of all manufacturing industries, every industry should identify and encourage these

can meet business leaders, make Read this article online at http://issuu.com/mediamart

presentation of their own manufacturing solutions, develop and sustain information regarding R&D as well as the industry people can also learn about the latest research on the technologies and manufacturing solutions. IITs and IIMs are already in execution of this kind of seminars. It will definitely help to re-define work-life balance making India globally competitive.

To know more about ‘Udaan’, please contact Mr. Srinjoy Das at srinjoy@imtma.in

62

industrial business MART

January 2013

Online High Pressure Washing, Ultrasonic Cleaning, Drying and Inspection System from NTB Subject system includes the following sections : 1. Washing Section : Equipped with largeopening plastic modular belt conveyor with side-walls. Components pass through multistage high pressure, high velocity jets of water and/or solvent from both top & bottom sides of the conveyor .High washing efficiency is achieved with a recycle system using a double diaphragm pump. After washing the components are transferred to Ultrasonic large-opening plastic modular belt conveyor.

2. Ultrasonic Online Cleaning Section : Ultrasonic waves generating transducers are built into the chamber of this section, just under the side-wall conveyor belt. Vacuum Bubbles formed due to cavitation collapse with enormous energy and pressure resulting

January 2013

into effective surface cleaning of the moving components.

3. Hot Air Drying Section : Components from ultrasonic cleaning section are then transferred to the high efficiency hot air dryer for continuous drying of wet components.

Washing Section

Ultrasonic Cleaning

4. Inspection Conveyors : This stage is equipped with belt suitable conveyors driven with a variable frequency drive for online inspection of components.

Applications :Online industrial ultrasonic cleaners are used in automotive, sporting, printing, marine, ceramics products,medical, pharmaceutical, electroplating, disk drive components, engineering and weapons industries.

For further details contact NTB International Pvt Ltd, 622/2,Kuruli, Pune - Nasik Highway, Tal: Khed, Dist: Pune- 410501 Tel: +91 2135 309 201/ 235,Cell no.9322594371 E-Mail: conveyor@ntbindia.com, j.muralidhar@ntbindia.com

industrial business MART

63

Ref Number : 7153622 Tender Number : 112MMETT12000088 Tender Prod. No : 112MMETT12000088 Buyer/Seller : Ordnance Factory Board Requirement : Supply of Herring Bone Gear Location : Katni - Madhya Pradesh Document Fees : INR250 EMD : INR246,000 Estimated Cost : INR8,200,000 Closing Date : 31/01/2013 at 17:00 Hrs. Contact Details : Rajesh Bhide 07622-227871 / 224082 General Manager, Ordnance Factory, Katni, Madhya Pradesh -483 503 Document Sale To: 31-1-2013 at 17:00 Hrs

Ref Number : 7159137 Tender Number : 2012000316 Buyer/Seller : Ordnance Factory Board Requirement : Supply of Herring Bone Gear Location : Katni Madhya Pradesh Document Fees : Rs.250 EMD : Rs. 246,000 Closing Date : 31/01/2013 at 17:00 Hrs.

Ref Number : 6975005 Tender Number : NCL/SGR/MMD/112A1081/82 Buyer/Seller : Northern Coalfields Limited Requirement : Conclusion of Rate contract (valid for one year) for supply Of worm wheel and worm pinion of p and h 1900 al shovel Location : Singrauli - Madhya PradeshDocument Fees : Rs.5,000 EMD : Rs.206,000 Estimated Cost : Rs.10,300,000 Closing Date : 31/01/2013 at 13:00 Hrs. Contact Details : Northern Coalfields Limited Singrauli, Madhya Pradesh Document Sale To: 31-1-2013 at 11:00 Hrs

Ref Number : 7123240 Tender Number : SWR/TM.506/YPR/S/TN/2012-13/03 Tender Prod. No : SWR/TM.506/YPR/S/TN/2012-13/03 Buyer/Seller : South Western Railway Requirement : Supply of Hydraulic Filters Location : Hubli - Karnataka - India Document Fees : INR172 EMD : INR2,000 Estimated Cost : INR95,600 Closing Date : 30/01/2013 at 15:00 Hrs. Contact Details : Shri D.G Diwate 0836-2289801. PCE office Head Quarters General Manger Complex, South Western Railway Club Road, Keshwapur, Hubli- 580023 Document Sale To: 30-1-2013 at 15:00 Hrs

Ref Number : 7129678 Tender Number : SWR/TM.506/YPR/S/TN/2012-13/03 Tender Prod. No : SWR/TM.506/YPR/S/TN/2012-13/03 Buyer/Seller : South Western Railway Requirement : Supply of Hydraulic Filters as per description mentioned in schedule Location : Hubli - Karnataka - India Document Fees : INR172 EMD : INR2,000 Estimated Cost : INR95,600 Closing Date : 30/01/2013 at 15:00 Hrs. Contact Details : Shri D.G Diwate 0836-2289801. PCE office Head Quarters, General Manger Complex, South Western Railway Club Road, Keshwapur, Hubli- 580023 Document Sale To: 30-1-2013 at 15:00 Hrs

Ref Number : 7151933 Tender Number : 2420122505 Tender Prod. No : 2420122505 Buyer/Seller : Chittaranjan Locomotive Works Requirement : Supply of Pneumatic Chisel For more detailed please log on to www.ireps.gov.in Location : Multi Location - Multi State - India Closing Date : 29/01/2013 at 00:00 Hrs. Contact Details : Chittaranjan Locomotive Works

Ref Number : 7137759 Buyer/Seller : Punjab Rural Water Supply And Sanitation Project Requirement : Providing & installing 200mm i/d straight Tube well with Reverse Rotary Rig up to 150 mm depth, Pump chamber, pumping machinery, disinfection unit and distribution pipe etc.

Construction of one No. RCC OHSR 100000 Itrs capacity having height 25.00 mtr up to FSL and 20.50 m up to bottom slab as per DWSS standard.

Location : Ludhiana - Punjab - India Estimated Cost : Rs.4,168,079 Closing Date : 30/01/2013 at 14:00 Hrs. Contact Details : Punjab Rural Water Supply & Sanitation Project, Ludhiana, Punjab Document Sale To: 26-1-2013 at 17:00 Hrs

Ref Number : 7137659 Tender Number : 65/2012 Buyer/Seller : Public Health Engineering Department Requirement : Drilling of Tube well, Hand Pump Installation & Platform Construction Location : Sarguja - Chhattisgarh - India Document Fees : Rs.750 EMD : Rs.11,960 Estimated Cost : Rs.598,000 Closing Date : 30/01/2013 at 17:00 Hrs. Contact Details : Public Health Engineering Department, Sarguja, Chhattisgarh Document Sale To: 28-1-2013 at 17:30 Hrs

Ref Number : 7157333 Buyer/Seller : Punjab Rural Water Supply And Sanitation Project Requirement : Providing Sewerage Scheme & Sewage Treatment Plant at the Village Rampur Kalan.

Supplying And Laying Of Upvc Pipes, Construction Of Sewage Treatment Plant Based On Waste Stabilization Pond Technology Of 0.224 MLD Capacity Including Pumping Station, Collecting Tank, Machinery, Specials, And Site Development Complete In All Respects Location : Patiala - Punjab - India Document Fees : Rs.5,610 EMD: Rs.253,000 Estimated Cost:Rs.12,671,000 Closing Date: 30/01/2013 at 17:00 Hrs. Contact Details: Punjab Rural Water Supply & Sanitation Project , Patiala, Punjab

Ref Number : 7117212 Tender Number : Tender Prod. No : Buyer/Seller : Eastern Coalfields Limited Requirement : Supply of 4 sets 250MH x 38 LPS Centrifugal Pump Set completion with Motor, Starter, Cable and other Accessories to operate in Indian Coal Mines Location : Burdwan - West Bengal Document Fees : INR5,675 EMD : INR111,942 Estimated Cost : INR5,597,088 Closing Date : 29/01/2013 at 13:00 Hrs. Contact Details : R P Pandey, 03416451079 General Manager (PR), Eastern Coalfields Limited, Sanctoria, Dishergarh, Burdwan, West Bengal, 713333

Ref Number : 7123316 Tender Number : SO(MM)/KTA/HEMM/NIT/12-13/1081 Tender Prod. No : SO(MM)/KTA/HEMM/NIT/12-13/1081 Buyer/Seller : Central Coalfields Limited Requirement : Supply of Spares – Gear Brake, Spring, Disc Fiction, Screw Flatihead, Plate Pressure, Screw Hsfh, Spring, Roto Seal, Switch Pressure, Valve Solenoid, Leven Trip, Pinion Crowd Motor, Shoe Slid, Plate Yoke Slid, Arm Lever for 182M,10 Cum Marion Shovel.

Location : Ranchi - Jharkhand - India Document Fees : INR2,000 EMD : INR20,772 Estimated Cost : INR1,038,600 Closing Date : 29/01/2013 at 13:00 Hrs. Contact Details : Gksingh, 06512360716/257 Darbhabga House, Ranchi, Jharkhand-834001 Document Sale To: 28-1-2013 at 16:30 Hrs

Ref Number : 6975419 Tender Number : NCL/SGR/ MMD/111A1093/85 Buyer/Seller : Northern Coalfields Limited Requirement : Conclusion of rate contract valid for two years for supply of spares of orbitrol valve assembly for bh 85 t dumper.

Location : Singrauli - Madhya Pradesh Document Fees : Rs.5,000 Estimated Cost : Rs.14,000,000 Closing Date : 29/01/2013 at 13:00 Hrs. Contact Details : Northern Coalfields Limited Chief manager(mm), nclhqrs., Singrauli, MP. Tel # 9406711641, Document Sale To: 29-1-2013 at 11:00 Hrs

Powered by:

The Global Tender Portal

64

industrial business MART

Get Access To 20 Lakh Global Tenders Annum only on www.TenderTiger.com Contact : Mr. Amit Bhanushali – Chief Manager, e-Procurement Technologies Ltd, B 704-705, Wall Street 2, Near Orient Club, Opp. Gujarat College,Ellisbridge, Ahmedabad 380006, Gujarat, Ph: (+91) (79) 4027 0506 – 90 Fax: (+91) (79) 4027 0516 Mob: (+91) 93745 19764 / 93745 30073. Email: amit@TenderTiger.com, sales@TenderTiger.com January 2013

THE LAST LEAF Dear Readers, Heartiest New Year Greetings for 2013! Emerald has been declared the official colour of this year. It signifies growth, renewal and prosperity through its lively, radiant and lush green colour. It is a symbol of regeneration, accomplished through Persistence.

Persistence gives confidence and continued right mental attitude followed by consistent action, which in turn brings success. A legacy in form of Sachin Tendulkar, India’s most admired sportsperson, proved this fact -time and again - in the past two decades of his Cricket Career. His recent retirement from the ODI Cricket was a reminder of this quality.

With the passage of 2012, there have been various lists of Most Admired People, and Most Admired Companies that have been published revealing the people and the companies who made greatest impact during the year. Barack Obama and Hillary Clinton were voted the Most Admired Man and Woman for 2012, as per a survey. Apple Google, and Amazon were sequentially the top three most admired companies as per FORTUNE’s survey. Such companies are structured for long terms and are able to deal with shortterm opportunities and threats. They go to great lengths to create the right conditions for their people to thrive. Finally, they make sure they have the right leaders and the right talent. Following are the four essential ingredients of their recipe for success : Strategic excellence, Structures and processes that sustain performance over time, Achieving success through their people, Placing a high value on leadership and talent.

The arrival of 2013 is also important for the ‘Internet’, a revolutionary and cheap communications system that has transformed the lives of billions of people across the world, since it turns 30 now. The computer network officially began its technological revolution when it fully substituted previous networking systems on January 1, 1983.

Meanwhile, a gauge of raw-material prices ranging from burlap to steel may point to improving global growth amid signs of an industrial recovery in China and the United States, the biggest users of commodities. As always, Chinese economic growth could give a real shot of adrenaline to many commodities, say most of the fund managers. In fact, some of them opined of a global resurgence in commodities markets. In fact, Wheat posted the biggest gain in 2012, among the 19 commodities in the Thomson ReutersJefferies CRB index, soaring 19.2% despite falling for three straight months. Corn and Soya beans were the next gainers, despite drought during the year. (Courtesy The Economic 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)

January 2013

industrial business MART

65

Window to the industrial world now comes out with a “Secure Wallet”

Gift Partner

“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”

66

mediamart

i n f o t e c h

industrial business MART

No: 217, 3B Main, OMBR Layout, Bangalore - 560 043, India Tel: +91 85530 12371/ 72 Fax: +91 80 25426934 Email: info@martinfotech.in Visist www.martinfotech.in January 2013

Looking for Sales Representatives in Europe and Asia

RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012/2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month