Volume 11 Issue 4 October 2014 Pages 52 `100
First Metal 3D Printed Bicycle Frame
by Renishaw
Possibilities with 3D Data Processing AM in finished part quality VO™ RP and AM with Big Data Analytics Having It all
The Choice Is Yours • The Power of Influence • Effective Supply Chain Management • A Gateway To Achieve Excellence In Quality•
October 2014
Specially-Crafted Feature Areas at MTA2015 • www.martupdate.com 1
2
www.martupdate.com
October 2014
100 %
KSP plus
clamping force block
control
© 2014 SCHUNK GmbH & Co. KG
300
NSR Robot Coupling kg load bearing capacity
NSA
100
Automated Palletizing System
kN Holding Force
Your automated machine loading. It’s time to use your machine’s full potential. www.in.schunk.com/machine-potential Jens Lehmann, German goalkeeper legend, brand ambassador of SCHUNK, the family-owned company, since 2012
October 2014
www.martupdate.com
3
4
www.martupdate.com
October 2014
The word “Anthropocene” was found interesting to me while going through one of my recent daily regular news bites time, the article pointed out the self destructive measures which human’s care is causing to Earth. Further googling, I found out that we are living in a Anthropocene era - as per a lot of growing scientists is changing Earth’s life support system. If we don’t change the way we live, the humans, like the dinosaurs will be destroying their own survival along with the whole life support system in our planet.
Foreword
Dear Readers,
Anthropocene, an informal geologic chronological term, was in use since it was first coined in1960’s by Russian scientists, popularized mainly during the end of the 20th century with Nobel Prize winning atmospheric chemist, Paul Crutzen who claimed that human’s behavior influences Earth’s atmosphere constituting a new geological epoch in its crust – the outermost shell of our planet. Today, the term derived from Greek roots - Anthropo meaning human and cene meaning new, have more significance as we created a new planet system, with our selfish approach for comfortable living that resulted in the extinction of several living beings. This change happened from time to time, with our changing behavior. The behavior of a person is critical in the world to create examples for both good and bad. From Socrates, Einstein, Mahatma Gandhi, Nelson Mandela, Malala to Nero, Hitler, Mussolini, Laden who were critical at different periods in bringing changes to the world by their behavior which in turn changed our lives. We always talk about possessing positive attitude in our life, and our attitudes come from our constant behavior. To change our attitude is the only way to bring steady and
“The Behaviour is what makes the Person you want to be. The Choice is Yours.” – From this edition of MART we are starting a column for the next one year on Behavioural Science and its impact on managing self as well as others’ behaviours and its impact on an individual’s personal and professional life. A coach and mentor in
Hari Shanker Managing Editor
constant change in our behavior.
Neuro Linguistic Programming Technology, Reena Jabran pens down this column which will definitely inspire our readers towards a positive note. A psychology student Reena heads “Jayakartha” – enablers of Personal and Organizational Excellence through behavioural and attitude changes. In this edition of MART we are featuring latest technologies available in Additive Manufacturing along with our regular columns on Quality, Manufacturing Excellence – Managing SMEs, Talent Management, Mart Updates, Technical Features and Fair Update for your monthly industry digest. With new vibrancies in the industry with aggressive manufacturing ventures like Make in India, we are optimistic of providing quality support to the Indian industry. Gearing up to the challenge is only possible by your feedbacks, so do write to us. Signing Off, October 2014
www.martupdate.com
5
Cover Story 8
Scan Anything from Foods to Factories:Explore the Possibilities with 3D Data Processing
12 First metal 3D printed bicycle frame manufactured by Renishaw for Empire Cycles
14 Rapid Prototyping and Additive Manufacturing with Big Data Analytics
18 Having it All 20 Additive manufacturing in
finished part quality VO™
Columns The Choice Is Yours !
22
Reena Jabran
The Power of Influence
24
Pavan Sriram
Effective Supply Chain Management
26
P S Satish
28
Internal Audits: A Gateway To Achieve Excellence In Quality Nikhilesh Mathur
Best Practices in Secondary Manufacturing Process
30
Ujwal Uday Kumar
Volume Issue412October June 2014 Volume 10 11 Issue 2014 Annual Annual Subscription Subscription `1200 `1200 Member Member INS 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
313, Dorikal Byelane, Jheel Avenue, Dum Dum Road, Kolkata - 700 041, India. Tel: +91 33 2560 4052
Mob: +91 9038000711 Email: info@martinfotech.in Visit www.martupdate.com
6
www.martupdate.com
Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2n Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed October 2014 Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every eff employees accept any responsibilities for any errors or omissions. © All Rights Reserved
34
Case Study
36
Fair Mart
38
Mart Update
49
The Last Leaf
Managing Editor Hari Shanker hari@martinfotech.in Editorial Team Editorial Assistant Anupurba Maulik editor@martinfotech.in +91 9038 002340 Creative Assistant Sayan Chaudhari martcreative@gmail.com Circulation & Subscription Circulation Manager Benoy Syam Krishna cm@martinfotech.in +91 9947733339
Advertisement Asst Manager Ahmedabad Bangalore
Debjani Mallick Biswas +91 9038 005670 Narendra Vora +91 8734999636 Sumithra Krishnaswamy +91 9845388869
Chennai
Subramaniam V +91 93827 48296
Delhi
C R Sathyanunni +91 9910727307
Mumbai
K Ravindranath +919820417240
nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, d in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 October 2014 ffort has been made to ensure the accuracy of the information published in this edition, neither the Publisher no any of its
www.martupdate.com
7
ADDITIVE MANUFACTURING
Scan Anything from Foods to Factories: Explore the Possibilities with 3D Data Processing As globalization advanced, mold fabrication methods shifted from manual to a greater reliance on machine fabrication, using computer-aided design (CAD) data. This influenced Ueno Kigata Seisakusyo in its decision to introduce a system to acquire and transform 3D data into CAD models for mold fabrication. In 2008, they invested in a FaroArm, a 3D measurement device in the form of an articulated arm, equipped with non-contact scanning capabilities. The device allowed the team to inspect tools and models, as well as to generate CAD data for products that it did not have drawings of.
Have you ever thought of creating a life-like copy or a miniature of your favorite foods and stuffed animals by scanning and digitizing them? Based in Ohbu, Aichi, Japan, Ueno Kigata Seisakusyo is a company that primarily serves the automotive sector, providing numerical control (NC) cutting model fabrication services and fabricating prototype models and tools for customers. As a form of new revenue and publicity for the company, Ueno Kigata Seisakusyo recently started fabricating copies of unique items, and carving sculptures with data collected by 3D measurement devices. A wide variety of objects have been reproduced, ranging from food (e.g. chicken wings, dumplings) to cultural assets (e.g. Buddha statues) and factories.
Scanning food with the FaroArm
Shift in Mold Fabrication As globalization advanced, mold fabrication methods shifted from manual to a greater reliance on machine fabrication, using computer-aided design (CAD) data. This influenced Ueno Kigata Seisakusyo in its decision to introduce a system to acquire and transform 3D data into CAD models for mold fabrication. In 2008, they invested in a FaroArm, a 3D measurement device in the form of an articulated arm, equipped with non-contact scanning capabilities. The device allowed the team to inspect tools and models, as
8
www.martupdate.com
Scanned and processed image of a chicken wing, ready for 3D printing.
October 2014
Models of a chicken wing, shiitake mushroom and dumpling produced by a 3D printer, using digital data acquired by the FaroArm
well as to generate CAD data for products that it did not have drawings of. Main Applications of FaroArm When considering the main applications of the FaroArm, the first one that comes to mind is inspection of the company’s output, which consists of the tools and processed models. Ueno Kigata Seisakusyo also relies on the FaroArm to
generate inspection reports for their customers in order to demonstrate that the products are within tolerance, especially for prototype models, mass production templates, and to check fixtures.
often unavailable for older molds. When that happens, Ueno Kigata Seisakusyo will scan the mold with the FaroArm to acquire and process the 3D data for re-fabrication.
Sometimes, a mold has to be re-fabricated due to a change in the model. To do so, a drawing or 3D data is required. However, both types of information are
The company also uses the laser scanner to acquire 3D data for the fabrication of thermoforming molds with the computer numerical control (CNC) laser cutting machines. “Since vacuum
Inspecting the prototype cut by the machine with a FaroArm. October2014 2014 October
moldings and plastic products are deformable, we cannot probe them with contact measurement methods. Scanning is more accurate and the results are always very convincing,� said Mr. Akira Ueno, deputy general manager of the company. Scanning Even Larger Objects In 2011, Ueno Kigata Seisakusyo purchased a FARO Laser Scanner
Large processing machine cutting prototypes
www.martupdate.com www.martupdate.com
99
Focus3D in addition to the FaroArm it already owned. The new device enabled the team to scan even larger objects. Combining the FaroArm and Focus3D, the company can now accommodate more new applications. For example, the laser scanner was used to help in determining the location of a new large NC processing machine in the factory. First, the interior of the factory was scanned to document the existing layout. The position of the new machine was then decided virtually with the digital data collected by the Focus3D. In a similar fashion, the Focus3D
allowed Ueno Kigata Seisakusyo to accommodate requests to scan animals and to generate 3D data for various objects in a short time. New Technology and Business Areas As news of its new laser scanner got out, Ueno Kigata Seisakusyo began to receive new orders through word-of-mouth. When a local government department decided to carve a bronze statue of a homegrown writer to commemorate his birth, Ueno Kigata Seisakusho made use of a clay model in the production of the life-sized sculpture, which was cut based on a digital model
of the clay prototype. “It is our desire to pursue more jobs that involve digitizing of data from clay models. We also wish to diversify our scope of work, to include projects that digitize hand-made objects for mass production,” said the deputy general manager Mr. Ueno, demonstrating his intentions to expand the business. Ueno Kigata Seisakusyo publicizes its work in this area by showcasing videos of the company’s capabilities on the Internet. “In order for customers to understand the fabrication process of scanning and digitizing, it is easier and
Scanned image of the factory acquired by the Focus3D. Layout of the large machine was determined digitally.
clearer to show them videos rather than catalogs. To keep up with the times, we choose to present information with new methods to publicize our technology,” explained Mr. Mamoru Ueno, Chief Director of Ueno Kigata Seisakusyo. FARO is a global technology company that develops and markets computer-aided coordinate measurement devices and software. Portable equipment from FARO permits the highprecision 3D measurement and comparison of parts and compound structures within production and quality assurance processes. The devices are used for inspecting components and assemblies, production planning, inventory documentation, as well as for investigation and reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites. With FARO, 3D measurement and documentation needs can be fulfilled confidently. As a pioneer and market leader in portable computer-aided measurement, FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate, reliable, and easy-to-use. The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs. Worldwide, approximately 15,000 customers are operating more than 30,000 installations of FARO’s systems. The company’s global headquarters are located in Lake Mary, Florida, with its European head office in Stuttgart, Germany and its Asia-Pacific head office in Singapore. FARO has branch locations in Japan, China, India, South Korea, Thailand, Malaysia, Vietnam, Canada, Mexico, United Kingdom, France, Spain, Italy, Poland, and The Netherlands.
3D documentation of a stuffed penguin as taken by the Focus3D.
10
www.martupdate.com
For further details visit www.faro.com
October 2014
October 2014
www.martupdate.com
11
ADDITIVE MANUFACTURING
First metal 3D printed bicycle frame manufactured by Renishaw for Empire Cycles Renishaw, the UK’s only manufacturer of a metal-based additive manufacturing machine that prints metal parts, has collaborated with a leading British bicycle design and manufacturing company to create the world’s first 3D printed metal bike frame. Empire Cycles designed the mountain bike to take advantage of Renishaw’s additive manufacturing technology, allowing them to create a titanium frame that would be both strong and light using topological optimisation - the new frame is some 33% lighter than the original.
The frame has been additively
• Complex shape with internal
manufactured in titanium
strengthening features
alloy in sections and bonded together. This offers a number of advantages: Design freedom • Rapid iterations; flexibility to make design improvements right up to production • Ability to make shapes derived by topological optimisation (see over) • Ultimate customisation and tailoring - make one-offs as
• Hollow structures • Built in features, such as the rider’s name Performance, titanium alloy • Seat post bracket 44% lighter than aluminium alloy version • Extremely strong - tested to EN 14766 • Corrosion resistant and long lasting
easily as production batches
Empire Cycles
Construction
Empire Cycles is a unique
Development process of the Empire Cycles 3D printed seat post
British bike designing and manufacturing company in the North-West of England. Passionate about using great British engineering to create elite products, the Company offers innovative designs to the world’s mountain bikers and downhillers. By working together, Renishaw and Empire The entire bike frame was arranged in sections with the seat post bracket on one build plate and fabricated in one go
12
www.martupdate.com
Samina Khalid
Cycles optimised
the bicycle design for additive
The project’s aim is to produce
manufacture, eliminating many
a fully functioning bicycle,
of the downward facing surfaces
so the seat post bracket was
that would otherwise have
tested using the mountain
needed wasteful support
bike standard EN 14766; it
structures.
withstood 50 000 cycles of 1
How strong is it? Titanium alloys have a high Ultimate Tensile Strength (UTS) of more than 900 MPa when processed using additive manufacturing and near to perfect densities of greater than 99.7% are achieved; this is better than casting and, as any porosity is both small and spherical, it has little effect on strength.
200 N. Testing continued to 6 times the standard without failure. Testing of the completed bicycle frame will continue, both in the laboratory using Bureau Veritas UK, and on the mountainside using portable sensors in partnership with Swansea University. What is topological October 2014
cm3 and 3 g/cm3 respectively. Therefore, the only way to make a titanium alloy version of a part lighter than its aluminium alloy counterpart is to significantly alter the design to remove any material not contributing to the overall strength of the part.
1. CAD model of seat post designed for aluminium
2. Topological optimisation using Altair’s solid Thinking
The original aluminium alloy seat post bracket is 360 g and the hollow titanium version is
to make use of additive manufacturing, the weight drops to 1400 g, a 33% weight
this already and says, “The durability of carbon fibre can’t compare to a metal bike, they are great for road bikes, but when you start chucking yourself down a mountain you risk damaging the frame. I over-engineer my bikes to ensure there are no warranty claims”. How was the project managed?
October2014 2014 October
advantages that this construction method bestows. The design has all of the advantages of a pressed steel
manufacturer.
Empire Cycles, has researched
Titanium alloys are denser than aluminium alloys, with relative densities of around 4 g/
Cycles is the performance
would be prohibitive for a small
Williams, Managing Director at
How light is it?
The key benefit for Empire
testing it could be reduced
bikes available, but Chris
From the Greek word for place, “topo”, topological optimisation software is the term given to programs that are used to determine the “logical place” for material – normally using iterative steps and finite element analysis. Material is removed from areas of low stress until a design optimised for load bearing is evolved. The resulting
AM250’s 300 mm build height.
the investment in tooling that
There are lighter carbon fibre
model is both light (due to the low volume) and strong. The historical challenge in manufacturing these shapes can now be overcome with additive manufacturing, enabling physical 3D models to be realised.
that it would fully utilise the
with further analysis and
saving.
optimisation?
the frame was sectioned so
This is just the first iteration;
in at 2100 g. Redesigned
Vertical force fatigue test diagram
on what would build well, and
‘monocoque’ construction used
The original bike frame weighs
4. Produce in titanium alloy on a Renishaw AM250 laser meltingstystem
Renishaw’s applications team
200 g, a weight saving of 44%.
further.
3. Re-designed by Empire cycles using the optimised CAD model as a templete
his design with guidance from
Chris had already produced a full size 3D printed replica of his current bike before he approached Renishaw, so had a good idea of what he wanted to achieve. Renishaw originally agreed to optimise and manufacture the seat post bracket only, but after this proved successful, decided the whole frame was a practical goal. Chris updated
in motorbikes and cars, without
The potential performance has not been completely explored yet, but we hope to continue to develop the project. As no tooling is required, continual design improvements can be made easily; and as the component cost is based on volume and not complexity, some very light parts will be possible at minimal costs. Research into bonding methods resulted in Mouldlife providing the adhesive, and technical specialists 3M providing test facilities. We will develop this further in partnership to look at iterative improvements in bonding methods, such as specific surface finishes. The wheels, drive train and components required to finish the bike were provided by Hope Technology Ltd. This project has highlighted that excellent results can be achieved by working closely with the customer. If you have a component that would benefit from additive manufacture please contact your local Renishaw office for further information. For further details visit www.renishaw.com/empire
www.martupdate.com www.martupdate.com
1313
LOGISTICS
Rapid Prototyping and Additive Manufacturing with Big Data Analytics “Today supply chains are big, complex and global. Keeping them humming is an enormous challenge. We think the world is entering the era of small, simple and local supply chains, powered by a new generation of manufacturing technologies such as 3D printing, intelligent assembly robotics and open-source hardware – also known as the Software Defined Supply Chain”. Rajesh Angadi Prototyping is used to evaluate and test the design, ergonomics, safety, functionality and other aspects of a device. Choosing the right prototyping process can enable companies to notice design errors and other issues that could later cause significant problems, thereby saving both money and time. Conventional prototyping methods such as machining, injection moulding and soft tooling can provide high-quality and highly accurate prototypes. However, these processes can be time-consuming, expensive and complicated. Rapid Prototyping Rapid Prototyping for Direct Digital Manufacturing deals
Motor Vehicles Consumer Products Business Machines Medical Academic Government/Military Others
with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker,
Differences between Traditional and Additive Manufacturing
Traditional Billet
Machining
Part
Scrap
Additive Manufacturing Foil/Powder
14
www.martupdate.com
AM
Part
Scrap
more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of Additive Manufacturing applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Rapid prototyping methods have dramatically changed the landscape, allowing for a prototype to be made in as little as one day.In some circumstances, the same methods can be used to make the final product, further speeding up the production process by means of additive manufacturing.
by adding material layer by layer. By contrast, subtractive prototyping methods create a and drilling.A rapid prototype originates with a computer model. Typically, this model is fabricated using computeraided design (CAD). In some cases, where the final product will be custom-made. A prototyping machine reads the computer data and slices it into different layers. The machine then builds the prototype by adding material layer by layer. Additive Manufacturing
Rapid prototyping methods
Additive Manufacturing enables the fast, flexible and cost-efficient production of parts directly from 3D CAD data – a technology that helps you to perform your tasks in an innovative way.
The most common types of rapid prototyping methods are additive technologies, meaning that the model is built
Additive Manufacturing refers to a process by which digital 3D design data is used to build up a component in layers by October 2014
October 2014
www.martupdate.com
15
components
Solution Classification
•To Introduce systematic solutions for process selection and design for AM
Addictive Manufacturing
LOWEST BARRIER TO PARTS
- Distributed globally - 3-10 day turn around avg - Alomost all technologies
3D Production Systems
3D Printers MOST AFFORDABLE SOLUTION
HIGHEST PERFORMANCE SYSTEMS
- $10 -$50K USD -Simple and easy to use - Optimized for form, fit some function
depositing material. The term “3D printing” is increasingly used as a synonym for Additive Manufacturing. However, the latter is more accurate in that it describes a professional production technique which is clearly distinguished from conventional methods of material removal. Instead of milling a workpiece from solid block, for example, Additive Manufacturing builds up components layer by layer using materials which are available in fine powder form. A range of different
- $50 - $500K & up USD
Highest cost per unit
Additive Manufacturing includes •Provides a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches •To discuss the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use
Cost per
Lowest cost per unit Fewer units
ADDITIVE MANUFACTURING INCLUDES THE FOLLOWING PROCESSES – Directed Energy Depositions:
- Binder jetting: a liquid bonding agent
A PROCESS OF JOINING METRIALSTO MAKE OBJECTS FROM 3DMODEL DATA, USUALLY LAYER UPON LAYER, AS OPPOSED TO SUBTRACTIVE MANUFACTURING METHODOLOGIES
Focused thermal energy is used
is selectively deposited to join powder
BED BASED METERIAL
materials. - Powder Bed Fusion: Thermal energy selectively fumes regions of a power
FEDER BASED METERIAL
deposited. build materials are selectively
- Vat Photo polymerization: Liquid
deposited.
photo polymer in a VAT is selectively cured by light activated polymerization.
LAMINATION
the materials are being – Material setting droplets of
bed.
Short lamination sheets of material
to fuse materials by melting as
– Material Extrusion:
EXTRUSION
Material is selectively dispensed through a nozzle
are bonded to form an object.
or orifice.
ADDITIVE MANUFACTURING Bed-Based Meterial Process
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7 STEP 8
After the item that will
The wench is
Customize parts by
The printer injects
Retrive the wrench
Remove excess the
Cure the wrench Now compare the
be printed is selected
manipulated by
selecting colours.
ink and binder into
from the composite trey
composite meterial
if neccessary
it is scanned into 3d
selecting individual
Then press print
powdery composite
cad software
parts in software
16
www.martupdate.com
The strengths of Additive Manufacturing lie in those
- Broad application
metals, plastics and composite materials may be used.
ADDITIVE MANUFACTURING:
Benefits
- Optimized for performance
Cost per unit manufactured
On Demand Services (Service Bureaus)
The technology has especially been applied in conjunction with Rapid Prototyping - the construction of illustrative and functional prototypes. Additive Manufacturing is now being used increasingly
in Series Production. It gives for most varied sectors of industry the opportunity to create a distinctive profile for themselves based on new customer benefits, cost-saving potential and the ability to meet sustainability goals.
meterial in thin layers
from the wrench
original wrench with the fabricated wrench
areas where conventional manufacturing reaches its limitations. The technology is of interest where a new approach to design and manufacturing is required so as to come up with solutions. It enables a design-driven manufacturing process - where design determines production and not the other way around. Additive Manufacturing allows for highly complex structures which can still be extremely light and stable. It provides a high degree of design freedom, the optimization and integration of functional features, the manufacture of small batch sizes at reasonable unit costs and a high degree of product customization even in serial production.
October 2014
Functional Principle The system starts by applying a thin layer of the powder material to the building platform. A powerful laser beam then fuses the powder at exactly the points defined by the computer-generated component design data. The platform is then lowered and another layer of powder is applied. Once again the material is fused so as to bond with the layer below at the predefined points. Depending on the material used, components can be manufactured using stereolithography, laser sintering or 3D printing. Big Data Analytics Analytics and prognostics in plants used to be the terrain of large, leading-edge companies. The ability to crunch plant data to predict failures, optimize throughput, and determine best-practices that a company that can save a fortune by making a plant half a percent more efficient. The number of benefits that come from using big data to analyze and optimize plant operations. Analytics can coordinate operations with reliable, timely, and contextualized information. You can reduce operating costs with real-time monitoring and data analysis. You can improve enterprise connectivity with anywhere, anytime information, and you can enhance decision-making for improved performance with integrated history, alarming, and trending. Those using analytics to improve plant efficiency are going deeper into the use of data. Where they used to use analytics to tweak equipment for improvements, they’re not using data to truly optimize their systems. You can monitor the equipment
October 2014
to get better availability and better throughput, or you can go further to the optimization side. Big data can also be used to compare one plant to another on the equipment-toequipment level. If you have 50 to 200 plants, you want to see the best practices across all of the plants. You can see what aspects of the equipment breaks down the most. The big data gives you temperature, pressure, and maintenance records. You can see shop floor notes that offer insight into why some equipment is breaking. When you’re producing a lot of data, you can use that data to get your efficiency up and your defects down. Big data, along with complex analytics that can help to better monitor and analyze parts during the laser sintering process. Perhaps most importantly, the technology will be able to monitor any temperature abnormalities that could structurally impact, compromise the nozzle during Additive Manufacturing. Companies estimated that the big-data-enabled “in-process” inspection could increase production speeds by 25 percent, while cutting down on inspection after the building process is complete by that same 25 percent. The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologiesresearch areas like Hadoop Ecosystem, Predictive \Analysis, Telematics, Clinical research with Analysis.
www.martupdate.com
17
ADDITIVE MANUFACTURING
Having it All When it comes to making prototype parts, Haas customer Proto Labs Inc., based in Maple Plain, Minnesota USA, Telford, England and in Tokyo Japan, has radically changed the economics of getting new products to market without compromising quality. Using proprietary, web-based software and a large and growing fleet of Haas CNC vertical machining centres, Proto Labs can deliver all three sides of the project triangle. No more dilemmas for the designer; no more compromises for the buyer. The Project Triangle: Fast, Good, Cheap. Choose two. You can’t have all three. This used to be the engineering designer’s dilemma and the beginning of the buyer’s frustration. But, when you combine the speed of the Internet, the power of cleverly designed software with the flexibility and precision of Haas CNC machine tool technology, the Project Triangle looks like a formula from the dark days of manufacturing, which is exactly what it is.
dedicated to produce plastic
Proto Labs provides two services: First Cut and Protomold. Both use the same combination of hard and soft technology to deliver prototype parts, but as the name suggests, First Cut is aimed at the early stages of the product design process.
development cycle by using
First Cut provides a service
Tumelty, explains:
and aluminium prototype parts, CNC machined directly from solid blocks of material as quickly and easily as they can be made using a traditional additive Rapid Prototype (RP) process. CNC machined parts are far superior to RP produced parts due to their greater strength, better surface finish and more accurate dimensions and First Cut allows customers to make functional prototypes much earlier in the production intent plastics and aluminium. But, what’s the difference between the many CNC machine shops that offer to cut plastic parts and First Cut’s service? Proto Labs’ European managing director, John
“First Cut customers can upload their CAD models to receive a FirstQuote™: an interactive and firmcost analysis, as well as a manufacturing feedback facility. As soon as the customer places an order, First Cut’s software - running on large-scale parallel processing computers with 1.9 teraflops of processing power automatically produces the tool paths required to program the Haas CNC machines. This eliminates the non-recurring engineering (NRE) costs and delays, making it a fast and affordable process for quantities of between 1 and 10+. With conventional subcontract machining, oneoffs usually can’t be obtained with short lead times and are often prohibitively expensive.” So, adds Mr. Tumelty, there’s no need to settle for a
18
www.martupdate.com
Matt Bailey
prototype part that resembles the finished part in appearance only. Whatever material the designer specifies – ABS, Nylon, PEEK, aluminium, etc. – a part produced by First Cut will embody many of the mechanical features and qualities anticipated in the production version. “This is a major development for designers,” adds Mr. Tumelty. “There is no other way of getting high-quality, functional plastic and aluminium prototype parts manufactured as quickly and so inexpensively.” As the product development process advances, a designer will often need more than just one prototype part. Several may be needed during the testing and development phase and, once the product has been signed off for marketing purposes, part runs of 100’s October 2014
and 1000’s are typical. This is the point at which designers can turn to Proto Labs’ Protomold service, which also relies on Haas CNC machines. In the past, manufacturing an injection mould tool for low volume or prototype purposes was a high cost, high-risk strategy. Times have changed and, thanks to Protomold’s low cost, high speed Haas CNC machine tools and its investment in CAD/CAM , so has the manufacture of aluminium injection mould tooling. “The Protomold process can deliver many thousands of moulded parts in days from a relatively inexpensive aluminium mould that can be made on the Haas CNC machines in as little as just one day. The precision-machined mould produces the same
geometry as subsequent steel production tooling so designers can easily replicate the intended shape and functionality of the finished product. Again, to make sure the actual manufacturing process was reliable, and to assure the quality of moulds, we needed the best CNC machine tools we could buy for the money.” When Proto Labs was founded, it was originally called Protomold and the concepts that are now also applied so effectively through its offspring First Cut were being developed, honed and delivered to product designers in the USA, Europe and more recently in Japan. Like First Cut, Protomold also uses a web-based quoting system to interact with its customers.
“Product designers submitting part models using the ProtoQuote™ receive detailed manufacturability analysis and an all-in production price in as little as an hour,” says Mr. Tumelty. “ Finished parts in production-intent material can then be ready to ship in as little as 1 day. We pass on these time savings to product designers, giving them the ability to better manage their product development programs, reduce the number of pre-production difficulties and bring products to market faster than ever before.” Customers can interact with the Protomold online system from anywhere in the world to view quotes, amend and update quote requirements, access large volumes of detailed information regarding design and manufacturing, check shipping details and order parts. Injection-moulded parts can be ordered almost as easily as a book on Amazon. com®, and design engineers who use the Protomold service can easily react to last-minute design changes, schedule revisions and reduce time-tomarket. To meet demand from its growing European customer base, Proto Labs has recently
October2014 2014 October
invested in several new Haas CNC vertical machining centres, including two VF-1’s, two VF2’s and two VM-3’s, all with high-speed machining options making them ideally suited to rapid manufacturing. Choosing Haas as the primary machine provider was one of the easier decisions faced by Proto Labs. “Haas stand apart from the plethora of machine tool manufacturers, offering a comprehensive range of machines and options coupled with great reliability and intuitive user interfaces, all at an affordable price.” says Tumelty, “When you sell time, as Proto Labs does, you need a highly reliable machines backed up by reliable, skilled and efficient service. That is why Proto Labs chose Haas. “The quality of the product that we produce is as important as the speed with which we can produce it,” says Mr. Tumelty. “Haas VMCs are capable and reliable highspeed machines. Together with our software and processing power, Haas CNC machine tools are vital to Proto Labs’ success. Our investments in the machines enable us to provide a better, faster service and pass time and cost savings directly to our customers around the world.” www.martupdate.com www.martupdate.com
1919
ADDITIVE MANUFACTURING
Additive manufacturing in finished part quality VO™ With the LASERTEC 65 AdditiveManufacturing, DMG MORI presents a hybrid machine, which currently is unique and incorporates generative laser deposition welding into a fully-fledged 5-axis milling machine.
In times of ever shorter product life cycles and increasingly more complex and more individualised bespoke components, additive manufacturing processes can help companies to manufacture produce new and innovative products more quickly. Additive manufacturing processes enable complex geometries and workpieces to be produced. The unique technology combination of laser metal deposition by means of a powder nozzle and milling gives the user completely new application and geometry options. With the LASERTEC 65 AdditiveManufacturing, SAUER LASERTEC now offers a hybrid solution for combined laser deposition welding and 5-axis milling. This method uses a deposition process by means of a powder nozzle, which is up to 20 times faster than generation in a powder bed. The market for additive processes has grown rapidly in
the past. However, up to now, these have been restricted to the production of prototypes and small parts, which otherwise could not have been manufactured using any other conventional method. With the combination of the two processes, metal deposition and chip removal, on one machine, additive technology supplements and enhances traditional machining methods. For generative manufacturing, the LASERTEC 65 AdditiveManufacturing is equipped with a 2 kW diode laser for laser deposition welding, while the fully fledged 5-axis milling machine from DECKEL MAHO in robust monoBLOCK® design also enables highly accurate milling operations to be carried out. “Thanks to the fully automatic changeover between milling and laser operation, the LASERTEC 65 AdditiveManufacturing
is suitable for the complete machining of complex components with undercuts as well as for repair work. It is also ideal for the application of partial or complete coatings for mould making and mechanical engineering or even medical engineering”, explains Friedemann Lell, Sales Director, SAUER LASERTEC, in Pfronten. Producing large parts generatively In contrast to laser melting in a powder bed, laser deposition welding enables large parts to be manufactured using a metal powder nozzle. With a deposition rate of up to 3.5 kg/h,
this process is up to 20 times faster than the laser generation of parts in a powder bed. The combination with milling opens up completely new applications. The component can be built up in several steps, whereby milling can be interspersed with deposition welding in order to allow areas, which the cutter would no
With the LASERTEC 65 Additive Manufacturing, DMG MORI presents a machine, which is currently unique and incorporates laser deposition welding into a fully-fledged 5-axis milling machine
A. Generative manufacturing
20
www.martupdate.com
B. Repair
C. Coating October 2014
longer be able to reach when the component was finished due to the component geometry, to be machined to final accuracy.
process is mounted in a separate electrical cabinet, which makes it easier to integrate this system into other DMG MORI machines.
Highlights of the LASERTEC 65 AdditiveManufacturing
The hybrid machine combines the advantages of milling, such as high precision and surface quality, with the flexibility and high deposition rate of laser welding. “In the case of some components, where today 95 % of the material is removed by milling, with additive processes, material is only built up where it is needed. As result, material loss is reduced to 5 %. This leads to significant raw material and cost savings”, explains Friedemann Lell.
Production of 3D contours
• Unique combination of laser metal deposition and milling provides optimum surface finish and component precision
The laser, complete with powder deposition head, is fitted into the HSK toolholder of the milling spindle. It can be automatically parked in a secure docking station while milling operations are being carried out on the machine. The machine is controlled by means of a 19” ERGOline® with Operate 4.5 on SIEMENS 840D solutionline. The controller for the laser
By means of a laser diode, the metal powder is deposited in layers onto a base material, and fuses with it without pores or cracks. In doing so, the metal powder forms a high-strength welded bond with the surface. A coaxial inert gas prevents oxidation during the buildup process. After cooling, a layer of metal which can be mechanically machined is produced. As laser deposition welding has long been established as a stand-alone technology, it is ideal for incorporating into DMG MORI’s high-quality CNC machines. “The combination of chip-removal and additive processes will become more important in future, as it opens up many new options and advantages for the user”, says Lell. One strength of this process is the option to successively build
Technical Data Axis travels (X / Y / Z)
mm
650 / 650 / 560
Max. speed
rpm
10,000 / 24,000*
Drive power (40 / 100 % DC)
kW
13 / 9
Torque (40 / 100 % DC)
Nm
83 / 57
Rapid traverse
m/min
24
Feed force max.
kN
6
Clamping surface
mm
Ø 650 mm
Table load max.
kg
600 / 1,000*
Swivel range B-axis
degrees
+120 ° / –120 °
Max. number of tools
n
120
*optional
October2014 2014 October
• Laser deposition welding with powder nozzle: 20x faster than powder bed processes • Ability to produce complete components • Many 3D geometries, including undercuts, can be realised without supporting structures • Repair of turbine components and in tool/mould making • Application of wearing surfaces • Complete machining with fully automatic changeover between milling and laser operation • Large work area for workpieces up to Ø 650 mm, 360 mm in height and max. 1,000 kg • Accessibility and ergonomics: Door opening 1,430 mm, optimum access from the front • Low space requirement with 7.5 m² footprint
up layers of different materials. Wall thicknesses of 0.1 mm to 5 mm are possible depending on the laser and the nozzle geo metry. Complex 3D contours can also be generated in layers without supports. The individual layers can then be accurately machined before the areas become inaccessible to a cutter or other tools due to the component geometry. The combination of the two processes is a sensible choice for repair work and the production of mould tools. However, it also offers many interesting options for lightweight components, prototypes or small batches production – particularly in the large-part manufacturing sector where other additive manufacturing processes cannot be used due to limited space. Economical solution Large machines, such as those
used for machining bulky components in the energy or aerospace industries, tend to be expensive. If roughing, deposition and finishing are reduced to a single machine, this represents a financially advantageous solution for the customer. Furthermore, in the energy and oil industry, components often have to be coated with corrosion-resistant alloys to protect against wear. Deposition welding provides protection for products such as tubes, fittings, flanges and special products which are used in aggressive environments. With a hybrid machine, machining of the base material, coating and finishing can be carried out on one machine. This results in cost savings and a reduction in throughput times. For further details visit www.dmgmori.com
www.martupdate.com www.martupdate.com
2121
BEHAVIOR MANAGMENT
The Choice Is Yours ! One always has a choice to choose his/ her Behaviour in this world. The Behaviour is what makes the Person you want to be -The Choice is Yours. (The Choice is Yours - a series of 12 articles based on Behavioural Science and its impact on Managing Self and Others. These articles bring in all that you want to know about Human Behaviour and its impact on an Individual’s Personal and Professional life) Reena Jabran
Turning the First Leaf....
“
In the journey of life, there are many a time that we hear this type of conversation..... ‘I do not like his behaviour’, ‘Her behaviour is quite irritating’, ‘I quite agree with you, how do you put up with such behaviour’, ’With this type of behaviour he cannot survive in this industry for long’, so far and so forth... ‘So.....the basic question that comes to one’s mind is - What do you actually mean by Behaviour?
This question rose in my mind too and I made it a point to explore what behaviour is and from where it originates. The first step on my list was to interview the all-knowing Mr Neuron, as my research pointed out to him as one of the source for the formation of behaviour from all directions. I went up his door and knocked. I wanted to ask him a few questions. He opened
the door with a smile and was all too excited to give me the answers I wanted. The Source : Thus Spake My Neurons When I asked him the question – Can you please tell me what you mean by Behaviour, he discarded my question and went into a thinking mode and said, ‘When I, the neuron was born,
I became aware of myself and understood my job profile perfectly. I am a specialized nerve cell that receives, processes and transmits information to the other cells in the body. I am a messenger who has to carry information [whatever it may be] from one point to another. I cannot judge, assume or modify the transmission and nothing is right or wrong for me. I just do my job which is to transmit the message without asking questions. ‘ I asked the neuron: ‘Well, what is this information that is carried forth, from where it originates, what influences it, and what happens to this information.........’ The neuron looked at me and abruptly answered back without any hesitation.... The flow : ‘Any type of information from the outside world like
22
www.martupdate.com
the images, words, feelings, smell and taste is taken into the brain through the 5 sense organs [the panchendriya] – the eyes, ears, nose, tongue and touch. This information which is taken in forms the Thoughts in the brain. The thought can be newly created as the information is new or the thought can be modified with already existing information. The thoughts are then responsible for the conscious actions to be created. Thus when we see an apple, we instantly recognize the colour, the smell, the taste, the smooth touch and the crunchiness. This information is already stored in the brain through a previous experience. So, we either pick up the apple if we like it or throw it away if we don’t. Similarly, When we look at a person and he reminds us of a person we do not like, we would for no reason at all dislike the person. Thus any experiences taken in through the five senses is processed by the brain are converted into action, words and expressions. This leads to how we behave in the outer world’. I exclaimed, ‘Wow, so the information from the outside world is directly or indirectly responsible for our behaviour...... Does it mean that our exposure to the outside world is the cause of our behaviour and the manner in which we act?’ October 2014
on mati Infor Information
Eyes In
fo
Information
Ears
rm
at
Action
Inform
io
n
ation
Information Infor matio n
Information Nose ormation Inf Touch
Tounge
I
a
rm
o nf
Hands
‘Well, it is like this my dear’, Mr Neuron said. ‘If you are exposed to a pup coming near you, you would either jump with fear or you would bend down to pet it. The action would depend upon the information you have collected before. If you have the information that the puppies are dangerous because somebody said so, or someone you know was bitten by a pup, or a pup snapped at you earlier or one of your parent hates pups then you may probably refrain from touching it. At the same time, if you have good memories or someone encourages you to touch a pup, then you would bend down and pet it. This is the same for all the experiences you go through’. As he said this, I suddenly went back into my thoughts to understand why I used to hate bitter gourd. I remember my mother not liking it and making faces whenever she saw one, and my grandmother forced me to have a bitter gourd dish which was so bitter. That was past. Recently, when my friend October 2014
Expression
n tio
Brain
made a lovely dish out of bitter gourd, I felt it was not bad after all. I have started liking the dish now.
Words
I take in and how it impacts my action.... The author Reena Jabran is
a student of Psychology and today she is a coach and mentor in the Technology called Neuro Linguistic Programming [NLP] which she believes originates from Neuro-science. She heads the organization called ‘Jayakartha’ who are enablers of Personal and Organizational Excellence through Behavioural and Attitudinal changes. She has coached more than 600 students from all over the world in NLP, and more than 25,000 participants has attended her seminars in the past 14 years. She is accredited to an International body to issue Practitioner and Master Practitioner Certificates. Her corporate trainings has its core in this technology. You can access her at www.jayakartha.com She loves writing and reflects the technology in her works.
Mr Neuron broke his silence and continued, ‘Thus any action performed has the influence of the already formulated Thinking patterns with regard to culture, environment, emotions, values, genetics, family interactions and beliefs. The action, expression, words and feelings exhibited in the outside world culminates into Behaviour. So, behaviours depend on the information taken and processed with the part played by the Influencers’ ‘Well, Mr Neuron, what are these behaviour influencers you were talking about? I enquired asking for more. Mr Neuron had a look at his watch and said, ‘Oh dear, I have taken enough time for the day and I need to go back to work. It would be wonderful if you came in next month.....’ I became aware of the cue and bade him goodbye for now...... and as I left I definitely decided to think on what he said and be aware of what information www.martupdate.com
23
TALENT MANAGMENT
The Power of Influence The Art of Getting Others to Follow your Lead People love to follow the crowd. No matter how much you believe that you are not influenced by others, the truth is we are influenced by what others are doing and saying.We tend to enjoy songs that others listen to – the best example being the Gangnam Style or Yo Yo Honey Sigh. We even tend to dress like others. Pavan Sriram Influence is defined as “a force one person (the agent) exerts on someone else (the target) to induce a change in the target, including changes in behaviours, opinions, attitudes, goals, needs and values” and “the ability to affect the behaviour of others in a particular direction.” Influence can be as complex as citizens forming an alliance to try to influence a country’s leadership to change its policies or as simple as a child smiling and extending his hand in an offer of friendship. Every time we try to affect how other people think, behave, or decide, we are trying to influence them. A smile and a handshake are attempts to socialize by influence, to form a connection and break down barriers. As people get to know us and like us, they are more likely to say yes to our requests. Influence is critical for our success in life and in business. So, how do you influence? There are numerous parts to influencing effectively. According to research done in Harvard, it takes only six seconds for people to judge
24
www.martupdate.com
us. Harvard provided university students six seconds worth of footage (with no audio) of professors teaching and asked these students to rate the teachers. They kept the ratings and at the end of the semester, compared the six second ratings to the ratings from students who actually attend the full semester of classes of these professors. They found that even with six seconds, the students evaluations of the professors were amazingly similar (and accurate) to the ratings of students who underwent a full semester of classes. These six seconds are our window of influence. Body language, words, your appearance, harnessing the power of story-telling and using various means of concessions are all part of the influencing arsenal. What is Leadership Influence? According to John Maxwell, the foremost authority on leadership in my opinion, “influence is the ability to move others into action”. Whenever we can change someone’s thought process and convince them to pursue a course of
action, we have exercised influence, hence demonstrated leadership. To be an effective leader, it is necessary to influence others to support and implement decisions that the leader and team-members perceive are necessary. Without influence, leadership does not occur. In other words, leadership is the act of influencing outcomes. The heart of strategic influencing is to gain willing cooperation instead of mere compliance. It’s about getting others to follow us because they want to and not because they have to. Influencing moves work from being merely transactional to relational. The most effective way to influence others is first to build a relationship of trust. A leader is a person who believes in a certain goal and who has a certain vision. Good leaders who influence others easily are the ones who strongly believe
in this vision. This means that unless you strongly believe in this vision or this goal you will never be able to influence others. Influence can be with people, things or events. Strength and effectiveness of influence can vary. The process the leader uses to influence someone can take a variety of forms. Interestingly, what I have discovered is that people don’t get influenced by a leader because of his words but rather because of the energy that is associated with his words. In fact a leader uses strategies or tactics, actual behaviours designed to change another person’s attitudes, beliefs, values or actions. Most of us would agree that leading with influence produces a better end result for the business, clients, employees, and leaders of the team. Unfortunately, you October 2014
you can help them grow and get better. You do not have to have the same skills sets; you simply have to provide a fresh perspective, ask key questions, and be focused on their growth.
cannot wake up one day and decide to be influential. Unlike authority, influence is not given to you in a title or promotion. Influence stretches past hierarchical structure and is earned through a careful series of behaviours and actions. Here are 4 elements of influence, and together they create a force far more powerful than authority. Trust - Trust is a small word with big implications. Think for a second about how trust
October2014 2014 October
might feed into influence. If people believe you have their best interest at heart, they see your actions in a different manner than if they believe they are simply doing your bidding. Consistency - To be influential means to exhibit both-act in a way that mirrors your vision and show predictable responses. Credibility - Building credibility happens when people believe
Investment - Investing in people is more about the quality of time spent than it is quantity. When you invest in someone on your team, you are showing them that you care about them, as more than just a member of the team, but as a person who has value above and beyond the task at hand. A key part to influencing others, especially teammembers and stakeholders, is not what you say but also how you portray yourself. Are you confident, single-minded and committed to the cause you are presenting? The delivery of your message may be much more important than what is said.
The most important body part for influencing is also your eye. Eye contact signals attention and creates a link that pulls people in your team together. So, while trust may take time to build, having eye contact with people you interact with at work and socially is something that can be easily done. All of us are influencing people or are being influenced in some way or form every day of our lives. Everyone needs to influence every day. Building trust gives you the seed of influence. Do write to me at pavan@ittige.com on how you are motivating your teams to become the best manager in your circle of influence. 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.
www.martupdate.com www.martupdate.com
2525
MANUFACTURING EXCELLENCE
Effective Supply Chain Management Managing a SME in India - Part 22 As a continuation of last article, we will discuss few more points to manage SME’s better in India. Typically in MSME’s, importance of supply chain management is either not known or not understood well. The myth here is that such management concepts apply only in big corporate or multinationals. In this article, we try to understand what supply chain is and concepts that can be applied even in small scale companies. P S Satish
34. Effective Supply Chain Management In simple term, supply chain management is about managing the flow of materials, information and money from our supplier’s supplier to Customer’s Customer. Here communication among various supply chain partner’s become vital. Supply chain partners are those in the chain who add value to Customer. Here supplier, manufacturer, warehouse and stores are integrated so that the product manufactured is distributed at the right quantities, to the right location and at the right time with minimization of overall cost while satisfying service level requirements.
26
management is purchasing. To emphasize importance of purchasing, I give here an example. If we take, sales price of a product is 100, with 10% profit and 15% overheads, the cost of product would be 75% of sales price. Normally, purchase cost would go upto 70% of sales price depending on raw material price and depth of value addition by the company. In our calculation if I take purchase quota as 60%, then it would be only 15% of cost where value is added in the company. That means, the influencing factor on profit or end price of the product is purchase cost more than valueaddition by the company. But where do you see the focus of the
Every partner in the chain would be aware of what their immediate Customer andend Customer wants and act accordingly. The saying that the strength of the chain is equivalent to strength of the weakest link holds good very well here. Purchase management which was purely a purchase or procurement function has evolved over the period into supply chain management integrating suppliers and Customers.
company? It would be more in
A part of supply chain
for you.
www.martupdate.com
Many companies have shifted their focus on supply chain to bring down the price or increase their margin
inside operations than at those happening at suppliers. Realizing this scenario, many companies have shifted their focus on supply chain to bring down the price or increase their margin. Without elaborating much on theoretical aspects of supply chain, I give here some practical steps MSME’s can follow to streng then the supply chain: • Treat supplier’s as Business partners as an extension of your business. Then they will work
• Work on enhancing relationship with Suppliers, Customers and all supply chain partners. • Encourage suppliers who are loyal to you for a long time • Do your homework well while selecting a supplier. Nonperforming suppliers can make the organization suffer. • It is not enough if the supplier provides what you want. Watch also on their process of how product is manufactured and audit regularly. This is critical if you are in automotive business. • Many of the problems will get resolved if you make your expectations explicit and clear
to supply chain partners. • Monitor performance of the suppliers regularly and share the report to them for improvements. Demand improvement measures. • Keep communicating with your supply chain partners regularly. • Support your partners including hand holding wherever required to come to your level of expectations. • When you make your business plan, remember to address constraints that may be posed by supply chain partners. • Outsource those activities that are available in abundance October 2014
in market at a better price so that you can focus on your core competency.
look for win-win. Do not squeeze so much to make them bleed.
• Have agreement with supply chain partners on the agreed services and service levels.
• Align Supply chain strategy as an enabler to achieve business strategy.
• Identify partners who can work with you for long time and spend more time with them to develop their competencies.
• Wherever applicable, have contract with suppliers on pricing, handling inflation, delivery, quality, material reconciliation, tooling ownershipetc. With this, confidence level of both the parties will increase.
• Develop a clear organization structure in the organization to handle supply chain. Define the roles and responsibilities clearly. • Supply chain colleagues in the organization should have targets based on business plan on which they should focus. The target should include also long term development of suppliers. • Use extensively IT as enabler to improve supply chain effectiveness. Remember that technology alone will not help to improve unless supply chain process is improved. • Involve suppliers right at the beginning of development so that they can contribute better to reduce cost, lead time and to define manufacturing process • Respect professional contribution of supply chain partners. See what they are good at and how their strengths can be used. • Follow PDCA (Plan-Do-CheckAct) cycle in all processes in supply chain. • Focus on increasing competency of supply chain colleagues in the organization. Provide them training so that they become supply chain professionals. • It is the responsibility of the management to provide enough resources, authorities to supply chain managers to do their function well. • While negotiation with suppliers or service providers, October2014 2014 October
• In-house, have an approved list of suppliers and partners for dealing with them. The approval should from competent authorities or from cross functional team. • Whenever, new location is identified for business, include supply chain colleagues in the decision process. They will be able to add value by checking on availability of suppliers around, logistic aspects etc. • Ensure all purchases like direct material, indirect material, services, and capital purchases are done by purchasers only to have a better control.
• Push supply chain colleagues to focus on waste in supply chain for elimination for cost reduction. It may be argued that how MSMEs with scarcity of resources can manage all of above points. The message here is to take spirit of implementation and how to implement can vary from company to company. You do not need a big structure to address these
points. To stay competitive, companies need to focus on product development (NPD), engineering (process development), manufacture (cost and delivery) and Customer responsiveness (flexibility and speed). In all these aspects, supply chain partners are linked and have a major role to play. Hence do not miss focus on supply chain management 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.
• Define ethical practices within which Purchasers can operate. • Excess Inventory is a killer for the organization. Purchasers along with manufacturing in charge play a greater role in controlling. Monitor and define inventory levels. • Allow purchasers to attend outside relevant seminars and trainings for networking with others. One of their core jobs is to be aware of what is happening in the market. • Clearly define purchase processes and procedures so that everyone follows and becomes basis for further improvements. • Be supportive to see that Purchasers have good working relationships with other functional departments/ colleagues within the company. www.martupdate.com www.martupdate.com
2727
QUALITY
Internal Audits: A Gateway To Achieve Excellence In Quality The consumer is the best and least expensive model one can have to enhance marketing. So why do we keep spending on expensive models to have the competitive edge. An easier long term option is to keep taking the quality level towards the sky. Internal Audits of our manufacturing systems is the precious tool which can make the Manufacturers in us walk hand-in hand with the consumers in us for a win-win situation for both
W Edwards Deming, considered the Father of Quality, had said many years ago that;
competition as far as the price factor is concerned. The goods under fast moving category, the electronic products, the food items etc. all seem to flood the courtyards of the households world-wide with their different grades, colorful exteriors, imaginative slogans and with a price tag always better than that of yesterday making it all look like battles in a boxing ring. The customers in us have awakened but do the manufacturers inside us have stirred ourselves sufficiently enough to feed the un-satiating hunger for quality in us customers?
“We have learned to live in a world of mistakes and defective products as if they were necessary to life. It is time to adopt a new philosophy.” Edward Deming
The customers in all of us have certainly picked up the essence in the statement. It is as evident from the scene in the local market as it is from the global business scenario. We as customers have picked up the thread somewhere and have started pulling the strings. It has certainly led to a much awaited increase in
28
www.martupdate.com
It does not seem so because the focus everywhere seem to pushing the manufactured goods down the throats of the consumers using tools such as attractive figures & faces, catchy hummable tag lines, or trapping the innocents amongst us in the web of loan facility. Agreed, the fact pace at which we are moving does require shouting from roof tops in all possible acrobatic manners to attract the passersby & create an urge in them to make a beeline for the product. But should we take it for granted that the modus-operandi would last for the entire generation? We are surely mistaken if we happen to think so. The generations mature with time and it would
not be long before they would ably separate the wheat from the chaff. The manufacturers in us need to sit back to sincerely make note of it, and more importantly establish systems by which the ‘Quality’ in the product manufactured does all the kind of advertising by itself. The consumer is the best and least expensive model one can have to enhance marketing. So why do we keep spending on expensive models to have the competitive edge. An easier long term option is to keep taking the quality level towards the sky. Well, this is much easier said than done, any of us would say that. So should we do? Yes, we need to focus on the tools that would make said thing easier in application also. There are many such tools, but for now let us focus on the tool called ‘Internal Auditing’. When we manufacture any product we follow a set process which is continuously repeated in cycles with the help of machines and manpower. In doing so we keep ourselves convinced that a machine in working condition would do no wrong and that the manpower is sufficiently trained and paid to give us the desired output, which to most of us means quantity. We generally fail to realize that the term ‘output’ refers more to ‘Quality’ than to ‘Quantity’. And by the time
Nikhlesh Mathur
the correct meaning of output dawns upon us manufacturers, we find half a dozen players fighting for the space which we once owned. Internal auditing is a precious tool to help us prevent from running into such a debacle. Few of us manufacturers get continually audited by our customers. Not all of us are that lucky. Many of us may have to build our own auditing system. Internal audit is audit done by our own team members of our own system in the same way as any customer would come and do it. Infact we also have Customers within our own processes of our business enterprise. A product is an outcome of several processes in series where-in the starting material (we also call it raw material) is processed to some different-different forms at different stages and finally given the shape & quality it is known to have by the customers of it. The machine or the person operating the subsequent process stage always remains the customer of the machine / Operator of the stage or stages prior to his section. So in a sense we need to market the in-process materials within our own manufacturing company before we put the final product for sale to the ultimate consumer. Therefore every department
October 2014
/ section of a manufacturing company is both a Purchaser as well as the Seller. If such important activities are preformed within the organization itself then why do we need our final customers to come and shake us into doing the needful? If we establish system whereupon the team members audit our processes & quality systems on regular basis we would soon begin making effective savings on the Cost of Reprocessing because the inhouse rejections would reduce. The Supervisor Incharge at every stage of the process would specifically await the best quality material at the feed point of his unit so that the product of his unit is to the complete satisfaction of the Supervisor controlling the next unit operation. When the series of checks and rechecks through such audits get absorbed in the normal system of manufacturing the final product from the business enterprise can be a delight to the actual consumer. Internal audit needs to be done on the same basis which an outside customer follow for auditing of the company. The focus needs to be on the following factors; 1. Availability of Standard operating procedures of all the unit operations in writing to the people at the shop floor. The language used in the documents need to simple and should be readily understood by all the employees of the unit / section. 2. Evidence of the compliance with the standard operating procedures at each step. A log book duly signed or a program in the computer with a provision to allow data entry only by the employees permitted by management can be a type of evidence.
October2014 2014 October
3. Availability of specific formats for all log books, computer programs pertinent to the operations. 4. Evidence of sampling, quality checks by standard procedures, analytical results and corrections made for the parameters going out of specifications. 5. Identifying the ‘Training Needs’ of the personnel of the unit / section. Making an evaluation of the manpower for the skills they have been trained in the past. 6. Speaking to the people at the shop floor to evaluate their understanding of the process and their awareness about maintenance of quality in the product. 7. Checking the preventive maintenance schedule of the machineries in the processes from the point of view of ensuring regular supplies. 8. Checking the record of past variances in the unit and the correctness of the steps undertaken to prevent reoccurrences.
lost for simple checks, which otherwise should be done by the team members of their own unit. No, internal audit is not a check process alone. It is mingling with the other team to share the viewpoints from different angles such that the best can be incorporated. A person doing a particular work regularly can also keep making the same error without realizing it. Any other person from a different section recognizes such discrepancies faster. Correction of even a minor error can prevent losses happening unknowingly into instant gains. Internal audit is the need of the hour in all organizations. Only then the manufacturers in us will be able to walk along with the consumers in us to create a long term win-win situation for both. Perhaps William Edwards
Deming might then smile in his grave. The author Nikhlesh Mathur, a Chemical Engineer from N.I.T. Rourkela and MBA (specialization: Total Quality Management) from SMU is working in the senior management cadre in the private sector and have vast experience in the management of chemical and allied industries. He is a ‘Member’ of the Institution of Engineers (India). Besides, he has been associated with Indian Merchants’ Chamber as an ‘Examiner’ for Ramakrishna Bajaj National Quality Awards (RBNQA) for Business Excellence. Besides being in the Engineering & Management profession, he is a keen student of Astrology and practice the same simultaneous to his job. His articles on astrology have been published in magazine and on the net in both Hindi & English languages.
UBJ ENGINEERING CORPORATION
9. Evaluating CAPA (Corrective Action Preventive Action) done for the recommendations made in the previous audits. 10. Discussing with the team members of other units on methods to further improve the Quality and Productivity. Internal audits should be a never ending exercise. It must be done at regular intervals with a motive of facilitating improvement. It should not be a fault finding exercise as most tend to believe. It should focus on how to eradicate errors from creeping inside a process. The causes and not the culprits should be surfaced out. Another myth which is associated with internal audits is that it is a costly affair and that precious man-hours are
MANUFACTORS: • UNIVERSAL JOINT • SOCKETS • SPINDLES • CLUTCH ASSY.
• JIGS & FIXTURES • BUSHES ALL TYPES OF GEARS AND MARINE SPARES ETC.,
UBJ ENGINEERING CORPORATION NO.74, S2, Radha Nagar, 3rd Street, (Near Sri Lakshmi Nagar) Velasaravakkam Chennai- 600 087 Mobile : 94440 01801 Email Id : ubjenggcorpn@yahoo.com
www.martupdate.com www.martupdate.com
2929
BEST PRACTICES
Best Practices in Secondary Manufacturing Process With the world’s largest installed capacity, Indo-MIM’s modern facilities have a combined strength of over 2700 skilled engineers, scientists, technicians and manufacturing associates. Both of its facilities are ISO 9001:2008, ISO/TS 16949:2009, ISO 13485:2003 and AS 9100 Rev.C certified. The capability to offer the best of world-class technology at competitive prices provides a significant advantage to customers all over the world.
Indo-MIM has an integral manufacturing set-up that includes MIM process as well as the in-house secondary (post-MIM) processes for MIM parts – this entire journey came a long way after having begun in 1998. It has always been a challenge for improving productivity in this area of post-MIM machining processes since most of the operations depend on the skill of the people. We have been used to a practice of hiring people whenever we have higher load in the shop.
focusing on productivity improvement projects in ISP (in-house secondary process) and thereby reducing the manhours in secondary processes. Generally secondary processes carried out are press coining, manually operated toggle coining, drilling, reaming, 100 % dimension checking, and 100% visual inspection sometimes using microscopes based on critical requirements of the customer. History and Early Implementation:
In the past, we used to produce the parts in the job production method. Parts were processed at each processing station and then moved from one process to another without balancing the cycle time. We observed that this method of operation resulted in some operators loaded heavily whereas few very less, resulting in less output although consuming more manhours. Dr. Shivashankar, Vice President - Operations SMED / universal base plate concept for drilling machine of Indo-MIM With sales going up every year by over 50%, we realized that surviving in such an industry will be very difficult unless we accomplish an element of de-skilling in our processes. It is since 2009 that we started
30
www.martupdate.com
Ujwal Uday Kumar
had a dream of bringing in cellular manufacturing concept in secondary process. This initiation triggered into action when we started KAIZEN events in ISP for implementing cell concepts like cycle time, TAKT time calculations and allotting the jobs to the operators equally, so that all are uniformly loaded. In the first KAIZEN event itself we could see that manpower could be reduced by half for the same output. It took more than 4 Kaizen events for us to completely understand the concept and also for the training of our supervisors and employees about this concept. In every kaizen event, critical parts with low
Output monitoring sheet at ISP for every 15 minutes. Single piece flow concept with clear marking
October 2014
outputs were selected and this gave an opportunity for us to prove ourselves that this will be a game changer for Indo-MIM. Earlier the outputs were monitored by supervisors on hourly basis, however, now these were converted to a monitoring every 15 minutes. The operator was asked to tick mark the output sheets when he gets one good part out after finishing the complete process cycle. This way, we had an account of the operators’ time clock. This monitoring itself gave us the benefit of 10 % on time saving. Some initial successes motivated us to start digging deep into this concept and start learning more about
this Lean manufacturing concepts. Culture of Kaizen Events: One of the major benefits that we found in a KAIZEN event was that a team was formed everytime with a process owner as the leader. The team consisted of the persons from the supporting departments. This team formation facilitated brainstorming under the guidance of experts in the company and resulted in the team to come out with an optimum solution. The team has to implementthe solution within 5 days of the Kaizen event. We deployed the program of KAIZEN
production process reducing cost and time to market. The implementation of Kaizen activities has immensely helped in improving the productivity thereby reducing the overly hard work on any individual. The effective distribution of the work plays a very important role in meeting
Sreenivasulu S GM-Operations, Indo-MIM
Indo-MIM aims for customer
A wide array of in-house
secondary operation do have
secondary operations allows
a major role to play to achieve
the parts to stay under
the same. Above all, people
one roof throughout the
are our strength!
event whenever we faced a productivity issue and we found a best solution with the team work, rather than an individual working on it finding a solution. The best benefit that we saw, was that since the decision was taken in a team ( as a group), there were no communication gaps about the decision taken in KAIZEN event among the production and service or supporting departments. The ownership was certain. Documentation of the changes made during KAIZEN event were done in the system so that nobody missed the implemented concept. TPM Board
Multi fixturing concept October2014 2014 October
the growing sales every year.
Low Cost Automation and SMED: Even the lean concept of JIDOKA� automation with human touch� was a right selection for our reaming applications, where manual feed was replaced with auto feed with the use of sensors and hydraulics built in house by our technicians. This low cost automation is one of the Key for our success which helped us to double to triple times
satisfaction and in-house
improvement in productivity. We could also see that the set up time was more in ISP due to non-standardization of the fixturing concepts. We now brought the SMED concept where operator could replace the setup for another job within 5 minutes instead of 15 minutes taken earlier. This concept was deployed for all the drilling machines and coining fixtures, where standard base plate/ universal fixturing was for a large variety of parts. This gave job satisfaction to the operators in addition to the savings in time and fatigue. Frequent calibration of the jigs and fixtures was introduced to monitor their life and improve the capability of the fixture there by improving the first pass yield and thus reducing the rework levels in ISP. This helped us to save large amount of reworks spent on reworking parts. TPM and SPC Implementation: We could also observe that www.martupdate.com www.martupdate.com
3131
machine breakdown was also one of the major factor affecting productivity, since the machines not ready for work wasa huge loss in production. Meanwhile, we conducted a KAIZEN event on TPM (Total Productive Maintenance) of the key machines for production, wherein major factors which could be the reason for breakdown were listed down and with the help of WHY WHY analysis the team could come out with solution. With this solution as the basis, TPM team would prepare a checklist with TPM board fitted on the machine
and checks were carried out as per the schedule displayed on board. Regular checks of daily, weekly, monthly basis were prepared with green and red token systems as shown in the figure. This helped us for ZERO BREAKDOWN of the machines which indirectly helped us for production improvements. We also implemented the multi cavity fixturing concept in all areas of production where we could find productivity improvements up to 25 % and also capability of the process was monitored through SPC system(Statistical Process
SPC monitoring
PMS System showing Target and Actual
Control) thereby fine tuning the process and helping eliminate 100% inspection. Productivity Monitoring:
industry practices with the right spirit, to sustain the global positioning attained in such a short span of time. We believe in doing it right from the first time; which definitely make us apart from our competitors in the global MIM industry. We have always
Saikrishna Rayalu
32
believed in attaining Quality
Quality Head, Indo-MIM
by process using a pro-active
Indo-MIM has a rule of
through a post-mortem
thumb, that we believe in
approach. Customer is God
implementing the best of
for us.
www.martupdate.com
approach than by inspection
Recently we implemented productivity monitoring boards at ISP which displays the actuals Vs. target, which keeps the operator constantly working and if any delay in production or down time was highlighted on the board as RED, the supervisors could attend to it and attend the issues on the spot (Gemba). Also Implementation of 5’S including 6thS for safety, we could give a professional look to our Organization and were appreciated by our major customers during their visit.In every organization growth is a never ending process and we
also would be learning in future to improve every day. The author Ujwal Uday Kumar has been serving Indo-MIM as the Manager, In-house Secondary Process (ISP) since ten years now. With 11 years of overall industry experience, Mr. Kumar has been efficiently leading production team of 180 employees including 25 engineers. With responsible for handling secondary operations on MIM parts, he is actively involved in productivity improvement of critical parts thereby reducing the lead time and man-hours spent in production. Timely delivery of the products to the customers is his priority. Not only in the operations; implementing new manufacturing concepts in the shop floor with enhancing the production of the parts is his additional forte. October 2014
October 2014
www.martupdate.com
33
CASE STUDY
Grinding with half of the axes At Bottero Group, KOLLMORGEN’s AKD series drives perform multiple functions. With the “Titan” series, Bottero Group developed a fully automated plant for glass processing that performs bilateral grinding of pane edges. The grinder is composed of a large frame that allows the standard processing of sheets with different sizes and shapes without any operation modifications. The main objective during the design process was to create the simplest, most fully automated driving system without jeopardizing its efficiency. To achieve this aim, Bottero developed in co-operation with KOLLMORGEN a solution that is based on a single AKD servo-converter for driving two servo-motors that are not simultaneously operating. In the highly specialized market of glass processing machines, more and more automated solutions are being required. This trend is not determined so much by the need to achieve higher speeds, but rather by the need to ensure maximum machining precision. In fact, it is important to ensure both a dimensional precision and a processing quality that are optimized for every sheet of glass. This need is determined also by the development of increasingly small lots and custom sizes. For its new “Titan” models, the Italian Bottero Group, a leader in cutting and grinding glass, chose a highly efficient automation solution. The drives of the KOLLMORGEN’s AKD series operate two motors in a non-simultaneous way for widely different fields of application. The whole system is controlled by an intelligent AKD PDMM system with integrated PLC and motion control functionalities, which combine the qualities of the actuators with the most advanced functions for sequential and movement control. In Bottero plants, the
AKD PDMM performs two main drive tasks: the positioning of the glass sheets and the drive of a grinding wheel. In addition, the device is also used to control the drive system with 9 AKD series drives. Thanks to its rapid regulation circuits and to the powerful control unit, the KOLLMORGEN automation platform provides ideal conditions to ensure the maximum bandwidth and to improve the efficiency. These intelligent devices with integrated motion control, cut in half the number of drives in the glass processing machine. This breakthrough, which led to a drastic reduction of costs in terms of hardware and installation was made possible, thanks to the collaboration of KOLLMORGEN, as design partner from the early stages of the project. A single drive for two functions In the Titan series, the glass is transported through four toothed belts - two upper belts and two lower belts. Each belt has its own drive
KOLLMORGEN drives allow the precise positioning of the glass sheets and the drive of grinding wheels
34
www.martupdate.com
Fabio Massari
For the “Titan” series grinders, Bottero selected a highly efficient automation solution based on the AKD PDMM smart drives
with synchronized axes. KOLLMORGEN’s synchronous servomotors of the AKM series use the Hiperface feedback system. Once the positioning of the plate is completed, the drives act as simple threephase speed controllers for the induction motors that operate the wheels. The tasks of the other 6 AKD drives are structured in a similar way to distribute the 16 control operations to half of the drives. The operation of induction motors is performed through incremental transducers, with either U/F characteristic curve or open regulation circuit (open loop). This rather unusual choice has come from intensive development, in which the experts at KOLLMORGEN drive systems have actively collaborated in. During the project it became clear that the motors integrated in the “Titan” models are never operated at the same time. This gave rise to the idea to connect two motors with a single servo drive. The technical implementation of this project was possible only
because the KOLLMORGEN’s AKD drives have two separate X9 and X10 interfaces, which permit two different feedback systems to be connected, which in turn are connected with two programmatic function blocks based on the application. Collecting plant data As soon as the task completed, the respective parameters of the motor are transmitted by the central AKD PDMM through the EtherCAT Ethernet bus in real-time. The drives support communication through I/O connections on the device. In the configuration developed in collaboration with KOLLMORGEN, the drives feature 75 digital inputs, 22 digital outputs and 10 analog inputs and outputs, respectively. With this “on board” technology, Bottero saves 30% of decentralized I/O systems, reducing the hardware and installation costs, as well as space in the control cabinet. The communication with the upper level control unit with a October 2014
in a single order, a wide range of thicknesses and sizes of the product.
Integrated IPC: the freely programmable AKD PDMM drive.
touch panel display system is realized through Modbus TCP. Increasing automation With the Titan series, Bottero has managed to meet the needs of mass production, allowing the use of the production lines both in major industries and in mediumsized enterprises. This plant is a concrete example of the increase of the automation level in the glass processing industry, oriented to a mixed production in order to provide,
October2014 2014 October
“The companies that work the glass must be able to respond to these requests with the appropriate facilities,” says Andreas Dürrstein, Bottero Sales Manager in Germany. He foresees that, in the future, the detection of the plates in the plants will take place automatically. In this case, the reading of the information occurs, for example, by means of bar codes, and allows to automatically launch the following work steps. In a highly competitive international market, dominated by mediocre products, the choice of special products, with a customized finish, offers German companies “an excellent opportunity to gain a foothold in the market,” Dürrstein stresses during an interview with the Glaswelt magazine. The unique selling point of the company, based in Cuneo
Bottero plants follow the current market trend that prefers small batch sizes.
(Italy), is to provide high-tech and extensive know-how in all areas of the construction of machines for glass processing. Bottero builds full plants for processing of laminated and monolithic flat glass, as well as for the production of glass containers. About Kollmorgen Kollmorgen is a leading provider of integrated automation and drive systems along with corresponding components for machine builders all over the world.
With more than 70 years of Motion Control Design and application experience and profound knowledge of constructing standard and special solutions, Kollmorgen supplies solutions time and again that stand out in terms of performance, quality, reliability, and ease of use. As a result, customers can achieve a market advantage which is beyond question. For further information please contact think@kollmorgen.com or visit our website www.kollmorgen.in
www.martupdate.com www.martupdate.com
3535
FAIR MART
Specially-Crafted Feature Areas: a Focus at MTA2015 MTA2015, Asia’s premier precision engineering industry event, will return from 14 to 17 April next year at the Singapore Expo. With its hallmark showcase of high-value manufacturing capabilities, MTA2015 will highlight manufacturing excellence in industries such as Aerospace, Complex Equipment, Electronics, Energy, Medical Technology and Oil & Gas / Marine & Offshore Engineering. Feature areas to bring
Society of Singapore (OPSS)
technologies to life
is happy to participate in
Apart from the Capabilities Hub which drew strong interest from trade visitors, this upcoming edition will unveil a brand new feature, the Optical Engineering Focus Area. Optical Engineering Focus
MTA2015 in the Optical Engineering Focus Area. MTA2015 is a great platform for industry players and companies to come together to share ideas, network and continue our support for each other in the region’s high-value
Area
manufacturing industry. Co-
Working with the Optics and
conference, the industry can
Photonics Society of Singapore
also update themselves on
(OPSS), an area dedicated
the latest technologies and
to products and services in
trends in optical engineering,”
the field of laser and optical
says Professor Anand Asundi,
engineering will be developed
Chairman of OPSS.
located with the icOPEN2015
for the event. The focus area will bring together optical engineering technology suppliers from China, Germany
“Manufacturing in the Asian region is no longer simply supplying the labour to make
and Malaysia.
many of the products we use
“The Optics and Photonics
technological advances and
today. It has evolved with
Visitors checking out products at Mitutoyo booth
manufacturers and suppliers are
Exhibition Services, organiser
now looking at how to create and
of MTA2015.
add value to their manufacturing processes,” says Mr. William Lim, Crowds exploring the exhibition halls at MTA2013
36
www.martupdate.com
Project Director at Singapore
Capabilities Hub The Capabilities Hub will once
October 2014
research and development grow, MTA2015 is well-placed to provide the links between major industry players and suppliers across the value chain. MetrologyAsia2015: Serving
Metrology Asia Pacific, Jenoptik South East Asia, Mitutoyo Asia Pacific, Optical Gaging, Renishaw (Singapore) and Wenzel Asia. Knowledge sharing and discussions at MTA2015
industry’s demands for precise
icOPEN, now known as the International Conference on Optical and Photonic MetrologyAsia2015, an area Engineering, and the PE COI dedicated to metrology Annual Conference will also equipment, will cast a spotlight return. These two conferences on companies specialising in will feature technical and high-end test and measurement industry experts giving their apparatuses and systems. insights on the latest trends Attendees will be exposed to the and issues facing the precision latest in metrology technology engineering industry. and equipment to meet their measurements
Guest of Honour at the Opening Ceremony of MTA2013 Mr Lee Yi Shyan, Senior Minister of State, Minstry of Trade & Industry and National Development
again bring together local parts
highlight their manufacturing
and component manufacturers
competencies in the high-
and service providers to
value sectors of Oil & Gas,
precision measuring needs.
MTA2015 will incorporate iAutomation2015, MetalAsia2015, The last edition of MTA saw Outsource&SubCon2015 and participation from metrology ToolTec2015, specialised events bigwigs such as Blum Production that cater to the individual needs Metrology, Carl Zeiss, Hexagon of Asia’s manufacturing industry.
Medical Technology, Aerospace and Complex Equipment. A collaborative effort with the Singapore Institute of Manufacturing Technology (SIMTech), this area will connect local and overseas manufacturers and enhance their ties through networking and collaboration. To-date, exhibition stalwarts such as A&ONE Precision Engineering, ACP Metal
William Lim
Finishing, CEI Contract
Project Director, SES
Manufacturing, Eratech,
“MTA has been moving
Meiban Group, Microcast,
in tandem with industry
Nanotechnology
trends and the addition
Manufacturing, Onn Wah
of new feature areas will
Precision Machining, PCI,
not only provide a premier sourcing platform of the latest state-of-the-art precision engineering technologies and solutions,
Fujicon Engineering,
Shine Precision Engineering, SolidMicron Technologies
Show:
MTA2015 - The 20th Precision Engineering Industry Event (held alongside Metrology Asia2015
Incorporating:
iAutomation2015, MetalAsia2015, Outsource&SubCon2015, ToolTec2015
Date:
14 – 17 April 2015 (Tuesday - Friday)
Venue:
Singapore Expo, Halls 3 & 4A
and ST Kinetics Integrated Engineering, have confirmed their participation in this space.
it will also create a
MTA2015: High calibre
comprehensive and holistic
manufacturing showcase
Opening Hours:
10.30am to 6pm daily
As manufacturing processes
Admission:
Business and trade professionals
become more sophisticated
Website:
www.mta-asia.com
experience for attendees,” he adds.
and requirements for advanced October2014 2014 October
www.martupdate.com www.martupdate.com
3737
MART UPDATE
Delta conducts Seminar on Power Management Approach for Critical Applications Power management company Delta hosted a Seminar at Hotel Green Park, Hyderabad on Power Management Approach for Mission Critical Applications. The Seminar highlighted how energy
efficiency can be improved & save costs for the industry owners. Also, showcased Delta’s industry leading offerings that help to improve energy efficiency, increase uptime in critical operations
“Delta is well positioned and committed to partner with industry leaders to make them competitive in their respective businesses by providing world class power management solutions that improve energy efficiency, ensure business Suhas Joshi
continuity and decrease
Vice President
energy costs.”
Delta Power Solutions
and protect people, property and the environment.
owners to significantly reduce total cost of ownership.
The Seminar was a platform initiated by Delta to reach out to customers, influencers and end-users and enable effective market interactions across major regions and key industry segments.
Delta’s Mission Critical Infrastructure Solutions (MCIS) business unit (BU) has developed a variety of UPS solutions. Positioned as “The power behind competitiveness,” the MCIS strives to play an important role in making our customers’ businesses and operations more competitive. Our mission is realized by providing highly reliable and efficient power management products, including UPS and datacenter infrastructure solutions that ensure the continuity of mission critical operations and better total cost of ownership (TCO). For further details visit www.deltapowersolutions.com
More than 240 IT Heads/ Partners/ CEO/ Consultants from Pharma, Hospitality, Constructions, and Manufacturing industries participated in the event. For the manufacturing and IT/ Data Center industries, achieving a balance between maximum functionality and cost optimization is essential. Delta’s innovative technologies from UPS and Data Center Solutions help the industry
Schneider Electric India launches EnergySaving Smart Panels Schneider Electric, the global specialist in energy management, today launched the Smart Panel concept to ensure sustainable energy savings in buildings, such as public and commercial offices, modern retail premises, hospitals and hotels apart from industrial setups. Based upon Schneider Electric’s energy management principle of ‘measure, connect, and save’, Smart Panel is a simple-to-deploy plug and play solution contributing towards by addressing the urgent need to curb energy costs and meet norms for green buildings. During the past decade, Schneider Electric has revolutionized low-voltage switchboards technology. Today Schneider Electric has
38
www.martupdate.com
introduced the Gen Next lowvoltage switchboards: Smart Panels which are intelligently embedded with metering, control, and communication capabilities. In the ‘measure’ stage, the Smart Panel system ensures energy consumption metering at source is automated. This simplifies daily operations and eliminates the traditional error-prone manual data gathering. In the second ‘connect’ stage, Smart Panels use reliable, simple to install and use displays, and Ethernet and Modbus interfaces on the communication system enabling data access locally as well as remotely over cloud. The third stage, ‘save’, assists building owners, facility managers or residents to
undertake energy analyses. This is achieved through onsite real-time monitoring and control (on touchscreen displays connected to the Ethernet or on a computer display with IE browser), which gives a clear under-standing of the building’s energy consumption by zone and usage types. Building owners and facility managers can then undertake appropriate measures for the best use of energy resources without affecting the comfort and productivity of occupants. Beginning with Bangalore,
For buildings and industrial applications, Smart Panels ensure energy management in 3 simple steps: measure, connect, and save Smart Panels will be launched between 16 September and 10 November in 10 other cities across India. Worldwide, Schneider Electric has a longstanding legacy of offering integrated solutions that make energy safe, reliable, efficient, productive and green across multiple market segments. For further details visit www.schneider-electric.com October 2014
Small but powerful! Balluff MICROmote® sensors The miniaturized MICROmote® photoelectric sensors from Balluff with separate electronic processor unit provide a large amount of optical performance in a tiny amount of space, thanks to the miniaturized LEDs, photodiodes and phototransistors. Balluff
specially developed a new, patented manufacturing process for its production. This provides the micro-optical components with high optical precision. The MICROmote® sensors are ideal in small installation spaces and on moving machine parts and robot grippers, where low weight is necessary. The robust sensors integrated into the metal housing are operated with a separate amplifier, which can be positioned outside the action area. Highly flexible electrical cables provide secure transmission of the sensor signals between the sensor head and the amplifier. In this way,
the sensors are also a technical alternative to fiber optics. An additional plus: The amplifier features ergonomic indicators and operating elements. The photoelectric sensor heads with dimensions of just a few millimeters not only have impressive technical characteristic values, but also numerous other unique selling points. Thanks to a sophisticated modular system, users can find the ideal solution quickly and cost-effectively. It does not matter if the application involves position detection of small parts, identification and counting of objects or detecting the filling levels of foaming liquids.
Available products not only include, diffuse sensors, through-beam sensors, highvacuum sensors, fork sensors, but also precision hose sensors used, for example, in the detection of liquids and bubbles. For further details visit www.balluff.co.in
Indo-MIM: Leaping at each level with innovation! Indo-US MIM Tec Pvt Ltd (Indo-MIM), a leading global supplier of precisionengineered products using Metal Injection Molding (MIM), has successfully carved a global positioning in the MIM industry. In an attempt to extend its reach, Indo-MIM had conducted a MIM-Technical Expo in Detroit, Michigan on 30th September 2014. With an intention to reach the MIM professionals and disseminate the details of the process along with advanced applications, the Technical-Expo was conducted on a larger platform. The technology, which is still not a common understanding with engineering professionals, was effectively revived by Indo-MIM with valued presentations and
October2014 2014 October
““This Technical Expo helped us to reach more than one potential MIM customers at the same time. Our capabilities in terms of the technology and details of our fully integrated infrastructureconvinced Jag Holla
many at the Expo to
VP-Marketing, Indo-MIM
seriously consider the MIM
discussions. The objective was to share the best practices and case studies in addition to the MIM process details with control parameters and design guidelines. The participation was encouraging. Mr Jag Holla, VP-Marketing,
Indo-MIM led the expo with detailed discussions on MIM Material applications and the tooling concepts. Mr Param Gutti- Sales Manager discussed the plant capabilities, MIM Process design guidelines in addition to process cost drivers.
process for their future programs as well as for the current production parts that could result in significant cost reductions. We will conduct many more Expo events in the next 12 months that would help Indo-MIM connect with more potential users in the US Market.”
Mr Jeffery Donovan- Business Development Manager, specific to automotive market discussed the potential applications with the attendees along with the details of success stories from the Automotive Segment using MIM process.
www.martupdate.com www.martupdate.com
3939
Grundfos India launches the new range of BMS Pumps used in water treatment Grundfos India announced the launch of the new range of BMS Pumps for high flow and pressure applications, including reverse osmosis and ultra-filtration. The
new range of BMS pumps are light-weight ultra-filtration booster module. Identifying the need that sustainable water treatment solutions
require the pumping solution to be durable, cost effective and offering trouble-free operation, the simple design and durable components of
these pumps eliminate costly downtime.
David McMillan Chief Operating Officer - Sales Grundfos India
“We are happy to announce
and alignment due to
the new range of BMS
improved design are key
pumps. We have focused
benefits of the BMS range
on simplicity of the product
of pumps. Last year we
which has removed
launched the S-tube impeller
maintenance-heavy
for the wastewater segment
components and resulted in
which was a huge success.
easy access to all vital parts.
Likewise, we are confident
Energy savings due to high
that this product will be well
efficiency, easy maintenance
received in the market too.”
Combined with a permanent magnet motor, the efficiency of the pump has been improved by up to 5% and the weight is reduced by more than 75%. This is in line with Grundfos’ continuous endeavour to increase their products’ efficiency and sustainability. For further details visit www.grundfos.in
New Anybus gateway makes Modbus devices talk BACnet The new Anybus BACnet to Modbus gateway makes it possible to connect Modbus devices to a BACnet network. The gateway handles conversion between Modbus (RTU, ASCII, and TCP) and BACnet/IP and makes each connected Modbus device appear as a BACnet compliant device on the BACnet network. As BACnet networks are increasingly being used in buildings and infrastructure installations, there is also an increasing demand for integrating devices that communicate on Modbus into BACnet networks. Therefore, HMS now presents the Anybus BACnet to Modbus gateway. This gateway works as a translator between the two networks allowing Modbus RTU, ASCII and TCP-devices
40
www.martupdate.com
to show up as individual BACnet-compliant devices on a BACnet/IP network. This enables central BACnet control and supervision of Modbus devices such as drives, HVAC controllers and measuring equipment in building installations. Making BACnet system integration easier “The Anybus BACnet to Modbus gateway gives system integrators and building owners more flexibility, as they now can use Modbus devices in BACnet projects as well,” comments Markus Bladh, Product Manager at HMS. “The gateway is also a good fit for machine builders who want to offer their products to the building automation market. We are seeing an increasing general
market demand to connect Modbus devices to BACnet networks, and this new gateway adds yet another gateway combination to the over 300 Anybus gateways already available off the shelf for fieldbus and industrial Ethernet connectivity.“ How the gateway works ? Two ports are available on the gateway to connect to serial Modbus (RTU and ASCII) and Ethernet (BACnet/IP and Modbus TCP). When connected, users will be benefitted from a free library of common Modbus device profiles in order to quickly establish communication between the networks. HMS also provides a straight-forward tool with instructions on how to create
device profiles for Modbus devices not yet covered by the library. Commissioning and troubleshooting is done in the included web interface. The new Anybus gateway is available as of October 1st 2014. For further details write to in-sales@hms.se September October 2014
High performance in a compact design Backlash-free ROBA®-DS servo couplings with split clamping hubs The high-performance ROBA®-
transmit high torques even
DS shaft couplings transmit
at comparatively smaller
the torque backlash-free and
diameter, which makes them
with high torsional rigidity.
the ideal shaft couplings for
They compensate for shaft
dynamic drive systems with
misalignment and are both
high speeds. These couplings
wear- and maintenance-
are made of steel and high-
free. On the sizes up to 150
strength aluminum alloys,
Newton meters, mayr® power
which forms the basis for the
transmission are going to
extremely compact design.
extend its standard hubs for mounting the shafts by a radially divisible hub – for easy and fast installation, even in difficult ambient conditions. Short dimensions, little installation space requirements, reduced weight and low mass moments of inertia – the ROBA®-DS servo couplings win over customers due to their high performance density. They are able to
Fig. 1 : Radial installation: The ROBA®-DS servo couplings with split clamping hubs guarantee easy and fast installation, even in difficult ambient conditions: They are suitable for large shaft distances and in all applications, in which the drive aggregates must not be moved any more.
Backlash-free torque torsional rigidity. Therefore,
transmission The couplings compensate for radial, axial and angular shaft misalignments by means of the flexible disk packs. This way, they protect the bearings from unwanted wear and tear and prevent unnecessary downtimes and costs. In order to achieve backlash-free torque transmission, the disks in the fixing area are treated with a special blasting procedure. The ROBA®-DS disk pack couplings are robust and reliable. They are temperatureresistant, wear- and maintenance-
Fig. 2 : High-performance ROBA®-DS servo couplings: They transmit high torques even at comparatively small volumes and are the ideal shaft couplings for dynamic drive systems with large speeds.
free and transmit the torque with very high
they are especially suited for applications in extreme ambient conditions. Fast and easy installation The area of application of servo couplings is growing. Therefore, mayr® power transmission has extended the standard hubs for shaft attachment by a radially divisible hub, the so-called split clamping hub, also for sizes 3 to 15. At permitted speeds of 3000 rotations per minute, these sizes for shaft diameters of 45 to 79 millimeters cover torques from 35 to 150 Newton meters. The half-shells guarantee easy and fast coupling installation, even in difficult ambient conditions. Therefore, the hubs are used preferably in applications, in which the drive aggregates such as the motor
Auro offers WatchDog® 2000 Series Weather Stations Professional grade solutions for early pest/ disease forecasting, efficient irrigation management and microclimate and field research. WatchDog 2000 Series Weather Stations deliver accurate, real-time weather information directly from your orchard or October2014 2014 October
vineyard. Together with Spec 9 Pro software, you can monitor, record and analyze over a dozen important growing conditions for more effective and profitable crop and pest management. For further details write to auroindia@gmail.com or visit www.auroindia.net
and the gearbox must not be moved after the positioning and aligning for coupling installation. These hubs are also recommended for large shaft distances, for example, for cardan shafts in linear actuators, as in these cases the coupling is installed last and therefore has to be easy to install. High performance density Installation is carried out radially: To do this, the coupling is brought to the shafts and pre-assembled with the axially moveable half-shells. Here, it is important that the markings on the half-shells and on the hub bodies overlap. Then, the cap screws must be tightened evenly and in several sequences to the required tightening torque. The ROBA®-DS servo couplings are available as double-jointed couplings with a connection plate or a variable-length sleeve. Their compact design, the short installation times and the high performance density make these couplings a particularly efficient and economic solution. For further details write to National Engineering Company (NENCO), J-225, MIDC Bhosari, Pune 411026 Tel: +91 20 27474529 Email: nenco@nenco.org
www.martupdate.com www.martupdate.com
4141
Switchgear configured efficiently: New coupling between EEC and Eplan Pro Panel The new interaction between EEC and Eplan Pro Panel ensures collaboration: control cabinets and switchgears can now be automatically configured instead of being planned manually. This saves time and sustainably ensures quality and reutilisation. Configuration instead of planning, this maxim has been a key factor for the continuously growing requirement of accelerating product development processes since the introduction of the Eplan Engineering Center (EEC). With the coupling of EEC and Eplan Pro Panel Professional to form a integrated solution, the future-orientated technology of configuration is now also moving into control cabinet and switchgear manufacturing. The main advantage for users: configuration is based upon predefined rules and standards. All of the knowledge relating to components, modules, mechanical forms and electricalrequirements are deposited in the system. These considerably improve the quality of documentation. The optional connection of Eplan Pro Panel to the EEC is available with the new release of the Eplan Engineering Center,
which will be appearing at the Hannover Messe. Knowledge anchored in the system Companies that produce their own control cabinet scan map the various components of control cabinet or switchgear manufacture in one modular system with the integratedsolution of EEC and Eplan Pro Panel. This modular system is the basis for the configuration of new, customer-specific control cabinets and switchgear. The options for reutilisation increase within the framework of configuration. In this way, users not only save time and money, but also optimise the quality of documentation through standardisation and quality control of the modules. If the modular system is filled with corresponding information, the mounting layout can automatically be generated in 3D. If required, the configuration can be expanded or adapted to suit the customer’s needs. This also supports last-minute changes. The options for configuration in conjunction with the 3D software Eplan Pro Panel unlocks new potential for use in technological
engineering within the field of control cabinet and switchgear manufacturing. Manufacturing, assembly, tender preparation At the same time, the mounting Control cabinets and switchgear can be automatically conlayout is the basis figured with the new coupling of EEC and Eplan Pro Panel. for numerous other process steps in the manufacturing and optimised. This also effects assembly of the control cabinet related disciplines such as solutions, such as virtual control the automated generation cabinet wiring including length of quotations. In addition, calculation of wires and cables. engineering also benefits In this way, a continuous product development process is supported from the first concept draft via hardware and technological engineering right up to manufacture. In addition, manual manufacturing steps can then be completely automated by the creation of component and assembly lists, drilling templates and also manufacturing and assembly drawings. In addition, NCmachines for mechanical processing, automates for the wire- and terminal-assembly androbotics for automated device wiring are also supported.
from this deep integration:
The process chain in product development is thus significantly
For further details visit
Mechanical drawings,electricals chematics and PLC programs can be generated via EEC. Due to the automated generation of 3D mounting layouts, the efficient process of product development based on a mechatronic configuration is completed. Thus clear savings potentials can be achieved, especially for companies in the field of machine construction and also control cabinet and switchgear manufacturing.
www.eplan.in
NI Collaborates With CROWD to Define 5G Wireless Communications National Instruments, the provider of solutions that enable engineers and scientists to solve the world’s greatest engineering challenges, announced today its collaboration with CROWD, the European Union Framework Project 7 (EU FP7), to define next-generation wireless 5G communications. CROWD researches the combination of
42
www.martupdate.com
small- and large-density cells in a heterogeneous wireless network for an efficient architecture in which small cells meet traffic hot-spot needs while large cells offer reliable coverage for high-mobility users. NI, one of seven collaborators in the CROWD consortium, leads the testbed activities
within the EU FP7 CROWD research project in the domain of future communication and ICT services infrastructures. An NI PXI chassis running FlexRIO FPGA modules, NI 5791 RF front-end modules and LabVIEW system design software provides the infrastructure for an LTE/ WiFitestbed for conducting
experiments to showcase software defined networking concepts proposed by various partners in the project. As a CROWD member, NI researches reliable high-speed data access at all points in dense networks through small cell densification. To read more about how NI is improving the future of 5G, visit ni.com/5g September October 2014
CXT® UNO: Based on Proven Solutions The new crane, the CXT®
technology, and will extend
UNO, has been developed to
Konecranes’ product offering
give small and medium-sized
for these markets. The CXT
customers in emerging markets
UNO is primarily intended
access to Konecranes’ proven
for companies operating in manufacturing, construction, and logistics.
Saeesh Nevrekar Country Manager Konecranes India
“The CXT UNO is important for us because it expands our product offering into a segment where we haven’t been present before. The CXT UNO offers customers in this category access to Konecranes’ quality and reliability in what we believe is a very attractive and competitive overall package.”
The CXT UNO is based on Konecranes’ existing CXT hoist, and delivers many of the industry-leading strengths of the CXT. It is Konecranes’ second product to be launched for emerging markets this year and follows the BOXHUNTER, an innovative new type of RTG for ports and terminals.
to 10 tons up to 9 meters off the ground, the CXT UNO features a 2-speed hoisting and travelling design with a fixed pendant controller, tagline festooning, and compact single-girder construction, and can operate over spans of up to 20 meters.
launched in India, a market
Thanks to its simple, standardized design, the CXT UNO will be available with very competitive delivery times.
A new product based on proven solutions
The design draws on input collected in the field and prioritizes issues such as quality, reliability in both intensive and lessfrequent usage, and ease of maintenance.
Capable of lifting loads up
The CXT UNO is being initially
The CXT UNO combines a strong range of features based on a simpler set of components and technical solutions compared to existing CXT products. This simpler design, together with easy access to spare parts, means that the CXT UNO will be easy to maintain.
with significant potential for industrial cranes and one where Konecranes has been building a growing presence over the last few years. Following the rollout in India, the plan is to introduce the CXT UNO in other countries in the near future.
For more information about Konecranes’ CXT UNO please visit http://www.konecranes.com/ cxtuno.
ANSYS, Stanford and Honeywell Collaborate to create more Fuel-Efficient Aircraft Engines Engineers from Stanford
engine component material.
hole-placement on turbine
resonance velocimetry to
University, Honeywell
A well-established method
airfoils has been optimized
measure the velocity and
International and ANSYS
for maintaining turbine blade
by elaborate experiments,
concentration field in a test
are working together with
temperatures at acceptable
sometimes necessitating
section. These methods measure
simulation software to create
levels is to employ “film-
engine testing. For decades,
the turbulent interaction of
more energy-efficient aircraft
cooling,” a technique in which
research engineers have
crossflow jets with the main flow,
engines at lower costs.
cooler, compressor-discharge
been developing computer
for a variety of jet configurations
air is detoured around the
simulations of film cooling
and orientations. These data sets
combustor and then ejected
geometries with the ambition
provide an important benchmark
from precisely-machined holes
of reducing – if not eliminating
against which the large available
placed over the surface of the
– the need for expensive, time-
range of ANSYS turbulence
turbine airfoil. Excessive use of
consuming rig testing.
models and computational
As demand grows for increased gas turbine efficiency, engine manufacturers are challenged with creating designs that operate at higher temperatures. But that becomes a significant challenge as temperatures approach the melting point of some October2014 2014 October
compressor air for turbine film cooling can, however, reduce engine efficiency. Historically, film-cooling-
Stanford, with support from Honeywell and ANSYS, is performing a new type of testing with 3-D magnetic
methods can be compared. The objective is to develop validated models, methods and best practices for prediction of film cooling. www.martupdate.com www.martupdate.com
4343
Dormer innovates Milling Programmes To coincide with the forthcoming launch of their new rotary tooling catalogue in November, Dormer has strengthened its solid carbide milling programme with the introduction of several new ranges. These include additions to existing cutter families as well as completely new ranges, such as, corner radius and super finishing cutters. The most significant impact concerns Dormer’s multiapplication carbide milling range. Numerous unequal helix, corner radius and ripper variants greatly expand the options available to customers looking for multi-material
Gautam Ahuja Managing Director Dormer Tools India Pvt Ltd
The new range is one of the largest additions into Dormer family at one time. The new Solid Carbide End Mills target a wide range of difficult to machine materials including Stainless Steels, Titanium and Nickel alloys. This gives the distinct advantage to customers looking for multi-material versatility and consistent performance, resulting in reduced inventories and savings of tool change over times.
44
www.martupdate.com
versatility and consistent performance.
Achieve True 90o Shoulder Milling With High Performance
Designed primarily to improve production efficiency, the new cutters are recommended for use in a wide range of machines, applications and material types with the subsequent benefits of reduced inventory and time saved on tool changeover. Also included in the multi-material machining programme are three chamfer cutters, available with 60°, 90° or 120° angles.The company’s ball nose cutter range is another bolstered by new additions. The introduction of several surface finishes and rake angles broadens the range of applications across the full spectrum of material types, extending to hardened steels (up to 63HRc). A completely new addition to Dormer’s carbide milling portfolio comes in the form of several four flute corner radius end mills. All feature unequal helix geometry and a variety of corner radii for smoother cutting action and increased corner life in a range of tough applications including fillet radii machining. Two new cutter families target milling operations in a wide range of difficult to machine materials including stainless steels, titanium and nickel alloys. The first features unequal helix and unequal pitch geometry and supports operations from slotting to semi-finishing. The second new range consists of multi-flute super-finishing cutters. Available with either Aluminium Titanium Nitride or Titanium Silicon Nitride coatings, all feature very high helix and low rake angles for
As a job-shop owner, how would you describe an ideal, go-to tool? Certainly, it should be a high-performance tool that can cover multiple functions such as shoulder milling, slotting, pocket milling, ramping and helical interpolation.
consistent performance and tool life in target materials, including hardened steels, stainless steel and titanium and nickel alloys. Finally, several new single and two flute cutters support milling operations in Aluminium and other nonferrous materials. All feature highly polished surfaces to reduce friction between the surface of the tool and the workpiece, promoting fast, efficient, swarf evacuation and reduced machine downtime. A true diamond coated version is also available for highly abrasive materials – predominantly graphite. All cutters are available in a variety of cut and overall lengths to promote use in a range of operations. Further information on all new milling cutters can be found in Dormer’s new catalogue, available via your local sales office from November, or visiting the website www.dormertools.com
All inserts are available in the latest WIDIA VictoryTM grades for a variety of workpiece materials. And naturally it should have the performance and working life that make it an economical win for present and future production tasks. This ideal product is the new VSM11 platform from WIDIA. Designed for low horsepower draw and free machining, the VSM11 delivers an effective onetwo punch of reduced horsepower at the machine and higher speed and feed rates that get jobs done faster. VSM11 cutter bodies have an integral chip gash design for excellent chip evacuation along with hardened-steel construction and hardened pocket seats for improved resistance to deformation. They are available in shell, screw on, cylindrical shank, and Weldon shank models with internal air and coolant capability. VSM11 11-mm insert has an optimized cutting edge and positive rake face that provides a true 90-degree wall while concurrently reducing cutting forces and providing excellent, stepless surface finishes. Six WIDIA VictoryTM grades and five geometries make up a well-rounded portfolio of first-choice recommendations covering multiple material types and machining tasks. To locate a WIDIA distributor, contact: WIDIA Products Group +91 80 2219 8341 or visit www.widia.com September October 2014
e-cord micro protects the smallest hoses Modular system from igus to guide and protect very small hoses and cables Moving small scale capillary tubes reliably and safely often poses major problems to design engineers, especially in the medical industry. igus has now developed the e-cord micro system to address this. The modular system of straight, curved and mounting parts, means that even the smallest tubes can be fitted into moving equipment with confidence. Medical machines often contain dosing and pipetting functions which require
designed the e-cord micro to help in these cases. The system ensures the hoses do not fall within a pre-defined minimum bend radius of 45mm, and are also given some physical protection. The modular nature of the system and the elasticity of the material allows machine designers lots of flexibility when designing moving capillary tubes into the smallest of spaces. Modular Design
The e-cord micro is made of low friction tribo-plastics with predefined bending radii to reliably move small capillary tubes and cables.
the constant movement of
igus assembles the e-cord
capillary tubes, which are only
micro to order, ensuring a
a millimetre or so in diameter.
perfect match to the required
In these applications the
motion and space of the
fragile capillary tubes are often
machine. In this way, different
squeezed into a small bend
movement directions and
radius which can cause damage
travel path lengths can be
challenges. By producing a
to the tubes or blockages in the
implemented easily and
flexible solution, many other
flow through them. igus has
flexibly. The concept for the
applications in different
e-cord micro, like many other igus products, was driven by customer requirements for a novel solution to their specific
industries can be realised too. For further details write to Harish Bhooshan, Product Manager, E-ChainSystems® & ReadyChains® , igus (India) Private Limited at Harish@igus.in. Visit www.igus.in
HARTING bags Robotics China Excellence Supplier Award HARTING (Zhuhai) Sales Ltd and ABB Engineering (Shanghai) Ltd Robotics BU maintains a long term cooperation in terms of R&D, manufacturing and application of robotics. HARTING (Zhuhai) Sales Ltd won the award of 2014 Robotics China Excellence Supplier presented by ABB Shanghai among over 200 suppliers. HARTING products have been widely used in the production of robots and robotic system and application solutions in ABB Engineering (Shanghai) Ltd Robotics BU. As a professional connector supplier, HARTING provides a powerful support and October2014 2014 October
guarantee for the safe and reliable production of ABB Engineering (Shanghai) Ltd Robotics BU with its excellent product range, customized solution and fast-responding service capabilities. ABB is a pioneer and leader in China’s industrial robots and the only one multinational company to date which develops whole value chain business in China, from R&D, production, sales, engineering and system integration to service. ABB boasting the largest and strongest industrial robot R&D, production and application base in China. (Source: ABB) HARTING, founded in 1945
Kevin Sjoberg represented HARTING to receive the award.
is the market leader in connectivity and industrial networks technology. HARTING meets high requirements in numerous disciplines. All products fulfill high quality and offer outstanding robustness
and reliability to sustain tough environment. HARTING is the first global connector manufacturer in the China market awarded the China Compulsory Certification (CCC). For Further details write to www.harting.in www.martupdate.com www.martupdate.com
4545
HaasTEC India events set for November and December The popular HaasTEC shows are returning to India later this year with two events arranged for different regions of the nation. Managed by the Haas Factory Outlet (HFO) in India (Phillipscorp, CNCSSIPL division), the first HaasTEC will take place on 19th-22nd November at Ahmedabad in the western state of Gujarat and will be followed closely by HaasTEC Manesar from 10th to 13th December, in the industrial district of Gurgaon near New Delhi. In line with previous HaasTEC events, a number of innovative, affordable Haas CNC machine tools will be on view. Indeed, two machines will be on show for the first time in India, the UMC-750 five-axis universal machining centre and the ST-35 big bore CNC lathe. All of the Haas CNC machine tools on display will be powered and performing demonstrations, cutting metal. Haas specialists from the HFO will be available to guide visitors through the demonstrations and answer any questions about the machines. The UMC-750 five-axis vertical machining centre offers a capacity of 762 x 508 x 508 mm in the X, Y and Z-axis
respectively. It features a two-axis inbuilt trunnion rotary table and a 40-taper, 22.4 kW, 12000 rpm direct drive spindle. Other features of this advanced machine include a 40+1 side mount tool changer, 25.4 m/ min rapids, co-ordinate rotation and scaling, rigid tapping, a wireless intuitive probing system and a 284 litre flood coolant system. The Haas ST-35 big bore CNC lathe can accommodate bars up to 102 mm in diameter and offers a capacity of 533 (dia) x 660 mm (length) with 806 mm of swing. The 29.8 kW, 2400 rpm spindle is served by a two-speed gearbox, while additional features include a 381 mm chuck, 12-station bolt-on turret and rigid tapping
capability.
technologies and advice.
Other Haas CNC machine tool models scheduled to appear at both HaasTEC events include the ST-10Y turning center with Y-axis, the ever popular DT-1 Drill Tap machine with new 30 taper 15,000 rpm spindle, a VF-2 VMC, a VF-2YT VMC with a new inline 15000 rpm 40 taper spindle, and the VF3YT/50 VMC, which provides extended Y-axis travel and the heavy cutting capacity of a 50-taper machine in a mid-sized footprint.Visitors are invited to bring along components or drawings for a full evaluation of optimized machining solutions. Indeed, the HaasTEC events will also feature a number of the company’s industrial partners, all able to offer complementary
Demonstrations, tours and a live Q&A counter will be among other event highlights. In fact, there are even plans to give away a limited edition Haas wrist watches to those who pre-register before 5th November. Pre-registrations go live on 1st October at: www.haascnc.com/openhouse Event address: HaasTEC Ahmedabad 2014 Vatva Industries Association, Phase I G/1, Gidc Estate, Vatva, Ahmedabad, Gujarat 382445 Event address: HaasTEC Manesar 2014 HFO, a division of CNCSSIPL, Plot No. 226, Sector 6,IMT Manesar, Gurgaon, Haryana 122 050
Hypertherm appoints new Asia Pacific Regional Director Hypertherm, a U.S based manufacturer of plasma, laser, and waterjet cutting systems, is pleased to announce that Israel Gonzalez has been appointed the Regional Director for the Asia Pacific Region, which consists of Australia, India, Japan, Indonesia, Malaysia, New Zealand, Philippines, Singapore, South Korea, Taiwan, Thailand, and Vietnam. Israel joined Hypertherm
46
www.martupdate.com
Mexico in 2008 as a Consumable Sales Manager. In 2010, he was promoted to lead the Mexican team, where he demonstrated his impressive organizational skills, excellent knowledge of Hypertherm’s products and their applications, and strong team management capabilities. Prior to joining Hypertherm, he was the Customer Solutions Manager for Festo Pneumatic S.A. and led a team of 16 Associates,
based throughout Mexico. Israel holds a Master’s Degree in Mechanical Design and Robotics from the Universidad Nacional Autonomá de México. He will be responsible for the continued development of the full spectrum of sales, service, logistics, financial administration and Hypertherm’s go-to-market strategy in Asia Pacific, a rapidly emerging and strategically important market. September October 2014
October 2014
www.martupdate.com
47
Miniature Gripper from SCHUNK for High-Precision Assembly Applications The precision version of the miniature parallel gripper MPG-plus from SCHUNK has been specifically developed for automated assembly of electronic components and other small parts. The standardized module has been manufactured with tolerances that are tight enough so that high-precision applications are feasible. Its exchange accuracy amounts to 0.1 mm, the eccentricity of the gripping center amounts to 0.05 mm, and the equal height is 0.02 mm. The maximum accuracy of the mounting sur-face to the clamping center is always ensured. With this precision gripper, even filigree parts can be exactly positioned. Moreover, it is possible to locate several modules next to each other on a mounting surface at the same height. If required, the high-precision MPG-plus can be exchanged by Plug & Work and no tedious fine-adjustment or re-teaching
is necessary. Due to an
allow for dynamic applications,
efficient, highly standardized
surplus material at the gripper
production process the gripper
housing has been saved, and
is extremely attractive in price
components inside are made
as well.
of special high-performance
Particularly powerful The miniature parallel gripper MPG-plus from SCHUNK is currently the most powerful mi-niature parallel gripper on the market. Compared with similar modules which require the same input, it achieves a considerably higher output, and paves the way to progressively smaller and efficient systems. Due to its high force and moment load, longer gripper fingers can be used, and higher gripping forces are achieved at the same size. Optionally designers and users can work with smaller sizes at the same requirement of force. A powerful, individually adjusted cross roller guidance ensures high load capacity of the whole guidance, minimum wear, and long service life. To
aluminum. To increase the chance of flexibly designing processes and systems, the module can be screwed through or screw connected laterally and from the bottom. Besides an inductive monitoring, the MPG-plus can be also monitored via integrateable and programmable magnetic switches. The sensors detect two positions, e.g. “Open” and “Closed” without creating larger interfering contours. For increasing process stability, the switch-off points can be also programmed, and even for very low strokes, a safe position monitoring and detection of various workpiece
MPG-plus: At the first go, the precision version of the miniature parallel gripper MPG-plus ensures perfect eccentricity, parallelism, and equal height.
available in sizes from 16 to 64 with finger strokes from 1.5 mm to 10 mm, and gripping forces
sizes is possible.
from 25 N to 350 N. Depending
The standard version and
weightamounts between 0.13
also the precision version of
to 1.25 kg. For further details
the small parts gripper are
visit www.in.schunk.com
on the size, the maximum part
Drive Solution by NORD at BC India NORD Drivesystems Pvt ltd (hall 6, J30-I29) will showcase drive solutions for industrial applications in many sectors such as cranes, airport technology, cement industry, construction machinery & material handling at BC India exhibition, India Expo Centre, Greater Noida, New Delhi from December 15 – 18, 2014. One of the main highlight of exhibits would be modular Industrial Gear Unit with an output torque range of 242,000 Nm in a one-piece unicase housing. Also NORD will present “Power
48
www.martupdate.com
Saving and Cost Efficient model Decentralized Drives all in one of Motor, Gear box, & Frequency drive’’. Complementing the SK 200E line of frequency inverters, the new inverter focuses on the core requirements of speed control and efficiency. It is suitable both for stand-alone variable frequency drives and for synchronized operation with several units. The SK 180E also contains all necessary functions for many fan and pump applications. Here, it can save up to 30 % energy by automatic magnetization
adjustment under partial load. In addition to the SK 180E and the SK 200E, which can also control diagonal and vertical conveying tasks with safety requirements up to SIL3, NORD’s decentralized solutions also include the very economic new SK 135E soft and reverse starter which can carry out simple switching tasks in
Decentralized Drive – SK180E
logistics and conveying. For further details visit www.nord.com September October 2014
THE LAST LEAF Dear Readers, You get what you pay for in life. A very bizarre phrase but very true, almost 99.9 % (if not 100 %) times. Having been a globe-trotter, I have had multiple chances of experiencing this phrase to assess comparative quality of items and people with also an opportunity of benchmarking them. It all relates to ‘value for money’ not just for us as a user of the commodity or service, but also for the manufacturer. If he does not pay enough, he sacrifices on his incoming quality as well, thereby affecting the quality of his output. The world has become digital as people and businesses are now able to interconnect more seamlessly using technologies. It is hard to predict and defend. Therefore, businesses need to start building sustainable competitiveness and flexibility in order to react fast and reap benefits as the first mover to gain an upper hand in competition. We have the benefit of leapfrogging technologies around us. Evidence of this is all around. Hardware, in form of processors to cameras to sensors, continues to get better, smaller and cheaper, opening up opportunities for drones, robots and wearable computers. In fact, innovation is spilling into new areas : in finance, for example, crypto-currencies like Bitcoin hint at new payment technologies, and in education the development of new and more effective online offerings may upend the business of higher education. Employing about 40 % of India’s workforce and contributing 45% to India’s manufacturing output, Small and Medium Enterprises (SME’s) have played a critical role in the industrial development of India. We have 48 million SME’s (second only to China at 50 million SME’s) that have the unique attribute of being less capital intensive that suits the Indian economic environment of scarce resources and large population base. It is the most important employment-generating sector and is an effective tool for promotion of balanced regional development, producing about 8000-odd items. The state of Madhya Pradesh is offering a string resource base with robust infrastructure and favourable policies for consistent economic growth. It has declared itself as a power surplus state. The Global Investor Summit at Indore, held recently, attracted huge investments. India has 65% of population below 35 years of age. “The Prime Minister of India, Mr. Narendra Modi has been focusing on good and effective governance”. With an aim of taking India to greater heights, he launched a website “www.mygov.nic.in” that aims to help citizens contribute in governance by giving their opinions and views on important societal issues. The website will be a technology driven medium, that will provide citizens an opportunity to contribute towards good governance. Being genuinely contrite about the current manufacturing disproportion in the country’s GDP, he has launched a “Make in India” campaign to encourage manufacturing in India. He has launched a 3D campaign –Democracy, Demographic dividend, and Demand. Against the ‘Jan Dhan’ campaign, 4 crore new bank accounts have been created in two weeks - banks have visited door to door to open bank accounts. The people of India have deposited Rs. 1500 crore into bank accounts although a zero balance account was permitted. His dream is that by 2022, all Indians to have house for themselves. As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s solutions. Till then, Happy Technology! Manoj Kabre Member, Editorial Advisory Board (EAB) October 2014
www.martupdate.com
49
50
www.martupdate.com
October 2014
October 2014
www.martupdate.com
51
52
www.martupdate.com
October 2014