Mart May 2016 by MART INFOMEDIA PRIVATE LIMITED

Volume 12 Issue 11 May 2016 ` 100

VISIONS BECOME REALITY MECHATRONIC HANDLING

Cluster and Vendor Development in MSME Sector Set to Facilitate ‘Make in India’ Mission Time to Embrace the Change in Manufacturing Predictive Industrial Maintenance through Internet of Things Challenges and Opportunities to become a Global OEM Supplier

VISIT US AT

STALL NO : C- 43

May 2016

“CUSTOM-MADE SOLUTIONS CAN FETCH GREAT RESULTS” Nagraj C M Managing Director, Right Engineers

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May 2016

Renishaw Solutions Centres... lowering the barriers to Additive Manufacturing UK

Stuttgart Shanghai

Chicago

Pune

Toronto

Dallas

Renishaw Solutions Centres - your pathway to innovative AM products Renishaw Solutions Centres provide a secure development environment in which you can build your knowledge and confidence using AM technology. Equipped with the latest AM, machining and metrology systems staffed with knowledgeable engineers, a Solutions Centre offers you a fast and accessible way to rapidly deploy this exciting technology in your business. Renishaw will support you throughout your investigation and business case development process, helping you to optimise your design, build your confidence in the process, and gain the evidence you need to make investment decisions.

For more information visit www.renishaw.co.in/solutionscentres

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

www.renishaw.co.in May 2016

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May 2016

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May 2016

foreword Vendor, Excellence! Hi Readers, Dubai always strives hard to achieve what other cities not even dreamt of! In the midst of desert they created a wonderful city in Palm Jumeriah, Palm Islands, Burj Khalifa to name a few, all stands tall in the world by its uniqueness. The latest to add into their achievements are the world’s first ever 3D printed office which was built at a cost of around USD 1,40,000 and just took 17 days to complete. The building was constructed through a 3D printer owned by Winsun Global, Chinese Company, measuring 20Ft long and 40Ft wide. The initial printing was done at China and then shipped to Dubai, and took just 2 days to assemble the basic structure. Curved shape was given in the design of the building for safety and stability purpose and constructed with a special mixture of cement. With a work area of around 250Sq Ft the building is dubbed as the “Office of the Future”. It’s no doubt Additive Manufacturing is going to bring great revolution in our daily life. From facial reconstruction to precision aerospace engineering we are witnessing the growth of 3D Printing technology in the manufacturing sector. Being committed to bring world class technology to India, UK based global engineering solutions company Renishaw is opening its new Additive Manufacturing Solution Centre in Pune on 15th June 2016. The new facility will help their customers to expand their knowledge and confidence on Additive Manufacturing. In their latest press release Renishaw states that they see the new Indian Centre as a corner stone in its ambition to be a major contributor to the adoption of AM in the established and fast growing high technology Indian manufacturing sector. We wish Team Renishaw all the very best for the new venture and sure Indian manufacturers are going to get benefited with this step. It’s a fact that India is still at an infant stage when it comes to Manufacturing. For the first time ever the country as a whole is trying to bring investments on manufacturing and project it as a cost effective quality manufacturing global destination. Several OEMs are setting up their manufacturing unit in our country, and the challenge they will be facing is to procure components locally. Importing and assembling products locally is not going to make much difference on the cost factor as well as help our economy. For that creating quality vendor network is essential. It’s not possible to produce quality in a short time. Quality comes with hardship and time, and the responsibility lies between all stake holders – Policy Makers, OEMs as well as Vendors. Discussing Vendor Development and management in detail is our main story for this edition. MART is the media partner for ACMEE 2016 exhibition at Chennai, the leading manufacturing expo organized by Ambattur Industries Association. Please do visit us and collect a free copy from our stall at C-43, a preview of the expo published in this edition. We included our regular contents in this edition along with the interview of Mr. Nagaraj C M, Managing Director, Right Engineers Bangalore, who recently expanded their manufacturing facility at Jigani Industrial Area, Bangalore. We are sure you will find our contents useful, and do write back with your feedback to make MART, SMART! Signing Off,

Hari Shanker hari@martinfotech.in May 2016

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24 MAIN STORY

10 INNOVATIONS

Cluster and Vendor Development in MSME Sector Set to Facilitate ‘Make in India’ Mission

28 Time to Embrace the Change in Manufacturing

Predictive Industrial Maintenance through Internet of Things

34 Challenges and Opportunities to become a Global OEM Supplier

36 Robust performance at peak times Volume 12 Issue 11 May 2016 Annual Subscription `1200 Member INS Editorial Advisory Board

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

Mart Infomedia Private Limited

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

CONTENTS 40

Nagraj C M Managing Director, Right Engineers

ON FACE

Columns

52 Building a High Performance Culture – Why Leaders are pivotal?

Managing stress in the Organization

44 SPECIAL FEATURE

56 CASE STUDY

74 TECHNICAL FEATURE

84 97

MART UPDATE THE LAST LEAF

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Hari Shanker

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Priya Kundu

HR & Admin

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Regional Office Chennai Bangalore Delhi

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

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

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E4.1L from igus – Low weight, easy assembly and cable-friendly design The universal solution is now available in new sizes from stock

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Due to the modular design, the E4.1L energy chain can be adapted to any specific application. As an open standard version for cable routing, with brackets for hoses, or enclosed in a chip-resistant tube in a guide trough – just three of many customising options. (Source: igus GmbH)

Optimum use of installation space, light weight and high stability – these are just some of the benefits of the E4.1L energy chain from igus, which is now available in new heights and widths from stock. Compared to the E4.1, weight can be reduced by 30 percent, with this light version, meaning that the chain is well suited to highly dynamic applications. It was developed especially for unsupported applications; long gliding travels are also possible with the e-chain. The E4.1L of the motion plastics specialist igus combines the strengths of different series of chains from igus and also has a design that is very kind to all the surfaces in contact with the cables. “Rounded edges of the crossbars and separators of the chain ensure a long service life of hoses and cables,”

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explains Harald Nehring, authorized representative for e-chain systems at igus. “You can therefore call E4.1L an energy chain in which the moving cables feel at ease.” In addition to the rounded surfaces that come in contact with cables, gridding and positioning scales are used for the best possible separation of the chain. Along with the easy assembly and high stability it displays its strengths especially in fast unsupported applications, such as in automation or in machine tools. Technical tricks for design freedom The simple snap-open mechanism of the crossbars in the outer and inner radius ensures a quick filling of the e-chain. The captive crossbars, which can be

opened with a screwdriver, open by 115 degrees and latch into final position. If necessary, they can even be removed completely, placed again and closed by simply pressing in. The patented positive-fit tongue and groove of the chain links and the double stop dogs with large stop surfaces that allow a high degree of stability were carried over from the heavy duty E4.1 chain. Here a ‘brake’ also ensures a lower rolling noise and a very smooth chain travel. Due to the variable mounting of the outer links, the chain can be installed either with or without camber. This is a decisive advantage especially in limited installation space, such as in machine tools. “Perhaps the best e-chain in the world” Compared to E4.1, the

application-oriented design of the E4.1 L could save so much mass that the chain is about 30 percent lighter. This brings an additional advantage: “In this way, users save not only a lot of drive power,” says Harald Nehring, “it can also accommodate more hoses and cables in a given space envelope – all these advantages perhaps make the E4.1L the best e-chain in the world.” The energy chain is now available from stock in more interior heights between 31 and 64 millimetres and new widths, as well as fully enclosed options for the protection against chips. As for the open energy chain, igus also has an ESD version and even a high-temperature option for the enclosed energy tube. For more details, please visit: www.igus.in

May 2016

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Hengstler ACURO® AX65 is market’s most compact explosion-proof absolute encoder

Just two screws are required to secure the terminal box

AX65 is differentiated by its compact dimensions

Users can choose from SSI or CANopen interface options

Offering dimensions of 70 mm depth and 59 mm diameter – typically half the size of conventional explosion-proof encoders – the new ACURO® AX65 encoder from Hengstler will prove extremely valuable to system designers seeking space-saving solutions (image 1). Furthermore, the fact that the device can be replaced separately from the cable, the presence of fewer hood screws, and the potential for ring network configuration (less wiring), makes the AX65 an attractive proposition for customers looking to lower their total cost of ownership (TCO). Among numerous attributes, international explosionproof certification (both ATEX and IECEx for mining, gas, dust) makes the AX65 ideal for global markets that include oil and gas platforms, mines and chemical plants to list but a few. Moreover, the design team at Hengstler has also ensured the AX65 is equally adept in environments subject to constant salt water exposure (thanks to the use of a marine-grade stainless steel

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housing), while shock resistance of 2000 m/s² and axial/radial shaft load capability of 300 N brings into a range a whole host of applications such as enamelling production line equipment, bottling machines, mixers and silo works, for example. Despite its size, there is almost no compromise on performance with the AX65. The unit has been subjected to extensive trials at selected customer sites, particularly those suffering previous encoder failures due to a lack of robustness. Typical customer test applications included providing accurate and reliable position feedback in cranes, winches and other types of materials handling equipment deployed on both offshore and onshore oil drilling equipment. Importantly, the encoder is able to function in ambient temperatures down to -40°C.

takes place magnetically), the AX65 is particularly resistant to shock (200 G) and vibration (30 G). The use of magnetic technology for both the singleturn scan and the encoder’s new electronic multi-turn, makes the AX65 extremely reliable in harsh operation environments.

The new multi-turn is completely self-sufficient (no battery) and is devoid of contact parts and gears to ensure zero wear and long operating life. Indeed, low TCO is a particular feature of the AX65. For instance, not only can the encoder be installed quickly and easily due to its flexible, quick-connect terminal system, but in the event of servicing, the entire encoder can be replaced separately from the cable. This represents a significant advantage since many platforms use cables of 40m in length or more. Such cables are heavy and cumbersome, and must be laid in No issues of insufficient ducts. Replacing both the cable robustness were reported with and the encoder can therefore be the AX65 encoder over the course extremely challenging and costly of the three-year trials. As the if they cannot be exchanged decoder has no disc (scanning individually.

Another ease-of-maintenance design innovation is the use of just two screws for the terminal box of this IP66/IP67 rated device (image 2). Hengstler is aware than many comparable encoders use six or even eight screws, while insufficient corrosion protection makes such units very difficult to uninstall. Instead, special agglutinated screws are deployed on the AX65 to protect against dust, water and corrosion. Further value-added design innovations include a shaft load rating that reduces the need for load modules, and a choice of SSI or CANopen interface, which can save wiring costs by allowing a ring network configuration (image 3). Ultimately, no matter how demanding or challenging the application, the compact and cost effective AX65 brings a guarantee of safety and reliability that represents a step-change in the selection, deployment and servicing of explosion-proof encoders. For more details visit www.hengstler.de

May 2016

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Dormer adds new carbide burrs and cobalt drill

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Dormer has added several new material specific carbide rotary burrs to its existing assortment. The ST cut geometry is suitable for machining steels, while the VA design is for machining stainless steels. Available in a variety of shapes, both offer improved operator control and generate less temperature which, in turn, increases tool life.

These latest designs offer

to its burrs assortment.

improved performance

This includes five piece

and up to 50 per cent

sets featuring the ST cut

higher metal removal

for steels, the VA design

rates, compared to

for stainless steel and

standard carbide burrs. In

a coated Double Cut

addition, the new GRP cut

set. Dormer launched

inverted cones varieties.

tool life.

Meanwhile, a new high

Its addition supports

speed cobalt (HSS-E)

Dormer’s existing high

jobber drill has been

speed steel (HSS) quick

launched by Dormer.

spiral jobber drill – the

The A147 is primarily for

A108 – which also machines

is for machining fibreglass

its new range of carbide

machining stainless steel

stainless steel in general

and composite materials.

burrs 12 months ago to

and titanium. Capable

applications. Dormer’s

Available with drill point

enhance its ancillary tools

of drilling to depths up

versatile A147 can also be

program for general

to 6xD, the Bright finish

used for a wide variety of

machining applications.

A147 features a split point geometry. This improves

materials including steel,

The comprehensive

exit surface quality.

assortment of designs and

penetration through

shapes include ball nosed

the work-piece allowing

To download a pdf version

To support the

cylinder, pointed tree,

for reduced torque

of the new carbide burrs

introduction, Dormer has

oval, flame, 60° and 90°

requirements, improved

brochure visit www.

added three new sets

countersinks, cones and

hole-quality and longer

dormerpramet.com

and end mill styles, its design reduces splintering and improves entry and

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copper and aluminium.

May 2016

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Motion Control Solutions for Any Mission, For Any Environment

Ultra-High Current, Ultra Rugged, Ultra Small Servo Drives

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May 2016

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FabX 3 from Redd Robotics- High end functions at a low end price

FabX has launched the third generation of its famous budget 3D printer which is introduced with a simple mission to bring high-end functions to the budget realm.

The FabX 3 retails at just $499 and yet it comes loaded with features that we have become accustomed to seeing in highend printers. The highlights

The goodies just keep coming, too, with an LED-illuminated cabin and bottom, twin cooling

a printer that is aimed at

more than any other single

beginners, but it’s versatile

development globally and the

and can print 20-50mm/s at a

same wave has started to take

resolution of 50-300 microns.

place in India,” he said. “Low

The nozzle temperature gets

cost 3D printers are catalysts

up to 500 degrees Fahrenheit

for the professional as well as consumers.”

include a full aluminium frame,

fans and high-grade materials

SD card support and auto bed

that should help improve the

and it can handle a variety of

levelling and calibration to

quality of the finished product

materials. They include the

ensure a perfect first foundation

each and every time. A Hiwin

printer’s favourites PLA, PET-G

each and every time. A Bowden

linear guide rail and an ultracore

and T-Glass, but it is also hot

mechanism with moving weights

XY axis are sturdy components

enough to deal with metal

combats vibrations during the

that should stand the test of

composite filaments that could

print process.

time.

open up new avenues for the

An E3D series nozzle, a

The powder-coated aluminium

removable and magnetic build

home printer.

Redd Robotics was launched in 2013 and brought Indian costs and innovation to the global world of robotics, consumer electronics, the Internet of Things and, of course, 3D printing. It now has offices

frame provides rigidity and

Mr. Surendranath Reddy, the

across India and is working on

strength, as well as a sleek look,

CEO, CTO and founder of Redd

opening branches in Singapore

Robotics, is clearly happy with

and the US. The company is

that can affect the final outcome.

his work. “The increased sale

committed to constant evolution

of 3D printers over the past

and this is clear in its 3D printer

touch of a button. This will save

The build volume of

few years has taken additive

line-up. For more details visit

you time and materials in the

120x120x120mm means it’s

manufacturing mainstream

www.redd.co.in

plate and one-touch printing also feature on the FabX. In fact, you can start, stop and pause the whole process with the single

long run.

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that help eliminate vibrations

May 2016

Intelligent Drivesystems, Worldwide services Intelligent Drivesystems, Worldwide services

COMPLETE DRIVE SYSTEMS FROM A SINGLE SOURCE

National Product News_base.pdf

06/04/2016

15:12

The modular structure of our products guarantees maximum variability and flexibility for the The modular structure of our products guarantees maximum variability and flexibility for the configuration of a wide range of individual drive solutions from a single source. High efficiency configuration of a wide range of individual drive solutions from a single source. High efficiency gear units combined with energy-efficient motors and decentralised or centralised frequency gear units combined with energy-efficient motors and decentralised or centralised frequency inverters provide a wide range of system solutions with great efficiency and economy. inverters provide a wide range of system solutions with great efficiency and economy.

www.nord.com www.nord.com

NORD DRIVESYSTEMS Pvt.Ltd. NORD DRIVESYSTEMS Pvt.Ltd. 282/2, 283/2, plot no. 15, Village Mann, Taluka Mulshi 282/2, 283/2, plot no. 15, Village Mann, Taluka Mulshi Adj.Hinjewadi MIDC-II, Pune411057 Maharashtra INDIA Adj.Hinjewadi MIDC-II, Pune411057 Maharashtra INDIA Toll Free No. 1800 200 2042 Toll Free No. 1800 200 2042 India@nord.com, www.nord.com India@nord.com, www.nord.com Member of the NORD DRIVESYSTEMS GROUP Member of the NORD DRIVESYSTEMS GROUP

May 2016

D DR RIIV VE ES SY YS STTE EM MS S www.martupdate.com

Industrial gear units with 190 kNm output torque

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Even more comprehensive UNICASE gear unit portfolio

A new size in the NORD industrial gear unit range provides the proven advantages: high load capacity, applicationspecific configuration, and flexible installation

NORD DRIVESYSTEMS extends

nominal transmission ratios

adapters, turbo couplings,

closely meshed sales and

the successful industrial gear

from 7.1:1 to 400:1, or even up

axial fans, motor swing bases,

service network ensures

unit range by adding a new size

to 30,000:1 with an auxiliary

torque limiting backstops, and

optimum availability for short

with 190 kNm output torque.

primary stage.

cooling and heating systems are

delivery times and customer-

available as well.

oriented services.

can be freely selected. NORD

NORD DRIVESYSTEMS develops,

NORD produces a wide variety

industrial gear units can be

produces and sells drive

of drive units for torques

mounted on any of the six sides.

technologies with around

from 10 to 200,000 Nm,

The manufacturer configures

3.200 employees, and is one

electric motors with powers

industrial geared motors for

of the international leaders

a diverse range of uses from

in the industry. In addition

from 0.12 kW to 1,000 kW as

Featuring a single-piece UNICASE

steel works to process plants.

to standard drives, NORD

housing as is standard for all

Application-specific features

supplies application-specific

NORD gear units, they achieve

and options include reinforced

concepts and solutions, even

a longer bearing life than gear

bearings and shafts, extra-large

for special applications, for

casings manufactured from

bearing distance, extended

example with energy-saving

jointed parts and ensure efficient

output shafts, and Drywell

drives or explosion-protected

power transmission and high

designs with an additional

systems. Gross sales amounted

tolerance for load peaks and

oil drip disc and a leakage oil

to approx. EUR 540 mn in the

jolts. They can be assembled as

display or oil sensor. Disc and

2015 business year. The company

two or three-stage helical inline

drum brakes, dual-gear setups,

founded in 1965 now has over

For more details visit

or helical bevel gearboxes with

auxiliary motors, IEC motor

36 subsidiaries worldwide. The

www.nord.com

The series now comprises nine sizes and covers torques from 25 kNm to 250 kNm. The addition of the new size 14 units allows for configurations tailored even more precisely to individual applications.

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The input and output direction

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.

May 2016

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StruxureWare Data Center Operation v8.0

Latest Schneider Electric DCIM suite bridges the gap between facilities and IT, enhances capabilities for colocation providers

Schneider Electric, a global specialist in energy management and automation, introduced StruxureWare Data Center Operation v8.0, an enhancement to Schneider Electric’s StruxureWare for Data Centers, Data Center Infrastructure Management (DCIM) suite. Data Center Operation v8.0 includes new functionalities that enable a higher level of asset visibility for key data center stakeholders, including tenants in colocation environments, and across both IT and facilities. This empowers businesses to prosper by managing their data centers across multiple domains, providing actionable intelligence for an ideal balance of high availability and peak efficiency throughout the entire data center life cycle. “Data center managers – across enterprises and colocated facilities – are facing a growing number of challenges as they look to keep up with the pace of business, including industry-wide shifts in capacity and performance needs, in an increasingly competitive market,” said Soeren Brogaard

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Jensen, vice president, Solution Software, IT Business, Schneider Electric. “Schneider Electric’s StuxureWare Data Center Operation v8.0 provides the asset visibility, capacity planning capabilities and risk management functionality data center users need to optimize the performance and efficiency of their system while also enabling business growth through new services offers for clients.” Building on already existing features of StruxureWare Data Center Operation that simplify data center management, new capabilities in v8.0 include: • Web Client: allows user visibility into data center assets, power usage and power capacity via any modern web browser. This lowers maintenance costs and empowers managers to make better and more informed real-time decisions. • Tenant Portal: expands on Schneider Electric’s commitment to colocators and their customers by enabling colocation providers to offer

additional services on the basis of their DCIM solution, including management of individual tenant services. The portal provides tenants with an instant overview of their hosted data center solution, including insight into the rooms, cages and racks, reserved capacity, measured power and rack temperature. Tenants also have access to a KPI dashboard. Through the portal, tenants can view their assets without direct access to the colocator’s local network. The colocation provider can, with a single mouse click, enable or disable the tenant portal access for each individual tenant, and decide what information is shared. • Direct Current Capacity Planning and Risk Management: Schneider Electric is the first and only DCIM vendor to offer direct current capacity planning and risk management as well as the ability to support a mixed power infrastructure (both AC and DC). This enables data center managers to model DC-powered devices within their data center, allowing them to more intelligently and accurately plan

capacity and assess risk for the DC power path. • Predicted Power: provides rack and breaker level capacity planning and the potential to unlock stranded capacity as estimated load values are automatically derived from actual power measurements. StruxureWare Data Center Operation v8.0 will be available in June through Schneider Electric and its partners. StruxureWare for Data Centers management software suite is designed to collect and manage data about a data center’s assets, resource use and operation status throughout the data center lifecycle. This information is then distributed, integrated, and applied in ways that help managers optimize the data center’s performance and meet IT, business and service oriented goals. From IT assets to racks, rows, rooms and buildings, StruxureWare for Data Centers delivers the right information to the right users at the right time. For more information on Schneider Electric’s complete line of DCIM solutions, visit www.schneider-electric.com

May 2016

Witness a true international event with state-of-the-art infrastructure

Venue: The Exhibition Center, Helipad Ground, Gandhinagar, Gujarat, INDIA.

May 2016

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Time synchronization in the nanosecond range with IXXAT software

Adding to the existing and proven IXXAT IEEE 1588 solutions, HMS now presents protocol software for IEEE 802.1AS – the first commercially available software package for highly accurate time synchronization of AVB and TSN networks.

IEEE 802.1 AS is an adapted

– and has a modular structure

synchronization times (< 1

develops and manufactures

version of the IEEE 1588

with a clear separation of the

microsecond within one second)

solutions for connecting

profile – specially designed

media dependent and media

and optimization of memory

automation devices and

for AVB and TSN systems

independent layers. This

usage.

systems to industrialnetworks

(audio/video broadcasting and

enables easy porting and fast

time sensitive networking).

implementation into various

As the most important core

target systems. As a time-

technology for AVB and

aware, slave-only end station,

TSN systems, IEEE 802.1AS

the software is the receiver

enables high-precision time

of time-synchronization

synchronization of devices and

information provided by a

systems.

products such as the IEEE 1588

under the Netbiter, Anybus and IXXAT brands.

protocol software, the IP Core

Development and

and the manager tool, HMS also

manufacturing take place

offers a wide range of services

at the headquarters in

based on the deep experience in

Halmstad, Sweden and in

grandmaster and enables

the IEEE 1588 area. HMS assists

Ravensburg, Germany. Local

synchronization of local

the customers in all phases of

sales and support are handled

Using the IXXAT IEEE 802.1AS

Real Time Clocks (RTCs).

the development process, from

by branch offices in China,

protocol software, customers

The software supports the

consulting and specification,

Denmark, France, Germany,

benefit from a proven and

Best Master Clock algorithm,

to implementation, target

India, Italy, Japan, UK, and

tested software package as

which can be optionally

adaptation and testing of the

USA. HMS employs over 350

well as from a professional

disabled.

final product.

people and reported sales of

further development.

In addition to meeting the

HMS Industrial Networks is the

requirements of AVB and

leading independent supplier

The 802.1AS protocol software

TSN systems, special needs

of products for industrial

offered by HMS comes as ANSI

within automotive systems

communication including

For more details visit

C code – inspired by MISRA-C

are supported such as fast

remote management. HMS

www.ixxat.com/1588

product maintenance and

Besides other IXXAT IEEE 1588

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57 million EUR in 2013. HMS is listed on the NASDAQ OMX in Stockholm.

May 2016

I N N O VAT I O N

New High Torque 24DCT Coreless Brush DC Motor

Portescap introduces the new DCT range of Athlonix™ Brush DC motors. The 24DCT miniature motor features Portescap’s proven energy efficient coreless design with an optimized self-supporting coil and magnetic circuit which ensures higher performance is delivered, all in a compact 24mm diameter size.

With torque carrying capabilities reaching up to 14.96 mNm, the 24DCT provides high performance with efficiency reaching up to 90% while maintaining a long lifetime. Due to the inherent design of the 24DCT motor, it can deliver higher torque per ampere which leads to better battery life. This makes it ideal for battery driven applications such as medical and industrial pumps, drug delivery systems, robotic systems (bionic fingers), miniature industrial power tools, tattoo machines,

May 2016

mesotherapy guns, dental tools, watch winders and more. Other applications such as lab automation, security and access and humanoid robots can also excel using the 24DCT Athlonix motor.

life of the motor.

Athlonix 24DCT miniature dc motors are available in 2 variations, precious metal commutation and graphite commutation with a Neo magnet inside. The unique constant force spring design for carbon brush provides consistent performance. An REE (Restriction of Electro Erosion) coil is an available option, which prolongs the

Sunil Kumar, Brush DC

“Athlonix motors are powered by a proprietary self-supporting coil resulting in maximized magnetic flux and ampere-turns for a given diameter” says Product Line Manager at Portescap. “In contrast, typical self-supporting coils have inherent ampere-turns limitations that affect the magnetic flux density in the magnetic circuit, which further limits power output and endurance of the motor”. Component standardization

and design modularity allow quick customization capability for samples across various applications. Standard configurations can be delivered with maximum one week lead-time Athlonix motors are compatible with encoders and gearheads of various sizes and ratios and are also available on our online motor configurator MotionCompass™. They are manufactured in an ISO certified facility, and are RoHS compliant. For more details visit www.portescap.com

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MAIN STORY

Cluster and Vendor Development in MSME Sector Set to Facilitate ‘Make in India’ Mission One of the key aspects of Indian economy is India’s vibrant Medium & Small Scale Enterprises (MSME) sector. The MSME sector in India in divers in terms of its size, levels of technology employed and range of products and services starting from grass root village auto components, micro processors, electronic components and electro medical devices.

Arnab Mondal arnab.mondal@email.com

MSMEs have shown constant growth rate of 10% in recent years much ahead of the large-scale corporate sector. This sector contributes 8% of India’s GDP, 45% of the manufactured output and 40% per cent of its exports. MSMEs provide employment to over 80 million people through over 36 million enterprises producing over six thousand products. India is one of the few countries which have a legal framework for the MSME sector in the form of MSME Act 2006. The MSME sector finds its importance several times increased in the wake of Government’s ‘Make in India’ campaign, a move aimed at assisting Indian firms in and attracting global firms to invest and

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partner in India’s prospective manufacturing sector. For a thriving MSME sector clusterization and vendor development are imperative. While clusterization is defined as the concentration of similar industries of same scale within the same geographical boundary, vendor development is a concept practiced by big MNCs of moving from manufacturing in entirety to procurement of different parts or equipment and assembling at the OEM end. Cluster and vendor development however expands beyond the limitation of MSMEs and to large scale economic organizational activity and produce excellent results for (local assistance and market). Clusters have gained increasing prominence in debates on economic development in recent years.

Governments worldwide regard clusters as potential devices of enterprise development and innovation. Cluster initiatives are also considered to be efficient policy instruments in that they allow for concentration of resources and funding in targeted areas with a high growth and development potential that can spread beyond the largest locations. Example of international renowned clusters such as that of the Silicon Valley cluster in California, the Information Technology cluster of Bangalore in India, or the Chilean and Australian wine clusters demonstrate that clusters are environments where enterprises can develop a competitive and global edge, while at the same time generating wealth and local economic development in the process.

Another inevitable move to this end is vendor development. In post globalization scenario, the competitiveness in world economy in manufacturing has pushed the large MNCs or brands or OEMs to assembly lines for the components procured from the vendors. However, to provide price competitiveness the OEMs need to get the best deal from the vendors as well as make sure that the technologies applied are of global standards. MSMEs developed as vendors play an important role in the economic development of countries worldwide. In the last decade or so, OEMs and governments have put enough efforts to nurture skills and capabilities of vendors. National Manufacturing Competitiveness Programme is one such initiatives run by the government. The

May 2016

MSMEs provide employment to over 80 million people through over 36 million enterprises producing over six thousand products.

National Manufacturing Competitiveness Programme (NMCP) for the MSMEs, aims at enhancing the competitiveness of enterprise in this sector. There are various components of the NMCP, which have been approved and are available for MSMEs. These are:• Lean Manufacturing Competitiveness Scheme (LMCS) for MSMEs • Design Clinics Scheme for design expertise to MSMEs manufacturing sector • Marketing Assistance and Technology Upgradation Scheme for MSMEs • Enabling manufacturing sector to be competitive through Quality Management Standards (QMS) and Quality Technology Tools (QTS). • Technology of Quality Upgradation Support for MSMEs • Promotion of Information

May 2016

and Communication Technology (ICT) in MSME sector. • Building Awareness on Intellectual Rights for MSMEs • Scheme for Providing Support for “Entrepreneurial and Managerial Developments of SMEs through Incubators”. Major achievement under various programmes to promote cluster & vendor development: The Government of India notified Public Procurement Policy for MSMEs, vide Order dated 23 March 2012 (effective from 1 April 2012) for goods produced and services rendered by micro and small enterprises. The Policy mandates that all the central ministries/departments CPSUs shall produce minimum of 20% of their annual value of goods/ services required by them from micro and small enterprises. For developing MSE vendors, all the ministries/departments/ CPUs have been urged to organize Vendor Development

Programmes (VDP) and a buyer-seller meets between MSE-suppliers and government procurement agencies. In 2013-14, 56 CPUs organised 1007 VDP for MSEs. The Office of Development Commissioner (MSME) through its fieldDevelopment Institutes has planned for the year 2014-15 to organize over 55 National Vendor Development Programmes throughout the country in order to develop MSE Vendor with a budget allocation of Rs. 5 crore for 2014-15. The Ministry of MSME has adopted the cluster approach for holistic development of micro and small enterprises in a cost effective manner. Soft Interventions(such as diagnostic study, capacity building, marketing development, export promotion, skill development, technology upgradation, organizing workshops , seminars, training, study visits, exposure visits, etc.) , Hard intervention (setting up of common Facility Centres) and infrastructure upgradation

(create/ upgrade infrastructural facilities in the existing industrial/ clusters of MSEs). A total of 848 interventions in various clusters spread over 28 States and one UTs in country have so far been taken under the programme for Diagnostic study, soft and hard interventions. The efforts under the scheme are focused on covering of more and more clusters from all States / UTs. So far sanctions of Rs. 41.50 crore have been issued till 30th November, 2014 during the current financial year under MSE-CDP. To ensure transparency and speedy implementation of MSE-CDP, online application system has already been started from 1st April 2012. So far, 32 clusters with financial assistance-9 clusters out of these have already been established benefitting more than 14,000 artisans. Under the National Manufacturing Competitiveness Programme Rs. 14 crore is earmarked for implementation of lean manufacturing technology in

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100 mini clusters. Rs. 135 crore will be spent on setting up 5 common facility centres and 5 infrastructure development centre under MSE Cluster Development Programme. 65 National Vendor Development Programme (NVDP) and 200 State Vendor Development Programmes (SVDP) will be organised during 2016-17. Further 300 Rurban clusters will be developd under the Shyamaprasad Mukherjee Rurban Mission to incubate growth centres in rural areas by providing infrastructure amenities and market access for the farmers. They will also expand employment opportunity for youth. Government policies apart, the MSMEs and OEMs have taken on steps to improve the quality of service and rendered and overall cluster and vendor development. Due to small, MSME individually are unable to realize the economies of scale and thus find it difficult to take advantage

of market opportunities that require the delivery of large stocks of standardized products or compliance with international standards. Even so, located within the cluster the MSMEs face barrier to growth and become nonperforming clusters which has much to do with their isolation in terms of lack of proper facility, unwillingness in adopting new technology. This is where the concerted effort from the vendors, OEMSs, customer companies/ donor companies play a big role in obviating the obstacles. Spatial proximity and shared strategic interests allow enterprises and their support institutions to realize shared gains through the organization of joint actions between cluster enterprises and between enterprises and their support institutions (provision of technical assistance or investment in infrastructure

by customer company/ private sector/ public. This reaps collective efficiency such way. Also to nullify the disadvantage of size either alliance should be be shared or formed with similar firms to increase the rate of market penetration. Often differences arise on both MSMEs and OEMs ends. MSMEs complain of delayed payments, longer credit demands from customer companies, lack of technical support and push for adapting capital intensive technologies from the customer company. However, in the last decade the customer companies have become more inclined towards developing better manufacturing facilities and manufacturing process and vendor during its development. OEM s put their best effort to source components of assured quality duly inspected and certified. Like in automotive sector consistent quality maintenance of vendors are

upgraded and redefined as Direct on Line suppliers. OEMs ensure that the vendors are accreditated to QMS and they undergo third party audit for the purpose. OEMs help in grouping the vendors in the form of clusters which participated in collective training module programme on QMS, TQM, and TPM. The vendors are also keen on improving areas like Entrepreneurs Resource Planning, inventory management and just in time supply system with the help from the customer companies. And lastly to motivate clusters and vendors annual award schemes based upon their annual performances and maximum share of component schedule. Cohesive approach from the MSMEs, OEMs and government are on the right trajectory for the development of cluster and vendor development. â&#x20AC;&#x2DC;Make in Indiaâ&#x20AC;&#x2122; is all set make it big from the development of cluster and vendor system in the MSME sector.

Like in automotive sector consistent quality maintenance of vendors are upgraded and redefined as Direct on Line suppliers

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May 2016

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MAIN STORY

Time to Embrace the Change in Manufacturing Growth and sophistication in the manufacturing industry has opened Pandora’s Box with many never seen before challenges. These challenges are forcing the industry to change. This time change is ruthlessly fast and furious. Keeping ahead of the competition is the ultimate test of endurance and responsiveness for major global manufacturing giants. Inevitably Supply Chain becomes integral part of success for these OEMs. All major successful organisations have been doing exceptionally well on selecting, managing and developing their supplier base.

Khushal Birari khushal.birari@woodwad.com

Paradigm is shifting. Rules of the games are changing. OEMs are keeping very core activities with themselves. Some of them have even gone to the extent of not having any in-house manufacturing at all. Suppliers & Vendors have becomes partners & strategic extended manufacturing collaborators. Supplier base is no more just buying and selling shops. Concept of LCC or BCC is diminishing. Innovation and automation is giving hard time to the Labour cost & demographic competitiveness. We are heading to a point where manufacturing cost are converging towards becoming more or less same globally and benefits we enjoyed in the past are becoming increasingly

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irrelevant. To summarise, cost is not the only driver in sourcing decision anymore. This is where cluster & supplier Development is bringing greatest value on to the table. Supplier development is expected to bring step change improvements in the area of Supplier performance, lean mindset, operational efficiency, responsiveness & communication. In this write up, more focus is given to elaborate on these areas based on our experience working with some of the leading manufacturing companies in India. CommunicationCommunication is the most important and

neglected area which has got the highest impact on the business relationship between OEM & suppliers. Lots of technically capable suppliers fail to make transformation from small start up to sizeable business house because they don’t invest on this aspect. There are simple ground rules to excel in this area. Communicate as soon as possible whether its good news or bad one. This ensures your customer gets enough time to respond to a situation & there are no surprises at later stages. Responsiveness is the key here. Be transparent and open while sharing your problems. Your customer might have gone through all the learning curves for years. You can just use the information to fix the issue

and save your resources, time and embarrassment. Learn to ask right questions. Make sure you are communicating at all levels and functions. Faster you engage people better are chances for the success. Don’t make assumptions by yourself, get the customer endorsement and document it. Lastly, commit what you can deliver and deliver more than what you committed. Establish your credibility and sustain it. Lean mind-set and operational efficiency- As mentioned earlier customer is not coming to you just because you have low cost product. If you don’t have lean mind set and continuous improvement in the DNA of organisational culture, sustainability of

May 2016

Training And Development

OEMs cannot expect their supplier to be at the same level as their organisations are. OEMs have huge learning experience, resources, access and capacity to spend to acquire latest and greatest techniques and tools. Train and help your suppliers by creating awareness, need and usefulness of these tools and techniques. This will reduce your work to great extent.

your competitiveness will be challenged. If not today, tomorrow for sure. This is applicable not just to shop floor or manufacturing areas but also transactional functions like Project Management, Marketing, sales, HR, Finance & Accounting. Supplier PerformanceThis is go gate for any new opportunity. There is no alternative to perfect performance metrics. This is the first filter most of the customers will use even before bringing any opportunity on the table. If you don’t have perfect metrics nobody will even talk to you. Quality, Delivery, Responsiveness and Cost are the four facets of performance metrics. All needs to be at perfect. There is no compromise on any of the four measures in long run. Failure to maintain any of the area will take you down. Couple of things to the other side of the tableEngagement is the key to be successful- If you are under

May 2016

the assumption that you will receive perfect components by just throwing drawings to your supplier, you might be inviting a big trouble. Lots of work needs to be done on the engagement and handholding in the beginning. It’s like a marriage. Two cultures need to blend so well that they start speaking and understanding same language. Resources, time and money on this aspect shouldn’t be looked at as expenditure; in fact you are making great investment to ensure you get maximum out of the relationship. Your onsite presence will make huge difference. Try to get end customers (buyers, engineers, quality experts etc.) onsite occasionally so that they feel engaged and get a sense of ownership to the supplier. Another area is to guide, coach and mentor the supplier. OEMs cannot expect their supplier to be at the same level as their organisations are. OEMs have huge learning experience, resources, access and capacity to spend to acquire latest and greatest techniques and tools. Train and help your suppliers by creating awareness, need and

usefulness of these tools and techniques. This will reduce your work to great extent. Frequently share learnings, lessons and best practices between your supplier bases. Showcase one or two suppliers onsite to others would be a good idea. Supplier conferences could be another great platform to share the idea and get everybody aligned to your roadmap. We have developed couple of in house tools which Systemically measures the maturity of suppliers. Only strategic suppliers & suppliers who have got growth potential with us are selected for this program. This tool is different than regular business assessment sheets. In this process our focus is to be on the journey of continuous improvement through a structured roadmap. Various elements are assessed at set frequency onsite and offsite to understand the current standing of the suppliers. We have rating (Zero to five) based on the guidelines. Any element which has rating less than 5 needs an agreed action

plan along with the timelines. Progress is reviewed on monthly basis and revaluation is updated. Typically it takes one to two years of timeframe to reach to the desired level. Changing business environment brings new challenges therefore, Supplier development needs to be dynamic and never ending journey. All the best! The author Khushal Birari, a Mechanical Engineer from MIT, Pune is currently holding a position of India Sourcing Leader in Woodward Inc. Prior to Woodward he worked for Sauer Danfoss in Global Sourcing for various commodities. He did his MS in Manufacturing Management from BITS Pilani and later he had done his Executive MBA from S P Jain, Mumbai. He possesses a successful track record of establishing and leading International Sourcing office for Global Aerospace Company. With proven leadership, interpersonal and problem solving skills, he demonstrated performance in strategic and tactical elements of business

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MAIN FEATURE

Predictive analytics for vendor development and management A vendor management system (VMS) is an Internet-enabled, often Web-based application that acts as a mechanism for business to manage and procure staffing services – temporary, and, in some cases, permanent placement services – as well as outside contract or contingent labor. Typical features of a VMS application include order distribution, consolidated billing and significant enhancements in reporting capability that outperforms manual systems and processes.

Rajesh Angadi rajesh_angadi@hotmail.com

Vendor management is a discipline that enables organizations to control costs, drive service excellence and mitigate risks to gain increased value from their vendors throughout the deal life cycle. Vendor management research helps clients select the right vendors; categorize vendors to ensure the right contract, metrics and relationship; determine the ideal number of vendors; mitigate risk when using vendors; and establish a vendor management organization that best fits the enterprise.This enables organizations to optimally develop, manage and control vendor contracts, relationships and performance for the efficient delivery of contracted products and services. This can help clients meet business objectives, minimize potential business disruption, avoid deal and delivery failure, and ensure more-sustainable multisourcing,

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while driving the most value from their vendors.Vendor management system includes planning, development and implementation of work through vendor. VMS’s integral part includes Vendor relationship management (VRM) which has a category of business activity made by software tools that aim to provide customers with both independence from vendors and better means for engaging with vendors. Vendor development is developing your product/product parts/unfinished product from vendor(S) for the betterment of the business from aspects like finance, growth, relationship, manufacturing and supply chain. Vendor development is one of the popular techniques of strategic sourcing, which improves the value we receive from suppliers. Vendor Development can be defined as any activity that a Buying

Firm undertakes to improve a Supplier’s performance and capabilities to meet the Buying Firms’ supply needs.Buying Firms use a variety of activities to improve Supplier performance, which includes,

Vendor development?

* Assessing Suppliers’ operations

* Creating dedicated supply developments teams…

* Providing incentives to improve performance * Instigating competition among Suppliers * Working directly with Suppliers either through training or other activities Supply chain management is the combination of art and science that goes into improving the way your company finds the raw components it needs to make a product or service, manufactures that product or service and delivers it to customers. What are Best Practices in

Following are few of the Best Practices in Vendor development if adopted successfully would enable World Class Supply Chain Management (WCSCM).

* Teaching a supplier on the tactics of self-development, after initial guidance from the supplier development team… * Focusing on underlying causes of long cycle times… * Involving suppliers in new product and process development at the buying firm… * Providing on-line training programs and off-line education programs to suppliers… * Conducting frequent improvement-focused seminars for suppliers…

May 2016

Teaching Tactics of SelfDevelopment

Providing on-line training programs & off-line education programs

Dedicated Supply Developments Teams

Best Practices in Vendor development

Conducting Frequent Seminars

Creating Supplier Support Centers

* Creating supplier support centers at their locations itself… * Loaning-out process engineers and quality managers to share their expertise with suppliers. * Setting ‘stretch goals’ to encourage radical change as well as continuos improvement schemes for suppliers. * Improving proper metrics for supplier development improvements…

Improving Supply Management System

Setting Continuos improvement schemes

Loaning-out Experts to share knowledge

strategic intent is to create winwin situation wherein both the buyer and supplier gain. * Collaboration requires COMMITMENT on the part of the buying firm -To provide financial assistance for supplier investment needs, -To share all savings from supplier development projects,

* Sharing the savings from supplier development activities with suppliers.

-To educate supplier on waste management techniques, improve quality, better delivery, reduce cycle-times, reduce costs etc.

* Last, but not the least, improving the supplier’s supply management system

- To treat supplier as if, they are a department within the buying company.

WCSCM requires a commitment to collaboration between customer and supplier. The commitment must be approached with mutual benefit in mind. Effective supplier development is more than getting cost reduction for a particular part; it means helping suppliers remove wasteful costs from their processes. The

* Collaboration requires COMMUNICATION on the part of the buying firm,

May 2016

Involving in new product & process development

- To ensure that supplier is well informed of all aspects of the supplier development programs. - To provide a very transparent feed-back system available to suppliers on their reaction to all

Setting ‘Stretch Goals’ to encourage

supplier development initiatives of the buying firm * Collaboration requires MEASUREMENT mechanism - To ensure that all members of the supplier development programs, are benefited

glimpse of what the future would look like? Wouldn’t it be great if with existing data it was possible to predict trends? Predictive Analytics is seen as a new panacea to better procurement. Why Predictive Analytics?

With the arrival of Big Data, organizations realized that Basic Analytics and the huge amounts of data available could help them identify and study tends and make strategic decisions. Basic Analytics of * Collaboration requires TRUST Big Data finds interesting building measures between the patterns in the historical data. parties Links emerge between events and causes. This helps to look - To ensure that mutual beliefs at and analyze events, which and trust between the two allows organizations to alter organizations personnel must their strategies. However, Basic be present, while sharing all Analytics only helps with past confidential information. data. It can only help by giving reasoning to what goes wrong. Effective management of the supplier base is first on the list of Anticipatory Analytics moves one step forward by calling out a procurement transformation unique drivers for past events. It strategy. It is possible to have real-time monitoring of suppliers even gives a view of the changed scenario emerging out of the and look at the past to make deviation of the unique drivers. adequate changes. But, what if procurement organizations land This, of course, helps in making future decisions and chalking out upon something that gives a - To ensure success of the collaboration efforts, there must be transparency in sharing accurate costs of both the parties.

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strategies. The urge to act quickly and anticipate the future has led to the rise of Predictive Analytics. With Predictive Analytics, organizations can find out the best case scenario. A situation that can occur with prevailing conditions can best be determined with the help of Predictive Analytics Predictive Analytics has been used in areas such as marketing, financial services and actuarial science. Procurement is the latest area where Predictive Analytics is seeping. Predictive analytics is used to analyze large amounts of data with different variables. Tools include Optimization, Simulation and Predictive modeling. Decision-making in procurement has had long been based on intuition and faith. Crucial decisions such as selecting a supplier and managing the supplier base were never given much importance. Organizations are slowly waking up to the fact

that complete supplier visibility and good relationships with suppliers can help combat issues such as supply market volatility and supply chain disruption. The recent past has witnessed incidents which highlights loopholes in lack of visibility in procurement decision making. Earlier this year, the issue of meat adulteration in a Walmart store in China, due to lack of supplier visibility, caused a huge loss of trust from the consumer end, not to mention the monetary loss incurred in recalling the products. Similar was the case in which BMW had to recall about 220,000 vehicles having a faulty airbag supplied from its Japanese supplier Takata. About 4% of organizations still have little or no tier 1 supplier visibility. Fortunately, most of the organizations have woken up to the fact that maintaining close supplier relationships will benefit them in the long run. This can be clearly seen

from the fact that about 49% of organizations have some amount of visibility into their tier 1 and tier 2 suppliers. However, 32% of organizations know everything about their tier 1 and tier 2 suppliers. Leading the race are 9% of organizations which have complete visibility on the vertical side. Organizations have to be ready with an alternate plan to deal with the situation if some form of disruption hits the supply chain. Hence, procurement organizations have to take a new look at their supplier base and act accordingly to minimize risk. Moreover, maintaining proper relationships with critical suppliers is on top of the priority list for any organization. Choosing the right supplier with whom the relationship can be extended is another challenge faced by the organization. How can Predictive Analytics help? Predictive Analytics allows

organizations to build futuristic models that provide an idea of how the future might look. This helps with consolidating the supplier base. Worthy suppliers are identified and appropriate relationships maintained with them. Apart from this, the organization learns from past trends and finds out if they are the customer of choice for their preferred suppliers. Models can be built, which give valuable insights on what would happen considering the current situation. The procurement organization can cause relevant strategic changes which would benefit them in the future. Not only managing supplier relations, Predictive Analytics can link spend data with marketing data and bring out interesting insights. Predictive Analytics can be the connecting link between the top line and bottom line. Predictive Analytics would give a new direction to procurement. Predictive

A vendor management system (VMS) is an Internet-enabled, often Web-based application that acts as a mechanism for business to manage and procure staffing services â&#x20AC;&#x201C; temporary, and, in some cases, permanent placement services â&#x20AC;&#x201C; as well as outside contract or contingent labor

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May 2016

Analytics has many advantages. However, much ground work is required before an organization can start reaping the benefits. To start, top management support in implementing analytics is important. Before Predictive Analytics can be implemented, organizations must have exposure to basic procurement analytics specially Spend Analytics. Spend Analytics gives the current state of the organizationâ&#x20AC;&#x2122;s spending. This analysis is very important to plan for the future. Many organizations face the problem of maintaining proper Master Data. Still, many organizations have suppliers using paper invoices. So it is inadvertent for errors to creep in while feeding the data

May 2016

into the system. Master Data Management can make or mar the entire game of analytics. This is because analytics considers past data to build future models and simulations. The degree of information required for analytics to work is very high. Another challenge to be faced by the organization while implementing Predictive Analytics is having the right talent in the department. It is very important to appoint someone who knows what to do with the data. Predictive Analytics requires a proper mix of IT and Procurement talent. Right from developing the model to selecting the variables and the granularity degree of data required, the decision lies with the team. Procurement would guide IT to develop

models to see the future. Predictive Analytics comes only after the organization is comfortable with basic procurement analytics. When the organization has analyzed the past, only then it is possible for it to anticipate the future. Apart from constantly monitoring suppliers, it is also important to foresee the situation. Moreover, it is also important to analyze whether the organization is the customer of choice for the preferred suppliers. This would allow the organization to take necessary steps such as modifying the relationship with the supplier or changing the organization strategies. Supplier base management is one of the integral parts of procurement and the entire supply chain depends on how

the procurement is done. Predictive Analytics gives an insight of how the future might look, which helps the organization manage the supplier base. The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.

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MAIN FEATURE

Challenges and Opportunities to become a Global OEM Supplier The Indian market is looking at a changed scenario since the impetus of “Make in India”. The entire government machinery has synced with this mission to popularise the same, easing the business scenario, removing the glitches. Thus we are looking at a huge opportunity to become directly or indirectly a global supplier and taking the Indian Manufacturing Industry to another paradigm.

Manish Kothari rhino.mk@gmail.com

Some recent interactions

with, and ISI Mark also.

The remuneration of the

The authenticity of the QS

real worker is therefore

norms have been so much

transferred to the

distorted in India that it is

supervisor, creating a

impossible for somebody

huge imbalance in the

to really assess and believe

socio-economic structure.

in the certifications. There

Secondly the output per

addressed.

is an urgent need to get

person or in other words

the sanctity of the QS to

productivity is very poor.

supplier and given the first

1. Attitude – the first and

rebuild lost confidence in

chance. This is a complete

foremost challenge is our

Indian “Certificates”.

180 degree turn from the

attitude towards quality…

earlier scenario where

”Chalega” is a word

“imported” product was

which has to be thrown

preferred.

out of the manufacturing

with top corporates such as Mahindra & Mahindra revealed that even for their capital goods purchase the Top Management has mandated to have products falling into the “Made in India” as a preferred

Challenges: Every opportunity places some challenges in front of us, which need to be recognised, evaluated and

4. Reliability – This is related to the “Zero

3. Skilled Work Force –

Defect” term used by the

there is a huge shortage

PM. The production of each

of trained, skilled work

stage of manufacturing- be

force in the country.

it component, assembly,

Instead we have more

machine or project has

of “unemployable”

to be of the right quality

engineers, who are totally

and right specifications.

disconnected from the real

The buyers, OEM or

industry world. Typically

intermediate or the end

time criteria.

an Indian manufacturing

user, all are unsure of the

needs a hierarchy approach

reliability of the products

in my own life span, this is

2. Quality Standards – ISO

– Supervisor to watch over

of India. In addition, the

the first time, such a feeling

has been played around

the work of technicians.

cost of reliability due to

The second example is the growing public focus of the product being made in India. The nationalistic fervour has been rekindled, after more than sixty years of independence. At least

has been seen nationwide.

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dictionary. However, the core strength of Indian attitude of accepting and adapting to situations has to be balanced, without affecting the quality and

May 2016

What cannot be measured cannot be control. Embracing and understanding of solutions to map the costs, time and means of optimising shall ensure timely delivery, at lower costs, making the organisations more competitive. The issues are always resolved on a long term & short term basis.

the time lost in inspection,

of time and embrace

to ensure the quality of

verification also increases

systems to capture this

product. Lack of resources

the cost of manufacturing.

huge opportunity.

are a common issue faced

Recently during our garment manufacturing, we changed the policy of inspection at the Vendor end, which created a direct accountability of the vendor, and at the same time increased the production two fold with the same manpower. 5. Value Stream Mapping or Lean Manufacturing Practices – to compete in the global supply chain, it is essential to recognise, identify and eliminate non-productive costs in the manufacturing processes. This has to be embedded in the core business values and documented. Whether it is a domestic supply or an export supply – the quality of goods and the standards need to be uniform. We have to start treating our own country on equal platform, imbibe the quality of goods, importance

May 2016

Ways Ahead: Every Opportunity has a challenge, and every challenge should have a way out…it is a continuous process. Looking at the major challenges, here are some suggestions from our own experiences and interactions with several industries. • Quality - The final quality of the product comes from the bottom most working hand in the manufacturing process. It is important to engage at all levels of organisation collectively and inject quality into their blood. This will require not only QMS tools, but equally important to change their personal habits and align them to the system needs. Recognise the need for the right tools, instruments and right working environment for the working team,

in Indian environment.

• Private Cluster approach – instead of depending on the long process of govt support for clusters, industries should come

• Cost & Time

together to invest

management – What

collectively, allowing

cannot be measured

them to have access to

cannot be control.

sustainable manufacturing

Embracing and

facilities, where they

understanding of solutions

themselves cannot justify

to map the costs, time and

due to underutilisation. The

means of optimising shall

industry has to come out

ensure timely delivery,

of “secrecy” mind set, and

at lower costs, making

move forward.

the organisations more competitive. The issues are always resolved on a long term & short term basis. Here are some long term solutions which need to be addressed.

The author Manish Kothari (BE Mechanical – 1991 MSU Baroda) is the Managing Director of Rhino Machines – Foundry Machines,Director ACE Foundation for Skill Development, Director

• Sharing of Information

Composite Solutions

– the market is huge,

for Strategic Solutions,

and sharing information

Promoter & Advisor

with competitors should

Meemansa – Women’s

be encouraged at all

Ethnic Wear manufacturing.

levels to embrace best

His innovative solutions

practices. They industries

have been recognized at

must change the mind set

National & Global Level

and interact with similar

for Energy Efficient &

producers and improve

Environment Friendly

their quality.

Solutions.

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INDUSTRY FEATURE

Robust performance at peak times Hard-wearing drive solutions for cable car stations and garages

In the Alps, tens of thousands of people take to the mountains every day, especially during the skiing season. To avoid long queues at aerial ropeway stations, failsafe equipment is indispensable. That is why Doppelmayr/Garaventa, the world leader in ropeway engineering, employs long-life, low-maintenance geared motors from NORD DRIVESYSTEMS.

In Ischgl, in Tyrol, Austria, a so-called tricable detachable gondola lift scales the Pardatschgrat mountain. Tricable type systems feature two fixed track ropes on which the carrier travels and a circulating haul rope. With a climb of 1,251 meters, the Ischgl lift set a new world record for tricable ropeways when it went into operation. The journey takes less than 10 minutes to complete

â&#x20AC;&#x201C; the rated maximum speed is 7.5 m/s. Obviously, the traveling speed inside the stations has to be much lower to allow for safe disembarkation or entry. When the cabins get to the station, they are therefore detached from the haul rope and smoothly decelerated by a tire conveyor. At the passenger platform, they move at slow walking speed. Inside the station, the carrier

wheels run on rails instead of track ropes. When the cabin is taken off the haul rope, friction modules make contact with the tire conveyor to ensure power transmission. Several NORD geared motors are installed here, each propelling multiple axes via a belt. The gondola lift was built by Doppelmayr, a member of the Doppelmayr/Garaventa Group, the global leader in cable car engineering and

manufacturing with more than 14,600 completed projects in 89 countries. Doppelmayr has been working with the Austrian NORD subsidiary, Getriebebau NORD GmbH in Linz, since 2005. Johannes Moritzhuber, responsible for detachable gondola lifts at Doppelmayr, says: â&#x20AC;&#x153;Working with NORD, we always know we will get drives suitable for any type

The tire conveyor lets the cabin move through the station at a safe, comfortable pace

NORD geared motors drive tire conveyor sections via belts

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May 2016

on overhead rails, the Grasjochbahn cabins are pulled into the garage by a conveyor chain

conveyor chain featuring catches is actuated by a NORD helical inline geared motor

of installation. We choose drive solutions from NORD because they meet our expectations of maximum availability, superior safety, and excellent serviceability. NORD is extraordinarily flexible in implementing optional features. The drives are very reliable and silent, and NORD ensures fast delivery of spare parts throughout the world.â&#x20AC;? Overnight garage

on the Grasjochbahn circulating monocable ropeway in the neighboring Vorarlberg. Both there and in the Tyrol project, all the cabins are kept in a garage overnight. This accommodation, which extends the service-life of the equipment, was pioneered by Doppelmayr. Initially, this required a lot of manual effort, but nowadays much of it has been automated. Both ropeways comprise a multi-track garage located under the valley stations.

Doppelmayr and NORD DRIVESYSTEMS also collaborated

In the case of the Grasjochbahn, cabins are transported to the

garage floor via a sloping ramp, smoothly passing from the tire conveyor to a conveyor chain. The weight is still supported by rails that run through both the station and the garage. At the Ischgl garage, the facilities are even more space-saving: the cabins travel via a vertical conveyor driven by NORD. Horizontal transport is carried out with tire conveyors. The motors are equipped with temperature sensors and encoders, and are centrally controlled.

Embracing standardization Doppelmayr introduced modularization to its various product lines many years ago. Each cable car is still individually configured to suit the geographical, geological, and climatic conditions at the installation site. However, modularization reduces the engineering and manufacturing costs and allows for standardized planning and quality assurance. The manufacturer has switched entirely to IE3 premium

Parking using as little space as possible in the Grasjochbahn garage

Proximity switches and NORD brake motors featuring air gap monitoring ensure that the cabins keep a safe distance from each other in the Ischgl garage

May 2016

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Slow-running motors in the passenger area are cooled by an external fan

Convenient power plugs allow for easy connection and swapping of geared motors

efficiency motors in stations, including the garages where the drives are not in continuous operation. The advanced energy efficiency class IE3 has only recently been made mandatory in Europe, and even then only for a part of all applications. Even so, Doppelmayr has opted for NORD IE3 motors due to ancillary benefits, such as a reduction of the number of variants, extended thermal and overload capacity, and suitability for worldwide deployment in countries with either 50 Hz or 60 Hz supply. Used to special features Above everything else,

Doppelmayr appreciates the reliability and long service life of the drive solutions. Dietmar Fessler, who is responsible for tricable detachable gondola lifts at Doppelmayr, says: “The drives we use in aerial ropeways must operate safely at temperatures from -30 °C to + 50 °C. NORD drives easily meet this requirement.” Johannes Moritzhuber, his colleague responsible for the Grasjochbahn ropeway, adds: “NORD understands the application. For instance, they have alerted us to the fact that we could increase the gearbox temperature tolerance by 5 degrees with a non-standard lubricant. In our Alpine projects, this is highly

relevant and helps us achieve a long-lasting, low-maintenance drive solution. “ NORD offers drive options for a very wide temperature range and has implemented standstill heating, corrosion-protected brakes, and moisture protection insulation in Doppelmayr projects. The drives on the tire conveyors operate at slow speeds, which is why they are equipped with external fans: these are stronger than motor fans and can be switched on as required, thus offering an energy-efficient solution. Instead of two-pole fans, NORD has provided four-pole versions, achieving significantly lower noise emissions in the passenger

area. NORD supplies the drives ready to use with plug-in power and signal connectors. In addition to simplified maintenance, this has resulted in great savings during commissioning. The drive manufacturer also implemented air gap monitoring for the brakes. A micro-switch signals when the brake disks have worn down beyond a set limit, ensuring that the brakes always operate reliably and that the brake disks are adjusted or replaced in time. For more details visit www.nord.com

Doppelmayr’s chief engineers at the Pardatschgratbahn aerial ropeway in Ischgl, Dietmar Fessler and at Grasjochbahn in St. Gallenkirch, Johannes Moritzhuber

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May 2016

Since its inception in 1983, Electrotherm India Ltd., through its progressive and competency backed approach, has become the only company with indigenously developed world-class technologies, for the engineering metal melting industry. Electrotherm's customer centric working philosophy, backed by sound understanding of the industry's need, has enabled the company to provide customized engineering and metallurgical solutions, which are assets for continued growth and success. |Induction Melting Furnaces | Electric Arc Furnaces | Electrotherm Rening Furnaces (ERF) |Metal Rening Konverters (MRK) | High Speed Continuous Casting Machines | Coal based Rotary Kiln (Sponge Iron) Plant | Coal based Tunnel Kiln (Sponge Iron) Plant | Turnkey Projects for steel melt shop for producing billets / ingots|Turnkey Projects for Integrated Plant through DRI – SMS route |Plant design and engineering| Plant Automation |Product Improvement Equipment (PIE) for improving plant productivity, end product's quality and plant efciency.

May 2016

ELECTROTHERM (INDIA) LTD. 72 Palodia, Via Thaltej, Ahmedabad-382115, Gujarat, India Phone: +91-2717-660550 Email: mkt@electrotherm.com Website: www.etenp.com / www.electrotherm.com

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ON FACE

“Custom-made solutions can fetch Great Results” Nagraj C M Managing Director, Right Engineers

Right Engineers, the material handling solution provider, has recently opened up its new office at Jigani, Bangalore with proposals of custom-made solutions in the field of Cranes and components manufacturing. In an exclusive discussion with Mr. Nagaraj C M Managing Director and the Founder Director of the company, a lot has been revealed about the process of cranes designs and of course about their new manufacturing plant. Excerpts:

Tell us about your core area of

trolleys, lean manufacturing

manufacturing?

solutions, storage solutions,

“Right Engineers & Equipment India Private Limited” is a manufacturer of Material

tool management, customization, work stations and hydraulic equipments.

Handling equipments and

Owing to the world class

storage solutions for industrial

products, fair and ethical

and logistics sectors. Product

business practices and attitude

range includes EOT cranes,

for continuous improvement,

Right Engineers have mustered a wide client base spread across the country. When you use our solutions, it will help you ease out the materials handling problems completely and thereby causing increased productivity which could further translate into higher productivity.

Tell us about your new Manufacturing Plant? Since last two decades, we have served 650 valued customers throughout all industries across India. Our company is the registered vendor for most of the PSUs and MNC’s. It is also an ISO

The newly built plant has been inaugurated by Mr. Ravin, Executive Director- Terex India on 29th of May 2016.

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May 2016

The new factory and corporate office is now situated at single premise in Jigani industrial area, Bangalore. Overall land area for the entire office is around 50000 sqft. and the manufacturing area is around 30000 sqft.

9001:2008 certified company. Our company has recently set-

How do you provide quality products with such low cost?

up new manufacturing facility

Right Engineers & Equipment

to manufacture crane girders

India Private Limited is

and other material handling

backed by Demag cranes and

equipments in bigger capacity.

components as a channel

The factory and corporate

partner (Terex group) to

office is now situated at single

provide world class technology

premise in Jigani industrial

and crane components to

area, Bangalore. Overall land

manufacture world class cranes

area for the entire office is

at affordable pricing. The

around 50000 sqft. and the

complete crane components

manufacturing area is around

like Hoisting unit, Drives,

30000 sqft. The corporate and

Electricals, End carriages,

marketing office is built up in

etc are supplied directly by

8000 sqft. in 3 floors.

Demag to Right engineers to

The newly built setup is the

manufacture complete crane.

projects simultaneously. Tell us about your key features of success? Customisation is the key strength of Right engineers. We are well equipped with in-house design team backed by solid works professional software. The team is strong enough to study the process flow and the flow of material and to suggest various type of solutions by pictorial presentations and making 3D views of the objects by using the software. The design team is also capable of calculating

material handling equipments at the right place at the right time. Any specific R&D method to design new products? We develop products after a thorough market research and study of on-going trends. Based on the feedback from researchers and in accordance with client demands, the development of the product line is initiated. The market analysis allows us to procure latest machinery and equipment for an enhanced productivity and supreme

state of the art facility and built

The cranes vary from single

the strength of material,

with global standard working

girder, double girder,

selection of material by using

practices and aesthetic

Monorails, under slung crane,

simulation technique by using

Apart from cranes the plant

point of view. The plant is

Jib cranes, Gantry cranes and

solid works software. We

is well equipped to fabricate

fully equipped with modern

many more. Right Engineers

consider following points into

heavy steel super structures,

technical support machineries

& Equipment India Private

consideration while designing

Gantry, Monorail etc by using

and handling equipments to

Limited is also the sole dealer

the solutions.

Mig welding process. Other

manufacture crane girders.

for complete range of Demag

The newly built plant has been inaugurated by Mr. Ravin, Executive Director- Terex India on 29th of May 2016. Display of the products and plant tour has been arranged for huge gathering on the same day.

May 2016

made crane components and spares. We have local stock to cater immediate requirement. And also we are the authorized partner for executing the projects for pan India. They have strong and dedicated well trained team to execute the

• Design safety into the system

performance.

material handling equipments like customised Dolly’s, racks,

• Design for simplicity

trolleys, work stations, tools

• Design for flexibility

be manufactured by this unit.

• Design capacity for present and future volume • Provide a means for having

handling system etc. will also The team consisting of well trained professionals is the core strength of the company. We have local dealer offices at

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Chennai, Hyderabad, Belguam,

expand our manufacturing

According to you, to open

as women entrepreneurs.

Shimoga, Hubli.

base by setting up the new

up a new office, what are

Making dream a reality is a real

manufacturing facility at Jigani.

the basic infrastructure

challenge and one must not

Itâ&#x20AC;&#x2122;s a very huge investment

difficulties an SME can face

give-up his vision at any cost.

for us right now, and we are

into manufacturing?

What are the challenges you facing as an SME manufacturer in India? In India SMEs face various

open for further expansion based on market potential and

challenges. Some of the points

forthcoming business trends,

I would like to highlight here

but yes we are very positive

is about the competition

about our plans.

Indian manufacturers are facing in the global level for quality deliverables, need to implement advanced technology of manufacturing

The key demand of Indian SME sector is the availability of adequate infrastructure, power and finance at reasonable rates. One of the major reasons

What about the current

why Indian SMEs, despite being

ongoing positive sentiment

so competitive, fail to compete

into manufacturing?

effectively in the global market is the unavailability of

There are no doubts about the

adequate infrastructure and

opportunities waiting for the

power, which are the keys for

Indian industries in the national

running business operations

and international arena. For

successfully. Policy makers

us at Right Engineers we have

need to create an enabling

huge possibility of growth in

environment by providing

Aerospace and Automobile

adequate infrastructure to

sectors. However, with

attract investments in India,

the positive brand building

most importantly in the SME

for the next five years?

campaign, the Government has

sector. Further, more emphasis

really fetched some good trust

needs to be given to the SME

As mentioned above, as per

from among global leaders and

sector, by providing them

the demand created by our

thereby, created a universal

with special schemes and

company during the last two

platform for the manufacturers

incentives for new start-ups,

decades we were able to

to showcase their products.

young entrepreneurs as well

practices, proper investment of infrastructure etc. By partnering with global leaders of relevant area for technology and investment we can sure bring a lot of changes in our manufacturing capabilities. Any further expansion plans

What innovations we can expect in the Material Handling segment? The global market for Material Handling is projected to reach heights driven by the growing emphasis on production automation. Automation of manufacturing processes against a backdrop of growing pressure to optimize raw material, resource and energy consumption is a key factor fuelling adoption of Material Handling Equipment in mass production. There are lots of innovations happening and new technologies are rolling down in MHE sector globally, where as in India research and development on this sector is considerably low. Demag has developed V-girder for the crane in order to reduce the self-weight of the crane.

The newly built setup is the state of the art facility and built with global standard working practices and aesthetic point of view. The plant is fully equipped with modern technical support machineries and handling equipments to manufacture crane girders.

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May 2016

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SPECIAL FEATURE

Chennai ready to seal the Sentiment of Manufacturing at ACMEE 2016 It is now proven that ‘brand India’ is getting noticed globally by Modi’s ‘Make in India’ campaign. Many reforms have been initiated in the field of tax, infrastructure and skill development. But, how many of us are interested in hardcore manufacturing yet? Has this industry really been able to remove that tag of ‘niche market’ from general mindset? Are people really interested to develop entrepreneurship into Machine Manufacturing?

Hiya Chakrabarti hiya@martinfotech.in

However, with all the possible answers, ACMEE 2016 is all set to hit the exhibition ground with much more in its offer. This is the 12th edition of the International Machine Tools Exhibition jointly organized by Ambattur Industrial Estate Manufacturers Association

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(AIEMA) and National Small Industries Corporation (NSIC). The exhibition will showcase the latest innovations during 16th to 20th June, 2016 at Chennai Trade Centre.

in the Chennai Trade Centre

ACMEE 2002 happened to be the first industrial exhibition

temporary halls are a regular

and since then the Chennai Trade Centre has been hosting ACMEE continuously once in two years. As the constructed halls are still inadequate, feature in ACMEE events.

With each edition, ACMEE has been growing in all directions … number of participants, exhibition area, visitors and business transacted. Over the years, ACMEE has been specializing in machine tools and is now recognized as one stop platform for sourcing the

May 2016

best in machine tools available anywhere in the world. The event has also been getting international recognition and many international machine tools associations are participating. ACMEE has been fortunate in getting guidance from leaders of the industry and support from all members. For each edition of ACMEE, a separate Organising Committee has been guiding in organising the event. The Committee takes care of all aspects of fair â&#x20AC;Ś from marketing the event amongst exhibitors to mobilizing visitors, publicity, actual organizing the event at site and so on. This year, there are over 465 participants from among 25 countries to showcase their offerings for the manufacturing industry. Among the many world leaders participating in the show are AMS, Schunk, Mitsubishi Minerals,OSG, Makino, DMG, Fanuc, Tsugami, Korloy, LMW, BFW, Jyoti, HMT, Tungaloy, Fagor, Mitutoyo, Losma and many more. Manufacturers from Japan, Taiwan, China, and Germany are also participating in a big way. There will be coverage for a wide range of products like CNC, Special Purpose machines, Industrial Robotics and Automation, Material Handling equipment, Welding, Hydraulic and Pneumatic systmes, Tools, Dies and Moulds, Fabrication and many more. A number of product and technology launches, especially suitable for Indian Market and all devoted to improve productivity, cost reduction, energy saving are slated to be launched in ACMEE 2016. Concurrent with the

May 2016

show, Technical Sessions, live demonstrations have also been planned for better visibility and visitor involvement. ACMEE 2016 is getting sponsored by Ace Micromatics, Schunk and Mitsubishi as Title Sponsors. Apart from them, many are there as Gold and Silver Sponsors of the show. The organizer Ambattur Industrial Estate Manufacturer Association was formed in 1963. It is one of the oldest and well maintained industrial estates in India. More than 2000 manufacturing units are functioning in the estate manufacturing and offering a wide range of products and services - auto components, industrial machinery, electrical machinery, machine tools, accessories, welding, moulds& dies, CNC, leather and garments, IT related services, etc. AIEMA is currently celebrating 50 years of illustrious service to the industry. ACMEE 2014 was a trend setter and showcased the latest in machine tools all aimed at perfection, time and cost cutting, energy saving and mass production. The product profile included CNC, Special Purpose Machines, Hydraulics, pneumatics, instrumentation, cutting tools, low cost automation, industrial robotics, welding, etc. A record number of 45600 visitors visited the fair. This year, with much more vibrant economy and with some active Governmental initiatives, we can expect more flow of visitors at the exhibition ground. ACMEE 2016 with the recent positive vibrancy into manufacturing is going to be another milestone of success!

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SPECIAL FEATURE

Self-Repairing Doors- the Latest from Gandhi Automation in ACMEE 2016 Visit Hall No- 1 Stall No- A114

Samir Gandhi Director, Gandhi Automations

Mr. Samir Gandhi, is a Chemical Engineer from Institute of Chemical technology, Mumbai (earlier University Department of Chemical Technology). He has over 20 years of experience in Entrance Automation & Material Handling equipment Industry. Mr. Samir Gandhi is steering Gandhi Automations pan-India sales network. Further, he steered the setting up of state of the art manufacturing & warehouse facility in Mumbai. His decisiveness in strategizing and implementing has helped Company to reach newer heights. His visionary effort was crowned with success when the Company started exports in year the 2011. He has invested heavily into research and development. A well respected, renowned professional with innate technical & management skills, Mr. Samir Gandhiâ&#x20AC;&#x2122;s approach to business has always been ethical. Excerpts from the talks we had with him about the latest developments in the Handling industry.

Your expectations from

Tell us about your

Mega Industrial Sliding

We are launching our

ACMEE 2016?

participation in this show?

Doors, Motorized Gates

new product in ACMEE

ACMEE is great place to

We are participating

& Boom Barriers, and Fire

2016, high speed self-

showcase our products

for first time in ACMEE,

Sliding Doors. We long to

repairing doors. We

to decision makers from

it is a huge event, and

showcase our products

have been working

manufacturing industry. We

lot of manufacturing

to these giants, and to

on self-repairing high

expect to generate some

giants participate in this

increase our presence in

speed door for industry

good leads and business.

event. Our product range

southern India. We are very

for quite some time

I very firmly believe that if

comprises of High Speed

confident of our product

and we have been able

you have a better product

Doors, Dock Levelers, Dock

quality.

to achieve a break

to offer with great quality

Shelters, Rolling Shutters,

New Innovations/ Products

and service you can achieve

Fire Rated Rolling Shutters,

to be exhibited from your

desired results.

Sectional Overhead Doors,

end?

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through. Our research & development team has worked very hard and I must say we have come

May 2016

up with a best product for the industry. We are very confident that this product will be welcomed by clients and in coming years it will contribute to our top and bottom line.

visitors and exhibitors? Business stalwarts from various manufacturing industries come together and can see lot of

and how much volume of

innovative products.

turnover do you expect

Important purpose of

from this show?

such events is exhibition

automation business, every organization needs entrance solutions for their warehouse, factories, manufacturing facilities therefore CEOâ&#x20AC;&#x2122;s, projects managers are our

May 2016

Any message to the

Your potential visitors

We are into entrance

Self Repairing High Speed Doors

good business.

of innovative and quality product. Such events are good for healthy competition within industry and growth of sector. Your Stall No and Hall No?

target audience, we are

Hall no: 1

very hopeful of generating

Stall no: A114

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SPECIAL FEATURE

Energy Efficient Industrial Cleaning Visit Hall No- B Stall No- 143

Mangesh Agarwal General Manager, Dürr Ecoclean

Mr. Mangesh Agarwal, is a Mechanical Engineer from Government college of Engineering, Pune (Pune University) and has done his Masters in Production engineering from RWTH Aachen in Germany. He has nearly 10 years of experience in component cleaning Industry. Mr. Mangesh Agarwal is heading the India business of Dürr Ecoclean since 2009 and has formerly worked at Dürr Ecoclean in Germany looking after sales in Asia Pacific. He has been actively working on localization of Dürr Ecoclean German engineered machines in India. His knowledge in component cleaning is appreciated not only by his colleagues but also by the customers. Mr. Agarwal’s approach towards customers is always professional and ethical and has been caring for the customers at each level.

Your expectations from ACMEE

exchange of information for the

hydrocarbon technology which

for marketing, brand building

2016?

Machine Tool Industry in India

has been highly economical on

and B2B networking. The show

and the global participants. They

the ‘cost per unit’ for cleaning

opens different avenues to

form a platform for knowledge

and ensure the quick ROI. We

exhibit a broad range of efficient

sharing.

are demonstrating the energy

parts cleaning solutions to a

efficient cleaning machines that

wide spectrum of manufacturing

deliver the best cleaning quality

industries. Participation in

consistently both in terms of

the show will not only help in

gravimetry (Millipore) and

exploring untapped markets but

particle size.

also give an opportunity to meet

ACMEE show attracts key decision makers, entrepreneurs and business visitors from various manufacturing

We look forward to the show

industries. Giving us an

as one-stop solution, giving an

opportunity to connect, network

opportunity for showcasing

and tie-up with large and

products, process and

small scale industries in India.

technologies. Another important

Moreover the show creates

expectation from the show is a

Tell us about your participation

options for lead generation and

good footfall of visitors and visits

in this show?

business expansion in India &

of key decision makers to our

abroad.

Stall – B143 in Hall B.

Exhibitions especially ACMEE are

What are the new

forward to ACMEE as a platform

platforms for networking and

manufacturing trends to be

for exhibiting world class

highlighted in this show?

Industrial Cleaning Technology in

showcasing the latest products, innovations and technologies. They provide a platform for

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Dürr Ecoclean is focusing on made in India aqueous and

Dürr Ecoclean (A division of Schenck Rotec) India looks

Indian Markets. ACMEE is an excellent platform

key decision makers at the show, thus strengthening the market presence of Dürr Ecoclean in India. New Innovations/ Products to be exhibited from your end? Dürr Ecoclean brings the state of art closed loop highly economical hydrocarbon

May 2016

cleaning technology made in

to meet all the key decision

India.

makers from component

For example our Minio 85C is a compact, economic, highly

Any message to the visitors

efficient solvent based system

and exhibitors?

which can be used for cleaning of a wide range of applications for parts cleaning, also the wellknown German technology is now available “made in India”. To know more visit us at Stall B-143.

Dürr Ecoclean offers a broad range of energy efficient component cleaning systems to meet stringent cleaning quality demands. Dürr Ecoclean manufactures economic, highly efficient and environmental

Your potential visitors and how

friendly systems which can

much volume of turnover do

be used for a wide range of

you expect from this show?

applications for parts cleaning.

We at Dürr Ecoclean as such

Your Stall No and Hall No?

do not believe in numbers but

Minio 85C

manufacturers to OEM’s.

quality. We are sure that ACMEE will provide us the platform

Translift brand cranes exclusively assembled with Demag - BAS series of components. Translift will give you lifting solutions in alliance with Demag ( Terex group ) thus making the crane more affordable.

Hall no: B Stall no: 143

Single girder EOT Cranes. Double girder EOT Cranes up to 20 Tones. Under slung and Monorail Cranes. Jib Cranes. Solo hoist and drive units.

Plot No. 66, Road No. 4, 1st Phase Jigani Industrial Area, Anekal Taluk Bengaluru, India Contact: 080-42147300, 9845205428 8861205674, 9845134315 Email: translift@rightengineers.com www.rightengineers.com / www.tarnslift.in

May 2016

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SPECIAL FEATURE

Unipunch Ready to Showcase in ACMEE 2016 Visit Stall No- B-15

Vikram Sarathy Managing Director, Unipunch Toolings Pvt Ltd

Mr. Vikram Sarathy, a graduate in Mechanical Engineering is the Managing Director of Unipunch Toolings Pvt Ltd and has been working with the company for the last 20 years. He shares the initial journey of Unipunch and the future plans with our readers, excerpts.

Your expectations from

Unipunch have long been

participant from the

ACMEE 2016 ?

into sheet metal working

inception of ACMEE (i.e.,)

tools and machines. Our

over the past several shows.

Expecting good response of visitors from Tamilnadu and Karnataka. Anticipate the automobile units in Sriperumpudur belt to visit and recognize skills and sources available in the state. What are the new manufacturing trends to the highlighted in this show?

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emphasis for ACMEE 2016 would be on machine and tools for pipe fabrication. New technologies of pipe piercing, pipe enlargement / reduction, high speed pipe cutting would be highlighted. Tell us about your participation in this show? We have been regular

New Innovations / Products to be exhibited from your end? Tools and machines for creating pipe joints, highly useful to two wheeler, furniture industries. Your potential Visitors and how much volume of turnover do you expect from

this show? (We are not guessing) Any message to the visitors and exhibitors? Measures are available to introduce new technology and to increase output. These steps alone will keep current manufacturer as future manufacturer. Your Stall No. and Hall No.? Our Stall No. B - 15

May 2016

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TALENT MANAGEMENT

Building a High Performance Culture – Why Leaders are pivotal? Creating a performance culture requires a systematic approach to managing the performance of organizations, teams and individuals. Leaders who are clear about their company’s culture are able to deliver and sustain both performance and employee satisfaction over time.

Pavan Sriram pavan@ittige.com

Human performance is the function of many influences: accountability, feedback, motivation, skills and knowledge, rewards and recognition. These influences are interdependent. It is the combination of these factors that results in the desired performance and the associated leadership behaviours that support the performance culture.

Performance culture on the other hand is the “operating system” of the company, the organizational DNA.Leadership in highperformance cultures does not reside only at the top of the organization. It also emerges from, and cascades down to, those in customerfacing roles. For example, when Michael Dell was asked by Fortune

Magazine to reveal the source of his competitive advantage, he said: “Our direct business model.” He was immediately challenged by the writer, who noted that his business model was not new and had been around for years. Dell simply responded by saying that, “The difference is that we actually EXECUTE it.” (Fortune, June 1999). A highly disciplined

organization that has clear accountabilities and demands results may create the impression that it is stifled by hierarchy and rules. In fact, such demands have the opposite effect. I. When you have clearly articulated strategic intent and core values, along with disciplined people, you don’t need hierarchy.

Company culture is at the heart of company performance, because it determines how things are done and how people behave

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May 2016

High-performance companies got where they are not by chance but by choice

II. When you have disciplined thought, you donâ&#x20AC;&#x2122;t need bureaucracy. III. When you have disciplined action and strong leadership capability, you donâ&#x20AC;&#x2122;t need excessive controls. Hence, performance leadership demands that you exercise self-restraint and enable your employees to learn and take intelligent risks so they contribute at their full potential. This means you spend more time listening and asking than speaking and telling. This approach will yield insights, which fuel curiosity, which in turn cultivates knowledge and wisdom. Having facilitated leadership workshops for several clients,our research and experience tells us that most people want an opportunity to demonstrate their competence, to contribute and to learn. When given the chance to focus on what they are best at, they will deliver and surprise. Responding to them strengthens a performance culture.

May 2016

Let me suggest the following three integrated steps. a) Define values in behavioural terms:Some organizations attempt to define their culture by establishing elaborate purpose andvalues statements and then publishing these statements far and wide - posting them in theworkplace and on company sites. However, the most effective approach is to draftstraightforward declarations of purpose with values defined in behavioural terms, whichenable values metrics to be established The result over time is a loss of respect,increased stress and anxiety, and inconsistent treatment of employees, leaders and customers. b) Clarify performance expectations:Leaders can help contributing employees gain an understanding of their performance expectations through formal planning forms or more informal

discussions. The critical outcome is for everyone to agree on standards for key goals. This step reduces confusion, clarifies targets, and focuses efforts for everyone. One key to creating a sustainable business that creates passionate employees who exceed performance standards is to formally hold leaders and managers in hisorganization accountable for both performance and values. c) Hold leaders and staff accountable:Many organizations struggle to hold leaders, managers, and staff members accountable for performance or for values. The reality is that without consequences management, we are only creating more chaos. The process of creating a high performance, valuesaligned culture requires consistentattention by company leadership and day-to-day reinforcement by managers throughoutthe

journey. It can take 18-24 months from the process kick-off to achieve the demonstratedvaluesaligned behaviours across the organization. To summarize, in high performance cultures, effective leaders clearly articulate a strategic framework of mission, vision and values, strategic goals, and measurable priorities. They design and take accountability for managing service-oriented, efficient business processes and structures. Leaders engage their people and work hard to learn their strengths and preferences. They manage their talent well and encourage ongoing learning. They communicate rigorously and often. I look forward to hear from you at pavan@ittige.com on how you are facilitating a strategic framework of mission, vision and values, strategic goals with measurable prioritiesfor leaders to work collaboratively in teams. Pavan Sriram is the CEO of ITTIGE Learning, a performance-based training company that works with organisations to improve learning outcomes.www.ittige.com

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MANUFACTURING EXCELLENCE

Managing stress in the Organization Managing SME in India - Part 41

With pressures from Customer, market and other dynamics, stress in the organization cannot be eliminated totally but can be kept in check by taking some action. The article focuses on factors which normally causes stress in the Employees of the Organization. By understanding causes, it is possible for the companies to take corrective and preventive actions.

P S Satish gotopssatish@gmail.com

As a continuation of last articles, we will discuss on few more points to manage SME’s better in India. •Not being explicit Many times, a lot of things are expected from the Employees in the Organization but they have not been told clearly what is expected out of them. This creates a stress in the Employee. Being explicit will reduce the stress level. In one of the Company I visited, the CEO called all the first level managers and informed that considering current growth of the Company, there is a need to reduce headcounts by 10% and everyone needs to work on that. After the meeting is over, each functional head tried to assume the way it fitted them. R&D and HR heads thought that this target is not applicable for them being in supportive role. Unnecessary rumours created stress in the Organization. This could have been avoided had the CEO made some homework and made his intentions more explicit. In the Indian

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context, please understand many Employees and managers will not seek clarifications easily if something is not clear. •Non Clarity on responsibility Clear organization structure is one of the enablers for the success of the Organization. Organization chart is not just a diagram showing blocks with names. It has to be expanded to include key responsibilities for each. In many organizations, it is not clear who is responsible for a particular activity and creates confusion. Confusion can lead to stress. Also by defining responsibilities and reporting structures properly, it will be easy to identify competencies and skill gaps do carry out those assigned responsibilities. •Missing Targets Sometimes, we see no targets or targets defined very vaguely to the employees. If not for all, at least for managerial positions

there should be clarity on what is expected out of them. Better to define target in a SMART way i.e. Specific (S), Measurable (M), Achievable (A), Relevant(R) and Time bound (T). If there is no basis for target and expecting a moon in a short time, nothing will move. In one company where I trained recently, the Quality manager was given a target to reduce inward ppm from current level of 6000 to 200 in one year. This is extremely difficult one and they had linked the achievement of this to his increment. This only demotivated him and I could see a stress level in him. If targets are not realistic, it is likely wherever possible; people try to manipulate just to show short term gains. •No resources To carry out any process successfully resource is a must. It is one of the key responsibilities of the management. Expecting good results and not providing required minimum resources will

induce stress. More over quality of work will also suffer. Overloading a person with too much work without providing any assistance will create stress especially when there is no one to take care if he goes on leave. •Fire fighting culture This culture in organization is terrific. In this, everything in the company happens in the last minute. Surprisingly the fire is created inside and those people will only fight to extinguish fire. Stress can be removed to a great extent if we change fire fighting culture to planning culture. That means no activity happens in the company without planning unless something comes up beyond control. The management should follow planning in their activity and encourage others to do so. A study was done in USA among SMEs and the areas they need to improve for overall growth. The top point of result was ‘To focus on planning’. It could be financial planning, business planning,

May 2016

Many times in the Organization, many things are expected from the Employees in the Organization but they have not been told clearly what is expected out of them. This creates a stress in the Employee. Being explicit will reduce the stress level.

strategy planning including planning a meeting. We should agree on famous saying, ‘Failing to plan is same as planning to fail’.

should be beyond hierarchal is correct and whether there is a aspects. Poor relationship among better way to do the things. employees will create stress in some portion of the organization. •Improper Communication

•Poor Time management

•No delegation

There is a tendency to believe that being busy is good for the company. With this thinking, many times CEO believes that everyone in the company should be engaged always and thereby they are utilizing time well. The time management is not just about utilizing time but about setting right priorities. People should be encouraged to do important things than urgent things. Actions are different from significant actions. Using time with right priorities will reduce stress to a great extent.

I have seen Managers who want to do everything themselves. They would not trust subordinates and spend lots of time in verifying what is done by them. People having tendency to do everything perfectly have this issue. We cannot find another person who can think and do exactly in the way we think and do. Be ready to accept 80% correctness and push slowly to improve further.

•Missing relationship

Individually few employees may lack in a skill and may be suffering from stress because of that. If they are supported by others and any issue is addressed by the team, stress in the organization can be reduced. Team has the power and utilizing synergy of team makes 1+1 = 4

As per GRID theory, 3R is to be focused in the companies for success. The first ‘R’ is resource, second one is ‘R’ relationship and the outcome of these two ‘R’ is result. Believing that only having enough sources will not give effective results. How resources are used fully depends on the type of relationship between the employees. Developing a culture where cordial relationships are nurtured among employees is one of the key jobs of the Management. With good relationship, employees will come out openly on what is bothering them. The relationship

May 2016

•Not using team synergy

•Working harder but not smarter Simply working hard will not give good results. Working with a plan, clear priority and focus in a smarter way will definitely give results and stress also will come down. It is worthwhile to pause in between hard work to think whether the road travelled so far

More than 80% of the issues in the organization or personal life can be attributed to poor communication. Open communication with subordinates, with bosses will eliminate many unwanted assumptions and presumptions to reduce stress level. Bottom up communication is equally important as top down communication. Giving an opportunity for the employee to communicate his feelings, ideas and thinking will automatically bring down the communication. •Too much control Micromanagement of every activity of the employee will lead to stress for the employee. In the process, he may not be able to concentrate and set his own priorities. Too much control of anything is to be avoided. •Reduce expectations When a person is not performing up to our expectations, it will create stress. Many times it will be unrealistic expectations. Reducing expectations is better. Other way round is to spend time in coaching, mentoring and teaching the employee to make him capable to meet

one’s expectations. Making expectations more explicit will also help. Implicit expectations create stress to both. •Only work and no fun There is a saying, ‘All work and no play makes Jack a dull boy’. Similarly, in the Organization if every time only work is being talked, it may create stress. Employees should be encouraged to go out once in a way with family members. Involving in voluntary social work is also good. Some recreational facility inside the company which Employees can use to break monotony is a good idea. Stress in the organization will kill creativity and also will reduce productivity. By identifying and taking few steps to tackle, employees can be made to contribute more. Please send your inputs,remarks,opinionsand suggestions toP.S. Satish,Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103, MantriPara diseApartments,Bannerghat ta Road, Bangalore-560076. Email:gotopssatish@gmail. com;www.linkedin.com/pub/ satish-cp-pii/35/153/85b;Mob: 9845043202. Have a nice day

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CASE STUDY

New Haas for Long Parts at Retro Track and Air

Gloucestershire, UK-based Retro Track and Air has invested in a Haas CNC VF-5/40XT – a 40-taper vertical machining centre with an extra-long, 60 inch (1524 mm) table – to machine cylinder heads for the famous V12 Merlin aero engine.

Installed in Retro’s newly

Air specializes in rebuilding

engines, some of which are

built facility, beside the

and maintaining winged and

the property of the Royal

company founder’s family

wheeled masterpieces from a

Air Force Battle of Britain

home, the VF-5/40XT is a snug

bygone era. Housed in various

Memorial Flight.

fit, towering over an adjacent

outbuildings – as well as a

Haas CNC Tool room Lathe, and working long hours under the supervision of Gavin Faulks, head of design.

hangar at a nearby airfield – are various single-seat racing cars undergoing rebuild and maintenance before the new

Gavin Faulks: The Haas VF5XT is perfect for machining the Merlin cylinder heads, designed more than 80 years ago by Rolls Royce. With

As the company’s name

season. There are also partly

all the parts we make for

suggests, Retro Track and

restored aircraft and aero

old engines, we work from

drawings that are at least as old, which means we often have to reverse engineer components or best-guess dimensions, etc. The castings are made to a material specification called RR50 – created by Rolls Royce. It’s exactly the same material and part design as it was when the Merlin engine

Les Older and Fred Adams red

Retro 2 red

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May 2016

Retro 3 red

Retro 4 red

was first run, in the early

The new Haas has enabled us

1930s. It would be relatively

to keep more of this type of

straightforward to modernize

work in-house, and not rely

aspects of the engine design

so heavily on subcontractors.

– to remedy small design

As a company, that’s the

faults – but the demand is for

general direction we are

authentic parts, without any

heading in. To do so mean

changes from the original.

making an investment, of

This particular batch of cylinder heads – seven off – will take us two years to finish and deliver to the Royal Air Force. Tolerances – between the arrays of bolt holes, for example – are 0.025 mm. Each face takes around a week to machine; the inlet/exhaust faces take another half a week. All the programming is done offline on One CNC.

May 2016

course, but the difference between the parts we used to get – or make in-house on old machines – is night-andday. The repeatability of the Haas is excellent, and it’s very reliable and easy to use. Although we can’t change the design of the parts, we are machining them to a higher standard, which, in itself, is a big improvement.

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CASE STUDY

Better accuracy enables Godrej to redefine quality norms and help reduce costs Accuracy and on-time delivery are key requirements for the tooling industry. Godrej Tooling Division (Godrej) relies on Renishaw solutions to save time, money, reduce scrap and achieve a high level of accuracy.

Samina Khalid Samina.Khalid@renishaw.com

Company background Godrej is a household name in the Indian market, with international presence in The Netherlands, Saudi Arabia, the UAE, Oman, China, Vietnam, Malaysia and Singapore. Founded in 1935 as a captive

tool room, the Godrej Tooling Division commenced commercial operations in 1993 and manufactures press tools, die casts and special-purpose machines, jigs and fixtures. With revenues exceeding INR 1.2 billion, the company caters to the tooling needs of Toyota,

TATA, Honda, GM, Maruti Suzuki and Siemens, amongst others. Godrej, Indiaâ&#x20AC;&#x2122;s largest tooling solution provider, has unsurpassed capabilities in the manufacture of complex dies, with 15-20% of its products

being exported around the world. As part of its Total Productive Maintenance (TPM) initiative Godrej follows PQCDSM (Productivity, Quality, Cost, Delivery, Safety, and Morale) and Kaizen guidelines. The main objectives of its TPM initiative are to reduce down

XL-80 laser for high performance calibration

Godrej technical personnel calibrating a CNC machine using an XL-80 laser

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May 2016

QC20-W ballbar test set up in the Godrej manufacturing facility

time to zero and ensure on time deliveries. Therefore, maintaining the accuracy of its equipment, including CNC and EDM machines, with high precision calibration equipment is essential. Experience with Renishaw’s precision In the early days, Godrej’s evaluation of accuracy was difficult to obtain. National Aerospace Standard NAS979 tests (standardised cutting tests for CNC milling machines) were performed by a highly skilled expert as part of machines commissioning. These tests were problematic and time-consuming to carry out. In 1996 Godrej purchased Renishaw’s ML10 laser system after hearing about the quality of the product and was impressed with its accuracy and reliability. Furthermore, Godrej was surprised how simple it was to use and avoided expensive errors common in the NAS test. Although the ML10 only measured 9 parameters, as compared to 13 in NAS tests, the improvement in results

May 2016

quality was more important than the parameters left undiagnosed. The data reading was instant and easy to analyse. Godrej soon realised that the Renishaw laser system would save time, money and reduce scrap. Its accuracy prompted Godrej customers to specifically request ML10 certification. Mr S M Nayak, Senior General Manager at Godrej, explained, “The product is rugged and stable, we only call Renishaw for upgrades. There has never been an instance of product failure.” Godrej has since upgraded to Renishaw’s XL-80 laser system designed with simplicity and ease of use in mind, reducing the need for a highly skilled expert. Mr Nayak says, “Renishaw’s service is second to none, and they have an immediate response time. We requested training and were delighted that in a week the training was complete.” The XL-80 laser measurement system offers high performance calibration for motion systems, including CMMs and machine tools.

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The journey continues As part of its expansion, Godrej Machine Tools purchased multiple CNC machines in its tooling division. This posed new challenges as the machines needed to be tested for additional parameters like circular interpolation and drive tuning. Once again Godrej turned to Renishaw and found a solution in the QC20-W telescoping ballbar system which identifies machine errors easily with a high degree of accuracy. It directly determines servo mismatch, geometric accuracy, squareness, positional errors and reversal

spikes in all 3 planes (xy-yz-zx). Since the adoption of QC20-W ballbar testing Godrej’s down time and rejection rates have reduced. Delivering results In the tooling industry quality parameters are critical and customers expect a product life span of 10 years. Through its adherence to the highest quality and accuracy standards, Godrej has been able to deliver products with a life span of 125,000 cycles, far ahead of the industry norm of 50,000 cycles. Godrej’s customers in defence, aerospace and nuclear application industries request audits during the

manufacturing process to ensure quality measures are being maintained, and will insist on seeing ballbar certificates for the machines. Mr Nayak explains, “Renishaw has helped Godrej to redefine quality norms, boost in-house capabilities, competence and confidence and help reduce costs.” Beyond savings to revenue generation Die and mould customers choose Godrej because of the long life span of its dies resulting from their tightly controlled quality parameters. The customer demand for high quality and precision

measurement prompted the company to provide laser and ballbar certifications. Now Godrej offers calibration services to others, generating an additional revenue stream. Godrej’s manufacturing facility is equipped with state of the art CNC, EDMs and jig boring machines. Mr Nayak states, “High precision calibration of these machines with a Renishaw laser or ballbar is key to quality and reliable performance.” For further information on Renishaw’s calibration and performance monitoring products, visit www.renishaw.com/calibration

Mr Nayak, General Manager of Godrej Tooling Division

Godrej technical personnel after successfully completing their calibration training

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May 2016

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CASE STUDY

Boost in productivity thanks to complete machining Equipped with a C-axis and Y-axis plus powered tools the NLX 2500 from DMG MORI supports turning operations at Buchholz Hydraulic.

Founded as the handcraft enterprise Buchholz in Kiel in 1884, the Buchholz Hydraulik GmbH of today has concentrated on the solution-orientated development and production of valve controls for mobile hydraulics since 1959. The medium-sized enterprise now has over 300 employees and from its locations in three continents supplies customers from many different branches, including the construction and automotive engineering branches and the maritime industries. In its production, Buchholz Hydraulik trusts in high-quality and high-performance CNC technology in order to meet the high demands placed on productivity. In October 2014, DMG MORI installed an NLX 2500|700 in the turning division, which, with its C-axis and Y-axis, enables complete machining of the sophisticated workpieces. In addition the new DMG MORI design and the intuitive GUI CELOSÂŽ ensure work on the lathe is ergonomic and user friendly.

Fork lifts and excavators are just two examples of the wide field of application of hydraulic solutions. Thanks to its consistent customer orientation Buchholz Hydraulik has established itself as a competent development partner that carries out a project from the concept phase

right through to commissioning and optimisation in the vehicle. The core of the work is always the focus on individual product solutions that fulfil the requirements of the customers in respect of functionality and where the question of costs is concerned.

For many years, Buchholz Hydraulik has stood for high product quality and customerorientated order processing including short delivery times. This high standard is ensured by both well-trained specialists and innovative machine tool technology. Complete machining is an important

keyword here, because this kind of production meets the high productivity requirements. In addition to diverse automated systems, Buchholz Hydraulik also upgraded recently in the area of turning where it replaced an old 2-axis lathe with an NLX 2500|700 from DMG MORI.

Since 1959, Buchholz Hydraulik GmbH has concentrated on the solution-orientated development and production of valve controls for mobile hydraulics.

In October 2014, DMG MORI installed an NLX 2500|700 in the turning division, which, with its C-axis and Y-axis, enables complete machining of the sophisticated workpieces.

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May 2016

The NLX2500|700 is supplied with the state-ofthe-art CELOS® user interface and a user-friendly 21.5” ERGOline touch display.

Buchholz Hydraulik also produces complex turn-mill parts for hydraulic solutions on the NLX 2500|700.

Improved work ergonomics thanks to CELOS® and the new design Produced for the European market at GILDEMEISTER Italiana, the NLX 2500|700 is available with very customer-specific expansion options so that it can ideally accommodate the specific application required. Buchholz Hydraulik uses a version equipped with a counterspindle, C-axis and Y-axis as well as powered tools. “This enables us to both turn and mill the workpieces, and what is more, we can do this on the

front and the back”, explains Heiko Neßler, the responsible machining technician. This is an enormous gain in productivity compared to the previous solution. “For the simple reason that we no longer need a second machine for milling.” Another new aspect for Buchholz Hydraulik is the user interface of the NLX 2500|700. Since last year, DMG MORI has been supplying the machine equipped with CELOS® and a 21.5” ERGOline touch display. Operation of the interface is carried out intuitively and DMG MORI achieves a high

degree of functionality with this combination of advanced software and hardware. Heiko Neßler programs the job order directly on the underlying MAPPS V control – often parallel to primary machining. One great advantage of CELOS® is its 3D-simulation of the program: “This warns us of potential collisions and also calculates the runtimes of the workpieces.” This option is used for calculations and other work scheduling. The new DMG MORI design rounds off the ergonomic operation of the NLX 2500|700 ab. “The large door provides good access to

the work area”, says Heiko Neßler. Buchholz Hydraulik comes to a very positive conclusion with regard to the NLX 2500|700 and the new CELOS® user interface: it has been possible to integrate machine concept perfectly into everyday production. This verdict is clearly confirmed by the fact that another two NLX 2500|700 machines are to be installed in the coming months. For more details visit www.dmgmori.com

The new DMG Mori design ensures users optimum access to the work area.

May 2016

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CASE STUDY

Industrial Internet of Things: Drives commissioning from anywhere

When Newton Tesla sets up new variable speed drives for their customers, they can do configuration, re-programming and monitoring from any location. By connecting a Netbiter gateway to their drives systems, they can offer their customers immediate assistance and do remote commissioning during the critical start-up period.

Newton Tesla drives control

have been working with

before everything is 100%

explains: â&#x20AC;&#x153;At some sites, we

and Netbiter

drives and inverters since

finished. That means that you

need special permits or have

1987.

often have to go back to the

limited access to our drives.

Newton Tesla is one of

site several times resulting

Britainâ&#x20AC;&#x2122;s leading experts

When commissioning an

in variable speed drives

automation system, it is often

and a supplier of advanced

hard to solve everything in

automation systems to

one go. Usually, there are

Another issue is physical

factories and plants across

certain processes you have

access. George Newton,

the world. Specializing in

to wait for or other systems

Managing Director at Newton

Mitsubishi products, they

that need to be installed

Tesla and drive system expert

in expensive and timeconsuming service trips.

For example, we recently built a system for a silver and platinum processing plant in America. Security was so tight that our mechanical commissioning engineer could not take any tools,

Remote commissioning of crane

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May 2016

George Newton commissioning drives at a customer site

-Newton Tesla and Netbiter

mobile phone or even his

The Netbiter communicates

naturally, connection stability

laptop into the area. This

even if the customer only

via the cellular network and

is a few kilometers away,”

makes on-site commissioning

was a main concern for

sends data from the PLC to

Newton Tesla. “The Netbiter

says George Newton. “If

a challenge.”

the cloud-based Netbiter

connection is really robust

you calculate the costs for

which is very important for

a service engineer to get all

us,” says George Newton.

the gear ready, take the car

To get access to their drives systems remotely, Newton Tesla had been looking for a remote management system for some time, but no system had quite lived up to their demands. George Newton continues: “I always had the fear that a remote management system would be complex — that it would be hard to establish a connection and, above all, that the connection would be unstable which could really be a problem if you are programming a PLC. But when we found Netbiter, it was surprisingly easy.” How it works When Newton Tesla delivers a new drives system, they connect a Netbiter EC350 gateway to their Mitsubishi PLC which controls the drives.

May 2016

Argos service. By logging into www.netbiter.net, Newton Tesla can see data such as operating frequency, running hours, energy consumption and much more. By using the function called “Remote Access” they can also use the gateway to establish a secure data tunnel to the PLC, through which they can debug, program and commission the drives

“In fact, I have so much confidence in the connection that I even operate our drives remotely. On a recent

quickly realize that even a short service trip is costly.” Nowadays, Newton

a specific position from the

Tesla always equip their

office, being confident that

systems with a Netbiter

the connection wouldn’t be

EC350 gateway. Since the

interrupted.”

Netbiter itself is quite easy

Quick return-on-investment The first time Newton

tunnel, and can then access

Tesla used Netbiter in a

their Mitsubishi PLC, just as if

customer project, was when

they were connected on site.

they shipped a system to a

important

everything on site, you

project, I moved a crane to

system. They simply open the

Connection stability

to a customer and connect

customer in Phoenix, Arizona. After the initial set-up on site, they could handle the rest of

to connect, this process can be done by someone who isn’t a PLC programmer, giving the PLC programmer more time to focus on the system itself. “Netbiter has given us the convenience of not having to travel to the site every time we need to adjust a system. It has given

When programming a

the commissioning remotely

PLC, you do not want the

from the office in Warrington,

connection to go down

UK. “Naturally, the Netbiter

as it can corrupt your

quickly paid for itself on

offer faster support and

programming and cause the

the Arizona project, but the

commissioning,” finishes

system to malfunction. So

return-on-investment is quick

George Newton.

our offering an edge since we can spare our customers expensive service trips and

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CASE STUDY

Demag Cranes for Refuse Incineration Plant

Terex Material Handling is to equip another refuse incineration plant in China with process cranes. The company received the order from Shanghai SUS Environment Co., Ltd. for three semi-automatic Demag process cranes for the refuse incineration plant in Yinzhou, a district of Ningbo. The cranes are to be used for storing materials, assembling the correct blend of fuel and for serving the furnace.

The three Demag double-

delighted that our crane

refuse bunker. By restacking

and 29.4 metres wide.

girder process cranes will in

technology helps transport

refuse on multiple levels,

Each crane will handle

future be operated in semi-

the rising volume of refuse

they play a decisive role in

around 2,250 tons per day

automatic mode, and also

to be processed as fast as

homogenising the material to

for clearing and blending

in manual mode if required.

possible”, says Dr Thomas

be incinerated. This process

processes as well as for

They will handle 4,500 tons

Bönker, Senior Director

and controlled feeding of the

feeding the incineration

of refuse and feed another

Global Product Management

required quantities of refuse

furnaces. These very high

2,250 tons to the three

& Process Cranes at Terex

ensure constant incineration

handling rates are achieved

rates in the three furnaces.

by high working speeds

incineration lines every day.

Material Handling. “In this

The grabs used to pick up the

way, Demag cranes also

material each have a volume

actively contribute towards

of twelve cubic metres and

protecting the climate and

an active integrated load-

the environment.”

sway damping system. This prevents load sway and

Precise and fast feed

protects against damage to

operation

the grab and bunker walls

commissioned for this project have a span of 35.9 metres, a load capacity of 18 tons and are designed for a lifting height of 41 metres. The cranes travel on a

with long-travel motions up to 100 m/min, cross-travel motions up to max. 90 m/min and load-dependent lifting/ lowering up to 90 m/min, and the active Demag antisway system for fault-free operation.

The crane installations

114-m-long crane runway and

assume key functions

are equipped with position

Semi-automatic cranes

directly at the start of the

measurement and distance

combine the requirements

“Due to the high population

process sequence in the

monitoring systems. Their

of the operator for manual

density, Chinese cities

refuse incineration plant.

low-maintenance multi-jaw

operation of the cranes

generate a particularly

They clear the tipping areas

grabs have a capacity of 12

with the advantages of

large amount of refuse. We

in the delivery zone and

cubic metres. The refuse

automatic operation. In

are therefore all the more

place the material in the

bunker is 90.4 metres long

order to guarantee constant

result from collisions, for example.

The process cranes

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May 2016

Three semi-automatic cranes will feed the furnaces at the refuse incineration plant in Ningo.

supply of the furnaces, configurable storage strategies are integrated in the crane controls to ensure automatic positioning and filling of the three incineration lines. Alternatively, the cranes can be fitted with a clamshell grab that has a load capacity of 2.5 tons. This is used to remove any piles of refuse caught in the feed hopper or to

production has increased

Shanghai SUS Environment

Terex Corporation is

accordingly, which indicates

Co. Ltd. is a general

a diversified global

a major need for action on

contractor who, with its

manufacturer engaged

refuse management. The

broad technical expertise,

in the mechanical and

planned refuse incineration

offers sustainable solutions

plant engineering

plant at the site in Yinzhou,

for both the private and

sector. A core activity

a district of Ningbo, is

public sector.

of Terex Corporation is the provision of reliable,

part of a strategy to avoid landfills and, at the same

Terex Corporation is one

customer-driven solutions

time, to use the constant

of the worldâ&#x20AC;&#x2122;s leading

for many applications,

volume of refuse in a cost-

suppliers of crane

including the construction,

effective and eco-friendly

technology with Demag

infrastructure, shipping,

manner by means of

industrial cranes and

transport, quarrying,

incineration.

crane components. The

mining, refining, energy,

core competence of the

utility and manufacturing

Residential and commercial

Terex Material Handling

industries. Terex reports

refuse is used as fuel for

business group lies in the

in five business segments:

Additional information

power generation plants

development, design and

Aerial Work Platforms,

that supply households

production of technically

Construction, Cranes,

Ningbo is an important

and industrial facilities.

Material Handling & Port

seaport on the south-

sophisticated cranes,

The planned refuse

hoists and components

Solutions and Materials

eastern coast of China,

incineration plant is to

approximately 300 km

and the provision of

incinerate 750 tons of

south of Shanghai. For

services for these

refuse per day in three

years Ningbo has been

products. The business

furnaces. The steam then

characterised by fast

group manufactures in 16

drives two 25 MW medium-

economic growth; GDP

countries on five continents

pressure condensing steam

is almost three times

and is present in more

turbines, which serve two

as high as the national

than 60 countries, reaching

30 MW generators. The

For more details visit

average. Pro-capita refuse

customers in more than 100

refuse disposal contractor

www.demagcranes.com

countries.

and www.terex.com

fetch specific objects from the refuse bunker.

May 2016

Processing. Terex Financial Services offers a wide range of products and services to assist in the acquisition of Terex equipment.

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CASE STUDY

Stellar Success

Stellar is used to meeting demanding requirements. Recent projects include components for RAM Block II anti-ship missiles, the CCtCap crew transport vehicle, 155mm Long Range Land Attack Projectile (LRLAP) advanced gun system, rocket motor cases for the Atlas Five launch vehicle, and others. Their newest project, however, would be one to test the mettle of machinists and management alike. Solid ceramic endmills from Kennametal help this aerospace job shop meet a critical delivery date.

Most shops evaluate new

Jeanette, Pennsylvania, did

cutting tools in an effort

it for an entirely different

to reduce machining time,

reason. “We’d just taken

increase tool life, or improve

an order for some Inconel

part quality, and sometimes

parts,” says production

all three. Stellar Precision

manager Edward Frieze.

Components Ltd., a Tier

“None of us were really

II aerospace supplier in

worried at that point about

tool life or making a profit on the job—our only concern then was how the heck could we get them shipped in eight weeks.” Opening Doors Four decades earlier, Mike

Vucish Sr. was working for a manufacturer of naval nuclear components when he saw an opportunity to go into business for himself. He bought some equipment, invited a few students from the technical school

This solid ceramic endmill might feel like plastic in your hand, but its cutting performance in nickel-based alloys is often twenty times that of carbide tools.

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May 2016

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Stellar Precision owner discusses tooling on the shop floor with production manager Ed Frieze

The mix of machine tools on Stellar’s shop floor is one of continuous improvement and adoption of new technology

where he taught shop class at night, and opened the doors of Stellar Precision in 1978. He continued to work at his day job until his fledgling company was firmly established, but in the meantime brought some family members on board to

Stellar also has several wire

material blanks for the job

continual updates to its

EDMs, a dozen or so 3, 4, and

measured 18 in. square x

equipment list, and has an

5-axis machining centers and

3 in. thick (457 x 457 x 76

eclectic mix of CNC machine

mill-turn lathes, and offers

mm), and weighed nearly

tools from Haas Automation

value-added services such

300 lb. each (134 kg). The

and Okuma, although that

as non-destructive testing,

project team suffered little

balance is steadily tipping

welding, heat treating, and

indigestion over the tough

in Haas’ favor as the shop’s

Teflon coating.

material’s poor machinability;

older machines go into

help out.

retirement. Albright says not

“We started out doing a lot

less expensive than its

of overload work from other

foreign-built competition,

larger shops in the area,

but that “Made in America”

but that evolved into direct

resonates with many of

support of several nuclear

Stellar’s customers. “This

programs because of my

approach also lets us replace

father’s experience in this

our equipment on a more

area,” says daughter Lori

regular basis, which in

Albright, now owner and

turn keeps us current on

president of Stellar Precision.

technology.”

“We’ve since become a key supplier to a number of prime aerospace and defense contractors including Boeing, Lockheed, and Raytheon, as well as various nuclear and medical customers, and have over 70 employees and sales revenues of nearly ten million dollars US.”

Stellar prides itself on

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only is the Haas equipment

Not Too Tough Stellar is used to meeting demanding requirements. Recent projects include components for RAM Block II anti-ship missiles, the CCtCap crew transport vehicle, 155mm Long Range Land Attack Projectile (LRLAP) advanced gun system, rocket motor cases for the Atlas Five launch vehicle, and

Key equipment includes an

others. Their newest project,

Okuma LB-45 lathe able to

however, would be one to

turn 36 in. diameter parts

test the mettle of machinists

up to 120 in. long (91 mm x

and management alike.

305 cm), and a Haas VF-11 5-axis machining center with 10 ft. of X-axis travel (305 cm) and a table load capacity 4000 lb. (1814 kg).

Frieze explains that Stellar had just received a purchase order for a handful of Inconel 625 prototypes. The raw

Stellar routinely cuts Inconel and other nickel-based superalloys, as well as tungsten, maraging steels, 60 Rc 4340 (300M), and tool steel. Nor was tolerance an issue. Frieze points to one recent titanium part that called out a 0.005 in. (0.127 mm) profile tolerance over its 12 in. length (304 mm), the equivalent of holding “a couple tenths” in parts that cost over $5000 apiece before machining. Meeting the relatively wide open tolerances on the Inconel part was not a concern. The problem was one of raw material removal: when

May 2016

finished, the Inconel plates weighed in at a svelte 30 lb. (13.6 kg), 90-percent lighter than their starting weight. Frieze knew there weren’t enough hours in the day to remove that much material using conventional carbide tooling, not if he were to meet the deadline. He needed a better solution. Seminar Payoff Earlier that year, Frieze and several of his coworkers had attended a learning event sponsored by a local chapter of the National Tooling and Machining Association (NTMA), and hosted at the Kennametal technical center in the nearby town of Latrobe. There he met

product manager Matthieu

conditions. Despite the far

Frieze remained skeptical.

Guillon, who introduced him to

higher cutting speeds, we have

He’d tried indexable ceramic

a cutting tool that Frieze was

some customers who have

cutting tools on both milling

initially skeptical of. “It looked

reported 2 to 3 times greater

and turning jobs in the past

and felt like a plastic toy end

tool life than carbide.”

and had mediocre results.

mill,” he laughs.

Stellar didn’t have any

In this case, however, he was willing to try anything

That tool was Kennametal’s

immediate use for the ceramic

series of 4 and 6-flute high

tools, but after making

performance full ceramic

some quick feed and speed

end mills. Constructed of

Guillon arrived a few days

calculations, Frieze knew they

later with the ceramic

would be an effective solution

end mills, Frieze followed

given the right application.

Kennametal’s feed and speed

Several months later, that

recommendations to the

application arrived with the

letter, crossed his fingers, and

Inconel plates. He called Guillon

pushed cycle start.

SiAlON KYS40 grade ceramic and designed specifically for roughing in nickel-based hightemperature alloys, these end mills often out-produce carbide by up to 20 times. Says Guillon, “We recommend a starting speed of 825 SFM up to 3300 SFM (250 to 1000 m/min) and feedrates starting at around 0.001 IPT (0.03 mm) depending on the tool diameter and other

to say he might have a good use for those ceramic cutters they were talking about, and wondered how soon he could

if it meant meeting the customer’s deadline. When

“We weren’t certain what would happen so started out with a block of test

get some.

material,” he says. “You

Skeptic to the Last

with ceramic—only an air

don’t use cutting fluid

Lori Albright in an early morning strategy discussion with Kennametal product manager Matthieu Guillon

Young people and fresh ideas are two of Stellar’s biggest assets, says owner Lori Albright

May 2016

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blast—and everyone in the

was so predictable we were

figures it might be time to put

At the forefront of advanced

shop was crowded around

able to run lights out. It was a

up an entirely new building

materials innovation for more

the machine saying, ‘Wow,

drastic savings.”

on nearby property. She also

than 75 years, Kennametal

looks forward to bringing

Inc. is a global industrial

additional young people

technology leader delivering

Best of all, Stellar delivered

to the machining trade.

productivity to customers

the parts on time with zero

“We have apprenticeship

through materials science,

scrap, and is now quoting a

programs with several of the

tooling and wear-resistant

second, even larger order.

area schools, one of which

solutions. Customers across

Owner Lori Albright was quite

my father used to teach at,”

aerospace, earthworks,

pleased with the outcome.

she says. “I find that it’s often

energy, general engineering

“This type of situation is

our younger people that drive

and transportation turn to

the nature of our business.

our innovation. It’s too easy

We have to react to our

Kennametal to help them

to keep doing things the old

customers’ needs and employ

manufacture with precision

way and not invest in tooling

the best technology available

and efficiency. Every day

and equipment, or pursue

to do so. That’s one of the

nearly 12,000 employees

new technology. The days of

reasons why Kennametal is

high volume, round-the-clock

are helping customers in

look at that!’ There was fire shooting everywhere. It was something we’d never seen before. But within the first hour, we knew it was going to work.” “The tools aren’t inexpensive,” he says. “At one point, Lori had around $20,000 worth of end mills sitting in her office and we were starting to question the investment. But once you calculated in the machine costs and reduced cycle time, we figured it was three to four times more costeffective to go this route. Each end mill gave us one half hour of cut time, at which time we replaced it whether it was worn or not. The process

Enjoying the Heat

so welcome here. We work together as a team to solve challenges.” Looking forward, Albright anticipates continued growth. Having expanded Stellar’s existing facility six times, she

fender clip manufacturing are gone, and it’s only by continually improving their manufacturing processes that companies can succeed and

more than 60 countries stay competitive. Kennametal generated more than $2.6 billion in revenues in fiscal 2015.

grow. For us, Kennametal is

For more details visit

part of that success.”

www.kennametal.com

Hot stuff. Kennametal’s full ceramic end mills operate at spindle speeds up to 10 times faster than carbide and provide far greater tool life

Kennametal’s SiAlON KYS40 4 and 6-flute ceramic end mills are designed for high productivity in tough materials

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May 2016

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TECHNICAL FEATURE

Superior surfaces with high freedom in design RIM casting lacquer system for plastic and wooden parts - efficient coating in injection mold

Exceptional scratch resistance, from colorless to colored up to new metallic accents and self-healing effects are some of the properties with which decorative plastic and wooden parts can be finished directly in the reaction injection molding process. Continued development of the Puriflow casting lacquer system has made this possible. A coating that meets the highest optical and tactile demands, is done in the mold quickly and efficiently without external release agent, so that no sanding or polishing is needed.

Reaction injection molding (RIM) is a prototype process in which on one hand, molded parts are made from plastics through low-pressure injection and on the other hand, this technique is also used in back injection molding of trim parts, for e.g. of real wood veneer and foil. In both applications, the continued development of the tried and tested RIM casting lacquer process

Puriflow of Votteler Lackfabrik offers potentialities to coat surfaces in the RIM process rapidly, economically and with design freedom previously unknown. Thereby the lacquer is applied in one shot process, so that when the part exits the machine it is already coated and finished. Internal release agent increases productivity and

lowers costs The new generation of Puriflow coatings is equipped with an internal release agent for self-de-molding. Thus, there is no need to apply an external release agent on the mold after each shot any more. The production can run fully automatically without any interruption. This increases productivity on one hand,

and on the other hand the component can be packed or processed without any post treatment. Last but not least, the costs for an external release agent are saved. Modular system for individual design freedom The solvent-free, twocomponent-Puriflow casting lacquers based on

Votteler RIM Kunststoff : The continued development of the tried and tested RIM casting lacquer process Puriflow offers potentialities to coat surfaces in the RIM process rapidly, economically and with design freedom previously unknown.

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May 2016

Votteler RIM Leder: The coated surfaces are light, chemical, heat and climate change resistant, low in yellowing and UV-resistant. Regarding scratch resistance, they exceed the stringent requirements of the automotive and consumer goods industry.

Votteler RIM schwarzer Bogen: The solvent-free, two-component Puriflow casting lacquers can be used to coat various plastics such as PC, PC-ABS, ABS, PC-PBT, PC-ASA, ASA, TPU and even PP as well as carbon and composites.

aliphatic Polyurethanes can be processed on casting machines bubble-free. With this lacquer various plastics such as PC, PC-ABS, ABS, PC-PBT, PC-ASA, ASA, TPU and even PP as well as carbon, composites as well as glass, foils and real wood veneers can be coated. This versatility opens up a very wide application range for interior and exterior parts in the automotive industry, in consumer goods, in electronics as well as everywhere where visible parts with high quality surface standards in large quantities are produced.

design. The gloss levels range from high gloss to matt, the surfaces may be smooth or structured with soft-touch.

regularly achieve good results. Therefore, this coating system has the approval of various automobile manufacturers.

Coatings with leather grain or open-pore wood structures can also be depicted. In doing so, the variable hardness of coating - shore A 50 to D 83 - ensures that not only the visual impression, but also the tactile appears deceptively real. Compared to the originals, surfaces achieved in this manner are much easier to clean and more durable.

Self-healing effect makes the scratches disappear on their own

The modular structure also makes a substantial contribution to the casting lacquer system. It enables to customize the visual and tactile properties of the coating according to individual wishes and requirements. Whether transparent, piano black, high-quality reflective chrome finish or elegant iridescent, metallic accents, with innovative effects, deco and brilliant varnishes in many shades, Puriflow opens up unprecedented freedom of

The high resistance is owing to the high physical and chemical stability of the coating system. The coated surfaces are light, chemical, heat and climate change resistant, low in yellowing and UV-resistant. When it comes to scratch resistance, they not only meet the stringent requirements of the automotive and consumer goods industry, but exceed them, sometimes even up to 1.8 times. Even with the “car wash” test of AMTEC Kistler, parts coated with Puriflow

May 2016

High resistance

Since, even with high resistance not every single scratch can be avoided, this coating is equipped with a certain self healing (reflow effect) potency. This will ensure that scratches, above a certain temperature – depending on the system – sometimes also at room temperature -regress and/or are no longer visible. Easy, safe and clean to work with the new 3K-mixing head The two components of the lacquer are injected in to the form during the casting process. When color is added to it as the third component, the new 3K-mixing heads make it possible for the lacquer to be directly injected on to the part. This makes changing color so easy and fast as in a spray application and prevents the contamination of the plant.

The casting over and cross linking takes between two and three minutes depending on the part geometry and Puriflow type. The attributes profile of materials with regard to viscosity, reactivity and color stays stable on the production plant for the duration of the application over several days. Compared to multi- layer coating, RIM casting offers besides significant time savings also significant material savings. There is no over spray. The coating is used virtually 100 percent and it produces no emissions. In addition, the fully automated process ensures minimized rejects and thereby for overall reduced lacquer costs and at the same time higher sustainability. Weitere Informationen: Votteler Lackfabrik GmbH & CO. KG, Schwieberdinger Straße 97/102, 70825 KorntalMünchingen, Deutschland, Telefon +49 (0)711 9804-5, Fax +49 (0)711 9804-642, d.info@ votteler.com, www.votteler.com.

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TECHNICAL FEATURE

Weber Ultrasonics Ultrasonic Submersible Transducer Concept

Individualisation is a major trend. As such, more and more components are now being produced in small series. However, these small series often have quite different requirements in terms of component cleaning. To meet these requirements both effectively and efficiently, Weber Ultrasonics has developed an innovative multifrequency ultrasonic concept with vacuum-resistant submersible transducers for chamber cleaning units. With this trendsetting new solution, cleaning tasks that previously required two different cleaning systems can now be performed with just one.

More and more parts manufacturers are today required to offer flexible production of small series. Component cleanliness is also a key quality criterion in this regard. Chamber cleaning units with ultrasonic

Reducing the number of necessary cleaning units With its SONOPOWER 3S system for 25/50 kHz, Weber Ultrasonics, one of the worldâ&#x20AC;&#x2122;s leading

efficiency for both coarse and fine cleaning. As a result, cleanliness specifications can be met efficiently and with a high level of process stability with a single unit, even

its maximum process stability and power output, but also its exemplary easeof-use. Optimised cleaning efficiency

with a changing or altered

manufacturers of ultrasonic

The use of submersible

parts range. This advantage

components, presents an

transducers in vacuum

particularly pays off in

innovative ultrasonic solution

cleaning processes

component manufacturing in

that now also enables use of

represents a completely

small series, which previously

multifrequency ultrasound

new and advanced

often required two cleaning

in vacuum chamber cleaning

ultrasonic solution. It is

units. The basis of this

made possible by the

cleaning efficiency, cleaning

systems. The flexibility

innovative and trendsetting

and range of possible

special, vacuum-resistant

systems are generally

system solution is the

applications of these

design of the transducers.

designed for one specific

redesigned SONOPOWER 3S

systems is thus considerably

multifrequency ultrasonic

This was conceived through

process. If the cleaning task or the parts spectrum then

increased. Vacuum-tight

generator with up to 3,000

changes, the existing system

submersible transducers

W power output. The

is often not capable of

with switchable ultrasonic

innovative plug-and-play

delivering optimum cleaning

frequencies of 25 and 50 kHz

device is fully digital and

results. Versatile cleaning

ensure optimised cleaning

impresses not only through

systems are often used to meet corresponding specifications. Since the frequency of the sound waves generated by the ultrasonic generator is the key factor in terms of

units are therefore required.

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simulation of the forces acting on the transducer during evacuation of the vacuum chamber. The boiling point of the

May 2016

SONOPOWER 3S 3 kW ultrasonic generator With its capacity of 3 kW, this innovative ultrasonic generator boasts double the output of conventional generators, making it more compact and cost-efficient than comparable solutions.

cleaning medium is lowered

wide range of applications

as precision workpieces,

the SONOPOWER 3S

as a result of the vacuum.

in the field of industrial

optics, PCBs and

to perform numerous

This boosts the cavitation

component cleaning and

instruments. Components

settings automatically.

effect of the planar sound

represents an optimum

from the solar industry and

For example, the

waves released and thereby

solution, particularly for the

workpieces with sensitive

selected frequency is

improves the cleaning

requirements in the field of

coatings can be cleaned

continually monitored and

effect. At the same time,

electroplating. The 25 kHz

just as effectively as any

automatically adjusted

the reduction in pressure

frequency is, for example,

components that do not

during the cleaning

allows the air trapped in

used to clean away rough

require superfine cleaning.

process. This ensures that

boreholes and other cavities

particles following machining

With this versatility, the

the optimum output is

of the parts to escape. This in

operations, as well as to

new multifrequency

always used, even when

turn leads to more effective

degrease stamped and

ultrasonic concept offers

working with changing

cleaning, especially when

deep-drawn parts or remove

massive benefits for a wide

operating conditions

processing components

polishing paste.

range of target sectors.

such as temperature

Large cavitation bubbles

Built-in intelligence for

are created at this low

greater process reliability

with complex geometries. Designed for use with the respective system concept, Weber Ultrasonics employs

frequency. Its high energy

fluctuations, and also guarantees greater process and operational reliability.

delivers highly effective

With a power output

cleaning on the surface

of 3,000 W, which can

of parts. The smaller

set in 1% steps, the

cavitation bubbles of the 50

multifrequency ultrasonic

kHz frequency enable the

generator is perfect for

cleaning of fine particles and

these diverse cleaning

soiling from pores, boreholes

tasks. In addition to this, it

and structures in a gentle

comes with an intelligent

For more details visit

With its frequencies of 25 and

and process reliable manner.

control system based

www.weber-ultrasonics.

50 kHz, the new ultrasonic

This frequency is used for

on a 32-bit processor

de/

generator covers a very

cleaning sensitive parts, such

architecture. This allows

www.insightengg.com

the latest simulation technology when producing individual vacuum-tight submersible transducers. Trendsetting solution for many target sectors

May 2016

The new developments are available both individually and as packages comprising a generator and two vacuum-tight submersible transducers.

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TECHNICAL FEATURE

Visions become reality Mechatronic Handling

Admittedly, the iron hand of the legendary knight GĂśtz von Berlichingen and SCHUNKâ&#x20AC;&#x2122;s 5-finger hand have very little in common. Yet it cannot be denied that the first personal handshake with the agile high-tech gripper creates an unnerving feeling. The soft hand-shake soon dispels all skepticism, however, giving way to enthusiasm for the possibilities of modern mechatronics.

Since the Hannover Messe

cautious fascination or

While visionaries like to

mechatronic handling solutions

2015, where the mechatronic

endless enthusiasm: the

cultivate images of self-

are not arriving with a big

masterpiece caused a

mechatronization of handling

organizing robot fleets and

bang, but rather are gradually

sensation in the media, the

has many facets and offers

skeptics just as vehemently

creeping into everyday use.

innovative SCHUNK gripper

huge opportunities for

attempt to make nonsense

And pragmatism prevails:

has become the shooting

users who dare to let go of

of the concepts of Industry

the easier it is to integrate a

star in the area of flexible

convention and courageously

4.0, a brief look at the

mechatronic component in

handling. Whether uncertainty,

embrace innovation.

actual situation shows that

the process, the more reliable

EGP application: SCHUNK offers a diversity of mechatronic products, enabling users to implement customized solutions.

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May 2016

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LDx application: SCHUNK LDx linear direct axes are already widely used today in high-performance assembly.

it will function; and the less

of complexity. At SCHUNK

principles, such as the junction

know-how is needed during

the standard products extend

roller guide in the case of small

installation and operation, the

from the simple mechatronic

component grippers or the

greater will be the acceptance.

module that can easily replace

patented multi-tooth guidance

a pneumatic component on

for universal grippers are being

a one-to-one basis, through

transferred by SCHUNK to the

adaptable modules that can

mechatronic products. This

Linear direct axes are already an integral component in high-performance assembly

be equipped with different

appli-cations in the electronics

servomotors, to intelligent

industry; the automotive

mechatronic grippers. The

industry unreservedly

latter offer an entire bundle of

combines pneu-matic and

convenient functions, such as

mechatronic modules to

control via an integrated web

create equally reliable and

server, gripped part detection

flexible hybrid gripping sys-

or stepless regulation of the

tems; and in the handling of

gripping force. The mechanic

small components, simple

who in the past put pneumatic

mechatronic small component

components into operation can

grippers are replacing the

do the same today with simple

previously widespread pneumatic pickers. Simple grippers facilitate entry

mechatronic components, without first having to acquire extensive know-how.

cre-ates confidence, shortens the development time and ensures maximum process stability, since the guidances have withstood the test of time in thousands of pneumatic modules. The more strenuous task at present is to convince users that a gripper can be positioned, that a force is returned and that the use of mechatronic modules could possibly eliminate entire stations. While enterprises in the electronics industry and

Opening and closing of the

medical technology are quite

The leading suppliers cluster

mechatronic alternatives is

progressive in the case of

their mechatronic drive

no more complicated than

more complex components,

and handling components

with pneumatic grippers.

other sectors are only gradu-

according to different levels

Proven and efficient guidance

ally starting to trust the new

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technology. SCHUNK offers a diversity of modules as a response to these differing rates of mechatronization, therefore enabling custom solutions. They extend from conventional pneumatic components with no sensors whatsoever that fulfill only their core function, through pneumatic components with simple or complex sensors to intelligent mechatronic modules. With the help of optional accessories such as analog magnetic switches, users and system planners can also equip pneumatic modules with intelligence. More than ever before it is possible to define how much of it should be used in the particular applications. Field components collect more process data Three central issues currently

May 2016

dominate the development of

acquisition take place directly

data, uses it to determine

A bus system can be used

mechatronic handling systems:

in the component and not

which component is gripped

to connect the mechatronic

connectivity of components

only in the PLC.This method of

and automatically reduces

components both with each

all the way to the field level,

acquiring information at the

the gripping force in the case

other and with the higher level

functional safety and man/

component level is not entirely new, because grippers have

of sensitive parts that are

system controller to create

robot collaboration. The trend

long been able, by means of

susceptible to deformation, for

a cyber-physical system. This

is toward field components

single point magnetic switches,

example.

connec-tivity of the modules

that can do more than their actual function, i.e. more than

to provide information on

Contact pressures or torques

opportunity, however also

gripping, turning or linear

whether a part is gripped or

during assembly can also be

one of the biggest challenges,

motion. In short: the field

not. What is changing is the

measured and monitored in

due to the large number of

components of tomorrow will

depth of this information.

real time. New component

real-time Ethernet interfaces,

types can easily be integrated

each of which creates its

in such processes. In addition,

own standard. In order to

intelli-gent workpiece carriers

fully utilize the potentials of

or intelligent type plates

mechatronic handling, the field of mechanical engineering

generate information.

The use of an analog

is undoubtedly a major

The gripper not only grips,

magnetic switch instead of

but also reportsback a force,

a conventional magnetic

for example. Such data can

switch, for ex-ample, enables

be converted into useful

the precise differentiation of

make it possible to uniquely

information, such as whether

single components. Even more

identify the single components,

or not a part is in order. This

advanced are mechatronic

allowing adaptation of the

increases the functionality

grippers with the capability

process precisely to the

of the components, but also

of storing information about

particular part, as well as

decentralizes calculation

which measured value belongs

documentation. In extreme

processes; in other words, data

to which component. Such a

cases, individualization down

processing and information

gripper analyzes the acquired

to a quantity of one is possible.

will have no choice but to narrow the focus to essential standards. Currently PROFINET, EtherCAT and EtherNet/IP are the most promising worldwide standards. Safety functionality increases

LWA application: The SCHUNK LWA 4P Powerball Lightweight Arm enables very flexible and even mobile handling operations.

May 2016

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cost effectiveness In addition to “connectivity”, “functional safety” and “man/ robot collaboration” are the primary issues in mechatronic handling. Experts assume that direct collaboration between man and robot will extend throughout the entire production process in the middle and long term. Instead of working next to each other in mechanically separated spaces as at present, man and robot will cooperate in a barrier-free environment in the future. Especially in assembly applications there will soon be a drastic increase in the number of collaborating systems.

Certified safety gripping

Another advantage of

systems today already allow

certified safety systems is

the functions SLS (Safe

that the safety certification

Limited Speed), SOS (Safe

can be limited to the pool of

Operating Stop), and STO

system components, so that

(Safe Torque Off). In Safe

the system does not have

Operating Stop the modules

to be certified as a whole.

are continuously supplied with

The functional safety of

power, so that gripped parts

components presents new

are held safely even without

challenges to manufacturers,

mechanical gripping force in

from separate specifications,

the event that a process is

through the actual certification

interrupted. As soon as the

and qualification of the as-

safety zone is released, the

sembly and service employees

grippers directly switch back

to documentation.

to regular operating mode without delay and without having to restart the system. Such safety functions can increase productivity and cost effectiveness especially in large systems.

The mechatronization of handling systems is a process consisting of numerous small steps. The focus is on networked components and systems that continuously

monitor their own status,and that of their environment, but also allow a high variance. These components in the future will perform more than just their function; they will also generate information. In addition, collaborating and mobile systems will become increasingly important and will present new challenges with respect to process organization. To avoid being left behind by the market, companies will have to stay on the ball and continuously develop both their products and their processes, as well as the know-how of their employees. For more details visit www.in.schunk.com

PPU-E application: The mechatronic pick & place units of the SCHUNK PPU-E series are the fastest high-performance assembly units currently available on the market. They allow a variable process design with minimal cycle times.

SVH with needle: In service robotics the SCHUNK SVH 5-finger gripper hand opens up new dimensions in gripping and manipulation. It also allows man/robot communication via gestures.

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May 2016

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

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MART UPDATE

Lapp Group extends range for cable assemblies from component supplier to system supplier Lapp Group extends

for customers,

range for cable assemblies

including

from component supplier

consultation. For

to system supplier

that purpose, the company has

When people think of

been increasing

Lapp, they normally

its corresponding

think of cables, cable glands and connectors of excellent quality. That’s certainly true, but in fact the company’s

production and assembly capacities in America, Europe and Asia. As a

offering goes much further. Over the last 30 years, the Lapp Group has developed expertise in the field of cable

result, the number of sites has risen from 5 in 2015 to 12 in 2016. This means that Lapp is in an even better position than before to produce assembled

assembly at a number of locations – including Jigani, Bangalore - Lapp India manufacturing

cabling solutions around the world according to customer requirements.

right components, combine

dynamic applications, right

them in a system and ensure

up to the highly dynamic

optimum operational safety

extended line performance

as a result”, explains Marc

class. Lapp offers the

Jarrault, Managing Director

right solution for every

– Lapp India. “We do this

requirements profile. Our

on a global level, with local

servo cables can be built as

contacts boasting local

per the standards of Siemens,

market knowledge.”

Rockwell, FANUC, BOSCH.

ÖLFLEX®CONNECT is based

• ÖLFLEX®CONNECT CHAIN

on three cornerstones:

–assembly of entire drag

plant. With the company

The customers benefit

continuously expanding

from customised solutions,

its knowledge of the

high quality thanks to the

industry, it is now able

optimum interaction of all

• ÖLFLEX®CONNECT

to meet even the most

components and expert on-

CABLES – classic cable

complex requirements.

site consultation. “Nobody

assembly. This refers to

knows Lapp products as

all cables for which Lapp

well as ourselves: from the

assumes control of cutting

selection of the highest-quality

to length, marking, stripping

copper, and granulate for the

and connecting cables to

sheath, through to testing

connectors – in standardised

for series production. We are

designs or according

therefore able to select the

to individual customer

Under the new name of ÖLFLEX® CONNECT, Lapp is now extending these activities and standardizing all global cable assembly activities

requirements.

“We are the professionals for connectivity solutions. You can trust Lapp to provide innovative, reliable and highly efficient connectivity solutions to meet your industry requirements since we have deep application knowledge”, Marc Jarrault Managing Director, Lapp India.

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• ÖLFLEX®CONNECT SERVO –assembly of servo cables. They are available from the cost effective basic line servo solution for applications free of aggressive environmental influences, to the core line, specially designed for

chains. In this context, Lapp also assumes control of the integration of the cables into the drag chain. On request, Lapp will even perform assembly in the plant on the customer’s premises. Complex solutions are also possible in this regard – for example, fully equipped steel drag chains weighing several tonnes that are used in a wide range of industries. Whichever variety Lapp customers decide to choose, they always benefit from assembly provided from a single source, on schedule and at the highest level of quality – even in the case of complex requirements.

May 2016

Hypertherm Announces ProNest 2017 Hypertherm, a U.S. based

nesting. Color by part property

More changes to

manufacturer of plasma,

that fills parts with different

Hypertherm’s nesting

laser, and waterjet cutting

colors based on a designated

software family of

systems, announced a

attribute (name, priority,

products are also

major version upgrade to its

work order number, due date,

taking place as part

ProNest® advanced CAD/

etc.) and ProNest reports

of this major version

CAM nesting software for

that show fill colors in part

release. Hypertherm

automated cutting. ProNest®

images making it easier to

nesting software for

2017 contains a number of

locate parts. Redesigned drill

cutting in production

improvements designed to

machine interface for plasma

environments, formerly

make customers more efficient

or oxyfuel machines that

named TurboNest®,

with an active Software

and profitable.

incorporate drilling, tapping,

is now called ProNest LT.

Subscription can upgrade to the

and other spindle operations to

Also, Hypertherm nesting

new version of their respective

New features include: Manual

seamlessly tackle jobs directly

software for cutting in job

product at no additional

nesting improvements,

in ProNest. Native 64-bit

shop environments, formerly

charge and continue to receive

including drag array, anchor

support allowing ProNest to

NestMaster™, is now ProNest

unlimited technical support,

part to cursor, and automatic

take advantage of the extra

LTS. ProNest LT and LTS

and other benefits. More

bumping functionality for

accessible memory available on

contain many of the features

information is available at

greater control and faster

a 64-bit CPU/Operating System.

found in ProNest 2017. Users

www.hypertherm.com/CAM.

KBL to Display its Innovative Fluid Management Product at IFAT 2016 IFAT is the world’s leading

The 18th edition of this

(LLC) pumps and multistage

ISO 50001, BS OHSAS 18001

trade fair for Water, Sewage,

prestigious international

pumps - RKB. The stall in

and SA8000. In addition, the

Waste and Raw Materials

exhibition for business

itself will be an avant-garde

Kirloskarvadi plant is also

Management held annually in

facilitation and consultancy

statement in design and

certified for N & NPT Stamp.

Munich, Germany

services will be held at

display.

Showcasing its commitment to

Kirloskar Brothers Limited, a leading fluid management company, along with its global subsidiaries, SPP Pumps and Rodelta Pumps, is showcasing its state-of-

Munich in Germany and will be a powerful platform for displaying various environmental protection and waste disposal products by global companies.

the-art products at the IFAT,

At stall 133/232 in Hall No.

2016in Munich, Germany.

A6 and outside stall 56A.13,

The event, organized by

the spotlight is going to be

Messe Munchen GmbH, is

on the innovative range of

considered as the world’s

Kirloskar Brothers Limited

leading trade fair for

(KBL) products such as End

environmental technology

SuctionPump (ES), the large

in three sectors: recycling,

Split Case Pump (UPH), LS

water, sewage and resources.

Pump, Lowest Lifecycle Cost

May 2016

This event will allow KBL to showcase its strong international presence and expertise in manufacture of

environment, KBL’s corporate office in Pune is Platinum-Rated Green building, certified for ISO 9001 & SA8000.

world-class fluid management

All KBL factories deploy Total

products.

Quality Management tools

KBL is a leader in the global fluid management space with path-breaking innovations as well as highest standards of manufacturing and operations. All manufacturing facilities of KBL are certified for ISO 9001, ISO 14001,

using European Foundation for Quality Management (EFQM) model. KBL is the only pump manufacturing company in India and ninth in the world to be accredited with the N and NPT certification by American Society of Mechanical Engineers (ASME).

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Renishaw opens new Additive Manufacturing Solutions Centre in India Renishaw, the global engineering technologies company, is opening a new Additive Manufacturing Solutions Centre on 15th June in Pune, India. The new facility will provide a secure development environment in which customers can expand their knowledge and confidence using additive manufacturing (AM) technology. The Solutions Centre will be equipped with the latest AM systems and staffed by knowledgeable engineers to allow fast access to deploying the technology, all at fixed predictable costs. Additive manufacturing, often referred to as metal 3D printing, is widely recognised as a transformational manufacturing technology that will impact on everything from components in aircraft engines and satellites, to dental restorations and surgery for facial reconstruction. Renishaw, which is the UK’s

“Whilst AM can create complex geometries in a single process step, some level of finishing is generally required to produce functional products. Renishaw’s knowledge of metrology, machining and finishing processes can help customers to develop an integrated manufacturing solution for their innovative new product.” Marc Saunders Director – Global Solutions Centres, Renishaw only supplier of metal AM machines, sees the new Indian centre as a cornerstone in its ambition to be a major contributor to the adoption of AM in the established and fast growing high technology Indian manufacturing sector. When adopting any disruptive new manufacturing technology, companies will go through a rigorous assessment process to understand the potential benefits, and to prove the reliability and capability of the production process. The

investment in time, resources and equipment to achieve this can be significant. Renishaw Solutions Centres will lower this entry barrier by providing cost-effective access to machinery, facilities and AM expertise. Solutions Centres will provide a confidential development environment in which firms can explore the benefits that AM can bring to their products, and quickly build their knowledge and confidence in AM as a production technology.

“We are delighted to be opening the first Solutions Centre in India. The thrust of the additive manufacturing centres is to create a platform on which to work in close partnership with our customers to help them realise the benefits of AM in their products and manufacturing processes.” Rhydian Pountney Director - Indian Sales & Marketing Operations, Renishaw

“Renishaw’s vision is to make AM a mainstream manufacturing technology, used in series production of high performance parts for aerospace, medical, automotive, oil & gas, mould& die and consumer products. The technology will enable companies to design and make innovative products with spectacular gains in performance and efficiency.” Clive Martell Head - Global Additive Manufacturing, Renishaw

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Whilst the new Pune Solutions Centre highlights Renishaw’s continuing investment in the development, manufacture and application of AM technologies, it also maintains the company’s long term commitment to the Indian market. It will sit alongside Renishaw’s existing key strategic additive manufacturing development locations in the UK, USA, Canada, Germany & China, with additional centres also planned for other key markets. Renishaw has been trading in India for over 30 years and it established a representative office in Bangalore in 1993 which was converted to a wholly owned trading subsidiary in 2000. Today the company has offices in five cities, plus resident sales engineers in other key areas. In Pune Renishaw has a 80,000 sqft building which houses a customer demonstration and training facilities, a procurement operation to directly source high quality components from Indian vendors, a large software development team, and a 100% Export Orientated Unit (EOU) which manufactures certain products that were previously procured and where assembly costs are critical to competitiveness. Total employee numbers within India now number 340. For more details visit www.renishaw.com/ solutioncentres

May 2016

th INTERNATIONAL MACHINE

AIEMA

TOOLS EXHIBITION

Initiative

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16th - 20th JUNE, 2016 CHENNAI TRADE CENTRE, CHENNAI TITLE SPONSOR

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Precision Surfacing Solutions

SILVER SPONSORS

ORGANISED BY

For Show Details & Visitor Registration : www.acmee.in May 2016

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KEPL Awarded by CII for KAIZEN Practices Pune-headquartered Kirloskar Ebara Pumps Limited (KEPL), a joint venture of Kirloskar Brothers Limited in India, continues to prove its excellence in kaizen practices by bagging numerous awards and rewards from the Confederation of Indian Industry (CII). In yet another milestone, KEPL won the “Runner up” trophy at the Kaizen Competition organised by the Confederation of Indian Industry (CII) Western Region. After being awarded and recognised with the “Best Kaizen Excellence Award” for Consistency-2016 at the 11th Kaizen competition, organised by the Confederation of Indian Industry (CII), KEPL was recommended to participate at the “Confederation of Indian Industry for Regional Finals, 2016”. This event took place in Pune, Maharashtra where 21 teams from different location across Maharashtra

participated. The CII functions to create and sustain an environment conducive to the development of India, partnering with industry, government, and civil society, through advisory and consultative processes. Kaizen (Japanese term for “improvement” or “change for the better”) is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership. In today’s scenario, “Kaizen activity” is one of the benchmarked tools that not only enhances the growth of any organisation, but also uplifts the morale of the employees. It institutionalises a process of continuous improvement and innovation in work-practices and method in Lean Manufacturing by encouraging employee’s

creativity and innovation. Team “MSD” [Machine Shop Department] from the KEPL state-of-the-art manufacturing facility at Kirloskarvadi presented their case study on “Reduction in line organisation loss by enhancing machine capacity of Keyway Broaching machine and improving Broach utilisation” under large scale industries category. The case study started with an introduction of KEPL, introduction of Gemba, followed by problem definition, selection of Kaizen theme, root cause analysis, Kaizen idea,

implementation and horizontal deployment. Commenting at the occasion, Mr. S. S. Katare, Plant Head KEPL, said “Since last 4 years KEPL is receiving the CII State Level awards consistently for KAIZEN practices. We started this journey in April 2013 by introducing innovative schemes for challenging workforce towards implementing this process. We now have trained operators who implement this process, maintains SOP which is frequently audited for sustenance.” For more information, visit: http://kepl.in.net/

Smallest PROFIBUS Master Interface for Mobile Applications

Softing presents PBpro USB, the world’s smallest PROFIBUS master interface for PCs. It is so compact that it easily fits into a PROFIBUS connector housing. The PBpro USB has the size of a matchbox and can be easily stowed in any laptop bag - a convenient companion for mobile use.

a wide variety of tasks from network configuration and device parameterization to plant maintenance and production data acquisition. The interface is connected directly to a device on the PROFIBUS target system, thereby avoiding circuitinduced reflections of the field bus signal.

The fast PC connection via USB high-speed makes PBpro USB the ideal interface for

The product is also well equipped on the software side. The scope of delivery

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includes Windows drivers for XP to Windows 10, various programming examples, a communication DTM for FDT applications and a PROFIBUS configurator with commissioning function. PBpro USB is compatible to its well established predecessor PROFIusb and can be used directly in a variety of commercially available applications. A quick and easy integration of OPC Client

applications is possible via an optional PROFIBUS OPC Server. For further details visit www.softing.com

May 2016

Intelligent sensors pave the way for the industry of the future At the Hannover Messe (HM) trade fair, SICK AG presented innovative sensor solutions for forward-looking applications under the slogan “Industry 4.0 ready”. As a technology supplier in the field of industrial sensors, SICK’s presentation explained how intelligent sensor data can be used: from highly aggregated, complex web services in the cloud and shop-floor systems

for logistics transparency to autonomous robot control. From its stand at Hannover Messe – the world’s largest industrial fair, featuring 3,342 exhibitors – SICK demonstrated the importance of its role as a technology driver in the field of Industry 4.0. Alongside the company’s own intelligent systems and sensors, SICK also presented various examples of its collaborations with research and industry partners. These joint exhibits featured integrated solutions typical of Industry 4.0, which were a big hit with visitors.

In particular, the exhibit on human-robot SICK presented innovative sensor solutions for collaboration forward-looking applications at the proved to be Hannover Messe trade fair. a major draw,

featuring a robot arm which took a glass cup from a visitor. The robot used the RFID tag affixed to the cup to read the individual print job and performed the task by itself. As the station was protected The exhibit on human-robot collaboration at the with microScan3 SICK stand in Hanover proved to be a major draw. laser scanners, the robot was able to work transparent paths within the without partition screens in this factory. application. As soon as anyone came within a certain distance The device is the first to be able to of the robot during operation, measure the movement direction its movement slowed down. If of an RFID tag bearer when read. someone came even closer, the This means that, in the future, it robot stopped completely. will be possible to record not only the position, but also the transport Meanwhile, the trade fair also path of workpieces with minimal featured a first in the field of effort. In this way, the current track and trace technology in location of a part will always be the form of the RFU65x RFID evident in real time. read/write device, which creates

Raytek, Ircon, and Datapaq join forces to create Fluke Process Instruments Fluke Corp. is integrating its Raytek, Ircon, and Datapaq product lines into a new brand: Fluke Process Instruments. All three companies have been part of the Fluke Corporation portfolio for some time. Raytek, Ircon, and Datapaq branded products include a complete line of rugged and dependable infrared sensors, line scanners, thermal imagers, and

temperature profiling systems for use in harsh, high-temperature industrial manufacturing environments. The company has launched a new website, www. flukeprocessinstruments.com, and will operate all related global activities under the new corporate name. Fluke Process Instruments designs, manufactures, and markets

a complete line of infrared temperature measurement and profiling solutions for industrial, maintenance, and quality control applications. Distributed worldwide under the Raytek, Ircon, and Datapaq

“Fluke Process Instruments combines more than 125 years of experience in pioneering new technologies into one integrated company.By joining the three companies under a single brand, we can improve our communications and accelerate our product innovation. We are proud of the legacy these brands bring and will continue to grow them as Fluke Process Instruments.” Ankush Malhotra General Manager, Fluke Process Instruments

May 2016

brands, the products reflect the combined experience of over 125 years in manufacturing the world’s finest temperature measurement tools and devices. Founded in 1948, Fluke Corporation is the world leader in compact, professional electronic test tools. Fluke customers are technicians, engineers, electricians, and metrologists who install, troubleshoot, and manage industrial, electrical, and electronic equipment and calibration processes. For more details write to india@ flukeprocessinstruments.com

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Certified quality for offshore applications - ROBA®-DS shaft couplings tested by DNV GL robust, reliable and temperatureresistant: They are therefore particularly suitable for use in extreme environmental conditions at sea. Furthermore, the ROBA®-DS couplings are wear-free, i.e. they reduce the maintenance effort required to a minimum. Just as for the previous model ROBA®-D, mayr® power transmission has also received the type approval from the DNV GL (Det Norske Veritas und Germanic Lloyd) for this even more compact and high performance density ROBA®-DS all-steel coupling up to construction size 2200. This certificate confirms the high quality and reliability of the coupling with customary safe dimensioning and design, and The high performance and robust ROBA®-DS disk ensures the maximum possible pack couplings are especially suited for operations operating and in extreme environmental conditions at sea. The functional safety type approval by the DNV GL confirms the high for use on the high quality and reliability of the couplings and ensures seas. maximum possible operating safety on the high seas. Image source: mayr® power transmission High performance Whether in the drives of ship propellers, mobile platforms such as drilling platforms for oil and gas extraction, or also in tidal power plants – the areas of application for disk pack couplings in the maritime industry are diverse. For example, if the main drive of a ship propeller is an electric motor, then spring steel disk pack couplings such as the ROBA®-DS by mayr® power transmission provide decisive advantages. These couplings are

and backlash-free The nominal torques stated in the catalogue can be utilised without any limitations using the ROBA®-DS disk pack coupling. A reduction of The compact and high performance ROBA®-DS disk the nominal torque due to pack couplings by mayr® power transmission have misalignment, been certified by DNV GL. They ensure maximum overall load possible operational and functional safety for users on configuration the high seas. Image source: shutterstock/am70 or balancing requirements is not necessary. disk pack couplings transmit The couplings are compact and torques up to the nominal torque feature a high performance absolutely backlash-free and density and small dimensions with a consistently high torsional – ideal for ship engines, in rigidity. The shaft misalignments which only little installation stated can be utilised to space is available. In case of 100% without influencing the providers who have to take transmitted torque. The disk misalignments and alternating pack couplings compensate torques into consideration radial, axial and angular when dimensioning, a larger misalignment of shafts, and as coupling frequently has to a result protect the bearings be selected for the same against undesired loads, and nominal torque and also the therefore against unnecessary same speed. The ROBA®-DS downtimes and costs.

Matrix bags Indian Design Mark Award 2016 Matrix Telecom and Security products SPARSH VP330, SPARSH VP510, NAVAN CNX200 and COSEC VEGA have been awarded the India Design Mark, by the India Design Council. The India Design Council is affiliated with India’s Ministry of Commerce & Industry and is made up of eminent people in academia, design and industry organizations. India Design Mark is initiated in cooperation

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with Good Design Award, Japan. Design Mark symbolizes product excellence in form, function, quality, safety, sustainability and innovation and communicates that the product is usable, durable, aesthetically appealing & socially responsible. Through India Design Mark the India Design Council seeks to inspire Indian manufactures to design remarkable products that enrich the lives of people in India.

“I am very pleased with this recognition that four of our flagship products have received. This award not just realizes our efforts but also motivates us to continue creating more new and innovative products. It stands for the quality of Matrix products.” Ganesh Jivani Managing Director, Matrix Comsec

May 2016

Innovative Automation Products

B/24, MIDC Satara 415004 India

+91 2162 246509 +91 2162 245966 sales@innovativedro.com www.martupdate.com 91

Sensorik 4.0®: Cloud-based Sensor Services. The Industrial Sensor in the Internet of Things Sensors are valuable sources of information and can also be used outside of conventional machine and plant engineering to optimize processes and conserve resources.

materials are avoided. In addition, if the filling level falls below a critical level, a message is sent to the mobile phone of the person responsible for replenishment.

The Internet of Things opens up new possibilities for networking even sensors spread over long distances. Sensor signals can be provided at exactly the right time in the place where the information contained in the signals can be used profitably.

A different application has been implemented together with SAP. A sensor for type verification of light units for mobile compressors is used in this application and the data from this sensor is supplied in the cloud of an MES system that organizes the material flow for the complete assembly of the compressors.

For example, the detection of filling levels using modern sensor technology is possible in most cases with lesser or greater ease. Where containers are spread over long distances, however, greater cost is often involved with the transmission of sensor signals. This means automated solutions have to be disregarded and filling levels have to be monitored manually with more or less regular observations. With networking via the Internet, level data from a large number of sensors spread over long distances can be processed centrally and prepared for further processing. Pepperl+Fuchs shows connections of sensors to various cloud platforms in a solutions park. An application has been developed with partner connectavo which uses sensors to record the filling levels of the reservoirs of a number of filling machines in use across various production sites and manages these levels centrally. The replenishment logistics are simplified as a result and downtimes due to a lack of

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Status data from sensors in company IT The increase in overall equipment effectiveness (OEE) is one of the most important applications of Industry 4.0. The retrofitting of existing production systems poses major challenges for plant operators. The application presented as a joint project by Pepperl+Fuchs, TE Connectivity, and Software AG uses hardware that can easily be retrofitted. This is based on the sensor level of the SmartBridge interface from Pepperl+Fuchs and on the control and fieldbus level of the spark device of TE Connectivity. These two data ports transmit the extracted performance data via cable or via a radio interface to the business platform of Software AG. This platform allows three important added value services within the context of Industry 4.0 through data consolidation with a downstream analysis: 1. Process optimization Spark uses the process data from sensors and actuators from the control level and

displays this on a dashboard, which also reveals less obvious delays or micro-downtimes with the help of a historical data recorder.

our goal.

Photoelectric sensors from Pepperl+Fuchs even provide information about diminishing detection capability due to soiling of the exit lens or the reflector. This information is extracted from the machine circuit with the help of the SmartBridge interface and transmitted to a service platform via an Internet gateway. The platform evaluates the status information from the sensors and, where necessary, triggers a field service application, which can be completed either by internal or external maintenance service providers.

A willingness to take entrepreneurial risks, a pioneering spirit, and a firm belief in their own inventive powers – these were the assets that Walter Pepperl and Ludwig Fuchs started out with when they opened their Mannheim radio repair shop in 1945. Their invention of the proximity switch a few years later proved their strength. It was also the starting point in a successful history defined by close customer relationships as well as innovative automation technologies and procedures. Then as now, our focus is directed squarely on the individual requirements of each customer. Whether as a pioneer in electrical explosion protection, or as a leading innovator of highly efficient sensors – the close communication with our customers is what allowed us to become the leader in automation technology. Our main objective is combining state-of-the-art technologies and comprehensive services to optimize our customers’ processes and applications.

Automation is our world. A Perfect application solution is

For more details visit www.pepperl-fuchs.com

2. Status monitoring A correlation of historical events with the actual machine runtimes and maintenance recommendations of the manufacturers provide a good picture of the actual (maintenance) status of the machine or plant. 3. Service on demand

May 2016

Three days focusing on the new formula for production HELLER WerkTage 2016 Last year, more than 800 international visitors attended HELLER WerkTage to experience how HELLER is producing, living and assuring quality in Nürtingen. In 2016, the company shines the spot-light on “the new formula for production”. There is good reason to do so, because HELLER will be presenting a new generation of versatile machining centres. Additionally, handson demonstrations at the “Manufacturing Center” and moderated panel discussions will underscore the practical orientation and attraction of the event. Proven, and at the same time, innovative solutions will again be the focus of HELLER WerkTage in 2016. Under the motto “The new Formula for Production”, the company will be presenting high-end machining with maximum productivity from 15 to 17 June 2016. With a new generation of versatile machining centres, HELLER opens new perspectives. These machining centres feature a fifth axis provided by the workpiece and have been designed for dynamic 5-sided as well as simulta-neous 5-axis machining. For this concept, HELLER has re-combined proven compo-nents also used in existing machine series to develop an extremely productive machine suited for a wide range of parts and materials. All rotational axes are provided by the workpiece. As a logical expansion of the existing product portfolio, the new machine concept is synonymous with high proc-ess stability, with the fifth axis designed as a bridge with counter bearing to guarantee

May 2016

a high degree of stability, whilst the horizontal spindle guarantees fast tool changes, resulting in mini-mal idle times. High flexibil-ity was another priority for HELLER in the development of the machine. Therefore the machining centre is ei-ther available in table design or equipped with pallet changer. Additionally, proven motor spindle tech-nology lets users choose between HSK63 and HSK100 spindle taper. Transparency practised In addition to the presenta-tion of the new machine, HELLER will again provide extensive insights into pro-duction and assembly during WerkTage. As in previous years, numerous guided plant tours are on the agenda. They will give visitors an opportunity to experience quality “Made by HELLER” in application in-stallation and final assembly of machining centre and modules. Exhibits at the “Manufacturing Center” in-clude the new machine concept, mill/turning centre model CP 4000 and 5-axis machining centre model FP 16000. The CP 4000 mill/turning centre places the emphasis on turning opera-tions in addition to its proven milling characteristics. For this purpose, the machine is equipped with a fifth axis provided by the tool com-bined with a direct driven rotary table. Vertical and horizontal turning operations of outer and inner contours can be accomplished with-out any problem with the C axis and optional A and B axis. 5-axis machining centre model FP 16000 provides traverse paths of 2400x1600x1600mm (X/Y/Z), a speed range between 5 and 8,000rpm and 60kW drive power. Visitors will have the opportunity to see

these machining centres live in action and to discuss details with the machine operators. The exhibition programme is rounded off with pallet automation tech-nology. Three well-known manufacturers will be dem-onstrating how to integrate logistics processes and how to establish a seamless flow of information in the manu-facturing process in order to maximise utilisation in pro-duction. No less interesting will be the guided tours through the education and advanced training facilities. Having received a certificate for outstanding commitment in education 2015/2016, HELLER will be presenting the ProfiTrainer. This fully functional faithful model of a CNC controlled machine tool features four axes, a horizontal main spindle and a B axis as rotary table. It allows to perform all operat-ing functions with the movement sequences re-quired for NC machining. The Siemens 840 D sl con-trol and the control cabinet are equipped with real con-trol components like they can be found in HELLER’s current machine series. That means that the ProfiTrainer can be used to model all steps in the value-added chain from development and design through to production and assembly. To HELLER, the ProfiTrainer presents a special building block of its customer-oriented didactics since the ProfiTrainer has been proven to help overcome inhibitions about large machines as far as opera-tion and programming are

concerned. Productivity, quality and machining expertise in concentrated form Following the successes in recent years, HELLER will again be offering moderated panel discussions this year. Under the motto “From Practice for Practice”, users will be sharing their experi-ences with HELLER machin-ing centres with the audi-ence and will answer visi-tors’ questions. On the whole, productivity, quality and expertise in machining “Made by HELLER” will again be the topics in focus from 15 to 17 June 2016. With the workshops in Nürtingen temporarily trans-formed into a transparent factory and the presentation of a new machine concept, nothing is likely to prevent the in-house event from turning into a success. After all,transparency simply re-mains of paramount impor-tance. For more details visit www.heller.biz

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Corner Wrap Applicator for Videojet 9550 Print & Apply Labeling System Videojet has announced its

to equipment. For example,

numerous

new Corner Wrap applicator

a mis-timed tamp applicator

moving parts

for its highly successful 9550

stroke can result in a collision

which have a

Print & Apply Labeling system

with an advancing pack and

tendency to

-www.videojet.com/9550. This

can damage the applicator.

fail and require

applicator option provides substantial improvements in production throughput for applications that require labeling on two sides of the case so it can be seen from multiple orientations.

Conversely, the 9550 Corner Wrap system uses Videojet patented Direct Apply™ labeling technology to affix the side section of a label. Next, a single pneumatic stroke of a wipe roller wraps

maintenance, while at the same time helping to eliminate jams. The result is a reduction in downtime which

“The 9550 Corner Wrap system

the label onto the back of

prints the information on

the case. This simple design

one continuous label and in a

eliminates the swing arm

single process applies it to the

that is typically used for

two adjacent panels of a case,

corner wrap labeling and can

The trend

replacing two conventional

often be a point of failure.

toward

applicators while ensuring that

Additionally, the 9550 method

increasing

the information on both sides

reduces wear and tear, as its

retailer and

of the package is synched,”

applicator rolls across the

regulatory

says Bob Neagle, business

back of the case as opposed

requirements,

unit manager for Videojet.

to the front of the case where

as well as

“The new applicator also

the case can directly impact

increasing SKU

follows in the path of previous

the applicator arm.

complexity, is

9550 series applicators by eliminating most of the causes of failures, adjustments and maintenance in conventional applicators.”

Manual adjustments are frequently required in conventional LPA systems, and when these sensitive adjustments are not made

The 9550 Corner Wrap system helps to increase production throughput by reducing downtime

helps increase production throughput.

a concern for manufacturers seeking to safeguard their operations from

The 9550 Corner Wrap system uses Videojet patented Direct Apply™ labeling technology

costly labeling

The conventional approach

correctly, the result can

to two-sided labeling uses

include label, web and

two labelers to apply two

ribbon jams and mechanical

different labels with duplicate

failures, all of which can result

information. These label printer

in downtime that brings

applicator (LPA) machines

the line to a halt, reducing

use either blow applicators or

production throughput. The

telescopic tamp applicators to

Videojet 9550 Corner Wrap

apply printed labels to packs.

system overcomes these

Both of these methods rely

problems by using Videojet

on the accurate and timely

patented Intelligent Motion™

placement of the label from

technology to maintain the

the print engine onto an

correct amount of tension in

applicator pad. When this

the media supply reel from

A single, integrated user

mechanical process fails, the

the first label to the last. This

interface removes the

result is missing or wrinkled

design eliminates the need

difficulties associated with dual

For more details visit

labels and sometimes damage

for manual adjustments and

interfaces common on systems

www.videojet.in

www.martupdate.com

errors. In order to help manufacturers

based on OEM print engines. As

improve quality and adhere to

few as three user touches are

applicable standards, the 9550

needed to select a job from an

Corner Wrap system comes

on-board job database. A step-by-

equipped with the Videojet

step guided entry allows correct

industry-leading CLARiTY®

fields to be edited and bar codes

touch screen interface, which

to be created automatically by

includes intuitive job selection,

linking data from multiple text

comprehensive feedback and

fields. Additionally, a preview

diagnostics to minimize human

of the job selection and the final

error.

message is available for additional confidence that the correct job is programmed.

May 2016

NI Presents Cutting-edge Tools and Technologies National Instruments

off-the-shelf hardware, and

India (NI) recently hosted

the powerful NI LabVIEW

a series of automotive

development environment,

roadshows across the

users can create user-

country to showcase NI

defined solutions for

platform-based tools and

applications ranging from

technologies specifically

HIL and functional test to

designed to cater to the

in-vehicle data logging and

automotive industry in India.

dynamometer control.

The roadshows which were hosted through live demos,

NI provides automated

and technical presentations

testing & data acquisition

were attended by over

solutions for all stages of

100 engineers across cities

automotive development.

from various automotive

Their flexible and scalable

companies, both OEMs and

hardware and software

tier 1 suppliers.

platforms can be used for

NItools save time and moneyacross all stages of the automotive engineering process as they provide a customizable & high performance platform for measurement, validation and automated test.The number of features as well as the number of units produced is increasing day by day and this makes the testing of these components

high volume production testing for complex automotive components and significantly increase profitability. NI’s solutions include Hardware-inthe-loop testing, Data Acquisition & Logging, Test Cell Measurement & Control, Infotainment Test, Automated Visual Inspection and end of line component test.

more challenging.With

For more details visit india.

industry-leading I/O, flexible

ni.com/company

“Automotive Industry is a big focus area for National Instruments in India. As the presence of electronic control units is increasing in modern automobiles, so is the emphasis on Hardware-in-the-loop testing. In this context, one of the main focus of our automotive roadshow was Hardware-in-the-loop testing (HIL Testing), especially how this technology is enhancing to incorporate test strategies for Hybrid Electric Vehicles too.” Jayaram Pillai Managing Director – IndRA, National Instruments

May 2016

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February 2015 November May 2016 2014

THE LAST LEAF Dear Readers, India has shown that it has the ability to be a low-cost, yet effective contender in space. Indiaâ&#x20AC;&#x2122;s Mars mission, Mangalyaan, cost much less than what many other countries spent. More importantly, it has been largely successful where many other countries failed. If Team Indus succeeds in soft landing a spacecraft on the moon and wins the Lunar X Prize, it could set the stage for the company and India to be a big contender in space engineering. The challenge itself is deceptively simple: land on the moon, get a rover to traverse 500 metres from the landing spot, take pictures and transmit them back to earth. The first group to do this before the end of 2017 will win $20 million.Team Indus has made reasonable progress so far. The mission concept was formulated in 2012 and systems design started a year later. A major motivational boost came from winning one of the milestone prizes worth $1 million for landing technology in January 2015. All going well, the Indian Space Research Organisation (ISRO) will launch Team Indus into space through a dedicated polar satellite launch vehicle in September 2017. Team Indus has serious global competition of course, but is currently rated among the top three firms in the race for the prize. The Team Indus project represents a major challenge for Indian engineering. Lunar landing is just one of the challenges that Team Indus spacecraft will encounter but gives us a sense of the technical complexities involved. The 75-people-strong system engineering team of Team Indus includes 15 former ISRO engineers but Indus can take limited direct help from ISRO as the Lunar X Prize rules allow a maximum of 10% support from the government. Soft landing on the moon has been achieved only by three superpowers, the Americans and the Russians in the 1960s and 1970s, and China in 2013. ISRO was successful in building a lunar orbiter in Chandrayaan, but the Indian space programme has not attempted to land on the lunar surface so far. The launch cost is expected to be of the order of $60 million. Team Indus is exploring creative ways of raising funds through crowdsourcing, appealing to national pride and the inherent romance of space exploration. Meanwhile, a German startup is developing the worldâ&#x20AC;&#x2122;s first ultralight personal electric plane that can be powered from a wall socket, take-off and land vertically even from back gardens, and is eco-friendly. The two-seater plane uses a ducted fan which makes it much simpler, quieter, and safer than conventional helicopters. Daniel Wiegand, CEO of Lilum, said that their goal is to develop an aircraft for use in everyday life. (Courtesy: Economic Times) Nuheara, an innovative audio Wearablescompany co-located in Perth, Australia and San Francisco, has launched an innovative product in the Hearables market. Nuhearahas developed intelligent earbudsto deliver multi-functional intelligent hearing technology that augments a usersâ&#x20AC;&#x2122; hearing and facilitates cable free connection to smart devices. It will seek to allow users to hear what they want to hear in both their digital world and the world around them.The key point is that Hearables are not just another wireless earbud, but a new category of devices more like mini computers than headsets.Think sensors, intelligent use of microphones, audio digital-signal processing, smart battery miniaturization and other technologies more commonly associated with computers, not headsets. Consciously, we are making an attempt to create a positive outlook around us aimed at facilitating to stimulate and energise our industry atmosphere. Your feedback in this regard is welcome, to enable us improvise our channel of information and motivation to our readers for a better tomorrow. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board

May 2016

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May 2016

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Lakshmi Towers, 2/770, Kazura Garden, !st Street, Neelankarai, Chennai- 600041 Phone: 044-45671200 Email: sales.india@kemppi.com 100

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May 2016