IFO’s FOCUSSED APPROACH helped to achieve several reliefs to Foundries in a very short span
GOVERNMENT FOCUS
On Manufacturing will be a major driver for Indian Foundry
INDIAN FOUNDRY Going Forward
E
SID
15 0 IN 01:2 90 irst w O F vie IS er Ov
FACING AUDITS VISIT US AT
Customers and Third Parties
3-7 December 2015, The Exhibition Centre, Gandhinagar
SUSTAINABLE DEVELOPMENT Climate Change and Energy Efficiency in Foundry November 2015
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1
UMC-750SS at
HAASTEC PUNE SHOW 9-12, December 2015 10 a.m. to 6 p.m. 2
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OTHER MACHINES ON DISPLAY:
ST-35, VF-7/50, DT-1, VF-2SS, ST-10Y Super Mini Mill, VF-2 SHOW DETAILS:
Date: 9-12, December 2015 Time: 10 a.m. to 6 p.m. Venue: Hall – B, Plot No. C-181, Auto Cluster
Exhibition Center , Pimpri - Chinchwad Pune, Maharashtra: 411019 November 2015
November 2015
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3
NURTURING MANUFACTURING
4
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November 2015
November 2015
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5
Pressure Range
Capacity
Discription
Sr No
M3/Min
CFM
Bar
1
Lubricated SCREW Compressor
0.23 to 43.70
8 to 1545
8 to 13
2
Oil Free SCREW Compressor
5.30 to 51.40
187 to 1815
8 to 10
3
Lubricated PISTON Compressor
.125 to 6.20
4.5 to 219
8 to 40
4
Oil Free PISTON Compressor
.156 to 1.30
6 to 45
8 to 40
5
BOGE FLEXPET
1.55 to 17.9
54 to 634
40
BOGE AIR. THE AIR TO WORK.
BOGE India , No. 216, Third Link Street, Industrial Estate, Nehru Nagar, Kottivakkam, Chennai - 600 096, india@boge.com* www.boge.in Chennai Mr. F C Jayakaran
: +91 9600041656 : fc .jayakaran@boge .com
/ Chennai Mr. Muthu Ganesan : +91 9003172111 : muthu.ganesan@boge.com
Hyderabad Mr.W.Narendra
: +91 9704770930 : w. narendra@boge.com
/ Mumbai Mr. Hasan Hasware : +91 9840956161 : h.hasware@boge.com
Delhi Mr. Deepesh Upadhyay
: +91 9818556732 : d.upadhyay@boge.com
6
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November 2015
foreword Growth, Constructive! Hi Readers, As an Indian, I believe we are going through one of the difficult times, and each one of us should shoulder the responsibility and self consciousness to keep our heritage, pride as well as diversity of our nation, not to get perished in the hands of fringe elements. This is another freedom struggle we should undertake to free our nation from the clutches of antisocial elements which are spread across every section of the society, irrespective of regional/ political/ social affiliations. The recent division of the society on the subject of “Intolerance” is not going to help us for building a constructive nation, and the solution is to restrain ourselves from joining the bandwagon of different groups, spreading venom in different Medias, especially the social media chaos. As Swami Vivekananda taught, our thoughts make the difference, and one need to think before reacting. India Manufacturing PMI reported by Market Economics shows that the October 2015 output is the lowest in the last 22 months, which is slightly below market forecasts. The general mood in the industry is a bit frustrating with low orders, uncertainty in the near future and the diversion of national leaders deviating from constructive politics. India is poised to grow ahead, compared to other developed and developing nations, and the good news is that India has moved up to 7thposition as the “Valued Nation Brand” with an increase of 32% in its brand value than last year, as per the annual report on world’s most valuable nations brand compiled by Brand Finance. All the top five countries retained their respective places this year, with US on the top followed by China, Germany, UK and Japan. France like India moved one position to 6th, but the growth of 32% India achieved is the highest among all the top 20 countries on the list. Success of building a nation or a product needs to go through a lot of process. The challenging part is to sustain the result we obtained through our commitment and hard work. In this edition of MART, we are featuring our main story on the sustainability in the Indian Foundry industry. India was the second largest producer of castings for the last few years, but now we are on the third position (9.4 million MT of casting per annum) with USA (10 Million MT) taking back the second position. But with the focus India is having in manufacturing now, it is expected to gain back its second position by next year, with China being the undisputed leader with a whopping 42 million MT of casting per annum. In September 2015, ISO 9001:2015 superseded ISO 9001:2008, and we are pleased to give you the first overview of the same by our senior editorial advisory board member Saravjit Singh in this edition. He will be continuing the article in the next edition covering Annex SL in detail. Along with our regular columns we are including case studies, latest technology articles/ news in this edition of MART for your update. We look forward your suggestions to make MART, SMART! Signing Off,
Hari Shanker hari@martinfotech.in
November 2015
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7
36 MAIN FEATURE
10 INNOVATIONS
30 ISO 9001:2015– First Overview 36 Foundry: Sustainable Development, Climate Change and Energy Efficiency
40 “IFO’s focussed approach helped to achieve several reliefs to Foundries in a very short span”
44 “Present Indian Governments focus on Manufacturing will itself be a major driver for Indian Foundry Industry”
48 Indian Foundry: Going Forward 54 Sustainability in Foundries by using Big Data Analytics Volume 12 Issue 5 November 2015 Annual Subscription `1200 Member INS Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre
MediaMart Infotech
Siji Nair
Sandeep Hingne
Digital Edition at
B/28/1, Katjunagar, Near Kalimandir Kolkata - 700032 Mob: +91 9038000711
9830122946 Email: info@Martinfotech.in Visit www.Martupdate.com
8
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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manne the Publisher no any of its employees accept any responsibilities for any errors or omissions. © All November Rights Reserved 2015
CONTENTS
68
Image Source: Delcam
MAKE IN INDIA
Columns
62 66
Journey towards excellence Why Outbound Training?
84 CASE STUDY
80 97
MART UPDATE THE LAST LEAF
Managing Editor
Hari Shanker
Associate Editor Hiya Chakrabarti General Manager
Priya Kundu
HR & Admin
Sonalisa Dey
Creative Assistant
• Three Years (36 issues) at `3000 You save `600
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• Five years (60 issues) at `4800 You save `1200
Adrita Baidya Subramaniam V C R Sathyanunni K Ravindranath
• One Year (12 issues) at `1200 Send your subscriptions to: The Circulation Manager - MART Mediamart Infotech, B /28/1, Katjunagar, Near Kalimandir, Kolkata - 700032 Mobile: +91 9038 000711 Email: mart@martinfotech.in Web: www.martupdate.com & www.martonline.in
IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post. m. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 er whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither November 2015
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9
Seco introduces rough and fine boring heads for Steadyline® vibration-damping bars
I N N O VAT I O N
Roughing Head with Steadyline Workpiece
Boring Heads Group for Steadyline
Seco has extended the versatility of its Steadyline™ vibration-damping system with the new EPB® 610 rough boring heads and EPB 620 radial type fine boring heads. Featuring the patented GL Connection, these heads are used in combination with Steadyline turning bars. This allows the same Steadyline bar to be used for both static turning and rotating boring operations in deep machining applications of up to 10xD. Covering diameter ranges from 36 mm to 69 mm, the EPB 610 rough boring heads have a robust design that easily withstands the rigors of
10
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heavy, roughing operations
to reduce preparation times
This is accomplished via a
in challenging materials. The
via fast, simple mounting and
“dynamic passive system”
compact EPB 620 fine boring
setting procedures. This is
inside the holder body where
heads cover diameter ranges 34
made possible by its strong,
a heavy metal mass counter
mm to 69 mm and features fine-
fast locking capability via a
acts vibrations created by the
pitch micro-adjusting screws
single integrated clamping ring
holder’s flex during machining
that allow for precise head
that draws in the tool head
operations. Steadyline
adjustability. Used in correlation
for a secure, stable taper-face
products can perform typical
with the Steadyline vibration
contact. When it comes to
long overhang operations
damping bars, Ra<1 surface
static, turning operations, the
with higher productivity than
finishes are easily obtained,
connection has a polylobe taper
traditional tools, reducing
even in 10xD boring operations.
interface with two 180-degree
spindle stress as well as offering
These user-friendly boring heads
positions that orients the tool’s
high metal-removal rates,
feature hardened stainless steel
cutting edge either face up or
smooth part surface finishes
bodies and through-coolant
face down for effective chip
and long tool life.
capabilities that contribute to
control.
high-precision machining and
For more information on the
Overall, Seco’s Steadyline
EPB 610 and EPB 620 boring
boring bar system effectively
heads, please contact a local
The highly precise GL
reduces unwanted vibrations
Seco representative or visit
connection also allows users
in extreme cutting conditions.
www.secotools.com/boring.
long tool life.
November 2015
More Information
Smart Focus Pure Energy With just a few settings you will achieve best cutting results up to 80 mm â&#x20AC;&#x201C; even under challenging conditions.
Sharp-edged cut surfaces on the top and bottom side of the material Precise holes 1:1 with Contour Cut Low angular deviations & smooth surfaces
Marking
High cut quality & contour accuracy
cutting and welding india Phone: +91 20 26741042 | Fax: +91 20 26741001 vertrieb@kjellberg.de | www.kjellberg.de Made in Germany
November 2015
SMART FOCUS
Plasma Cutting Units
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11
Intelligent Earth Leakage Relay (iELR)
I N N O VAT I O N
One more milestone ElMeasure proves that to be in the controlling segment is “Intelligent Earth leakage Relay” (ELR). Conventional ELR works with the settings through the potentiometers / DIP switches and whenever it crosses the limit it trips.
Problem with this kind of
faster.
relays are accuracy and
2. Continues leakage current
malfunctioning. ElMeasure
display (Programmable)
committed to have good
–Leakage current displays
products and first time
to enhance the user to
Microcontroller based IELR
understand the quality of
with 4digit 7 segments RED
Electrical network / Machine
bright Digital display, which is
online. This can be disabled
very unique as compared to
through setup.
conventional ELRs. Unique features 1. Inverse curve - Trip time is inversely proportional to leakage current. This IELR is Intelligent, when the Leakage current is 10 times higher than the set current it trips 10 times
12
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3. Continuous Display of Trip Leakage current (Programmable) - In case of tripping IELR captures and Displays the tripped Current with the resolution of 4 digit helps the user to analyze and correct the problem. This can be disabled through setup.
4. Continuous scrolling display for set current and set Time. 5. Field Programmable through front panel keys with password protection – No limitations on the Leakage Current settings. 6. Wide input range 60mA to 12A and the trip time programmable from 300ms to 30 seconds. 7. Manual test and Reset Keys
3. 4 Digit 7 segment RED brigh display
4. Panel mountable 96 x 96 x 45 5. Accuracy : Class 1.0 FS 6. Relay contacts – One pair of potential free NO & NC, 2A at 250VAC or 24VDC 7. CBCT standard size – 40, 65, 100, 150, 200, 250, 300mm
Specification:
Tape wound.
1. 1 Second update.
8. Weight (Approx):
2. Auxiliary supply 80 to 300 VAC. Burden 4VA max.
Shipping – 350 Grams
Unpacked – 250 Grams
November 2015
November 2015
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13
Hanna Instruments, Inc. introduces the New Pocket pH Tester HI 98100 Checker plus
I N N O VAT I O N
Hanna Instruments is pleased to announce the release of new pocket pH Tester HI 98100 checker plus.
The HI98100 Checker Plus is the next generation of the original Hanna Checker pH tester. The Checker is the most popular pH meter in the world with over 1 million meters used since its introduction in 1991. From students to researchers, the Checker has been helping people with their pH measurement as a meter that is simple to use and operate. This meter is very toeasy operate, it has lot of good features like single button operation, Replicable pH electrode. The HI98100 Checker Plus pH tester has been designed with many advanced features while maintaining the look and feel of the original Checker. The Checker Plus now offers
automatic calibration to one or two points, automatic buffer recognition, calibrated buffer tags, stability indicator, low battery indicator, and selectable automatic shut off. The Checker plus still maintains the iconic pentagon design with a probe that measures 103 mm in length and tapered to a 8 mm diameter making it ideal for test tubes and vials. Features at-a-glance: Economical – The Checker Plus is a full-featured pH tester at a price that anyone that needs to measure pH can afford. Large LCD - Enhanced LCD that displays reading, stability indicator, low battery indicator and calibration tags.
Replaceable pH Electrode - The HI1271 supplied gel filled pH electrode is 103 mm long and tapers to an 8 mm diameter at the sensing end. This narrow electrode easily fits into test tubes, vials, and other containers with small opening. Automatic Calibration - The Checker Plus is calibrated automatically to one or two points. The calibration buffers are automatically recognized and after calibration the buffer values used are shown on the display as a tag. Stability Indicator – An hourglass indicator is displayed on the LCD until a stable reading is obtained. Once a reading stabilized the indicator disappears and a reading can be recorded.
Automatic Shut-Off – The meter can be set to automatically turn off after 8 minutes or 60 minutes to conserve battery life in the event that the meter is left on. The auto off feature can be disabled. Long Battery Life - The Checker Plus has an exceptional long battery life of approximately 1000 hours. When the battery power is running low a low battery indicator is displayed. Plastic Carrying Case – The HI98100 Checker Plus is supplied complete with meter, probe, calibration solutions and cleaning solutions packaged in a durable plastic carrying case. For more information visit the Hanna Instruments website at www.hannainst.com.
“In the year 1991 we introduced our most popular pH tester named Checker, which is used by more than 1 million people worldwide. The beauty of the checker is that, it’s very easy to use and cost effective solution for pH testing. Now we are re-launching this product with new attractive feature like replaceable pH electrode, auto calibration facility and one button operation. The upgraded version of the checker will be called “Checker Plus pH tester HI 98100.” Kondiba Metkari Business Manager, Hanna Instruments
14
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November 2015
3-7 December 2015 The Exhibition Centre, Nr. Mahatma Mandir, Gandhinagar, Gujarat, India
Creating Global Opportunities
STORAGE SOLUTIONS
Organised by:
Contact:
November 2015
Supported by:
+91 79 40048594, 40305602
Diamond Participant:
Gold Participant:
Silver Participant:
info@kdclglobal.com | admin@imtos.com
Awards By:
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15
Mettler-Toledo Boosts Food Safety with Next Generation Bulk Flow Inspection
I N N O VAT I O N
Thesix-scoop reject mechanism of the X36 Bulk Variant reduces product wastethroughminimal eliminationof good products, while a troughed conveyor prevents product spilling from the line.
The X36 Bulk Variant ensures no misalignment and increases ease-of-use for operators with itsmagnetic interlock.
Mettler-Toledo X-rayâ&#x20AC;&#x2122;s X35 Bulk Variant has optimised detection sensitivity, whichallows manufacturers to remove contaminated products precisely at high throughput rates up to 14,000kg/hour.
Manufacturers of bulk flow food products can now benefit from optimised detection sensitivity and maximised productivity with the X35 Series Bulk Variant x-ray inspection system from Mettler-Toledo Safeline X-ray. Incorporating high-performance technology and software algorithms developed specifically for bulk flow product lines, the X35 Bulk Variant offers precise removal of contaminated product at high throughput rates. The system is ideal for the inspection of dried fruit and nuts, processed meats, cereals, grains, frozen fruit and vegetables, seafood and dried pet food as well as other bulk flow products boosting production line efficiency and
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ensuring compliance with food safety legislation. The X35 Bulk Variant is a single vertical x-ray beam system capable of sensitive detection of dense contaminants, including metal and glass shards, calcified bone, mineral stone and high-density plastic and rubber. The system is capable of throughputs up to 14,000kg/ hour, depending on product depth and density, ensuring food safety whilst maximising line efficiency. Advanced detector technology also allows for lower power consumption thereby reducing Total Cost of Ownership (TCO) and increasing bottom line savings.
A specially developed six-scoop rejection mechanism enhances precision contaminant removal with minimal rejection of good product, while a troughed conveyor prevents product spilling from the line, reducing product waste. The X35 Bulk Variant is also available with a range of optional rejection devices to suit the individual needs of specific applications, options include air blast reject systems. Built according to the principles of the European Hygienic Engineering and Design Group (EHEDG), the X35 Bulk Variant features an Ingress Protection (IP) 69 rated stainless steel cabinet, making it capable of
withstanding the harshest wash-down regimes. Sloped surfaces and curved edges minimise bacteria traps and allow water to run off, enabling quick and effective cleaning with minimal downtime, further enhancing line productivity. In addition, the x-ray cabinet gives easy access to internal mechanisms for essential maintenance, while the rejection mechanism can be easily removed for cleaning. The conveyorâ&#x20AC;&#x2122;s automatic tracking feature corrects any belt misalignment without the need to stop the conveyor, maximising production uptime.
November 2015
November 2015
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17
New generation Leroy-Somer LSA 46.3 & LSA 49.3 alternators l
I N N O VAT I O N
Leroy-Somer Electric Power Generation in Emerson announced the launch of two new Leroy-Somer products that will renew the brand offering in the 180-1000 kVA power range.
The Leroy-Somer LSA 46.3
alternator also benefits from
180 - 365 kVA (400V - 50Hz)
a reduced footprint, with
generator features an
enhanced electromechanical
improved power density over
performances. The electrical
its predecessor, the LSA 46.2.
performances of the LSA 49.3
The bulk of the body has been
have also been increased, with
significantly reduced thanks
an efficiency now up to 95% and
to an innovative and improved
a high motor starting capability.
air cooling system, and an
The LSA 49.3 terminal box
integration of the excitation
has been optimized for faster
system in the main body of the
deployment and to provide a
machine. The new design of
better support to the latest
the connection box allows for
generation of digital regulators.
a quicker wiring of the machine and easier access to key electronics for maintenance.
18
“The launch of these new products demonstrates our continuous commitment to
The Leroy-Somer LSA 49.3
innovation and growth.” said
660 – 1000 kVA (400V - 50Hz)
Xavier Trenchant, President of
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the Electric Power Generation division “In a challenging economic environment, we continue to invest to better anticipate our customers’ expectations. This means that our products are continuously improving to deliver top-of-therange performances, offering reliable, cost-efficient solutions for demanding applications. We have also recently extended our offering to provide a competitive solution on less demanding applications. Consequently, we do provide the best value proposition to our customers across all power ranges and types of
applications, keeping our historical focus on quality and services.” The LSA 46.3 and LSA 49.3 are optimized for continuous and demanding applications, including marine, power plants, cogeneration, rental or critical standby in commercial and industrial premises. The Leroy-Somer LSA 46.3 and LSA 49.3 will be available to order starting Q3 2015. For more information, please visit www.emersonindustrial. com/electricpowergeneration
November 2015
I N N O VAT I O N
Mehta Cad Cam features ME 3030 & Gloria
Fiber Laser Metal Cutting Machine – Gloria
CNC Engraving Machine – ME 3030
CNC Engraving Machine – ME 3030 After 7 years of experience in manufacturing different types of CNC, Routers, Laser engraver, Laser marking machines, Mehta Cad Cam Systems has introduced their own manufactured low cost CNC Engraving machine called ME 3030 which can engrave in the area of around 300 x 300 mm and can engrave on aluminum, brass, MS,etc. This machine is made up with user friendly design, high quality of ball screw to have high accuracy with cast iron bed and casted columns. ME 3030
November 2015
is available with servo motor as well as stepper motor as per the need of customers. They are also focusing on the export market. ME 3030 can be use for making mould and die from different material for different application. Fiber Laser Metal Cutting Machine – Gloria Continuous innovation and development has kept Mehta Cad Cam No. 1 brand in Laser, CNC & digital printing technology. They are not just famous for providing advance and latest technology but also for cost effective solutions as well. One of their
product which is in demand is Metal cutting machine with Fiber laser technology. Fiber laser are getting cheaper day by day and because of its many advantages it is becoming popular worldwide. The major advantages of fiber laser are: • High quality laser beam. • Long life of around 1 lac hours. • Trouble & maintenance free, etc. Because of their vast experience in manufacturing X, Y table for CNC, routers,
laser engraving, they have made high precision, accurate, qualitative fiber laser cutting machine with the different voltage like 500, 750, 1200 kw for different thickness of SS and MS and for different size. It can cut maximum 6 mm of SS and 10 mm of MS. Mehta’s Fiber laser cutting machine called Gloria is getting famous not only in India but also several parts of the world. For more information you can visit to our website, www.mehtaindia.com or can contact on 09033000150, 09227678044, 07926840551
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19
Complete PROTUM Office system: New connection components for the proven desk cable carrier system
I N N O VAT I O N
Kabelschlepp Energiefuehrung Buerotische Bodenanschluss: The weight of the free standing floor connection provides increased stability and is primarily designed for a clean connection to the floor
Kabelschlepp Energiefuehrung Buerotische Tischgestellanschluss: Desk frame connections with magnets for fast and easy mounting
Kabelschlepp Energiefuehrung fuer Buerotische: The PROTUM Office P0240GS desk cable carrier system recently won the iF DESIGN AWARD 2015 and now TSUBAKI KABELSCHLEPP has added new desk top, floor and frame connections to the range
TSUBAKI KABELSCHLEPP has added new desk top, floor and frame connections to its PROTUM Office P0240GS desk cable carrier system. This makes it a complete system allowing particularly fast and easy mounting on office furniture. And it looks great, too: PROTUM Office recently won the iF DESIGN AWARD 2015. The new PROTUM Office system can be used on heightadjustable desks and on simple tables with four legs. “Until now, PROTUM Office cable carriers were mainly used by manufacturers of office furniture who tended to install them in height-adjustable stand/sit workstations,”
20
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explains Werner Eul, Product Manager Cable Carrier Systems at TSUBAKI KABELSCHLEPP GmbH. “Our extended system on the other hand offers customers a simple combination with all types of desks.” For this purpose, TSUBAKI KABELSCHLEPP developed standard connections for desk tops, floor and desks. The table connections are screw-fixed directly to the underside of the desk top. The weight of the free-standing floor connection provides increased stability and is primarily designed for a clean connection to the floor. The alternative is a round or flat desk frame connection which is suitable for height-
adjustable desks. It can be fixed with magnets as a standard or optionally with screws, cable ties or adhesive tape. For all connections, users can choose between the colors black, white and silver-gray. The components are also available as a set. The PROTUM Office cable carriers are especially designed for use in office environments. The generous inner width of 50 mm and the option for double filling provide sufficient space for cables in office environments, i.e. for telecommunication, energy and data cables. The cable carriers consist of a flexible strip and the side parts of the cable routing are simply clipped onto this. The
elements can be extended at any time by connecting more strips and clipping on more side parts. Shortening can be achieved by simply cutting the strip. The cables are simply pressed into the clips, making it easy to change cables at any time. The side parts and the strips for the cable carriers are optionally available in white, black or an elegant silver-gray. The colors can be combined to suit customer preferences. This means that PROTUM Office offers award-winning design in addition to convincing functionality. For more details visit www.kabelschlepp.de
November 2015
from dmg mori
Open House Bangalore 8th â&#x20AC;&#x201C; 11th December 2015
November 2015
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21
I N N O VAT I O N
Ha-VIS eCon Switches: 16 Ports in the most compact space
Ha-VIS eCon Switches: Customers require only a minimum of space in the electrical cabinet.
22
The installation of additional communication infrastructure within production facilities can be achieved quickly, cost efficiently and flexibly with Plug&Play Ha-VIS eCon Ethernet Switches. Thanks to the compact design, customers require only a minimum of space in the electrical cabinet.
a corresponding increase
The rapidly growing number of Ethernet-capable end devices in the field calls for
expansion of existing
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in the number of ports for the Ethernet switches. With 16 RJ45 ports, the new variants of the Ha-VIS eCon family offer the perfect solution for these demands. Developed and optimized for deployment in tough industrial environments, the “unmanaged” Ethernet switches allow a low-cost network infrastructures, and also the creation of new
industrial networks. With approvals for industry, the maritime market and for transportation, the switches can be optimally selected for every application. The switches of the Ha-VIS eCon Family fit in anywhere, thanks to their compact dimensions. Users can choose exactly the combination of performance characteristics and port combinations from the over 200 switch models
that will perfectly match their particular application. Two different compact and space saving housing designs guarantee the best possible utilization of the available space in switching cabinets. For more details write to Harting India Pvt Ltd, 7th Floor (West Wing), Central Square II, Unit No.B-19 Part, B 20&21, TVK Industrial Estate, Guindy, Chennai – 600032 Tel : +91 44 43560415 or visit www.harting.in
November 2015
November 2015
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I N N O VAT I O N
Renishaw announces new non-contact vision probe for the REVO® multi-sensor system
Renishaw is pleased to announce the launch of a new vision measurement probe (RVP) for use with the REVO® 5-axis measurement system on co-ordinate measuring machines (CMMs). RVP increases the multi-sensor capability of REVO-2 by adding non-contact inspection to the existing touch-trigger,high-speed tactile scanning and surface finish measurement capability of the system.
For certain applications, non-
positioning provided by the
When using RVP, part
software capability includes
contact inspection provides
REVO-2 head.
illumination is provided by
RVP configuration, image
integrated programmable
processing with application
LED lighting inside each
specific options and
module. Background feature
automatic image storage for
enhancement is also available
review and further analysis.
clear advantages over traditional tactile probing techniques. Thin sheet metal parts or components with large numbers of holes as small as 0.5 mm, and parts which are not suited to tactile measurement, can be fully inspected with the RVP system. RVP also gives exceptional improvements in throughput and CMM capability by utilising the 5-axis motion and infinite
24
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The RVP system comprises a probe and a range of modules that are automatically interchangable with all other probe options available for
using backlighting combined with bespoke part fixturing..
From 5th – 10th October
sensors is automatically
The RVP system is managed
will be able to see the new
referenced to a common
by the same I++ DME
RVP system demonstrated
datum. This flexibility means
compliant interface as REVO-2
by Renishaw in hall 5, stand
that the optimum tool can
and full user functionality
D15.
be selected to inspect a wide
is provided by Renishaw’s
range of features, all on one
MODUSTM metrology
CMM platform.
software. New MODUS vision
REVO-2. Data from multiple
2015 at EMO 2015, visitors
For further information, visit www.renishaw.com/cmm.
November 2015
High-Performance WIDIA VSM17™ Platform Adds Versatility to True 90o Shoulder Milling
I N N O VAT I O N
Excellent cutting and tool life promise big advantages for job shops
The versatile and robust VSM17 platform from WIDIA provide true 90-degree walls and excellent stepless finishes.
With cutters that can be used for shoulder milling, profiling, face milling, slotting, ramping, helical interpolation, and circular interpolation, all while achieving true 90-degree shoulders, the Victory Shoulder Mill (VSM) 17 platform from WIDIA is a robust and versatile job-shop winner. Designed for low horsepower draw and free machining, the VSM17 delivers an effective one-two punch of reduced horsepower at the machine and higher speed and feed rates that mean more parts per shift. “For a wide range of work materials, the entire
November 2015
VSM 17 platform is optimized to provide higher productivity for job shops” says Adarsh Sowcar, global product manager, indexable milling. VSM17 cutter bodies have an integral chip gash design for excellent chip evacuation along with hardened-steel construction and hardened pocket seats which provide high resistance to deformation. VSM17 offers aggressive ramping capability up to 8.8° and a maximum 0.642” (16.45mm) depth of cut. VSM17 is available in shell mills, screw on cutters, cylindrical shank and Weldon shank end mills
with internal air and coolant capability. VSM17 inserts have strong cutting edges, multiple corner radii, and positive rake faces that provide a true 90-degree wall while providing excellent wall and floor surface finish.
WIDIA’s digital process knowledge application. With powerful process knowledge available on iPad™ and other digital devices, NOVO helps users define machining features, such as ramping or slotting in specific work materials, and then immediately reduces
VSM17 starter kits are available now through local authorized WIDIA distributors. These kits feature a cutter body and ten inserts. For more information, visit http://www.widia.com/
the product set to those like
Featured in NOVO
time.
Moreover, the VSM17 platform is available through NOVO™,
For more information, visit
VSM17 that can do the job. This provides far more useful process knowledge than any online catalog alone, all obtained in a fraction of the
www.widia.com/novo.
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I N N O VAT I O N
TaeguTec Releases New Indexable Gundrill, Deep Drilling Hears with Unique Trigonal Insert
Drilling deep into any material can be a challenge that is best answered by the right cutting tool.
TaeguTec’s new indexable gundrill and deep drilling heads with its unique trigonal insert evacuates chips without damaging the surface finish and delivers coolant directly onto the material while also offering accuracy, repeatability, an excellent surface finish and minimizes cycle times.
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shipbuilding, machine tool, railways and oil and gas. To accompany the new additions to the T-Deep family, TaeguTec is introducing the TOGT line, a new series of inserts specifically designed for deep hole machining.
The new addition to the T-Deep line covers single and double tube systems and is designed with a direct mounting system that reduces down time.
The important features of the TOGT insert are a three cutting edge chip splitter that generates optimized chip shapes, a positive rake angle as well as a wiper for high hole surface quality and high feed.
With a diameter range from 16 millimeters to 28 mm, the new T-Deep indexable gundrill is a versatile tool that can be applied to several industries such as mold and die, power generation, windpower, automitve,
By combining both new products into one powerful tool, chips will be reduced into small pieces, making it easy for them to move up the tool’s flute and out of harm’s way, a procedure that
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minimizes damage to the surface finish and reduces premature tool wear or breakage. The T-Deep’s rigid clamping system and low spindle runout repeatedly hits targets accurately, while its coolant delivery mechanism that shoots spray directly to the tool’s tip forces the chips out of the hole with ease so that the T-Deep and workpiece remain cool even under the hottest of temperatures. Furthermore, the new insert line is available in five sizes – 08 mm-12 mm – and is coated with TaeguTec’s versatile TT9030 PVD grade, an important factor when choosing a tool that cuts cost and increases the productivity of high quality parts.
The TBTA-TR Deep Drilling Heads works in perfect unison with the new T-Deep gundrill in order for it to reduce downtime due to its direct mounting system design, and is available in either a single or double tube system. New TBTA-TR head is offered either as a single tube with a diameter range of 16 mm-28 mm or as a double tube with a diameter range of 18.4 mm28 mm. The TRGD / TRGDL type gundrill holder comes as a driver type or flute length and is designed specifically for machining center and gundrill machines. For more details visit www.taegutec.com
November 2015
November 2015
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Sensors for T-slot cylinders MZT7, RZT7
I N N O VAT I O N
The MZT7 magnetic cylinder sensor enables quick, precise and contactless sensing of the piston’s position in compact pneumatic cylinders. It is easy to mount, can be used in numerous applications and offers an outstanding price-performance ratio.
The SICK MZT7 magnetic cylinder sensor with GMR technology reliably detects the piston position in pneumatic drives. The MZT7 can be mounted directly into all cylinders with standard T-slots. SICK also has an extensive range of adapters which enable the MZT7 to be used with other cylinder types. The MZT7 is characterized by its simple mounting principle: Insert the sensor into the slot and rotate the locking screw a
quarter turn to fix it securely to the cylinder. The Sensor Design: For Almost Every Cylinder Profile The MZT7 magnetic cylinder sensor never loses its grip: when mounted directly in the T-slot, the universal housing design compensates for the various slot dimensions from the widest range of cylinder manufacturers. And for cylinders without a
T-slot, such as round, tie-rod and profile cylinders, an extensive range of mounting adapter accessories are available. The Application Areas: Universal in Factory Automation Assembly and handling machines, packaging machines and electronics production: The MZT7 magnetic cylinder sensor is the ideal solution for a multitude of applications and the widest
range of cylinder types. It is so versatile that you only need one sensor variant. The advantages not only include savings on warehouse space and costs, but also the time spent on documentation and maintenance. The sensor is also available as RZT7 with reed technology and a supply voltage of up to 230 V - an especially costeffective solution. For more details visit www.sick.de
Compact electric Rotary Gripper Unit from Schunk
Ha-VIS eCon Switches: Customers require only a minimum of space in the electrical cabinet.
The SCHUNK EGS electric rotary gripper unit defines a new efficiency class in the handling of small components and facilitates the switch to pneumatic-free handling solutions. It is the first unit to combine electric gripping and rotation in a single compact housing. The low-maintenance and affordable module paves the way for highly efficient pneumatic-free systems. Coupling of the gripping and rotation gear, patented by SCHUNK, allows continuous rotation without an electric loop feed-through. Since
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the module is equipped only with stationary, brushless and therefore non-wearing 24V DC motors and requires no moving cables, slip rings or shock absorbers, it provides for increased process stability and availability in assembly systems. Backlash-free pre-loaded junction roller guides ensure high-precision gripping and virtually constant gripping forces over the entire finger length. Commissioning of the SCHUNK
EGS could not be easier: both the angle of rotation and the gripping force can be adjusted independently of each other directly at the module. Inductive proximity switches allow monitoring. The module is digitally controlled or via a fieldbus distributor. The entire control and power electronics for decentral control of the motors are integrated directly in the module. This eliminates the need for external controllers and additional programming.
The compact SCHUNK EGS rotary gripper unit is only slightly larger than a pack of cigarettes, with dimensions of 58 mm x 45 mm x 89 mm. It features a torque of 0.04 Nm and a freely definable angle of rotation between 40° and 320°. The gripping force is 30 N, the stroke/ jaw 3 mm. The swiveling time is 0.18 s/180° and the gripping time is 0.05 s/stroke. For more details visit www.in.schunk.com
November 2015
Plot No. 347A, 2nd Phase, KIADB Industrial Area, Harohalli, BENGALURU-562112 Kanakapura Taluk. Ph: 080-26396461 / 41632962 / 99456 95322 Manfred Maier Email: fenmet@gmail.com , www.fenfemetallurgicals.com Managing Director & COO, HELLER November 2015
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QUALITY
ISO 9001:2015– First Overview Enhanced Holistic Approach to Quality
In Sept-2015, ISO 9001:2015 superseded ISO 9001:2008. This revision now gives us a flexible, organization-wide performance excellence model for doing business. It is based on Annex SL, a high level structure developed by ISO to frame all its standards.
Saravjit Singh saravjit.singh@gmail.com
ISO 9001 is the definitive international standard that specifies requirements for a quality management system (QMS). Certification to it demonstrates the ability to consistently provide products and services that meet customer and regulatory requirements. ISO periodically review sits standards. Any standard found to be out of synch with changing business and customer needs is a candidate for revision. ISO 9001 formation and revision history • 1987: ISO 9001 introduced. Standard had 20 elements. Focus was on quality assurance. • 1994: ISO 9001:1994 as published had minor changes. • 2000: ISO 9001:2000 had
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major changes. Introduced the concept of process management. It mandated involvement of upper executives to integrate quality into the business system and avoid delegation of quality functions to junior functionaries. • 2008: ISO 9001:2008 clarified some specifications, making it more consistent with ISO 14001:2004. Today, over one million organizations have ISO 9001:2008 certification, making it the most popular amongst nearly 20,000 ISO standards. • 2015: ISO 9001:2015 was introduced in Sept-2015. It is a major change, giving much greater depth to the standard. Why was ISO 9001:2008 revised? The objective was to make the new standard more compatible
with today’s market and customer needs. Required changes identified, and accepted as necessary by ISO on the basis of a world-wide survey include: 1. Change is required to effectively deal with today’s complex environments. 2. Quality must be at the heart of the enterprise and aligned with its business strategies. 3. QMS should improve quality across the organization, with all employees aligned to increase customer satisfaction.
ISO management systems, viz. ISO 9001, ISO 14001 and others. 6. Publish a QMS that will not be changed till 2025. ISO recognized the necessity of incorporating above changes. In May 2012, revision of ISO 9001 was proposed to a technical committee. After going through four prescribed stages, the new standard was published in September 2015. ISO 9001:2015 includes path breking changes, important ones being:
4. QMS must accurately record the needs of employees, customers and other stakeholders.
• It is based on Annex SL, a new high level structure created by ISO. This enhances its compatibility and alignment with other ISO standards.
5. ISO should adopt a common structure for all standards. This will enablean organization to smoothly implement multiple
• Focus is on management of total business process in order to achieve desired business outcomes.
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September 2015 ISO 9001:2015 Published
Figure 1: Transition Timeline for ISO 9001:2015
• Concept of risk based thinking introduced to compete in today’s business and regulatory environments. • Simplified wording to aid understanding and consistent interpretations of requirements. • Holistic approach now enables use of standard by all types of enterprises. It is mandatory for ISO
9001:2008 certified companies to obtain ISO 9001:2015 certifications by September 2018. See Figure 1: Transition Timeline for ISO 9001:2015. The vision of Annex SL is given in Figure 2. This signifies that an organization achieves meaningful sustainable development, and contributes effectively to overall economic growth, only when its operating practices ensure environmental integrity and
September 2015 start of 3 years transition period of ISO 9001:2008 to ISO 9001: 2015 ISO 9001:2008 Certifications invalid from October 2018
social equality. This theme is going to be the hallmark of all ISO standards that incorporate Annex SL. Companies which adopt ISO 9001:2015 will have to abide by this guideline.
an organization to prepare, use and integrate multiple ISO standards.
Notable changes in ISO 9001:2015
Annex SL framework has ten clauses and four appendices. This format transforms ISO 9001:2015 into a business excellence model.
1. Use of Annex SL, a universal high-level structure for all ISO management system standards MSS of the future. This makes it much simpler for
2. Emphasis on Leadership. Top management is accountabile and must ensurethat all requirements integrated into the organization’s
Environmental Integrity
Sustainable Development
Economic Growth
Social Equality
Figure 2: MSS Integration Vision of Annex SL
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processes are compatible with the policy, objectives and strategic direction of the organization. Leadershipis also responsible for communicating the importance of the QMS and increasing employee awareness and involvement. It is no longer mandatory to have a Management Representative. 3. Understanding the context of the organization and connecting it to the needs and expectations of all interested parties. This means first identifying why the organization exists. Then identifying internal and external issues that can impact intended outcomes and other stakeholders. 4. Risk based thinking replaces preventive action.This is the cornerstone of the new QMS. Risk management as a governance tool is reinforced by Deming’s PDCA cycle. See Figure 3.
Keeping context in mind (see para 3 above), leadership has to identify risks and opportunities relevant to the organization. Then they have to specify how these will be addressed through planning. However, ISO 9001:2015 does not require a full, formal risk assessment. Risk is defined as the effect of uncertainty on expected results. Risk is expressed in terms of a combination of the consequences of an event and the associated likelihood of occurrence. Effect is a deviation from the expected positive or negative outcome. Uncertainty is the state of efficiency of information related to the understanding or knowledge of an event, its consequence, or likelihood. 5. Quality and continuous improvementis part ofthe
organization’s strategy. Quality management is integral to and aligned with business strategies. This should improve performance and drive real value in the organization, embedding healthy performance improvement processes over time. Higher emphasis has been placed on achieving value for all stakeholders, with everyone working to add value to the end customer. 6. There is decreased emphasis on documentation. There is no specific need for preparing a quality manual. Flexibility is allowed in documentation.The terms ‘document’ and ‘record’, as given in ISO 9001:2008, have been replaced with ‘documented information’. Documented information can be from any source and in any format and media Documented information is required for management processes (not mandatory for procedures),
evidence of results and for information created in order for the organization to operate. Change of terminology has made the standard more user-friendly and flexible. See Table 1: Terminology Change. Furthermore, having your own terminology is also allowed. 9. Practical approach to dealing with non-conformities. Clause 10 of the new standard looks at ways to address non-conformities and take corrective action, as well as strategies for proactively dealing with failures on a continual basis. Above significant changes have made ISO 9001:2015 a holistic tool for achieving meaningful business success. Comparison with EFQM Excellence Model See Table 2: Comparison of EFQM, ISO 9001:2015 and ISO 9001:2008. In this table, areas
Terminology Change ISO 9001:2008
ISO 9001:2015
Product
Product and Services
Documentation
Documented information
Work environment
Environment for the operational process
Purchase product
Externally provided products and services
Supplier
External provider
Management responsibility
Leadership
Table 1: Terminology Change
Identify your context based risks and opportunities Analyze and prioritize your risks and opportunities Plan actions to address the risks Implement the plan - take actions Check the effectiveness of the action
Figure 3: Risk Based Thinking Approach
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Learn from experience
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in which compared model/
Companies which have already adapted EFQM will find it very easy to transit from ISO 9001:2008 to ISO 9001:2015. Other companies may need the services of a trained facilitator.
standards are superior have been highlighted. We see that whereas ISO 9001:2008 is way behind EFQM excellence model, ISO 9001:2015 is comparable in all parameters
Benefits of early transiting
the writer has considered.
Existing ISO 9001:2008 certified companies should transit to the new version as early as possible. The five main benefits of doing so are:
In fact, ISO 9001:2015 is both a quality standard and business excellence model. The author is of the opinion that a progressive organization should adopt both ISO 9001:2015 and EFQM. Both have their own merits, although equal in most respects.
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1. Superior business performance: This structured standard is completely aligned with the business strategies of the organization. Its usedelivers high value to the
customer andgreatly improves overall performance through use of unique context based enabling processes.
This does away with cumbersome documentation of requirements and rigid procedures.
2. Risk and opportunity management. This processwill capture available opportunities and improve overall operational efficiency.
5. Early certified companies will get noticed. Early adaptors always get noticed. Customers will have higher confidence in your capabilities and professionalism.
3. You deploy Annex SL. Knowledge gained will enable you toquickly integrate ISO 14001:2015 and other standards that use Annex SL. 4. Flexible approach. You benefit from Annex SL prescribed flexible approach.
EFQM Excellence Model
ISO 9001:2015
ISO 9001:2008
Criteria is flexible
Criteria is flexible
Criteria is standard
Driven by Leadership
Driven by leadership
Driven by management
Measures business performance Based on best practices and opportunities for improvement
Checks conformance and also measures business performance Based on Annex SL which accepts use of best practices
Covers all business functions
Covers all business functions
Assessment is based on pairing of business drivers and results
Assessment is based on criteria related to the context of the company
Emphasis is on achieving long term consistently good business results against benchmarks
Emphasis is on achieving long term consistently good business results. Company is free to use benchmarks
Audit assessments are used as a tool to improve performance and become best in class
Corrective controls plus provision for internal auditor to assess performance and suggest areas for improvement
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The author Saravjit Singh is Principal Consultant (Automotive and Farm Equipment Verticals) with Pushkarna Consultants. You can seek his advice on Make In India at http://saravjit-singh.strikingly.com
Checks conformance
Focus is on achieving conformance to defined quality parameters Focus is on quality management system This important aspect is not within the scope of ISO 9001:2008
ISO 9001:2008 does not use benchmarking of results
ISO 9001:2008 audits effective implementation of in-place quality management system
Table 2: Comparison of EFQM, ISO 9001:2015 and ISO 9001:2008
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MAIN FEATURE
Foundry: Sustainable Development, Climate Change and Energy Efficiency
Sustainability in business operations is today’s reality and requires businesses to mould their strategies to remain sustainable in long term. We should make commitment to sustainability because it allows us to understand, share, monitor, compare and benchmark our performance on sustainability through universal set of indicators as mentioned in World Business Council for Sustainable Development (WBCSD).
Dr. P B Rastogi pb.rastogi123@gmail.com
The concept of sustainability– meeting today’s needs without jeopardizing the ability of future generations to meet their needs – is penetrating boardrooms across multiple industries. Undoubtedly, commitment towards clean and green creates more profit and happiness. The two important events in the year 2015, finalization of
Sustainable Developmental Goals (SDGs) and International Climate Agreement will realign the sustainability agenda across the world. One of the key pillars of our sustainable agenda is climate protection. Climate change is a significant risk to mankind and no business can deny the adverse effects of this anthropogenic activity.
The Indian foundry industry has grown rapidly in the past decade and is ranked 2nd in the world with more than 6,000 foundries with a combined installed capacity of 7.5 MTPA. It employs more than 2 million people directly and indirectly. Indian foundries are emerging as a major auto part manufacturer in the world.
The metals are used for variety of applications, from needle, kitchen to household items to space technology besides applications in automobile, tractor, railway, machine tool, earth moving, textile, cement, electrical, power, machinery, and defence sectors. Their demand and consumptions are directly linked to the
The Indian foundry industry has grown rapidly in the past decade and is ranked 2nd in the world with more than 6,000 foundries with a combined installed capacity of 7.5 MTPA
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Reuse of waste heat from foundry processes such as melting operations, core drying and shower water heating, etc. resulting in saving of 15-20% or more of energy
development of society. At the same time, metallurgical (ferrous & non-ferrous) industries are known as hazardous and polluting industries since they generate large amount of solid wastes like slag, tailings, red mud, heavy metals, anode slimes etc., toxic effluents, flue gases, discharge of thermal emissions and noise. Similarly, production of Aluminium from bauxite produces red mud from refining of bauxite and fluoride emissions and spent pot lining from electrolytic stage. Red mud contains iron, aluminium, silica, calcium and alkalis and causes ground water pollution. Exposure to high level of fluoride poses risks to all living organisms including slow growth and yellowing of leaves in plants, affect joints, bones teeth in animal and humans beings. Disposal of spent pot lining and electrode is also a threat as it contains cyanide. This affects the flora, fauna, terrestrial and aquatic ecology and also health of the population in the vicinity of the plant. The steel industry alone requires 8.1% share of the total
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world energy indicating major energy consumer in the world. This polluting and excessive energy use image of the steel industry can be reversed by using green technology. Green metallurgical industries means adoption of environmentfriendly technology, reduction in energy consumption in the process, consumption of less fossil fuel or electricity with minimum emissions, use of natural resources efficiently and recycling and reuse of waste to become green foundry. Forsustainable foundry development, we have to find ways and means to save huge energy, reducing emissions, effluents, solid/hazardous wastes in the foundry industry. We have to find possibility of an alternative energy use and also reduction in energy consumption by undertaking short-term and long-term goals.The potential to save a huge amount of energy by adopting Green Technology in the foundry Industry throughout the country is immense. For example, the following measures will result in significant saving of energy, if implemented: • Review and selection of
appropriate lighting fixtures in foundry area and its layout by qualified engineers. • Proper design of heat pump to utilize waste heat from air conditioning or chilling systems to maximize the year round benefits. • Reuse of waste heat from foundry processes such as melting operations, core drying and shower water heating, etc. resulting in saving of 15-20% or more of energy. • Major improvements in design of piping, bag house, duct and computer monitoring to control and enhance the efficiency of the emission system. • Proper melting practices with elimination of non-metallic materials, paints, surface rust. • Reduction in energy consumption by 15-20% by purchasing right quantity of scrap and usage of cleaned gates and risers. • Introduction of ingots directly into the hearth and not to be placed on the hearth as it promotes oxidation prior to melting in furnace. • Avoiding superheating of metal as it deteriorates the
quality of metal and also increases power consumption. • Avoiding holding of molten metal since it deteriorates the nucleation potential of the metal. • Use of lids to close the crucible to avoid radiation and convection losses. • Installation of Automatic Power Factor Correction (APFC) to improve the power factor. • Placement of Furnace transformer close to the furnace to minimise transmission losses and current losses. • Compressed air- Save one third energy by proper leak evaluation and repair. • Better piping arrangement in the suction and delivery system, including equipment like air grinder, pneumatic torque wrenches, etc. by placing near the electrical appliances. • Maintain air pressure at the minimum possible range just to perform the work. Reduction of 1 kg/cm2 pressure saves 7% of input power. • Utilization of waste materials like slag, sand collected from
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knocked out castings, dust collected from the shot blasting machines for making pave blocks and dust collected from grinding machines to be used by fire cracker companies.
compared with the world best available technology (13.7 kWh/ kg).
• Use of latest technology like Simulation Software and ERP software packages with human skill for making Green Foundries to be the prime objective of foundry clusters
This electrical energy amounts to 148.4 GJ/ton aluminium, forming 85% of the total energy (174 GJ/ton) input. The remaining 15% energy (25.6 GJ/ ton) is used for other purposes in the plant. Average Indian aluminium plant energy use is very close to the best practice in the world. The Hall and Heroult process has been used for the past 100 years without any change in basic process, except for some changes in design and operational features.
One of the best examples is the energy use in Aluminium Industry. You will be surprised to know that energy required for aluminium production was 257 GJ/ton in the recent past but now as per the best available technology (BAT), needs only 174 GJ/ton in Hall and Heroult process. The amount of electrical energy required by plants in India (average 14.55 kWh/kg) and the European Union (average 15.78 kWh/t) is
Another best example is production of aluminium by recycling of scrap which eliminates the energy-intensive extraction process. The minimum energy requirement for aluminium production is 0.39 kWh/kg (1.4 GJ/tonaluminium). It may range from 3.5 GJ/ton (electric induction melting) to 14-16.5 GJ/ton (oil furnace melting). Waste recycling requires only 6-10% energy to extract virgin aluminium.
• Installation of energy efficient pollution control equipment and setting up of sand reclamation plant to protect natural resources in a better way.
Nearly, 4 kg of bauxite ore is need to produce 1 kg aluminium, generating more than 2 kg red mud as waste. The recycling of scrap avoids mining, waste generation and use of excessive energy. Most of ideas are already known to the foundry owners but have not been implemented properly. We need to be more focused and think green in all aspects of the foundry. We have to be more open to the possibilities, make a conscious effort and be determined to achieve the goal of Green Foundry. Adoption of greener engineering processes in foundry industry will certainly improve the environment by reducing consumption of natural resources and pollution. The Twelfth Five Year Plan of India recognizes that India needs to adopt a low carbon strategy for inclusive growth in order to improve the sustainability of its growth process. Prime Minister’s National Action Plan on Climate Change (NAPCC) has already recognized the need for low-
carbon and energy efficient technologies in different areas including foundry as detailed in the ‘National Mission on Enhanced Energy Efficiency’. Keeping the post-2015 climate agenda at the 21st Conference of Parties (COP) to be held in Paris under the United Nations Framework Convention on Climate Change (UNFCC) in December, 2015, we should concentrate on low carbon development and energy efficiency in India. Achieving the low carbon goal through application of energy-efficient technologies is the main focus in India. GOI has taken initiatives in national policy to include National Clean Energy Fund and ambitious targets for renewable energy. Let us make use of these funds to reduce carbon footprint as well as install energy-efficient technologies to reduce energy consumption. We should adopt energy efficiency in foundry industry at the earliest. Enhancing energy efficiency means using less natural resources i.e. coal/oil
Foundries that are taking proactive initiative to reduce carbon footprint by installing energy-efficient technology to reduce energy consumption and march towards sustainable development will certainly have a competitive advantage over others
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which means less emissions in the environment on one hand and conserving natural resources on the other hand. Less emissions means real contribution towards improvement in climate change. It is presumed that adoption of these proposed aspects will make a difference and certainly reduce pollution which is necessary for the survival and welfare of human being.
social and economic challenges by engaging themselves with customers, local communities, suppliers, policy makers and even competitors. The time has come for business – large and small – to re-evaluate their business approach and align with the sustainable growth context. Companies that are taking proactive initiative in this regard hold a competitive advantage over others.
Now, the foundries should have holistic approach towards sustainability by addressing workforce, society, human rights, product responsibility, environmental performance, transparency, governance, GHG emissions, biodiversity, energy efficiency, green buildings, health and safety issues etc. Sustainable industry development through improved Efficiency, Productivity, Quality and Environment is required in foundry sector. To summarize, the time has come for business – large and small – to re-evaluate their business approach and align with the sustainable growth context. Foundries that are taking proactive initiative to reduce carbon footprint by installing energy-efficient technology to reduce energy consumption and march towards sustainable development will certainly have a competitive advantage over others.
This paper entitled ‘Sustainable Development in Foundry’ was presented at the Sustainable Development Foundry Meet organized by Indian Foundry Organization at Hotel Le Meridien, Bangalore on 15th October, 2015.
It is necessary to build capabilities of business in India on sustainability and also build the ecosystem necessary for sustainable business to thrive. Many companies are now delivering profits from their sustainability efforts due to their collaborative approach as they tackle environmental,
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The author Dr. P B Rastogi is the Secretary General, Indian Foundry Organization, Bengaluru, Karnataka.He was former Advisor to the Government of India, Ministry of Environment, Forests and Climate Change, New Delhi, India. Dr. Rastogi is Ph. D in environmental toxicology from the University of Allahabad and has carried out post-doctoral research at the University of Massachusetts & Massachusetts Institute of Technology (MIT), USA. He has wide experience in appraisal, environmental impact assessment and monitoring of all category of development projects including steel, metallurgy, foundry, mining, nuclear, defence and strategic projects. He has been in multiple committees of Govt. of India as member and member secretary and advisor to several organizations. He can be contacted at pb.rastogi123@gmail.com; pb.rastogi@nic.in
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MAIN FEATURE
“Government focus on Manufacturing will be a major driver for Indian Foundry”
Nithyanandan Devaraaj Chairman – IIF Southern Region & Head Foundry Business Unit, L&T Coimbatore Dr. Nithyanandan Devaraaj is the Chairman of Indian Foundry Association (IIF) Southern Region and the Head of Foundry Business Unit, L&T Coimbatore. He has undergone leadership training at IIM-C and awarded Doctorate in Management for research work on ‘Management of Innovations in Engineering Industry’. He talks to MART about the future of Foundries in India, and the excerpts.
Can you brief about your organization and your successful journey? IIF Southern Region, amongst the most active regions will be celebrating its 54th Formation day on 19th Dec 2015. During these 54 years, the industry has seen tremendous growth despite many challenges. It is the capacity and capability of Indian Foundry Men – both employers and employees, combined with fast adaptability that has helped our country emerge amongst the most successful countries with respect to Foundry Industry. In 2011, Indian Foundry Industry has been acknowledged as world’s second largest producer of Castings. What can be the
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scenario in 2016? Thanks to the new impetus given to Manufacturing by Indian Government, Indian Foundry Industry is expected to continue to quicken its pace of growth matching with user industries. Being the Mother of all Industries, there is no manufacturing without castings. While we aspire for the contribution of Manufacturing to GDP to grow from its current 12% to 25%, Foundry Industry has to grow a minimum of 3 times along-side. This is central to the strategies adopted by Indian Government. For the first time, Indian Foundry Industry is accorded an Independent Industry Status under the aegis of DIPB.A Foundry
Development Council chaired by Secretary, DIPB is formed to steer the industry to higher levels. However, in terms of Global Position, a change is not foreseen in the immediate future but the gap will be significantly narrowed. For Indian Foundry, land is one of the major challenges faced during production. What are the measures been initiated to support investment? It is a misconception that land is a challenge for Foundry Industry. Certain developed states in India have specific allocation of land for Foundry Clusters. Across the country, many such clusters are functioning successfully. In line with escalation in real estate prices all over, land cost
is today expensive, though. Hence, choice of locating a Foundry is narrowed down. Foundry Industry is relatively a low entry barrier industry. Today investment in land for a decent size of a foundry is easily about 20 to 25%, but still not prohibitive. Looking at the positive side, prevailing cost of land will help Foundries optimise land utilisation and hence will be driven towards being lean & mean. Earnings per squaremeter of investment will significantly improve as space utilisation becomes efficient. This will further improve other resources utilisation by at least 25%. 80% of Foundries in India are SMEs. Any plan from
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Castings for Wind Energy â&#x20AC;&#x201C; Metallurgy for Extreme Conditions
the Government to provide them with a pro-business environment? Present Indian Governments focus on Manufacturing will itself be a major driver for Indian Foundry Industry. As mentioned earlier, for this initiative to succeed, it is imperative that Indian Foundries Modernise & Grow. Thanks to the enormous talent pool and Indian
entrepreneurial zeal, Foundry Industry will continue to remain a domain of SMEs. As in any maturing Industry, though consolidation may happen, many niche and specialised foundries will continue to flourish. Recognising Foundry Industry separately and forming a Foundry Development Council is a major step in the right direction. Many schemes have been drafted and mostly
accepted by the Government â&#x20AC;&#x201C; like reclassification of Foundry Sector, Investment subsidy for modernisation, Sector specific and Country specific export incentives, liberalisation of sand mining. As we progress, many more such developments will evolve along-side. What is your opinion regarding the quality of production?
most of the players in User Industries (OEMs) are either MNCs or Indian entities with Foreign Collaborations. These customers of Indian Foundries have a universal standard. There are a lot of part specific Indian casting suppliers. Such Indian Foundries are usually in the Global supplier list of MNC OEM Customers and thus export across the Globe.
It is a fact that quality is non-negotiable. Today
In Auto & Valves Sector, a large number of Indian Foundries
Castings are large size Transmission Housings used across Industries
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are successful Global Players. Given this scenario, there are no specific challenges in meeting the Global Standards in terms of quality, though right pricing matters a bit. Indian Foundry has a major drawback when it comes to Pollution Control and Energy Savings. What actions have been initiated to give it a permanent solution? As much as we believe Indian Manufacturing is still evolving, Indian Foundry Industry also evolves along-side. Indian Foundry Industry is wide spread in-terms of ownership patterns. About 3% are corporates, about 30% are Medium Scale, 30% are Small Scale and remaining Micro. Thanks to the necessities imposed by customers, Small, Medium and Corporate Indian Foundries can be considered to be meeting the prescribed pollution norms. (Today it is mandatory to have ISO 14001 if we are to be a supplier to Global Customers). Price realisation drives the energy efficiency and this
depends to a large extent on Product Mix and Alloy Mix, apart from quality and capability of the facility. Emerging power scenario and requirements of State Electricity Boards will also drive Indian Foundries towards Global Energy standards. Can you brief about the opportunities Foundries have in the national and international market? There is enormous potential for Indian Castings across industries. As mentioned earlier, growth and modernisation of Indian Foundries will decide the pace of growth of Manufacturing in India, and thus the economy as a whole. This will be felt across industries and major influencers will be Infrastructure, Defence, Mining & Construction, Consumer Durables, Power Generation & Distribution, Medical & Space. International business for some time will continue to remain traditional – Automotive and other consumer durables, Oil & Gas. Many proprietary products
(like Pumps & Valves) & OEM exports will also augur well for Indian Foundries. These apart, there are atleast 50% of Indian Foundries moving up the value chain – from being mere casting suppliers to ready to fit parts/ sub-assemblies / sub-system suppliers. This will help in enhancing the prospects of Indian Foundries in terms of cost competitiveness and profitability. Latest innovation by your organization? Barriers are natural drivers for innovation. The segment in which we operate is predominantly a Niche segment and hence it is cross border competition. In our foundry, innovation is a day to day process and continuous change is a culture. Focus of innovation is on Energy Efficiency, Material & Labour Consumption efficiency. Mantra for innovation is Reduce-Reduce-Reduce…With this focus, we have been able to contain our cost to a great extent and become a bench-
mark in Industry. The major products and services offered? Critically engineered castings to Non-conventional Energy, Power, Construction & Mining Equipment, Machine Tools and Large Size Transmission Housings. Your mission and vision, and your company contributions to the Indian Foundry industry? We wish to be Indian Casters for Global Markets with atleast 20% Business Share and 5% Market Share. We have a significant presence in the new age, emerging industries – both renewable and conventional power and work mostly on import substitution thereby resulting in quite a good Forex savings to the country and improved cost competitiveness for our end customers. Being in predominantly Human dependant processes, employment generation is also better than normal Indian standards.
Critically Engineered Castings for varied applications
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MAIN FEATURE
“IFO’s focussed approach helped to achieve several reliefs to Foundries in a very short span”
Dr H Sundara Murthy President, IFO & CEO Fenfe Metallurgicals The Indian Foundry Organisation (IFO) was founded almost a year back. The objective of the IFO is to work with the Metal Manufacturing units including foundries, forging units, cast houses, recyclers, steel manufacturers and re-rollers etc. The main concept is to bring together all manufacturing units as most of the problems are common to all of them. Dr. H Sundaramurthy, President of IFO is the founder of Bangalore based Fenfe Metallurgicals manufacturing high precision aluminium alloy castings. He did his B.E. Metallurgy, M.E. in Foundry Technology and PhD in Foundry Technology from Indian Institute of Science, Bangalore. The excerpts from an exclusive interview with Dr. Murthy about how IFO is revolutionizing the Foundries in India as well as his plans about Fenfe Metallurgicals.
In 2011, Indian Foundry Industry has been acknowledged as world’s second largest producer of Castings. What can be the scenario in 2016? It was the second largest few years back and now it is the third largest with USA coming back to the second place. The first place is occupied by China with a whopping 42 million
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MT of casting per annum, USA with 10 million MT and India with 9.4 million MT. Hence it is not very important whether we are in 2nd or 3rd position, but we should rather compare our previous performance with the next year. The projection for 2016 indicates that India may spring back to the 2nd position. But this year all the industries are undergoing severe recession
and the actual production may not be very high this year. The critical factor is how the industry behaves in the last two quarters. Can you brief about IFO and how it’s going to support the foundries in India? The IFO was started a year back but it was dormant. The main objective was to help the
Metal manufacturing units. There are already other associations then why IFO is a good question. IFO is started with the main objective of helping the manufacturing units. The main problem for foundries is the issues of taxation, import duties, raw material availability, availability of quality uninterrupted power, helping the foundries on marketing of
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Tribute to Missileman Late President APJ Abdul Kalam by IFO
castings etc. IFO has a very strong coordination with the Government- both Central and State. Within a short span of time, IFO has been able to get the invitation from MSME, Power, Mining, Finance ministries to brief the problem to get some solution. I think this focussed approach was required for foundries and we will intensify our effort in the days to come to get relief to the foundries. For Indian Foundry, land is one of the major challenges faced during production. What are the measures IFO is going to initiate to support investment? Land is a very critical issue in all the States. It is being used as a lucrative investment. This is also State subject and depends on the local issues. Generally foundries are not in a position to invest so much of resource in the initial stage
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itself. Hence we propose to help the foundries by forming clusters. Just to give an example, the foundry cluster in Bangalore got 45 acres of industrial land in Bangalore and many foundries have already started. There is no concession in the prices but the Karnataka Government issued it on priority. We followed up with the Government for over two years to come to this stage. We are confident that the problems of foundries can be solved by close interaction with the State. 80% of Foundries in India are SMEs. Any plan from the Government to provide them with a pro-business environment? More than 80% of foundries are in Micro and Small sector. They need lot of hand holding in Technology upgradation, skill development of the workmen and marketing
of castings. I am happy to state that IFO has already started intensive activity in the above areas. We have formed a team of experts who have spent their life time in foundries and are willing to give their talent to the MSM foundries almost free! We have got great success in many cases. Primarily the foundry owner has to be oriented towards improvement and then only it will be a success. What is your opinion regarding the quality of production? It is improving over the last many years but a lot needs to be done. Now many of the foundry men are of the firm opinion that unless they improve the quality, the bottom line of their company finance will be in danger. In other words, they have realised that effort to improve the quality is a must.
This fact is a great morale booster to the consultants and experts and things are improving. Indian Foundry has a major drawback when it comes to Pollution Control and Energy Savings. What actions have been initiated to give it a permanent solution? The main emphasis of IFO is on Energy Conservation and Environment Friendly process development. Hence the very first summit we made is on Sustainable Foundry Development. We are planning to have intensive awareness program and we are confident that the foundries have realised this fact. Not only that Energy Conservation is a must but they have realised that it is also a revenue generating concept than mere investment. This is a motivating factor for all the foundry men and the results
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are really satisfactory. Can you brief about the opportunities Foundries have in the national and international market? The scope in the National market itself is quite good and small foundries need not worry on the market realisation of their castings. It is the identification of the core areas and improvement in that area is the key factor. If you see the small foundries producing castings which are very intricate and precision requirement it is really amazing. Each foundry has its core strength and exploiting its core strength has not happened over the years. This gap of knowledge is to be supplemented by IFO and IFO has very clear idea on what should be done to
MSM foundries to improve their level of achievement. Large foundries have their own talent being available in house for these operations and IFO wants to help them in sorting out their problems with the Governments. MSM units must upgrade to higher level of operation before thinking seriously of International markets with some exceptions of niche markets.
for quantum development. Personally if you are asking this question to our company, Fenfe Metallurgicals, we have obtained a patent on Aluminium Metal Processing almost ten years back and the benefits are many fold. Every foundry must work towards inventing something new or new process and should invent schemes to reduce waste and optimising the operation.
How Foundries can innovate with changing times?
The major products and services offered by Fenfe Metallurgicals?
Your mission and vision, and your company contributions to the Indian Foundry industry?
Our unit manufactures Aluminium alloy casting for the upper quality requirement market. Most of our castings go through Radiography testing and go for critical applications. We have standardised several
The mission of our unit is to produce quality components to suit the requirement of our customer most economically. Our customer end rejection is NIL from the last ten years and we, the staff and workmen of our unit, are very proud of this fact in our unit.
This is one area where our foundries must invest time, talent and treasure. IFO intends to start an Innovation Centre in the near future in collaboration with a State Government. IFO strongly believes that Innovation is the only way
processes which are unique to the product and our customers are very happy on the quality performance of the components. We have developed several unique processes which no other foundry applies to the process and that is where we have excelled in the quality output. Each foundry should try to develop its core strength and improve form there on.
IFO Felicitation to Shri. Hem Pande IAS, Special Secretary, Ministry of Environment, Forest & Climate Change, Govt of India
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MAIN FEATURE
Indian Foundry: Going Forward
Manish Kothari Managing Director, Rhino Machines Mr. Manish Kothari, Managing Director of Rhino Machines brings hands on experience of 25 years with in installation, servicing, engineering, design, development, process, shop floor management, lean manufacturing, system engineering, customer relationships and innovation in the Foundry Industry. Recently awarded in 2015 by MSME for Innovation in industry as a result of continuous product development for the foundry industry. He talks about the sustained growth achieved at Rhino Machines and how he plans to take his organization ahead. He talks about the sustained growth achieved at Rhino Machines and how he plans to take his organization ahead.
Can you brief about your organization and your successful journey? Rhino Machines started in 1983 under the leadership of R C Kothari as a Project & Consulting firm and it grew into a full-fledged manufacturing firm in 1991 after the joining of Manish Kothari – Gold Medallist Mechanical Engineer from MSU, Baroda. In 1994 Rhino started its most important collaboration in technology with Renzo Cappelletto in the Green Sand Process Technology space. Combining the rich project and wholesome project experience with the equipment and process knowledge with this new association Rhino started its own manufacturing in the engineering hub of
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Vithal Udyognagar, Anand in 1996 forming Rhino Machines Pvt Ltd. With its first high pressure moulding line of 90 m/hr executed in Kores (I) Ltd, they stepped into a domain so far untouched by the Indian Equipment and Project manufacturers. Thus grew the dream and journey of being the market leader in Technology products and Innovations. Year 19992000 saw the birth of the first innovation which was patented – CO2 sand reclamation which took Rhino through one of the first recessions it faced in early 2000’s. The period from 2004 – 2007 was an important and difficult phase of Rhino Machines having accepted the challenge
of building fully automatic lines in India and overseas, which were put into production, though without the success envisaged. As they say – every failure is the step to another success – this difficult period forced Rhino to introspect, understand the “real” need of the Indian Industry. Thus started the journey of building the first standalone High Pressure Moulding Machine – a design completely developed from scratch with the process and concept support of Renzo Cappelletto. Making the first drawings, prototype was taken up in 2009 inspite of tough market conditions, with the Team Rhino and its Vendors providing undivided support. A design put on paper in 2007,
was built and tested in Rhino in 2009. In this period, the reins of Rhino were with Manish Kothari, the office from Baroda was relocated in the factory. It was a combination of several factors which converted this exercise into the first order of the new MULTIFLEX series machine, displayed in the IFEX 2010. The first and only MSME organization and a home grown Foundry Machine manufacturer received its boost by getting acknowledged for the best new technology at the IFEX. The product was established in the industry for 2 years, before full-fledged commercial launch. Looking at the replacement market, MULTIFLEX machine sales quickly picked up across India. The technology was
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Rhino Machines was selected as one of the semi-finalists under the Global Cleantech Innovation Program (GCIP)
then shared with other stake holders in Italy, France & China. Rhino has crossed more than 25 installations of these machines.
Arabia finalized plants with just one look at the solution. In short span of 2 years more than 20 installations are put together in all domains.
During the same period, another key technology product – again a niche product of Renzo Cappelletto the Mixer-Cooler – RMC Series was adapted to India and successfully proven in the tough and demanding Indian Foundries.
MSME – PPDC, Agra having the mandate of the Government of India to promote and support Foundry & Forging, identified this innovation and gave it the GCIP (Global Cleantech Innovation Program) platform. Being the ONLY Foundry Equipment manufacturer to be in the Innovation and Clean Technology space, it was a great pride and challenge at the same time. With 2.5 months of mentoring by UNIDO &Cleantech Open, Rhino ended in the top 6 of the Indian Innovators out of the 20 Semi-finalists – shortlisted from 160 applications pan India. Having been recognized at the national level by the experts from the Industry has been a motivating experience.
Having the key core technologies for the Foundry Sand & Moulding Process well established, Rhino continued on its path of Innovation. In 2012, Rhino launched its next product line ECOFLEX – the compact and energy efficient sand plant. The 20+ years of project and consulting experience, foundry process knowledge, understanding the customer needs evolved into the birth of an innovation which caught the imagination of foundries within India and overseas. The prototype plant built in 2012 and its simplicity, compactness, clean environment was appreciated by one and all during the IFEX 2014. Customers from Saudi
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The innovations and development did not end at the ECOFLEX. The journey is continuous even as we write. In the year 2014 Rhino signed the license agreement with FATA for Sand Reclamation – a subject close to its heart.
The first prototype Green Sand Reclamation machine was displayed at IFEX 2015, and put in production testing at Rhino’s facilities. Rhino complemented this with a full fledged Sand testing laboratory for testing & validation. The challenge was to downsize the FATA technology to the Indian foundry needs, hand hold them for technology, and implement the same. The process of establishing the technology in the industry is going on as we write this article. ROBOFLEX – an imagination of Renzo Cappelletto, was put into operational animation by Rhino in India and displayed by the Chinese counterparts in GIFA 2015…another path breaking technology is born and history in the making. The quest for translating technology led to identifying the need to fill the skill gap for the industry. Rhino joined hands with ACE Foundation in 2015 to launch the SwissMEMSkillSonics licensed niche training program for multiskilled technicians, and IOT Anewsha designed Project & Construction Management courses for making engineers
industry ready. This year has also seen Rhino joining hands with MSME-PPDC Agra in setting up the Metallurgy School in Anand & Howrah for the school & college students, to train and attract the new generation to the Industry. As our tag line states “Meeting Challenges is the Way of our Life” and the vision of our present PM – “Make in India” & “Made in India” – we have always followed this challenging path and continue to do so. In 2011, Indian Foundry Industry has been acknowledged as world’s second largest producer of Castings. What can be the scenario in 2016? The scope for growth for the Indian Foundries is enormous. During one of the technical presentations the writer had commented to remark by one of the foundry men – “instead of price cutting and price war within the country between Coimbatore & Rajkot why not focus on competing with the other foundry market leaders like China and get into their market”.
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It is necessary to start thinking beyond our boundaries in addition to the domestic casting need. Even though there was an increase in the output of Indian foundries in 2013 over 2011 as per the world census, USA crossed India to leave it at third. It was not that the need in India had reduced, but the misplaced policies, indecisiveness over last 4-5 years, improper handling of the infrastructure, mining projects ate away into the foundry production, and in fact the total industry is in a not in a great shape. Orders are existing, but the money has dried up. The new government has infused some life into the industry, the market survey predicts an average 19.6% growth in foundry industry over 4 years, the Indian competitiveness has increased in the world market, however, the liquidity crisis and cash strapped projects have slowed down the growth. Those who invested without the right techno-economic
fundamentals, or were new to the industry have faced closure or sell-off. Plants with huge capacities lay idle working at 1520% of their installed capacities. For Indian Foundry, land is one of the major challenges faced during production. What are the measures been initiated to support investment? Land is not the “Direct” challenge for the foundries. However, inability to pass the land bill and clearing the hurdles has brought the infrastructure projects to almost a stand still. Mining, road construction, railway freight corridor are few of the projects which once put on the roll will have a cascading effect on the growth of the foundry and in fact the entire economy. The cycle of money has to start from the government, and there is a need to infuse funds into the infrastructure. 80% of Foundries in India are SMEs. Any plan from the Government to provide them with a pro-business
environment? The new government has already starting taking a lot of steps to improve the business environment. The active participation of the MSME into the skill development and training modules, clusters promotion and recognition of foundry & forging as the prime focus of the government is one step in the right direction. However, since the past experiences of the previous governments and schemes have not been so good, the industry is not sure of the schemes launched. Sensitisation of the schemes and hand holding to implement them will be a major task. An SME does not have time out of its normal day to day fight to look for schemes from the government and getting the benefit. The govt will have to take an extra effort to wipe off the “old” image, become pro-active and implement schemes, make demonstration projects, and then market the demonstration
projects. Some new initiatives from MSME-UNIDO in the foundry sector of setting up “Demonstration Projects” and “Cluster Projects” is already on. However, making the solution actually benefit the SME is probably the more difficult. The industry also has to come forward to embrace the renewed support and take it forward. What is your opinion regarding the quality of production? “Quality” is a very subjective matter in Indian foundry. What may be rejected for one foundry man is acceptable to somebody else. Most of the Indian foundries discuss quality “qualitatively” rather than with quantitative data. Maybe their quality is good, but on what measure. For example – surface finish – within Ra value…so & so, weight variation within +/- x %, and a CPk of ….., actual rejection, salvaged rejection…. Till we start to acknowledge
Ecoflex- the energy efficient GCIP Top 6 Innovation award winner solution for foundries
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Driving manufacturing processes of the future
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that quality can be measured and not just a feeling, we don’t think we can say that quality of production is good. The inability to connect the process variation particularly in the sand process with the defects, and the importance of sand process is cause of major quality issues. There are few foundries with excellent systems, and quality measures – but how much of the vision is percolating to the bottom level, and how much are the people working at the lowest level sensitised with the effect on their actions with quality of production. We are still way behind to reach the internationally acceptable and standardised norms of quality of castings. We need a major correction on our outlook on quality to capture the international market.
During the GCIP 2015 program, I had visited couple of foundries with the UNIDO Project Director Ms Amrit Raj. Being a first visit to the foundry, she was appalled at the lack of safety, poor working conditions in the foundry. Maybe 90% of our foundries lie in this state of affairs. Though majority of the pollution norms – dust, noise in addition to poor safety are contrary to the requirements, industries continue to work.
Indian Foundry has a major drawback when it comes to Pollution Control and Energy Savings. What actions have been initiated to give it a permanent solution?
Why is it so? This is a question of balancing between the investment and work environment. Even if the industry wishes to provide better pollution or energy
Similar is the case with the energy efficiency. First of all there is no measure or benchmarks on energy efficiency, nor the sensitisation on the effect and benefits. We have Euro I, II …norms for the automobile, but no established yard sticks to measure & benchmark the energy efficiency of a foundry.
efficiency solutions, those available are either not suiting their needs, too oversized, or maybe not viable economically. The industry only does what is required to get the “certificate” of adhering to pollution control, safety, and as far as energy efficiency is concerned, passing on the cost to the buyer. In order to get out of this situation and make the foundry a more honourable and favoured work place, the Government not only needs to enforce the working environment, but also hand holds them with solutions leading to Workplace Transformation. The present initiative of the government to set up clusters in major industrial belts is one welcome step and intiative. Bringing Foundry Industry to the GCIP participation and sharing the solutions available within the country is another important step of the MSME & UNIDO. Can you brief about the
opportunities Foundries have in the national and international market? The opportunity can be seen – not a big calculation. India is just below 10% of the market share and China at 44%. Being the two big production centres with their own strengths and limitations, India of late has got an advantage of stronger fundamentals. The infusion of capital, improvement in infrastructure, and change in our outlook to quality are the key factors to easily grow in the international market. India has never been tagged as “cheap and low quality” castings supplier, unlike China which carries a very poor brand image on quality and reliability. It is time for Foundries in India to leverage this very strength of India on the platform being provided by the present government. Our PM has marketed our country worldwide, and it is for us as an industry to support this marketing effort with the right quality and value for money products. Even in
Multiflex Moulding Machine from Rhino Machines
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a market which seems to be static or going down, the 4 fold difference in production gives sufficient growth potential. Remember we are talking of 19.6% growth in Indian Foundry production which means just 2% odd increase in world market share! In addition to this the starting up of domestic infrastructure, coal mining, ore mining, railway projects, road projects, will ultimately generate a huge casting demand. Those who understand this growth potential have already started investing and planning for the future. Though this demand can be seen only after 8-9 months from now, preparing ourselves for the opportunity and belief in the growth are important factors. Latest innovation by your organization? Innovating at Rhino Machines is a continuous exercise. ECOFLEX – an innovation already recognised and awarded at the national level GCIP. MULTIFLEX – the stand alone high pressure moulding consuming 50% energy, noise level < 70 dB, operator safety, consistent weight – already embraced by Indian Foundries and soon going international. COMPAFLEX – a concept launched in 2012, an innovation combining automation and simplicity – again getting the best out of energy & manpower efficiency. S1 – the green sand reclamation for moulding sand. Innovating on the basic technology provided by Fata, we have downsized, and made it viable for SME’s as well. S3 – the green sand reclamation for core sand. Once again bringing smaller
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and viable sized projects to the doors of Indian foundries, enabling recycling and solid waste recovery even at small capacities. ROBOFLEX – concept of Renzo Cappelletto – displayed live at GIFA 2015 and now being launched in the foundry industry. The major products and services offered? Rhino today is offering: • ECOFLEX – Turnkey Sand & Moulding Solutions incorporating the Multiflex, RMC & RTC Technologies with Manageable automation. • Sand Reclamation – CO2, Green Sand for Moulding, Green Sand for Cores, Thermal for Chemically Bonded Sand • Sand Testing and Process Support – Green Sand process • Training of skilled personnel –in Mechanical, Electrical, Automation, Pneumatics & Hydraulics • Training of Engineers – Project & Construction management • Turnkey Foundry projects including melting, moulding, sand, core, fettling, pattern making and production, operations & management team. Your mission and vision, and your company contributions to the Indian Foundry industry? Our vision is to optimize Techno Commercial Solution, Supply, Service & Resource Provider to the Foundry Industry and we value building strong & lasting relationship with our Customers, Vendors & Global Technology Providers. Our mission is to develop and Establish Waste Recovery and Energy Saving Solutions as Social Responsibility.
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MAIN FEATURE
Sustainability in Foundries by using Big Data Analytics The Indian foundry industry has a long history. It has been transformed from making artefacts, jewellery, etc to making the most complex components for application in automobiles, railways, aero, space and nuclear power, etc. The industry has tremendously changed since then to align itself with changing requirements of the consumer industry.
Rajesh Angadi rajesh_angadi@hotmail.com
The industry has logged growth of 10-15 per cent over the past 10 years, except in global recession. But after the opening of global economy, competition has increased and also the cost of raw materials, energy, labour, and environmental costs have tremendously gone up over the years. The availability of some materials like good quality foundry sands, iron ore for making pig iron and steel has become serious issues due to mining problems and environmental pressures. The environmental norms and pressures have also impacted the cost of operations and these pressures will continue to grow as we go forward. Moreover, the expectation of buyers with regard to quality, response time for development of value added and ready-touse components at a reduced costs are going up. At the same time due to poor image of the industry, the sector does not attract the talent as it is
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not considered a preferred employer.The foundry industry in India is largely in MSME category and due to pressure of margins, lack of awareness, high cost of capital, modern design, manufacturing tools and equipment is not able to invest in modern technology. Therefore, going forward and to sustain the growth in this sector, the stakeholders need to focus on various aspects. The government has to be a facilitator for having policies to support ease of doing business and create supporting infrastructure and strengthen institutional support. The industry associations too need to build capacities to stimulate activities which will help the sector, especially the SMEs. Focus on the following aspects: Promote co-operation and cluster working to harness the strength of collaborative approach and enable cluster
members to access modern design/manufacturing tools and common training facilities to the extent possible for better productivity and competitiveness. Strengthen institutional capacities as a support system Promote lean manufacturing by cutting down wastage, rejections, promoting recycling, energy management, scientific designing by using quality management tools and modern software for improvement in yield. Promote energy management with a target to reduce energy intensity by 10-15 per cent over next 5 years by having energy policy and systematic and periodic energy audit. Every unit must have a defined & stated energy policy like the quality policy and pursue it religiously. Focus selectively on low-cost mechanization, especially for hazardous processes which will to an extent improve
productivity and also address partly the manpower issue. By systematic record keeping, measurements and control of various parameters to continuously monitor the processes and upgrade these. Skill development to meet future needs. This can again be done in clusters in-house. Promote hygiene, health & safety in shop floor working & management. This will not only improve the per-man productivity, but also improve the image of the sector to attract the younger generation. Quality management, standardizing of processes and continuous upgradation. Big Data is a great opportunity for organizations. Data turn into a strategic resource, whose smart utilization represents a high value and competitive advantage. Establishing the right infrastructure able to keep
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The Indian foundry industry has a long history. It has been transformed from making artefacts, jewellery, etc to making the most complex components for application in automobiles, railways, aero, space and nuclear power, etc. The industry has tremendously changed since then to align itself with changing requirements of the consumer industry.
processing time constant while volumes are increasing is a challenge which should not be underestimated.Big Data is a one stop solution where organizations can get optimized Big Data infrastructure solutions including hardware, software and services – all from a single source. Big Data is about large data volumes in the range of many Terabytesto Petabytes coming from versatile internal and external data sources,such as databases, audio and video files, e-mails, IT logs, web logs, social media and the millions and billions of sensors which are built in everywhere. Especially new sources provide data which rarely is structured, but rather unstructured, semi-structured and poly-structured. Very often this data is continuously generated at a very high velocity, and the same high velocity is also demanded when it comes to analyzing the data in real-time to create value for the organization. By discovering facts and insights about customers and suppliers, market conditions, operations and root causes of costs are revealed, that would otherwise remain hidden. This
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helps you predict things that are going to happen in future, take the right decisions, and initiate the respective actions. Betting on the right horse, skipping useless activities, and optimizing the allocation of resources will increase performance and productivity, accelerate business processes, minimize risks, improve efficiency, effectiveness and profitability and finally give you the competitive edge that you need in today’s tough business world. The Big Data analytics promise is all about plucking insights, knowledge and trends from deep reservoirs of raw data. But the reality is that massive troves of data are difficult for commercial and institutional computer systems to collect, sort, manage and analyze in a cost effective and speedy way. Curating and “cleaning” data to improve quality requires access to powerful computing power. Data analytics infrastructures entail complex techniques such as machine learning, visualization and cloud computing - to name a few. Businesses, government and other organizations looking to big data analytics to gain
insights and solve challenges typically do not have the core competencies required to process and analyze giant databases. PARC, a Xerox company, (R&D services), Cisco (IT leader), Hitachi Data Systems (big data storage) and Quantiply (enterprise architecture) have created the Big Data Foundry (BDF) that pools together experts in software and hardware who can help enterprise harness data in a more powerful and efficient manner. The foundry offers a Big Data Rapid Experimentation Platform made up of readily available technology and an “algorithmic toolbox” designed to accelerate experimentation and reduce risk. Our mission is to help organizations develop innovative data driven methods to find answers to business problems and develop models that focus on solutions that can make a difference. Rapid Experimentation Cloud Big Data Foundry brings collective expertise and technologies to help you experiment and scale new ideas with reduced risk and time-to-value. We provide all
the tools and technologies you need to connect, explore, experiment, and validate your hypotheses and problems. •Reference architectures, data scientists and tools that reduce technological complexity and deployment costs. •Pre-assembled reference architectures to validate your business solutions on target reference architectures before investing in these complex tools and technologies. •Support development of data driven infrastructure to empower your employees to sense, analyze, interpret and act fast on the data insights. Data Sciences Innovation Big Data Foundry member companies collaborate to help you engage world-class data scientists, data engineers, cloud experts, innovators, and ethnographers all in one place to help you find new routes to revenue and profitability in your organization.With Big Data Foundry as a strategic partner, you no longer need to delay exploring and implementing new Big Data technologies.
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In the past few years or so, manufacturers have been able to reduce waste and variability in their production processes and dramatically improve product quality and yield (the amount of output per unit of input) by implementing lean and Six Sigma programs. However, in certain processing environments— pharmaceuticals, chemicals, and mining, for instance— extreme swings in variability are a fact of life, sometimes even after lean techniques have been applied. Given the sheer number and complexity of production activities that influence yield in these and other industries, manufacturers need a more granular approach to diagnosing and correcting process flaws. Advanced analytics provides such approach. Advanced analytics refers to the application of statistics and other mathematical tools to business data in order to assess and improve practices. In manufacturing, operations managers can use advanced
analytics to take a deep dive into historical process data, identify patterns and relationships among discrete process steps and inputs, and then optimize the factors that prove to have the greatest effect on yield. Many global manufacturers in a range of industries and geographies now have an abundance of real-time shopfloor data and the capability to conduct such sophisticated statistical assessments. They are taking previously isolated data sets, aggregating them, and analyzing them to reveal important insights. Thermodynamic framework to characterize the material and energy resources used in manufacturing processes. Analysis and data span a wide range of processes from “conventional” processes such as machining, casting, and injection molding, to the so-called “advanced machining” processes such as electrical discharge machining and abrasive
waterjet machining, and to the vapor-phase processes used in semiconductor and nanomaterials fabrication. The results show that the intensity of materials and energy used for unit mass of material processed (measured either as specific energy or exergy) have increased by 6 orders of magnitude over the past several decades. The increase of material/ energy intensity use has been primarily a consequence of the introduction of new manufacturing processes, rather than changes in traditional technologies. Relevance of thermodynamics (including exergy analysis) for all processes in spite of the fact that long-lasting focus in manufacturing has been on product quality—not necessarily energy/material conversion efficiency. Use of thermodynamics tools for manufacturing processes analysis with the context of rapidly increasing relevance of sustainable human enterprises.
Metal China is leading the foundry industry. In the ‘Big Data’ era, automation, intelligence and digital have been the trend for foundry industry. Die casting industry is currently the most robust branch in foundry industry. With the growing trend for lightweight automobile, the die casting industry in China will continuously maintain a double-digit growth in the next 10 years. Metal China and the Die Casting Exhibition have seen the big progress of China foundry industry. The technology research and development ability is increasing significantly and foundry companies are more professional than before. In future there is need for the Indian Foundry Industry to have partnership globally with manufacturing leaders to strengthen and build its capacity to support the sector for continued and sustainable growth.
Promote lean manufacturing by cutting down wastage, rejections, promoting recycling, energy management, scientific designing by using quality management tools and modern software for improvement in yield.
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“Manufacturing Fasteners is Very Critical
A P Juzar CEO, FACO Fasteners Pvt Ltd Faco Fasteners Pvt Ltd, an ISO 9001:2008 TUV Certified Company was established in 1957. FACO Group is a prominent name in the Engineering Industry in India. With more than 52 years of Experience FACO Group understands and caters to the needs of its customers. FACO Fasteners is one of the world leader in manufacturing industrial fasteners such as Foundation Bolts, Connections Bolts, Stud Bolts and U-Bolts and manufacture as per DIN, ASTM, BS, ANSI, JIS, IS and ISO standards in Imperial as well as Metric sizes. A P Juzar, CEO of Faco Fasteners Pvt Ltd shares with the readers of MART, the changes Indian manufacturing industry undergone over the years and how critical it is to manufacture fasteners.
Fasteners are one of the small components going into a machine/ product. But without fasteners it’s impossible to get the product made. How critical is a fastener in manufacturing? If we talk about fasteners generally we think, “Oh, it is a small thing and can be easily get in the market or can be made” but the fact is manufacturing fasteners is a very critical thing. In fasteners there are lots of Indian and International Standards. In fasteners there is a huge range of items starting from nails to bigger sizes bolts and every item to manufacture is also a very tough task. If we talk about manufacturing the machinery it is a critical engineering item in which you have a very less tolerance to make. Fasteners are totally
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engineering items and are as critical as making aeroplane or doing an operation in the OT room. You are one of the oldest fastener companies in India. Can you brief the changes Indian fastener industry witness over the last six decades? Being the oldest in the industry, we did not find out any drastic change in the industry. People are using the same type and same thing what they are using decades back, may be because lack of awareness or funds or due to government policies. If we look and compare to other countries infrastructures and machines we are not having even 10% of that in India. The products manufactured
by Faco Fasteners and what’s your major markets and market share? The product what we manufacture is basically Industrial fasteners and is being widely used in Industries like Oil & Gas, Petroleum, Constructions, Bridges, Railways, Power Sector, Telecommunication, Marines, Water Treatment Plants, etc. Can you share the opportunities for exports?
Fasteners? Being the oldest manufacturing company, now we are moving with new machines and techniques what generally other countries are using. We have installed latest machinery by which our production is 4 times more than what we were doing previously. The research and development undertaken by Faco Fasteners?
If you are having a good team and good quality with system certified company there is a chance for exports. Many European & Overseas Countries are now importing fasteners from India because of Antidumping Duty.
We believe in growth. We always look for better machine and better technique to raise our production and our efficiency. We welcome suggestion upon the same from our top management as well as from the soft floor supervisor or helper also and we use to review upon it.
Latest innovations by Faco
With more indigenous
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Industrial fasteners manufactured by Faco Fasteners is being widely used in industries like Oil & Gas, Petroleum, Constructions, Bridges, Railways, Power Sector, Telecommunication, Marines, Water Treatment Plants, etc.
manufacturing expected in the critical defence, aerospace etc through Make in India, what are the opportunities for the fastener manufacturers in India? The Government says they are promoting Local manufacturing through SME, MSME but the ground reality is that the industries are not being benefitted. Letâ&#x20AC;&#x2122;s take our example, we are looking for expansion and we have purchased a plot just near to our works 3 yrs back. We are
not getting permission to start construction from 3 yrs saying that the property is under Costal Zone. How come one plot is in Industrial Zone and one in coastal zone when it is in same area? Indian fastener industry is completely not in the organized sector and how a customer can choose the right manufacturer for fasteners? Very true! In India not only the Fasteners industry, but mainly all industries are not in the
organized sector as because of government policies and state policy. Being a customer we will suggest to not only focus for the price what one company is offering, we will suggest to check the other aspects like the certification, facilities, manpower etc. Because, in India many companies are created only in books and in real they donâ&#x20AC;&#x2122;t exist also so one has to be very careful while choosing a right manufacturer. Your future plans and where
you see Faco Fasteners in the next 5 years? In next 5 years we have so many things to do apart from the approval. We have to double our production; we have to go with expansion with all international machinery and technology. We have decided to go with ERP systems with having Bar Code, etc. In fasteners we want to develop new items as per customized requirement of clients which can be used in critical defence, aerospace, power.
Faco Fasteners is planning to develop new items as per customized requirement of clients which can be used in critical Defence, Aerospace and Power.
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MANUFACTURING EXCELLENCE
Facing Audits of Customers and Third Parties Managing a SME in India - Part 35
As a continuation of last article about Facing Audits of Customers and Third Parties, we will discuss on few more points in our column about Managing a SME in India- Journey towards Excellence.
P S Satish gotopssatish@gmail.com
47. Facing audits of Customers and third parties â&#x20AC;&#x201C; Part 3
this also on how Customerâ&#x20AC;&#x2122;s needs are captured.
As briefed in earlier part of article, every Auditor has his own way or style of asking questions. Apart from this, we see a pattern in questions itself and are considered as core questions of Auditors. These core questions are starting point to drill further. What are they?
How are problems identified and also prevented?
How do you access product or service requirements? The Auditor tries to check whether product requirements are complete, how is it ensured that correct versions are available to all concerned, how the requirements are reviewed before acceptance, how to know whether the product has met the requirements and how is it handled when the product requirements change. Part of
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The problems do occur. Identifying and focus on prevention will be to avoid reoccurrence. The TS16949 standard focuses on repeated problems. When the problem reoccurs it only means that the earlier actions are not implemented fully or the root cause analysis of problem is inadequate. The problem identification, analysis and prevention is one of important aspect in the company to improve the quality. The Auditor would be keen on how problems and corresponding corrective actions are documented, whether there is an analysis of problems including monitoring the
trend, is cross functional team involved in analysis of the problem, is team familiar with the use of problem solving tools and statistical methods, is there a focus on identifying preventive actions and if any formal method adopted for problem solving. Problem here refers to anything and focus is on approach rather than the problem itself. Belief is that if there is a proper structure to handle problems, any problem can be handled leading to improvements. How Customer complaints are handled? In spite of best system, Customer complaints do happen. This can be risky some times. At the same time, it provides opportunity for improvement of Organization. Key aspects will be on what
methods are used to capture Customer complaints, tools used to identify core causes, is there a repetitive nature of complaints, whether employees handling are trained, how Customer interests are protected, how Customer is updated on the actions taken, is there a trend of decrease of complaints over the period, how effective is the actions identified and taken, when is complaint is formally closed and how lessons learnt from handling a complaint documented and shared. While addressing customer complaints, it is to be ensured that related documents like FMEA, control plan etc. (specific to automotive) are updated. As I have seen in manufacturing companies, typical focus will be only on customer complaints and
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C Co ust m om pl e ai r ns
In spite of best system, Customer complaints do happen. This can be risky some times. At the same time, it provides opportunity for improvement of Organization
internal rejections and more from technical aspects. But companies in the pursuit of excellence should focus also on customer concerns and internal concerns. E.g how concern of Customer to follow up too much for a product is addressed? Similarly internal concern could be that the operator has no proper light in his area of work. It is a good practice to document concerns each month and address for prevention in future. How does the top Management involve and review the performance of the Organization? Does the company have any MIS (Management Information System) to know the performance of the company over period and how is this reviewed by the Management,who are all involved in the review process, whether actions identified in the review are documented, whether issue of resource requirements discussed and later provided, records
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of review are maintained, emphasis given for closed loop actions and whether the management efforts in improvement of the system and organization is visible.
site itself if possible by the
The process of Audit completion has following steps:
Tips to face an Audit from
o Conducting closing meeting with the Auditee team along with the top management of the company to highlight critical observations.
It gives an opportunity for us
o Disclaimer will be mentioned meaning that audit is done with samples and non-conformities in the other area cannot be ruled out. o Mentioning positive and points with opportunities for improvements o Agreeing on the time-plan for corrective actions including re-audit as needed. If there are issues that may jeopardize the quality, action plan is filled immediately. o Concluding audit report at
Auditor. o Thanking the team by the Auditor for the participation and support.
Customer or third Party Every audit is a great lesson. to start thinking in new way or gives a new perspective for a thing which we have been doing. Here I give some tips to face the audit successfully: o Get clarity from the Auditor on the schedule, purpose of the audit and their expectations. Make preparations accordingly. o Support the Auditor in reaching your facility without hassles. He should be comfortable. o Make sure that on the day of Audit, no other Customer visit is scheduled. Inform all key persons in the organization about the Auditorâ&#x20AC;&#x2122;s visit.
o Keep all necessary documents, records and presentations ready for the Audit. Suppose there is a process audit of a product, make a file with all necessary papers which will help for faster audit. Searching of documents or records before the Auditor gives a negative message on filing and retrieval. o Inform the team to come well-dressed on the day of audit and brief them to be calm with the auditor. Behavior of The Auditee has an influence on the Auditor. o Ensure that toilets & sinks are clean and basic house keeping is taken care well. o The Team should be in facility before the Auditor visit. Inform Security for a hassle free entry. o Welcome the Auditor as he arrives and introduce the team. Top management personnel to be present at this time. o If the Auditor is coming for the first time, offer to make company presentation. Ask
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whether he or she would like a plant tour before the start of Audit. o Check with the auditor his preference of food and beverages to made available as needed. o Clarify with the Auditor his agenda for the day and his focus to make sure concerned persons are available in time. o Based on the agenda, one person or Management representative can accompany the Auditor. Make sure that not too many persons join him and he is not crowded with people during the Audit. o The person accompanying the Auditor should carry the relevant file and make notes on the spot about observations of Auditor.
Auditor take his own time. o Answer only to the point of Auditor. You need not have to demonstrate your knowledge on a subject but can explain your point in brief. o Be organized and calm. Do not become impatient. o If there is obvious deviation, instead of defending, it is good to admit and take Auditorâ&#x20AC;&#x2122;s point for improvements. Do not try to cover up. o Appreciate good points of Auditor and thank him. But do not use too flattery words o Auditor always would like to see records or thinking on paper rather than your good intentions in the mind.
o Do not argue with the Auditor and take down his observations.
o Answer boldly and with confidence. Show enthusiasm. Do not blame management or colleagues if you are not able to answer a point clearly.
o Do not rush and let the
o Ask questions wherever
something is not clear instead of wrong understanding of the question o Let everything look normal. He should not feel that special efforts have been made only for the sake of audit. o At the end of the Audit, ensure a closing meeting with the team and the top management and note down points observed by the Auditor. At that time, if you have evidences to modify his view, please do so. o Agree on the time line for next steps including action plan. o Thank the Auditor for his time and the observations. Present a small memento if it is customary in the organization. But it should not be too expensive and should not embarrass him. o Next day, send thanking mail to the auditor on behalf of the
Company. Send action plan as per agreed date. Once actions are completed, send report with relevant records and if possible photo evidences. Like said before, Audit by Customer or third party can go well with positive experience for the team, when the Audit process with all the tips given above are noted and practiced. Remember that audit should not be viewed to just comply with the standard but must strive to identify gaps hindering to meet Quality objective of the Company. Try next time. Good luck. 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, MantriParadise Apartments,Bannerghatta Road, Bangalore-560076. Do visit www.satishps.com. Have a good day.
Every audit is a great lesson. It gives an opportunity for us to start thinking in new way or gives a new perspective for a thing which we have been doing
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TALENT MANAGEMENT
Outbound, Indeed!
When the need of the hour is smart thinking, swift action and effective people skills â&#x20AC;&#x201C; can we develop these qualities more effectively in an experiential setting than through classroom training.
Pavan Sriram pavan@ittige.com
The proverb â&#x20AC;&#x153;A chain is only as strong as its weakest linkâ&#x20AC;? is very relevant to most organizations, teams and businesses globally today. This stems from the fact that most professionals tend to highlight their strengths
and blithely overlook their weaknesses. The few that talk about their weaknesses tend to bury the same under a mass of perceived strengths. Additionally, in unfamiliar environments and unpredictable situations,
stretched beyond their normal comfort zones, people tend to lose their inhibitions, shed their masks and become more receptive to learning. In the environment thus created, it becomes possible for an experienced facilitator to
identify strengths and trouble areas, and suggest new coping behaviour. Outbound Training (OBT) has been found to be predominantly valuable in most business skills that engross
Working together increases bonding
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Explore Business Simulation that can drive Learning
interpersonal relationships,
deal with factors that hamper,
The most obvious - and
conviction and bonding,
and these strategies are then
immediate - benefits of OBT is
communication of shared
put to use in the activities
a building up of interpersonal
vision and goals, stimulus,
that follow, to trial on their
relationships, trust and
behaviour alteration in
effectiveness.
bonding.
The concept of using
While organizations look to
the outdoors as a tool in
foster the hidden potential,
management training was first
personality traits and team
developed in the 1940’s by
spirit when they send out
Dr. Kurt Hahn, a philosopher
individuals from varied
outdoorsman who believed
roles and departments to
that the outdoors has many
experiential learning, we at
lessons for city people which
ITTIGE Learning have been
will enhance their personal
working with clients to
thresholds as well as group
develop, sharpen and fine-
thresholds. It was Dr.
tune the behavioural skills
Hahn’s belief that advancing
and qualities of employees
civilizations and technology
and bring out latent facets of
were depriving many persons
one’s personality.Whether you
the opportunities to develop
are doing a team-building or
self-reliance, physical fitness
leadership outbound activity,
Learners are usually divided
and a compassion for others.
we believe your OBT’s should
into teams and assigned tasks
An established corporate
possibly have the following
or activities for completion in
training tool in western
outcomes:
a specified time. Achievement
countries, OBT is gaining
and performance during
increasing popularity in India
the activities is reviewed in
today as many corporate
group discussions to identify
houses are discovering its
behaviours that enhance
ability to solve a number
performance or lead to failure
of issues that cannot be
or decreased performance.
completely addressed in
Strategies are formulated to
classroom training situations.
response to transform, and individual effectiveness. While studying a skill, the learners can be thrown into an outside environment which is really helpful to the learner to interact among themselves to reproduce what they assimilate. After spending a few hours in an outdoor situation, research has proved that team members tend to bond together in a way that is impossible in an urban office atmosphere with its attendant worries and stress.
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• Building in Self-Confidence and Team Bonding in individuals. • Develop, Sharpen and Finetune the behavioural skills of your employees and also the mutual trust and understanding
between members of a group. • Generate fresh ideas and better attitudes which act as a trigger to reconsider existing work related attitudes. • Team-members working for the betterment of the team. • Employees who work together to the fulfilment of a larger objective to achieve the organisation’s mission. • Gain powerful and immediate insights into their work situation, bond & relate better with peers and teammembers. Inculcate leadership & delegation qualities, enable them to take calculated risk, plan, execute and communicate better. I look forward to hear from you at pavan@ittige.com on how you are encouraging teamwork and thinking outside the classroom but also being strategic and going about accomplishing goals and targets. Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to improve learning outcomes.
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TALENT MANAGEMENT
BRAND INDIA – From Buddha to Make In India! In the 2015 Annual Report on world’s most valuable nations brand compiled by Brand Finance, with a 32% increase in brand value than last year, India had moved upto 7th position. An international brand is the name of a product, or of a concept, or a philosophy that has made an impact on the human mind, irrespective of time and place. It connects you to the country of its origin. The product is recognized by its brand. Where the brand itself is a country, the human mind connects itself to all the good things given by it to mankind.
Surendra Kumar precinter@gmail.com
The first tribute for creating a
laden with items to sell. In the
In the years that followed,
Today, India has a leading role
Brand India goes to Gautam
excavations in Rome was found
Brand India was immediately in
in the world. It offers itself
Buddha. We all know that while
a coloured ceramic figure of an
vogue through Rabindranath
in the vanguard of Software.
Siddharth was born in Nepal,
Indian peacock. By looking at it
Tagore – the poet; Mahatma
Speak about it in any part
he attained enlightenment and
the first thought that used to
Gandhi – the apostle of peace;
of the world, and people
Nirvana in India. The religion
come to the mind was of India.
and Jawaharlal Nehru. For
immediately connect it to India.
people who remembered India
India offers itself as the largest
in the later years, we include
source of skilled manpower;
Maharshi Mahesh Yogi; The
and for outsourced services.
Hare Krishna Movement; and
Car factories of some of the
our present Prime Minister
most reputed international
Modi, including the Yoga Day!
brands are owned by Indians.
‘Buddhism’ that he created spread around the world; from Afghanistan in the West to China in the East. Those who heard of him connected themselves to India.
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In more recent history, in the nineteenth century, India became known around the world for its philosophy, classical dances, forts, temples, and the
India became a brand in the
Maharajahs. The contribution
On the industrial front, India
ancient times for its gold,
in creating the Brand India
became a brand through the
spices, and silks in which it
in those times came from
work of Sir Jamshetji Tata; Shri
traded. The glory of that period
Swami Vivekananda; Anand
G.D. Birla; Mr. Pirojsha Godrej;
is still reflected in “Carnival’
Coomaraswamy; Uday Shankar
and many others. Air India
the annual boat-festival of
amongst mortals; and the Forts
floated by Mr. J.R.D. Tata too
Venice. It shows Indian traders
of Rajasthan; Tajmahal – the
made a mark in the world for
arriving by sea with their boats
immortal.
Brand India.
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India is going to become the largest manufacturer of motorcycles. Indian machine tool industry has played a large role in import-substitution. India has a large captive internal market. Our ISRO successfully landed
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The news of India’s global brand rank at 7th position is a very positive sentiment and fresh breath of air for countrymen at present. We should celebrate our growth story and help India to maintain it’s Incredible India image.
Sankar Tekwani Chief Executive Spectrum Cables
its vehicle on the Moon; and then sent its satellite in orbit around Mars sending sharp photographs back home. Recently it had the distinction of launching 10 different satellites in a single thrust from the earth. It has become the most economical launch-pad for the launching of international satellites belonging to other countries. ISRO was born through the pioneering work of late Vikram Sarabhai. India is of interest to the world for several reasons, as enlisted below, and each one of these is helping to promote Brand India. Automobiles: Indian companies are having their truck-making plants outside India too. Cars
cynosure of all; abroad. Auto Components: India has become one of the leading suppliers in the world for auto-components; both for O.E.s as well as for the aftermarket. The supplies to
return home.
And Wooden Furniture:
destinations.
These have been traditionally
Steel-Forgings: Major German
recognized for Brand India.
plants are now owned by the
Indian Food And Restaurants
Indian industry here.
Abroad: The new addition to
Pharmaceuticals: India has become one of the top producers and exporters. Jewellery: India made designer jewellery has become a trend around the world.
brand and has started
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discovered only on their
Korea; and Japan as their
being exported too.
Royal Enfield has become the
in Ludhiana’ which they
Marble And Granite Items,
Khadi is an Indian product-
Motorcycles: India-made
to have the label of ‘Made
Handicrafts, Also Including
being produced here and are
belong to Tata Motors.
abroad by them were found
France; Italy; Turkey,
Khadi And Silk-Products:
Rover are now brands now
from India that items bought
O.E.s have USA; Germany;
of all brands worth a name are
British made Jaguar and Land
many of the foreign-travelers
becoming popular not only in India but also abroad. So is
this traditional and famous range is India made beer and wine. It has received good recognition abroad. Medical Tourism: India is becoming a hub for medial treatment in its hospitals for people from all countries; also from the West. Its genericcomposition medicines are drawing patients also from abroad, as happened recently with a person from Australia.
the case for silk-products.
The cost for the medicine for
Textiles, Ready-Made
tenth of that in his own land.
Garments, And Woollens: It has been the grouse of
treatment of cancer was one-
Religious Tourism: Buddhist-
Tourism to India is becoming popular amongst countries like China, Japan, and Thailand for visiting all sites related to Buddha. Investment In Infrastructure: India has become the top destination for the manufacturers abroad, those supplying to the Railways; Metro-Trains; Highways; so much so that some of them have started putting their plants in India for greater profits. Make In India: This slogan for manufacturers abroad is also pushing BRAND INDIA The author Mr. Surendra Kumar, graduated in Mechanical Engineering before he was 21, from Roorkee (now IIT). He is one of the founder members of the Indo Italian Chamber of Commerce and Industry in India and has been in its alternative Chairman for North India. In 2007 he was decorated with Knighthood by the President of Italy for this contribution in bringing together the industries of India and Italy. For more details do visit www. precinter.com
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“Focus should be on building Small-Medium Industries”
Ganesh Jivani Managing Director, Matrix Comsec
Ganesh Jivani, Founder and Managing Director, Matrix Comsec Pvt. Ltd not just brought to the table over two decades of technical acumen and expertise, his company has acquired a formidable reputation for bagging numerous awards along with good business. Right from the company’s inception Jivani has been leading Matrix’s Research and Development team with his passion for innovation which has empowered the company to be a leading player in the telecom equipment market. Matrix has also achieved another milestone by successfully foraying into the security domain. Jivani’s astuteness and strategies have been the strong pillars of Matrix success. So much so, that the company is today leader in telecom and security solutions for modern businesses and enterprises. Jivani is a graduate in Computer Science from the Faculty of Technology, M. S. University, Baroda and has successfully completed his management from IIM Ahmedabad. Brief excerpts from the interview MART had with Ganesh Jinvani on Make In India.
The Prime Minister of India announced Make In India last year. What do you think the impact of this mission? Through Make in India initiative, the government plans to build physical infrastructure and digital networks to prepare India as a global hub for manufacturing goods ranging from electronics,
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telecommunications, electrical, defense, automobiles, pharmaceuticals and others. This initiative is nothing less but a giant leap and bound to impact all economic and social aspects of our country. How does your company plan to leverage the current positive sentiment in India? Would you look at expanding
the products you manufacture locally? Expecting favorable conditions for domestic manufacturing, Matrix is focusing on two important initiatives. First, we are working harder to scale up by increasing our business. Second, we are actively developing domestic manufacturers for the parts we
were importing in the past. Our cost and delivery parameters can significantly improve if we replace our imports with indigenized-localized parts. Is the focus on Import substitution or Export promotion? We are focusing on both. For our inputs, we are
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Established in 1991, Matrix is a leader in Telecom and Security solutions for modern businesses and enterprises. An innovative, technology driven and customer focused organization; Matrix is committed to keep pace with the revolutions in the telecom and security industries.
replacing imports with locally manufactured parts wherever possible. On the sales side, we are working harder to increase our exports by developing new markets and improving penetration in the markets we are already present. What are the steps that the government should take to promote manufacturing in India? We have three expectations from the government - worldclass infrastructure, businessfriendly policies and simple yet robust regulations.The government should promote indigenous design by providing more direct and indirect support for DSIR certified R&D centres. I believe the government should not waste money on front-end schemes which are not only difficult to implement but are also misused at times. Instead, government should incentivize actual and real output or performance. This will ensure that Indian R&D is not just on paper but it actually translates into real business. For example, instead of incentivizing projects and investments, government should offer higher incentives for export sales. To promote domestic
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manufacturing, the government should simplify taxation and labour laws and improve infrastructure (electricity, road/ rail/ air connectivity). Further, India should follow the automobile import policy of imposing some nominal uniform duty of 10% on all imports irrespective of category and class. Identical customs duty should apply on raw-material, components, products and equipment to attract all classes of manufacturers to setup plants in India. We need this impetus for about 5 year to build entire eco-system required for worldclass manufacturing. What are your suggestions for better productivity? First, infrastructure is a big reason for lower productivity. How can we talk about productivity without electricity and transportation? Second, ease of doing business. Complex and multiple taxes and paperwork kill productivity and competitiveness. Third important factor is labor laws. How can we improve productivity if a factory shopfloor manager cannot plan his man-power in sync with his orders? Government should allow industry to pursue business objectives freely.
Government should also avoid shifting its social obligations on to the industry. Businesses can run more efficiently and compete at global level when they are not distracted. How can India compete with the global Engineering market? We have real the potential to compete at a global level. In fact, we are already successfully competing in few domains. One thing we need to realize is every country is different in its culture, resources, opportunities, strengths and weaknesses. Therefore, we cannot copy a model from Japan or China and implant it in India. In my understanding, India can be more effective if we focus on building small-medium industries instead of relying only on large industries. What are the challenges that you face on a regular basis while dealing with the government authorities and how can they be eased? We face hurdles in re-importing our own products to offer warranty to our customers on the products sold in the international market.
Do subsidies reach the industry? Yes. We are beneficiary of few schemes including indigenous R&D and for exportsof focused products to focused markets. Which do you think is preferable: concentrating on the SMEs of India or inviting foreign companies to invest in India? Both are necessary. We cannot excel in isolation. I believe Indiaâ&#x20AC;&#x2122;s own industry is driven by SMEs. On the other hand, large foreign companies bring technologies, innovation, know-hows, skills and processes. We should make every effort to invite foreign companies to manufacture in India. The steps government should take to develop entrepreneur skills in young engineers from the academic level? We Indians are inherently very entrepreneurial. From this perspective, entrepreneurship training is not a burning issue or a high priority. Instead, the government should focus on providing conducive atmosphere and make doing business in India as easy as possible.
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CASE STUDY
Small, Lean, and Very Keen Based in the south of Germany, Metallmanufaktur GmbH has come a long way in a short time. From a standing start in 2013, when the company found early business by simply cold-calling potential customers, Metallmanufaktur now serves a variety of different industries. Investing only in Haas CNC machine tools, including automated five-axis and high-speed models, the firm has thrived, and has recently entered an agreement with local Haas Factory Outlet (HFO) Katzenmeier to be a regional Haas showroom.
In 2013, Jochen Schumacher’s dream of running his own business became reality with the establishment of Metallmanufaktur GmbH in Orsingen-Nenzingen, Germany, 130 kilometers south of Stuttgart, close to the Swiss border. Although not an
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obvious location for a machine shop, the company has been able to fill a small but lucrative niche for a reliable, fast, costeffective subcontract machine shop that the area was lacking.
and a Haas UMC-750 five-axis
“We started in 2013 with a Haas VF-2SS Super-Speed CNC vertical machining centre,
department at medical
universal machining centre,” explains Mr. Schumacher, who first heard about Haas in his previous role as head of the mechanical production technology specialists, Leica Biosystems, near Heidelberg.
“Although I never had the opportunity to buy Haas technology during my time at Leica, I always said that if I were to ever start my own business, I was going to do it with Haas machines.” In the very beginning, Mr. Schumacher had to cold-call
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potential customers to secure
expand into a neighbouring
Bernd Katzenmeier, CEO
business for Metallmanufaktur.
building.
of Haas Factory Outlet
He would use the Internet to research trade fair exhibitors whose products and parts might be a good match for his capabilities. Happily, coldcalling is no longer required – new customers now find him, typically through wordof-mouth recommendations. Fresh contacts are added almost every week, which has allowed Metallmanufaktur to
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In early 2015, Metallmanufaktur agreed to become a Haas Factory Outlet (HFO) showroom for regional Haas distributor, Katzenmeier. “There was nowhere south of Stuttgart where it was possible to demonstrate the potential of Haas machines,” says Mr. Schumacher. “So, after discussions with
Sueddeutschland, and Jens Thing, managing director of Haas Automation Europe, it was decided that here would be a good location. We had around 220 people attend the grand opening of the showroom earlier this year: a mixture of existing and potential Haas customers. Of course, having all of those engineering companies come
and see the Haas machines on our premises is also good for us. It’s great networking!” A short time before the grand opening, a second Haas UMC-750 five-axis universal machining centre was acquired by Metallmanufaktur in March 2015, this time fitted with an automated loading system. “The idea was to purchase a machine that could run unsupervised the whole
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day, through the night or at
Metallmanufaktur keeps
The machine’s 12,000-rpm
weekends. It’s difficult to find
demonstration machines on-
spindle and rapid travels
fully trained and qualified
site, including a Haas Super
ensure Metallmanufaktur can
personnel in this area,”
Mini Mill and an ST-20Y CNC
be competitive on all job types.
explains Mr. Schumacher.
turning centre with Y-axis
For example, in early 2015, the
capability.
VF-2SS was used to successfully
Parts produced on this
Although the company
batches of industrial metrology
currently out-sources any
components, and similar
turning operations, the
quantities of parts used on
plan is to bring turning in-
Anything complex is, of
garbage collection trucks –
house. For now, however,
course, assigned to one of the
all loaded automatically and
Metallmanufaktur is focussed
UMC-750 five-axis machines.
completed on the Haas UMC
on prismatic parts, machined
A case-in-point are batches
five-axis machine in a single
from all types of metals and
of 60 aluminium chassis parts
setup. When a part is finished,
plastics. For instance, the
for a German manufacturer
the door opens and a robot
company produces around 180
of workholding and gripping
arm extends inside the working
different components (from
systems. Machined from
envelope before lifting the part
various materials) for special
solid to tight tolerances, each
from its fixture. The gripping
hospital beds designed for
component demands around
device then rotates 180° and
overweight patients.
3½ hours of machining time.
The Haas VF-2SS Super-Speed
To simplify job scheduling
CNC vertical machining centre
and programming, the
owned by Metallmanufaktur
Haas machining centres
also plays an important role.
at Metallmanufaktur are
deposits a fresh blank in its place, before exiting. Chip-tochip time is around 30 seconds. As an HFO regional showroom,
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complete a series of 30,000
machine include 200-off
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relatively simple parts featuring a large number of holes.
configured identically, using zero-point workholding systems, and the same type of cutting tools in corresponding stations in the toolchanger. On average, changeover times at Metallmanufaktur are just 5 to 10 minutes, with parts fully interchangeable between machines. “The moment I differentiate between machines, I lose flexibility,” concludes Mr. Schumacher. “From a process and technical perspective, our operation is nearly perfect now. This is important because, aside from price and delivery, we need to show customers that we have the best offer for all industries; an offer that is based on Haas technology. And just because we are relatively small, doesn’t mean we can’t compete. We’re as lean and competitive as any company.”
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03
1 U0
CIS CISU 01035
5
MAX GR TAPE NET
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CASE STUDY
“It’s a revolutionary product!” claims Unimac following a return on investment of just four months using the new Primo™ twin probe system. The Pune-based Universal Manufacturing Company (Unimac) has consistently reduced inspection time by 90% over four months after installing a Primo™ twin probe system, designed for on machine part setting, part inspection and tool setting. Unimac manufactures components for railway engines, power generation plants, cement manufacturing plants, and other heavy engineering applications. For Unimac, maintaining accuracy of 15-20 microns on large parts is vital.
Samina Khalid Samina.Khalid@renishaw.com
A major challenge for Unimac has been the inspection of large parts during the manufacturing process. According to its Director, Mr Ashok Mungale, “The issue was resolved five months back when Renishaw’s
Primo system was installed on the machine, based on application requirements. The on machine probe is not only easy to use, but performance driven, which has resulted in increased machine utilisation time. Renishaw has truly been
instrumental in our growth by providing an outstanding probing system that helped shorten our cycle time.” Innovative probing The Primo twin probe system consists of a Radio Part
Setter and a Radio 3D Tool Setter. It enables automated on-machine part setting, part inspection and tool setting, helping to eliminate manual setting errors, improve accuracy and part conformance, whilst reducing
“Advantage of the Primo system is that it combines part set up, part inspection and tool setting capabilities in one system so there is no need to source separate items. The Primo system is definitely worth recommending for every engineering industry.” Ashok Mungale Universal Manufacturing Company (Unimac)
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Primo â&#x20AC;&#x201C; twin probe system
non-productive time and scrap. All of which increase productivity, improve quality and boost profits. The Primo system is straightforward to install and use, and represents a low initial financial outlay. It also has an exclusive, enhanced warranty to offer users peace of mind. Up and running in a day
used in railway engines and one-off single components, for its customers. Before the Primo system was installed, the cycle time for machining a turbo charger housing was 46 hours. During this process, at the semi-finished stage, the part would be taken to an inspection facility to be checked for flatness, squareness, parallelism and positional accuracy. The part would then be brought back
It is so easy to use the Primo system that at Unimac its installation and evaluation were completed on the same day. The Primo GoProbe training kit and pocket guide make it very quick to learn and implement the system. A key benefit is that there is no need for extensive G-code knowledge. Simple, single line commands are used instead of multiple lines of code, removing the necessity for any special training. Making a difference Unimac manufactures precision components, such as turbo chargers that are
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to the machine, and have to be realigned and set before further machining could take place. This process would take three hours and have to be carried out twice, meaning that the machine lay idle for six hours during each manufacturing cycle. In this manual process, part setting itself takes 30 minutes.The Primo twin probe system enables inspection to take place on machine, removing the need to breakdown and move the part, and reset it once it has been inspected. Now at Unimac, the new process takes just 30 minutes, has reduced inspection time
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by 90%, reduced cycle time by 12% and led to a very fast return on investment (ROI) in just four months. Optimising throughput Mr Mungale said, “After installing the Primo system, the manpower cost, material handling costs, material equipment and power consumption charges are saved so no additional investment is required. This gives flexibility to the manufacturing unit in accepting orders for any size and for segments such as the machine tool industry. The
manual analysis of results is also avoided, as the data is available on the same controller. It’s an amazing experience to use Renishaw machine tool probes, which are being used by us for the first time.” “Another advantage of the Primo system is that it combines part set up, part inspection and tool setting capabilities in one system so there is no need to source separate items. The Primo system is definitely worth recommending for every engineering industry.”
Building trust Unimac first heard about Renishaw when ten years ago it purchased its CMM, which came fitted with a Renishaw probe. Following this, Unimac formed a relationship with Renishaw, and received regular updates about new product developments. Renishaw engineers analysed all of the machining applications at Unimac thoroughly, and offered best practice advice and guidance on which Renishaw products would be most suitable for Unimac’s needs. The Primo
system is the company’s first machine tool probe. Mr Mungale concluded, “Since we were convinced with the sales, service and application aspects of Renishaw, we installed its telescoping ballbar to help maintain machine accuracy. After this, it was easy to ascertain whether the fault was during machining and the errors could then be eliminated. Results from the ballbar are always perfect so a mutual trust has developed between Renishaw and us”. www.renishaw.com
A Primo system was installed at Unimac five months ago, following a process audit
Amazing 90% reduction in inspection cycle time on turbocharger housing
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CASE STUDY
SPRINT 50 for more Flexible Productivity For several months now three new SPRINT 50 automatic lathes have been fortifying the range of services at Flühs Drehtechnik GmbH in the areas of system technology and precision-part manufacture
Ankur Agarwal ankur.agarwal@dmgmori.com
Flühs Drehtechnik GmbH has been active consistently and exclusively in the fittings sector since 1926. And for the entire 88 years from its site in Lüdenscheid. Initially it operated solely as a toll manufacturer of precision turned parts made of brass, but gradually moved into complete machining and later even started with the development of complete modules and systems. With around 450 employees Flühs today ranks as a leader in all its fields of activity – and with its system developments even as a quality trademark in the
international sanitary industry. Metal cutting always was, is and will always remain the basis of the success of Flühs Drehtechnik GmbH in Lüdenscheid. Every day Flühs machines around 75 tons of brass to produce over a million turned parts. There are countless multi-spindle machines in the production halls used in three-shift operation to accomplish its high-volume business. These are supplemented by any number of single and doublespindle production turning centres used for more flexible
manufacturing orders with volumes ranging from between 10,000 and 20,000 parts. And this is exactly where the three SPRINT 50 machines from DMG MORI have been in operation since the end of last year – each in the version with a main and counter-spindle, TWIN concept, two turrets each with 12 driven tool stations and the TRIFIX® tool clamping system plus two Y-axes for optimising milling options. One of the key arguments mentioned at Flühs for investing in the SPRINTs is first and foremost the TWIN concept
with the cross stroke of the counter-spindle / tailstock combination. After all, this version offers virtually two separate work areas on the main and counter-spindle, which enables collision-free parallel machining even of longer workpieces. Another machining alternative offered by the SPRINT 50 is 4-axis machining using the top and bottom turrets which, claim the people in Lüdenscheid, in interaction with the two Y-axes enables a multitude of complex turn/mill operations.
For almost 90 years Flühs has ranked as an expert in turning technology. Its product portfolio today includes valves and system technology for the sanitary industry.
An extensive high-bay warehouse with 1,400 tons of brass raw material ensures both a high degree of availability and flexibility. Flühs processes 75 tons of the metal a day.
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The TWIN concept of the SPRINT 50 enables collision-free parallel machining on the main and counter-spindle.
In 2013 Flühs invested not in one, but in three SPRINT 50s in order to give a significant boost to flexibility in the manufacture of precision parts with a high level of productivity.
The stability of the machine is another important aspect. Where Flühs was previously limited to the use of smaller tools with their correspondingly longer processing times, wide sectional steels can now be used with the SPRINT 50 thus giving productivity an extra boost. An attribute which of course applies equally to the TRIFIX® quick change tool holders of the two turrets as these come as standard equipment with
the SPRINT 50, they allow tools to be clamped with maximum precision and a repeat accuracy of just a few µm. So the time-consuming procedure of re-adjusting every tool, i.e. having to measure the tool holders with a dial gauge every time and optimising them where necessary, is now a thing of the past for many standard operations thanks to TRIFIX®. Where the demand for precision machining is concerned, here, too, the three SPRINT 50
machines fulfil all expectations, one reason, of course, being their already mentioned stability. In addition the processes benefit from the optimised thermal management of the machines. Both the motor and the spindles are cooled keeping thermallyinduced changes to a minimum.
positive acclaim after their first
In view of the above-mentioned features, functions and machining results, it is little wonder that the three new SPRINT 50 machines received
towards individuality is on the
few months in operation. The more so as Flühs claims the question of flexibility will be given higher priority in the long term, particularly where toll manufacturing is concerned. Because even in the sanitary fittings sector the trend rise, with the result that more diversity is being called for and batch sizes are on the decline.
The stability of the SPRINT 50 allows the uncompromised use of wide sectional steels for more productivity.
The degree of accuracy and complexity of brass workpieces is often very high – an ideal range of parts for the SPRINT 50.
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MART UPDATE
Transducer BTL with real-time Ethernet interfaces The new transducers in rod and profile housings with an Ethernet interface from Balluff offer multiple advantages for machine manufacturers and operators with respect to startup and machine output. The standardized communication protocols and automatic address assignment simplify integration of the transducer into the controller and the plant network. Because of this, a complex programming process is no longer necessary. This leads to a shortened machine startup time, low implementation costs and reduces fault sources simultaneously. The 4 diagnostic LEDs on the sensor head can check both the sensor status and the status of the Ethernet connection. This supports easy maintenance and quick service.
The transducer is ideally suited for use in advanced applications (those involving controlled axes, for example) due to synchronous, extremely fast and secure real-time data transmission and the precise, highly dynamic position measurement with 1 Âľm resolution. This advantage contributes to a higher machine output and improved production quality. The transducers of the BTL7 series can detect and process up to 16 position encoders. Two values can be output for each position encoder: the position and the speed. Because of this, a single measurement can yield up to 32 measured values. Selectable real-time Ethernet interfaces include Profinet IRT, EtherCAT and Varan. The product portfolio includes a total of four designs: the classic
rod housing for installation in the cylinder and three profile versions for flexible mounting on a machine. The profiles are divided into a square 36x36 mm design, an extremely flat profile with an overall height of 21 mm and a round profile 30 mm in diameter. The transducers with real-time Ethernet interfaces can be used in any setting in which high control dynamics and accuracy are required. This includes areas of material processing, the
plastics industry, reshaping technology and the food industry. For more details visit www.balluff.co.in
Kjellberg Expands Smart Focus Series Plasma Cutting up to 100 mm with the Smart Focus 400 One year after the successful launch of the plasma systems Smart Focus 130, 200 and 300, Kjellberg presents a new model of this series at the international trade show Blechexpo in Stuttgart: The Smart Focus 400 with a maximum cutting current of 400 A for material thicknesses up to 100 mm expands the application areas of this reliable plasma series considerably. Since it was launched last year, the Smart Focus series has ensured the best cutting results among users all over the world.
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When cutting electrically conductive materials, the Smart Focus 400 achieves precise cuts and highest cutting speeds while at the same time the costs per cutting metre are low. The results are sharp cut edges and smooth cut surfaces, fine markings and low angular deviations. With the wellproven Contour Cut technology for cutting mild steel the user can cut fine contours and small holes with a material thickness to diameter ratio of 1:1 in highest quality. When planning the new system the requirements of our
customers in all application areas, e.g. 2D plasma cutting, bevel cutting up to 50° or underwater plasma cutting were foremost in our minds: The user-friendly system achieves best results with only a few settings and also under challenging conditions. In Stuttgart, Kjellberg presents the Smart Focus series with the systems Smart Focus 130, 200 and the new model Smart Focus 400. In daily cutting demonstrations, visitors can see for themselves the patented cutting technology Contour Cut - Kjellberg Finsterwalde, hall 5, both 5110
For more details write to www.kjellberg.de
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3
NEC Class 2 Approval for Murrelektronik’s MICO Murrelektronik’s MICO protective modules for UL508A control cabinets are a proven solution for intelligent power distribution and efficient branch circuit’s protection. 8 different MICO modules are now NEC Class 2 approved, so you can efficiently design your power distribution scheme.
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Class 2 Circuits are circuits with limited energy and a maximum power of 100 VA. According to the NEC & UL definition, class 2 circuits limit the risk of electrical fires and electric shocks due to their limited energy. Therefore, according to UL508A standard (for control cabinets), any component used and attached devices on the branch circuit in a Class 2 circuit don’t require investigation. So far, an individual NEC Class 2
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approved power supply was used to create a class 2 circuit and it required a lot of space. This method wasn’t cost effective and caused a lot of wiring and planning effort. With Murrelektronik’s MICO NEC Class 2 approved module, it is now possible to design NEC Class 2 circuits even faster, in a more compact and cost effective way. All you need is a standard power supply unit (that doesn’t necessarily has to be NEC Class 2 approved) combined with MICO to design two, four or eight separate load circuits with limited energy in a simple way. By connecting several MICO modules with the integrated bridging system, the number of channels can be increased up to a total current of 40 A.
SMPS
DC/DC Converter
Water Proof SMPS
Adaptor
3 Phase Transformer
LED Drivers
Components attached to the MICO’s marked NEC Class 2 outputs devices no longer need UL-approval.
supply and limit the operators need to enter the control cabinet.
For more details write to Phase Transformer Charger Solar Lartern MICO’s1proven functions like BatteryTechworks Engineering Pvt channel-specific switch-off in Ltd, Unit 18, The Executive Vihar, Jandli, City (Haryana) India. Tel: +91-171-2801711/3291897 case65,ofLaxmi overload, visual Ambala warning Centre, 11th Floor Canberra, UB Faxerrors : +91-171-2801289 : +91-9416020078/9215720078 notice, storing and the MobileCity #24, Vittal Mallya Road, cascading of the current / naceiamb@gmail.com Email : start nacei@rediffmail.com WebsiteTel: : www.nacei.com Bangalore - 560001 +91 990 paths provide additional benefits 0057344 Email: chetan.t.a@ and enable using a smaller power murrelektronik.in
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Italian Machine Tool Orders: On The Rise In the third quarter 2015, the index of orders for machine tools, processed by the Studies Dept. & Business Culture of UCIMU-SISTEMI PER PRODURRE, reported a 16.3% increase compared with the same period of the previous year. Therefore, there has been an extension to eight consecutive quarters of the positive trend registered by the order index, whose outcome was due to the positive results achieved by the Italian manufacturers both in the domestic and in the foreign markets. In particular, domestic orders grew by 5% in comparison with the period July-September 2014, whereas an even stronger upturn was recorded with regard to foreign orders, increased by 18.5%. The analysis of data, conducted by the method of the “moving average”, - which considers the trend of the last four quarters, thus allowing to reduce the effect of seasonality determined by the different collection of orders in the different quarters,
- is currently showing a value of 130.1 (base 2010=100). Luigi Galdabini, President of UCIMU-SISTEMI PER PRODURRE, asserted: “This last survey has confirmed that the Italian industry of the sector has taken a favourable path, proving to be able to seize the opportunities offered by the recovery of Italian and foreign demand”. “On the other hand, - went on Luigi Galdabini - the success of EMO MILANO 2015, the world exhibition of the sector, promoted by UCIMU, which was on scene in Milan at the beginning of October, is a confirmation of this trend. With over 155,000 visits from 120 countries and 120,000 square meters of net exhibition area, EMO MILANO 2015 will be remembered as a recordbreaking edition, also for the inclination to invest shown by visitors”. “The displayed technology suggests our Government authorities that the intentions of Italian users should be supported by special “ad hoc” actions, since
they are again ready to purchase new production means, as foreign users are”. “In this connection, continued the President of UCIMU - we warmly welcome the provision of super depreciation, which allows 140% depreciation on the value of the purchased asset. This is an excellent reply to the necessity of supporting domestic demand, as this provision, included in the Stability Law, can be applied to all purchases of machine tools and others, made between 15 October 2015 and 31 December 2016, even on lease or according to the procedures provided for by the Sabatini Law”. “Moreover, it is precisely the great effervescence of foreign demand, experienced at EMO MILANO 2015 and confirmed by the last order index that compels us to reason on the evident necessity of encouraging and further stimulating Italian consumption. The modernisation of factories’ machine stock
in our country is actually an essential premise to maintain the competitiveness of Italian manufacturing production against foreign competitors”. “For this reason - concluded Luigi Galdabini - a measure should be implemented to encourage voluntary replacement of obsolete machinery installed in Italy. In this way, the production systems may meet the new requirements of productivity, energy saving and compliance with the current EU regulations on work safety, while ensuring an appropriate competitiveness to the Made in Italy”.
Delcam video from ‘Future of Machining’ event at Mazak now online Delcam has added a video to the Delcam.TV website filmed during two free workshops on the Future of Machining held at Mazak’s European Technology Centre in Worcester during June. To see the video, please go to http://www.delcam.tv/opendaymazak The day included demonstrations of the major developments in the 2016 releases of Delcam’s PowerMILL CAM software for high-speed and five-axis machining and the FeatureCAM feature-based programming system. The
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software demonstrations were followed by live machining demonstrations, with PowerMILL five-axis machining shown on a Mazak Integrex 400 and feature-based machining with FeatureCAM on a Mazak Vertical Center Smart 430A. The PowerMILL demonstration focused on the new Advanced Simulation & Verification modulethat can undertake complete verification of a project for machine-tool issues such as collisions, rather than having to undertake verification of each individual toolpath in turn.
Comprehensive verification is performed, including ensuring that the machine tool is capable of running the proposed strategy, as well as checking for both machine-tool collisions and tooling collisions, during cutting moves and for all leads and links, including machine-tool movements as tool changes are executed. For FeatureCAM, the main focus was on speed, highlighting both the speed with which programming can be completed with the software and the shorter machining times that
are possible with the Vortex high-efficiency area-clearance strategy.
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CNC SSIPL opens New Haas Factory Outlet at Nashik; Record 500 people attend Haas Demo Days in Nashik Haas Factory Outlet – A Division of CNC Servicing & Solutions India Pvt. Ltd. (CNCSSIPL) has opened its new HFO at Nashik Engineering Cluster, MIDC Ambad, Nashik. Mr. Tom Thomas – DGM, Mahindra & Mahindra along with Mr. Gune - CEO, Nashik Engineering Cluster inaugurated the new Haas Factory Outlet at NEC on 15th Oct’15. Facility tours & live cutting demonstrations were among the highlights of a highly successful event which witnessed over 500 visitors in 3 days. Haas Factory Outlet – A
of our attendees were newcomers &a 20% increase in visitors YoY. It highlights the growing importance that this high The infrastructure would be tech, engineering-driven equipped with HAAS CNC city gives to adopting the Vertical Machining Center/Tool latest CNC technology’’ Room Mill, CNC Turning Center says Mr. Ram Kripal Yadav & HAAS Control Simulators – GM, CNC Servicing & CSMD Mill & Turn in order to strengthen the skill development Solutions (I) Pvt. Ltd. & machining services domain Nashik is a rapidly expanding of NEC & for the promotion of industrial hub located products/applications in and around 100 miles northeast around Nashik. of Mumbai. Sectors like Precision engineering, “I am happy to see that 55% Division of CNCSSIPL has tied up with Nashik Engineering Cluster to upgrade quality in the industry.
“An HFO at Nashik was long awaited & we are happy that we will also be engaging in skill development for the people of Nashik in partnership with NEC. We would like to develop an even stronger & more widespread HFO network in India & set it up in all key industrial cities. We do not want our customers to travel more than 100kms to find an HFO. The main idea of an overseas company to have HFOs in India is to present a localized approach.’’ Terrence Miranda Managing Director – Haas Factory Outlet Mumbai
Electrical engineering, Forging, Automobile, Aerospace engineering, General engineering, and Export oriented units are well represented in the area. In addition to VF-2YT & ST-10, visitors were amazed to see ST-10Y too for the DEMO. Like all Haas CNC machines, the VF-2YT, ST-10 and the ST-10Y are built at the company’s one and only factory in California, US. Haas Factory Outlet has a network of local HFOs in India that support all Haas products, each one employing factory-trained engineers and stocking official Haas spare parts.
New heart beating in all NORD inverters In a design change implemented from October 1, 2015, NORD DRIVESYSTEMS will equip all motor-mounted and cabinet-installed frequency inverters with new, more versatile microcontrollers and a new firmware. Notably, this architectural upgrade enables the inverters originally designed for asynchronous motors to also control synchronous motors, which is becoming increasingly important particularly with the advent of IE4 efficiency motors. Highly dynamic drive tasks can now be executed even without encoder feedback. There are substantial benefits: for instance, customers who have been using IE3 motors
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with an encoder can save energy and costs by switching to IE4 motors without an encoder. Moreover, new generation NORD inverters are capable of performing drive-related PLC functions, which can significantly relieve external controllers. In some cases, previously used minicontrollers may even become redundant and be completely omitted. The inverters support the manufacturer-independent PLCopen function blocks for motion control. They can be freely programmed according to IEC 61131-3 in “Structured Text” or “Instruction List”. This makes application development less complex and
The upgraded inverter generation is an in-house development by NORD’s electronics branch in Aurich, Northern Germany, were every single unit is tested prior to delivery reduces the associated costs. Customer-specific drive-related functions can be implemented by means of the inverter PLC without an application-specific firmware and free from cost-
intensive verification and validation. For more details visit www.nord.com
November 2015
Milling stainless steel? Look to Pramet A completely new range of cutters and inserts for economical face milling of stainless steel form part of a launch of products by Pramet. The versatile range includes OEHT octagonal inserts for cutting depths 4 – 10 mm, alongside REHT (round) and XEHT (wiper) inserts. By utilising eight cutting edges – the highest number available for positive inserts – the new range provides an economical offer for customers, while the wiper insert option boosts feed rate capabilities and surface finish quality. Pramet’s new double positive 45° milling cutter, S45OE, is available in diameters up to 200mm and supports internal coolant delivery. Its versatile design allows the same cutter body to be used with both the octagonal inserts for face
November 2015
Pramet’s OEHT octagonal inserts. milling and the round inserts for face and copy milling applications. Suitable for use even on machines with limited power, the combination of new inserts and cutter offer high metal removal rates with low cutting force. The risk of chatter is also reduced – an important consideration when machining valuable components.
For use with the OEHT inserts, three new positive geometries – MF, MM and M – have been introduced for various cutting conditions. The MF is a sharp and highly positive geometry for finishing applications in stainless steel, mild carbon steel and non-ferrous metals. MM is a sharp and positive geometry for machining stainless steel in medium cutting conditions.
The M is a positive geometry with stabiliser - suitable for difficult cutting conditions in materials such as carbon steels and harder stainless steel. The new geometries offer reduced cutting forces and increased durability for machining with or without coolant. To download a pdf version of the brochure visit www.dormerpramet.com.
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New ways to interconnect the PROFI-world Automation engineers frequently need to bridge the gap between different protocols and networks used in a plant, but they also need to enable communication between equipment within the same network family. For example, in the PROFINET and PROFIBUS-world, there are many devices and sub-systems that cannot necessarily communicate with each other. It may be necessary to connect different physical formats such as copper and fiber optics or couple/ de-couple I/O data between two controlling networks. With their recently upgraded Anybus X-gateways, HMS Industrial Networks can offer ways to get heterogeneous PROFI-equipment connected. “According to our latest market research, PROFINET and PROFIBUS are two of the most dominant networks on the global market today,” says Markus Bladh, Product Manager for gateways at HMS Industrial Networks. “So naturally, we get a lot of requests for connectivity to the PROFI-world, but we also get requests for connectivity within these networks. Although our Anybus gateways are mostly known for interconnecting all types of networks, it is
really interesting to see the attention Anybus X-gateways get as a cost-efficient way to connect different physical formats and standards within the PROFI-world. This enables system integrators and factory owners to connect otherwise incompatible devices and systems.” Here are a few examples of how Anybus gateways can solve connectivity issues within PROFINET and PROFIBUS.
Anybus X-gateway
1. Coupling a PROFINET IRT machine with a controlling PLC
become galvanically and logically
Many factories need to couple or de-couple I/O data between two controlling PROFINET IRT networks – for example between two segments in a factory. The Anybus X-gateway can act as a PROFINET/ PROFINET coupler enabling fast transfer of I/O data. The PROFINET interface works as an I/O-Device on the PROFINET I/O or IRT network.
3. Coupling PROFINET I/O
2. Coupling PROFIBUS networks
PROFINET FO is especially
Coupling or de-coupling of I/O data between two controlling PROFIBUS networks are other common tasks for the Anybus X-gateway. This functionality is often called DP/DP coupling. The two PROFIBUS networks
isolated from each other.
networks It is also possible to couple or de-couple I/O data between two controlling PROFINET I/O networks. A well-known name for this functionality is PN/PN coupling. 4. Connecting a fiber optic network to a copper network
popular in the German automotive industry. However, many machines and systems do not come with fiber optic connectivity. Anybus X-gateway can act as a coupler between the two network versions, enabling them to communicate.
“Trends such as the Industrial Internet of Things and Industry 4.0 require more and more industrial machines to become networked and this also requires more connectivity within the different network worlds. With the Anybus X-gateway product range, HMS offers an easy and cost-effective way to get connectivity between different devices and networks within the PROFI-world.” Markus Bladh Product Manager, Gateways
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5. Migration from PROFIBUS to PROFINET Many factories have wellfunctioning PROFIBUS networks, either as their main factory network or as subsystems within the factory. However, there is often a need to install devices or systems which run PROFINET. With an Anybus X-gateway, this switch is easily done. The X-gateway acts as translator between the two networks and can be installed within minutes – a very fast way to migrate from fieldbus to industrial Ethernet. End users will be able to reuse and connect well-working existing equipment to new high-performing automation systems. “We see both fieldbuses and industrial Ethernet networks increasing at the moment,” says Markus Bladh. For more details write to HMS Industrial Networks India Private Ltd, “Corporate Plaza”, Unit 1A & 1B, Ground Floor, Senapati Bapat Road, Near Chaturshrungi Temple, Pune – 411016 Tel: +91 20 2563 0211 Email: in-sales@hms.se
November 2015
November 2015
Innovative Automation Products
B/24, MIDC Satara 415004 India
+91 2162 246509 +91 2162 245966 sales@innovativedro.com www.martupdate.com 87
LASELEC: At the forefront of performance for automated cable processing equipment LASELEC, the world-renowned French expert in the field of lasers, manufactures high quality machines that are used in very demanding industrial sectors such as: aeronautics, aerospace, rail, automotive, energy, medical, and polymers.The company will be presentingits new products and solutions at the Productronica trade show in Hall B2 – booth #326 on November 10-13, 2015. The brand new system, RapidShare, demonstrates full automation for the postprocessing of wires. It is a modular and flexible solution where workstations for postprocessing such as sorting, labeling, kitting, storage, etc. – adjust themselves according to the user’s needs. Coupled with the ULYS Modena laser wire marker that cuts and marks the wire, the RapidShare robot offers advanced grouping and sorting capabilities for cables to speed up the production of electrical wire harnesses. Laselec is well established in the aerospace industry. Their laser wire marking machines, the ULYS Modena(http://www.
laselec.com/en/range/ulys-slmodena/),the MRO200 Series http://www.laselec.com/en/ range/mro-200-line/) and their laser wire stripper, SYLADE (http://www.laselec.com/ en/product/sylade-7-2/), are predominantly used worldwide by aircraft manufacturers, their subcontractors and maintenance centers. Additionally, the interactive wiring table, EASYWIRING (http://www.laselec.com/en/ product/easywiring-line/), is increasingly being utilized in the railway and automotive wiring shops that want to modernize their production methods. Also too, LASELEC has just launched its new braiding machine. The BRAIDO machine provides the perfect solution to the demanding production requirements of electromagnetic shields and mechanical protection for electrical harnesses. The quality and precision of the braid are guaranteed by the machine’s software which also ensures the complete traceability of your operations.
The software, developed by LASELEC, offers many functions allowing a significant increase of productivity. BRAIDO customers especially appreciate the simplicity of the braiding operation as well as the machine’s impressive speed and impeccable production quality. Moreover, by networking different BRAIDO machines, the user can begin braiding on one machine and transfer the job to another machine, while maintaining the continuity of the traceability data.
processing equipment and has a solid reputation in the design and manufacture of laser systems. The Laselec UV laser wire markers have been widely adopted by the harness manufacturing industry. By marking the wire directly, as compared to heat shrinkable sleeving that must be manually attached to each wire, wire shops equipped with Laselec UV laser wire markers can considerably reduce their production times by 20 to 40 percent.
Laselec thus specializes in high-performance wire
For more details visit www.laselec.com
Pyrotech’s Energy Saving LED CFL Retrofit Pyrotech offers Energy Saving LED CFL Retrofit for Office Lightning & Retail Store Display applications as per industry standards with optimum thermal management & highly efficient constant current driver having short circuit & open circuit protection
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in aluminum housing. With these lights you can save upto 80% power over CFL The Salient features of CFL Retrofi are upto 80% Power Saving, 110- 270V AC, No UV or IR Radiatio, P.F >0.9, 2 pin Type and PL Replacement. These are manufactured
in-house using latest machinery. The manufacturing facilities available are: SMT Line for electronic driver assembly, Powder Coating Booth and CNC/ LATHE Machines. For more visit www.pyrotechlighting.com
November 2015
Athlonix 22DCP Brush DC Motors deliver speed-to-torque performance in a cost-efficient package Portescap introduces the next generation of Athlonix™ high power density brush DC motors. Athlonix DCP motors offer an optimized price-to-performance solution ideal for a broad spectrum of applications. Available in a 22mm diameter, the new 22DCP motor will feature an energy efficient coreless design with an optimized selfsupporting coil and magnetic circuit, which ensures optimum price to performance ratio is delivered. Athlonix 22DCP motors are available in 2 variations, precious metal commutation and graphite commutation with Alnico magnet inside. The unique constant force spring design for carbon
brush ensures consistent performance. An REE (Restriction of Electro Erosion) coil is an available option, which ensures extended life of the motor. With maximum continuous torque up to 6.5 mNm and higher stall torque than similar comparative motors. Athlonix 22DCP motors are ideally suited for use in applications such as medical & industrial pumps, gas analyzers and security & access and power tools. “Athlonix motors are powered by a proprietary self-supporting coil resulting into maximized magnetic flux and ampere-turns for a given diameter” says Sunil Kumar, Brush DC Product Line Manager at Portescap.
“In contrast, typical selfsupporting coils have inherent ampere-turns limitations that affect the magnetic flux density in the magnetic circuit, which further limits power output and endurance of the motor,” he says. Component standardization and design modularity ensures quick customization capability for samples across various applications. Standard configurations can be delivered with maximum one week leadtime
are manufactured in an ISO certified facility, and are RoHS compliant.
Athlonix motors are compatible with encoders and gearheads of various sizes and ratios and are also available on our online motor configurator MotionCompass™. They
For more details write to Portescap, Unit No. 2, SDF-1, SEEPZ-SEZ, Andheri East, Mumbai - 400 096 Tel: +91 22 4200 6200 Email: sales.asia@ portescap.com
C-Tech bags Star Performer Award Pune based C-Tech Engineers Pvt Ltd bagged Star Performer Award for regional exports given by Engineering Export Promotion Council under the category of Machinery for Mining, Quarrying & Construction & Parts, Small Enterprises. CTech is consistently winning this award for the last eight years. Satish Mutha, Director, CTech Engineers received the award from Suresh Prabhu,
Honourable Union Minister of Railways, Govt of India during the presentation ceremony held at Hotel Taj President, Mumbai on 29th September 2015. C-Tech Engineers was formed by experienced Technocrats in 2001 with an objective of achieving customer satisfaction by developing & supplying quality precision components for global market. After delivering to various OEM’s in
“This award we are getting 8th times in row from 200506 and no doubt this is the result of our team work. All our export data HS code wise is with Engineering Export Promotion Council, and they declare these awards every year.” Avinash Chabukswar Director, C-Tech Engineers Pvt Ltd
November 2015
Europe, USA & Australia in the field of Construction Machinery, Excavators, Automobile & General Engineering Companies, they established their brand in domestic market by competitive cost, technological expertise,
timely delivery & quality product.
“Having had a very humble beginning and gone through tough times, we regard every such win as a very important milestone in our company’s life. We would like to express sincere gratitude to EEPC and Award Committe for selecting us”
Satish D Mutha Director, C-Tech Engineers Pvt Ltd
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Grooving and Cut-Off Made easy -- Beyond Evolution™ Game-changing design brings true ease of use, notably fewer components, and high performance in multiple applications. In a manufacturing world of growing complexity, a straightforward solution that works excellently and saves money can be a breath of fresh air. In grooving and cutoff, Beyond Evolution™ from Kennametal is that solution. “What would it take to launch the world’s best grooving and cutoff system?” asks
Kennametal senior product manager Mark Filosemi. “We began with the expected -- longer tool life and higher cutting speed. But our customers added something different. They wanted simple. That was it. They wanted to stop leafing through hundreds of pages of catalogs and thousands of items because it was difficult, time-consuming, and expensive.” Easy to choose, easy to use became the foundation of Beyond Evolution’s development. The goal to offer a system that was less complicated to navigate and select, complimented by an equally simple approach to using it. “But we didn’t stop there,” Filosemi adds. In developing Beyond Evolution, the team questioned every detail to enhance our customer’s experience. With deep design and innovative engineering experience, Kennametal pioneered the most versatile high-performance platform to enter the market.
Coolant is directed precisely to the cutting edges underneath the chip, dissipating heat and extending tool life.
Proprietary Triple V Beyond Evolution is a singlesided grooving and cutoff system for deeper grooving capability than double-ended systems. A proprietary “Triple V” design with top, bottom, and backside V-shaped seating in the holder pocket creates a pull-in effect for exceptionally high stability for deep grooving, face grooving, side turning, and profiling, among other applications. The results:
Beyond Evolution will groove deeper than doubleThe proprietary Triple V design provides ended systems, turn with high side load stability comparable to 90% of the stability and longer double ended inserts. allow interchangeability
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regardless of geometry or application. It offers tighter indexing tolerances, longer cutting depths, and new plunge and turn geometries One platform that does it all. Cut-off, grooving, deep The most grooving, face grooving, side turning, visible result of Beyond and profiling applications. Evolution’s “one system for all applications” design is the most requested – fewer items, up to 35% compared to competitors. This makes Beyond Evolution easy to choose in addition to easy to use, reducing or requesting a print copy, visit inventory and expenses. And www.kennametal.com. where conventional product Moreover, Beyond Evolution launches focus on a single line is available through NOVO™, item, Beyond Evolution will be Kennametal’s digital process launched in multiple grades for knowledge application. dozens of applications – a full line offering that promises higher With powerful process knowledge available on iPad™ performance and reduced costs and other digital devices, immediately. NOVO helps users define Innovations 2016 and NOVO machining features, such as profiling or grooving in Whether you’re digitally native specific work materials, and or prefer print, much more then immediately reduces information, including grade the product set to those like descriptions, feed and speed Beyond Evolution that can do recommendations, and full the job. This provides far more ordering information is available useful process knowledge than in the new Innovations 2016 any online catalog alone, all catalog from Kennametal – an obtained in a fraction of the invaluable resource for the latest time. advances across the entire range of Kennametal applications. For For more details visit downloading the digital version www.kennametal.com
November 2015
Philip Harting succeeds his father as Chairman of the HARTING Technology Group After almost 50 years in the management of the HARTING Technology Group, Dietmar Harting (Dr.-Ing.E.h.) handed over the position of Chairman of the Board to his son Philip Harting on 1 October 2015. Dietmar Harting nevertheless remains a member of the company group’s Board as personally liable partner and will focus on matters concerning “the future and new technologies”. Together with his sister Maresa Harting-Hertz, President Finance and Purchasing, Philip Harting represents the 3rd generation of the family-owned company which was founded 70 years ago by his grandparents Wilhelm and Marie Harting in Minden. The company group has been headquartered in Espelkamp
November 2015
since the early 1950s. “I am very delighted, together with my sister and supported by my parents and fellow Board members, to continue my father’s successful work,” says Philip Harting.
partner of the company group at the end of 2013.
“Handing over the baton to my son is a major step in Philip Harting (left) with his father Dietmar Harting, After completing an electrical the successful Margrit Harting, Senior Vice President and Partner, and generational engineering apprenticeship, Maresa Harting-Hertz (right), Senior Vice President transition. Philip Harting studied electrical Finance and Purchasing as well as President and General With the new engineering in Braunschweig Partner, in the second and third generation. management and business administration in line-up we have Cologne. In 2005, he assumed a set the course position of responsibility at his for the company’s successful company in 1967 and managed parents’ company for the first future development,” explains it together with his mother time as Managing Director Asia in Dietmar Harting. until 1987. After her death, he Hong Kong. He has been head of headed the company together the company’s largest Business The entrepreneur and Honorary with his wife Margrit, turning it Unit “Connectivity & Networks” President of the German into a market and technology since 2008. He and his sister Electrical and Electronic leader in industrial connection Maresa were also appointed to Manufacturers’ Association technology. the position of personally liable (ZVEI) joined his parents’
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Bonfiglioli new focus on the Marine and Offshore market With its comprehensive product range, Bonfiglioli is a one-stop provider of cuttingedge marine and offshore gear solutions that come with the highest certifications and offer unparalleled reliability for harsh marine environments. The company offers diverse solutions for lifting, pulling and slewing machinery for marine and offshore applications like shipboard cranes, offshore cranes, deck machinery, azimuth thrusters and pipe layers. Products include planetary gearboxes, bevel helical and parallel shaft gearboxes, electric motors and frequency controllers. They have been assessed by major Classification Societies like ABS, DNV, LR and can be delivered with a 3.2 Certification in all major Classes and are classed with full traceability of the load carrying components. Bonfiglioli has also developed a specific range of gearboxes for jacking machinery with rack and pinion design, intended for jack-up drilling rigs, service liftboats, accommodation and windmill installation vessels. Solutions for Shipboard Cranes Winch gears and slewing gears are offered by Bonfiglioli for marine cranes such as cargo cranes, utility cranes, hose handling cranes, etc.
Bonfiglioli´s Trasmital 700 series with hydraulic drive is a standout in the company´s portfolio of mobile machinery. The plug-in 700C design is compact and light with gear train integrated into the winch drum. The brake can be integrated inside the gearbox or mounted externally, with common lubrication of the gears. Compact electricdriven variations have been developed as well. Solutions for Deck Machinery Several applications like mooring & tugger winches, anchor handling systems, traction & storage winches, capstans and windlasses offer a bench test for the 700C series in medium-light power cases, and HDP/HDO series in medium-high power cases. The 300 series and 700T series are used for pinion ring transmission systems.
The winch drum is generally supported on the opposite side of the gearbox, but strong bearings in the 700C series enables it to have a console setup as well. Hydraulic and electric driven variations, as well as in-line or right angled configurations, are available throughout the Bonfiglioli range. Solutions for Offshore Cranes & Winches Oil and gas applications like cranes and winches for supply vessels (PSV, OSV), FPSO, drilling rigs, anchor handling sytems, riser pull-in systems, turret winches, ROV winches with AHC function and A&R systems have bigger demands for power. Bonfiglioli products for winches are often designed with multiple pinions to drive a toothed ring fixed to the drum. The trasmital series 700T responds very well, with the same versatility of the shipboard cranes. Solutions for Azimuth Thrusters Bonfiglioli gears are used for steering the azimuth thrusters on tug boats, drilling rigs and cruise vessels. Gear and bearings life is calculated based on Class requirements for both dynamic positioning mode as well as cruise mode operation. Solutions
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are available with integrated pinion 700T Series and 3.2 Class certified pinion and 300 series with female spline connection to the steering block. Solutions for Jacking Machinery For many years, Bonfiglioli has been developing and supplying gearboxes for jacking machinery for offshore platforms. The customized design of the 700T and 300 series have been assessed by ABS to work in lifting and lowering legs and hulls of drilling and service jack up rigs, lift boats and windmill installation vessels. Solutions for Pipelayers Bonfiglioli track gears of the 700C series represent a perfect solution for the most demanding pipe tensioners in terms of torque, life and power. The cooling system is provided with forced lubrication of the gear train and bearings. A torque range up to 600 kNm covers almost all known applications. Modular gearboxes of the 300 series are capable of torque up to 2000 kNm. For more details visit www.bonfiglioli.com
November 2015
November 2015
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Top Cut 4 Indexable Holemaking Platform from WIDIA: One High-Performance Tool Series for Many Applications The new Top Cut 4 indexable
platform from WIDIA™. A true
high-speed
drilling platform from WIDIA
multi-problem-solver in one
applications,
is targeted to end users that
platform, Top Cut 4 is targeted
high
machine a broad assortment
to end users that need one
toughness
of products and need one
drill that can be applied in a
demands,
drill for a variety of drilling
variety of drilling applications
and high
applications and workpiece
and different workpiece
metal-
materials.
materials. Top Cut 4’s breadth
removal rates
of application capabilities
in general.
include through- and cross-
Specific
holes, inclined entry and exit
geometries
opportunity, 45º corner, half-
are available
cylindrical, concave, and chain
with such
drilling. And four true cutting
features as
edges combined with WIDIA-
reinforced
grade technology results in
cutting edges
notably higher speeds and
and a steep
feeds, higher metal-removal
chipbreaker
Expanded capabilities and improved performance combine for outstanding results in the new Top Cut 4™ indexable holemaking
rates, and extended
for steel,
tool life, all of
cast iron,
which means
chipping
per edge.
materials, or
Top Cut 4 periphery and center inserts
Robust cutter bodies are marked by deep helix angled flutes for efficient chip evacuation even at 5XD length.
Large coolant holes mean efficient coolant delivery and extended insert life.
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and short-
lower cost
each feature
an optimized chip groove for stainless steel, long-
Top Cut 4 users need only one drill platform for a wide range of jobs.
chipping steels, and where low power consumption is required.
angled flutes for efficient
cutting
In addition, Top Cut 4 is
length. Large coolant holes
profiles for
featuring high-stability shanks
mean efficient coolant delivery
excellent
in lengths of 2XD, 3XD, 4XD,
and extended insert life.
centering
and 5XD, in both metric
capability and
and inch configurations.
workpiece
Diameter ranges from 12 to
penetration.
68 mm (0.473 to 2.5 inches).
The inner and
Eight insert sizes cover the
outer (center
complete diameter range. The
and periphery)
cutting edge profile of the
inserts
central and periphery inserts
are clearly
works together, leading to
differentiated
high stabilization of the drill,
for no
preventing tool drifting even
mixups, and
on irregular surfaces.
fraction of the time.
Robust cutter bodies are
For more details visit
proprietary
are available in grades for
marked by deep helix
chip evacuation even at 5XD
Moreover, Top Cut 4 is available through NOVO™, WIDIA’s digital process knowledge application. With powerful process knowledge available on iPad™ and other digital devices, NOVO provides far more useful process knowledge than any online catalog alone, all obtained in a
www.widia.com
November 2015
Red Lion Commits to Bring Clarity to IIoT Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced a new initiative dedicated to helping customers realize the promise of the Industrial Internet of Things (IIoT). A new Red Lion facility in St. Louis, the IIoT Innovation Center, will drive the effort througha focused engineering, product and sales team dedicated to building on Red Lion’s existing IIoT expertise. Many customers and partnerstoday rely on Red Lion to meet IIoT requirementsbyusing industrial automation and networking products to: • Extend equipment lifespan: increase the value oflegacy equipment with powerful protocol conversion • Improve process visibility:gain insight and drive productivity with data logging and communication capabilities • Push control to the edge:scale systems management with control capabilities at the device instead of the central office Specifically, Red Lion’s RAM® 4G LTE cellular RTUs provide a secure all-in-one platform that seamlessly integrates with existing equipment to enable critical remote monitoring and control. In addition, to fulfill the need of organizations to connect disparate systems and enable communications across devices from different manufacturers, Red Lion’sData Station Plus and Graphite®HMI enable protocol conversion for information sharing. Red Lion’s new IIoT Innovation Center will not only work to enhance these products, but also develop new solutions for M2M and human-to-device communication.To help drive these efforts, the following executives will lead Red Lion’s
November 2015
IIoT-focused team: •Brian Rosema, Director of IIoT Strategy – Brian has an executivelevel background and over a decade of experience in wireless data, M2M, cloud computing and wireless network architectures. He has directed sales, business development, marketing and strategic alliances in a variety of roles with Red Lion, Protect Cell, Digital Highway Inc., Red Leaf Consulting Group, Invoice Insight and Oreon, Inc. He has a BA in Business Administration from Hope College. • Steve Gallagher, Vice President of IIoT Sales – Steve is a sales professional with 25 years’ experience delivering growth and leadership in M2M, wireless device and technology, manufacturing and industrial automation. He came to Red Lion through the acquisition of Sixnetin 2011, where he served as Vice President of Sales, North America. Previously he held positions at BlueTree Wireless Data, Red-M and Motorola. He has a BA in Business Administration and Commercial Studies from the University of Western Ontario, and a Diploma in Marketing Management from Centennial College. • Timothy Burgener, Director of Planning and Software Engineering – With 18 years’ networking experience and 13 years in cellular data communications, Tim brings deep engineering and technical knowledge to Red Lion. Previously a director and software engineering manager at Sixnet, he also spent 10 years as a senior software architect at JBM Electronics, Inc. He has a MS in Electrical Engineering and Computer Engineering and a BS in computer science and math, both from Southern Illinois University. For more information,visit www.redlion.net/connect.
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February 2014 November November 2015
THE LAST LEAF Dear Readers, Most of us carry a pernicious idea that makes us believe that economy is a mechanism like an automobile, although it is not. It cannot be manipulated or guided (by the government) - on the contrary, economy are a collection of individuals, working together in organisations, small and big, to enable turning out products and services. As a part of this process, new businesses open while some close, more jobs are created, and eventually an ecosystem is evolved that facilitates improvement of the quality of our life. The government of each country can definitely have a role to play in influencing this ecosystem, through appropriate taxation, monetary policies and regulation. (Courtesy : Forbes.com) The ‘Make in India’ campaign launched by Modi government in India, is one of the best such examples. Within a year of its launch, this initiative has helped India to register upto 48% growth in foreign direct investment in a climate of contracting worldwide investment. Foxconn, the manufacturer of Apple’s iPhones has announced plans for creating 10-12 facilities in India, which will include factories and data centers. Foxconn expects to sign the first contract by the end of 2015. The advantages of the arrival of a big company to the country can be manifold. Foxconn’s arrival can trigger the arrival of companies along its supply chain and also help to multiply the indirect jobs created due to this. Japan’s Suzuki, which controls 56% stake in Maruti, has decided to make India a global manufacturing hub for its upcoming premium compact car ‘Baleno’, which will be exported to over 100 countries, including the Western European nations. “India is the South Asian economy recording the biggest increase in the distance to frontier score since 2004,” the World Bank report said in context of “Ease of doing business” ranking, taking note of the fact that the country has cut down days take to start business. The latest number of days is 29. India is all set to produce the world’s largest number of engineers. The first ever global report commissioned by the Queen Elizabeth Prize for Engineering has revealed that while just 20% of 16 to 17 year-olds from the UK and 30% from the USA are interested in an engineering career, in India the rate is as high as 80% - the highest in the world. Showcasing its responsibility on environment friendliness, Apple – the world’s most valuable company – is now working on producing 2.2 gigawatts of solar power and other renewable energy at its China plant. Apple will install panels that will generate 200 megawatts of solar power in various regions of China, where its suppliers are located. It estimates 20 million metric tons of greenhouse gas pollution to be avoided by 2020, as a result of this effort. That’s like having four million fewer cars on the road for a year. Foxconn, which is the main producer of iPhones in China, is pledging to contribute 400 megawatts of solar power. Google, Facebook and other technology companies also have been investing heavily in renewable energy in an effort to cut the pollution. (Courtesy : ougur.com) We need your input on any industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our readers about a better tomorrow. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board
November 2015
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Since its inception in 1983, Electrotherm India Ltd., through its progressive and competency backed approach, has become the only company with indigenously developed world-class technologies, for the engineering metal melting industry. Electrotherm's customer centric working philosophy, backed by sound understanding of the industry's need, has enabled the company to provide customized engineering and metallurgical solutions, which are assets for continued growth and success. |Induction Melting Furnaces | Electric Arc Furnaces | Electrotherm Rening Furnaces (ERF) |Metal Rening Konverters (MRK) | High Speed Continuous Casting Machines | Coal based Rotary Kiln (Sponge Iron) Plant | Coal based Tunnel Kiln (Sponge Iron) Plant | Turnkey Projects for steel melt shop for producing billets / ingots|Turnkey Projects for Integrated Plant through DRI – SMS route |Plant design and engineering| Plant Automation |Product Improvement Equipment (PIE) for improving plant productivity, end product's quality and plant efciency.
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ELECTROTHERM (INDIA) LTD. 72 Palodia, Via Thaltej, Ahmedabad-382115, Gujarat, India Phone: +91-2717-660550 Email: mkt@electrotherm.com Website: www.etenp.com / www.electrotherm.com
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Kemppi India Private Limited Lakshmi Towers, 2/770, Kazura Garden, 1st Street, Neelankarai, Chennai - 600 041 Phone: 044-45671200 Email: sales.india@kemppi.com Web: www.kemppi.com www.martupdate.com
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