MART September 2013

Volume 10 Issue 3 September 2013 Pages 52 `100

A World First

Hand-Guided Core Drilling

for Metal

Electronics to Increase Productivity Creating New Designs of Automation

Make one out of two Hybrid servo cable with bus element for the energy chain from igus September 2013

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September 2013

September 2013

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September 2013

A day begins with a lot of challenges. Some see it as a Problem, and the others takes it as an Opportunity to excel, learn and grow. The challenges we face are different, with the responsibilities involved in his personal and professional front. Being a publisher of an engineering magazine, we are a service provider in the current troubled manufacturing sector, professionally we are going through a lot of challenges to survive.

When companies decides to cut down the cost, the first axe falls on the promotional activities like branding, advertising etc. And with marketing opportunities mushrooming in this digitalized age, companies are getting confused to spend with their limited budget, the publishers’ nightmares further comes with a projection of print media going through a slow death.

Foreword

Dear Readers,

How this has been achieved? Along with the market and readers feedback it was the journals, magazines and other digital platforms around us given different perspective of creative thinking to find unusual solutions. Every month MART comes with a lot of information in different manufacturing segments, with regular columns written by experts. Being a reader of MART, the first column I go through is of P S Satish, who is penning down the regular column on “Managing a SME in India”. The articles helps me to look our business perspective in a different direction. There are no doubt that Manufacturing in India has to grow drastically and without developing Micro, Small and Medium industries we will not succeed.

Government of India is offering a lot of packages to MSME’s to support them establishing new arenas in manufacturing. The majority don’t know about these offers, and the others ignorant. The only way to be updated about the industry is to keep ourselves open to communication. From the October edition we are starting a regular column on different schemes the Government is offering to the industry as well as the financial institutions.

There is a need to change, and if you can do it with the right tools, you are going to stay in the market always with the job on hand. Our survival is connected with the flourishing industry, and we are committed to that. We being the knowledge partner for one of the fastest growing industries in the world, we are looking for new opportunities to provide the best solutions towards upliftment of manufacturing in India.

Hari Shanker Managing Editor

The basic initiative of MART is getting Engineers and Manufacturing India updated through its informative pages. Now it’s the challenge to perform this duty responsibly overcome the existing problems. Our Vision and Mission is Delivering Knowledge and Delivering Value. In our initial years of establishment we never had problems in finding readers. Our growth were consistent and our readership grew steadily. But we admit the fact that before five years, the subscription department witnessed serious decline.

Since the last two years of market feedback and continuous content development we were able to come back on track with a complete product change as well as a team to get the reader aware of the benefits.

It’s you, our readers who always guide to make the best out of us. Your criticism earns us more reach, and we look forward to hear from you.

I wish you a happy and informative reading experience with MART.

September 2013

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Cover Feature 8

Electronics to Increase Productivity

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Make one out of Two

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Advanced Research in Microelectronics with the VHX

Columns 20

Journey Towards Excellence

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Applying Lean to New Product Development

P S Satish

Gorur Sridhar

Crossing the people Managment Chasm a Neccessity of Start up Growth

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Tomasz Tunguz

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GGB Bearing Technology The Global Leader in High Performance Bearing Solutions

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Innovative Energy Technology to Create Environment-friendly Products Volume 10 Issue 3 September 2013 Annual Subscription `1200 Member INS

Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre Mahesh R P

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Siji Nair

Managing Editor Hari Shanker hari@martinfotech.in

Art & Creative

Assistant Editor Arundhati Bhattacharya

+91 9038 005670

Accounts Suresh

Creative Assistant

Pradeep Jayaprakash Sayan Chaudhuri

Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2n Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed Industrial Business Mart reserves the right to use the information published here in any manner September whatsoever. 2013 While every eff ployees accept any responsibilities for any errors or omissions. Š All Rights Reserved

Case Study 16

ESS ARR Metal Industries Raises Productivity with HyPro2000 Torch

Feature Article 28

SPINEA –Solution for Precision

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New Beyond Shield™

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Small, Strong, Smart: New High-Performance Ejectors with Integrated Added Value A world first: Hand-Guided Core Drilling System for Metal

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Available now : New Eplan Platform 2.3

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IXXAT Econ 100: Highly customizable master solution for EtherCAT, CANopen and Powerlink

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Superior by Far Safe controls for safety brakes minimise risks and save effort

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Macpower CNC showcases Indian Innovations at EMO

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Mart Update

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The Last Leaf Advertisement & Circulation

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nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, d in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 September 2013 the accuracy of the information published in this edition, neither the Publisher no any of its emffort has been made to ensure

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COVER FEATURE

Electronics to Increase Productivity Creating New Designs of Automation

Arundhati Bhattacharya editor@martinfotech.in

In recent years the electronic industry in India is growing at a brisk pace. The largest segment is the consumer electronics segment. The demand in the Indian market is growing rapidly and investments are flowing in to augment manufacturing capacity.

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Not only is electronics one of the world’s fastest growing industries, but it has a major effect on other industries as what it produces is meant to increase productivity and change cost structures. An industry’s competitiveness depends significantly on its ability to incorporate electronics.

Electronics have replaced mechanical and electro-mechanical parts in many goods such as telecommunications switching equipment, electric motor speed controls and automobile ignition and control systems.

India is also an exporter of a vast range of electronic components and products for the following segments :

In recent years the electronic industry in India is growing at a brisk pace. The largest segment is the consumer electronics segment. The demand in the Indian market is growing rapidly and investments are flowing in to augment manufacturing capacity.

• Transmission & Signaling equipment

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• Display technologies • Entertainment electronics • Optical Storage devices • Passive components • Electromechanical components • Telecom equipment

• Semiconductor designing • Electronic Manufacturing Services (EMS) This growth has attracted global players to India and leaders like Solectron,

Flextronics, Jabil, Nokia, Elcoteq and many more have made large investments to access the Indian market. In consumer electronics Korean companies such as LG and Samsung have made commitments by establishing large manufacturing facilities and now enjoy a significant share in the growing market for products such as Televisions, CD/DVD Players, Audio equipment and other entertainment products.

The growth in telecom products demand has been breathtaking and India is adding 2 million mobile phone users every month!

With telecom penetration of around 10 per cent, this growth is expected to continue at least over the next decade. Growth in demand for Computer/ IT products, auto electronics, medical, industrial, as well as consumer electronics is equally brisk.

September 2013

India is well-known for its software prowess. But on the hardware front, the progress is rather slow. However, the country has been making gains in this sector also. Already, more than 50 Electronic Manufacturing Services (EMS)/ Original Design Manufacturers (ODMs) providers are operating in India, ranging from global players including Flextronics and Solectron to indigenous firms including Deltron, TVS Electronics and Sahara.

Further moves by international players are expected to add production in India in the coming years.

The recent acceleration in EMS activity is mainly due to rapid growth in the electronic Hardware market in all segments. Fast growth has taken place in Telecom Infrastructure Equipment, computers, Consumer & Hand held devices. Behind the impressive growth of the electronics industry is the robust and consistent growth in Electronic Hardware market of approximately 25 per cent due to a stable economy & large middle class of 350 million people.

September 2013

Electronics is now a matured industry sector in the country at least as far as various application segments is concerned.

State-of-art and reliable SCADA, PLC/Data Acquisition systems are being applied across various sections of the process industry. Latest AC drive systems from smaller to very high power levels also find application in large engineering industries like steel plants and/or metal industries.

World class UPS systems are being manufactured in the country to cater to the need of the emerging digital economy.

A good number of Indian companies in the control and instrumentation sector are able to acquire orders for export systems through international competitive bidding.

Some of the latest technology development and applications in this area include Intelligent SCADA Systems for monitoring and control of Mini Hydel Plants, Advanced Traffic Control System for urban transportation, Intelligent Power Controllers for improvement of quality of electric power, etc. These systems have been successfully developed and applied

in real field conditions. However, the creation of knowledge base in the country through industrial R&D in this critical sector still has to be improved by the industry looking at the global market.

To mention the Mechanical sector, mechanical designs are closely related to and controlled by electronic engineering.

Electronic engineering gives an impression of dealing with bits and bytes and some circuit design while mechanical design is through a series of calculation, designing the desired mechanics using software. But when both are used together, they create what is today’s automated machinery, that is using electronic circuit to control machineries.

The use of electronics in the automotive industry is truly exploding with many new and innovative features. Fortunately, the test and measurement industry is keeping pace with support for new standards and breakthrough tools. When looking at electronic systems or, more specifically, ECUs (electronic control units) for these

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systems, however, growth is expected to be much stronger. Nowadays, electronics run pretty much everything in a vehicle.

Between consumer’s love of electronic conveniences and hybrid or electric vehicles, the use of electronic systems in the automotive industry is accelerating at a furious pace. Of course, with new technologies come new challenges.

Among the design trends are faster transport buses; more wireless applications, often using a variety of standards; higher switching power, especially when talking about hybrid or electrical vehicles; and the sheer amount and density of electronics in modern vehicles, for example, what was a simple steering wheel in the past now is a multifunction steering wheel, adding the ability to control almost everything without taking your hands off the wheel. All this,

and more, increases the number of ECUs and wireless functions in a vehicle.

Almost half the value of next-generation automobiles is expected to come from onboard electronics and electromechanical components. Manufacturers in this industry are using advanced electronics within sophisticated engine and safety controls and electric/hybrid electric drives as well as in the design of navigation, audio systems and LED lighting. As a result, automotive electronics engineers face a variety of design challenges.

In a recent interview published in a leading daily of India, former Chairman of HCL Infosystems and head of the committee set up by the Union government to suggest ways to revive and recreate the electronics design and manufacturing industry in India, Mr Ajay Chowdhry have said that the aim of

the proposed ‘National Electronic Mission’ will be to promote India as an electronics hardware manufacturing hub and it will also market `Brand India’ in electronics.

An electronics development fund of Rs 10,000 crore has been proposed. It will fund projects in hardware design, R&D, semicon, nano-electronics and other electronics manufacturing. The fund will promote innovation, IPs, R&D and commercialization of products.

The committee has proposed to develop modified special incentive package schemes, electronics manufacturing clusters and to create standards for India, all of which can drive the industry and reduce costs. Bosch has already expressed interest in investing Rs 550 crore to set up a components manufacturing facility off Bangalore.

Smooth and Uninterrupted Business at ELECRAMA 2014 ELECRAMA-2014 is envisaged to be an experience beyond compare from its previous 10 editions. The 11th edition of the world’s largest power T&D confluence now unfolds in a brand new location; in the heart of India’s Infotech nucleus and the technology superhub – Bangalore, in January 2014.

ELECRAMA’s philosophy of consistent innovation, improvisation based on participant feedback has elevated the quality of services and amenities up to the international standards. ELECRAMA-2014 venues have been planned and arranged to heighten exhibitor and visitor delight.

Spacious layout with optimum space planning, HVAC, passages, utilities and conveniences are designed to reduce fatigue and improve productivity of participants.

Conveniently located help facilities and proactive service teams ensure that the exhibitors are able to conduct business smoothly without the least of hindrances.

Built in redundancies will be there to handle any kind of disruptions without affecting business.

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ELECRAMA-2014 is designed to maximize the participant experience by its multilateral approach to exhibitions and allied events.

Each and every stakeholder in the lifecycle has been identified and attended to in terms of takeaways. The highlights are: > INTERNATIONAL REVERSE BUYER / SELLER MEET with support of Ministry of Commerce, Govt. of India > TRAFOTECH - International Conference on Transformers > INNOVATION DAY & STUDENTS PAVILION > CEO NITE with cross stakeholder debate and Awards ceremony ELECRAMA-2014 will continue its commitment and vision of scouting new

talent in the field of electrical and allied engineering. The continual focus on innovation and recognising talent pays manifold in directing young energies into seeking new, improved and sustainable solutions of today’s and tomorrow’s problems and needs. The Student pavilion and the innovation recognition platform of ENGINEER INFINITE will enthuse the youth into exploring careers in the Industry and also offer a peerless platform for Industry Student interaction and a readymade technology showcase - both in incubation and global product releases.

September 2013

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COVER FEATURE

Make one out of two: Hybrid servo cable with bus element for the energy chain

Sreejith Menon sreejith@igus.in

Igus connects the power supply and the encoder cable in a single-cable solution (One Cable Technology)igus GmbH, specialist for energy chains and cables, now has a single-cable solution for servo motors in it’s program: The hybrid servo cable has an integrated hyperface bus element. With it, the company takes up the currently emerging trend of the single cable technology for servo motors. The hybrid servo cable is based on the chainflex cable series CF270.UL.D. In the field of drive technology, servo motor and the converter are generally connected with two cables - one servo cable for the energy supply of the motor and an encoder cable to give data about rotation speed and position of the motor back to the control. Currently, drive manufacturers increasingly offer servo motors with single-cable technology. The principle: Energy supply as well as data feedback are coupled in one cable. In this case complex measuring system cables, which are usually used for the encoder function, are replaced by bus technology.

Hybrid-servo cable from igus: single-cable solution with hyperface bus igus already anticipated the present trend of single-cable solutions for servo motors on the current year’s Hannover Fair and has introduced a single cable solution with integrated hyperface bus element. The main advantage over a “standard” servo cable is it’s space-saving function, a very important aspect for the use in energy chains. Apart from that, the number of plugs and therefore the costs for additional

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material and installation is reduced.

Protecting shield for maximum EMC A good and durable shield is especially important for servo cables to prevent possible disturbances of neighbouring cables within the energy chain.

This is even more important in the case of the newly developed hybrid cable, because the sensitive bus signals are directly integrated into the servo cable. For this reason the element shield as well as the entire shield of the hybrid cable from igus is made of a particularly bending-resistant shield made of tinned copper wires with an optical covering of 80%. The highquality shields ensure the electromagnetic compatibility of the cable.

High-end – durable and developed for the energy chain Above that the hybrid servo cable has been developed especially for the use in energy chains and disposes of a maximum bending radius of 10 x cable diameter.

The basis of the hybrid cable is the technically high-level chainflex family CF270.UL.D that has been in the market for more than 5 years. It’s good durability is permanent under excessive load conditions, this is the result of the specific igus design: The core pairs, stranded with optimal pitch length, satisfy the high mechanic demands of constantly moving use. They offer a constant high protective effect to ensure proper electric performance. A low-adhesion PUR outer jacked covers the cable. It is customised to the specific demands in energy chains and provides a long lifetime of the cable due to the proven igus materials.

Moreover this hybrid cable corresponds with relevant standards such as UL, CSA and NFPA79.2012 and is oil resistant. Due to its Desina conforming orange outer jacket, its flame-retardance and freedom of halogen, this new cable fulfils the demands especially for the use in machining centres and machine tools. Such features are also appreciated in conveyor technology as well as in cryogenic temperature applications.

For further details visit www.igus.in September 2013

September 2013

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COVER FEATURE

Advanced Research in Microelectronics with the VHX Keyence’s VHX-1000 digital microscope allows French researchers to observe surfaces at 1000x magnification, capture images as large as 100 megapixels, and share these images all with very little effort.

The Montpellier Laboratory of Computer Science, Robotics, and Microelectronics (LIRMM) is a joint research unit of the University of Montpellier 2 (UM2) and France’s National Centre for Scientific Research (CNRS). It conducts research in the field of sciences and technologies for information, communication and systems.

The applications are varied and include medicine, with the implantation of ASICs to compensate for neurological disorders or paralysis (functional electrical stimulation).

The objective of LIRMM’s Microelectronics Department (MIC) is to propose innovative solutions that have a genuinely disruptive impact on current approaches. The MIC Department’s operations range from the design to the testing of low-end integrated systems (electrical and/or transistors) to high-end integrated systems (architectures, systems).

The MIC Department also conducts research on adaptive architectures microprocessor systems interconnected by redundant networks for fault tolerance purposes - as well as cross-cutting issues such as digital security, reliability and resilience.

“We work with companies on prototypes and manufacturing processes that are not always stable. Failures are common and our job is to analyse every potential cause of these failures, such as poor traces and connections and the presence of dust.

These highly detailed observations require a high level of magnification and high image quality,” explains Laurent de Knyff of LIRMM’s MIC Department.

Generally, the chips used by LIRMM measure 2-3 mm in size and are made using 65 nm technology, meaning that the gate

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of the MOS transistor (a basic building block of microelectronics) measures 65 nm long.

lens, most often at 1000x magnification.”

The VHX features a 16-bit HDR function that uses 16 bits-per-pixel encoding and unique

“The VHX digital microscope suits our

HDR (high dynamic range) technology to

accuracy needs perfectly. It captures

create extremely sharp, perfectly exposed

extremely sharp, high-resolution images

images (neither too bright nor too dark)

easily and quickly. We use a 100 W VHZ

regardless of the contrast of the target.

September 2013

ultra-fast automatic image stitching function (2D stitching). When the image stitching button is pressed, the stage shifts and images are captured and automatically spliced together in real time.

“In addition, MEMS and certain other parts we analyse are not flat. The VHX supports automatic adjustments to achieve a large depth-of-field and produce sharp, highquality images regardless of differences in depth,” adds Mr de Knyff.

Getting to grips with the microscope was very simple. “The half-day of training we received from one of Keyence’s sales engineers was sufficient to allow us to start getting the images we needed. I’m sure that, after two hours of training, a sixyear-old would be able to produce quality images with the microscope. The optical adjustments are a little more complex of course, but you shouldn’t hesitate to use Close-up view of a MEMS

“One thing that we really like about the

analysis. Because ASICs are fragile and we

VHX is that it’s a digital tool that runs like

want to limit their handling to a minimum,

a PC. It’s clear, simple menus are intuitive

this is a major plus point,” adds Mr de

and enable us to create highly useful

Knyff.

automated functions.

the VHX’s automatic adjustments. They

The VHX-1000 produces panoramic images

We use the real-time on-screen

as large as 10,000 by 10,000 pixels, or

measurements and particularly like the

100 megapixels. That translates to a

image stitching function, which allows us

fiftyfold increase in the size of the high-

to create large images of ASICs in just a

magnification field of view (normal field

few dozen seconds regardless of the image

of view: 1600 by 1200 pixels). This is made

size. We then archive these images for later

possible by the market’s most powerful Close-up view of an ASIC

allow you to play with the lighting and other parameters,” says Mr de Knyff.

A simple way to share high-resolution images “In addition to its efficiency for our scientific observations, the VHX allows us to capture clear images and share them with colleagues, industrial partners and the scientific community. Our old method was amateurish and consisted of taking pictures through the eyepiece of an old microscope. It was both time consuming and inconvenient and the images were not as good,” concludes Mr de Knyff. www1.keyence.com/PRGGBVH Detailed view of a MEMS September 2013

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CASE STUDY

ESS ARR Metal Industries Raises Productivity with HyPro2000 Torch In a competitive manufacturing environment, productivity and the ability to produce parts at a lower cost are very often key differentiators between companies and their business rivals.And where metal cutting technologies in Indiaare concerned, plasma has proven to produce high quality cuts in the most cost-efficient manner on a myriad of metal types and thicknesses. For this reason, ESS ARR Metal Industries (ESS ARR) adopted plasma cutting for the company’s precision sheet metal fabrication processes in the early 2000s.Though the plasma system met the end-user’s needs for the most part, ESS ARR continued to look out for means to raise its operational efficiency. Upon taking advice from Hypertherm to adopt the HyPro2000™ retrofit torch, ESS ARR was able to attain optimal productivity, coupled with lower operating costs and better cut quality,on the shop floor.

Plasma Cutting in ESS ARR’s Premises Based in Faridabad, Haryana, India, ESS ARR manufactures precision sheet metal parts and fabrication components that are used in a wide range of industries such asearthmovers, automobiles, tube mills, and mineral and cement plants. The company’s products and are exported to the USA and Europe.

As a customer-centric company, ESS ARR prides itself in creating only the best quality goods, and has therefore since 2002 been an ardent believer of using plasma for its quality results in cutting.

In 2006, the company adopted the MAX200, because it had excellent heavy duty cutting capabilities. Over the years though, operators witnessed a decline in the equipment’s performanceas a result of less-than-optimal care. After 7 years of use, the MAX200 was only able to carry out 350m of cutting with a single set of consumables, which was almost half of the 600m that it used to be capable of.

Through maintaining a close relationship with ESS ARR, Hypertherm understood the issues that the end-user faced in using the MAX200 system. This led Hypertherm to introduce the HyPro2000 retrofit torch, which was proven to significantly improve a MAX200’s performance.

Tried & Proven In order to showcase the HyPro2000 torch’s capabilities, Hypertherm arranged

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Cutting table set-up at ESS ARR, with the Hypertherm Max200 power system

September 2013

for a week-long trial todemonstrate how the retrofit torch would enhance ESS ARR’s cutting processes and the quality of its sheet metal parts. Over the seven days, Hypertherm associates used the HyPro2000 retrofit torch on mild steel of varying thicknesses, comparing the new torch’s productivity with that of the standard MAX200 torch.

During the trial period, ESS ARR witnessed a significant increase in the productivity of its existing MAX200 set-up. It was able to perform900m of cutting (on thickness ranging from 3 to 25 mm)with a single set of consumables, and cutting speeds increased from 1,700mm/min to 2,500mm/min. The end-user also witnessed significant improvementin cut quality on holes and slots. With such compelling evidence placed in front of its operators, ESS ARR decidedly adopted the HyPro2000 torch.

Mr. Sudhir Singh Attri, Owner of ESS ARR, commented, “The results of the trial provided a strong case for us to replace the standard MAX200 torch with a HyPro2000 one. We were very excited about the positive benefits that we would reap from this new innovation.”

Lowering Operating Costswith HyPro2000 Torch In order to acquaint ESS ARR with the replacement torch, Hypertherm arranged for a full-day training.Operators became familiar with the torch in a single day, and quickly learnt how best to use it in a manner that would optimize metal cutting procedures.

Within just one month of adopting the Hypertherm innovation, the manufacturer began to reap numerous benefits. First of all, ESS ARR was impressed with the HyPro2000 torch’s consumable lifespan, which lasted 2.5 times longer than those in the standard MAX200 torch. The longerlasting parts reduced the end-user’s expenditure on consumables by 75%.

In addition, operators are now able to choose between 50A, 130A and 200A consumables for different jobs, according to required metal plate thickness.

Previously, consumable options were limited.

September 2013

Length of Metal Cut (m) 1,000 800 600

900

400 200

350

0 Hypro 2000

Standard MAX200 Copper Torch

Cut Speed (mm/min) 3,000 2,500 2,000

2,500

1,500

1,700

1,000 500 0 Hypro 2000

Standard MAX200 Copper Torch

HyPro2000 retrofit torch significantly improved ESS ARR’s productivity with improved cutting capabilities

This reduced spending on consumables was a key contributor to the overall cost savings that ESS ARR achieved as a result of purchasing the new retrofit torch.

HyPro2000 Retrofit Torch Expands ESS ARR’s Capabilities Another notable benefit that came with

the HyPro2000 torch was enhanced cut quality. This improvement was visible not just to ESS ARR’s employees - even its customers have noticed the difference, and many complimented ESS ARR’s decision to upgrade its cutting equipment.

The combination of faster cutting speeds and enhanced cut quality has effectively

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raised the company’s productivity.

Jobs that required 10 hours to complete in the past, can now be accomplished in less than 9 hours, allowing ESS ARR to accept even more assignments to boost its revenue.

“We are now achieving on an average 900mof cutting per set of consumables and we are very satisfied with the latest Hypertherm addition to our plasma set-up,” remarked Mr.Attri. “Beyond attaining tangible cost and productivity benefits, we are very happy to have reinforced the strong relationship with Hypertherm that we have developed through the years.”

With the positive experiences that ESS ARR has had with Hypertherm, as well as its associates and technologies, the enduser looks forward to adopting yet another Hypertherm innovation when the need arises, in order to keep its sheet metal cutting process at it optimum at all times.

On the right: a HyPro2000 torch cut sample.

About ESS ARR Metal Industries Set up in the year 1997, EssArr Metal is an ISO 9001:2000 TUV certified industry and is a well known name in

the field of manufacturing precision sheet metalcomponents & fabrication components. In its early years, the company was involved inthe production of small body parts for two wheelers. But since 2003, the manufacturing unit has expanded to engage in fabricating heavy body parts of cranes, tube mills, mining equipment, machinery plants and cement plants.

About Hypertherm Hypertherm designs and manufactures advanced cutting products for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair.

Its product line includes handheld and mechanized plasma systems and consumables, as well as fiber laser and now waterjet products, in addition to CNC motion and height controls and CAM software.

HyPro2000 retrofit torchnozzle after 1,600m of cutting.

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Hypertherm systems are trusted for performance and reliability that result in increased productivity and profitability for hundreds of thousands of businesses.

The New Hampshire based company’s reputation for cutting innovation dates back more than 40 years, to 1968, with Hypertherm’s invention of water injection plasma cutting. The associate owned company, consistently named one of the best places to work in America, has more than 1,300 associates along with operations and partner representation worldwide.

September June 2013

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MANUFACTURING EXCELLENCE

Journey Towards Excellence

P S Satish gotopssatish@gmail.com

Managing a SME in India - Part 9 As a continuation of last article, we will discuss on few more points to manage SME’s better in India

The time to start a business, escalating costs and beaurocratic hurdles are challenges one has to undergo in India.

20. Be ready for challenges ahead It is a known fact now that doing business in India especially in manufacturing is a challenge.

World bank report on ’Doing business 2013’, shows India in 132nd position out of 185 countries studied. The time to start a business, escalating costs and beaurocratic hurdles are challenges one has to undergo in India.

Take the example of Posco and Arcillor Mittal. They decided recently to stop their several billion dollars of investment in the steel manufacture. They waited several years and government could not acquire land for them. Another challenge is the

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inconsistent policies of the government.

Because the elected government has 5 year term, they are trying to take measures keeping vote bank in mind and not those beneficial to the country in the long range.

Take for example two bills passed in the parliament recently. One is food subsidy bill. Though per se from social aspects it looks good, can India afford it? In our deficit budget, how does the government manage to mobilise close to 1,75,000+ crore Rs.? Will the money really reach the targeted person?Will it not give opportunities for lot of middlemen to make money? Will it not create a bunch of lazy persons, ultimately detrimental to the economy of the country? Is vote

bank a criteria for this? Why is it being introduced in election year? Is it the right time when our economy is in doldrums?

And the second bill is land acquisition bill. Will this not increase cost of doing business in India? Will it have an effect on growth on the industry? Will it discourage foreign investments? Expansion by existing industries is going to be very expensive.

These two actsare short-sighted and were introduced in haste.

What industry can do about these Government measures other than discussing and debating? Putting forth opinions through various forums and associations is one aspect. But it will not help fully. We need to accept that

September 2013

uncertainty is certain in the future and be prepared for it. In the years to come, we have many challenges to manage: • Uncertainty: One thing certain about future is uncertainty. None of us know for certain how exactly future looks like. We have many predictions and statistics with many assumptions which may help fully to run our organization. Only way to manage uncertainty is to accept uncertainty and keep agility in the organization to respond.

Let us understand well ups and downs are healthy for us to keep fit. Like Ratan Tata said, ‘Ups and downs of life are good. If your ECG reading shows flat curve then you are dead’ • Complexity: Complexity of business is going be high. We have seen that complexity of design of product is on increase leading to complexity of manufacture. Tolerances are being cut down,product size is shrinking and quality expectation is changing from parts per million to parts per billion. Customer expectation is increasing day by day. Not to mention about complexity involved in supply chain etc. Consumer tastes and preferences are changing very fast • Competition: We being in a global village, competition is from all over the globe and not just from our neighbourhood. Our approach,way of doing business,leadership,product and competitiveness has to be better than our competitor to survive. We are on race and we need to compete with ourselves every day to be better than yesterday. With fast development of technology, we have a challenge of our product being replaced by a new product by our competitor or others.

• Competitiveness: With competition and new products coming up as a substitute for old products, being competitive is a challenge. We need to work on being more efficient by using our resources well and reducing wastes. Work on eliminating DOWNTIME wastes in the system.

DOWNTIME stands for – o Defect – Reduce defect in the system to reduce scrap, repair, warranty costs, lost customers o Overproduction – Do not make parts more than what customer wants. This could be because of wrong forecasts, in persuit of utilization, just in case September 2013

thinking or to get feeling of being busy.

Overproduction leads to inventory. o Waiting - This is the idle time wasted by employees waiting for materials, machines or equipment. Leads to loss of capacity, overtime and increases operating costs.

Better planning helps. o Non-Value added processes – Many processes look like value adding but in reality non-value added from customer perspective. E.g. Deburring is a non-value added process where customer is not ready to pay. Overprocessing like giving grinding finish when turning would do is also non-value add o Transportation – Unnecessary transportation of parts will add only cost and not value. Extra movements of parts within the company in view of poor layout planning is seen common o Inventory – Any material in excess of what customer wants is an inventory.

This is block capital leading to increase of operation cost o Motion – This is movement of people which does not add value. This could be because of searching for items or reaching for tools. Good 5S plays a role here o Employees underutilized –If we are not able to exploit full potential of the person then it is a waste. Understanding skill of the employee and providing suitable role and responsibility will help in overcoming this. Competency mapping by defining skills for each role is a good way to address this point.

• Compliance: Filling number of applications to open a new company is an indication of how compliance requirements are increasing. We have compliance like environmental, Legal, financial,accounting etc. We have new additional compliance of social accountability. I know one consultancy company focusing companies to meet hundreds of compliance requirements of labour laws and others giving an indication how compliance requirements are becoming complex. At individual we have many like PAN, AADHAR and KYC etc.

• Predictability: Though there are lot of theories predicting future, actually no one is sure. Did anybody could predict properly

the currency fluctuations country is undergoing?. The challenge on prediction is that number of influencing factors are too many and each factor varying differently.

• Volatility: Volatility of currency, raw material prices and fuel is a big concern for the industries. I remember the days long back as a purchaser I never discussed about price changes in view of material and currency for many years. No more such cases.

• Ambiguity: This point relates to policies formed by the Government. We see many measures which are not long term oriented and one policy contradicting another. Let us understand that some of Government functionaries survive on ambuiguity.

When one of the devotees asked Swami Vivekananda on how do we change people the way they are, he said that if he changes himself, at least there will be one number less in number of people to bechanged.

Changing the way we and our employees are working and thinking is not easy and needs lot of efforts by the CEO of the organization. Hoping external aspects to change for our favour is only a waste of time. We can onlysee what we can do about it.

One way to addressin company is to become lean and focus onreducing wastes.

We need to be an agile organizationby constantly reviewing the situation andresponding quickly to change. Making employeessensitive for the change and their totalinvolvement in decision process goes a long way in meeting challenges explained above.

Also we need to work on mind set of peopleinside the organization by propertraining to make themcapable to face challenges ahead. Remember the lines of John Welsch,‘ If rate of change inside the company is lower than rate of changes happening Outside of the company, life of company can be calculated’. Be ready to change to dash on challenges ahead.

I will continue the series of article in the next issue. Please send your inputs,remarks, suggestions toP.S.Satish,Mentor and Corporate Trainer, M/s Saraswati Industrial Services, Q-103 Mantri Paradise Apartments Bennerghatta Road, Bangalore - 560076 Email- gotopssatish@gmail.com www.satishps.com . Have a good day. www.martonline.in

21

QUALITY

Gorur Sridhar

Applying Lean to New Product Development

gnsridhar@gmail.com

Lean can be applied to any industry, not just manufacturing, because any business can benefit from improvements in cycle time, cost savings, productivity, efficiency and more. This case study examines the application of Lean to the engineering services industry in the areas of design, analysis and prototyping of parts to realize improvements in a subprocess of the new product development (NPD) lifecycle.

Lean Principles There are five general principles in Lean: 1. Identify customers and specify value: From the standpoint of the end customer, specify value by product or service group.

2. Identify and map the value stream: Identify all of the steps in the value stream for each product or service, eliminating when possible the steps that do not create value.

3. Create flow by eliminating waste: Make the value-creating steps occur in tight sequence so that the product or service will flow smoothly toward the customer.

4. Respond to customer pull: As flow is introduced, let customers pull value from the next upstream activity.

Project input and feasability study

START

Preparation of Schedule plan and estimation

Subprocesses of Lean Iplemantation

Generation of 3D models and manufacturing drawings

Finite element analysis and prelimnary design review (PDR)

Prototype testing and detailed design review (DDR)

Creation of reports and documentation

Project approval and kickoff meeting

STOP

Figure 1: New Product Development Process

Press Signal Canban

Manufacturing Process

2x per week

XYZ Corp

Truck Shippment

Outside sources

Inventary box

Electronic Information Flow

Manual Information Flow

Database

FIFO Operator

First-in-first-out sequence flow

5. Pursue perfection: As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced. Begin the process again and continue cycling through until a state of perfection is reached in which perfect value is created with no waste.

Simply put, Lean minimizes inputs and maximizes outputs at every process step.

Example: New Product Development in Design Department

Boat Shipment

Rework

Delay

Kaizen Lighning burst

Quality Problem

Figure 2: Value Stream Mapping Icons

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The NPD process in this example of applying Lean to a nonmanufacturing setting is in the design department of an organization. It represents part of the overall project management lifecycle.

September 2013

A macro-level process map of the NPD process is shown in Figure 1.

Since NPD activity involves many subprocesses, only one was selected for the pilot project. The subprocess under study was generation of 3D models and manufacturing drawings of the various parts that go into the manufacturing of prototypes. The metrics being monitored were cost of quality (COQ), cycle time and lead time.

Assumtions,

Delay

START

feasability study

Rework

of customers input

Estimation and approval of the proposal

Database

Q Quality Problems

Self - review,

Delay

Scheduling task

3D modelling and/

assingment and planning

or drafting activity

peer reviews Delay

The data captured to calculate the COQ were the total hours taken to carry out the quality check of the model and drawing, the total hours taken to carry out the rework identified during the peer review stages, and the actual total hours taken to complete the project.

schedule log

COQ = (total quality check hours + rework hours) * 100 / total actual hours

Lead time = sum of all subprocess lead

Q

Rework

Submission to

Metrics capturing,

customer and feedback

times + sum of all wait times between subprocesses

The cycle time clock starts when work begins on the request and ends when the item is ready for delivery or the task is completed. Lead time (also referred to as throughput or turnaround time) is the average time it takes for one unit of the product or service to go through the entire process – from start to finish – including time waiting between subprocesses.

implementation was identified, the

Delay

Electronic Information Flow

Once the subprocess for Lean five Lean principles were mapped as appropriate.

1. Identify customers and specify value: The customers were identified as internal customers from departments to whom the CAD (computer-aided design) models and drawings were being delivered.

Assumtions, feasability study

Quality Problems

peer reviews

Estimation and

Rework

approval of the proposal

of customers input Database

Electronic Information Flow

Q Self - review,

Delay

Scheduling task assingment and planning

3D modelling and/ or drafting activity

Delay Electronic Information Flow

Rework

Submission to customer and feedback

Metrics capturing, schedule log Database

Q Quality Problems

STOP

Electronic Information Flow

Figure 4: Process Map for Generation of 3D Models and Manufacturing Drawings – After Lean Implementation

September 2013

STOP

Figure 3: As-is Process Map for Generation of 3D Models and Manufacturing Drawings

Where COQ is expressed as a percentage of the total project cost

START

Quality Problems

2. Identify and map the value stream: The value stream was mapped and the as-is process map is shown in Figure 3. (Note: Figure 2 provides a legend for the symbols used in Figures 3 and 4.)

3. Create flow by eliminating waste: The areas of waste and non-value added (NVA) activities were identified (such as idle time, waiting for submissions, etc.), and appropriate actions were taken (such as automation, training, database creation, etc.) to minimize and eliminate the waste.

Figure 4 shows a revised process map with these improvements incorporated.

4. Respond to customer pull: Delivery target dates were set as internal targets and the schedule was developed by working backwards to ensure that the waiting time and delays were minimized.

This is similar to the pull system in a manufacturing setting with the immediate customer setting the target dates for delivery based on the project’s overall schedule.

5. Pursue perfection: The optimized process map was set as the new baseline to further improve. The metrics collected were continuously monitored to ensure the health of the process.

Value Additions A number of value-add activities were implemented to facilitate the improvements in the 3D modeling process. www.martonline.in

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1. Automation of the job submission process was introduced to speed up the work assignments and to avoid delays and wait times. This automation enhanced the work scheduling and allocation activity.

Benefits of Lean Implementation

2. Automation of the peer review submission process was achieved through product data management, which avoids the submissions’ being overlooked and helped avoid delays and wait times.

3. Automation of the drawing checking process (with respect to using spell check and implementing standards) to reduce the cycle time of self-reviews and peer reviews and to avoid defects.

4. Elimination and/or reduction of the NVA intermediate steps (such as rework) using the above automations to avoid delays.

After Lean Implementation

Number of subprocesses

18

11

Number of delay times/ waiting periods

9

4

Information flow (automation touch points)

3

8

Database availability/use

1

3

Cycle time (in minutes)

130

90

Lead time (in minutes)

200

130

COQ (percent)

20

11

this helped sustain the maturity level of the process.

6. Training in some modeling and drafting activities for all stakeholders was implemented to improve team members’ skill sets. This led to enhanced efficiency and productivity by way of fewer defects, improved first pass yield and shorter cycle times.

A Taste of the Benefits

7. Institutionalized best practices and lessons learned were documented and used to train new team members. Overall,

1. An average of reduction of 40 minutes

COQ (%)

5. Creation of a database helped generate and report the requisite metrics to top management and to the customer. Review steps took advantage of the easy access and speedy retrieval of data.

COQ (%)

Figure 4: Process Map for Generation of 3D Models and Manufacturing Drawings – After Lean Implementation

The table below offers a glimpse into the benefits that were derived out of this particular LSS application.

Another way of expressing these improvements is the following:

was realized per 3D model. This amounts to a 30-percent reduction in the cycle time

Adopted Six Sigma

30 25 20 15 10 5 0 2

3

4

5

6

7

8

9

10 11 12

20 25 23 20 18 19 16 14 15 13 13 11 Month

Figure 5: Lean Implementation Timeline www.martonline.in

Adopted LSS

Institutionalised Best practices and Lessons Learned

1

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Before Lean Implementation

Evaluating Factors

per model.

2. Assuming an average workload of about 300 models per month with a given team size of six, the total hours saved are about 200 – or 25 working days (8 hours per day) per month. Assuming an average hourly rate of $20 for team members, an additional $4,000 revenue was added to the bottom line each month.

The timeline shown in Figure 5 tracks the application of LSS as it contributes to the reduction of COQ. The author Gorur Sridhar is a Mechanical Engineer and a qualified Six Sigma Master Black belt with more than 26 years of industrial experience in Manufacturing, Quality and Design in Aerospace, Automotive, Engineering Services and Medical domains. He has been instrumental for substantial cost savings through Value Engineering, Process Improvements & Failure Analysis. He has got major achievements to his credit including filing of 6 Patents (4 granted, 1 under review) and authoring many articles on Quality to various International Quality Portals and Journals. He has mentored more than 100 Six Sigma & Kaizen projects and is a Qualified Internal Auditor for ISO 9000, QS 9000, AS 9100 & other Quality Systems and associated with the Implementation and Sustainance of CMMI L5 activities. He is also equally contributing in EHS and Community development programmes.

September 2013

September 2013

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25

CORPORATE MART

GGB Bearing Technology The Global Leader in High Performance Bearing Solutions GGB Bearing Technology, formerly Glacier Garlock Bearings, has the tribological, material science and applications expertise to provide innovative solutions to even the most challenging requirements, either with standard offerings or with customized products developed in collaboration with its customers. The company’s industry-leading R&D and testing capabilities generate technologically superior products, systems and tools, the performance, reliability and costeffectiveness of which are supported by local applications engineering.

With a history dating back more than 100 years, GGB revolutionized the bearing industry in 1956 with the introduction of its globally-known DU® self-lubricating, metalpolymer bearings, the first to use PTFE in the sliding layer. This milestone was followed in 1965 by its DX® bearings for lubricated applications, and in 1995 by its DP4™ lead-free, metal polymer bearings.

Today GGB offers the industry’s most extensive portfolio of self-lubricating and prelubricated bearings in a variety of configurations and materials, including metal-polymer, solid polymer, filament wound and metallic. Also offered are bushing blocks for fluid power applications and a complementary range of specialized housings and assemblies. These products are used in literally thousands of applications in hundreds of industries, where they offer users: • Lower system costs from space and weight savings of slim, compact designs • Low friction for energy efficiency, smooth operation, and longer bearing life • Reduced maintenance from elimination of lubricants and lubrication systems • Replacement options for costly roller bearings and greased metal bearings • Environmental compliance with EU ELV and RoHS regulations • Flexible production platform and global supply network

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Among the industries using GGB bearings is automotive with more than 50 applications per vehicle. In these applications the bearings’ absence of moving parts and low friction reduce noise, improve fuel efficiency and provide smooth, reliable operation. The company’s bearings are also used by the aerospace industry where their light weight helps reduce fuel costs, as well as in fluid power applications where their compatibility with hydraulic fluids and seizure resistance under low speeds make them ideal for use in gear and piston pumps.

In addition GGB bearings can be found in compressors where their self-lubricating properties offer superior reliability with low viscosity lubricants, and in construction and other off-highway equipment requiring low maintenance and grease-free operation under severe shock load conditions.

In sports and recreation equipment they provide smooth, maintenancefree performance, offering the same advantages plus corrosion-resistance and

environmental compliance for hydropower plants. In primary metals production, GGB bearings stand up to dirty environments and extreme temperature and load conditions. And in general industry they are used in more than 30,000 different applications.

As the global leader in high performance bearing solutions, GGB serves more than 50,000 customers worldwide through its four-continent production platform and supply network. The company employs more than 1,000 people in 10 manufacturing facilities in Germany, the U.S., France, Slovakia, Brazil and China and sales offices in 18 countries.

For more information visit www.ggbearings.com

September 2013

TOMASZ’s CORNER

Tomasz Tunguz ttunguz@gmail.com

Crossing the people Managment Chasm a Neccessity of Start up Growth

One of the hardest but least spoken about transitions in a startup’s life is crossing people management chasm.

Tomasz Tunguz, a venture capitalist at Redpoint Ventures, an IT venture fund with offices in Silicon Valley, China and Brazil continues his column in MART. You can follow him on twitter @ttunguz.

At the outset of the startup, there might be three people, then eight, then fifteen.

As they grow, startups often create ad hoc managers I call team leads.

Team leads manage 3 to 5 people. They work alongside their team, whether engineering, sales or marketing and contribute actively to achieving the goals of that team team. They code, sell or market for 50% of their time. With the remainder, team leads coordinate team members, set goals and measure progress.

In company sizes around 30 to 50 or so, team lead structures work well.

As the company scales, the number of team leads in the business grows, so someone must be appointed to manage the team leads.

This is the people management chasm.

The manager of team leads isn’t a team lead himself because he doesn’t actively contribute to any one of his team’s output - there’s not enough time to do both well.

He’s a different kind of manager, a team builder.

The team builder is responsible for cultivating the people within that team, recruiting and hiring additional members of the team, and guiding the team to perform at a high level. The team builder spends 90%+ of his time in one-on-one meetings, recruiting meetings and progress evaluation meetings. CEOs are team builders almost from the very first day of a startup’s life.

Crossing the people management chasm, hiring the first people manager, is challenging. After all, the interview process used to evaluate individual contributors is no longer valid. Nor will annual review processes work - the metrics to evaluate a manager’s performance differ from an individual contributor. Suddenly all the September 2013

criteria have changed. What got you here won’t get you there.

At this point, the startup has to develop another competency: how to hire and manage people managers. Like other skills, successful startups research this competency by speaking with experts, solicit advice from well-known and successful managers and founders

who have done this before. They speak with recruiters before launching search processes about the kinds of managers who will fit best into their startup’s culture and they iterate on their interview and evaluation processes.

Crossing this chasm is the key to growing the business. It’s not easy but it’s essential.

Source : www.tomtunguz.com www.martonline.in

27

AUTOMATION

SPINEA –Solution for Precision High precision is a term many manufacturers of working machines, manipulators and robots boast of. The achieved precision of equipment largely depends on the precision of the transmission system that secures the transfer of the mechanical energy from the driving unit to the point of its use. The highest precision can be achieved with the use of zero backlash reducers TwinSpin is the commercial name of a bearing reducer made by the Company SPINEA, s.r.o. It is an original Slovak solution, which is protected worldwide by three patents. The term ‘bearing reducer’ describes the full integration of a zero backlash trochoidal reduction mechanism with a radial-axial output bearing into a single compact unit.

The main benefit of the Slovak solution is a new method of transformation of the planet movement of trochoidal gears into the rotation movement of the output flange with a transformation element called a cross.

The robustness of the transformation cross gives the TwinSpin reducer its high precision and linear loading characteristics.

The benefit of the built-in radial-axial output bearing into a single unit is the possibility to load the reducer in the axial as well as radial directions without the need to strengthen it by expensive external bearings.

Bearing reducers are designed for applications that require:

6. High axial and radial loading capacity.

7. Low weight to transmitted power ratio.

2. High compactness. Compared with classic gearboxes with the same output torque, their installation dimensions are minimal.

The most frequent application of TwinSpin reducers is in working equipment, specifically in tool exchangers; in B axes and in the positioning of worked pieces; in hinge joints of robots and manipulators; in positioning systems for welding, manipulation and assembly; and, last but not least, in camera and navigation systems in the defence industry.

3. High kinematic precision. The average transmission error angle ranges between 18 arcsec in the case of large reducers and 36 arcsec in the case of small reducers.

The bearing reducers of SPINEA, s.r.o. are offered in four basic versions. Each version is specific by its parameters, which depend on a reducer’ field of use.

4. Zero backlash.

For the use in B axes of working equipment, i.e. controlled tilting of tool heads, a specially developed B version of the bearing reducer has been developed.

Each possible imprecision in the positioning of the tool head during the working would cause an imprecise or poor quality surface of the worked piece, therefore

1. High reduction ratio. The reducer’s reduction factor can be in the range between 35 and 191, depending on the size of the reducer.

5. Small lost motion. The ‘lost motion’ is a term used for zero backlash reducers and it expresses the relation between the torsion loading of the reducer’s output at the simultaneous fixation of the input and of the supporting body and the output’s

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deviation angle.

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the reducer has to secure smooth and precise movement. The reduction principle of TwinSpin reducers guarantees a high repeated positioning precision.

The internal design of the B version is modified, so that the reducer is able to absorb all radial and axial forces that occur during working without causing an undesirable deviation or oscillation of the tool. Another specific requirement for a reducer for the B axis is the extremely high demand for the geometrical precision of its external dimensions.

With special technological modifications, an axial runout of 0.005 mm on the biggest diameter of the output flange against the installation base and a radial runout of 0.005 mm on the installation dimension of the output flange against the rotation axis of the input shaft have been achieved.

For further details write to M V Krishna Prakash of Rotolinear Systems at rotolinearindia@vsnl.net or you can also reach him at his handheld at +91 984519675.

September 2013

September 2013

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29

MACHINE TOOLS

New Beyond Shield™ Combines Clamping System With New Superhard PCBN Grades for Excellent Efficiencies in Machining Cast Iron Clamping system and advanced cutting materials provide improved process reliability and output, meaning more parts at less cost.

Advanced hard turning, or the use of superhard polycrystalline cubic boron nitride (PCBN) cutting tools for machining hardened ferrous materials like cast irons, is eagerly sought across a number of key manufacturing industries. Hundreds of millions of brakes discs, brake drums, flywheels, and wheel hubs are required annually in motor vehicle, heavy equipment, and other industries, and although superhard tools show promise for turning such tough-to-machine parts, that promise has been stalled due to the tendency of these expensive tools to shatter and break under the extreme forces required.

With decades of experience in advanced materials science and tool design, Kennametal is announcing Beyond Shield™ as the solution (responding to modern challenges in machining cast iron machining) to this situation.

“For customers machining gray cast iron brake disks and

Beyond Shield™ by Kennametal provides a rigid and reliable clamping system for high-performance cast iron machining.

brake drums, Kennametal´s Beyond Shield™ PcBN inserts and clamping system provide up to 20% reduced tooling cost and up to 30% longer tool life compared to conventional systems,” says Dr.-Ing. Raouf Ben Amor, senior global product manager. “Beyond Shield™ provides a robust clamping system that allows smaller IC PcBN inserts to perform well in the same applications as the larger IC insert, and by excellent matchup of wear and tough-

Kennametal´s Beyond Shield™ portfolio offers a carbide-clad clamp with Kennametal’s unique technology to improve clamp wear resistance from chip flow.

ness in our grade properties proven in field tests.”

Meeting the Clamping Challenge

Kennametal´s Beyond Shield™ PcBN inserts are available in a variety of sizes in both coated and uncoated grades.

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High-performance cast-iron machining leads to extremely high mechanical and thermal

loads. Conventional dimplestyle clamps attempt to hold the cutting insert in place with direct point contact, which can break both clamp and insert under high pressure.

Beyond Shield has met the clamping challenge with a September 2013

Window to the industrial world at your desktop “Industrial business MART” popularly know as MART the largely read international engineering manufacturing monthly, now the one year subscription comes `300 less, Grab it today!

Kennametal´s Beyond Shield™ has met the clamping challenge with a three-point clamp design that applies clamping force toward the front of the insert, closer to the cutting edge and significantly reducing vibrations that can lead to cracking and failure.

three-point clamp design that applies clamping force toward the front of the insert, closer to the cutting edge and significantly reducing vibrations that can lead to cracking and failure.

In addition, cast iron machining is a very aggressive environment where constant chip bombardment also cuts down clamp life.

Beyond Shield provides a carbide-clad clamp through a unique Kennametal technology that improves clamp wear resistance from chip flow. Beyond Shield is also adaptable on standard toolholders, which can help control costs.

New PCBN Grades In addition to being tough by nature, cast irons present a number of machining challenges for cutting tools.

Casting quality can be unpredictable. Low sulfur content can lead to tool life decreases by up to 60 percent, and increased ferrite content can lead to high chemical wear, also substantially decreasing tool life.

With a unique “multimodal” PCBN structure, Kennametal´s KBK35™ grade has increased cubic boron August 20132013 September

nitride content that ensures increased wear resistance and longer insert life in both roughing and finishing operations.

A chemical vapor deposition (CVD) coating protects against chemical wear resistance, and post-coat treatments improve cutting-edge toughness. “Field tests have shown double the tool life for KBK35™ in aged and unaged cast iron, and in specific cases such as brake drums, up to ten times (compared to ceramic-based solutions) the number of parts completed per insert.”

For parts involving aged cast iron, Kennametal is also introducing grade KB1340™ to the Beyond Shield family. In brake disk field tests versus standard PCBN inserts, KB1340™ increased performance to 1700 pieces versus 1500 for the PCBN insert. In the same test versus ceramic inserts, tool life increases from 120 pieces to 4200.

“For customers facing the need to increase cutting parameters and yet improve process reliability and control costs, Beyond Shield™ is the way to high-performance cast iron machining,” Ben Amor says.

For more information, visit www.kennametal.com.

With the last nine years of networking and publishing of MART, we have succesfully made place in the Indian Manufacturing Industry.

Our growth was always triggered by the changes undertaken as per the needs of the industry. The contents of MART is unique, with regular columns by industry experts in the diversified feilds of engineering manufacturing, technical features, news updates, interviews, case studies, trade fair informations etc.

The guidance and support of the experienced industry professionals through our Editorial Advisory Board have helped us to understand the need of the indian Manufacturer better and produce a journal which is used by the industry as an utility.

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31

AUTOMATION

Small, Strong, Smart: New High-Performance Ejectors with Integrated Added Value Compact design, strong performance, intelligent integrated functions – the new ejector series SCPS/SCPSi with nozzle sizes from 0.7 to 1.5 millimeters raises the bar for efficiency in automation. The ejectors are used in a number of different industries including packaging, metal, plastics, glass and solar power.

At just 18 x 105 x 99 millimeters and with a suction rate of 65 liters per minute and a pressure range from two to six bar, these extremely compact solutions are ideally suited for handling suction-tight and slightly porous workpieces. This makes them perfect for use in systems with limited space and highly dynamic processes with demanding requirements.

Schmalz has equipped the SCPS and SCPSi compact ejectors with more functions than comparable ejectors of similar size.

The vacuum specialist also optimized the series in terms of fluid technology: High-performance nozzles ensure that the ejector can generate an extremely high vacuum in fractions of a second. Together with extremely fast valve switching times, the high performance levels of the new series ensure extremely short cycle times for applications up to well over 200 cycles per minute. Furthermore, the ejectors are also equipped with an automatic air saving function for economic operation. This reduces the amount of compressed air consumption by up to 80 percent compared to similar ejectors without controllers, which also reduces operating costs. If no vacuum is required at the moment, this function is simply

User-friendly display with clear menu structure

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switched off by the compressed air generator. At the same time, it permanently monitors the vacuum level and reacts immediately to extreme drops.

In order to adapt the ejectors optimally to the workpiece and to the process, Schmalz has equipped them with an automatic, strength-adjustable blow-off function. This allows for even quicker pickup of parts and increases the overall dynamics of the process. The particularly user-friendly display is another one of the features of the compact ejectors. It provides the operator with information about the most important vacuum parameters at a glance. At the same time, large buttons and a clear menu structure make it easy to operate. With the standard IO-Link interface, of the SCPSi, the

Compact shape, strong performance: Ejector series SCPS / SCPSi

operator can perform parameterization and diagnostics on the ejector from the central system controller.

The SCPSi ejectors also feature an integrated condition monitoring function.

This function continuously measures and monitors the leak-tightness and the vacuum level of the vacuum system.

The operator can recognize errors early on and can fix them before they lead to system downtime. The vacuum generators measure all of the important energy and performance data and communicate it to the higher-level field bus systems via the existing IO-Link master. This allows the system operator to read out, monitor and optimize the data in his or her control system. This reduces energy consumption, increases system availability and makes it possible to design the system based on performance. Furthermore, the compact and durable unit can be installed directly on the handling system. This simplifies installation and opens up more space.

For further details visit www.schmalz.com September 2013

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33

MACHINE TOOLS

A world first: Hand-Guided Core Drilling System for Metal FEIN invents new drilling procedure: hand-guided core drilling FEIN, the inventor of the power tool, presents the world’s first hand-guided core drilling system for metal. The system combines the benefits of a high-performance hand drill with those of a carbide drill. The hand-guided FEIN core drilling system KBH 25 allows users to simply, quickly and comfortably drill holes up to 25 millimetres in diameter in metals up to 20 millimetres thick. The new system enables metal-processing companies to work with all common metals on curved, painted and uneven surfaces and in hard-to-reach places. The FEIN KBH 25 is available in the market.

A new take on drilling The KBH 25 uses latest technology developed by FEIN to enable hand-guided core drilling that combines a highperformance hand drill with special carbide core bits. The new drilling technique avoids cutting material unnecessarily and therefore greatly reduces the amount of effort required. The drill is centred by a HSS

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bit which only drills for as long as necessary and is disconnected as soon as the core bit encounters the material. This allows the entire feed force to be used for core drilling.

Once the material has been broken through, a pressure spring moves the centring drill forwards and ejects the drill core. The carbide core bit with special

cutting geometry and a cutting width of just 2.8 millimetres has an optimised tool life and ensures rapid work progress with a low feed force.

FEIN also supplies a range of carbide core bits with a titanium-aluminium-nitrite surface coating. These are extremely heat-resistant and feature low friction properties, giving them a longer service life

September 2013

and 20 per cent more work progress than non-coated carbide core bits.

“FEIN power tools has been revolutionizing the power tools industry with inventing and innovating machines which makes day-to-day life easier and simpler. KBH 25 exactly does that.

The entire product range is imported from Germany which gives us an edge in precision, endurance and functional over our competitors.”

More than 117 years of experience embodied in user-friendly drill systems As the inventor of the world’s first electric hand drill, FEIN has 117 years of experience in developing application solutions for drilling. By launching the FEIN metal core drilling system KBH 25, the long-standing company is responding to the demands of users who need a universal and handy, yet high-performance core drill for use with different materials and in different situations. Traditionally, metal workers have had to use hole saws or core drilling units with magnetic feet for drilling large hole diameters.

Standard hole saws are attached to a normal drill with a drill chuck. They are easy to use, but require a lot of force and can only work with material up to eight millimetres thick. Stationary core drilling units are renowned for their outstanding performance, but given that they weigh at least ten kilograms, they are comparatively unwieldy and can only be used with magnetic metals at least ten millimetres thick. The FEIN KBH 25 can work up to three times faster than standard hole saws and up to five times faster than conventional spiral drills.

Quality and comfort for the tradesman The FEIN KBH 25 operates at an optimum speed for carbide drills. The tacho electronics maintain a constant speed and enable constant, rapid work progress even at high loads. The metal core drilling system is produced in Schwäbisch Gmünd-

Ameer Ahamed Munaff Managing Director, FEIN Power Tools India

Bargau, Germany, has a highly robust design and is characterised by a long service life.

handguided metal core drilling system can call FEIN India for a demo at +91-4443578680-83 or reach them at info@fein.in

A 1,200 W high-performance motor ensures the necessary power. The metal gear box head and fibre glass-reinforced, distortionfree motor housing with barrel design can be subjected to extremely high loads.

Rotating tool parts are safely mounted and ensure precise drilling. The safety of the tradesman has also been a focus of the new development.

The core drilling system is equipped with a torque-slipping clutch which immediately disconnects the drive spindle should the core bit jam. The FEIN QuickIN PLUS tool mounting ensures the rapid replacement of accessories without the need for any tools.

FEIN Power Tools India Private Limited based in Chennai is a wholly-owned subsidiary of German manufacturer C. & E. FEIN GmbH. The world’s first power tool was invented by C. & E. FEIN GmbH. Wilhelm Emil Fein founded the Company in 1867. In 1895, FEIN invented the electric hand drill, the first-ever power tool. The German manufacturer of premium products develops and produces application solutions for the metal working, interior outfitting and automotive sectors and is a specialist for professional and extremely reliable power tools for industry and manual trades.

Testing the hand-guided core drilling system

FEIN holds more than 800 active industrial property rights, including around 500 patents and patent applications.

FEIN markets its products through 17 international subsidiaries and more than 61countries representations around the globe. For over 146 years, FEIN has been synonymous with application solutions and premium quality.

Anyone interested in testing the performance and versatility of FEIN’s

FEIN India has their corporate office in Chennai and regional offices at Gurgaon, Delhi, Pune and Ahmedabad. FEIN products are available through extensive sales & service dealer network all over India. Since its inception in India in 2009, FEIN has been growing steadily with a huge clientele in various market segments.

The FEIN KBH 25 combines the benefits of a powerful hand drill with those of special carbide core bits

September 2013

With constant upgrading and inventions FEIN always moves a step closer to the user For further details visit www.fein.in

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35

INFORMATION TECHNOLOGY

Ramji Singh

Available now : New Eplan Platform 2.3

info.eplan@rittal-india.com

FEIN, the inventor of the power tool, presents the world’s first hand-guided core drilling system for metal. The system combines the benefits of a high-performance hand drill with those of a carbide drill. The hand-guided FEIN core drilling system KBH 25 allows users to simply, quickly and comfortably drill holes up to 25 millimetres in diameter in metals up to 20 millimetres thick. The new system enables metal-processing companies to work with all common metals on curved, painted and uneven surfaces and in hard-to-reach places. The FEIN KBH 25 is available in the market.

The latest Version 2.3 of the Eplan Platform, which has been available for download since mid-August, is characterised by standardised and largely automated engineering across a consistent database. There is comprehensive support for new standard-compliant designations based on EN 81346 and the safety values focused VDMA 66413 exchange format.

The central administration of phased-out items and a new search function for system settings are additional new features of the CAE software to allow interdisciplinary cooperation and configuration.

For example macros: Version 2.3 offers extensive options for handling macros/partial circuits and their

EPLAN 2.3 macros : Standardised and flexible configuration based on partial circuits and table-based macro editing

variations. What is new is the fact that these macros can be edited and if needed be updated across the entire project within

is particularly widely accepted on an

to Eplan’s parts management system via a

international level.

standardised interface.

within the project with just a few clicks

The Eplan Platform 2.3 allows project

The values are saved directly with the

of a mouse - potential error sources are

structures and project designations to be

components and are therefore directly

reduced by means of central data storage.

implemented on a user-friendly basis in

available for designing purposes. This

compliance with this current standard.

means there is no need for time-consuming

There is also the issue of fail-safety of

manual amalgamation of safety values and

components and safety function in line

the user can be sure to get things right.

an incredibly clear table view. This means that comprehensive changes can be made

Secure in accordance with standards: EN 81346 and VDMA 66413 The definition of mechatronic solutions and the appropriate designations in the documentation are typical everyday designing tasks. The norm EN 81346 “Industrial Systems, Plants and Equipment and Industrial Products - Structuring Principles and Reference designations”

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with machinery directive 2006/42/EU. Eplan supports a consistent electronic data exchange format for the relevant safety-related values for automation components in accordance with VDMA 66413. The relevant safety data from the device manufacturers can be transferred

Central administration of phased-out devices Phased-out items are generally replaced by a newer model, but are still used in existing projects and must be administered transparently. In Version 2.3, the Eplan

September 2013

Platform makes the central administration

users can now define whether and which

of phased-out articles easier by allowing

additional information is displayed in the

marking in the article administration

tree view.

system. There are also new check runs to

concepts customer-specifically and provides comprehensive services such as customizing, consulting and training.

Innovative development competence,

The display options have been harmonized

a consistently practical approach, and

and extended and made adjustable

international presence are the success

Once stored centrally in the parts

to allow this. This makes navigation

factors.

management system, the information

easier for the users and gives them

is available to all involved across the

additional flexibility in terms of individual

entire project. This means that the CAE

configuration. There is a quick overview of

software creates more transparency in the

important information to make engineering

engineering process and keeps existing

more productive.

give users even more safety in designing.

projects manageable. While we’re on the subject of manageability: The Eplan software offers extensive configuration options for individual adjustments to the way users work.

Easier searches, quicker results

EPLAN is part of Rittal International and thus of the FriedhelmLoh Group with 11,500 employees worldwide and generated revenues of about € 2.2 billion in 2011. EPLAN is therefore synonymous

Customers with a software service contract

with continuity and investment security.

can download the new Version 2.3 directly

The company’s presence in 50 countries

from the home-page of solution provider

support 35,000 customers with more than

Eplan.

95,000 installations worldwide.

EPLAN Software & Service develops

‘Efficient Engineering’ - the corporate

engineering solutions that accelerate

motto underlines the consequence of

The new Version 2.3 also incorporates a

the product engineering process.

optimized, efficient processes which keep

high-performance search function which

Interdisciplinary expert systems ensure

companies competitive in the long term.

makes it easy to find and adjust the system

a maximum of productivity and data

settings by means of keywords. For the

integration. The solution provider

project data navigators available in Eplan,

develops tailor-made PDM and PLM

September 2013 2013 September

For further details visit www.eplan.in

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37

NETWORKING

IXXAT Econ 100:

Highly customizable master solution for EtherCAT, CANopen and Powerlink The IXXAT Econ 100 is a universal ARM-based platform with a Linux operating system that comes as a standard version already with four Ethernet, two CAN and two USB ports. Whether “out-of-the-box” or adapted to specific customer requirements, the IXXAT Econ 100 is the right choice for various applications in terms of performance, flexibility and price.

For the implementation of EtherCAT and CANopen master applications or Powerlink Managing Nodes, special application development kits are available for the IXXAT Econ 100. These kits include a comprehensive board support package and, pre-installed on an SD card, the corresponding master software package and the Linux operating system.

For the enclosed sample applications, also a suitable IO module is included in the scope of delivery, as well as a detailed documentation, enabling the fast and easy start of the development.

The EtherCAT Master functionality is provided using the proven protocol software from acontis for EtherCAT Master Class A and B devices. A specially optimized link layer allows the IXXAT Econ 100 to operate with cycle times of less than 1 ms.

The CANopen master implementation is based on the CANopen master/slave software from IXXAT, which enables the Econ 100 to act as a multi-channel CANopen controller.

Powerlink has been implemented based

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on the IXXAT POWERLINK-master/slave software. Due to the integrated hub logic the managing node implementation also supports the typical Powerlink line topology.

Redundancy features, such as redundant master or line redundancy, enable the IXXAT Econ 100 to operate as highlyavailable Powerlink communication solution.

By combining the various master software packages, powerful controllers for heterogeneous systems with CANopen, EtherCAT or Powerlink can be easily implemented. Typical operation areas of the IXXAT Econ 100 are customer-specific control applications and gateway solutions in which the IXXAT Econ 100 is acting as master in one network and as slave within a superior network.

The remarkably high degree of flexibility by using the IXXAT Econ 100 is achieved by the unique combination of extension interfaces, FPGA, software and services.

In addition to the interfaces of the base version, custom interfaces or

enhancements (e.g. digital and analog IOs, DVI output) can be added quickly and easily via expansion slots and the integrated FPGA. This makes the IXXAT Econ 100 the perfect device for customized solutions.

During the development of the IXXAT Econ 100, special attention was paid to the requirements of the various fields of application. Thus, the unit has, despite of its fanless design, an extended temperature range from -40 ° C to + 70 ° C. The used CPU is a dual core Cortex A9. The internal RAM memory has a standard size of 256 MB and can be extended up to 1 GB. The operating system and programs are stored in flash memory on an SD card.

Besides the version within the robust metal housing, IXXAT offers the IXXAT Econ 100 also a board-level product for space-saving integration into already existing customer applications. On request, IXXAT can also deliver OEM versions including hardware and software adaptations - fast and economically priced For more information on the IXXAT Econ 100, visit www.ixxat.com/econ September 2013

INDUSTRIAL SAFETY

Superior by Far Safe controls for safety brakes minimise risks and save effort Mayr power transmission presents a new, reliable brake control for their proven “ROBA-stop” safety brake construction series. The “ROBA-SBCplus” brake control, developed together with the safety experts Pilz, is technically superior in every respect in terms of safety contactor circuits. The prototype module inspected by the TÜV (Technical Inspectorate) can be deployed up to the highest Performance Level PLe and SIL 3.

In order to enable safety brakes to contribute towards risk reduction in machines and systems, they require a reliable control. Vertical axes, for example, rank among the particularly hazardous machine parts through which people can be severely injured. A similar hazard potential arises from stage equipment, if actors are performing beneath suspended loads.

In order to protect people from all hazards in such situations, the remaining functional risks in accordance with safety standard DIN EN ISO 13849-1 must first be assessed, and subsequently suitable measures for the reduction of risks must be taken. As a mechanical component, the brake falls under the category of functional safety in accordance with this standard.

Function of the safety elements The safety brakes from Mayr power transmission function according to the “fail-safe” principle and are closed in a deenergised state. The brake control has the task of reliably interrupting the current in the magnetic coil when switching the brake off. The brake control module works using wear-free electronic semi-conductors, and therefore achieves practically unlimited switching frequency and switching reliability. The prototype module inspected by the TÜV Süd has a reliable internal construction and can be deployed up to Performance Level PLe and Safety Integrity Level (SIL) 3.

The fail-safe internal construction of the control includes, among other things, the internal diagnostic checks for short circuit, earth short-circuit and line interruptions, as well as reliable overexcitation for releasing the brake and switching to a reduced holding voltage with an open brake. Numerous other safety functions permit a comprehensive error diagnosis: as a result, the output voltage for the brake is monitored.

An excessively high voltage on the brake July 2013 2013 September

during switch-off could dangerously lengthen the drop-out time, if for example this causes the vertical axes to sag impermissibly. Monitoring the switching times which influence the brake distance is therefore a further integral component of the integrated error diagnosis.

The signal evaluation of the release monitoring with plausibility check enables monitoring of the brake switch status. Using the switch status monitoring can reliably prevent the drive being moved against a closed brake. Creeping faults, such as increasing wear, which have an influence on the switching times, can be detected in this way. The output signals of the brake control module regarding the switching state of the brake and error messages must be monitored via a secure PLC input.

This is usually already an integral component of the superordinate safety controls for the machine.

Advantages over contactor circuits The technical superiority of the brake control module in comparison to safety contactor circuits is diverse: Thanks to electronic, wear-free semi-conductor contacts, it is substantially more reliable, safer and foregoes complex hardware.

The module replaces a fast acting rectifier with voltage changeover, a safety relay, two contactors with mirror contacts and a spark quenching unit.

The reduction of these functional components saves a significant amount of space in the control cabinet due to the reduced wiring and constructional space requirements. The greatest savings potential is achieved if the performance capability of the module is fully utilised and two brakes are simultaneously reliably controlled. Brakes with a 5 A nominal current can be connected, and the two brakes do not have to be identical in construction.

Thanks to the multitude of integrated safety functions, the modules can be adapted very easily and quickly via the input of parameters to the respective brake and the requirements of the respective system. They are individually parameterised for every brake, for example for the determination of the switch-on voltage, the overexcitation time, the holding voltage or the type of switch-off. The effort otherwise required for programming and validation when switching using contactors becomes obsolete with the use of these reliable brake controls.

The ROBA-SCBplus can be used in the most diverse safety-critical applications thanks to the simple parameterability, if an input voltage of 24 to 48 VI is available on the power circuit.

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

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39

FAIR MART

Macpower CNC showcases Indian Innovations at EMO 2013 India’s fastest growing CNC Turning and Machining Centre manufacturing company Macpower CNC Machines Pvt Ltd is showcasing their latest innovations at the world’s biggest technology show at EMO 2013, Hall NO 26 - Stand No E 29.

MART features the innovations Macpower CNC exhibits at Hannover.

Established in 2003, Macpower CNC Machine Pvt Ltd is a part of the Macpower CNC group. The group isassociated with machine tool industry since more than 30 years. The Macpower group comprises MODERNMACHINE TOOLS (dealing in sales of small industrial machinery), MACPOWER INDUSTRIES (manufacturing ofconventional lathe and milling machines under TURNER and TURBO brands respectively) and MACPOWR CNCMACHINES PVT LTD (Engaged in manufacturing of CNC turning and Machining centers).

Founded by, Rupesh Mehta who has very rich experience of over 25 years in machine tool industry,Macpower CNC Machines Pvt Ltd is having active participation with all

45 degree slant design Featuring superior

Equipped with the advantage of an

the leading association acting on national&

workability and chip-discharging capability.

ergonomic design.

to name a few. It is his vision which has

25 grade Stress relieved casting provides

2. VMC

helped the company to achievewhat it is

dimensional stability.

local levels like IMTMA, UNIDO etc…

today.

stable and fast machining by optimum

Taking Macpower innovations to the global

structurally balanced machine, resulting

structure design.

arena, the following products are getting

in superior damping characteristics for

featured at EMO 2013, Hannover, Germany

minimized vibration to the work piece.

this month.

1.MX 200

4 circuit linear guide ways, designed

rigidity and satiability.

deceleration rates as well as increased

premium machine with the flexibility to

cutting pressure.

meet various needs and worth investment.

The heavy duty spindle cartridge with

The massive MONO block cast iron bed with wide base span, scientifically rib

grease lubricated precision bearings is rigidly anchored on the ribbed headstock, designed to minimize thermal effect.

reinforced to assure the best possible

The rigid tailstocks of the MX series-

rigidity and stability. Designed to absorb

machines are located on separate

cutting force during

hardened and ground Guide way. The

Heavy machining process.

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from heavy duty graded casting with scientifically reinforced to assure maximum

The MX -class machine is a next-generation

Frame &Built :

All major structural parts are manufactured

Extra wide span between slide ways to support increased acceleration and

40

VMC 544 offers a way to achieve more

FEA techniques were used to design a rigid,

tailstock is positioned manually on the guide way.

The enhanced C frame cast iron construction and more rigid design provides stable & reliable performance.

The size of the column, base, saddle, table are optimized through very stringent static & dynamic analysis and provides less friction heat and thermal growth to maintain rigidity and stability.

4 circuit linear motion guide way on all 3 axes, Machining can be done faster and efficiently.

September 2013

High precision class C3 ball screws are pre tensioned and supported at both ends by high precision bearings. Virtually this gives superior parts accuracy.

All three axes motors are directly coupled with ball screw. The direct positive drive provides backlash free, noise free and vibration free machining performance.

ATC - Swing-arm type ATC. The electro-mechanically operated ATC ensures stable operation and less affected by seasonal change in oil temperature than hydraulic.

4th& 5th axis compatibility, this creates powerful package that boots up productivity and reduces setup.

Ergonomic design 3. Turn O’ Mill 200 – Y

turrets and a Y axis, it is designed to handle

Over the period Macpower CNC has

challenging production requirements with

developed very strong technical ability

ease.

and adapted to latest & mostefficient

The generous stroke of 100 mm and the

The distinction between mills and lathes

rigidity of the Y axis frame are at the top of

has become clouded

its class.

Complete machining in one set-up

45 degree slant bed monoblock design

Multiple operations can be done in one setup which eliminaÂŹtes the need for a multi-

with wide guide slide way ensure long term rigidity and machining accuracy.

Featuring X-Y-Z roller guides designed

would involve two or three separate

with high rigidity, anti-wear, and vibration

Machine.

damping to support increased acceleration and deceleration rates as well as increased cutting pressure.

Servomotors directly coupled to high precision ball screws provide excellent acceleration and deceleration performance as well as precise feed movements.

The heavy duty spindle cartridge with grease lubricated precision bearings is rigidly anchored on the ribbed headstock, designed to minimize thermal effect.

September 2013

company offers very wide range of CNC Turning Centers, Vertical Machining Centers & Turn Mill Centers to suit different type of

step machining process that historically

With high-performance spindles, BMT tool

production and management practice.The

requirements achieve more sophisticated machining.

Right from the beginning Macpower CNC has very strong R&D approach which benefited the company to lay avery strong technical foundation and it is this capability that allows the company to offer customized solutionsto its customers.

The company understands that to suggest the proper solution, customers has to be attended personally by atrained sales person and to realize the same the company has established national wide network of sales forcewith its own offices in major centers and network of dealers.

A customer achieving high throughput using CNC machines would always want prompt after sales service; and at Macpower CNC they have trained Service Team members placed acrossthe nation to cater customers as quickly as they can.

The company provides regular training to its sales, service & managerial staff to maintain & upgrade themwith the latest methodology and this will further helps company to maintain its edge.

For further details do visit www.macpowercnc.com

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41

MART UPDATE

ProSoft Technology® releases the 802.11n Industrial Wireless Access Point/Bridge/Repeater with Fast Roam Technology The 802.11abgn Fast Industrial Hotspot is an advanced, high-speed wireless Ethernet solution designed for plant-floor automation, SCADA systems, mobile worker Wi-Fi infrastructure and process control systems. This Hotspot offers a broad range of industrial wireless capabilities including unique features such as Fast Roaming and has excellent packet-per-second performance and robust communications in demanding industrial environments.

ProSoft Technology® is pleased to announce the release of the 802.11 abgn Fast Industrial Hotspot. The new 802.11abgn Fast Industrial Hotspot (RLX2) features breakthrough advancements in client/bridge fast roaming between access points, Ethernet packet optimization, and enhanced diagnostics.

These new capabilities provide seamless high-speed Ethernet connections for moving machines and vehicles traveling long distances in assembly plants, crane systems and mining. The secure, high speed wireless network reduces project costs, while improving productivity by eliminating mechanical festooning, rails and slip rings for economical and reliable mobile applications.

The radio’s Fast Roaming technology uses less than 50msec time between access points and provides full device bridging. The module provides secure

802.11i and 128-bit AES Encryption and operates securely in the 2.4 GHz or 5 GHz bands. It also has advanced management tools. These tools include IH Browser Utility, web server and OPC server. The microSD card will automatically store/load configurations, reducing down time.

The Hotspot is designed for extreme environments and hazardous locations, including oil and gas systems. It is an ideal wireless solution for Producer/Consumer PLC/PAC networking, remote I/O, safety I/O, plant backhaul networking, remote video and mobile worker connectivity.

The Hotspot utilizes extended operating temperatures of -40 to +75°C (-40°F to +167°F) and has agency approvals and certifications with Class1, Division 2 and ATEX Zone 2. The module is high shock/ vibration tested. The Shock IEC is 60068 2-6 (20g, 3-Axis) and Vibration IEC is 60068 2-27 (5g, 10-150 Hz).

For further details write to ProSoft Technology, Flat No. 70, Trilok Apartment,Plot No. 85, I.P.Extension, Patparganj, New Delhi – 110092 Tel: +91 9810637873 Email: india@prosoft-technology.com

High-Speed Roller Cam Rotary Table from Haas Adding a 4th-axis rotary table to a machining center is a proven way to boost productivity, reduce setups, and increase accuracy on multi-op parts. Adding a fast rotary table to a fast machine creates a high-speed package that slashes cycles times even further.

The HRC210 from Haas Automation is a high-speed, cam-driven rotary table that provides cutting and indexing speeds up to 830°/second. It provides 149 Nm of spindle torque for synchronous 4-axis machining, and has a pneumatic brake that yields 182 Nm of holding torque for stationary work. Indexing accuracy is ±30 arc-sec, with repeatability of 4 arc-sec. The 210 mm platter of the HRC210 has a center height of 152.40 mm, with a (50.8 mm x 48.5 mm deep pilot bore and 45 mm through hole. Six radial T-slots simplify fixture and workpiece mounting, and both manual and

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pneumatic tailstocks are available for additional workpiece support.

The HRC210 is driven by a high-performance roller cam system that uses a high-torque servomotor to drive a globoidal cam meshing with cam followers equally spaced around the diameter of a roller gear. Needle bearings in the cam followers provide smooth contact with the cam, and a precision-engineered cam profile ensures accurate speeds and motion. Because the roller drive is preloaded during assembly, the system yields high stiffness, high torque, and high speeds, while providing low wear characteristics and reducing maintenance.

If you’re searching for a high-speed

rotary solution to reduce cycle times and increase accuracy, the Haas HRC210 is the answer. Like all Haas products, the HRC210 is backed by the worldwide network of Haas Factory Outlets – the most extensive system of support and service in the industry. For more information, visit www.HaasCNC.com September 2013

September 2013

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43

X-Y Linier Motor Stage With Industry Leading Geometric And Dynamic Performance New AerotechPlanarDL delivers straightness to ±0.4 µm and flatness to ±1 µm Aerotech (www.aerotech.com) has introduced a new X-Y linear motor stage with industry-leading geometric and dynamic performance for applications where straightness and flatness are critical, the company reports. The PlanarDL series includes nine different travel and performance configurations to support such diverse uses as surface profilometry Applications include: • Semiconductor manufacturing • Electronics manufacturing (LEDs) • Test & Inspection • Laser Processing • Metals inspection • Micro-machining • Nanotechnology • Medical • Laboratory

and high-speed scribing of semiconductor and LED wafers.

With anti-creep crossed-roller bearings, precision-machined surfaces and linear motors driving through the axes’ center-ofstiffness, the stages deliver straightness to ±0.4 µm and flatness to ±1 µm. Structural elements are optimized for high dynamics and stiffness.

New PlanarDL X-Y linear motor stage from Aerotech provides industryleading straightness and flatness coupled with high speed.

The stages achieve 1 m/s velocity and 1.5 g acceleration, enabling high throughput, high-accuracy processing and low total cost of ownership. Aerotech’s proprietary direct-drive technology assures long, maintenance-free working life.

Aerotech is a leading global supplier of positioning and motion control products for industry, government, science and research institutions. Its products provide critical performance for demanding applications requiring high precision, highthroughput motion control solutions.

High-performance options are available to enable accuracies and straightness values down to ±400 nm and orthogonality down to 1 arc second.

For further details write to Liberty Interntional, Tel: +91 7926926360 Email: molac.systems@gmail.com or visit www. aerotech.com

Powder Spray Gun With Smart Tracker from Mitsuba The latest 100 KV 700 Supreme Electrostatic Powder Spray System from Mitsuba, has received US Patent 5678770 for its innovative technology.

It’s unique integrated cascade incorporates a corona classic attachment which eliminates powder wastage, penetrates the Faraday Cage area and reduces powder coating cost by increasing transfer efficiency.

Mitsuba’s Multistatic 700 powder spray equipment incorporates a “Smart Tracker” - a self diagonizing performance monitor which indicates how efficiently individual

44

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components are working. “Smart Tracker” makes the operator smart enough to self trouble shoot at the site itself and thus maintain the highest operating efficiency in the powder coating process. The standard Multistatic 700 consists of both corona&tribo guns, controller with smart tracker, 25 kg stainless steel hopper and trolley.

For further details write to Mitsuba Systems, 34/H, LaxmiIndl Estate, New Link Road, Andheri (W), Mumbai – 400 053.

Tel : +91 22 631 8633 /633 4735 Email :mitsuba@vsnl.com or visit www.powdergun.com September 2013

Red Lion Panel Meters Win Control Design 2013 Readers’ Choice Award Survey Respondents Name Red Lion Industry-Leading Panel Meter Provider Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking,was recognized for its industry-leadingpanel metersby Control Design Readers’ Choice Awards 2013.

This is the 13th consecutive year that the readers ofControl Designhave selected Red Lion as the top provider of panel meters in the industry.

“Being recognized by our customers for the 13th time in a row in the face of fierce market competition reaffirms our determination to continually develop the best industrial automation solutionsin the industry,” said Jesse Benefiel, vice president of product management at Red Lion Controls. “We believe this accolade was earned by providing customers and partners with innovative technology, highquality products and responsive technical service.”

To determine this year’s winners, Control Design sent questionnaires to approximately 15,000 magazine subscribers who work directly with industrial automation and control products. The questionnaire included an unaided ballot in which participants were asked to identify the vendors that came to mind in response to the questions.

Respondents had to pull Red Lion’s name from memory or experience, further validating the company’s products and

services. Only companies that received at least five percent of the category vote were recognized. Since the survey beganin 2001, Red Lion has consistently dominated the panel meter category.

“There are dozens of top-notch suppliers in the automation and control space thatare constantly seeking affirmation for their product designs and offerings,” says Joe Feeley, editor-in-chief of Control Design.

“Our Readers’ Choice Awards recognize the market leaders that have been able to differentiate themselves by delivering truly innovative and cutting-edge products to the marketplace.”

With more than 3.5 million panel meters sold since the company’s inception, Red Lion’s digital and analog offerings are the most comprehensive in the industry. Red Lion panel meters easilyaccommodate a wide range of applicationsthrough varyingmodels, inputs, sizes and other capabilities. From compact CUB indicators to versatile PAX process meters, Red Lion provides flexibility that allows customers to seamlesslyadd or change capabilities with plug-and-play field installable option cards. The end result delivers real-time visibility that drives productivity. For more information, please visit www.redlion.net/ together.

Heavy Duty CNC Lathes (Flat Bed) from Supreme Supreme CNC Machines PvtLtd,

for better rigidity and most ideal

offered one of the world’s

machine for huge work piece. This

famous Heavy Duty CNC Flat Bed

machine comes with a host of

Lathes from M/s. CNC Takang

options that make it versatile.

Co., Ltd, Taiwan. Some of the salient features of these lathes are Solid Box construction casting headstock, spindle speed is operated by M code, infinitely variable speed is command by S code, Three (3) “V” Bed ways July 2013 2013 September

For further details write to Sunil Kumar, Supreme CNC Machines Pvt Ltd, 439/9, Royal Enclave, 3rd Avenue,Annanagar East, Chennai – 600 102 Tel:+91 44 26285075/ +91 9383285075

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45

Growth and Expansion Continued: 3DPD’s New Facility in Pune 3D Product Development (3DPD), India’s leading and one of the first Rapid Prototyping Services Company is launching its new facility in Pune during mid October. This state-of-the-art facility in Pune is located at Chinchwad, close to the traditional automotive hub of India Pimpri-Chinchwad and the emerging one - Chakan.

3DPD, established in 2000, has grown to be

preferred service provider for all most all major automotive OEMs --- like Tier 1, Consumer Durables and Consumer Electronics, Design Companies, Medical Equipment Manufacturers, just to name a few sectors.

The slowdown in the Industry in the last year has not deterred 3DPD from marching ahead. 3DPD has

“We believe that the last 10 years have been really exciting to sow the seeds of maturity and growth. Prototyping and Product Development in India is poised for an exponential growth. By opening the Pune facility, 3DPD is well prepared to ride this growth wave. It was our long desire to contribute back to the Pune region for the customers, as we believe that proximity to the customer helps us serve better.”

Dr. Mukesh Agarwal Founder & Managing Director, 3DPD the most diverse and largest prototyping service provider. 3DPD and its sister concern, Total Prototyping, together are the only company offering both plastic as well as metal prototyping services under one roof.

3DPD’s facilities, for plastic as well as metal, have been in Bangalore. Over these 13 years, 3DPD has served over 1000 customers in India. 3DPD has been the

made fresh investments throughout its existence and added new technologies or expanded its capacity every year. 2013 is no different. 3DPD is proud to launch its New Facility in Pune.

This facility replicates 3DPD’s Bangalore facility in Plastic Prototyping. It includes Stereolithigraphy (SLA), Selective Laser Sintering (SLS), CNC machining of plastics, and state-of-the-art Soft Tooling

Capability with Vacuum Casting facility. It is supported with Painting and Inspection infrastructure.

The Pune facility is headed by Mr. Sanjeev Kulkarni, a veteran of this industry, working for some 20 years. Founder of 3DPD, Dr. Mukesh Agarwal, continues to be personally engaged with customers in understanding and meeting their exact demands.

BOSCH honors SCHUNK with the Global Supplier Award Robert Bosch GmbH has honored SCHUNK, the competence leader for clamping technology and gripping systems with BOSCH Global Supplier Award in the category Indirect Purchase. BOSCH awards this prize, to those companies who show superior performances in production and delivery of products or services.

in Lauffen upon Neckar, “This award underlines the innovative strength, and the global performance of SCHUNK. It is our aim to develop new efficiency potentials in production automation with our superior modules and solutions, again and again in the future.”

“The Bosch Global Supplier Award is an award and incentive at the same time. With this prize we honor the merits of our best suppliers. We want to encourage all the other suppliers in also delivering such top performances,” said Dr. VolkmarDenner, Chairman of the Bosch Managing Board on the occasion of prize-giving in Stuttgart.

With 2,000 employees and a global The Managing Partner Henrik A. Schunk (2nd from network of our own subsidiaries and left), and the Technical Director Dr. Markus Klaiber (3rd from left) received the BOSCH Global Supplier distribution partners in more than 50 Award at the prize-giving in Stuttgart. The award was countries around the globe, SCHUNK is presented by Dr. Karl Nowak (1st from left), President considered to be the leading supplier for Corporate Sector Purchasing and Logistics, as well clamping technology and gripping systems. as Lutz Berg (4th from left), Vice President Head of Indirect Purchasing and Services.

The family-owned company has grown on average in the past 25 years by more than EUR 15 million is expected to increase to 12% per year. approx. EUR 300 million in 2013. About 60% of this turnover has been generated During this time, the annual turnover of outside of Germany.

According to Henrik A. Schunk, Managing Partner of the SCHUNK GmbH & Co. KG

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September 2013

Tool coding using Industrial RFID from Balluf Tool identification using Balluff Industrial RFID increases efficiency, as it makes incorrect tool allocation or missing tools a thing of the past. All the tool-relevant data are stored without contact on a data carrier embedded in the tool holder.

Automatic loading into the system memory means all the data are always correct and up-to-date. Because the data are continuously updated when the tool is loaded and unloaded. In modern production facilities this ensures maximum tool utilization and high machine uptime.

The established basis for tool identification systems is state-of-the-art RFID technology. Balluff identification systems are suitable for industrial use and designed for extreme loads from shock and vibrations and electromagnetic, thermal or chemical effects.

BIS C was the first RFID-based identification solution that ensures reliable data transfer, even in the area surrounding metallic materials. As part of

tool management systems, it enables automatic transfer of the tool parameters, which substantially reduces nonproductive time at the machine. This does not include the time and personnel savings for provision of tools and equipment and optimal utilization of the tool life.

Scrap and rework due to excessive use of tools are virtually eliminated. Additional rationalization effects include easier organization of tools and equipment, greater production assurance and avoidance of errors, for example due to incorrect inputs or mixed-up tools.

The core components of the Balluff identification systems BIS are robust data carriers in miniature design, a read/write head and a processor unit. In complex tool

management solutions, they are also used in configuration and measurement devices, where, according to current practice, the first programming of the data carrier with identification and geometric data takes place.

Balluff identification systems are available in a wide variety of versions Experience has shown that the investment pays for itself within a year or two.

For further details visit www.balluff.co.in

SK 135E : Wear-free decentralized soft starter and reversing starter with motor protection – the economic alternative NORD DRIVESYSTEMS presents a new motor-mounted starter with an extended performance range for the economic distributed implementation of soft start and reversing functions, for motors from 0.25 to 7.5 kW. The compact SK 135E integrates motor overload protection through PTC thermistor monitoring, mains and motor phase failure monitoring, I²t monitoring, and magnetizing current monitoring.

The electronic, wear-free switching technology replaces motor circuit breakers, reversing contactors, and brake rectifiers, thus rendering entire control cabinets unnecessary in large facilities.

As PTC thermistor connection cables and brake control cables are not required, either, installation becomes generally more cost-effective, space-saving, and faster.

When the drives are ordered complete and wired with gearbox, motor, and starter, any assembly effort is reduced to simply tightening the screws and establishing the electrical connection, which is optionally September 2013

with plugs.

The soft start function reduces mechanical stress, preventing shocks during start-up and braking. A voltage boost can be programmed for applications requiring high break-away torques. Various braking modes are available. The starter features four potentiometers and four DIP switches for adjusting the most important parameters. LEDs signal the operating status.

Parameterization and diagnosis can be carried out via parameter boxes or via a PC, using the free-of-charge NORD CON Featuring a compact, easy-to-clean enclosure, the SK 135E starter software. NORD’s entire provides for equipment-friendly soft start-up of distributed distributed electronics program, drives in all kinds of sectors which also includes the SK 180E and SK 200E series frequency NORD DrivesystemsPvt Ltd, 282/2, 283/2, inverters, provides the benefit of a uniform Village Mann,Tal. Mulshi, Adj. Hinjewadi operation concept.

MIDC II, Pune – 411057 Tel: +91 9765490890 Email: jyoti.mishra@nord.com For further details write to Jyoti Mishra, www.martonline.in

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Indo-MIM gets AS 9100 Rev.C Certified Indo-US MIM Tec Pvt Ltd, global leader in supplying precision-engineered products using Metal Injection Molding (MIM) as the core manufacturing technology has recently added another certification to their credit. Standard AS 9100 Rev.C, which is designed to be used by firms in the aviation, space, and defense industries and can be applied throughout the supply chain was credited to Indo-US MIM Tec Pvt Ltd early September this year for their achievements.

Indo-MIM QMS team set a record by

from UL DQS within three days against the standard lead time of 30 days. AS 9100 Rev. C standard is designed to be used by firms in the aviation, space, and defense industries and is intended for use by organizations that design, develop, and produce aviation, space, and defense products. It is also intended for use by organizations that provide post-delivery support and

Quality Certification Body UL DQS India Managing Director & CEO, Dr. K. Murugan visited the plant at Hoskote and presented the certification to Mr. Krishna Chivukula Jr., CEO and Mr. Sai Krishna, Quality Head.

“We are glad to receive this certification from UL DQS. Since we had established our Quality Management System meeting the AS 9100 Rev. C standard requirements, so it’s a pleasure to get recognized for our achievement from UL DQS at this platform. Presently this certification is for the Aviation requirements from the customers and it is definitely a feather in the cap of Indo-MIM.�

Sai Krishna Quality Head

achieving the certification in a short span of two months against the standard lead time of nine-twelve months slated by Industrial Experts and Consultants and at the same time received the certification

includes those that provide maintenance, materials, or spare parts for their own products. UL DQS India is the Indian Operation of UL DQS, which is a merger of UL Inc of USA and DQS of Germany, with

over 47000 certified sites and presence in more than 100 countries globally. UL DQS India is head-quartered out of Bangalore having presence with offices and auditors across India.

Build Machines Faster: Kollmorgen displays single-cable drive technology at Automation 2013 in Mumbai Machines with reduced cabling are faster to install: Kollmorgen demonstrates the advantages of single-cable motor power and feedback connection technology for servo motors at Automation 2013 in Mumbai, India.

AKD series servo drives and AKM servo motors with single cable technology are so cost effective that Kollmorgen can offer machinery and plant manufacturers motion systems with all the benefits at an attractive price. These include half the cabling effort, reduced wiring space and easier machinery cleaning - especially interesting for application areas in food packaging with high hygiene standards.

Kollmorgen is a leading provider of

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integrated automation and drive systems with their corresponding components for machine engineers all over the world. With over 70 years of experience in motioncontrol design and application and established know-how in structuring standard and customized solutions, Kollmorgen again and again supplies solutions that stand out as regards performance, quality, reliability and simple operation. Through these, customers can achieve an unquestionable market advantage.

For more information visit: http:// www.kollmorgen.com/hi-in/home/ Ready to install and finely scalable drive solutions are presented by the international specialist for motion control and automation at the Bombay Exhibition Centre, 23 to 26 September 2013 in Hall 1 (Stand E4).

September 2013

THE LAST LEAF Dear All, If we stop learning, we stop winning. This is the new mantra that we all need to remember and follow in India, considering the weakening rupee and the inadvertent implication it is having across the society and industry. ‘Learn and Win’ formula needs to be applied everywhere.

It was recently in the News that an Indian American KavitaShukla has won INDEX design award for her innovative design, FreshPaper, that helps keep food fresh for a longer period. The 500,000 Euro award, recognising the best of innovations addressing problems facing the world, is given biennially in Copenhagen. This is a fitting example of Learning and Winning.

Shukla is among the five winners in categories like Body, Home, Work, Play and Community. Her design won in the Home category - “FreshPaper is simple, low-tech and hyper affordable, with the potential to scale into new markets. The product has taken off in the United States, and has immense potential in other developed markets where access to refrigerators is limited,” said INDEX jury chairman MikalHallstrup in a release.

On the industry side, the atmosphere has been traumatized by VUCA – Volatility, Uncertainty, Complexity and Ambuguity at the domestic as well as international front.

However, as all unsavoury times must come to an end, internationally now there seems to be somestaibility returning to the US and some green shoots have begun to sprout in Japan & Europe(Coutsesy : ACMA Annual Report). Toyota, Ford, Nissan, Chrysler and General Motors all reported double-digit U.S. sales gains last month as strong sales of pickup trucks and small cars led the industry toward its best month in six years. In fact, Toyota posted the biggest gain, with sales up nearly 23 percent over August of last year. Nissan sales were up 22 percent, the best August in company history. At General Motors, sales were up almost 15 percent for the company’s best month since September of 2008. Chrysler and Ford each reported 12 percent gains.

It was Chrysler’s best August in six years, while August was Toyota’s best month in more than five years. This is bringing cheer to the industry.

Even back home in India, after contracting for two consecutive months, the industrial output grew at a four-month high of 2.6% in July. Manufacturing, which constitutes over 75% of the index, grew at 3% this month compared to stagnation in July last year. The big surprise came from capital goods sector which rebounded by a robust 15.6% against a decline of 5.8% last July. Export oriented sectors like textile (apparels) and leather goods have grown by 44% and 16.5% respectively. These industries form a silver lining amongst the gloomy atmosphere of economic crisis and help pep up the mood around us.

As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions.

Till then, Happy Technology!

Manoj Kabre Member, Editorial Advisory Board (EAB) September 2013

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

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