Volume 10 Issue 5 November 2013 Pages 52 `100
A World First
Sustainability and a Greener Tomorrow
Han速 HMC connector series from the HARTING
The Big Scaling of Moulded Metal Mechanical Vacuum Booster Journey Towards Excellence Secure hold using Vacuum Technology November 2013
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The largest Construction Equipment event of South Asia, EXCON 2013 was successfully held at the Bengaluru International Exhibition Centre from this 20th to 24th of November 2013. The event witnessed the launch of Eco 40 the first innovation of Valmova India. This was also the first ever made product from Valmova group to be initiated and manufactured outside Brazil. I had an opportunity to meet the Valmova Team a day before the start of the exhibition. It was a meeting in general to understand each other better and being in India was the center of the subject. I was so pleased and proud to project my being one of the largest democracy in the world, one of the fastest growing nation with strong heritage and culture, the torchbearers of one of the oldest civilizations in the world. We are going to be the super power of the world, and now one step ahead from all Asian powers like Japan, China with the recent Mars Mission.
Foreword
Dear Readers,
This is a common flat issue. After commonwealth games, I rate Delhi as the most developed city in our country. Once you are in the national capital you can see the crisis relating to areas where infrastructure needs to be developed. So there’s no need for us to look upon the other cities. Metro projects are running across the major cities like Delhi, Kolkata, Chennai, Mumbai, and Kochi thus making a byline passage among each. With the crying need of basic infrastructural developments, we are going through some hard economic crisis. We cannot say the government is running out of money. Petrol and Diesel prices are increasingly doubled and tripled comparing last fifteen years, and the Government is getting richer utilizing the elasticity of the revenue. The tax components are multiplied with the introductions of Service Tax, Luxury Tax, VAT etc. The common people are still in dark about the mystic exchequer of the huge democratic country like India, now the question that puts them in tizzy where is the mass money spent? The revelations of scams in-between are the only indications where the funds are leaked out.
Hari Shanker Managing Editor
On my query to why Valmova in India, Mr. Domenico Traverso, the Vice President of Stand-Alone Businesses, Valmova Italy replied that India’s urbanization and growing population is the inspiration for Valmova to invest in India. More and more people shifting to the urban cities to make a habitat that results in new housing projects, infrastructure developments making construction activities live and the need of construction equipments arise. Similarly, with the advancement of the huge population that grows almost every second, there is the need for more food along with the larger and better agricultural productions, where latest agricultural manufacturing equipments and technologies to be used. In both these equipments Valmova has its presence and the opportunities offered in India are huge.
It’s high time that we understand the real need of our country and act accordingly. The realization for this purpose must come first and foremost to each and every individual in this country and then only we can bring a revolutionary change. The elected representatives are much like us. If they feel superior, that’s only we are keeping them above us. Sure, they are our elected leaders who are paid salaries to do the work for us for the benefit of the country and its people. Let’s understand this basic, get our friends, family and associates know about this, and work towards the common goal of making Mother India strong. Do write to us to make MART, SMART! November 2013
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Cover Feature The Big Scaling of Moulded Metal
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Mechanical Vacuum Booster The Robotic Automation for Grinding & Finishing of Aluminium Parts of Industrial Vehicle
Columns 18
Sustainability and a Greener Tomorrow Sandeep A Hingne
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The Most Effective Way of Visualizing Funnels Tomasz Tunguz
Journey Towards Excellence
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P S Satish
Combining Six Sigma and CMMI Can Accelerate Improvements
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Gorur Sridhar
Fair Mart
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Volume 10 Issue 5 November 2013 Annual Subscription `1200 Member INS Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre Mahesh R P
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Siji Nair
Managing Editor Hari Shanker hari@martinfotech.in
Art & Creative
Editorial Assistant
Accounts Rupak Sengupta accounts@martinfotech.in
Debolina Dutta +91 9038 005670
Creative Assistant
Pradeep Jayaprakash Sayan Chaudhuri
Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2n Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed November 2013 Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every eff ployees accept any responsibilities for any errors or omissions. Š All Rights Reserved
Feature Article Secure hold using Vacuum Technology
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NTX1000 – High-Precision, High-Efficiency Integrated Turn Mill Center from
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Iglidur Universally accepted in place of Metal Bearings Proven WIDIA WMT™ Grooving and Cut-off System Adds New HighPerformance PH Geometry
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CANopen devices
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Kennametal Announces Breakthrough KM4X100™ Spindle Connection
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Elmo Motion Control Adds Advanced Features to its Gold Maestro Motion Controller
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Lighter, brighter, longer-lived:
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Mart Update
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The Last Leaf Advertisement & Circulation
Asst Manager Customer Shrabanti Hui Support +91 9038 003210 Executive Customer Support
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nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, d in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 November 2013 the accuracy of the information published in this edition, neither the Publisher no any of its emffort has been made to ensure
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CASTING & FORGING
The Big Scaling of Moulded Metal
Debolina Dutta editor@martinfotech.in
The science of foundry lies in casting and thereby forging it to get it to a shape. The casting and forging industry is a emerging one facing considerable growth keeping consistency with the present trend. The present scenario has been changed. Today India is competing with one of its major counterparts, China to capture the world market. Forging is a basic manufacturing industry that grows up in relation to the present GDP growth. The forging industry has close relativity with the automotive industry. Cheers to the outsourcing as well as the beneficial effect of the outsourcing. When the world market is undulating under the massive depression of dollar, it’s India that has shown the perspective, the newer avenues of the forging industry. Briefly, the composition of the Indian forging industry can be categorized into four sectorslarge, medium, small and tiny. Irrespectively, the Indian forging industry (an important segment of the Indian auto component industry) still remains a fragmented part with around 400 units (out of which only 9 -10 are large units scattered all over India). These SMEs are the backbone of the industry. The organized sector accounts for about 65-70% of the total forging production in the country, while unorganized players (who are mainly small and tiny units) cater mainly to job work and the replacement market or tier 3 or tier 4 component manufacturers. Notwithstanding this, a wide range of products are being manufactured, each being a potential part of the diverse meets the technology requirement, which has negated any possible concentration of the market in a few hands. It is perhaps because of this, cases of domestic consolidation have been few in the industry, unlike other industries. Rather the trend has been to cater to or set up base in global markets. Indian industry is one of the leading industries in overseas [ranked third] these
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acquisitions have largely been in Europe and USA because the auto ancillary industry in these countries has been collapsing. Indian forging companies like Amtek Auto, Bharat Forge, Sundram Fasteners and some others have also setup bases in other emerging economies to establish themselves as low cost suppliers. The Labour intensive industry reports that the industry provides employment (direct and indirect) to about 200,000 people. More than around 65% of the companies in the forging employ less than 200 people. Now with increasing globalization, the industry tends to be capital intensive. However, the high cost of capital (technology) still
remains a major constraint facing the forging industry (especially the SMEs). The total investment in the large and medium sectors is estimated to be around US $ 700 million. The demand is rising. The small scale units too are increasing their capital investment to keep pace with increasing demand in the global markets as also broadening the areas of demand for forgings. Many of them are now suppliers to Original Equipment Manufacturers (OEMs) in the Automobile sector, which speaks volumes about their efforts at technology and quality up gradation. A Surveillance of The Indian Forging Industry
The year 2007-08 (AprilMarch) was relatively not so good a year for the Indian Forging Industry as compared to the previous year due to a continuous and steep rise in the prices of its basic input – forging quality steel. The trend is uprising for India has seen the growth of 9.994 million tons in the year 2011. The capacity utilization did not improve as much as in the previous year. In the previous years the industry could utilize 65 per cent of the additional capacity . In the year 2007-08, the average capacity utilization in the industry stood at about 70%. (a growth of only 5% as against 10-15% in the previous year). Again, in the last quarter of the year 2007-08, the capacity
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utilization declined up to 50% of its capacity or even less due to the very high raw material costs as well as higher costs on other fronts like fuel and energy, finance, labour etc. This overall increase in costs however still remained, largely due to the spiraling prices of steel (as mentioned above) across the globe. Worldwide, while the automotive industry is the main customer for forgings, the industry’s continuous efforts in upgrading technologies and diversifying product range have enabled it to expand its base of customers. As a result, Indian forging industry has provided a solid growth to country’s growing exports. India exported forgings whose value is estimated at around US$ 472 million in 2007-08. Technological developments have also contributed to export growth. The industry’s major markets are USA, Europe and China. However, only about 30-35 manufacturing units are currently contributing to exports directly. Despite the slowdown in production in the last quarter, the industry expects to rationalize rate of inflation in the country. In view of this, many large and medium forging companies have taken important initiatives to improve capacity utilization by diversifying into non-auto alternatives and further reducing cost etc. Notwithstanding this, the industry had also to contend with its share of other problems. It had to bear the brunt of steep and frequent increases in the cost of major inputs like fuel, energy, labour and finance costs- a note of worry for the stake holders. Keeping a steady growth is a no mean achievement.
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Its advancement is like its challenges a stiff rock to ascend-may it be in the domestic front , inputs of prices, the compliance with stringent environment, high interest rates and some such cases like export-import feasibility, supply chain and user meet crisis etc. Indian Aspects Considering the viable change India has 4,600 foundry units, 80 per cent of them in the SME sector. The industry’s annual production is 7.4 million tons keeping a close sight of it’s valued at $8 billion production. The sector currently employs 0.5 million people directly and an additional 1.5 million people indirectly. The industry contributing of Rs 7,000 per ton produced to the national exchequer by way of excise and other levies. Its export unit touches $215 million in 2010/11. The manufacturing units are located in 12 identified and recognized clusters and in 20 other clusters. A Brief layer of the market size The expected growth is not only in the auto-sector but also in the casting sector. The domestic market also takes a leap at least three times by 2016. The auto sector alone is expected a steep growth to $10 billion by 2016 and the casting industry is projected to be a $19.2 billion industry by 2016. The global growth rate for castings follows approximately twice the global growth rate in GDP in absolute terms. The domestic demand is not the only sought after matter but the exports are likely to be up by $3 billion with a 20 per cent growth in direct exports.
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ON FACE
“Technology will lower Production Costs, Improve Efficiency and Innovate� Reena Bhagwati, the Chairperson of the International Commission on HR & Training of the World Foundry Organization (WFO) discussed in detail with MART about Indian foundry industry. An MBA from Carnegie Mellon University, Pittsburgh, USA, she is the Director of Bhagwati Group of companies with a turnover of more than 200 crores . We talked to her about the cluster of SME foundry industries, its future growth depending on the perspective. We are laying the unedited version for our readers. In which way is the future of the foundry industry developed? According to 46th world casting census as per Modern Casting, India is in the third position in the world in terms of tons of castings produced. India has produced 9.994 million tons in the year 2011 and it is growing at a CAGR of 6% since 2006-07. Due to growing demanfrom the automobile sector coupled with demand from other sectors like infrastructure, construction, agriculture, the foundry market is expected to grow strongly in the near future. At present the annual turnover of the industryThe present (FY 2012-13) turnover of the industry as
per The Institute of Indian Foundrymen is USD 15 Billion and exports worth USD 2 Billion (approx. Rs 12,000 Crore) Is there any crisis that the industry facing in these days? The industry is facing supply sides issues like a) Increasing Energy costs; b) Stringent environment and pollution controlnorms; c) lack of skilled human resource at affordable rates and challenge in attracting new talent; d) increasing material cost; e) high cost of technology implementation in the manufacturing process; f) sand reclamation; & g) water management Any Goverment assistance/ assurance? 80% of Foundries in India
Reena Bhagwati at the 61st Indian Foundry Congress
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comes under the category of SMEs.Government of India through CLCSS (Credit Linked Capital Subsidy Scheme) for technology upgradationis helping the small scale industries (SSI). Other schemes like MDA Scheme (Market Development Assistance), MAI Scheme (Market Access Initiative) are also available for the foundries. Various State Governments are also helping the SMEs through its policies. SIDBI and the Bureau of Energy Efficiency (BEE) are cooperating to promote energy efficiency in MSME clusters. SIDBI has also tied up a line of credit with the Japan International Cooperation Agency (JICA) to finance energy saving projects at concessional terms. What is the pledge to the Goverments?
We are working very closely with the Goverment of India to set up the Foundry Development Council, which will be of immense benefit to the Industry. In the next few years how is the industry going to be shaped up? Any future plan? In the next few years there will be increasing emphasis on technology, which will play an important role in lowering production costs, improving energy efficiency, enhancing environmental quality, and creating innovative new cast products. There could be a trend towards captive foundries and major consolidation of smaller foundries. Skill development will an important area of focus for the industry in the next few years. November 2013
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VACUUM PUMPS
Mechanical Vacuum Booster
Anil Mankad
High Vacuum Technology Against Steam Powered Systems
joyam@joyamvactech.com
Mechanical vacuum boosters are dry pumps that meet most of the ideal vacuum pump requirements. They work on positive displacement principle and are used to boost the performance of water ring/ oil ring/ rotating vane/ piston pumps and steam or water ejectors. They are used in combination with any one of the above mentioned pumps, to overcome their limitations. Vacuum boosters pumps offer very desirable characteristics, which make them the most cost effective and power efficient option. The major advantages are: • Can be integrated with any installed vacuum systems such as steam ejectors, water ring pumps, oil sealed pumps, and water ejectors etc • The vacuum booster is a dry pump as it does not use any pumping fluid. It pumps vapour or gases with equal ease. Small amounts of condensed fluid can also be pumped • Vacuum boosters are power efficient. Very often a combination of vacuum booster and suitable backup pump result in reduced power consumption per unit of pumping speed. They provide high pumping speeds even at low pressures • Boosters increase the working vacuum of the process, in most cases very essential for process performance and efficiency. Vacuum booster can be used over a wide working pressure range, from 100 Torr down to 0.001 Torr (mm of mercury), with suitable arrangement of backup pumps • It has very low pump friction losses, hence requires relatively low power for high volumetric speeds. Typically, their speeds, at low vacuums are 20-30 times higher than corresponding vane pumps/ ring pumps of equivalent power • Use of electronic control devices such as variable frequency control drive allows modifying vacuum boosters operating characteristics to conform to the operational requirements of the prime vacuum pumps. Hence they can be easily integrated into all existing pumping set up to boost their performance
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• Vacuum boosters don’t have any valves, rings, stuffing box etc, therefore, do not demand regular maintenance • Due to vapour compression action by the booster, the pressure at the discharge of booster (or inlet of backup pump) is maintained high, resulting in advantages such as low back streaming of prime pump fluid, effective condensation even at higher condenser temperatures and improvement of the backup pump efficiency How the boosters enhance the working vacuums of the processes when installed in combination with various types of industrial vacuum pumps, conventionally used in the industry. They can effectively replace multistage steam ejectors, resulting in considerable steam savings and reduced loads on cooling towers. Mechanical vacuum boosters are versatile machines and their characteristics depend largely on backing pump. Various types of backing pump can be used, depending upon the system requirement and ultimate vacuum needs. However, the final vacuum is governed by the suitable selection of the backing pump and booster arrangement. The table below gives a broad range of vacuum achieved with various backing pumps combinations. Vacuum Pump Vacuum On Range Installation of Booster
For example, if a process is using water ring pump, the estimated working vacuums would be of the order of about 670-10 mm Hg gauge (90-50 mmHg abs), largely dependent on the water temperature and pump design. When a booster is installed backed by water ring pump, vacuum levels of the order of 5-10 Torr can easily be expected. For higher vacuums a series of boosters can be used to bring down vacuum down to 0.01 Torr. Mechanical boosters offer a completely dry pumping solution and do not add to any vapor load, unlike steam ejectors, and therefore, do not require large inter stage condenser. At low vacuums, higher pumping speeds are required to maintain the through-put (mass flow rates), since the specific volume November 2013
increases with the increase in vacuum. Vacuum boosters enhance the pumping speeds by about 3-10 times depending upon the selection, by virtue of which one can expect higher through-puts and considerable reduction in process time. The drawbacks of steam ejector system such as sensitivity to motive fluid pressures and discharge pressure are overcome easily by the mechanical boosters, since the volumetric displacements/pumping speeds are relatively insensitive to the inlet and outlet working pressures.
Case study
Industrial installation of Boosters JOYAM’s technical team is fully geared to undertake design, supply and commissioning of these boosters for chemical processes. Since process parameters vary considerably in chemical plants a careful study of process and installation of suitable Booster arrangement is essential to get the desired objectives. Some of the case studies carried out by the technical team of Joyam are briefly described here.
Rough vacuum applications (Typically in range 1- 100 Torr)
Objective: Replacement of steam jet ejector – Energy saving
• Vacuum drying application
A large industrial unit at Barnala, Punjab manufacturing acetic acid anhydride was using steam ejectors for maintaining process vacuum of 720 mm HG for which the average steam consumption per day was 15 tonnes. The client was keen to eliminate steam from the process due to high-energy cost, huge load on cooling tower, and total process dependency on steam availability. Joyam’s technical team worked on the project. The estimated noncondensable load of the process was 100 Kg/hr apart from the steam load. Joyam vacuum booster with a 15 HP drive backed by water ring pump with a 30HP drive was suggested and successfully installed, replacing the steam ejector.
• Vacuum distillation processes • Solvent recovery • Vanaspathi oil deodorization • Replacement of steam ejectors • Enhancing the performance of water ring pumps /water ejectors • Vacuum flash cooling Medium Vacuum applications (Typically in range 0.001-1 Torr) • Efficient backup for diffusion pump systems • Thin film deposition /coating • Short path/ molecular distillation • CFL, tube light and general lighting industry • Object & roll metallizers • Vacuum heat treatment and degassing / vacuum furnaces • Semi-conductor processing • Transformer oil de-humidification • Chemical laser applications • Freeze drying • Vacuum impregnation The author Anil Mankad is the Director of Joyam Engineers & Consultants Private Limited, Ahmedabad. He can be reached at joyam@joyamvactech.com and for further details please do visit www.joyamvactech.com
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Major Advantages achieved • Huge energy saving – 15 Tonnes of steam was totally eliminated by electrical energy of 45HP. Net saving of Rs 7200/day on energy (taking steam generation cost @ Rs 0.70/Kg and Electrical unit @ Rs 4/-unit. Objective: To reduce load on cooling towers A multinational company in Aligarh, manufacturing milk powder, was forced to reduce its production during the monsoon season due to drop in cooling tower efficiency. The company was using number of multi stage steam ejectors and the total heat load of condensing steam was taken care by the cooling tower. The technical team of Joyam advised installation of vacuum booster replacing the steam ejectors, with an idea of reducing heat load on the cooling tower. On trials a steam ejector consuming 100 – 125 Kg steam was replaced with a 5HP vacuum booster reducing heat load of about 25 Tones. In case of multistage steam ejector systems the steam consumption is high for the initial stages. Inter-stage condensers
are generally installed to condense the steam before the subsequent stage. For every 100 Kg of steam condensed there is heat load added to water equivalent to about 20 Tonnes, and this heat load is to be dissipated to atmosphere which is generally done through cooling towers. During monsoons or in areas where relative humidity levels are high, cooling tower efficiency drops affecting the available water temperature. Most of the processes and vacuum pumps are adversely affected by the rise in water temperature reducing the plant/process efficiency. Vacuum boosters offer an ideal replacement overcoming steam ejector limitations as they do not add any heat load to the system. No inter-stage condensing is required as they run dry. Objective: Removal of steam boiler A South India based company manufacturing cardanom oil, from cashew nut shell extract, had installed a mini boiler only to run the steam ejectors backed by water jet ejector to get a process vacuum of 759 mm Hg in their distillation columns. Frequent production loss was a regular phenomenon due to boiler associated holdups such as drop in steam pressure, shortage of dry fuel, availability of cheap fuel, DM water, scaling etc. Joyam’s technical team proposed installation of a 10HP and 5HP booster, in series, backed by water jet ejector for the required vacuum of 759mm Hg and capable of handling the total plant load. The installation today runs on Everest boosters and boiler has been dismantled from the site. Massive energy saving have been reported with better product quality and process reliability. Associated problem with the boiler such as availability of fuel, DM plant, scaling etc, have totally been eliminated since there is no steam requirement by plant after installation of Joyam boosters. The unit has installed three parallel systems for their three columns with independent control. Major advantages achieved • Total elimination of steam, making the plant boiler free• Saving in the energy consumption • All distillation columns can now be independently operated. With single Boiler operations the entire plant was sensitive to boiler performance • Quick start and stop possible since no initial heating period is required • No need for inter-stage condensers, cooling water, cooling tower and allied accessories such as pumps, valves etc www.martonline.in
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AUTOMATION - FOUNDRY
The Robotic Automation for Grinding & Finishing of Aluminium Parts of Industrial Vehicle
Angelo Bonotti tiesserobot@tiesserobot.it
Robotic automation had come a long way in Foundry and Forging Industries. Many manufacturing Industries through-out the globe are using industrial Robots for grinding & polishing activities, which are labour and skill oriented & requires high level repeatability with consistency in quality. With the recent trend in using more and more Aluminium parts in Automobile Industries including Industrial Vehicle manufacturing Industries , more and more new challenges are being experienced by the system integrators for Industrial Robotic Grinding and polishing of Aluminium parts. Tiesse Robot spa have the know-how acquired in more than twenty years of robot applications in aluminium foundries, especially in the field of casting handling. The evolution of the sector has resulted in becoming increasingly more & more involved in specific process problems, and in being transformed from a simple executor to an active protagonist in the attained solutions, able to supply standardized packages with ‘turnkey’ islands, which enter the facility
aluminium chill & green sand cast finishing plant by a French company, who supplies parts to few Major European industrial vehicle manufacturers , for example trucks etc. After a detailed study of the actual jobs as shown in Figures above, it was also of paramount importance to know the customer’s exact requirement in order to design the complete Automation Cell. In short, the customer’s requirement consists of a robotized
ZX300S Robots, able to work at the same time on two different codes or, in the case of high volumes, work with a single code and be able to switch over the same piece at the same time to perform the various operations, as shown in the photograph.
ready to cater to all production requirements. Having done appreciable amount of developmental activities in the aluminium foundry automation field, the customer decided to repose their faith in Tiesse Robot spa to design & develop an
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In addition to the above, the automation system was also required to meet the different product mix as per the requirement of the customer. Hence to satisfy the need for managing high production mixes, a Piece feed system was developed for
& flexible island for flogging, sprue cutting and finishing a series of castings and are be sufficiently flexible to manage the production mix, as well. In order to meet the above requirements, the engineers started designing an automated island with two Kawasaki November 2013
the customer, comprising of a motorized belt conveyor and a viewing system. The Viewing system allows the robots to recognize the incoming code on the job and its orientation, thereby avoid the use of costly tooling and reducing the setup times of the island to the minimum as shown in the figure. The operating range of each individual robot extends from the flogging unit slaving phase to handling the piece for sprue
operating unit. Each robot features a casting placement and recovery station to enable the robot to change piece grip area, so as to be able to perform the finishing operations along its entire perimeter.
Window to the industrial world at your desktop “Industrial business MART” popularly know as MART the largely read international engineering manufacturing monthly, now the one year subscription comes `300 less, Grab it today!
An intermediate station for the switching over of the piece between the two robots permits – if the cycle so requires – passing the piece from the first to the second robot to be com-
With the last nine years of networking and publishing of MART, we have succesfully made place in the Indian Manufacturing Industry. Our growth was always triggered by the changes undertaken as per the needs of the industry. The contents of MART is unique, with regular columns by industry experts in the diversified feilds of engineering manufacturing, technical features, news updates, interviews, case studies, trade fair informations etc. cutting, to be done underneath a strip unit, with the possibility of performing the piece finishing operations using milling tools and a tape application
pleted. Piece unloading is done with the aid of two motorized belts.The cutting strip and milling and deburing tools housed in specific areas protected by
The guidance and support of the experienced industry professionals through our Editorial Advisory Board have helped us to understand the need of the indian Manufacturer better and produce a journal which is used by the industry as an utility.
Yes, we are interested to subscribe “Industrial Business MART” as per selected option : One Year (12 issues) at ` 900/- You save `300/Three Year (36 issues) at ` 2500/- You save `1100/-
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Subhrajyoti Mukhopadhyay Managing Director, Automation India Welding Technology Pvt Ltd.
“The aluminium Foundry industries globally are facing the never ending challenges like acute shortage of skilled operators and to control the cost outflow for experience, trained operators, raise in volumetric demand with higher & Consistent Quality but with thinner
Profit margin due to severe Global competition. In order to combat the above difficulties, many European industries have adopted Robotic automation in their manufacturing line, which had not only paid back the initial investment on ROI but also met the expected demand in terms of quality and productivity. Indian aluminium foundry industries are also facing the similar situations due to the severe competition in Automobile Industries, who are their ultimate customers. Time is ripe enough for them to adopt the rich experiences of using Robotic Automation Technology which will not only increase their productive output but also reduce the cost of manufacturing and thereby the ultimate profit margin.�
guards are arranged so the machining scraps are conveyed onto a motorized metal slat conveyor which removes them to an outer container, separating the aluminium cutting powder from the larger scraps. Once the sprues have been cut, the piece is finished with the aid of a milling unit consisting of electric spindles driven by a special inverter for speed adjustment, and of deburring tools fitted on pneumatic turbines equipped with compensator, as well as by means of
taping operations on pairs of taping units, these too inverter controlled. The entire island was placed inside a soundproofed booth so as to reduce noise levels, and fitted with its own connections to the dust extraction system installed by the customer. Special care was given to the pickup parts; only the end pieces need replacing in order to process one code rather than another. The operator has the ad-
vantage, with the aid of a supervision system featuring mimic and touch screen, and performing actions which do not involve the use of the robot programming keyboard, to be able to disconnect from the cycle any machining operation, whether required or not, including according to the extent of tool wear. Using the latest technology development in this Industrial segment, that is, the adaptation and development of viewing system, which can make it possible to determine the positions of machining areas in space, whatever the shape tolerances. In addition to the above, with the advent of Software technology, Off-line programming software were also developed which starting from the files sent by CAD or CAM systems, can automatically produce the operating trajectories of the robot tool together with the relative orientation vectors in conjunction with Viewing technology. By using these extremely advanced technologies, the traditional programming times are totally eliminated. This can also be extended by programming the robots without stopping production and thereby reduc-
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ing commissioning times and at the same time ensuring the utmost compactness, modularity and flexibility of the system. The outlined Robotic Automation Island was installed and commissioned upto the total satisfaction of the customer. With the execution of above designed system, Tiesse Robot spa once again proved its strong presence in designing & developing Robotic Automation systems, which are the careful combination of designing skills & innovative technology, suitable for a range of different industrial requirements. Tiesse Robot spa, though its Indian partner, Automation India Welding Technology Pvt Ltd is looking forward to Indian Foundry and Forging Industries for offering the-state-of-the-art solutions based on their proven experiences for, not only, to uplift the ultimate production quantity but also with assured quality with repeatability. For further details write to Automation India Welding Technology Private Limited, M-69, LGF, Greater Kailash 2, New Delhi 110048 Tel: +91 11 41099930 Mobile : +91 9311109930, 9810699930 or visit www.automation indiawelding.in November October 2013
November 2013
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17
GREEN IN
Sustainability and a Greener Tomorrow
Sandeep A Hingne sandeephingne@gmail.com
Many of us have been hearing this word for quite some time now, but has anyone given a real thought toward its exact meaning?
From a layman’s perspective, it can simply be described as effective management of nonrenewable and nonreplenishable natural resources. These resources are limited; they are getting scarce day by day, and are very critical for maintaining global ecological balance. Collective efforts at the universal level, right from each and every individual are required to balance our socioeconomic and environmental needs. Since changes are inevitable, we may have to relook into our own agendas from this environmental spectacle, in order to understand the impact on the environment. Environmental Sustainability requires
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changes in the age-old practices of doing things, and realigning and focusing them to the needs of Mother Earth. Until the 1980s, business leaders used the word sustainability to mean a company’s ability to increase its earnings steadily. The term became widely used in its present sense in 1987, after it appeared in a UN report by Norway’s former Prime Minister Gro Harlem Brundtland, who defined sustainable development as “meeting the needs of the present without compromising the ability of future generations to meet their own needs.” More recently, as Michael Pollan, the author of ‘The Omnivore’s Dilemma,’ writes, the whole idea has been
“in danger of floating away on a sea of inoffensiveness.” Everybody, it seems, is for it whatever ‘it’ means.” Sustainability even has a dark side: “Greenwashing”—that is, focusing more on communicating your green efforts than on the efforts themselves. In a real sense, sustainability has four equal components: 1. Social: This addresses conditions that affect us all, including poverty, violence, injustice, education, public health, and labor and human rights, etc.
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2. Economic: This helps people and businesses meet their economic needs. For people: Securing food, water, shelter, and creature comforts, etc. For businesses: Generating profits 3. Environmental: This is to protect and restore the earth— for example, by controlling climate change, preserving natural resources, and preventing recycling of waste, etc. 4. Cultural : This is to protect and value the diversity through which communities manifest their identity and cultivate traditions across generations throughout the globe Take some of the following examples from our day-to-day life:
With E-ticketing Indian Railways expects to save at least 3,00,000 pages of A4-size paper per annum, contributing significantly towards the conservation of trees.
1. Aviation
face are sad, even tragic, but sustainability isn’t about throwing your business down the drain and embracing your inner saint. That’s one reason for looking beyond the green aspects of sustainability and using its social, economic, and cultural sides as tools for building successful companies.
Almost 20 years ago, our flight tickets were very similar to a 10-leaf cheque book; but nowadays, it’s just like a simple printout on a paper. Even used paper is fine, so that both sides can be utilized effectively leaving very less chance for waste / nonutilization. 2. Railways The Indian Railways has been promoting its initiatives, like the e-ticket, wherein there is no need to print the railway ticket. You can simply carry and show the ticket in the form of a text message received from the Railways on your mobile phone. The Indian Railways expects to save at least 3,00,000 pages of A4-size paper per annum, contributing significantly towards the conservation of trees. 3. Banking This sector also promotes extensive use of online facilities, wherein you save a lot of paperwork (for all the mundane or nonvalue-add activities), ultimately culminating into conservation of natural resources. Although the challenges to sustainability are acute, there has never been a better time than the present for a company to play a critical role in helping to resolve them while building its business. Many of the social and environmental trends we November 2013
Green businesses, green jobs, and emerging green economies will be a central part of the new world now being born, but green alone isn’t a broad enough platform to sustain most businesses for the long haul. Those that take into account broader social issues will be better able to thrive and to lead. An organization that aims to achieve greater sustainability must, therefore, articulate a Pole Star target,which means a strategic direction that embodies a global human challenge bigger than any organization. Such a goal should be consistent with the organizational strength, have a connection to its core business areas, and ought to elicit the personal contributions and passions of its members. Finally, the goal ought to be optimistic and aspirational but not impossible— achievable, incrementally, within 10 to 15 years. Like Christopher Columbus, you as the leader must point to a destination, even though at the start of the journey you may
have no idea how to reach it. The stories of two companies, Method Home and Seventh Generation show how these ideas have played out in actual organizations. Method Home (www.methodhome.com) The household products company based in San Francisco, may be the most successful such business using a “cradle to cradle” process to develop its products. This process, pioneered by Michael Braungart and William McDonough, ensures that every ingredient of a product is nontoxic and energy efficient throughout its manufacture, use, and disposal. The company considers the past, present, and future of all its products by asking if they came from a sustainable source (past), are nontoxic (present), and will be reusable or recyclable (future). Founded in 2001 by Adam Lowry and Eric Ryan, Method quickly achieved $100 million in sales thanks to wide distribution through retailers such as Target. Its line of products extends from hand soaps to laundry detergents to cleaning sprays. All its products are recyclable, and a large portion of them incorporate recycled content. Yet the company doesn’t describe itself solely as a “green” brand. “Green is one aspect of Method,” said Lowry. “There is tremendous pressure on environmentally conscious businesses to make green their www.martonline.in
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primary message,” he adds. “But you need to be relevant to a wide audience, and leading with a single green message may exclude new consumers.” A brand needs unique qualities, and green won’t be unique for long. Eventually, competitive pressures, commodity costs, or regulation will make all products nontoxic, energy-efficient, and sustainably packaged, so greenness alone won’t be distinctive. To truly be sustainable, any product needs more than just the environmental aspects of quality. Yet Method hardly ignores the environment. Within the walls of the company’s headquarters near San Francisco’s Chinatown, visitors can easily see why it describes itself as deep green on the inside. Lowry’s job title is Chief Greenskeeper, and his role is to form and maintain the principles that govern the company. One of them is that it shouldn’t use any product that hasn’t been proved safe. Lowry maintains a list of “dirty” chemicals (such as ammonia, bleach, and phthalates) that Method won’t use in any of its products. Because it has yet to find what it considers a nonhazardous antimicrobial agent, for example, it doesn’t make antimicrobial products such as antibacterial hand wash. The company also has a “clean list” of ingredients safe for people and the environment. Small teams of “green chefs” use these ingredients to create products.
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that it’s much better to put them in liquids than in bottles. Take, for example, Method’s all-purpose cleaner, sold in a clear container made of 100 percent recycled polyethylene terephthalate (PET). The liquid inside is colored with 0.007 percent of a synthetic purple dye. But Lowry argues that “it’s completely degradable and nontoxic. It’s a good dye.” A white PET bottle, by contrast, may never get recycled. When white PET gets sorted in municipal-recycling programs, the operators frequently think its high-density polyethylene (HDPE), the stuff used to make laundry bottles, and send it to the HDPE reprocessor. There it gets punted out as an impurity and sent to landfill. “If you’re going to want to tint a PET bottle white, you’ll use a thousand times as much dye to dye the bottle and you’re going to make it less recyclable,” Lowry said. “We want a plastic bottle that will be recycled— not just capable of being recycled.” Seventh Generation (www.seventhgeneration.com) People have a strong, intimate connection with the household products they use. Perhaps that’s why I’m fascinated by the way companies such as Clorox, Method, and P&G are riding the new wave of consumer interest in sustainable products. But unlike these relative newcomers, Seventh Generation, a company based in Vermont, USA, started producing them long before they became trendy.
An organization so focused on saving resources faces an ongoing challenge to reconcile design, efficacy, and environmental considerations. Method, for example, could reduce the amount of plastic in some of its bottles by 5 percent, but the company believes that a bottle’s design is important for the brand, and that it occasionally takes 5 percent more plastic to make a beautiful bottle. Sustainability isn’t the only goal of the company’s design ethos—aesthetics also plays an important role—but Method ensures that so far as possible the plastic it uses is recyclable and recycled.
Seventh Generation got its name from the teachings of the Native American Iroquois confederacy: “In our every deliberation, we must consider the impact of our decisions on the next seven generations.” The company, founded in 1988 by Jeffrey Hollender, its “Chief Inspired Protagonist,” is widely respected as a leading sustainable producer of household products. For more than a decade before new entrants began to compete in this space, Seventh Generation built a loyal following among consumers who wanted to make a difference through the products they bought.
The use of plastics involves another hard choice. Most products have dyes, which green consumer circles condemn as evil. Method, however, looks at the dyes and the product as a whole—the dyes in the bottle and those in the liquid. Life-cycle analysis of dyes, in Lowry’s view, shows
The company’s global imperatives to use my terminology—connect the operations of the business with the aspirations expressed in its name. These imperatives answer a basic question that all executives should ask themselves: ”What can my company do that the world most needs?”
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Seventh Generation’s imperatives hold that all businesses should help everyone who works for them develop as people and approach everything they do from a systems perspective: a world that is endlessly interconnected, in which everything we do affects everything else. The imperatives also commit the company to ensure that natural resources are used at a rate that is always below their rate of depletion. The core of Seventh Generation’s ethos is the belief that the company can change society and the way other companies work by succeeding in its own business. Forty years of organizational-development research shows that this simple idea attracts highperformance employees and permanently infatuated customers. Of course, Hollender isn’t a typical executive. He plans to transfer his company to its employees over time. He gives away corporate secrets by actively blogging. He made one decision that might have cost the company millions of dollars: Until Wal-Mart started its sustainability initiative; he refused to sell products to the giant retailer, because he didn’t want to be involved with an institution that wasn’t actively working to improve its social and environmental performance. When Wal-Mart embraced sustainability, he spent many long hours in the company’s headquarters in Bentonville, Arizona, sharing his experience with its leaders. As a pioneer in the category and a person disposed to generosity, Hollender has reacted in a very interesting way as nearly every major consumer-packaged-goods company started to claim an interest in sustainability. For the most part, he is thrilled, pointing to these other companies as proof that his dream of changing the world is coming true. He worries, though, about greenwashing and the possibility that it will make consumers doubt all products, including Seventh Generation’s. “A company that proclaims its commitment to social and environmental responsibility in a clumsy or inauthentic way quickly breeds cynicism and distrust—and invites the inevitable backlash,” he said. Hollender has seen many fellow entrepreneurs sell their companies to larger conglomerates. “Massive buyouts, minimal buy-in” is how he described such transactions, which, he adds, “often act as a fig leaf for large corporations hoping November October 2013
Source : conjectblog.co.uk
to appropriate the virtues of the ethical company so as to rehabilitate their image.” He remains hopeful, however. Meanwhile, he enjoys driving his business from the fringe to the center. Practical applications In today’s modern age, technology is the key leverage for accelerating sustainability programs at the global level. The day is not far off when an entire family will be able to ride a solar powered car together. Very recently, some prototypes have been developed and tested in the streets of London, by students of the Eindhoven University of Technology, Holland. They have code-named this product as “Stella.” The solar cells of this car generate more electricity on an average than the car uses, which means that the surplus electricity can be returned to the power circuit; thereby making the car energy positive. Some organizations such as Schneider in France have developed customizable software like StruxureWare, which tracks, manages, and forecasts key sustainability metrics such as carbon, water, and waste. Schneider has also started a new concept called Energy University, an online e-learning repository; wherein one can learn how to utilize energy effectively. The courses provides the information needed to identify, monitor, and manage energy usage as well as find new ways to create efficiency in any building. This ensures that in addition to learning new energysaving ideas that contribute directly to the overall well-being of the earth, an employee becomes even more valuable by contributing to the bottom-line of his/her company. In India, some organizations have explored the commercial viability of transforming organic waste into odor-free, flowable, and homogenized raw compost in just about 15 minutes. When this is cured further, it gives nutrient-rich, soil enhancing compost which can be used to create terrace gardens, organic kitchen gardens, and landscaping; thereby creating a cleaner, greener, and healthier environment. This effectively improves an organization’s Green Quotient (GQ) significantly. This OWC (Organic Waste Converter as they call it) has the capacity to process waste from 100 kg to over 2,500 kg per day. October 2013 November 2013
There have been quite a few self-sustained models started in India long time ago. These basically operate at local /village levels. One such glaring example is Tilonia ~ a tiny remote village in the Ajmer district of Rajasthan state in India. The town has been relentlessly working toward improving the lives of the rural poor by addressing basic needs, like water, electricity, housing, health, education, and income. The town is influenced by the Gandhian philosophy of each village being self-reliant. The Tilonia model is an inspiring one. Hopefully, more and more organizations in the country, both big and small can learn and apply the lessons learnt from it. There has been a lot of emphasis on sustainability and its management from a business perspective for students. Many global business schools have started their full-time MBA course (1-2 years duration) in the same. Some of the prominent names are: India • Indian Institute of Management, Lucknow (Dean – Prof Sushil Kumar) • TERI University – New Delhi Europe • ESMT – Berlin, Germany • Rotterdam School of Management, Erasmus University (RSM), Rotterdam, Holland USA
• Stanford University • Darden University • University of Michigan • New York University • Columbia University • Clark University • Presidio Graduate School Conclusion: Sustainability management certainly helps organizations and their global supply networks to re-evaluate their 5Ps – People / Policy / Process / Program / Project in terms of desired results. It also helps facilitate planning, implementing, reviewing, and improving an organization’s actions and operations to meet ecological goals. Every crisis is an opportunity. The crisis we face now is our chance—to build a strategy for sustainability into the core of our organizations and our lives. Such a strategy is a necessity, not an idealistic illusion. The author Sandeep A Hingne an– Independent Management Consultant based in Pune was Chief Operating Officer of AHCPL a tier I auto component manufacturing organization based in Pune. A mechanical engineer with MBA in International Trade, worked in both Non IT and IT sectors for more than 20 years.
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TOMASZ’s CORNER
The Most Effective Way of Visualizing Funnels
Tomasz Tunguz ttunguz@gmail.com
Tomasz Tunguz, a venture capitalist at Redpoint Ventures, an IT venture fund with offices in Silicon Valley, China and Brazil continues his column in MART. You can follow him on twitter @ttunguz. I first learned about Sankey diagrams in my thermodynamics class and they’ve since become one of my favorite data visualizations and analysis tools. Sankey diagrams, like the one above of visitors to this blog, show the flow of things. Originally created for measuring the flow of energy through powerplants, they are incredibly useful for content marketing analysis, visitor analysis or any other kind of funnel analysis. The best Sankey diagram ever created is Charles Joseph Minard’s depiction of the Napoleonic War, which was made famous in Edward Tufte’s Book, The Visual Display of Quantitative Information. It’s amazing because there are at least five different dimensions of data displayed in an intelligible way. Try that with any other chart. I use Sankey diagrams to understand how people navigate through this blog. At the bottom of this page, I’ve created a Read This Next box. Google Analytics’ Sankey diagram showing user behavior is the most
intuitive way I’ve found of understanding and measuring the impact of that feature. To see your GA Sankey diagram, click the Behavior tab, then the Behavior Flow tab from the Google Analytics home screen. You’ll see a chart like the one above. When I log in, I look first at the 1st interaction to see the breakdown of how people arrive at my blog. Next, I want to understand how they navigate the site. By looking at the patterns for each subsquent interaction, I can get a sense and by tallying
the page views in each of the first eight interactions, I know that the Read This Next Feature increases page views by 10% in total. More importantly, for engaged users (those who click on at least one more page), Read This Next doubles page views. Last, the Read This Next Feature drives 10.5x the number of page views as the previous/next buttons on the index page and 128% more traffic than the home page link at the top of the page. Sankey diagrams can be applied in sales conversion funnels to understand how efficient teams are in closing customers and where in the process the most effective improvements can be made. They can be used to understand customer lifetimes, upgrade cycles. Properly applied, Sankey diagrams provide deep insight into longitidinual patterns. Give them a try the next time you’re tempted to employ a funnel. The two best ways I’ve found of creating Sankey diagrams are D3’s Sankey toolkit by Michael Bostock (which can also be done in Excel and RCharts in R; but there are many ways. Source: www.tomtunguz.com
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MANUFACTURING EXCELLENCE
Journey Towards Excellence
P S Satish gotopssatish@gmail.com
Managing an SME in India - Part 10 As a continuation of last article, we will discuss on few more points to manage SME’s better in India 21. Make use of external Partners It is important to build a great team within the company. It will be better if external partners are added as a part of this team to strengthen it. Many companies have the attitude that they know best and why money should be spent on external partners. It is not true and external persons will add a tremendous value to the company. Since they are not emotionally attached to the company, they give fair and unbiased views. Who are these external partners? • Mentor He is the one who has wide experience and will be able to give external perspective to the company. He will able to identify strength and weakness of the company. He would like a mirror. His name in brochure will bring credibility in marketing. Companies will get best if they implement his suggestions. Concept of having a mentor for the company or for individual is low in India and is catching up. • Domain expert The company may already have enough expertise in their domain. But still they get benefit if they have an external person. He will have experience from many similar companies and those can be tapped suitably. •Brand ambassador This is required more for companies whose products reach consumers. Visibility of the product will enhance through this. • Consultant For specific requirements and to focus on improvements like cost reduction, productivity improvement etc. Companies will get benefit in knowing from him new tools, approaches are applied systematically. • Board of advisors
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Branding is required more for companies whose products reach consumers. Visibility of the product will enhance through this. Depending on the size of the company and activity, eminent personalities can be taken as board of advisors. They will bring credibility to the company. Their contacts can also be leveraged. Having these external partners on a long term basis, companies will get benefit immensely. A word of caution. These persons should be used for specific tasks and not to do routine jobs of the companies. CEO should ensure that employees are learning from them continuously and not dependent on them too much. Also to ensure right candidates with credibility, integrity and experience are selected. 22. Take care of your Customer There is saying that purpose of business is to keep customer happy and all other things are details. We are existing because of our customers, one of the key stakeholders of the company. How do we take care of him?. What efforts are made to delight customer?. Are we pro-active to understand his needs and expectations?. You need to work with customers closely to understand their implicit expectations. As your business grows, be clear in selecting Customer. Like the Customer does an evaluation to select a supplier, you also need to do some work to decide whether Customer is a right fit for you
for long term business. Having decided to work with a customer, next step is to take care of him. Few points here will help – • Have the habit of meeting customer regularly even there is no problem/ issues. Go and ask customer on what improvements can be done for win-win • Invite Customer to visit your facility. You will be boosting not only his ego but his observations are valuable input to you • Once in a way you may have customer meet to update progress of company. The way it is conducted may vary depending on size of your company. • Classify your customers as ABC analysis. For A customers who are giving high business and going to be long term partners, you need to take extra efforts. This does not mean neglect C customers. • If there is an audit by Customer team, ensure that all observations and feedbacks are taken positively and actions are closed. Giving update to Customer after completion of actions will enhance relationship • Develop customer oriented mind-set among employees. I will elaborate on how to do this in one of next articles • Always think on how to enhance value November 2013
to customer. Analyse how he perceives value?. What is of highest value to one customer could be least for another. One formula will not work for all. In a short sentence, value is something what customer gets or perceives more than what he is paying for • Whenever there is a visit of customer to company, plan well and ensure all his agenda points are addressed. When a new customer visits, remember that his first impression should be the best • Do not do Customer satisfaction survey at the end of year just as a ritual for the sake of ISO/TS standard requirements. Do not go after numbers. The issue here is many Customers are not keen to rate a supplier for want of time or they do not want to be seen as bad. If the relationship of marketing manager with customer is very good , company will get good ratings which might be different from reality. Best would be to meet personally key customers to observe his body language, expressions, oral comments. If there is an observation from Customer, do not forget to give him feedback what is done on his observations.
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Customer Satisfaction Survey must be beyond ritual • In TQM (Total quality management), Customer is the focal points and anything and everything done in the company is to take care of customer interest. Nurture that culture. • Be pro-active in communicating with Customers. Many customers are comfortable with over communication Customer is no more a king but an emperor. While taking care of customers
ensure that he will not exploit you. If you do not take care of your customer, there are many of your competitors waiting to take care of him. I will continue the series of article in the next issue. Please send your inputs, remarks, suggestions to P.S.Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103,Mantri Paradise Apartments, Bannerghatta Road, Bangalore-560076. Have a good day.
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QUALITY
Combining Six Sigma and CMMI Can Accelerate Improvements
Gorur Sridhar gnsridhar@gmail.com
Design of experiments and Monte Carlo approach make short work of CFD
Abstract One way organizations have adapted CMMI is to integrate it with the Six Sigma DMAIC roadmap. The two frameworks complement each other’s strengths and combining the two can help accelerate quality improvements. Capability Maturity Model Integration (CMMI) is a framework for business process improvement. Like any other model, CMMI reflects one version of reality, and like most models, it may be more idealistic than realistic in some ways. Organizations can use the model as a jumping off point to create process improvement solutions that fit their unique development environment. Keywords: CMMI – Capability Maturity
Fig 1 : Six Sigma in short
Model® Integration, COQ – Cost of quality, CTQ – Critical to Quality, DFLSS – Design for Lean Six Sigma, DFSS – Design for Six Sigma, DMADV – Define Measure Analyze Design Verify, DMAIC – Define Measure Analyze Improve Control, FMEA – Failure Mode & Effect Analysis, FTA – Fault Tree Analysis, PDCA – Plan Do Check Act, QC – Quality Control, QFD – Quality Function Deployment, RCA – Root Cause Analysis, SIPOC –Supplier Input Process Output Customer, VOC – Voice of the Customer 1.Introduction This paper tries to blend both the Six Sigma methodology and the CMMI framework and focuses on how they can complement each other for achieving process improvements. Like Six Sigma, CMMI is essentially process oriented. Each method follows through
Fig 2 : CMMI in brief
certain phases. For a typical DMAIC Six Sigma project aimed at improving the
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existing process, the phases are Define,
CMMI follows maturity levels, from
(Defined) to L4 (Quantitatively Managed)
Measure, Analyze, Improve and Control.
L1 (Performed) to L2 (Managed) to L3
to L5 (Optimized). Some of the tools used
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Level
Process Areas Linked to Six Sigma (DMAIC) Phases
L-5
• Causal analysis and resolution (CAR) - Analyze
(Optimized)
• Organizational performance management (OPM) – Improve & Control
L-4
• Organizational process performance (OPP) Analyze
(Quantitatively Managed)
• Quantitative project management (QPM) - Measure, Ana lyze & Control L-3
• Decision analysis and resolution (DAR) - Analyze
(Defined)
• Organizational training (OT) - Improve • Organizational process definition (OPD) - Define • Organizational process focus (OPF) - Improve • Risk management (RSKM) - Improve • Integrated project management (IPM) – Define & Control • Validation (VAL) - Analyze • Verification (VER) - Analyze • Product integration (PI) - Define • Technical solution (TS) - Analyze • Requirements development (RD) - Define
L-2
• Process and product quality assurance (PPQA) - Improve
(Managed)
• Measurement and analysis (MA) - Measure • Configuration management (CM) - Define • Supplier agreement management (SAM) Define • Project monitoring and control (PMC) - Control • Project planning (PP) – Define • Requirements management (REQM) - Analyze
Table 1 : Mapping CMMI maturity level process areas to Six Sigma phases when following the DMAIC roadmap also can aid an organization in reaching out to the next CMMI level as shown in the mapping above. These blind spots can be attributed and linked to DMAIC phases and in turn to the corresponding process areas as shown in the figure1 below. This is where the Six Sigma tools come in handy. The above map can help in spreading the CMMI message through the more common Six Sigma approach. It also dispels the myth that CMMI is predominantly used Fig 3 : Black box while transitioning from CMMI L3 to L5 November 2013
in the IT sector but not in other sectors
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and demonstrates the use of CMMI, irrespective of the industry or domain. The below table gives a snapshot of the similarities between the various Six Sigma methodologies including DFLSS and the tools being used. Recognizing the Differences Although Six Sigma can help a company in achieving higher levels of CMMI, the two methods do have some significant differences as shown in the table in the next page. Fig 4 : CMMI & DMAIC Overlap
CMMI Process Areas
Engineering
2.Literature Review
Six Sigma tools
DMAIC
DMADV
DFLSS
Validation
FMEA Normality test
√
√
√
Verification
FMEA Gap analysis
√
√
Product Integration
Flow chart
√
√
Technical Solution
Pugh matrix
√
√
Requirements Development
QFD
√
√
Brainstorming Kano analysis Requirements Management
Process map In frame / Out of frame
√
√
Quantitative Project
Hypothesis testing
√
√
√
Risk Management
FMEA FTA
√
√
√
Integrated Project
Gnatt chart
√
√
Management
Project Management
Management Gnatt chart
√
√
√
Project Monitoring & Control
Gnatt chart
√
√
√
Project Planning
Gnatt chart
√
√
√
√
Supplier Agreement Management
QFD
Process Management
Organizational Performance Management
Bench marking
√
Organizational Process
Process map
√
Organizational Training
Baselining
√
√
√
Organizational Process
Gap analysis
√
√
√
Organizational Process Focus
Gap analysis
√
Causal Analysis and
Fish bone Hypothesis testing
√
√
Pugh matrix Scatter plot
√
√ √
Performance
Definition
Resolution
Support
Decision Analysis and Resolution Process and Product Quality Assurance
Baselining VOC
√
Measurement and Analysis
Pareto
√
Configuration Management
Gap analysis
√
√
√ √ √ √
Table 2 : Similarities between CMMI & Six Sigma methodologies
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I.“Relationships Between CMMI and Six Sigma”1 explores the relationships between CMMI and Six Sigma and how they can be used together. II.“Achieving Success via Multi-Model Process Improvement”2 discusses the various process improvement models like CMMI, LEAN, GQIM, PSM, EIA, COBIT, ITIL etc. III.“Integrating CMMI and Six Sigma in Software and Systems Engineering”3 offers perspectives on the synergy between software / system-specific initiatives & Six Sigma. IV.“Using Six Sigma to Accelerate the Adoption of CMMI for Optimal Results”4 Shares findings from a project that
Six Sigma
CMMI
Assumes processes have been identified and pre-defined.
Focus is on defining management and technical processes early in the life cycle.
Doesn't distinguish between organizational standards and project processes.
Organizational process definition is used to capture best practices and lessons learnt.
Emphasis is on training to motivate and communicate skills.
Emphasis is on infrastructure to ensure that the key processes are addressed.
Relies on statistical methods to manage performance.
Statistical approach is welcome but often not implemented.
Focus is on learning from internal experience and data.
Additional mechanisms to leverage external technology are encouraged.
Prioritization of efforts is based on business payoff.
Link to strategic planning is weak and often ignored.
Certification is for individual practitioners, not organizations.
Certification is for assessors and organizations, not practitioners.
explores a non-traditional but relevant Table 3 : Differences between Six Sigma & CMMI
view of Six Sigma. V.“Using Lean Six Sigma to Accelerate
“COQ”. COQ for the month was computed
for each of the high COQ items as per the
CMMI Implementation”5 gives an
as the average COQ for each of the
80-20 principle.
Overview of CMMI, Lean and Six Sigma and
deliverables.
how they combine in practice. Case Study When a particular company decided to go for CMMI L5 certification, they leveraged the strengths of Six Sigma and used it as a spring board to achieve the certification in a shorter time and without redoing the documentation and reinventing the wheel. In order to transition to L5, the company
Measure
Improve •
Brainstorming was carried
•The existing level of COQ was measured
out by the team to determine an action
using the above formula.
plan for addressing the root causes. The
The data was broken down further into micro levels and the respective metrics were captured as listed below. • First level peer QC time
identified actions were implemented and the data was gathered for the next set of deliverables. •Next, the COQ was calculated for the new set of deliverables. Using the two-sample
• Second level peer QC time
t-test, the new average was compared
They did this by adopting Six Sigma to help
• Rework time taken to rectify the
implementing the actions.
them to stabilize the processes and reduce
identified errors
needed to make quantum improvements.
the variation. For example, one of the metrics the company was trying to improve was COQ which was measured as: COQ = (Total QC hours + Rework hours)*100 / Total Actual Hours
• Total actual time taken including the QC time and the rework times. etc. Analyze • Analysis of the measured data and the corresponding COQ was carried out in detail. This involved identifying the type
DMAIC approach was adopted to address
of errors and listing out the number of
this issue.
errors identified in each of the deliverables,
Define • Voice of the customer and a SIPOC diagram were used to define the problem and identify CTQ characteristics. •The problem on hand was defined as
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capturing the QC times taken to identify those errors and the time taken to rectify them. •A Pareto of the COQs against the various deliverables was plotted. •RCA or Fishbone analysis was carried out
against the corresponding average before
Control •The reduction in the averages indicated the effectiveness of the process change. •The COQ data was monitored using a control chart for the subsequent months. • Any reoccurrence of the out of control situation was handled in the same process of raising a CAR and again following the DMAIC approach. Achieving CMMI L5 Through the Use of Six Sigma Once a process was established, matured and the data variation was found to be stable for a couple of months, the internal
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target was redefined and the bar was raised further. This revised target became the new target to be achieved for the subsequent months. This demonstrated the maturity of the process and effectiveness of Six Sigma in achieving and sustaining CMMI L5. This is depicted as shown in the figure below 3.Result & Discussion 1. Six Sigma DMAIC gels well with the CMMI framework at all levels of maturity.
Fig 5 : Process Maturity
2. Both Six Sigma & CMMI frameworks complement each other’s strengths and weakness and accelerate the implementation at all maturity levels. 3. CMMI can be implemented equally well across the industry segments. 4.Conclusion CMMI L3 focuses on the variation reduction and stabilisation of the process. References
CMMI L3 focuses on the variation reduction and stabilisation of the process.
1. 1Jeannine Siviy, M. Lynn Penn & Erin Harper “Relationships Between CMMI® and Six Sigma” December 2005. 2. 2Jeannine M. Siviy. M. Lynn Penn. Robert Stoddard, “Achieving Success via MultiModel Process Improvement” SEPG 2007. 3. 3M. Lynn Penn. Jeannine M. Siviy, “Integrating CMMI and Six Sigma in Software and Systems Engineering” SEPG 2003. 4. 4Jeannine M. Siviy, Eileen C. Forrester, “Using Six Sigma to Accelerate the Adoption of CMMI for Optimal Results” 2004.
The journey from L3 to L5 involves usage of Six Sigma as discussed in this paper and the continuous usage of the PDCA cycle to further reduce the variation and stabilise the process.
5. 5Diane A. Glaser, Michael D. Barnett, “Using Lean Six Sigma to Accelerate CMMI Implementation” 2008. 6. John Walz, “Life Cycle Models, CMMI, Lean, Six Sigma – Why use them?” September 2007. 7. Rick Hefner, “Using Six Sigma to Accelerate CMMI Adoption (and Vice Versa)” Software Engineering Process Group Conference March 2005.
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CMMI L5 focuses on the continuous improvement by raising the bar further.
November 2013
FAIR MART
Kaizen’s IndiZen 2014 5th National Convention on Operational Excellence IndiZen is a one of its kind event in India which gives an opportunity to Learn, Network, Celebrate & Share the work done by organizations in terms of implementation of Kaizen/Lean/Operational Excellence. The organizers Kaizen Institute has pioneered innovated and led in the operational excellence consultancy field. The event is scheduled on 11th and 12th February 2014 at Hyatt Pune. IndiZen 2013 overview - 150 Participants - 45+ Organizations - 19 Case studies for case study competition - 5 World class gemba tours - 2 Citations Theme for IndiZen 2014: Employee Excellence for Operational Excellence (OE) Description: Indizen promotes Operational Excellence, which is beyond the mere use of improvement tools. It is about building a culture that promotes excellence in all kinds of operations, be it operations within a factory, a telecom company, a hospital, a bank, a government office or a part! This is an Operational Excellence convention that celebrates Operational Excellence – be it in any form – Lean, Kaizen, 6-Sigma, TPM etc; we welcome people using any tool or approach to come share, learn and gain from this convention. For the first time introducing COACHING KATA and KAIZEN TEIAN two powerful approaches to boost your Operational Excellence program Why Attend? Lack of skills, transparency, belongingness, lack of stability, ignoring the people aspect, locked knowledge & skills, unclear roles & responsibilities, etc are few of the reasons why organization fails to improve or achieve their operational excellence (OE) goals. IndiZen’s 2014 theme & focus will be on PEOPLE EXCELLENCE for OPERATIONAL EXCELLENCE (OE). Whether you are beginning your OE journey or you are a seasoned veteran this convention has something in store for you. IndiZen 2014 will give you the opportunity to learn and network with others who have “been there and done that,” and proven first and applications, technical applications, and best practices. The 2014 convention will delivers valuable information for all industries, belt or organization levels, and November 2013
careers.
Take Aways
Who should attend?
1. Attend tutorials on Employee Excellence for Operational Excellence
Threats & Opportunities has taken many companies into the rigorous world of absolute quality standards. Companies have started evaluating their their progress & process in order to improve. So if you are one amongst such organization who have started reviewing the progress & process or are planning to do so, this convention is for you. You will benefit if you are actively involved in the process of organizational change, development, and group dynamics related to a successful Kaizen/Lean or Operational excellence culture. People who participate in our convention includes Vice Presidents/Presidents, MD/ Directors, HOD and Managers of: Operations, Quality, Training & Development, Manufacturing, Process & Discreet industries, Healthcare, Service, Financial Service, Government, Lean professionals, Process improvement team members, Continuous improvement managers, Master black belts, Black belts, Green belts, and Champions should also attend IndiZen 2014.
2. Compete in the National Operational Excellence Case Study competition 3. Visit Lean facilities – Excellence inside tours 4. Inspiring keynote speakers and case studies to learn from This year Mr. Donald A Dinero and Mr. Shyam Talwadekar will be keynote speakers. Mr. Donald has more than 40 years of experience designing and implementing manufacturing methods and processes and is the principal of the TWI (Training within industries) Learning Partnership while Mr. Shyam is a corporate coach, speaker and blogger and has authored over a dozen books on Lean. URL: http://in.kaizen.com/India-2014/ content-for-Indizen%202014.html For attending the Indizen2014 do contact D Soneji, Tel: +91 79 26407750 Email: dsoneji@kaizen.com www.martonline.in
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CASE STUDY
Paving the way through London’s soft core Conveyor Drives for RTC
Jyoti Mishra jyoti.mishra@nord.com
The metropolis London is currently adding a new East-West rapid transit connection with a length of more than 100 km to its much-frequented public transport network. For this major project, 21 km of new tunnels are being bored in the city center alone. The soil here mainly consists of soft clay with a sticky consistency that makes the transport of excavated material especially challenging. H+E Logistik and NORD DRIVESYSTEMS, two German industry specialists, are supplying suitable conveying technology including geared motors. Named after the mathematician Ada Lovelace and the city map pioneer Phyllis Pearsall, Ada and Phyllis are tunnel boring machines (TBMs) from German manufacturer Herrenknecht, each measuring approximately 100 m in length and weighing about 1,000 tons. Working for the rapid transit project “London Crossrail”, they have been pushing forward their 7 m wide “Cutterhead” blades below the City since 2012. After tackling the distance of six and a half kilometers between Royal Oak and Farringdon Station, they are planned to resurface in 2015. Besides Ada and Phyllis, more TBMs are currently boring similar tunnels in various other track sections for the East-West connection through London which will measure a total of 118 km. The first Crossrail sections will be put into operation in 2018. With an investment volume of more than 17 billion EUR, “London Crossrail” is currently Europe’s
The project also uses German conveying technology: every hour, several thousand tons of excavated material must be transported away
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German technology for new train lines in London: the tunnel boring machines supplied by Herrenknecht.
largest infrastructure project.
the Herrenknecht subsidiary H+E Logistik.
Demanding transportation task
In addition to special plastic coatings and other measures, a wiper system developed especially for the on-site requirements serves to prevent problems caused by conveyed material sticking to exposed system components.
The TBMs excavate up to 1,300 tons of “London clay” per hour in the two 6.2 m diameter tunnels that are being bored in parallel below the city center. The handling of this soft material does require solutions that are tailored to its consistency. In this case, the challenge lies in reliably transporting the excavated material away from the building site, which includes routing it over machine, tunnel, and hall conveyors before loading it onto trains. State-of-the-art tunneling includes the addition of tensides to the excavated material directly at the boring machines in order to facilitate handling. However, if the special London clay formation and these additives came into contact with standard conveyors, complications would soon arise: the mass would promptly and persistently stick to parts of the conveyor belts. Tunnel conveyors for the “London Crossrail” project were therefore custom-tailored by
Firstly: reliable, secondly: versatile Specifying and procuring reliable conveying drive technology proved similarly important. H+E Logistik approached its proven partner, NORD DRIVESYSTEMS from Bargteheide near Hamburg: “We have been cooperating with NORD for approximately ten years now, and have tackled hundreds of projects together”, says Dirk Uphues, the H+E project manager in charge of the London operation. “The reliability of geared motors on our conveyors has always been a decisive factor. NORD fulfills this key requirement, no matter which drive type they deliver for us.” For the London tunnel conveyors, NORD supplies helical bevel geared motors November 2013
NORD DRIVESYSTEMS supplied the drives for the conveyor belts
with a double-sided, smooth output shaft. An expansion coupling transfers the torque to the belt conveyor. “Of course we would like to minimize the drive variety, and the double-sided shaft allows for the versatility that we need: our systems typically complete not only a single tunneling project, but are often bought back on completion for other tasks. With a variable drive configuration, they can more easily be used in different locations”, says Uphues. Seamlessly and without delay All NORD gearbox housings are manufactured using a single piece construction with no joints or seams. This applies even to very powerful industrial gear units up to 242 kNm which are required for extreme conveyor inclines and moving very large amounts of conveyed material. The one-piece UNICASE housings of NORD’s industrial gear units feature integrated bearing seats. Thus, there are no sealing surfaces between the drive
side and the gearbox housing that are susceptible to damage through torque and radial forces.
planned in advance near Bond Street Station was scheduled on short notice. So as not to affect other project deadlines, H+E was tasked with providing suitable short conveyors within eight weeks. “The required drive technology from NORD arrived five days after ordering”, says Birgit Barian from the H+E purchasing department. “Particularly when a project is nearing completion, you can easily find yourself in a situation with tight delivery deadlines and considerable time pressure. Even if you have kept all of your own deadlines, many third party problems and sometimes unforeseen circumstances come into play. Without partners like NORD, that are available virtually on demand, you might easily find yourself in difficulty.” NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 3.000 employees, and is one of the international leaders in the industry. In
With its offset bearing shaft arrangement, the UNICASE design also ensures very compact dimensions but allows for the use of larger bearings for higher loads and extended working life. Industrial gear units can be installed as left or right side conveyor drives. Most types are globally available with fast delivery times. Even though tunneling projects can take many years, customers like H+E Logistik appreciate suppliers who can ensure short-term availability. Besides tunneling, The TBMs easily penetrate the clay soil found in London, although the London Crossrail project this poses a special challenge for the conveying technology also includes the remodeling of existing stations and the addition to standard drives, NORD supplies construction of new ones. application-specific concepts and solutions, Some time ago, additional manual even for special applications, for example excavation work that could not be with energy-saving drives or explosionprotected systems. Gross sales amounted to approx. EUR 450 mn in the 2012 business year. The company founded in 1965 now has over 35 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 200 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units.
German technology for new train lines in London: the tunnel boring machines supplied by Herrenknecht.
November 2013
For further details visit www.nord.com www.martonline.in
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AUTOMATION
Secure hold using Vacuum Technology With the PLANOS vacuum clamping system from SCHUNK, the competence leader for clamping technology and gripping systems, flat workpieces as well as those with a flat underside can be clamped on the machine table using vacuum simply, quickly and safely. In order to further enhance the user flexi-bility, SCHUNK has recently introduced a standardized adapter plate by which the vacuum clamping system can also be used on MAGNOS magnetic chucks. PLANOS consists of one or multiple combined matrix plates as well as a vacuum generator. During the clamping process, the workpiece is positioned and the vacuum is activated. In a matter of seconds the part is safely and precisely clamped in a level position with a height tolerance of +/- 0.02 mm. It can even secure thin plates precisely and deformation-free. Optional mechanical stops assist in the positioning and accommodate additional shear forces. The vacuum system has a modular design and can be expanded in a variety of ways. It can also be retrofit on existing systems. For this purpose, the matrix plate is secured to the machine table with a quick-change pallet system, clamping blocks, clamping claws or even using a magnetic chuck. The standardized matrix plates with base bodies made of high-strength aluminum elements are available in the sizes 300 x 200, 300 x 400, and 400 x 600 mm and with grid sizes of 12.5, 25, and 30 mm. The suction surface and the required grid size can be determined depending on the
PLANOS : By generating a vacuum, PLANOS clamps flat workpieces quickly, easily, and safely.
workpiece geometry, the machining and
matrix plates can also be equipped with
the horizontal forces.
friction pads which are automatically
The finer the grid, the stronger the holding force. In order to produce break-throughs,
activated through the vacuum feed and permit higher shear forces.
a grid table suction device can be used for
Compared with matrix plates without
the 30 mm grid to elevate the workpiece
friction pads, the horizontal holding
in its position. On request, the SCHUNK
forces with friction pads are up to 30% higher. In the process, no additional force is exerted on the workpiece. The friction pads are resistant to oil and ozone and are individually replaceable if necessary. To generate the vacuum, the innovative family-owned company offers special vacuum units to ensure maximum flexibility and process safety. They are equipped with an oil-lubricated vacuum pump and a liquid separator, which also serves as a vacuum accumulator. Various components for the system monitoring and interfaces for integration in the machine control ensure maximum safety. An emergency STOP function protects the vacuum pump
PLANOS application : Clamping can take place deformation-free on the bottom of flat workpieces using the SCHUNK vacuum clamping system.
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against damage from suctioned liquids. For further details visit www.schunk.com November 2013
MACHINE TOOLS
NTX1000 – High-Precision, High-Efficiency Integrated Turn Mill Center
The NTX1000 is an ideal choice for machining small precision parts for medical equipment and measuring instruments, which have complex shapes but need high-precision and high-efficiency machining. The machine is designed to meet the diversified needs of our customers with features including (1) original technologies, (2) high operability, (3) space saving, (4) measures against thermal displacement, (5) MAPPS IV + ESPRIT, and (6) a wide variety of models. (1) Original Technologies The NTX1000 uses MORI SEIKI‘s original DDM (Direct Drive Motor), ORC (Octagonal Ram Construction) and BMT (Built-in Motor Turret) technologies, offering highprecision complete machining of small precision parts. (2) High operability The NTX1000 uses a rounded cover design, which is commonly used by the X-class machines. Additionally, it offers improved operability by using a slanted keyboard. (3) Space saving The installation area has been reduced by approximately 40% compared to our conventional models. The NTX1000 offers dramatically improved productivity per unit area. (4) Measures against thermal displacement As one of measures against thermal displacement, the NTX1000’s Spindle 1 is designed to always maintain its center in the same position, and its headstock November 2013
structure is symmetrical to the X- and Y-axis directions from an anterior view. In addition, the slideways of the ORC are located diagonally opposite each other so that their distortion in response to heat becomes symmetrical. Since thermal displacement in the slideways is offset, the machine can maintain the center of the moving parts in the same position, achieving high-precision machining.
flexibly meet customer needs. In addition, the 3D interference checking function (standard) checks interference between spindles, workpieces, soft jaws, tools, holders, and turrets in 3D. If interference is detected, the machine stops, in both automatic and manual modes. This offers the world‘s best protection against interference.
(5) MAPPS IV + ESPRIT
Eight models for different machining needs are available. Although they are general-purpose machines, each of them flexibly handles machining that is usually performed on special machines. They can be used instead of special machines.
The NTX1000 uses the MAPPS IV highperformance operating system for its operation panel. The combination of automatic programming software (standard) and ESPRIT CAM software (standard) allows the machine to handle complex machining programming and to Chucker (C type)
Tailstock
Spindle 2
(T type)
(S type)
(6) A wide variety of models
For further details visit www.dmgmoriseiki.com Turret 2 (Z type) Milling (M type)
Workpiece discharge unit (W type)
NTX1000/SZ NTX1000/C
NTX1000/T
NTX1000/W
NTX1000/SZM NTX1000/S
NTX1000/WZ NTX1000WZM
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35
BEARINGS
Iglidur: Universally accepted in place of Metal Bearings
Deepak Paul deepak@igus.in
Plain bearings – In 30 years igus has built up an enormous range of plain bearings. These are used in thousands of applications, as is impressively demonstrated by the current manus award. The world of plain bearings is characterised by applications where the bearings have to meet a whole range of different requirements. This is best illustrated by competition entries. Cologne-based igus holds such a competition – the manus award – every two years, and the sheer amount of interest in this year’s competition was formidable. “It was the sixth time we have held the manus competition, and we had a recordbreaking 437 entries this year,” Managing Director Frank Blase reports. “Our highly qualified jury was faced with the difficult task of choosing the winners from a wide range of very different ideas related to the use of lubricant-free plastic plain bearings.” The flood of entries shows the variety of possible uses for plastic plain bearings –
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and proves how creative design engineers can be. “We were very pleased with the international share of participants,” Frank Blase continues.
Smoother running, less friction
Where so many entries are submitted, the variety of application areas is enormous and many have almost nothing to do with machine and plant construction. This year’s winner, for example, Ulrich Ghisler from the Danish company Thorax Trainer, has built a new training device for cross-country skiing. The slides run very smoothly and quietly on the rail thanks to a drylin linear guide, thus achieving optimum effects for the athlete.
The silver manus is somewhat closer to mechanical engineering. Christian Geistberger from Hitzinger GmbH in Austria was able to achieve high power levels and extremely fast reaction times with a new pneumatic USP system. The iglidur bearings in the flaps of the integrated pneumatic rotary piston engine are a lowcost solution guaranteeing a permanently frictionless function. Initial tests with Carobronze bushings failed because the bearings became clogged with dust particles after a short period of use and no longer opened.
Other projects included organiser items, miniature steam trains, table football or a device that simulates a horse’s back.
The bronze medal went to an agricultural technology project. Andreas Höck from GKN Walterscheid had an idea for a new
November 2013
bearing concept for heavy-duty overload protection in the drive train of a machine for harvesting green fodder. The project aimed to increase running smoothness. This was achieved through a new bearing concept where iglidur plain bearings were used in place of the metal bearings used previously. The enthusiastic participation from India totalling to 38 entries made India the 5th largest contributor to the competition. All this interesting applications from India can also be found in the manus manual which can be requested at the below address or an email to Deepak@igus.in. Two among these have also won Special Jury Mention, One is a special purpose machine developed by M/s Machine Studio design Pune, This machine is used for making uniform serrations in industrial files, and this is done using a chisel that moves on an igus linear guide. The chisel strikes more than 900 times per minute and this generates very strong vibrations, iglidur bearings and Drylinear guides from igus helps in the function and also viberation damping. Neubauplan also had another entry with packaging machines – where lubrication is a strick no and every day the machines are getting faster – this carton filling machine can fill a carton at the rate of 500 units/minute and almost all movements are guided on igus bearings, iglidur-plain bearings, igubal-self aligning bearings and Drylin- Linear guides. Another application was from Automotive Industry where our bearings are used more and more every year – because of its high service life with no maintenance and low weight, says Mr. Deepak Paul National Sales Manager. As per Mr. Munir Pansare of Tata Motors “Supporting the elements under forced excitation without any BSR (Buzz, Squeak & Rattle) issues is a big challenge faced by Automotive Industry in recent times. These are major customer irritants and costs OEMs huge by various BSR related warranty claims. We needed a zero clearance between shaft and bush in our steering column I shaft support to avoid impacts and rattle. At the same time there should be positive clearance fit for ease of assembly and movement”. “The requested bush material need to have low stick-slip effect to avoid squeaks and must also have high vibration dampening capacity to absorb road shocks”.
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Steering column
Support Bracket
Spherical Support Ball
Figure 1 Steering Column along with Support Bracket Natural choice to satisfy these requirements was to look for a well designed material. Mr. Munir Pansare says “ Thanks to igus for their work in the field of Plastics we could find a solution in JVSM bushes. Their bushes have spring elements for radial pre-tensioning giving the required zero clearance feel”. “The material iglidur J have high wear resistance and low co-efficient of friction. iglidur J was also self- lubricating as the other igus materials – and was also cost effective” Mr. Munir Pansare concludes. Deepak Paul, Sales Manager for plain bearings who has worked for igus for 14 years, provides an example of a customerspecific project: “An oscillating shaft in a heavy goods vehicle, a so-called knuckle joint, has to cope with extreme requirements. At first, we weren’t sure whether and with which kind of material this could work. As the first step, we developed prototypes and special tests for these. We used a preliminary test with customer shafts to show the customer that these practical tests are worth it. The wear curves with metallic bearings were compared with our materials. Then the customer was given the result showing which bearings were used, and the customer-specific solution was taken from there. This process sometimes results in the development of new products which then appear as standard solutions in the catalogue.”
The bearing dimensions range from 0.7 to 200 millimetres inner diameter. A bearing with 1.2 millimetres inner diameter for a music organ builder is at the bottom end of the scale. This bearing is located in the wooden deflection units. It is silent, extremely durable, economical and has a constant friction value. At the other end of the scale is the enormous 195 millimetre bearing for adjusting the tilt in a threshing machine. igus has been developing lubricant-free and thus maintenance-free bearing materials for a good 20 years now. Ranges for linear and pivoting bearings have developed out of the original plain bearings ranges. “We do not manufacture any metallic bearings, all our bearings are made of plastic, which enables us to produce bulk goods in an environmentally friendly way, and this materials are corrosion-free and light,” Deepak Paul says. Initially, the founder of igus, Günther Blase, delivered his plain bearings to textile machine manufacturers. The areas of application gradually extended to include automotive parts and packaging machines. What all the applications have in common is that they require materials or bearings which do not have to be lubricated. No-one wants to have grease on textiles or packaging items, particularly not on foodstuffs. In the case of agricultural machinery or vehicles, manufacturers want to avoid large quantities of lubricant www.martonline.in
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because low maintenance levels are always highly valued by end users. Environmental issues are also important these days. The materials which iglidur is replacing are typically metallic bushings, in other words bearings with Teflon coating, brass or bronze bushings, sinter bushings or wound versions. In today’s world where users are being increasingly discerning Deepak predicts even more applications. “There is enormous potential for our products,” he says. “Today, vehicles, machines or everyday objects all have more and more functionalities, more and more parts move, rotate and need adjusting and with our no maintenance, long life, cost effective bearing programme we believe we are still only at the beginning with our plastic bearings, although we have had a lot of success already.” Fast Selection Using igus Test results. igus has also developed configurators and
Neubauplan File chiselling machine selection programs for plain bearings. Tobias Vogel: “Within the framework of the newly developed iglidur expert system, customers can use the service
life calculator 2.0 to determine which material is best suitable for a special application. Selection is made quickly and independently online using the X-iglidur (The life calculation programme), no matter whether customers want to order five, 50 or 5,000 units.” igus regards this as a unique and unmatched benefit to aid today’s design needs. “There are only very few suppliers who offer such a service even for metallic bearings.” Wide range igus sees itself as a small supplier in the overall bearings market. However, as far as plastic bearings are concerned, the situation is different, Deepak says. “We are in a good position here, because we can deliver a wide range of different materials and have a high availability rate from stock due to fast and lean production systems. At the same time, we must continue working on new products and looking to improve existing ones,” the Sales Manager adds. One such example is the “conductive plastic bearing” materials required in areas where lubrication is not possible yet static electricity build up can be catastrophic for the application, or more recently the “detectable plastic” material for packaging industry which can be magnetically detected in case of contamination. For this reason and many more igus continually invests in research and develops plastic bearing materials which are “tribooptimised. For further details visit www.igus.in
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November 2013
MACHINE TOOLS
Proven WIDIA WMT™ Grooving and Cut-off System Adds New High-Performance PH Geometry Chipbreaker and rigid cutting edge are first choice for hard materials and interrupted cuts
New PH plunging and turning geometry for the WMT platform from WIDIA
Job shops around the world may have business and customer requirements unique to each company, but concerns on how to improve costs and secure more business are common to all. “Shops want more performance options, and at the same time don’t want multiple, job- or material-specific tooling solutions tying up their inventory,” says Mark Filosemi, global product manager, threading, grooving, and cut-off for WIDIA. “Where productivity is concerned, particularly in grooving, and cut-off, you have to have a versatile system to be serious. That’s where the WIDIA WMT platform is a proven winner, because shops can do more with it.” Now that platform is expanding with the addition of the new high-performance PH geometry, designed and engineered for plunging and turning in materials harder than 35 HRC or in heavily interrupted cuts across a broad range of work materials. November 2013
The new PH geometry fits in with the proven features that make WIDIA’s WMT platform a core program for grooving, and cut-off. One toolholder securely seats whatever insert geometries are needed: PT for plunging and turning, PC for plunging and contouring, CM for cut-off (or CM-W with wiper), and the new PH geometry for plunging and turning hard materials. The WMT toolholder is engineered with an extra-long clamping area for excellent insert stability. The proprietary “Double V” system makes it easy to securely seat inserts in the toolholder pocket for both optimal insert positioning and superior side-load resistance. Such precise insert positioning and overall system rigidity both translate into notably improved accuracy and tool life, whether it’s face grooving, ID grooving, OD grooving, plunging, or profiling that needs to be done.
With its 90o top and bottom clamping design, rigid cutting edges, and positive geometry, the new PH WMT insert is the first choice for plunging and turning hard materials or in accomplishing interrupted cuts in steels, stainless steels, aluminums, cast irons, or high-temperature alloys. The recommended WU25PT grade for interrupted cutting features an advanced PVD TiAlN coating for longer tool life, equating to more parts per edge. “Whether companies are familiar with the WMT system or coming to it for the first time, the value remains: one toolholder, multiple options,” Filosemi says. “Adding the new PH geometry for plunging and turning hard materials or doing interrupted cuts gives shops more options to get the jobs done.” For more information, visit www.widia.com. www.martonline.in
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MANUFACTURING IT
CANopen Devices
Connecting CANopen devices to the SIMATIC® S7-1200 PLC The CM CANopen module from HMS Industrial Networks enables users of the SIMATIC S7-1200 PLC to integrate CANopen devices into their automation systems (using the TIA Portal®). The CM CANopen is an extension module for the SIMATIC S7-1200, enabling the PLC to communicate with devices on a CANopen Network. The product is developed by HMS Industrial Networks and is fully approved by the manufacturer of the S7-1200 – Siemens AG. How it works The CM CANopen plugs into the S7-1200 and works as a translator between nodes on a CANopen Network and the S7-1200. The module fits mechanically into the standard S7-1200 system rack and can be configured to be both Master or Slave. No programming is needed to configure the communication between CANopen and the PLC – users set up how they want the data to flow in the accompanying CM CANopen
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Configuration Studio software.
distributors.
It is possible to plug in three CM CANopen modules per PLC, and 16 CANopen slave nodes can be connected to each module (each module supports 256 bytes input and 256 bytes output).
HMS Industrial Networks is the leading independent supplier of embedded network technology for automation devices. HMS develops and manufactures solutions for interfacing automation devices to industrial networks. Development and manufacturing takes place at the head office in Halmstad, Sweden. Local sales and support is provided by the HMS branch offices in Chicago, Beijing, Karlsruhe, Milan, Mulhouse and Tokyo. HMS employs over 240 people and reported sales of €42.5 million in 2011. HMS was formed in 1988 and is listed on the NASDAQ OMX Nordic Exchange in Stockholm in the category Small Cap, Information Technology with ISIN SE0002136242.
There is also support for transparent CAN 2.0A for custom protocol handling, and the module is integratable into the hardware catalogue of the TIA Portal configuration suite. “The CM CANopen enables users of the S7-1200 to integrate CANopen devices into their PLC system giving them a wider selection of automation products to choose from when designing their systems,” says Mikael Mårtensson, Product Manager at HMS Industrial Networks. “This is a solution that will bring a lot of value to users of the S7-1200, allowing them to build more efficient automation systems.” The CM CANopen is available as of October 2013 from HMS sales offices and
For more details do write to UL Electrodevices Pvt Ltd S.NO. 6/9/6, Bhairavnath Nagar Nahre Gaon, Tal Haveli, Pune - 411 041, Tel: +91 20 269 60040, Email: anybus@ulepl.com or visit www.ulepl.com November 2013
MACHINE TOOLS
Kennametal Announces Breakthrough KM4X100™ Spindle Connection Spindle connection helps deliver maximum machine tool power for maximum metal removal in titanium and hard alloys The spindle connection is the “handshake” -- the interface between the machine tool’s spindle and toolholder. As such, this vital component has to provide the torque and bending load capacity compatible with the machine-tool’s operating specifications. But when machining high-strength materials like titanium and other alloys, cutting forces generate bending moments that will exceed the interface’s limits prior to reaching the machine tool’s torque threshold. By combining high clamping force and optimized interference levels, Kennametal’s new KM4X100™ provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining high-strength alloys and other materials. The result is extremely high metal removal rates and more completed parts per shift. “In most cases, the tool-spindle connection determines how much material can be removed on a given operation,” says Doug Ewald, director, global product management, tooling systems at Kennametal. “This is because this interface must withstand high loads and yet maintain its rigidity. With the ongoing advances in cutting tools and machining centers, a spindle connection like KM4X 100™ that makes the best utilization of available power possible is an important consideration to investigate early in production planning.” Global Priority High-strength, lightweight materials such as titanium alloys, Inconel, and new aluminium alloys are eagerly sought by manufacturers in many industries, including aerospace and defense, energy, and transportation. These new materials present significant machining challenges in themselves. Add the competitive pressures in these global industries, and finding advanced manufacturing solutions becomes a top priority. Machine-tool builders have responded with milling and turning centers that feature improved stiffness and damping on spindles and sizable machine structures and motors, all to provide the significant horsepower, torque and thrust forces
November 2013
Kennametal’s robust KM4X100™ spindle connection provides three times greater bending moment resistance for improved milling, turning, and holemaking.
required while minimizing undesirable vibrations that deteriorate part quality and tool life. By using three-surface contact for improved stability and optimized clamping force distribution and interference fit, KM4X100™’s engineering results in three times the bending moment resistant capacity compared to other tool systems. This means: -Shops can leverage KM4X-equipped highperformance machine tools to increase speeds and feeds in difficult machining applications, thus gaining the full productivity potential from the machine tool. -Often, a smaller KM4X connection such as a KM4X100™ will provide the same or better cutting performance of a larger connection. -KM4X systems can be applied on multitasking, turning, machining centers and transfer machines in manual, semiautomatic, or fully automatic mode. “KM4X 100™ by design can perform in a wide range of operations, from low-speed/ high torque to high-speed/low torque, allowing manufacturers to get the absolute most out of their production equipment,” Ewald says. ”Milling, drilling, and turning
a wide range of materials just got more productive!” Celebrating its 75th year as an industrial technology leader, Kennametal Inc. delivers productivity to customers seeking peak performance in demanding environments. The company provides innovative wearresistant products, application engineering and services backed by advanced material science, serving customers in 60 countries across diverse sectors of aerospace, earthworks, energy, industrial production, transportation and infrastructure. With approximately 14,000 employees and nearly $3 billion in sales, the company realizes half of its revenue from outside North America, and 40% globally from innovations introduced in the past five years. Recognized among the “World’s Most Ethical Companies” (Ethisphere); “Outstanding Corporate Innovator” (Product Development Management Association); and “America’s Safest Companies” (EHS Today) with a focus on 100% safety, Kennametal and its foundation invest in technical education, industrial technologies and material science to deliver the promise of progress and economic prosperity to people everywhere. For more information, visit the company’s website at www.kennametal.com
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AUTOMATION
Elmo Motion Control Adds Advanced Features to its Gold Maestro Motion Controller Full Delta Robot Support, Enhanced Error Correction Support and Superimposed Motion are now an integrated part of the Gold Maestro Version 1.1.2.0. Elmo Motion Control, a leading provider of advanced and cost-effective motion control solutions, announced today the firmware release for Gold Maestro Motion Controller Version 1.1.2.0, including a range of powerful new features that make complex motion tasks easier to program and faster to implement. Elmo’s Gold Maestro (G-MAS) is an advanced, fast, precise, user-friendly and cost-effective distributed networking motion controller that leads the market. According to Benjamin Spitzer, Product Manager, “The Elmo team has implemented a number of new and advanced features into the Gold Maestro that enhance the functionality of the updated version, maintaining G-MAS as the preferred networking motion controller across all industries.” The Gold Maestro now offers full Delta Robot Support, including Linear, Circle, Polynomial, Table Spline and Table PVT. Simply define the Delta robot part lengths, and the machine is ready to run. Enhanced Error Correction Support is another new feature of the updated Gold Maestro Motion Controller, enabling position correction of both single and multi-axis positions in real time, based on correction data. Superimposed management of error correction is fully supported. In addition, the feature supports 1D, 2D and 3D error correction (http://www.elmomc.com/capabilities/7. GMAS Error Mapping Correction Support/1. GMAS 1D 2D 3D Error Correction Support/GMAS-Error-Mapping- Correction-Support. htm#page=page-1). The Gold Maestro enables Flying VisionTM (http://www.elmomc.com/news/ flying-vision.htm) with Superimposed Motions (that is, adding another profiler on top of an ongoing motion in real time), significantly improving machine
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throughput. Flying VisionTM is used mainly when the exact end position of a motion is unknown and needs to change during the motion, without crossing the initial location. With this functionality, the User can change the target position without changing the current Function Block. Elmo’s Flying VisionTM enables increased accuracy and motion stability, while reducing process time, with potentially improved speed of 30% or more. With the Fast Reference to Drive Functionality, the Gold Maestro now supports a fast referencing capability to enable the G-MAS to send an additional position reference to a drive. The position reference can specify the actual or target positions for axes in the system, as well as a position along a Group axis path. This can be used for numerous purposes, including Additional Auxiliary Profiler to drive, Advanced Gain Scheduling, and Touch Probe. To find out more about Elmo’s new range of features, and for a complete description of the functionality of the Motion Controllers line, please visit Gold Maestro (http://www.elmomc. com/products/multi-axis-machinemotion-controller-g.htm) and Elmo’s Motion Control Capabilities (http://www.elmomc.com/capabilities/ elmo-capabilities-main.htm?headerbar=0) on the Elmo website. Elmo develops and markets cuttingedge servo drives and network motion controllers that deliver the complete solution for any motion-control application. Inspiring motion since 1988 and with millions of drives performing
reliably in a wide variety of industries and military applications, Elmo boosts the success and profitability of our customers worldwide. In India Elmo is available through Rajdeep Automation Pvt Ltd, S# 143, Vadgaon Dhayari, Sinhaghad Rd, Pune # 411041 Tel: +91 20 24393755 Email: sales@rajdeep.in
November 2013
INDUSTRIAL SAFETY
Lighter, brighter, longer-lived: New generation of robust fluorescent lights for hazardous areas
R. STAHL’s new line of light fittings for use in Ex zone 1/21 and 2/22 hazardous areas achieves better energy efficiency than comparable devices and provides approximately 10% more luminous intensity. New EXLUX 6001 luminaires also feature a design that is considerably more compact, stable, and torsion-resistant than their EXLUX 6000 predecessors While more than one million of the longproven EXLUX 6000 lights have been deployed worldwide over the last twentyodd years, the new generation now meets increasing user demand for a similarly economic, yet enhanced product with improved technical features reflecting the most current state of the art. Depending on their performance class, the 6001 luminaires are a quarter to a third lighter than their predecessor models and many competing products. Users now also benefit from the extremely robust design of these slimmer, narrower units: unlike most lights, the new devices can be operated at extremely low ambient temperatures (as low as -30 °C). In many cases, this amounts to a decisive extension of the application range that saves costs by making extra specifications unnecessary. In order to facilitate a step-by-step exchange of existing EXLUX pendants, the installation of the new units remains fully compatible to the predecessor series. Moreover, swiftly removable replacement parts ensure quick and easy maintenance. Like before, the new lights are available with customer-specific modifications on
November 2013
request. In addition, R. STAHL provides especially cost-efficient standard models with a power consumption of 18 W, 36 W, or 58 W that are available at short notice.
also be available soon, though these will be based on a completely different housing and equipped with materials and features optimised for LED technology.
Featuring 4 mm² cage clamp terminals, 5-core through-wiring, and a full-phase safety shutdown, these models are adequately equipped for the majority of all typical applications. The new series fully complies with the requirements of all current industry standards. Notably, the new silicone-based foamed gasket has been optimised for maximum durability, as stipulated by IEC 60079. This sealing solution, which is resistant to various chemicals as well as UV radiation, the fitting’s hinge, and a newly designed central lock reliably ensure IP67 protection over many years.
For more than 80 years, R. STAHL has been a trendsetting manufacturer of safety technology for hazardous areas. Based in Waldenburg, Germany, the company is one of the world’s leading suppliers of explosion-protected automation, control and distribution, installation, operating and monitoring, lighting, signaling and alarm components and systems. Key products include customer-specific systems solutions for hazardous areas.
6001 series lights are available as of now. However, more products are due to follow in the new EXLUX generation: in 2013 and 2014, the program will be extended both by optional accessories, such as pole mount adapters, and by additional models such as emergency lights, lights with an address module, and T5 lights for use in zone 2. Moreover, LED lights from R. STAHL will
R. STAHL’s individual packages containing tailored product combinations and a wide range of services such as consulting, project planning, engineering and training courses for customers are designed to fully meet application requirements and customer needs. International certifications, approvals and patents demonstrate the company’s expertise and allow for R. STAHL’s products to be used throughout the world. For further details visit www.stahl.de
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MART UPDATE
Han® HMC connector series from the HARTING The connector for a large number of mating cycles - also in harsh industrial environments The new Han® HMC connector series from the HARTING Technology Group is the first to combine the properties of more than 10,000 mating cycles and protection against harsh environmental conditions in one complete connector. Devices and machines that are employed in different locations and that often are connected several times a day, e.g., in the medical sector and the laboratory and test engineering sector, require reliable connectors such as the Han® HMC. This connector meets these most demanding requirements. The increasing modularization in machine construction and automation is furthermore leading to a rising demand for connectors that have been developed for a large number of mating cycles. The new Han® HMC series is the perfect solution for all of the applications just mentioned. Han® HMC connectors are also ideal for use in tool and other interchangeable systems. Han® HMC connectors are based on the Han® industrial connectors that have been
tried and tested for decades. This has the advantage that all already existing processing tools can also be used for the Han® HMC. The complete Han® HMC series consists of: • Han® B HMC housings, • Han® HMC connector inserts with crimp connection in four different versions, • Han® HMC crimp contacts in two sizes,
contacts.
• diverse Han-Modular® modules together with the Han® HMC crimp contacts and
The crimp contacts are equipped with a special HMC gold surface and constant spring force. These special properties guarantee the complete connector’s flawless function - also after 10,000 mating cycles.
• two different docking frames. The Han® B HMC housings are equipped with a durable locking reel in order to continue to provide the connector with IP 65 protection against dust and water after more than 10,000 locking cycles. In order to be able to offer more than 10,000 mating cycles, Han® HMC connector inserts contain high performance grounding
For further details do write to HARTING India Pvt Ltd, No. 4-D, 4th Floor, ‘Doshi Towers’, No. 156, Poonamallee High Road, Kilpauk, Chennai - 600 010 Tel.: +91 44 43560415/ 16 or visit www.HARTING.in
Gates India Exhibits its latest Innovations at EXCON 2013 Bengaluru The 7th edition of the International Construction Equipment and Construction Technology Trade Fair, popularly known as EXCON 2013 was organized by CII at the Bangalore International Exhibition Centre during 20th to 24th November 2013. This expo, the largest of its kind in South Asia, attracted more than 730 exhibitors and 30,000 business visitors from 18 countries. Gates, an active participant right from the first edition of the EXCON, once again put up a stellar show presenting the latest in their portfolio to meet the challenging demands of the customers. Gates exhibited a range of hydraulic and industrial hoses and power transmission belts used in the various segments of the construction, earthmoving and mining machines. The MegaSys range of hoses and couplings, the micro V and synchronous belts used on large engines attracted the visitors’attention along with the range
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of other complimentary products like ball valves, hose protection products and quick couplers. Segment specialist products like Pilot line hoses targeted at the excavator market and AG hose for tipping gear and cranes were appreciated by the customers. Gates also launched three new products, 20 4XH spiral wire hose, far exceeding the requirements Inauguration of New year 2014 Calendar and Diary by Subir Kumar Chaudhary - Executive Vice President, JCB and of EN standard, G2XH hose for high Bagavathy Appan - Vice President Procurement, JCB temperature air and oil application, a class leading hose for the drilling rig segment and Plaster hose to convey among potential customers. cement and mortar for mechanized plastering. Another highlight was the metal Even in these challenging times for the tube and tube /hose hybrid assemblies infrastructure industry, Gates participation from the new tube assembly plant at Gates and offering was received well and Faridabad. The leak free technologies anumber of business opportunities were offered by Gates – ORFS end forming and generated along with feedback from end BSP end forming elicited lot of interest users. November 2013
Robust, Versatile Surface Roughness Tester with Extensive USB Connectivity New AMETEK Taylor Hobson Surtronic S-100 Series has large color touch screen for ease of use A portable roughness tester with robustness, versatility and extensive connectivity to support a wide range
of surface measurement applications has been introduced by AMETEK Taylor Hobson. For ease of use, the new Surtronic S-100 Series includes a large touch-screen and highly intuitive proprietary software. It is suitable for both shop floor and inspection room use.
New Surtronic S-100-Series portable roughness testers provide versatile surface measurement for multiple manufacturing quality applications.
Versatility features include a 50mm stylus lift with right-angle attachment and a stylus reach of over 70mm. This allows even the most challenging surface measurement without the use of expensive riser blocks, stands or fixtures. The robust stylus can also measure upside down.
Applications include: • Manufacturing Process Control • Automotive • Shipbuilding • Pipelines • Sheet Steel • Aerospace • Print Rollers • Flooring • Bonding • Quality Control Several connectivity choices are provided by the instrument’s industry-standard USB and USB mini ports. Roughness measurements for multiple parts can either be stored internally or saved to a standard USB memory device. The USB port also can also be used to attach a portable printer. This allows printed data to accompany a part to the next
New Surtronic S-100-Series portable roughness testers provide versatile surface measurement for multiple manufacturing quality applications.
Support stand with four degrees of freedom assists with awkward measurements.
stage of manufacture. The mini port can be used to charge the device with any standard USB charger or for connection to a PC for data analysis and reporting. The tester’s rubberized, impactresistant body offers protection and an improved comfort grip. It surrounds the recessed, Mylarprotected high-durability touch screen and a solid stainless steel drive mechanism with anti-wear gears and bearings. For further details write to Gabriel Suresh at gabriel.suresh@ametek.com
Compact Surtronic S-100 roughness tester features a large touch screen with highly intuitive software.
July 2013 2013 November
Crank system allows efficient measurement of thrust faces and journals.
Tel: +91 1860 2662468 Visit www.taylor-hobson.com
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40% More Space in Your Switch Cabinet; Remote I/O Modules Impress with Their Unique Compact Design Pepperl+Fuchs completes its wide range of I/O modules with the half-size, eightchannel digital input modules and offers the most compact remote I/O solution for process automation. The slim modules save valuable space in switch cabinets, thereby reduce the cost per channel. Pepperl+Fuchs complements its product range of extra slim modules with the newly developed eight-channel digital input modules. Pepperl+Fuchs has essentially made these new modules possible by creating a new electrical design. The new housings of the digital high-density input modules are half as wide as those of the previous version, but this is partly due to the compact plug construction. The two plug-in connectors found on the front of the housing each have eight contacts. In addition, the redesigned housing features status LEDs for each of the eight available channels, enabling quick diagnostics and accelerating both commissioning and maintenance. The new modules require around 40% less
installation space in a complete remote I/O system including com unit coupler and power supply, depending on the signal mix. This reduced installation space increases flexibility when planning automation solutions using Pepperl+Fuchs remote I/O systems. The innovative, slim modules can be installed in spaces where larger switch cabinets cannot fit. The high-density modules are half the size and their slim profile creates space for more modules. The analog counterparts were introduced some time ago and are the result of innovative electrical design. At just 16 millimeters wide, the high-density modules fit in existing backplanes and are easy to
Digital input module configure. For further details visit www.pepperl-fuchs.com
German Machine Tool Orders Rising again In the third quarter of 2013, order bookings for Germany’s machine tool indus-try rose by 9 per cent compared to the third quarter of 2012. Domestic orders were up by 12 per cent, while orders from abroad were up by 6 per cent on the preceding year’s figure. For the first nine months of 2013, there was an overall drop of 6 per cent: domestic orders fell by a tenth, and orders from abroad by 4 per cent. For the year as a whole, however, so far it’s substantial orders for forming technology
“Demand for machine tools has achieved the long-awaited turnaround. The two months of August and September, in particular, saw double-digit growth. This applies to both domestic and export orders, and to the two technology segments involved, metal-cutting and forming machine tools. In view of the improving order situation, the VDW’s current production output forecast for the ongoing year is not at risk” Dr. Wilfried Schäfer Executive Director of the VDW (German Machine Tool Builders’ Association), Frankfurt am Main
that have been driving the German manufacturers’ business for-ward. They were up by 61 per cent in the year’s third quarter, and by 27 per cent over the year as a whole. China, the largest market, continues to give cause for concern. Demand was still falling significantly in the year’s first half. “The new Chinese government is
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rigorously reviewing the entire investment programme of the ongoing five-year plan”, explains Wilfried Schäfer. Before this process has been completed, he added, a substantial recovery in demand cannot be anticipated. Contrary to expectations, however, Western Europe has been doing better than anticipat-ed. Order bookings in Central and South America have also shown double-figure growth. In Asia, the figures are up in South Korea and the South-East Asian countries. September November 2013
Increase Service life of Die-casting Die The primary factor that affects die-casting service life is heat checking. Heat checking is final test on surface of die which produce corresponding raised veins on die-casting. Heat checking is caused by repeated heating of die surfaces by injected molten alloys. Surfex Shot Peening Process prevents heat checking and extends life of die-casting die by 2 to 3 times. Thus there is substantial reduction in cost due to extension in service life of Die on account of saving associated for making new die. Water cooling holes are also drilled closure to cavity for obtaining better cooling but Die-casting Users report defects due to water seepage through cracks developed on water cooling holes. Surfex Shot Peening Process prevents water cooling holes from stress corrosion cracking. For further details write to Surface Finishing Equipment Co, E-100, M.I.A., Phase-II, Basni, Jodhpur - 342 005 Tel: +91 291 2740128 E-mail: sfec@sify.com or visit: www.sfecindia.net
November 2013
Electromech Widen its Spectrum with ROGOWSKI Coil Winding Machine Electromech’s continual advancement in development of coil winding equipments to cater to all the available types of coil winding applications helped to widen its spectrum of products. This Toroidal machine is used for winding ROGOWSKI TRANSDUCER coils. This complicated winding becomes considerably simple with the use of this machine. The range of wire gauges this machine can handle is 0.050 mm ~ 0.900 mm. This ergonomically designed machine with high precision can be used to obtain very efficient production rate. For further details write to
Electromech, # 4 Uttarahalli Main Road, Subramanyapura Post, Bangalore – 560 061 Tel: +91 80 26396200 / 2639 6159 Email: electromech@dataone.in or visit www.electromechindia.com
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Manek Offer Sand Casting by Alkaline Phenolic No-bake process Manek Investment Cast Private Limited based at Shapar, Rajkot is a TUV ISO 9001:2008 Certified manufacturer of SAND CASTING by Alkaline Phenolic Nobake process. Their monthly production capacity is 400MT. and job capacity is up to Maximum unit weight 2500 kgs. Their Sand Casting Plant is having facility of Pattern shop, Induction Furnace of 500 kg. and 1000 kg., Sand Lab., Radiography Testing, Ultrasonic Testing, DP Testing, MPI Testing, Chemical and Mechanical Testing, Qualified NDT Technicians, Acid Pickling & passivation, Charpy Impact Testing. They can take up Rough, Semi-finished or fully finished, Machined Sand Casting according to need of customer. Sand Casting is majority having applications for Magnet Frame, Brake Rigging Assembly, Case nub Bogie, Co-Co Bogie, C.S. Suspension Tube for Railway, Spacers, Blade Extenders, Rotor Hub, Blade Adapter, Main Carrier, Stator Bell,
Haas Automation: Going Racing!
Haas Automation, Inc., recently announced that it would be the primary sponsor of Stewart-Haas Racing’s #41 Chevrolet for the 2014 NASCAR Sprint Cup season. And on Wednesday, November 20th, the company revealed the new racing car’s color scheme. The driver of the Haas #41 Chevrolet is 2004 Sprint Cup Champion Kurt Busch, who joins Stewart-Haas Racing following an impressive 2013 season. Gene Haas, owner of Haas Automation, the largest machine tool manufacturer in the Western World, co-owns Stewart-Haas Racing with three-time Sprint Cup Champion, Tony Stewart.
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Stator Ring, Disc Rotor, Stator Frame for Wind Mills, Valve Bodies for Valves, Gear Casting, Mill Base, Coal Nozzle, Grinding Rings, Gear Castings for Power Sector, Bell Mouth & Casting, C.S. Mill Casting for Sugar Plant, Axle Housing casting, Sow Mould for Aluminum company, Flywheels, C.S. Wedge Crusher Casting, Large size Cyr. Liners & Sleeves, Heavy duty Marine Engines, Compressors, Diffusers, All type of Machineries, Construction & Mining, Automotives and Earthmoving vehicles & Equipments etc. For further details write to Manek Investment Cast Private Limited, In street opposite of Field Marshal High School,
Rajkot-Gondal National Highway 8-B, Village: SHAPAR, Taluka: Kotda Sangani, Dist.: Rajkot - 360 024 Tel: +91 2827 252355 E-mail: manekcasting2011@gmail.com Visit: www.manekcasting.com
Four Wheeler Vehicle Components from Lava Forge Rajkot based Lava Forge Private Limited is an ISO 9001-2000 certified manufacturer of four wheeler vehicles components by close die forging. Their plant is having facilities and arrangement of Forge shop, Die shop, Machine shop, Heat treatment unit, Shot blasting unit, Testing Laboratory and Computerized management. They can take up the forging job of four wheeler vehicles finished or semi-finished components as per drawing, specification and sample provided by customers. They take full care to maintain the quality, accuracy and timely delivery for such forging. They can forge four wheeler vehicles components like Small Crankshaft, Connecting Rod, Camshaft, Crankshaft Bearing Cap, Steering Gear, Housing, Wheel bearing hub, Camshaft Sprocket, Crankshaft Sprocket, Cross, Cylinder Liners & Sleeves, Pressure Plate, Hub, Ball joint, Axle hub, Differential Case, Damper, Rear Axle Housing, Knuckle Flanges, Brake Drum, Shifter fork, UJ Cross, Rocker arm, Wing nut, Under Chassis Parts, Flywheel Housing, Transmission Gear Case, Rear &
Front spring Shackle, Rear Spring, Spring Bracket, Base Plate, Rear & Front U-Bolt Bracket, Helper Bracket heavy duty, Wheel Bracket, Mounting Brackets, Tie Rod, Pins, Rockers, R.L. Plates, Clutch Parts Assembly, Three wheeler rickshaw parts, Clevis, Yoke etc. For further details write to Lava Forge Private Limited, Survey No.286, Shapar Main Road, Opp: Galaxy Cotton, SHAPAR – 360 024 Taluka: Kotda Sangani, Dist.: Rajkot. Tel: +91 2827 253670 E-mail : lavaforgepvtltd2013@gmail.com Visit: www.lavaforgepvtltd.com November 2013
THE LAST LEAF Dear All, With difficulties around and challenges surrounding us, we all need to realize that our lives are defined not by these challenges that we encounter everyday, but by how we respond to those challenges. The initiative of ISRO in launching the Mars Mission is one of the best examples of such a response. We all know that there is hardly any atmosphere at Mars, water exists only at the poles, and there is no scope of food and shelter. Inspite of all these facts, over two lakh people worldwide have volunteered to be a pat of the one-way trip to Mars to become the first residents of the Red Planet. This list includes 8000 people from India (Courtesy ET). One more initiative of responding to challenges, has been taken up by online taxi rental start-ups in Mumbai and Bangalore – Ola Cabs and TaxiForSure. They now plan to share the traffic data collected by their vehicles with government agencies to ease congestion on the roads. The data procured from accelerometers mounted on taxis to locate and measure potholes, will be used for data analytics, for instance. Most of their vehicles come fitted with Android and GPS devices, and these would be instrumental in implementing hi-tech solutions to manage Bangalore’s traffic woes – a challenge we face everyday ! Online food and restaurant listings platform Zomato has raised Rs.227 crore - one of the largest for a consumer internet company in India. This company is expected to have operations in 22 countries (Currently in 11 countries) over the next two years. Thirty-year old Deepinder Goyal, a graduate of IIT Delhi teamed up with college-mate Pankaj Chaddah, 27 to set up this company in 2008. It is poised to become the first global consumer internet company from India. Apple and Google dominate the list of global brands. This list, based on economic profit, role of brand and brand strength, signals the impact of technology on our lives. These two companies are connecting with consumers and have pushed the leader of the last 13 years, Coca Cola, to No. 3. They do two things better than most brands: they are great at design and superb at doing the thinking for the consumer. Innovation is clearly seen to be their differentiator. The top 100 list has 55 brands from the US, nine from Germany and seven each from Japan and France. As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board (EAB) November 2013
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RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012-2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month
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November 2013