RNI NO: MAHENG/2017/73912
30
Vo l u m e 2–I ssu e 1 M u mbai
41
Jan/Feb 2018
45
Pages 72
Pr i ce I NR 6 5
55
62
w w w. m es h m i x m ed i a . co m
CONSOLIDATING GROWTH
DMI sought the views of two industry experts to understand the challenges that caused the slowdown and how the revival can be leveraged to help the industry achieve its true potential.
CREATING AN AEROSPACE CULTURE IN TAMIL NADU
N SHEKAR President, Aerospace Industry Development Association of Tamil Nadu (AIDAT)
MARPOSS AEROSPACE
YOUR WORK IN GOOD HANDS Process monitoring Documentation
MRO Tools
Process monitoring Machine Protection Fastner holes inspection
ONE PARTNER, MULTIPLE SOLUTIONS. Marposs Aerospace produces tools for MRO inspection, assembly, and machining components used for the aircraft engine. With thousands of tools manufactured and over 40 years of industry knowledge, Marposs can do it all. Currently, Marposs Aerospace can be found in Mexico, China, and in the U.S.
www.marposs.com
MARPOSS INDIA Pvt. Ltd. 147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com
4
Volume 2–Issue 1 J a n /Feb 2 0 1 8
CONTENTS 15
16
26 20
32
36
5
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
38
44
50
Industry News Camille Bauer Dranetz
Events CII Carl Zeiss Excon 2017
Feature NORD Calibri
Cover Story AIDAT EMERGING DRIVERS OF MANUFACTURING GROWTH
12 14 15 55 60 16 46 20 26
Interview Stratasys
Case Study Stratasys Faro Renishaw
Product News CG Tech PORTESCAP SCHUNK Marposs Schuler
Way Ahead Radcam Technology
42
45
46
56
68
30 32 38 64
Success Story Magal
Primer DMG MORI
Special Feature Frank Jablonski
36 44 45 48 68 41
42 50 56
6
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Message | EDITOR’S LETTER
The Promise of Aerospace
I
f you ask me to make a list of my favourite Indian cities, I would put not one, but two cities at number 1 – Kolkata and Chennai. And I have travelled to and stayed for days in all the major cities in India. Let me tell you the biggest reason why I’d choose these two. To use a cliché, it is the people that make cities. However, a city attains greatness when it acquires a distinct persona that is identifiable by itself, you don’t need a slogan or branding to understand it. The moment you put your first step in a great city, you just know in your heart what a city stands for. To me, Kolkata and Chennai possess this quality that all the great cities have – they embrace the modern and the ancient with equal ease. They never make you feel like an outsider, no matter which part of the world or class you hail from. I like them to the extent that I feel I have a personal stake in the progress of these two cities. Which is why I felt a tinge of excitement when I read about how Chennai, Tamil nadu is quietly and steadily positioning itself as a potential Aerospace and Defence (A&D) hub. I read about Chennai Aerospace Park and the stellar ways in which AIDAT (Aerospace Industry Development Association of Tamil Nadu) is developing and promoting this initiative. Accordingly, we reached out to Mr N Shekar, President, AIDAT wanting to know more about the initiative. As luck would have it, he turned out to be the most generous, well-accomplished and learned person I have interacted with in a long time. You must read his profile and interview in our cover feature and you will be as pleasantly surprised with the variety and breadth of experiences that he has had. Here’s a hint: He was a part of the start-up ecosystem in Silicon Valley before start-ups became a buzzword. He worked with Sun Microsystems when it was still a start-up, launched a venture of his own that he sold successfully to an American company, and subsequently played a key role in establishing and scaling up a Boeing Subsidiary in India to great heights. He was kind enough to share his views on a whole range of subjects including why Tamil Nadu is rightly placed to leverage the recently unlocked A&D opportunity, his own career and his role at AIDAT. We are proud of the opportunity that we had with Mr Shekar for this edition and the insights that we were able to bring to you from the interview. Do please read the interview and let us know your feedback. Here’s wishing you successful 2018. Write to me at editorial@meshmixmedia.com
ANAND PANDEY Editor Meshmix Media
8
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Message | PUBLISHER’S LETTER
A Momentous Year
W
e would like to begin this note by wishing you all a very Happy and Prosperous 2018. With the January-February 2018 issue, Meshmix Media has successfully completed a year of publishing. We have acheived a number milestones in the first year itself, one, of course, has been the launch of Dynamic Manufacturing India Magazine, and the second one is that our web portal Machine Insider is now up and running. We have also collaborated and continue to do so with a few International Media Houses in 2017. This year began on a great note with Meshmix Media partnering with Network 18 Group for their Special Project i.e. our first Coffee Table Book which will feature manufacturing companies and entrepreneurs based in NCR. Our first two Issues of Dynamic Manufacturing India were GST Specials. In the launch issue we featured the main tenets of GST and its positives. The second issue had us carrying views of industry stakeholders on GST’s impact on the manufacturing sector in the near and long run. Third Issue had carried leadership insights from an industry stalwart, Mr Ravi Raghavan, CEO and MD, BFW. We also had covered insightful articles focusing on SME Growth and Industry 4.0. Our fourth issue, the one that you are flipping through puts the spotlight on the Aerospace Industry and how Tamil Nadu, has in the last few years emerged as a strong contender for the increased A&D business that is likely to flow to domestic manufacturers and suppliers with supportive policies. Not to mention that A&D is going to boost Mission Make in India in a big way. News from the Make in India front is positive too. Under the Make in India initiative, the Government of India aims to increase the share of the manufacturing sector to the gross domestic product (GDP) to 25 per cent by 2022, from 16 per cent, and to create 100 million new jobs by 2022. Business conditions in the Indian manufacturing sector continue to remain positive. The World Economic Forum (WEF) has ranked India at 30th position on a global manufacturing index. (Source: MOSPI ) Meshmix Media wishes a superlative growth to all of you this year and beyond. Once again, we thank you, esteemed reader, for your valuable suggestions and unbiased feedback and look forward to your views on this issue. We thank our advertisers for their continued support and faith in us. Check out our website www.machineinsider.com for the e-copy of our magazine as well as the latest industry updates. Do please write to me at preeti.m@meshmixmedia.com
PREETI MISHRA Publisher Meshmix Media
10
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Message | NOTES FROM THE FIELD
Create. Connect. Collaborate
I
n the last issue we carried an excerpt from Steve Millers’s highly acclaimed book ‘Uncopyable: How to create an unfair advantage over the competition.’ Personally, I was highly inspired with the message of this book, particularly the part that talked about ‘Building An Uncopyable Strategy.’ That, according to Mr Miller, is a summation of three things – experience, innovation and branding. When I apply these principals to Dynamic Manufacturing India (DMI), I see that, though we have put a lot of effort in each of these three areas, a lot more needs to be done. You will see us working more on the three areas in the months to come. Speaking of branding, last week we partnered with Network 18 Group. We will be working together to bring out our first Coffee Table Book titled ‘Legends of Delhi & NCR.’ The Book will feature organizations as well as entrepreneurs of NCR and showcase their goals and achievements. The current, January-February 2018 issue of Dynamic Manufacturing India, is focussed a lot on Aerospace Industry. The Cover Story features Mr N Sekhar, President, AIDAT (Aerospace Industry Development Association of Tamil Nadu). Mr Shekar, through his experience of global Aerospace Industry and the association, is well on his way to put Tamil Nadu on the global A&D map. The year 2018 starts with us putting the spotlight on growth in the manufacturing sector in another cover feature – it reflects us on our organisation also. As an organisation, Meshmix Media has grown strong. We have completed one year and this journey has taught many invaluable lessons to me personally and continues to do so. This year, our Mantra is 3C: Create, Connect, Collaborate. We will focus more on Creating content which is useful to the industry. We will Connect with more industry leaders, and reaching out to readers through different platforms including print, digital and TV. And we aim to Collaborate more with international media and manufacturing companies to bring more value to you. IMTEX, one of the industry’s most important events, starts from 25th of this month. We wish all the exhibitor a successful IMTEX 2018. Happy Reading. Write to me at advertise@meshmixmedia.com
DINESH MISHRA Senior VP – Strategy Meshmix Media
The ZEISS Quality Network A Game changer for In-Line Sheet Metal measurements New
New : us at Visit 2018 ilion) X IMTE erman Pav
(G o. 3A No. C-102 N l l a H Stall
AIMax
Digital-Optical 3D Sensor
CONTURA Coordinate Measuring Machine
RONDCOM NEX 200 Roundness Measuring Equipment
ABIS System
Surface Inspection
COMETÂŽ L3D 3D Scanners
PiWeb Data Management
Smartzoom 5
Industry 4.0 Platform & Networking System
Carl Zeiss India (Bangalore) Pvt. Ltd. Plot No. 03, Jigani Link Road, Bommasandra Industrial Area, Bangalore 560 099 Phone: 080 4343 8000 E-mail: info.metrology.in@zeiss.com I info.microscopy.in@zeiss.com
www.zeiss.co.in/imt
O-SELECT Digital Measuring Projector
Industrial Microscope
12
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Product News | CAMILLE BAUER
The new generation of IEC 61000-4-30 Ed.3 compliant power quality monitors: prevent power quality problems with LINAX PQ3000
P
ower quality monitoring often only gets talked about when there are disturbances, for plant malfunctions, device failures, process interruptions, data losses, IT failures or even an electrical power blackout. These types of failure are usually very time-consuming because the cause is not always immediately detected. In addition, breakdowns are always associated with avoidable costs. So continuous preventive monitoring of the mains with the LINAX PQ3000 from Camille Bauer Metrawatt AG produces a direct pay-off. The PQ3000 helps to detect problems in the mains supply before any financial damages or personal injuries are suffered. It generates data that assists in identifying the cause of failure as soon as an event occurs. It is rated as a Class A device and measures the power quality in compliance with IEC 61000-4-30 Ed.3. Certified compliance of the PQ3000 to all standards is guaranteed by an authorised test lab. This means that reliable and comparable data and information resulting from its measurements can be provided to regulation authorities, used in negotiations with energy suppliers, or for internal quality control. An EN 50160 voltage quality standard compliance report can also be generated in order to audit the quality agreed between the energy supplier and the consumer. The PQ3000 from Camille Bauer Metrawatt AG can be freely parameterised using either the display or a web browser. It captures periodic data as well as PQ-related events. The PQ3000 performs extremely reliable measurement of normative parameters, such as mains frequency, flicker, supply asymmetry, harmonics, interharmonics, voltage dips, voltage swells and voltage interruptions. The PQ3000 also provides configurable digital inputs as well as analogue, digital and relay outputs. These can be used for example, for alarm signals, counters, status logs
etc. Long-term recordings spanning several years using the datalogger are no problem for the PQ3000. An optional UPS can prevent unwanted data loss when a voltage event occurs. The PQ3000 can be connected via Modbus to a higher-level system (SCADA, for example) or to an industrial Energy Management System (for example SMARTCOLLECT from Camille Bauer Metrawatt AG) which creates extra added value. The LINAX PQ3000 is one of the first devices on the market which is not only capable of capturing ripple control signals as required by the IEC 61000-4-30 Ed.3 standard, but also of recording them as an event for a defined period of up to two minutes. This makes it possible to check at any time (to control a consumer for example or to switch tariffs) and determine if the ripple control level and the pulse sequences are in the expected range. This can be done directly on the device or through the web interface.
The PQ3000 is a Class A device for panel installation and is independently certified according to IEC 62586-2. A TFT screen with intuitive user guidance provides a range of different services. PQ data are in PQDIF format according to IEEE.1159.3, so they can be processed by a PQ analysis software (SMARTCOLLECT for example). Picture: CAMILLE BAUER
IN-EM-2017-Win.indd 1
2/27/2017 10:13:53 AM
14
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Product News | DRANETZ
The Dranetz HDPQ SP Now Has Power From the Phase HDPQ SP models are contained in an IP65 (weather/hardened) enclosure
P
ower from the phase has now been added to the Dranetz Technologies IP65 rated Dranetz HDPQ SP power monitoring instruments. The Dranetz HDPQ Visa SP, Guide SP, Xplorer SP, and Xplorer 400 SP instruments are intended for use in harsh, outdoor and remote environments, or for applications where a LCD display is undesirable.. “Having the ability to power the Dranetz HDPQ SP instruments from the circuit being measured is a great convenience to users, and it also enhances their safety, said Ross Ignall, Dranetz Director of Product Management. “With the new, built in, 600V AC/DC power supply, users no longer have to locate a separate 120/230V power source for the instrument; they now have the choice to either power the instrument from the circuit being measured or from a separate power source.” Dranetz HDPQ users can now choose between a traditional portable instrument with a local 7” color touch LCD display or a SP version
that can be powered from the phase, and is housed in an IP65 enclosure without a local LCD display. The HDPQ portable (with 7” display) and SP (IP65 enclosure without display) versions of each model have exactly the same measurement and strong remote communications capabilities. The Dranetz HDPQ Family of Power Quality, Demand & Energy instruments not only offer the industry’s best measurement capabilities, but also have the most powerful communications capabilities in the industry making it ideal for commissioning, engineering, and troubleshooting applications. The powerful communications available in the Dranetz HDPQ line enhances the end users productivity and safety by allowing users to control the instrument and download data remotely. Users no longer have to subject themselves to hazardous environments and can now manage power surveys remotely from the safety and comfort of an office or other more convenient location.
Picture: DRANETZ
15
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
CII | Event News
CII hosts 9 Edition of TN Manufacturing Summit 2017 th
Industry experts discuss intelligent manufacturing business strategies for global competitiveness.
Picture: CII
C
II Tamil Nadu organized the 9th edition of CII Tamil Nadu Manufacturing Summit in Chennai today, one of its key initiatives in the state. Eminent speakers from the Government and industry shared their thoughts and best practices in this forum. “Our business cooperation with Tamil Nadu has dynamically and favorably developed over a period of time creating over 2.5 lakh employment opportunities and an investment of about 2.7 lakh crores with 53.2% of manufacturing companies by the year 2015” said Mr Seiji Baba, Consul General, Consulate General of Japan while addressing the members. The Embassy of Japan had conducted a survey last year which revealed, that 205 out of 1305 Japanese companies are located in Tamil Nadu and 582 out of 4590 business operation bases are based here, he added. He suggested the industry to expand and explore business opportunities in sectors other than Manufacturing like, Chemical, Pharmaceutical,
Biotechnology, Food Processing etc., He raised another discussion plot on utilizing the Indian immigrant human resources and extending their business to Southeast Asian Region, African Continent etc., “Tamil Nadu, being a competitive and an investor-friendly landscape has more advantages pertaining to Ease of Doing Business namely the recently launched Single Window Portal over many other states”, said Mr P Ravichandran, Chairman, CII Tamil Nadu. CII is the nodal agency for this portal and it has been engaging in sensitizing industrialists to utilize this, he added. He briefed on the activities of CII Tamil Nadu like, involving in Water related initiatives across the state, engaging in developing India’s start-up ecosystem and much more. He appreciated the present Government for being very responsive to the concerns and issues of the industry and their efforts in re-positioning the state in the global map. Mr N V Venkatasubramanian, Convenor, CII Tamil Nadu Manufacturing Panel on sharing his thoughts said that there is a huge scope for the state to align its resources and manufacturing competitiveness to economically and industrially develop the state. Mr Vivek Vanmeeganathan, Managing Director, Caterpillar India spoke about how manufacturing industries in the state are gearing up towards skill development and technology advancement to retain the state’s position in this arena. The day-long conference focused on smart & sustainability manufacturing, skill developmentshaping of future manufacturing sector in the state, Ease of Doing Business – Business Facilitation Ordinance, opportunities in Aerospace and Defence sectors in the state and readiness of industries during disasters.
16
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Feature | NORD
An easy choice Cost-efficient logistics drives in three preferred configurations
I Illustration 1: Standardization can save up to 70% of TCO for drives in conveying systems. Picture: NORD
n plants with many drive units, the total cost of ownership can be reduced by up to 70% through intelligent management of variants. Therefore, NORD DRIVESYSTEMS has established three preferred sizes for efficient variable-frequency drives in materials handling and conveyor applications. These cover the typical functional and performance requirements in postal hubs, intralogistics applications, and baggage handling systems. The standardized drive systems greatly simplify purchasing, engineering, commissioning, and spare parts stocking. Moreover, they are particularly easy to install, operate, and maintain. Limiting the number of variants can yield greater total cost of ownership (TCO) savings than
any other measure except for lowering energy consumption. Therefore, drive manufacturers should be able to provide viable drive system standardizations for specific industrial segments. Preferred variants will also benefit customers by simplifying the procurement process, from the first drive purchase to any orders that may follow. Fewer variants also make inventory management much easier. Furthermore, they make planning and engineering processes less complex for everyone – the drive supplier, the OEM, and the end user. The challenge is to select as few drive configurations as possible in such a way that they adequately fulfill the varied tasks without being oversized. Drive engineers therefore need to thoroughly analyze sector-specific patterns of
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
and baggage handling systems can be reduced by up to 70%. Three variants, much flexibility The LogiDrive line is the solution for conveyor systems spanning many hundred meters. The variable-frequency drives (VFDs) allow for simple daisy-chaining; short power lines can be connected from one drive to the next. NORD has tailored this line to intralogistics and airport technology. Three geared motor variants meet all typical performance requirements. IE4 permanent-magnet synchronous motors with power ratings of 1.1 kW, 1.5 kW, or 2.2 kW are combined with efficient two-stage helical-bevel gearboxes in two sizes for torques up to 260 Nm. Robust frequency inverters from the NORDAC LINK series enable a wide range of speeds. The systems feature a high overload capacity and offer a uniquely versatile range of functions. Interfaces for all commercially available communication protocols are available, including PROFINET, Ethernet POWERLINK, EtherCAT, and EtherNet/IP.
Illustration 2: Setup and service switches are easily accessible on the field distribution system. Picture: NORD
drive operation and application-specific needs. NORD DRIVESYSTEMS has been designing efficient drive technology for intralogistics and airports for many years. Based on this wealth of experience, the German manufacturer has developed the LogiDrive line of three preferred drive variants optimized for these applications. LogiDrive systems ensure leaner purchasing, engineering, system maintenance, and staff training processes. Only very few spare parts must be kept in stock. As a result, the TCO in postal hubs, warehouses,
Extremely user-friendly and efficient LogiDrive systems are easy, quick, and safe to install thanks to coded plug-in connectors. Maintenance switches, key switches, and direction switches on the devices allow for flexible direct access to individual drive axes for setup or service. Sensors and actuators can be connected via M12 plugs. Sensor data collected by the inverters can be passed on to higher-level systems, which reduces otherwise necessary wiring. Plug & play, pre-parameterized inverters also simplify maintenance. Drive components can be easily replaced. Instead of swapping out entire
Illustrations 3, 4: LogiDrive systems are equipped with IE4 motors which pay for themselves very quickly in applications with frequent partial-load operation Picture: NORD
17
18
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Feature | NORD well as smart braking. Positions and distances can be programmed via the bus or directly on the device. Multiple drives in master/slave operation can synchronize speeds or positions. Featuring integrated PLC as well as PI controller functions and a wide range of sensor interfaces, these systems can even be used to drive fully autonomous modular equipment in a larger installation.
Illustration 5: A clip on the NORD YouTube channel about the NORDAC LINK series of field distribution systems demonstrates key features such as their simple and flexible connection options. Picture: NORD
drive units, for instance, only the geared motor can be exchanged. Thanks to their light-alloy housings, the compact drives are easy to handle as well: on average, they are about 25% lighter than steel-alloy drives. The LogiDrive systems’ IE4 or Super Premium Efficiency synchronous motors take their energy-saving potential to its full extent in conveying systems with frequent partial-load operation. By consuming significantly less energy, they pay for themselves in a very short time. Integrated safety LogiDrive systems efficiently and safely power horizontal, inclined, and vertical conveyors. A load monitor protects the driven equipment by stopping the motor in case of blocked applications. NORD can even implement the STO and SS1 safety functions according to EN 618005-2 for every single drive axis by means of TÜVcertified electronic modules. Employing fieldoriented vector control, the inverters achieve high-precision control. In hoist applications, for example, they provide full torque from zero speed and reliably deliver set speeds even under load fluctuations. Standard inverter features furthermore include connection options for incremental and absolute encoders. The drives manage absolute and relative positioning as
Conclusion NORD DRIVESYSTEMS has extensive practical experience in the field of conveyor technology. The drive manufacturer has designed efficient drive systems for hundreds of intralogistics plants and airports worldwide. The company draws on a large modular program of drive components that are manufactured in-house. The energysaving motors are suitable for worldwide use and available in all common efficiency classes. The NORD gear portfolio comprises numerous gear types and covers an extremely wide range of torques and gear ratios. The VFDs provide enhanced intelligence in plant segments and ensure high efficiency especially in partial-load operation. Furthermore, electronic inverters enable highly flexible speed adjustment. This allows for limiting the drive variants in a larger installation to only a few sizes and gear ratios. The new LogiDrive systems for airport and other logistics applications demonstrate the benefits of greatly simplified variant management and the major cost savings associated with it. Company background NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 3.400 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or explosionprotected systems. Gross sales amounted to approx. EUR 540 mn in the 2015 business year. The company founded in 1965 now has over 36 subsidiaries worldwide. The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services. NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 1,000 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers. Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units. www.nord.com
20
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Cover Story | AIDAT
Creating An Aerospace Culture in Tamil Nadu How Tamil Nadu is quietly but strongly positioning itself as a frontline contender for the Aerospace and Defence manufacturing opportunity. An illuminating account from N Shekar, President, AIDAT who is playing a key role.
21
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
I
n 2017, India was ranked as the fifth largest military spender in the world with an outlay of $55.9 billion, with about one-third of the outlay reserved for capital acquisition of defence equipment. What’s more, India is expected to spend more than $130 billion on modernisation of the defence sector by 2025. Historically, a large slice – more than 60 percent – of the modernisation outlay has been spent on imports. But that is set to change with recent policy measures such as doing away with licensing requirement for 80 percent of items used in defence equipment, raising the FDI ceiling in defence firms to 49 percent through the automatic route and 100 percent through the approval route, and of course, the Defence Procurement Procedure (DPP) 2016 which gives top priority to Indian manufacturers. The Aerospace sector is an allied and equally attractive area of growth for Indian manufactures in view of the fact that India is the ninth largest aviation market in the world at present and predicted to be the largest by 2030. Unsurprisingly, traditional aerospace hubs such as Karnataka, Andhra Pradesh (and Telangana) have recognised the huge A&D opportunity and introduced infrastructural and policy initiatives to attract investors and manufacturers. The surprising and inspirational story is about how Tamil Nadu, an automotive and electronics manufacturing hub, is positioning itself as a strong contender for the A&D investment over the last few years, thanks to the foresight, determined efforts and innovative approach of the state’s industry bodies and industry experts. N Shekar, President, AIDAT (Aerospace Industry Development Association of Tamil Nadu) is among the leading industry experts at the front and centre of Tamil Nadu’s A&D bid. DMI Editor Aanand Pandey had a detailed conversation with Mr Shekar on Tamil Nadu’s A&D vision, the development of dedicated facilities particular the Chennai Aerospace Park, and his global experiences and learning that he has brought to the campaign. Mr Shekar has more than thirty years of global experience with strong background in engineering design, software product development, sales and marketing of products and services in international markets. Since late 2014, he has been active as the President of AIDAT which is dedicated to support and enhance the aerospace and defence companies in Tamil Nadu. He is also charter member with TiE Chennai and advises Chennai based start-ups. Till recently, he was the Vice President of Corporate Strategy and the Managing Director for CDG India – A Boeing Company. In 2001, he co-founded a successful and first ever VC funded Software Product Company in India with investment from Softbank Venture Funds and exited in 2005. He is a graduate in Mech Engg from Bangalore University and also
N Shekar President AIDAT
holds a Masters degree in Mech Engg from Univ of Texas at Arlington, and a MBA in Marketing from San Jose State University, California. He is an advisor on the board of Prajnya, an NGO focused on gender violence and security issues. Edited and abridged excerpts of the interview. What are the capabilities and changemanagement lessons that you brought from CDG (Boeing) to AIDAT and to the large vision of Tamil Nadu as an A&D hub? And what role do you see as A&D sector in terms of supporting and boosting Mission Make in India?
I have been involved with start-ups as well as companies that had start-up like environment. My first job in the US in 1984 was with a start up [SuperCads Inc., CA, USA]. My second job was with a fast-growing and a bigger start-up called Sun Microsystems, so was the one with Sunsoft International Inc. in Singapore that had a start-up like environment where I was the second hire and had to start from scratch.
Picture: MeshMix Media
22
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Cover Story | AIDAT
Key Highlight: It is in the middle of over 2000 companies already engaged in the automotive sector and thus providing the base skills needed for the next higher level needed for the A&D sector.
You must have heard about the start-up ecosystem of Silicon Valley. I was fortunate to be there in the Personal Computer and Mid-range Systems era – which was the era before the Internet became a global phenomenon. I came back to India in 1995 to set up the India operations of an ERP company (SSA India). Then I launched my own start up in 2001 called Vergil Technologies, that was one of the rare VCfunded software service starts ups at the time. Rare, because everyone else was hitching the e-commerce wagon but we took a bet on software. In 2005, the company was sold to American Cyber Systems. In the US, most of my experience was in the area of CAD/CAM, which was a natural progression since I did my Masters in Mechanical Engineering from the University of Texas and MBA in Marketing from the San Jose State University. In 2006 I returned to the CAD/CAM world with a company called Infotech Enterprises, now rebranded as Cyient, where I interacted and worked with the aerospace industry – that is how my interaction with the A&D space began. At Cyient I got the opportunity to work with CDG, a Boeing subsidiary. An account that we got after a lot of work – we spent almost 20 man months pursuing the deal. Two years later I moved back to India and was working with a German Company called P3 that was into engineering services for Aerospace Industry. Then CDG called, saying that their relationship with Cyient was dissolved and that they wanted to work with me in India based on our past working experience. That is how I started with CDG in 2009 as a one-man army and then recruited the team – both the management as well as the initial core technical team. Luckily for me, in most of my jobs in India, I was the guy in the lead. That way it worked very well for me because I was able to set the work culture of the teams here in India. Even in SIFY, when I joined them as the President of E-Business, it was a fast growing start up. However, software services was a new area for them and their team mostly comprised hardware and networking guys, so I got a free hand in how to run the unit. CDG was an independent company for about 40 plus years when it was acquired by Boeing in 1999. The reason that Boeing acquired them was that CDG was becoming more and more critical to Boeing. By 1999, CDG had become almost a one-point source for most of the illustrated parts-catalogues and maintenance documentation. The work that we had to do was very critical for the maintenance of the aircraft – any error in the documentation could actually lead to the aircraft mechanic committing an error which could result in loss of lives. That reality had to be drilled into everybody’s head at the CDG India unit. If you look at the aerospace product develop-
ment cycle, the role of technical publishing comes at the very end, as it is an after-sales component. CDG wanted to grow into an engineering services company, which would bring them to the early part of the design cycle. They had brought me on board to fulfil that aspiration. Within CDG the change management that I did was, firstly I made them understand what engineering services entailed. Second change was, it was not a sales organization, it was more of a [services] delivery captive organisation to Boeing. So from a single customer to multiple customers and from a post-sales activity to early design and development activity – these were the two areas of major changes that I had the opportunity to drive. As a part of my role, I was also handling global sales and marketing I did for almost 6 years and left in year 2015. [Mr Shekar was the Managing Director of CDG's India entity and part of its Global Top Management team. He started as the first person in CDG India and built it to a team size of 250 plus.- Editor] My work with Cyient, CDG and P3 gave me a broad understanding of how the global Aerospace ecosystem works. If you look at local A&D environment, most Indian vendors supply to HAL, DRDO, and ISRO. If you look at most suppliers, except the big ones that have grown in the recent few years, most of them are still MSME with sub Rs 20 crore revenue. In terms of numbers, they are quite a few all over India there are probably over 1000 companies operating in the A&D industry; in Tamil Nadu alone there are about 150, and I am sure there are 400 or more in Karnataka. In short, to answer your question of what capabilities I brought to AIDAT – one is my broader understanding of the global aerospace ecosystem, the second one is the understanding of design and development and maintenance aspects of the aircraft and the third one I’d say is my ability to work in a start-up kind environment. That said, this whole drive and initiative is a combined effort – it is not only me driving the idea. At what point of time did you decide to advance the vision of making Tamil Nadu an A&D hub?
It started in 2009, even before I joined CDG. It was when some CII members were discussing about setting up an aerospace park in Tamil Nadu; they were trying to persuade the State government for the same idea but nothing happened. However, the idea did not find any audience with the successive state governments for many years. Perhaps, the reason behind the inactivity could have been that the erstwhile Defence Procurement Procedure (DPP) was not conducive to private A&D ventures.
Correct. The first DPP that came out in 2008 was very
23
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
restrictive. Over a period of time, the Indian govt learned with feedback and now we have a more industry-friendly DPP. Two, you can’t only preach – you have to practice it too. If you say that you need people to be punctual, you have to come to the meetings in time. You can’t be coming late to the meetings and expect the customer to believe that you can deliver the product to him on time. Most importantly, you can only become a leader if you have integrity. Could you share with us the name of the person in the govt circles who championed the cause?
Sure. It’s Mr B.Elangovan, General Manager, TIDCO (Tamil Nadu Industrial Development Corporation Ltd). We started revisiting the idea with TIDCO, and the govt finally allotted 600 acres of land. In the second half of 2015, we formed AIDAT to take the project forward. The official registration came in place six months later. AIDAT has starting moving on the project since the last one year and a half very fast -- we have ten companies now that have allotted land at the Aero Park and another 10 waiting for land allocation. Can you please share with our readers a view of the various stages of development, the current phase of development of Chennai Aerospace Park (CAP) and the different facilities already created and planned such as Design Engineering Centre and Test and Certification facilities?
The Chennai Aero Park (CAP) is a dedicated cluster for Aerospace and Defence related companies that are engaged in design, development, manufacturing, maintenance and support of Aerospace and Defence-related components, subsystems, systems and assemblies. CAP is a fully integrated park, currently under development, with facilities such as multi-floor manufacturing complex, advanced computing and design engineering centre (ACDEC), centralised testing facility, centralised warehousing for specialty materials and finished components, centralised composite manufacturing facility, advanced 3D or additive manufacturing facility with office space and conference facilities. A skill development centre focused on Aerospace and Defence is also planned at this location. The current extent of land allocation for the CAP is 260 acres. It is situated on the highway connecting Sriperumbadhur to Oragadam near Chennai. You can visit the URL ‘http://www.tidcoaeropark. com/’ for location map and other details. Another 350 acres has been earmarked for further expansion and potential use by a Mother Unit that we are working to bring to this CAP. The current stage of development is that land
has been allocated to 10 units to the extent of 40 acre and land of 20 acres allotted for the ACDEC which also houses all the above centralised facilities and the multi-floor manufacturing complex. Another 10 companies have applied for land to the extent of 30 acres which will be released soon. TIDEL Park, which is a TN-government owned entity, will be building both these facilities. What are the biggest infrastructural advantages of Chennai Aerospace Park (CAP) that should make it a preferred destination for Aerospace & Defence (A&D) sector investors and multinationals?
First and foremost CAP is not just a real estate venture. It is a fully integrated park with all the facilities outlined above with world-class infrastructure support from Tamil Nadu government for power, water, sewage and effluent treatment. It is in the middle of over 2000 companies already engaged in the automotive sector and thus providing the base skills needed for the next higher level needed for the A&D sector. Tamil Nadu, which contributes over 40 percent of engineering graduates in the country, is also the second largest contributor to the manufacturing sector in India [in terms of GDP]. The state is an ideal destination for anyone wanting to establish manufacturing units – whether it is in Automotive or Aerospace and Defence sector. Also, with defence and railway establishments like Heavy Vehicle Factory, CVRDE, Integral Coach Factory which also source parts and components from vendors across TN, the state automatically lends itself to be an ideal destination for this sector. Also the TN government will soon be announcing a comprehensive Industrial Policy with special focus on Aerospace and Defence sector which will incentivise prime investors as well the MSMEs who are vital to this industry. Many automotive MNCs have benefitted by establishing their mother plant in TN and supplier base around them - making TN the automotive hub in India calling it "The Detroit of South Asia". The TN government and AIDAT are very keen to welcome global MNCs in Aerospace and Defence sector to similarly establish their units here and benefit from the rich manufacturing culture here. In one of the media articles on CAP, you were quoted as saying, “Tamil Nadu is the rightly poised to become an aerospace manufacturing hub.” Could you elaborate on that please?
The idea was to highlight the inherent advantages that we have in Tamil Nadu. One is that, people in Tamil Nadu are work oriented, they have the right work ethic, people don’t jump ship here when they get inspirational leadership – these are also the reasons why I pitched for Chennai
Key Highlight: Mr Shekar was the Managing Director of CDG's India entity and part of its Global Top Management team. He started as the first person in CDG India and built it to a team size of 250 plus.- Editor.
24
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Cover Story | AIDAT
Key Highlight: Tamil Nadu is the second largest contributor in terms of manufacturing to the GDP. Three, Tamil Nadu has an automotive hub – there are 7-8 large OEMs located in and around Chennai.
as the right place to have CDG. Secondly, Tamil Nadu is known as engineering hub as it produces a large number of engineers. Then you have the manufacturing culture -- Tamil Nadu is the second largest contributor in terms of manufacturing to the GDP. Three, Tamil Nadu has an automotive hub – there are 7-8 large OEMs located in and around Chennai. Also, the Chennai-Coimbatore belt houses a lot of manufacturing and engineering units. Since, automotives require high precision manufacturing therefore engineers are quite well versed with global best practices on quality. Also, the competition is fierce in the automotive space, so the manufacturing has to be highly cost effective. As suppliers, they are constantly under pressure to do more for less. So the profit margins are always under stress. Therefore, all the companies are looking for newer avenues of growth. So Aerospace is an attractive growth area, one that provides the right opportunity to move up the value chain. Another opportunity is the focus on electronics manufacturing with many companies here already supplying to various DPSUs (Defence Public Sector Undertakings) and directly the defence forces also. They have good opportunity to grow bigger and faster.
manufacturing skill base. TN Government's intent to grow the A&D ecosystem can be seen by their investment in the CAP and make that a model for the rest of the country's Aero Parks.
Then, what has been the missing link? Why is it, that despite the presence of a manufacturing culture, a lot of aerospace business has gone in the past to Karnataka and Andhra Pradesh?
MSMEs contribute a significant portion of the needs of the Tier 1 and 2 and OEM needs in any market. That is no different in India – in fact it is even higher in India. Since most MSMEs do not have access to funds for land and building, etc. – unlike Capital goods where they have bank support providing them easy access to ready manufacturing infrastructure in terms of Multi-Floor Manufacturing where they can take the space they need – from 5,000 to 50,000 sq. ft. with power, water and sewage etc. – will help them in starting out sooner with less upfront investment. This model has proven to be successful in many countries like Singapore and Taiwan. Even in TN there are similar setups in other industries. Regarding CNC machine tools companies, these machines are used widely by the A&D manufacturing companies and thus these companies have a great opportunity to provide the support needed for the manufacturers in terms of sales and support near the latter’s facilities. Already a few companies that make or sell CNC machines are part of the eco system in TN.
I think the missing link has been the absence of a mother unit. Karnataka has long been in Aerospace and Defence by virtue of having HAL, NAL, ADA and other DRDO establishments, which are naturally more inclined to work with suppliers located in and around Bengaluru. TN has many defence establishments like HVF, CVRDE, Ordnance Factories. Many TN companies already services A & D establishments in Bangalore and other HAL locations. TN has long had manufacturing culture and has deep rooted belief in manufacturing as one of the core industries. Telegana (erstwhile Andhra), more specifically Hyderabad, has attracted a few private companies such as the Tata Group thanks to pro-industrial policy and aggressive deal-making. TN is now taking up the challenge and has made structural changes with new business friendly environment through "Business Facilitation Ordnance" which further eases the "Ease of Doing Business" in TN for new setups that want to operate in TN. Also TN Government through its SIPCOT agency, has acquired very large land banks across the state that are available for industries of all sizes to start their operations here. TN has one of the best state highway system, 5 international airports, 4 sea ports along the coast, huge engineering talent base (that has been going elsewhere also) and very strong
Do you envision the setting up of the mother unit at Chennai Aerospace Park (CAP)?
We would like to have a mother unit at Chennai Aeropark, but more than that, CAP has been developed as a cluster of units. We want to have the whole range of A&D companies set up base here. One other thing that gives CAP an advantage over other aeroparks, is that we are setting up centralised facilities such as centralised composite manufacturing facility, centralised 3D printing facility, centralised warehousing, skill development – that are high-capital in nature which are not possible for MSMEs to invest in, but they can use this infrastructure on an on-demand basis. What is the idea and strategy behind the setting up of Multi-floor Manufacturing Complex (MFMC) inside CAP? What are the benefits available to high-end manufacturing companies such as CNC machine tools companies that want to be a part of the ecosystem?
Can you share with us AIDAT’s role and the initiatives that it has undertaken to position Tamil Nadu as the leading A&D industry hub?
AIDAT (Aerospace and Defence Industry Association of Tamil Nadu), was formed a little over 18 months ago by the members of the industry with support from the TN government to create and sustain focus on developing the sunrise A&D ecosystem. AIDAT today has over 50 members who actively work with
25
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
the community to improve networking, business opportunities and skills within the ecosystem. AIDAT regularly conducts events that bring new opportunities to the member companies. AIDAT along with TN Government organisation TIDCO was responsible in showcasing the TN A&D ecosystem as a combined force under a unique "TN State Pavilion" - a first of its kind, when you normally see country pavilions, here was a state pavilion - at the 2017 Aero India show in Bangalore. Over 14 companies show cased their products and services to the visitors there. AIDAT facilitated the delegations to Australia (in coordination with AusTrade) in Feb 2017, outgoing delegation of A&D member companies to the USA (in conjunction with IACC), hosted the incoming Aerospace company delegation from Germany in Oct 2017 (in collaboration with IGCC). AIDAT works with the TN Government proactively with regular meetings with the Industries department. AIDAT has worked with the TN Government in drafting the proposed Aerospace Policy – a vertical sector-specific policy formulated to promote this sunrise sector in TN - which will be announced soon. AIDAT works closely with TN Government department TIDCO in conceptualising, creating the vision for the Chennai Aero Park and has worked with them to the level wherein the Foundation Stone laying was recently done by the CM in October 2017. AIDAT recently brought the Technology Development Fund team from GITA/DRDO to increase the awareness of the indigenisation opportunities funded by the Indian government. AIDAT office bearers and members are also on the A&D panels at various chambers and associations like ASSOCHAM, CII TN, FICCI regularly are speakers and panelists at events promoting the industry opportunities. AIDAT will continue to work to promote the growth of the A&D ecosystem in TN and achieve the vision to make TN produce over 30 percent of the nation’s need of A&D products and services over the next 15 years. Do you think A&D manufacturing can contribute in a big way to Mission Make in India?
Make in India I see is already anyway shaping up in India in all the major sectors – FMCG, consumer electronics, smart-phones and others. Since India is a major market and the import duties are high, it makes logical sense for companies to set up their manufacturing units here. However, the A&D sector has largely been dependent on imports -- 70 to 80 percent of components are still being imported. So I would go as far as to say that Mission Make in India was probably driven by the fact that we used to rely heavily on imports and there was a lot of foreign exchange going out even after 25 years of
liberalisation, compared to China that doesn’t have a trade deficit like us – they have a trade surplus. I would say that the idea of Make in India is excellent, but as you know any vision requires significant effort to be turned into reality, especially in India where things move slow. When you have new vision you need to sell it to every constituency and make sure that people believe in it. Even after three years of launching Mission Make in India we haven't made any significant dent at all. However, at least there is a Brand Building going on. For example in Tamil Nadu, it took as an year and a half, of all the associations working together, for the state government to say, Make in India, Make in Tamil Nadu. That’s a way of saying that we, as a state, want to align with Make in India, but we want it to happen in Tamil Nadu. Now if you see some of the recent CII and FICC industry events that have the participation of state governments, you can people promoting the idea. I think the maximum Impact of Make in India should be felt in the A&D industry. That said, A&D is globally a very slow-moving industry. And with the insufficient technological prowess and the near-absent intellectual property it will take a lot of effort. The good part is, that the govt is proactive on this front. We’ve had a few discussions with Ms Nirmala Sitharaman (India’s Defence Minister) and we have seen that even during Mr Parrikar’s (ex-Defence Minister), the govt’s message to the public sector defence units is that: ‘Don’t think that you can do everything on your own; get the private sector involved. You be an assembler and integrator, but not a manufacturer.” This is the right way to go forward. Boeing, for example, doesn’t manufacture anything; it only assembles. They control the design, the intellectual property, the manufacturing process, and vendor development. They do the assembly, testing and the documentation that goes with the aircraft. That should be the mindset that is needed in India. I am hopeful that we will see that happening in the next ten years. Many companies are starting to see the opportunity -- Tata, L&T, Mahindra, LMW, TVS Group and many others. I read a great quote of yours in a media report that said: “Tamil Nadu needs an aerospace culture.” Can you please elaborate on that?
We need to create passion for Aerospace – it is not an easy industry. It’s not like something you produce and forget. A&D needs a lifecycle support and unlike automotive products that have a lifecycle of 10 years, aircrafts have the lifecycle of 40 years. In automotive, the best company provides 95% quality but in aerospace, you can’t have any less than 100%. We have to develop that mindset.
Key Highlight: AIDAT works closely with TN Government department TIDCO in conceptualising, creating the vision for the Chennai Aero Park and has worked with them to the level wherein the Foundation Stone laying was recently done by the CM in October 2017.
26
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Cover Feature | EMERGING DRIVERS OF MANUFACTURING GROWTH
Consolidating Growth
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
End of 2017 brought good cheer to India’s manufacturing industry. The industry, that had posted negative growth in June 2017 and had been struggling since, showed a sharp rebound in November 2017. The Index of Industrial Production (IIP) posted a 17-month high of 8.4 percent for November (see IIP graph).
W
hile experts had, here at DMI and elsewhere, attributed the past slowdown to the adverse effects of demonetisation and GST adaption, the prevalent sentiment is: How to consolidate and maintain the growth momentum of the manufacturing industry hereon after. DMI sought the views of two industry experts to understand the challenges that caused the slowdown and how the revival can be leveraged to help the industry achieve its true potential. Presenting the views of Rajesh Nath, Managing Director, VDMA India Services and Asim Behera, Chief Operating Officer, Daifuku India on the subject.
Job Creation Should Be The Main Agenda Did the big bang reforms such as demonetisation and GST hurt the manufacturing industry’s growth in the short run?
Rajesh Nath (RN): Recently, the economy shrugged off the disruption caused by the GST and any lingering after-effects of demonetisation to post higher growth in the second quarter setting itself on a course for revival. Manufacturing activity expanded at its fastest pace in 13 months in November indicating that the economy is strengthening in the third quarter. The Nikkei India Manufacturing Purchasing Managers’ Index (PMI) rose to 52.6 in November from 50.3 in October, backed by strong growth in new orders and higher production. A strong manufacturing performance helped reverse more than a year of declining growth in the wake of the country’s crackdown on the use of cash. The data showed manufacturing growth of 7 per cent when compared with the same period last year, a sharp jump from the 1.2 per cent growth in the sector registered in the second quarter. Strong factory production levels translated into fastest rate of employment creation since September 2012. VDMA India conducted the 2nd edition of the VDMA Business Climate Survey in October 2017.
97 participants from all sectors of the mechanical engineering industry shared their evaluations regarding their company's business and the situation of their most important customer industries. Their current business situation was seen as good by 42% of the participants, whereas 49% considered it normal and 8% bad. The balance of positive and negative evaluations was therefore plus 33 percentage points. The current
27
28
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Cover Feature | EMERGING DRIVERS OF MANUFACTURING GROWTH utilization of the affiliates’ production or service capacities was evaluated more cautiously; the corresponding balance value is plus 6 percentage points. Asim Behera (AB): I think it's not apt to generalize that all the sectors performed poorly last year. Automotive has been booming and so are sectors like e-commerce. I feel the slowdown you saw in some sectors was a systemic issue where these sectors were are on a path to course correction. On 16 December, the government decided the increase the import tariffs on a number of electronic goods including mobile phones and TV sets to help the domestic industry. Will such protectionist policies give the industry the much needed boost or will they render the local industry globally competitive?
Key Highlight: A strong manufacturing performance helped reverse more than a year of declining growth in the wake of the country’s crackdown on the use of cash.
RN: The rise in tax from 10% to 15% on handsets will make imports of phones – including most of Apple's iPhone models more expensive. Aside from mobile phones, the government also raised the import tax on video cameras to 15% from 10% and doubled the one on television sets to 20%. Prime Minister Narendra Modi launched the flagship Make-in-India programme to expand the domestic industrial base. The tax hike will help domestic manufacturers who are making about 500 million mobile phones a year, more than double the output three years ago. AB: It’s too early to tell. Whilst increasing import tariffs is a very popular way to reduce imports but the manufacturing ecosystem should support foreign players setting up factories here.
"VDMA India conducted the 2nd edition of the VDMA Business Climate Survey in October 2017. 97 participants from all sectors of the mechanical engineering industry shared their evaluations regarding their company's business and the situation of their most important customer industries." Rajesh Nath Managing Director VDMA India Services
What are the main factors hurdles and challenges that are holding back the manufacturing industry in India from achieving its true potential?
RN: Despite an abundance of human resources and a demographic advantage, the absence of adequate managerial and leadership talent is a major challenge to Indian companies. Talent pools are shallower than they appear at the first glance. Supply-demand gaps exist, not only in terms of total numbers, but also in terms of quality. External challenges facing Indian MNCs include a limited understanding of overseas markets, an inability to navigate regulatory complexities and a weak brand or reputation in overseas markets. In addition to external challenges, Indian companies face a number of challenges within their operations – primarily
centred on inability of attracting and retaining talent, cross border cultural issues and inability of building cultural barriers and lack of global mindset. AB: It’s many things but I will try my best to summarize. Most of the manufacturing that happens in India is assembly of imported components. This is because logistics cost has become very inexpensive – thus its cheaper to import parts. Further, currently there is very little OEM (Original Equipment Manufacturer) suppliers that exist (except the auto industry). As I have said earlier, for India to think of becoming a manufacturing hub the OEM ecosystem needs to mature rapidly.
29
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
"It’s many things but I will try my best to summarize. Most of the manufacturing that happens in India is assembly of imported components. This is because logistics cost has become very inexpensive – thus its cheaper to import parts." Asim Behera Chief Operating Officer Daifuku India
What are the major steps, measures, and reforms required on part of the industry as well as the government to pull the industry out of the prevailing growth plateau and put it on the road to fast growth?
RN: With a large consumer base, India is a consumption-driven economy and manufacturing for domestic consumption has to be encouraged and facilitated, with the twin objective of creating large employment opportunity in the organized sector and fuelling the economic growth. The large scale manufacturing for domestic markets would make us more competitive from both cost and quality points of view and provide
opportunities for exports to the developed countries. But before that, the government has to view the manufacturing sector from the macro as well as micro levels to understand the levers that would accelerate the growth of this sector. A thriving and competitive manufacturing industry needs an excellent infrastructure that would enable it to be competitive on cost, quality and supply chain, three important parameters that determine the success of the industry. However, most states do not provide grid power and the cost of captive power to grid is 1:3, while water is a huge challenge in almost every state. The time taken for clearances in ports is anywhere between three days to one month. Country-wide regulations on land acquisition have been enforced in a non-uniform fashion, causing delays. Even lenders are unwilling to support projects unless clearances are available and 100 % right of way has been secured. These inefficiencies add to the cost and impede the ability to supply quality products on time and form deterrents for new entrants to this sector. What should be the main objective of Mission Make in India – creation of jobs or making India a global manufacturing hub? Do you think both these objectives can be achieved together?
RN: As a matter of fact, India’s manufacturing sector has the potential to touch US$ 1 trillion by 2025, which accounts for 25-30 % of the country’s GDP and will create up to 90 million new jobs. The “Make in India” programme of the Government of India is expected to raise the manufacturing sector output to 25% of GDP by 2025. Recently, India also ranked 4th among 190 economies for protecting minority investors in the Ease of Doing Business rankings released by World Bank. The country jumped 30 positions compared to last year to speed its way to the 100th overall spot. However, there is more to it than just the three figure mark. The indicators used for devising the index are: starting a business, dealing with construction permits, getting electricity, registering property, getting credit, protecting minority investors, paying taxes, trading across borders, enforcing contracts and resolving insolvency. AB: No country can really become a global manufacturing hub now; that boat has long since passed. I think job creation should be the main agenda but with how things are going in the areas of IOT (Internet of Things), Industry 4.0, and AI (Artificial Intelligence), we will have to wait and see if Make in India does really create jobs.
Key Highlight: No country can really become a global manufacturing hub now; that boat has long since passed.
30
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Interview | STRATASYS
We Fuel Innovation at Every Stage
S
tratasys, a leading manufacturer of 3D Printers and 3D Production Systems, organized a User Forum on Wednesday, 13th December 2017, at Hotel ITC Gardenia, Bengaluru, India. DMI got the opportunity to speak with Omer Krieger, President (Asia Pacific & Japan), Stratasys and Rajiv Bajaj, M.D. Stratasys India about the
Omer Krieger, President (Asia Pacific & Japan), Stratasys and Rajiv Bajaj, M.D., Stratasys India at Stratasys User Forum
company’s journey, vision, sector focus, recent initiatives and future plans. Presenting, edited excerpts from the interview. Can you walk us through the journey of Stratasys India? Rajiv Bajaj (RB): Stratasys India has been present for over 15 years in India. We started as a
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
liaison office in India and three years ago, in April 2015, we set up the India subsidiary Stratasys India Pvt Ltd. We made a few investments in terms of setting up our office in Bengaluru and Gurgaon. We also set up a state-of-the-art 3D Printing Experience Center in Bengaluru which have all our latest machines and technologies that users can experience and build test cases before they invest in the technology. We serve more than 500 customers across aerospace, automotive, medical devices, education and multiple other domains. We have a set up of four channel partners with the total team strength of 100 present across various part of the country to serve customers closer to their place of work. Which are the major industries and solutions that you are focusing on currently? Omer Krieger (OK): The major three industries we serve globally are automotive, aerospace and healthcare. Obviously, we have very strong presence in the consumer product on the prototyping side because any consumer product should be prototyped to validate the solution before it is mass-manufactured. Another market which is very important to us is education as it creates the next generation of innovators. We have a great belief in budding engineers and developers that they will take this technology far ahead in the future. Who are your customers in aerospace and what are the regions in this part of the world that you are focusing on? OK: In Civil Aviation, we serve leading companies globally such as Boeing and Airbus. We also have gained a significant amount of traction in the after-sales market with airline companies. Singapore Airlines and China Eastern Airlines are good examples of companies that we have partnered with. These are all highly advanced engineering companies that are bringing additive manufacturing to aftermarket repair and maintenance activities. We have a significant activity globally in the Aerospace and Defence (A&D) sector as well. Domains that we want to focus more on are Drones and the commercial aerospace marketspace.
In terms of regions, China, Singapore, and India are our main hubs of activity in Asia Pacific. Globally, of course, we have a strong presence in the US and Europe including and France and the UK. RB: In India we work with the state-owned Defence R&D and manufacturing entities such as DRDO and HAL. Lately, we have also been working with many tier-one private suppliers who work for these defence labs in areas such as the latest Drone technologies. India is an important region for us. What are the challenges you face when you reach out to your clients in India with the next-gen technologies you have? RB: In our experience, most of the companies we approach know about 3D printing. However, only a few of them know what it can do for them. Therefore a lot of our discussion is around helping them understand the positive disruptions it can bring about to their businesses and the problems it can solve for them. The next stage of the interaction is to help them think differently about manufacturing because the process of additive manufacturing brings in a critical element called ‘design for additive manufacturing’ which is integral to the entire process. So the entire journey, from the point we start our first discussion to the point where the customer is prepared to adopt the technology, takes a bit of time. I’d say that India is not a ready market per se but we see it as an opportunity and not a challenge. OK: For example, if you take an aircraft’s duct, it is hard to create with traditional manufacturing since it needs to be built from different parts and follow certain dimensions – the entire process involves a number of steps and different specifications. With 3D Printing, the whole process can be done at one go, directly with the printer. An innovation like this opens up new possibilities – you can create more complex geometries that have higher functionalities. This kind of a process, which is called ‘design for additive manufacturing’, requires a new mindset and a high level of competency with the technology. This is why we have established the User Experience Centre in Bengaluru and we have user events where people can experience and engage with the technology in person.
31
32
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Interview | STRATASYS
In what ways can Stratasys contribute to the economic growth of India particularly the growth of sectors such as A&D and automotive? RB: In India, companies like Maruti have forecasted that the consumer demand trends are changing – people demand newer designs and faster upgrades. The design cycle time is reducing and product differentiation has become more important than ever. These are the keys areas which the 3D printing technology addresses directly. If you have to complete your prototype in a few days instead of three months, you need to look at 3D printing. In today’s presentation Maruti and Ashok Leyland shared a few examples where additive manufacturing gave them a significant competitive advantage. It helped them develop their products faster and better and more suited
CasteStudy | STRATASYS
An automotive wheel concept model printed by an Objet Eden500V. Picture: Stratasys
towards customer requirements. So when that happens, of course, newer models get produced, newer jobs are created and the overall customerbase expands – that is an ongoing cycle. We keep fuelling innovation at every stage. For example, when we say that we are introducing new carbon-fibre-filled nylon material, the customer is able to see how he can replace one of his metal tools with that material and use it as durably on the shopfloor that in turn increases productivity and improves quality. How can the technology contribute to Mission Make it India? RB: Make in India is a great initiative taken by the government. Our vision fully aligns with Make in India and we can add to that with saying that make more innovative products in India because
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
that is the core area we address – our solutions let you design faster, produce faster, help you make quick decisions, as you see in the case of large companies like Maruti and Ashok Leyland. We are proud of being able to play that role.
also joined hands with private institutes like AK Garg College of Engineering in providing quality education to the engineers, collaborating with the industry to solve their challenges, and creating start-up and innovation hubs.
What are your plans and initiatives in the education sector? RB: Education is a key focus area for us because it cuts across all the domains – students who are trained in this technology can take the expertise to all the fast-growing sectors such aerospace, automotive, consumer goods and so on. Since the last 15 years, leading institutes such as IISC, IIT, and NIT have been using our technology as part of their research and training modules. We are also working closely with the government and Niti Aayog that have put a lot of emphasis on 3D printing. We have
What are your future plans? OK: We are looking at two things – one is the engagement with the innovators. It is the companies like Maruti that innovate and not Stratasys. How close can I be through our Experience Centre and other active engagements to the innovators to help them solve their problems. The second one is innovation in our technology – we need to make sure that every requirement we get is filtered, assessed, and addressed in order for us to keep pushing the boundaries of this technology to open up new possibilities and applications.
Manufacturing the Future THE NEXT ERA OF GLOBALIZA TION WITH 3D PRINTING
Tyler Benster, 3D Printing Evangelist and Researcher When it comes to manufacturing, there is no bigger story than the impact of globalization. As the world flattens and interconnects more than ever before, the global market becomes a winner takes all affair. The global economy rewards manufacturers that quickly adopt best practices and crushes those who linger in the ways of the past. Three key manufacturing trends build upon globalization—infrastructure productivity, responsive supply chains and product life cycle efficiency and dictate success for manufacturers in the 21st century. Companies that adopt 3D printing in their manufacturing and embrace these trends will have an advantage over the competition.
33
34
Volume 2–Issue 1 J a n /Feb 2 0 1 8
CasteStudy | STRATASYS
A poured gypsum model (left) and 3D printed model (right).
Pre-surgery planning and rehearsal using 3D printed models has reduced the time for complex surgeries and improved success rates.
Picture: Stratasys
A 3D printed injection mold for a domestic-brand toilet rim block. Picture: Stratasys
Picture: Stratasys
A
ccording to the Harvard Business Review, higher infrastructure productivity is essential for tackling the world’s infrastructure problems. For example, streamlining the delivery process of production tools, parts and prototypes via improved transport infrastructure could save up to $400 billion a year. 3D printing brings improvement to transport productivity at minimal cost by providing a rapid digital link between remote design and local manufacturing. Logistical and infrastructure shortcomings can be overcome via in-house production in regional or local R&D facilities. In-House Solutions ASO International, a leading Japanese orthodontic laboratory, has built such a ubiquitous digital manufacturing business thanks to 3D printing. Toru Kawakami, general manager for the company’s CAD/CAM division, explained, “We can receive STL data from anywhere in the world and then create models using our Eden260V™ 3D Printer. Now we can work with an orthodontist located just a few miles away or one that is located 5,000 miles away.” In addition to reaching more customers, the company reduced costs associated with logistics and storage. “We have centralized the collection of all models from orthodontists at our Tokyo headquarters. Sending scanned 3D data instead of physical models to customers produces significant savings on transport costs, while eliminating the risk of damaged models in transit,” adds
Mr. Kawakami. Companies like ASO International can potentially expand their business everywhere. As long as there is an internet connection, a design file can be transmitted and 3D printed in a consistent fashion, thus increasing efficiency by streamlining the production process. Businesses can ultimately do most of their development work in-house, thereby minimizing the need to outsource while maintaining high quality standards. Re-Engineering Resources This digital thread also enables manufacturers to swiftly react to time-sensitive orders from buyers. Buyers increasingly demand responsive supply chains with short lead times for new orders or design changes. Companies like Unilever have seen substantial reductions in lead times by adopting 3D printing. Stefano Cademartiri, R&D, CAP and prototyping specialist at Unilever, explains, “Having previously outsourced our thermoforming requirements for handmade wooden molds, we found that we were accumulating significant labor costs and having to contend with lengthy lead times. However, since 3D printing the injection molds ourselves, we have reduced lead times in the conceptual phase by approximately 35 percent.” A few bleeding-edge companies have gone even further to meet short lead-time demands by turning to digital manufacturing techniques, thus enabling flexible manufacturing lines that can easily change production from one product to the next with no retooling or rearrangement required.
35
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
A 3D printed fog light garnish. Picture: Stratasys
The final production part. Picture: Stratasys 3D printed components help streamline Western Tool & Mold’s manufacturing process. Picture: Stratasys
This addresses the need for customization or any high-mix, low-volume production. Collin Wilkerson, Managing Director of Western Tool & Mold, looked into 3D printing to ensure an aerospace customer could manufacture its parts on time. “We can provide fast reactions to immediate needs,” he noted. “In traditional manufacturing, you have to deal with quick spikes in the need for resources, but [with 3D Printing] our clients can re-engineer resources to their greater benefit, resulting in a leaner manufacturing process, which includes a smaller workforce and less idle time.” Efficient Customization The automotive and aerospace industries demand high degrees of responsiveness and availability. With competition growing even fiercer in the global economy, greater efficiency is required through the entire life cycle of the product. Such efficiency can be improved both in initial as well as subsequent manufacturing runs to support products through end-of-life. Honda Access, a subsidiary of the Honda Group headquartered in Tokyo, manufactures accessories for cars and motorcycles worldwide. The company specializes in customizing accessories to local market preferences. “3D printers allow us to synchronize the development schedule with that of the vehicle itself and create the accessory parts simultaneously, improving both the quality and speed of the prototype process,” commented Hiroshi Takemori, senior researcher from the product planning department.
Streamlining Future Demand The benefits of adopting 3D printing for endof- life goods may be even more substantial than the cost-savings from prototyping. Omer Krieger, General Manager of Stratasys Asia Pacific and Japan, commented that “Spare parts supply from the product life cycle is a growing space for us, because companies start to think about, ‘Now, how do I deliver this part 15 years from now?’” With traditional manufacturing, a company must anticipate future demand a decade or more in advance. Then, the spare parts must be stored and distributed as demanded. Should inventory run out, a new run must be made at great expense with poor lead times. Omer explained that rather than putting the part on a shelf and waiting, with3D printing “I can put files in my memory disk, print and deliver it in 15 years.” These three trends represent tremendous opportunity for the bold manufacturer. Enhancing infrastructure productivity by replacing physical delivery of goods with digital transmission will enable a company to generate growth in markets previously inaccessible. Optimizing for responsiveness in manufacturing operations empowers a business to profitably produce short runs on tight time schedules. Increased flexibility in supply across the product life cycle promises to improve customer satisfaction and potentially provide higher margins in long-term contracts. Companies that adopt 3D printing in their manufacturing will have an advantage over the competition for embracing these trends.
36
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Power Feature | CG TECH
Vericut for Aerospace Manufacturers The next version of Vericut, set for release this year, lets programmers “see” additive and subtractive operations, just as they will occur on the machine
C
GTech’s Vericut is widely used in aerospace and defence to improve the efficiency of all types of CNC Machine Tools. Vericut is a CNC machine simulation, verification and optimization software that enables users to eliminate the process of manually provingout NC programs. Vericut simulates all types of CNC machining, including Multi-axis Milling, Drilling and trimming of composite parts, water
jet cutting, robotic machining and mill/turn Centres. Vericut runs standalone, but can also be integrated with leading CAM systems used in aerospace including Dassault Systems CATIA, Siemens PLM NX, Autodesk PowerMill and Open Mind HyperMill. Aerospace applications featuring the World’s leading CNC Machine Tool suppliers including DMG MORI, MAZAK, Starrag, GROB, CMS and Hermle will be featured.
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
Simulation as additive, subtractive share stage It’s no secret that Additive Manufacturing (AM), while often regarded as “emerging” technology, has secured its place in the manufacturing arena. There is good reason for this: AM offers a lure of solutions to previously impossible to solve design and manufacturing challenges. It also offers the potential of reduced costs for those willing to endure a rather steep learning curve, retrain their brains to embrace new concepts that sometimes defy common manufacturing sense, and charge into unknown territory fraught with unforeseen issues, pitfalls, and potentially devastating events. This is the inherent risk for those who tread into a new manufacturing frontier. Machine tool manufacturers have stepped up to the AM challenge by offering machines ranging from simple 3D printers (CAD model goes in, an actual part comes out) to complex multitasking CNC machines capable of alternating between additive build-ups and traditional “subtractive” machining, such as milling, turning and grinding. This unique breed of additive/subtractive “hybrid” CNC machines often comes with a hefty price tag (more than $ million), and it is extremely challenging to create NC programs that successfully and safely utilize its multitasking abilities. Many sites only have one such hybrid machine so if the target machine is taken down, they typically can’t just move jobs to another machine. That makes on-machine mistakes not only costly but also crippling to delivery schedules. For these reasons, shop owners and NC programmers want to do everything they can to protect them, which makes robust simulation of all these processes a top priority.
Programmers working in additive and hybrid manufacturing environments have surprisingly few options when it comes to simulation. As CAM vendors strive to offer more, and more elaborate methods for building up parts become available, NC programmers are left with the difficult challenge of figuring out which combinations best suit their needs and will work safely on their shiny new, uber-capable hybrid machines. The most basic level of simulation is the CAM system just showing material that will be added. While this does show the programmer’s “planned” order in which material is to be added, it does nothing to show how the NC machine might behave. A higher level of simulation can be obtained by running additive operations through the CAM system’s “internal” simulation. This can provide an idea of how the NC machine might move when executing additive operations, but there are some significant shortcomings to consider. Most CAM systems cannot show additive build-up combined with subtractive machining processes. And even if they could, this form of simulation is still only the CAM system’s idea of how the machine should move. As many programmers have learned, the actual NC machine can behave differently. The most comprehensive simulation available for additive/hybrid manufacturing comes by way of using third-party simulation software, such as Vericut by CGTech, to simulate the same post-processed NC code that will be used to drive the machine. The next version of Vericut, set for release this year, lets programmers “see” additive and subtractive operations, just as they will occur on the machine. The software detects potential collisions between machine and/or laser components, and the additive part being built—before any collisions can occur in the shop. The software also provides monitoring of key additive machine functions, such as laser use/ power, material feed rates, shielding gas controls, and verifies they are properly used for the type of material being deposited. For many companies, it is only a matter of time before realizing that additive manufacturing is not only a viable option but a necessary addition to their manufacturing portfolio. For those, simulation provides a key role in showing how various additive and subtractive strategies can be combined to efficiently and safely produce more types of parts, and deliver them faster.
37
38
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Case Study | FARO
Turbine Manufacturer Enjoys Multi-Fold Improvement in Productivity
T The FaroArm Fusion performing non-contract scanning of a turbine. Picture: FARO
he Fusion has a spherical working volume of approximately 2.4m, which satisfies Swan Turbine’s object size range of 1OOmm to 3m (for each turbine blade). With the Fusion, the team at Swan Turbine is now able to inspect the manufactured turbines accurately,easily, and quickly. With these new in-house measurement capabilities, Swan Turbine immediately managed to save precious time on transporting its products.” We now have better control of our
project timelines,” said Mr.Gummadi. “In fact,we are enjoying nearly 100% time-savings since investing in the Fusion.The increased productivity means we can deliver faster or make use of the time we saved elsewhere.” Electric power is an integral part of people’s lives today and the power generation industry is all about harnessing and providing energy in a reliable and safe manner. Likewise, suppliers to power plants have the same expectation placed upon them, which makes precision and quality
39
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
control doubly important. For Indian after-market manufacturer and service provider, Swan Turbine Services Pvt Ltd (Swan Turbine), technical excellence and certification were identified early as two critical pillars of its business. The Hyderabadbased company places great importance on hiring people with the right skillsets and experience, and on providing its employees with the right equipment and technology to do their jobs well. Mr. P. Satyanarayana, Managing Director of Swan Turbine, expressed, “We endeavor to deliver components of impeccable quality to our customers, and my vision is to attain an annual revenue of US$5 million by 2016, and US$1 billion by 2020. In order to do so, we must constantly explore ways to increase our productivity.” Specializing in steam, gas, hydro turbines, and rotators, Swan Turbine is a one-stop shop for refurbishment, spares and services, repairs and retrofits, EPC contracts, O&M contracts, as well as the re-engineering and relocation of power plants. Across Swan Turbine’s projects, measurement needs typically revolve around inspection, dimensional calculations, alignment, and reverse engineering. The company first invested in a Germanmade laser alignment system to cope with these measurement needs. While the system did serve its purpose, the team recognized that these measurements were prone to human error, and were not as accurate as they would have like them to be. In addition, as newer and better technologies became available, the laser alignment system was gradually becoming insufficient for the team’s work demands. The existing equipment could not measure some
of the larger objects nor provide digital data for measurement reports, which were increasingly important factors for the team. Moreover, Swan Turbine had to outsource some of the other measurement tasks, as the process was tedious and time-consuming. This was not an ideal arrangement as the measuring services would take almost three full days, including transportation, when Swan Turbine only had two weeks to turn the project over. As a result, when FARO first reached out to suggest an on-site product demonstration, Swan Turbine was interested to find out more. “Once we saw the device in action, there was no doubt in my mind that it would improve our production processes tremendously,” said Mr. Srinivas Gummadi, General Manager of Swan Turbine. “Outsourcing our measurement needs was tedious and time-consuming. However, our greatest area of concern was having to depend on a third-party for something as basic as accuracy and precision of our products.” A Better & Faster Way to Acquire Measurements
After observing Swan Turbine’s business and assessing its measurement requirements, FARO recommended an 8-ft ForeArm Fusion to Swan Turbine. One of FARO’s best-selling product lines, the ForeArm is a portable coordinate measuring machine (CMM) that resembles a human arm in appearance. Equipped with several articulating joints, the ForeArm is able to determine and record the location of a probe in 3D space, and report the results through software. The Fusion has a spherical working volume of approximately 2.4m, which satisfies Swan Based in Hyderabad, India, Swan Turbine Services Pvt Ltd specializes in steam, gas, hydro turbines, and rotators. Picture: FARO
About Swan Turbine Services Pvt Ltd: Founded in 2001, Swan Turbine Services is an Indian after-market manufacturer and service provider for the power generation industry.Specializing in steam, gas,hydro turbines, and rotators, the company is a one-stop shop for refurbishment, spares and services, repairs and retrofits, EPC contracts, O&M contracts, as well as re-engineering and relocation of power plants. Swan Turbine Services employs over 200 staff members in its headquarters in Pashamylaram Medal. Hyderabad. As business expands,new plans for a second plant that is twice the size of its first facility are under way. For more information,please visit www.swanturbines.com.
40
Volume 2–Issue 1 J a n /Feb 2 0 1 8
About FARO:
The turbines that Swan Turbine manufactures range from 100mm to 3m in size. Picture: FARO
The portability of the Fusion enables engineers to take measurements anywhere on the shop floor. Picture: FARO
Turbine’s object size range of lOOmm to 3m (for each turbine blade). With the Fusion, the team at Swan Turbine is now able to inspect the manufactured turbines accurately, easily, and quickly. With these new in-house measurement capabilities, Swan Turbine immediately managed to save precious time on transporting its products. “We now have better control of our project timelines,” said Mr. Gummadi. “In fact, we are enjoying nearly 100% time-savings since investing in the Fusion. The increased productivity means we can deliver faster or make use of the time we saved elsewhere.” Since investing in the Fusion,Swan Turbine has also enjoyed better accuracy and reliability in its measurements, eliminating human error from the equation.The device’s versatility and portability are also qualities that Swan
FARO is a global technology company that develops and markets computer-aided coordinate measurement devices and software. Portable equipment from FARO permits high-precision 3D measurement and comparison of parts and compound structures within production and quality assurance processes. The devices are used for inspecting components and assemblies.production planning,inventory documentation. as well as for investigation and reconstruction of accident sites or crime scenes. They are also employed to generate digital scans of historic sites. With FARO. 3D measurement and documentation needs can be fulfilled confidently. As a pioneer and market leader in portable computer-aided measurement. FARO consistently applies the latest advances in technology to make its industry-leading product offerings more accurate. reliable. and easy to use. The focus is on simplifying workflow with tools that empower customers, thereby dramatically reducing the on-site measuring time and lowering overall costs. Worldwide, approximately 15,000 customers are operating more than 30,000 installations of FARO’s systems. The company’s global headquarters are located in Lake Mary, Florida, with its European head office in Stuttgart.Germany and its Asia-Pacific head office in Singapore. FARO has branch locations in Japan. China, India, South Korea. Thailand, Malaysia, Vietnam, Canada, Mexico, United Kingdom, France, Spain, Italy, Poland, and The Netherlands.
Turbine appreciates. While the team still uses vernier calipers occasionally for simple manual measurements, the Fusion is heavily utilized for at least 8-9 hours each day across applications of alignment, inspection, and testing -all with a single device. Implementing the Fusion onto its production line was a decisive change that required Swan Turbine team members to adapt. Commenting on the effectiveness of this change, Mr. Gummadi revealed, “It is almost mind-blowing how the Fusion has impacted our production schedules. We used to take 3-4 days to inspect one to two turbines, but we are now checking 5-6 turbines within a day! The timely aftersales support we receive from FARO team has also made this transition easier. I am deeply satisfied to say the least, and this is a stepping-stone that will help us achieve our company’s vision for 2020.”
www.faro.com
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
RADCAM TECHNOLOGY | Way Ahead
Talent Meets the Industry Siddhu Jolad, Director, RadCAM Technologies shares the vision of his company, near-term plans and his take on Industry 4.0
A
s a technology company, our vision is clear, to be a successful partner in many ways with our clients whilst we upgrade and modernize India and its ecosystem. Hence, we are diversifying this year to cater all departments in an organization. This can happen in many ways like collaborating with technology companies outside India and bring their expertise and technology to the country or it can be the incubation centers we plan to start with many Indian universities. Either way the industry is benefitted to the core. The first option is again classified into two, being a channel partner or Indian face for a foreign entity is something we have always been doing since inception or we can buy the technology and use it to our own good. We are already representing software companies from different countries in the field of CAD and CAM. This should get expanded to other requirements in the organization which can be in the lines of other peripheral software requirements in the organization, consumables for the shop floor, machinery supplies etc. The second one comes with a sense of moral responsibility towards the country and society that we live in. This is a long-term goal to be achieved by process of hiring fresh talent from the universities or even drop outs and grooming them to market standards and making them understand what they are capable of and what is the need of the hour. As they say “your attitude, not your aptitude that will define your altitude.” We would like to offer these industry ready candidates to our partnering organizations, after they are exposed to the actual work cultures and requirements. In this way, the talent meets the industry! For Industry 4.0 this skill development process is very much essential as people are the key players for any industrial revolution. It has also been seen that, employment displacement is often confused with employment creation which needs to be addressed through such programs. We have often seen companies struggling
Siddhu Jolad Director www.radcamtechnologies.com 9591704404 Picture: radcam
to locate technology partners, good suppliers, consultants, talents and we feel strongly to fill this gap. There is so much advanced technology and process which still is at far reach to Indian organizations and we are looked down because of that. At the same time, many western organizations want to enter Indian markets with such technology and knowhow but don’t find the right way of approach as our territory and culture is far from understanding to them. We would like to welcome these companies and assure them that India is still unexplored and there is a lot of potential to start today and grow big in this territory. It is much easier than ever today to enter Indian market. The ecosystem has never been this friendly to step in and start your manufacturing setup. The local consumption of every good that is manufactured is already so high that you are sold out before even making it!
41
42
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Success Story | MAGAL
The Evolution of Magal
M
agal Engineering founded by the visionary Mr M K Narasinga Rao in 1992, quickly gained a reputation for quality products and service in the sheet metal forming line. Magal Engineering became the go-to for companies looking for Sheet metal working solutions. As the business grew, new technologies were introduced giving the company unique advantage over their competitors. Our integrated approach to our customers’ needs enable us to go beyond the sale of top-of-the-line machine tools, and offer 24/7 post-sales support, maintenance service, spares and machine refurbishment as well. Spread across India, Magal Engineering’s proficiency and strength has always been high performance presses. We have over two decades of experience backed by strong technical skills in press application and service. We provide consultancy on-
Mechanical press erection and commissioning up to 3000 tons Reconditioning of all types of presses and retrofitting of C-Frame & H-Frame presses for up to 3000 tons (sheet metal, forging and hydraulic deep drawing) Designing and fabrication of press automation Service and online support 24x7 That’s why our expertise is leveraged when companies are setting up a new plant, planning to upgrade to new machines or planning to automate newer sections of their plant. IngYu Presses Magal has taken over Ingyu business and operation in India. We are the partners for Ingyu in India. Magal take care of the sales, service and application. Our engineers are experts and are trained by Ingyu in Taiwan. They have all the experience and the expertise needed to guide you and give the right solution for your needs. We can resolve any issues you have with the machine and keep your machine uptime to the maximum. Ingyu presses, a product of Taiwan, are popular and most trusted in the manufacture of switchgear parts, connector terminals, complex formed precision parts and motor lamination. Ingyu presses are sturdy and are built to last with speeds from 200 to 1200 SPM. The best in market components are used to ensure the accuracy. The presses are built on needle bearings for high precision, accuracy, paparallelism, perpendicularity and very high static and dynamic accuracy. The BDC control in these machines is very high, therefore ensuring consistent precision. The various models like Apex, Saga, HD and HS series are designed for different applications. Some models are available in linked motion. High coining activities are also possible. Magal can design your automated production line with integrated material handling like coiling, straightening, etc. Taiyida Presses Magal introduces high performance presses,
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
with high efficiency from Taiyida. With technical collaboration from Japan, they produce 15-500 Ton press machine series. Taiyida’s product is highly appreciated by a number of customers across the globe for the efficient performance of both hardware and software systems. The machines are exported to more than 30 countries in Europe, Latin America, Middle East and Southeast Asia. The quality of service provided is impeccable; this gives the customers an edge over their competitors. The Taiyida presses have a highly rigid design, built using quality steel, treated by tension elimination to improve the stability, reliability and better precision. The components used in manufacture of machines are from market leaders the world over. The clutch is from OMP, controllers from Siemens and other components from Japan. Advanced design, low noise, low power consumption increase the machine efficiency optimises energy consumption and reduces cost. These machines not only meet the customer’s requirement, but also have a strong competitive superiority and distinguished quality. Taiyida presses are available in C frame, and H frame both single and double crank versions. These machines have been wide application in many fields, such as automobile, communication, IT Sector, telecommunication sector, media PCB, White goods sector capital goods sector, furniture, medical instrument sector to name a few. The machines can be customised according to the needs of the client. It can give the clients the right machine as per their production requirement.
Magal Engineering is the sole authorised distributors in India for the presses and its accessories. The company make these presses available for you in any corner of the country. We are authorised by these companies for servicing and supplying spares for these machine across India. Our key differentiator lies in our extensive exposure to the needs of the industries we service, insights into the pain points of our customers and our ability to combine our knowledge and customer trust to deliver state-of-the-art solutions. This relationship of partnering with our customers enables 50% if not more, to come back to us for repeat requirements for their expansion projects.
43
44
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Product News | PORTESCAP
High Power 35DBM Can Stack Linear Actuator Portescap introduces the new 35DBM high power Stepper Can Stack Linear Actuator. This 35mm linear stepper motor offers an enhanced design ideal for applications demanding high linear force. The new 35DBM features an optimized magnetic circuit powered by high energy neodymium magnets. The 7.5 deg step angle provides finer incremental movement with a high degree of accuracy and repeatability.
W
ith a holding force of 112N, the 35DBM stepper linear actuator is ideally suited for use in applications such as auto injectors, laboratory automation, medical pipettes and valve actuation. Portescap’s 35DBM high force actuators are fully customizable for adaptor tips, stroke lengths, windings, flanges and end of motion detection sensors. The 35DBM is available in captive and non-captive versions with various leadscrew pitch and winding options on our online motor selection tool, MotionCompass™. They are manufactured in an ISO certified facility and are RoHS compliant.
45
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
SCHUNK | Product News
Mechatronic gripping modules
Intelligent 24 volts powerhouse with PROFINET certification
W
ith the intelligent SCHUNK EGL PROFINET parallel gripper, the competence leader for gripping systems and clamping technology SCHUNK has been exploiting the potential for highly flexible applications for users in the diverse Industry 4.0 environment. The world’s first PROFINET-certified universal gripper with integrated electronics unites power, diversity and intelligence. Its high-performance PROFINET interface creates the optimum conditions for real-time process regulation and maximum performance. With a variable gripping force between 50 N and 600 N, the compact gripper covers an extremely wide range of components. In force-fit gripping, it can handle a wide range of parts up to 3 kg alternately – circuit boards in the electronics industry as well as components in the assembly of consumer goods or in mechanical engineering. The finger position, the closing speed, and the gripping force can be freely programmed within the maximum stroke of 42.5 mm per finger. In order to shorten the cycle
time, the fingers can also be prepositioned wherever necessary with a speed of up to 150 mm/s. Interactive commissioning assistant
The SCHUNK EGL PROFINET is the world’s first gripper with certified PROFINET interface and integrated electronics. Picture: SCHUNK
The complete control and regulation electronics are installed inside the EGL PROFINET in space-saving fashion, which makes it possible to utilize it in a decentralized manner; thanks to its 24 V DC operating voltage, it can also be used in mobile applications. Due to standard plus connectors, certified PROFINET interface and commissioning assistant, the gripper can be integrated into installations quickly and easily. The latter guides the operator step-bystep through the entire commissioning process – from the configuration of the hardware, through the incorporation of the GSDML file right up to the programming of the PLC. Integrated test functions make it possible to check each procedure. Furthermore, a diagnosis interface allows access to the most important process and status data of the gripper. A solid aluminum housing, stable guides and a brushless servomotor ensure a high level of robustness and long-lasting and reliable operation with minimal maintenance costs. In the case of a power failure, an electrically activated brake ensures that the position of the gripper fingers is held and no referencing is required. Besides the version with PROFINET interface, the gripper is also available in versions with Profibus DP and CAN.
The SCHUNK EGL PROFINET, like here with circuit board handling in the electronics industry, facilitates highly flexible processes and real-time process monitoring.. Picture: SCHUNK
46
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Feature | POWER CENTRE
HPC Turbo-Boosts Your CNC Machine The HPC Jet Spindle helps you take advantage of machines with high pressure capability for better machining results and longer tool life.
H
igh-pressure, high velocity coolant gives you the power needed to effectively remove heat generated by the cutting process before it can accumulate and increase temperatures to the point where tooling and work piece surfaces are damaged. With traditional flood cooling, coolant is delivered at low pressure, but the high performance levels of machine tools generate so much heat that the coolant is heated beyond boiling point and creates a blanket of vapor that insulates the cutting zone from the coolant; drastically reducing the coolant’s ability to remove heat. On the other hand, high-pressure coolant
Picture: Colibri
can effectively eliminate the vapor barrier so any heat generated can be removed at a high rate. High pressure coolant can also penetrate to the tool’s cutting edge to provide a short shear zone that leads to the creation of thin chips that readily break into small pieces over the base material. Low-pressure or flood coolant results in a long shear zone that produces a thick chip in many materials that does not readily break. This results in long, stringy chips that can damage the machine, the work piece and cause line stoppages for manual chip removal. High pressure coolant on the other hand, significantly helps control chips; critical to smooth
47
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
Picture: Colibri
CNC operations. The high velocity coolant force allows for shorter, broken chip formations that easily fall away from the tool and work piece, or that are simply flushed away by the coolant pressure; preventing an array of nasty chip problems. In standard CNC machines, external coolant hoses are being replaced by more focused delivery systems such as through-spindle and through tool coolant. Colibri has recently launched the only coolant-driven high pressure, high-speed spindle speed increaser specifically designed to work on CNC machines with high pressure coolant pumps: The patented HPC HSM Jet Spindle. The HPC Jet Spindle allows you to take advantage of machines with high pressure capability for better machining results and longer tool life on both new machines with high pressure coolant systems and older machines that have been upgraded with a high pressure coolant pump. The HPC Jet Spindle is applicable for a broad range of turning, milling and drilling operations on an equally broad range of materials and machines, including challenging materials such as titanium and hardened steels. Selecting the right tools and pump (pressure and flow) for each application,
correctly applied, will ultimately improve your bottom line, by providing quicker ROI through increased machine utilization and optimized metal cutting efficiency. Picture: Colibri
GENERAL INDUSTRY TEST SUMMARY – MILLING OPERATION
Customer tested the unit to improve productivity, tool life and to reduce production cost. Colibri’s TJS-HPC (High Pressure) Jet Spindle
Machining time per part (min) Machine Spindle Test Date
2017
Country
Czech Republic
Industry
General Industry
Application
Milling
78.3%
Picture: LEROY
Material Group
1.2842 220HB
Machine Power & Pressure
Haas VF-3 13kW; 70Bar
Coolant
Emulsion
Test Data Cutting tool (Iscar)
IC 702
Overall Productivity %: Machine Spindle vs. HPC Jet Spindle
90%
38
175
8,064
37,136
Fz (mm)
0.0081
Overhang (mm) Vf (mm/min)
602 1.5
ap (mm)
0.1
80%
50%
65%
13%
40%
22%
30% 20%
l (mm) Q cm3/min
0.02
0.09
10%
Parts per edge
1.5
127 27
0%
19:26
75%
70% 60%
20 131
ae (mm)
Machining time/part (min)
04:13
100%
2
Grade N (RPM)
19:26 POSITIVE RESULTS: Time savings 78.3% Productivity savings 65%
1.5
No. of teeth Vc (m/min)
Cutting time savings
Machine Spindle HPC Jet Spindle EC-A2 015-025-4C6R.2H50
Tool Dia. (mm)
Savings
HPC Jet Spindle
04:13 78.3%
3%
22%
HPC Jet Spindle Costs
Machine Spindle Costs Tool
Overhead
Material
Savings
48
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Product News | MARPOSS
Picture: MARPOSS
TBD HS Laser-Based Detector Saves Time TBD HS is a programmable System for non-contact high-speed tool-breakage detection
I
ndustrial realities, where productivity represents the priority to achieve, aim to implement tool measurement solutions, which prove to be quick, accurate and reliable. Aware of such need and willing to develop an application that could avoid affecting production efficiency, Marposs presents TBD, the Tool Breakage Detector, a time-saving laser-based solution for broken tool detection on machine. TBD on milling machines and machining centres permits to keep under control the process, thanks to a very short tool checking cycle. Fast and reliable detection achievable by the TBD allows to reduce production time and to avoid expensive work-pieces scrap due to wrong cutting process
by damaged or broken tools. All functionality is contained within the TBD unit compact housing, which can be mounted outside the machine area, saving space on the table. It is possible to choose among different working modes, which endow TBD with a great flexibility. Switching the power to the maximum gives TBD the chance to recognize a tool placed at a longer distance (up to 2 meters), with a standard capability to check the breakage. If a smaller tolerance is required, the reduced power can be set obtaining a smaller beam. Furthermore, an user can choose the filtering level of the signal. In fact, during the checking cycle, some coolant drops could interrupt the beam or coolant stuck
49
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
on the tool could create variation in the signal received. Setting “Hi Filter” makes the software of the TBD more restrictive in order to give the more reliable response. On the other hand, choosing “Low Filter” TBD responds in a faster way, as the filter is less severe. Lastly, it is possible to choose the appropriate range of spindle speed, up to 5000 rpm.
BOOK YOUR SPACE NOW...
The new TBD HS
Marposs S.p.A. has recently introduced the new TBD HS, High Speed, on its wide range of products for tool checking on milling machines and machining centers. The new TBD HS is a programmable system for non-contact checking hi-speed tools, particularly committed to those applications where there is the need for hi-speed spindles, up to 80.000 rpm. Thanks to its rotary switch selector, the TBD HS is able to recognize the tool in two different ways, depending on the actual rotational speed, thus minimizing cycle times, generally crucial in this kind of process. Selecting “Quick Recognition”, the tool checking is performed for 10.000 rpm spindle speed and its multiples; on the other hand, it is possible to choose “Hybrid Recognition” if the speed is 1.000 rpm and its multiples or 10.000 rpm and its multiples. With a reflective, clean tool an impressive 150 msec checking time is achieved, approximately half the time compared to the standard TBD. High spindle speeds and small tool dimensions lead to the need for a fine adjustment for positioning the TBD HS in a very precise way: that is the reason why an effective system has been designed to make accurate and easy the searching procedure of the tool verification position. Once TBD installed and tool approximately pointed, now is even more quick and simple to optimize the laser beam and to find the checking position. The tool breakage detection performed by the TBD HS is improved by the presence (upon request) of a blower for cleaning the receiver glass: taking advantage of the usual standard inlet, both in terms of air flow and pressure, it has been developed a solution able to protect the glass from swarf and scraps without increasing the air consumption. Moreover, when the conditions are particularly harsh because of the aggressive presence of shavings, there is the chance to substitute the standard protection glass with one in sapphire crystal: being 9 out of 10 its hardness degree on the Mohs scale, this kind of protection lets the receiver performance always at its maximum, no more damaged by the extreme machine conditions.
Key Highlight: Marposs presents TBD, the Tool Breakage Detector, a time-saving laser-based solution for broken tool detection on machine
Hi Filter
Low Filter
Quick Recognition
Hybrid Recognition
CONTACT:
DINESH MISHRA SENIOR VP – STRATEGY M: +91 9833076669 E: advertise@meshmixmedia.com
50
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Primer | DMG MORI
DMG MORI Technology Excellence: Aerospace In order to meet the high requirements of demanding users DMG MORI concentrates its entire expertise in the Aerospace Excellence Center. Picture: DMG MORI
DMG MORI realises optimum manufacturing solutions for the aerospace sector through early involvement in the product development of customers. Doubling of aerospace sales thanks to technology Excellence
torqueMASTER spindles up to 1,000 Nm for
Over 20 years of technological experience for
Aerospace speedMASTER 30,000, with 79 kW
all applications and materials in the aerospace industry – from customer consultation to the turnkey solution 20 years of mill-turn technology – Best in Class for casings and rotatives Technology integration: grinding and ULTRASONIC NEW: DMU 200 Gantry and DMU 340 Gantry with up to 0.5 g
for an up to 8 l/min metal removal rate for aluminium ADDITIVE MANUFACTURING: Laser deposition welding with LASERTEC 3D hybrid / LASERTEC 3D and selective laser melting in a powder bed with LASERTEC SLM In-process measurement & process monitoring More machining options thanks to DMG MORI technology cycles
the machining of titanium components
51
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
Average growth rates of over seven percent make aerospace one of the global growth branches. DMG MORI supports OEMs and suppliers with productive manufacturing processes thus participating to a disproportionally high degree in the growth of this sector. In order to meet the high requirements of demanding users DMG MORI concentrates its entire expertise in the DMG MORI Aerospace Excellence Center. The machine tool manufacturer offers its customers far more than simply excellent high-tech machines and outstanding technological performance. The DMG MORI experts are being involved in the future projects of customers at an ever earlier stage. This results in the development of optimum manufacturing processes and complete turnkey solutions. “Sales of several hundred million euros certainly make us the leader in the aerospace sector where machining is concerned. It is our aim to double this figure over the next few years”, says Michael Kirbach, Head of the DMG MORI Aerospace Excellence Center, with a view to the future. In the year 2016 alone DMG MORI sold around 450 machines in this market in 25 countries. Early involvement in customer projects is a basic condition here for developing production solutions that have a promising future. A prime example of such a future-oriented field is the additive manufacturing of metallic materials. This is currently in the fast lane, especially in the aerospace sector. DMG MORI has been offering a unique hybrid solution with laser deposition welding using a powder nozzle and integrated machining since 2013 and since this year has added selective laser melting in a powder bed as well, a process that is already being used by many manufacturers for “flying” components. “This makes us one of the few suppliers offering not one but two alternative processes, with each one covers a special component segment. We see ourselves therefore as a full-liner with the entire expertise in this sector”, states Michael Kirbach. Additive manufacturing demands a profound knowledge of the processes in order to produce highly complex components with maximum process reliability and reproducibly on an industrial scale. “On principle additive processes also require a digital process chain - from the idea to final measuring of the workpiece.” Competence partner for all component sizes and materials
“In the DMG MORI Aerospace Excellence Center we support our customers from the feasibility analysis to profitability assessments and on to installation of the machines including customised application technology and an extensive after-
Their optimum chip fall make horizontal machining centres such as the DMC 80 H linear from DMG MORI the ideal solution for the high chip volume involved in the machining of aluminium. Picture: DMG MORI
Sophisticated components made of titanium: Landing gear components are milled productively and reliably on duoBLOCK machining centres. Picture: DMG MORI
sales service”, is how Michael Kirbach describes the service portfolio. The time scale here, from the first enquiry until acceptance of the project, can take anything up to two or even three years. “Our service commitment applies equally for the entire DMG MORI portfolio, of course - from turning and milling to the integration of technologies and on through to include ULTRASONIC, LASERTEC and ADDITIVE MANUFACTURING.” DMG MORI’s ambitious growth targets require a dynamic market. But air traffic is booming and so, of course, is the sale of aircraft. Leading aircraft manufacturers such as Airbus and Boeing, for example, expect the aircraft fleet to more than double by 2036. A large passenger plane is made up of over three million components. Capacities must therefore be expanded enormously if this demand is to be met. In contrast to its competitors, DMG MORI covers by far the majority of the different workpieces with its manufacturing solutions. The machine tool manufacturer also benefits from the work in the DMG MORI Aerospace Excellence Center on a technological level, explains Michael Kirbach: “Due to the fact that our experts are involved very early on in the development of customer products, we gain a lot of important experience as well as extensive knowledge. Both are incorporated directly in the development of new machines and components in close dialogue with
52
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Primer | DMG MORI
DMG MORI continues with the consistent expansion of its software solutions in order to also generate added value for aerospace customers by means of specific digital solutions. Picture: DMG MORI
the design engineers in the DMG MORI production plants – for example where it is a question of the efficient machining of special aerospace materials. We have been pursuing this strategy consistently for over 20 years.” Lightweight construction is the dominating topic
Aircraft are getting lighter and more efficient – in particular due to new materials. New materials in turn open up undreamt of freedoms in the design of components. The structural parts of aircraft contribute greatly to the total mass, so there is an increasing tendency to use CRP and titanium for such parts in addition to aluminium. The low density of the materials plus their high degree of stability enable advanced geometries such as thinwalled components, for example. This also applies in the construction of engines, where titanium alloys and especially increasingly heat-resistant nickel alloys play a key role. The choice of material alone indicates just how application-specific a manufacturing solution has to be”, stresses Michael Kirbach in connection with lightweight constructions. In particular, the volume of chips produced during the machining of aluminium from the solid is a challenge – up to 90 percent of the raw material often has to be removed. The machining of titanium components, on the other hand, demands machines designed especially for heavy-duty metal removal. “It is exactly in the question of the material where our customers benefit from our enormous range of machines and technologies. Highly dynamic horizontal centres and our new gantry machines for aluminium and CRP/GRP components, duoBLOCK machines for the high-speed milling of titanium are just as much part of the portfolio as mill-turn or turn-mill machines for the 5-axis machining of rotationally symmetric workpieces in just a few
setups in engine construction, for example.” There is virtually no component for which DMG MORI cannot offer a manufacturing solution. Aerospace speedMASTER 30,000
The topics speed, acceleration und jolting are decisive for aluminium. The machines in the DMC H linear series for horizontal machining with their steeply angled interior covers and open-bottom machine beds enable direct chip fall. Combined with high-pressure cooling and the right machining strategy this results in a high level of process stability, longer tool lives as well as optimum heat dissipation and surface qualities of the machined parts. Michael Kirbach sums up: “In a nutshell, we offer an ideal complete package for the machining of structural components made of aluminium: highly dynamic linear drives with 1 g acceleration for more complex geometries, our swivel rotary table and our newly developed aerospace speedMASTER 30,000 for up to 8 l/min metal removal rate for aluminium. Gantry series expanded
DMG MORI has developed the Gantry series for the dynamic machining of larger components. The DMU 200 Gantry impressively combines the machining of large parts with maximum dynamics with workpiece weights up to 10,000 kg and 0.5 g acceleration. The DMU 600 G linear has a work area of 6,000 x 4,500 x 2,000 mm making it predestined for large integral components. With regard to component size the DMU 340 Gantry operates with a work area of 3,400 × 2,800 × 1,250 mm between the two sister machines – whereby the machine can be expanded to up to 6,000 mm in the X-axis and 1,500 mm in the Z-axis. Efficient milling with ULTRASONIC
The fibre structure and hard-brittle property of
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
CRP materials present a challenge for every type of conventional machining. That is why ULTRASONIC-supported milling is the answer here. The additional oscillation of the tool with up to 10 µm and 20 to 50 kHz mean higher cutting speeds can be achieved with lower temperature impact. At the same time the fibres are cut better and this adds up to a reduction in fibre splitting and delamination. The formation up of built-up edges on the tool due to the adherence of carbon fibre powder is also prevented. Sturdy machine design for the machining of titanium
The machining of titanium requires maximum rigidity and performance. DMG MORI relies on its duoBLOCK machining centres for high-speed milling with five axes when it comes to the production of complex titanium components, such as landing gear components of aircraft, for example. “For over 18 years now this concept has been used mainly by our customers in the aerospace industry for hard to machine materials and has been consistently further developed in line with the continuously rising demands”, says Michael Kirbach of DMG MORI’s the many years of experience. “Customers even speak of today’s 4th generation as the benchmark, which of course makes us as machine builders especially proud.” From the DMU 60 P duoBLOCK to the DMU 160 P duoBLOCK, the series offers space for a multitude of different component sizes. Their travel paths range from 600 × 700 × 600 mm to 1,600 × 1,600 × 1,100 mm. Added to these are the DMC U models with pallet changers for higher productivity and increased spindle efficiency. The duoBLOCK concept combines machining performance, precision and dynamics to a unique overall picture. Its rigidity is supported by extensive cooling measures ensuring that the
In the field of ADDITIVE MANUFACTURING DMG MORI offers manufacturing solutions in both laser deposition welding and powder bed processes with its LASERTEC 3D hybrid and LASERTEC SLM models. Picture: DMG MORI
The DMG MORI Aerospace Excellence Center advances the development of processes for extremely demanding components with its many years of experience. Picture: DMG MORI
high demands on accuracy required by aerospace customers can be fulfilled in the long term. The spindles available guarantee perfect performance: Both the 1,000 Nm and 77 kW powerMASTER 1000 motor spindle and the 5X torqueMASTER with its 1,800 Nm and 52 kW meet the demands of the aerospace industry to the full. An optional highlight of the duoBLOCK models is the heavy-duty machining package. This comprises damping pads for the Y-axis, a hydraulic clamp on the NC rotary table and – in combination with a Siemens control – the heavy-duty machining ATC, a special DMG MORI technology cycle for this application. Taken all together this results in an up to 50 percent higher machining performance, in the case of materials that are difficult to machine to lower tool wear and better surface qualities. Complete manufacturing in engine construction
“The technology integration of our mill-turn or turn-mill machines opens up the path to the process-stable complete machining of rotational symmetrical enginepartsmade of titanium or nickel alloys ”, explains Michael Kirbach. Leading manufacturers of engines such as GE Aviation, Rolls-Royce, Pratt & Whitney or MTU Aero Engines have in fact been using the FD machines of the monoBLOCK, duoBLOCK and Portal series successfully for milling and turning in only a few setups for 18 years now. Nowadays high-precision components can
53
54
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Primer | DMG MORI
The DMU 340 Gantry is designed for applications in the aerospace, general mechanical engineering and tool and mould industries. Picture: DMG MORI
The DMU 200 Gantry from DMG MORI impressively combines large part machining with maximum dynamics. Picture: DMG MORI
be produced even more productively thanks to further technology integrations. Even grinding wheels with internal and external cooling can, for example be changed over automatically with the FDS machines. Special DMG MORI technology cycles and structure-borne sound sensing help users with handling the technology. In addition systems for in-process measurement and integrated process monitoring support the operator on the path to the perfect process. Michael Kirbach points out a trend towards the use of materials that are extremely difficult to ma-
chine, such as ceramic matrix composites (CMC), especially in the field of engine construction: “We have been working on these advanced materials for years. For such applications DMG MORI offers its LASERTEC and ULTRASONIC technology.” The focus here is always on expanding and improving conventional manufacturing processes. “It is not only important to be better and faster, but more cost-effective as well – e.g. by using ULTRASONIC to machine even materials such as CMC reliably and productively.” Digitisation in the aerospace industry
The overall trend in the aerospace industry is towards the integral networking of machines, products and services to digital process chains. DMG MORI is also actively advancing the topic of digitisation with its “Path of Digitization”. All high-tech machines, for example, are equipped with the APP-based control and user interface CELOS. CELOS enables consistent management, documentation and planning of orders. In addition CELOS APPs such as “CONDITION ANALYZER” or “PERFORMANCE MONITOR” provide customers with a detailed view of the machining processes and the status of machines as the basis for a continuous improvement process. CELOS also functions to an ever greater extent as an IoT interface thus creating the basis for crosscompany interaction in the production networks of the future.
55
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
IMTEX PREVIEW | Event
Carl Zeiss Aims To Make The Most Of IMTEX 2018 Sridhar V Pissay, VP – Sales & Marketing, Carl Zeiss India shares a preview of the company’s offerings at this year’s IMTEX What do you expect from this year’s IMTEX and its focus on the Forming industry?
Manufacturing industry is a large sector that contributes to the GDP of our nation. Automobile, Aerospace, Wind Energy, Auto Components Industry, Gear, Machine Tool and Cutting Tool Manufacturers, Tools and Dies, Plastics etc are some of the verticals that will help drive growth in India. IMTEX FORMING is expected to be a greatly expanded fair which would feature all aspects of forming technologies, predominantly in sheet metal forming. This exclusive B2B event will attract Indian and foreign exhibitors who would offer innovative manufacturing and engineering products. The event also honors the veterans of the industry. Many decision makers and business heads from across the spectrum of Indian metalworking industry are expected to visit the show. Sridhar V Pissay, VP – Sales & Marketing, Carl Zeiss India Picture: Carl Zeiss India
Can you share with us a view of your offerings at this year’s the show?
We are showcasing measuring technology is rapidly transitioning into the digital age. ZEISS offers systematic quality assurance in car body construction for “Online”, “At-line”, and “OffLine” inspection systems. We shall be launching two new products in this show: 1. AIMax : The ZEISS AIMax digital-optical 3D sensor is the new benchmark in robot-based 3D inline metrology for sheet metal processing and car body construction. The unique combination
of three measuring principles in one compact sensor enables the measurement of complex geometric characteristics such as holes, bolts and gap flush with maximum robustness, as well as attributive characteristic recognition 2. ZEISS ABIS II : The surface quality of a product – particularly in the automotive industry constitutes an important criterion for customers and is generally associated with the quality and value of the entire vehicle. The timely detection and objective classification of surface defects with the high-precision ZEISS ABIS II surface inspection system opens up new frontiers in quality assurance. It allows the fast, reliable and ultra-accurate detection of surface defects. If the customer opts for our new software – PiWeb – Solution , we are able to co-relate the measurement results and also able to compensate the values as required by the production department thus avoiding any manual calculations. What will be your target sectors at the show?
The target sectors would be from auto components, car body, BIW, metal casting, metal forming, metal machining, metal joining and finishing and sheet metal industry How do you plan to make the most of IMTEX 2018?
The exhibition witnesses many decision makers and business heads from across the spectrum of sheet metal and forming industry. We plan to leverage the maximum by introducing new products with state-of-the-art technology in Automated Inspection, Quality Control, Process control for sheet metal measurements. Consequently, we also conduct webinars and customer forums for this show. Visit Carl Zeiss India at Hall & Stall Number: 3A (German Pavilion) Booth No.C-102
56
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Special Feature | IMTEX PREVIEW
Supporting The Forming Process Virtually and Mechanically German exhibitors of IMTEX to reciprocate Make in India with Made in Germany
T Dipl.-Ing. (Diplom-Ingenieur) Frank Jablonski frank@mylkandhoney.de Frank is freelance journalist and owner of Mylk+Honey. He has 20 years of experience in media production print and digital. Mylk+Honey is a specialized B2B communications agency supporting companies in manufacturing and process industries.
he last six days of January 2018 in Bangalore will again see about 40,000 experts on the subject of forming technology meet at IMTEX. The exhibitors and experts will include many some German companies that will present their solutions. A small preview of what the German Companies will showcase at the exhibition. At the IMTEX in Bengaluru, India, engineers and technicians from all over the world are meeting, who will be particularly interested in one subject: the forming and processing of metal. Among the more than 400 exhibitors, there
will be many German companies that will be exhibiting products for the entire process chain of forming technology. Whether it’s the solutions for sheet-metal converters or solid transformers, for end-users or mechanical engineers, all German exhibitors agree on one aspect: ‘The Indian market is currently very interesting for industrial suppliers due to its excellent growth prospects.‘ However, one question begs an answer: ‘Does it make sense to develop a product specifically for the Indian market or, is it better to use European product strategies that will succeed in India?‘ A question that will be probably answered during the discussions at IMTEX.
Eye-catcher precise cutting of mild steel. Picture: Frank J
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
Large Quantities Preferred It’s not just equipment manufacturers that are targeting industries with high throughput rates, but it’s even the large system suppliers that are focusing on automotive or white goods manufacturers. Modern technology is in demand here. For example, the German company Dreher will present its high-speed roller-feed Innofeed. Thomas Kern, vice president of sales and marketing, sees great potential in the area of small and medium enterprises, “We are sure that the Indian automotive industry will procure our systems for large-scale plants. As a system supplier, we are used to first understanding for the needs of our customers and then finding the optimal solution for each individual case. This is our approach not only in India, but everywhere in the world,” Kern explains the strategy. In addition to the automotive industry, the exhibition is likely to see visits from manufacturers of electrical equipment as well as classic household appliances. Here sheet metal and forgings must be produced in large quantities. The demands are always similar: increase cycle times, shorten set-up times and ensure highplant availability over the entire machine lifecycle. Even though the experience of the Dreher experts indicates that India’s needs are still very different from European standards, “India is an interesting market because of its large population. The growing prosperity of the middle-class and its increasing consumption presents attractive sales opportunities. We are sure that the demand of the Indian population for consumer goods will grow. Correctly addressing and serving these needs will be the biggest challenge in the Indian market,” says Kern.
Especially automotive industry is interested in high throuput systems, like this circular blanking line with buffer station from Dreher Automation. Picture: Frank J
German Companies Participating in IMTEX 2018 Arku Maschinenbau GmbH August Ruggeberg GmbH & Co. Kg - Pferd Toos Automatic-Systeme Dreher GmbH C. & E. Fein GmbH Data M Sheet Metal Solutions GmbH Felss Shortcut Technologies Frechem GmbH & Co. Kg Kjellberg Finsterwalde Plasma Und Maschinen Gmbh Ortlinghaus-Werke GmbH
Metal Pressing and Presswork Automotive sector OEMs as well as suppliers of automotive parts come to IMTEX to find out about presswork solutions. International exhibitors like Ortlinghaus have on their visitor list Indian manufacturers of machine and forming equipment . The company from the west of Germany is a specialist in the field of clutches, brakes and slats, including hydraulic power units and control and regulation units. In January, Ortlinghaus’ engineers want to present the product Cee.go tailored to the Indian market. Cee.go is a unit for C-frame presses, which consists of a clutch-brake combination, a bell housing and a rotary inlet. The clutch-brake combination works independently and requires no external oil supply. As a wet runner, it offers higher power density, high thermal endurance and a long service life compared to the dry running systems commonly used in press applications, says Industry Manager Metal Forming Technology Rafael Rutkowski. “Due to the higher thermal load capacity, we can achieve higher number of cycles and thus higher output rates compared to dry running systems. In addition, the unit is easy to assemble and thus reduces the assembly time for a press, “ Rutkowski explains the advantages of his product. As a further highlight Ortlinghaus Prot.act will take you to Bangalore. This is the name of a hydraulically released brake specially developed for the requirements of servo presses. The brake has been on the market for more than ten years, but is still up-to-date, as it is designed efficiently and withstands high thermal loads, such as those
57
58
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Special Feature | IMTEX PREVIEW encountered during emergency stop operation. Technically, this is achieved by the experts using a dry-running friction system with friction pads instead of lamellae (friction disks) with toothing. In this way fretting corrosion is avoided. In order to lock the plunger in any position, however, a combination with a linear motion lock is necessary, which is a positive connection with which the press ram can be held. This locking coupling meets the requirements of DIN 692 and the American OSHA. Efficient Construction and Production Today there is no better way of producing parts or setting the best parameters in production than using simulation and digital design. Automobile OEMs, Tier 1 suppliers and aerospace companies know how to use digital products to enhance their productivity. Exhibitor data M is an engineering software house specialising in the field of metal forming processes with a focus on roll-forming and metal bending. As Maximilian Sedlmaier, the managing director of data M Software India and data M Sheet Metal Solutions GmbH explains, his products are used to simulate the complete roll forming process with pre- and post-operations like stretch bending. Answering the question of why IMTEX is an important place to be for his company, Sedlmaier says: “The slogan ‘Made in Germany’ has a high value in India. Due to the growing demand for locally produced, high quality products and machinery in India, we follow a ‘Make in India with German technology‘ strategy.” The data M booth will give a live demonstration of Copra Profile Scan Desktop. The device offers quality control for tubes and profiles. Since quality management and closer tolerances are important topics in the industry this solution is currently in high demand in India. Additionally, managing director Albert Sedlmaier will present a paper on the company’s latest technology, the ‘3D Roll Forming Center for Rapid Prototyping of Automotive Parts’ – a firstof its kind technology for the production of loadoptimized roll formed profiles with variable cross sections - during the “International Seminar of Forming Technologies –ISFT18” organized by the IMTMA. Welding and cutting Live demonstrations are an important part of Kjellbergs exhibition strategy. Besides the obvious touch-and-feel effect, visitors be able to experience the reduced sound pressure level during the plasma cutting. The subsidiary Kjellberg Cutting and Welding India Pvt. Ltd. in Pune, near
Thomas Kern, Vice President Sales and Marketing: “I see great potential in the area of small and medium-sized plants. But we are also sure that the Indian automotive industry will procure large-scale facilities.” Picture: Frank J
Hand-guided belt grinding for flexible working on site. Picture: Frank J
Mumbai in the federal state Maharashtra, takes care of all activities concerning sales and service in India since 2015. This year Industry 4.0 will certainly be the center of discussion. As in other sectors in the metalworking industry, there are various approaches in the metal forming Industry 4.0. The latest results of the companies development work is the new generation Q Plasma Power Sources. The Q Power Sources are one example of how networking and communication will change production processes of the future. According
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
“Made in Germany” has a high value in India. Due to the growing demand for locally produced, high quality products and machinery in India, we follow a “Make in India – with German technology” strategy,”,says Maximilian Sedlmaier, managing director of data M Software India and data M Sheet Metal Solutions GmbH. Picture: Frank J
to the requirements of Industry 4.0, the power sources with a modular design can form networks and exchange information with their own as well as other components. The emphasis here is on the digital process monitoring and process control as well as the possibility for remote access. Kjellberg has therefore developed an extensive operator interface for the user that is device and location independent. Additionally, the plasma-cutting technology Silent Cut will be shown. This device reduces the sound pressure level by up to 15 dB(A) during plasma cutting of mild steels with a material thickness between 4 and 30 mm in the current range between 60 and 160 A. Even the high frequencies perceived as particularly disturbing are considerably reduced. Hand-operated machines Although large presses and three-dimensional simulation rooms are the first eye-catchers at a metal forming trade fair, hand-operated machines must not be missing. It is they who, in the literal
The data M software Copra FEA RF simulates the complete roll forming process with pre- and post-operations like stretch bending. Picture: Frank J
sense, often put the finishing touches to keeping the entire production process flowing without delays right up to the very end. An example of this sector is the German company Fein, which invented the first power tool in the world in 1895 with the electric hand drill. Today, the company focuses on the metal and automotive sectors in the Indian market, among others. Highlights at the fair include the new cordless screwdrivers, which are tailored for metalworking, as well as Grit belt grinders, accessories and modules. Already last summer in Germany and now available for the Indian market, the company has introduced two new modules for the processing of edges and large surfaces with the hand-held grinding system GHB. Users connect the belt sander GHB without tools and in less than 45 seconds with one of the five compact grinding modules. Together with the belt grinding module GHBD, the GHB serves as a stationary grinder for chamfering, deburring or grinding small workpieces. The radius grinding module GHBR allows precise grinding of radii. The GHBM module guided on rollers, which removes welds cleanly, is suitable for heavy grinding work. For edge processing of long and straight metal plates, the new module GHBK is used, which is suitable for chamfering, for example in the preparation of welds, as well as for deburring or satin finishing after laser cutting. The user guides the hand-held belt sander on rollers evenly and without any effort on the workpiece. The grinding angle is from 0 to 60 degrees, and the Anfastiefe is infinitely adjustable up to 20 millimeters. Metal-working companies achieve a homogenous surface finish in one work step and also work on longer grinding distances with high material removal, energy-saving and clean - the flying sparks are led directly into a spark box. In addition, the company will present core drilling machines and products specifically for the automotive industry. Schwäbisch Gmünd is particularly proud of its 7.5 kg lightest device on the market. By using an angle gear, it has a low overall height of 169 millimeters and can thus be used for drilling in steel girders, in vehicle construction or for assembly work in metal construction. The requirements of the Indian market can gauged from the marketing approach of the German companies at IMTEX. The international companies, which are active on the ground, not only show the desire to grow with the market, but also offer to develop specific solutions of the users, so that the advertising slogan, ‘Make in India ‘ becomes more realistic.
59
60
Volume 2–Issue 1 J a n /Feb 2 0 1 8
PhotoFeature | EXCON 2017
Excon 2017 Puts Sharp Focus On Construction Equipment Industry
Key Highlight: 1,000 exhibitors from India and Overseas.
Featuring dedicated pavilions for 12 countries
Largest construction equipment expo in South Asia.
61
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
Industry and govt dignitaries releasing the Excon 2017 catalogue and industry report. Photo: EXCON
62
Volume 2–Issue 1 J a n /Feb 2 0 1 8
PhotoFeature | EXCON 2017
Industry leaders deliberate the significance of Green Construction on Day 4. Photo: EXCON
Azim Premji, Chairman, Wipro and Chandrajit Banerjee, Director General, CII in conversation. Photo: EXCON
C
onfederation of Indian Industry (CII), India’s Premier Industry Association organized the 9th edition of Excon 2017 between 12th 16th December 2017, at Bengaluru International Exhibition Centre (BIEC). The Trade Fair was
1 1 Shri Anant G Geete, Honourable Union Minister for Heavy Industries and Public Sector Enterprises, Government of India giving the inaugural address. 2 Shobana Kamineni, CII President and Executive Vice Chairperson Apollo Group. 3 Amitabh Kant, CEO, Niti Aayog 4 Vipin Sondhi, Chairman, EXCON. Photo: EXCON
supported by the Indian Construction Equipment Manufacturers Association (ICEMA) as Sector Partner. Excon 2017, with participation from 1,000 exhibitors from India and overseas, featuring
2
63
Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8
Industry and govt dignitaries including Heavy Industries and PSE Minister Shri Anant G Geete, Niti Aayog CEO Amitabh Kant, Excon Chairman Vipin Sondhi, CII President and Executive Vice Chairperson Apollo Group Shobana Kamineni inaugurating the event. Photo: EXCON
dedicated pavilions for 12 countries, was the largest construction equipment expo in South Asia. The expo saw visits from 40,000 plus business visitors and over 300 product launches over five days. It also hosted the CII Infrastructure
3
Summit conference on the first day of the event that saw the presence and participation of leading names from the echelons of industry and the government. Presenting, a photo feature of Excon 2017.
4
64
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Case Study | RENISHAW
On-machine user interface boosts productivity of mould base manufacturing
T
he market for mould base assemblies used in plastic injection moulding is changing. Plastic part makers are producing increasing varieties of short-run products in all kinds of different sizes, shapes and finish – each requiring a custom-made mould base. As a leader in precision mould base manufacture, GM Enterprise needed to ramp up its production throughput to meet rapidly rising customer demand. It needed to increase capacity and reduce lead times, but it also needed to avoid introducing human error. To achieve its goals and help it to capitalise on its new market opportunities, GM Enterprise specified an on-machine graphical user interface and tool setting probes with radio transmission from Renishaw for its new CNC machine tool acquisitions.
Background
Founded in 1982, GM Enterprise is regarded as one of Taiwan’s leading manufacturers of mould bases, which are highly complex multi-part assemblies of critical importance to the plastic injection moulding process. GM Enterprise’s home market currently accounts for 60% of its business, while important export customers include the likes of Mabuchi Motor, Futaba and YKK in Japan, and SHL tooling in Hong Kong. With manufacturing tolerances needing to be controlled within ±5 µm and more complex mould bases taking up to three days to produce, minimising scrap rates and boosting production throughput are constant goals for the company. To achieve the high level of precision involved in designing and producing a custom mould base, GM Enterprise had, for many decades, employed
including the infra-red transmission MP10 probe, TS27R
While large
hard-wired tool setters and RMP60 radio transmission spindle Vo l u m e 2 – Is s u e 1 J a n /Feb 2 0 1 8 probes.
recognised a 65
The use of such probes had already enabled GM Enterprise to typically avoid up to four setting or measurement errors per week, resulting in a dramatic reduction in scrap and increased throughput. Renishaw machine tool probes to ensure the accuracy of its CNC machining centres. The company was operating six CNC machines, equipped with an array of different Renishaw machine tool probes, including the infra-red transmission MP10 probe, TS27R hard-wired tool setters and RMP60 radio transmission spindle probes. The use of such probes had already enabled GM Enterprise to typically avoid up to four setting or measurement errors per week, resulting in a dramatic reduction in scrap and increased throughput. With its strong zero-error philosophy, GM Enterprise had established an enviable reputation for quality and precision, both in its highly competitive home market and its developing overseas markets. Challenge
While large volume production remains a key characteristic of the plastic injection moulding industry, GM Enterprise recognised an increasing trend towards a more diverse range of unique moulds and much smaller volume production runs. As a result, demand for the company’s precision custom mould base assemblies was growing very rapidly, with new export customers requesting progressively shortened lead times and heightened quality assurance. Faced with this increased production demand, the amount of time involved in machine operators manually setting workpieces and tools was identified as an increasing source of production delay. At the same time, longer working hours and the demand for rapid turnaround in custom mould base production was increasing the likelihood of human error in setting or measurement, coupled with the additional cost of damaged probes and scrapped components.
With its strong zero-error GM Enterprise had In response to the changingphilosophy, market dynamics
of the plastic
of unique m As a result,
mould base export custo
times and he
and its new business opportunities, GM Enterprise established an enviable reputation for quality and precision, needed to increase its production capacity both in its highly competitive home quickly market and its developing while simultaneously reducing the chance of overseas markets. human error and raising production throughput.
Faced with t
Solution What
At the same
is a mould base?
In acquiring two new CNC machines for its Withinmanufacturing a plastic injection moulding machine, a mould base is Taiwan plant, GM Enterprise took the decision to make the move to the Renishaw used to securely mount a two-part (core and cavity) mould, graphical user interface (GUI) for tool and part and plays a crucial role in the sequential clamping, injection setting, inspection and machine tool diagnostics. and process. As aejection proven supplier of machine tool automation solutions, Renishaw has a range of GUIs compatible A support plate on the front half of the mould base holds with controllers from a wide range of market-leading the mould cavity in place. It also controller manufacturers, including Boschprovides Rexroth, a sprue bushing through which is injected theand hotSiemens. moltenAplastic, and a Fanuc, Heidenhain, Mazak, Okuma variety of language options is available. locating ring that ensures perfect alignment with the injector In this case integrated into a YCM gantry-type nozzle. vertical machining centre, the on-machine GUI presented Enterprise with its base first opportunity The rearGM half of the mould is composed of a mould toejection greatly simplify their traditional machine system, which attaches to thetool mould core on its programming process and so boost throughput. inside and a support plate on its outside. Providing an intuitive, user-friendly software environment, the on-machine GUI was programmed As the machine’s clamping unit pulls apart the mould core to guide GM Enterprise machine operators step-by-
of time invol workpieces
of production
for rapid turn
was increas measureme probes and In response
business op production c chance of hu
and cavity, an ejector bar activates the ejection system, pushing the now cooled plastic part out of the open mould. Locating Ring
Sprue Bushing
Mould Cavity Mould Core
For a small company like ours, the cost of machine tool probes is certainly not insignificant, and many of our operators worried about damaging them through human error. The intuitive, easy-to-use nature of the GUI, coupled with its protection setting has made this a thing of the past. There’s a lot more confidence now and operators no longer need to worry.” GM Enterprise (Taiwan)
Ejector Box
Ejector Pin
Support Plate
Ejector Bar The components in a typical mould base. Picture: Renishaw
The components in a typical mould base
RMP60 spindl
66
Volume 2–Issue 1 J a n /Feb 2 0 1 8
What is a mould base? Within a plastic injection moulding machine, a mould base is used to securely mount a twopart (core and cavity) mould, and plays a crucial role in the sequential clamping, injection and ejection process. A support plate on the front half of the mould base holds the mould cavity in place. It also provides a sprue bushing through which is injected the hot molten plastic, and a locating ring that ensures perfect alignment with the injector nozzle. The rear half of the mould base is composed of a mould ejection system, which attaches to the mould core on its inside and a support plate on its outside. As the machine’s clamping unit pulls apart the mould core and cavity, an ejector bar activates the ejection system, pushing the now cooled plastic part out of the open mould.
Renishaw GUI on a Fanuc controller. Picture: Renishaw
RMP60 spindle probe measuring a mould base.
RTS tool setting probe.
Picture: Renishaw
Picture: Renishaw
step through standard measurement operations, including probe calibration, workpiece and tool setting and probe inspection cycles. By eliminating multiple manual set-up tasks and increasing usability, the on-machine GUI removed much of the difficulty and time involved in traditional machine tool programming. Importantly, it also took away the need for extensive programming training for machine tool operators. At the same time as choosing to use the Renishaw on-machine GUI, GM Enterprise also took the decision to specify the RTS cable-free tool setter on the new machine tools to provide additional levels of flexibility. GM Enterprise’s first radio transmission tool setters, the RTS probes added greater installation flexibility and unrestricted machine movement, with the probes providing both broken tool detection and rapid measurement of tool length and diameter at ±1 µm repeatability. Results
In the first year of operating the new machines, GM Enterprise increased its productivity by a factor of 30%; a dramatic increase that General Manager Mr Shen Ming Pao attributes to the pivotal role played by the Renishaw on-machine GUI.
He commented, “As soon as we started using the GUI, our design engineers were able to get back to focusing their time on program development, leaving CNC machine tool operation to the operators. We were able to work more efficiently.” Additionally, Mr Shen explained how the introduction of the GUI has also gone a long way to reducing a certain anxiety experienced by his machine operators in using CNC machine tool probes. An anxiety only heightened by language differences within a mixed nationality workforce. He explained, “For a small company like ours, the cost of machine tool probes is certainly not insignificant, and many of our operators worried about damaging them through human error. The intuitive, easy-to-use nature of the GUI, coupled with its protection setting has made this a thing of the past. There’s a lot more confidence now and operators no longer need to worry.” GM Enterprise’s investment in Renishaw equipment and the increased production capability it has delivered has been warmly received by both customers and staff. The company is now producing around 2,500 mould bases every year and has placed an order for a further three CNC machine tools, each specified with a Renishaw GUI and tool setting probes.
68
Volume 2–Issue 1 J a n /Feb 2 0 1 8
Product News | SCHULER
Laser blanking lines exceed expectations New systems from Schuler do the job without dies producing up to twice the number of contracted blanks
L
Under actual production conditions, the laser blanking line outperformed the contractually agreed upon output by up to 100 percent. Picture: SCHULER
aser blanking lines don’t require dies, but can’t match the productivity of conventional blanking lines: This commonly held assumption has now been proven false based on real production data collected by a Schuler customer. Over the course of the first year in production, Schuler’s newly developed systems outperformed the contractually agreed upon yields by 20 to 100 percent, depending on the specific part produced. This means that, in some cases, output was double the contracted amount. A single shift was all it took to produce over 8,500 outer body blanks, and there is still room to increase that figure furthermore. It’s enough to supply a Schuler servo press line with a production capacity of 18 strokes per minute. Particularly where sensitive surfaces like those found on aluminum blanks are involved, the laser blanking line provides nearly the same output as a conventional die-based press blanking line.
Cutting edges with increased quality and less burr Another benefit is that since the blanking shape can be changed at the push of a button, customers save money by eliminating the costs of purchasing, storing, maintaining and repairing expensive dies and the work required to equip their machines. The laser blanking technique also provides higher-quality blank edges. Aside from these advantages, the first year of production showed a significant reduction of contamination caused by detached burrs (flitter) accumulating in the forming die. A number of laser blanking lines featuring DynamicFlow Technology are already in use in the automotive industry. Customers have been impressed by the ability to save material (thanks in part to flexible nesting), and by the fact that costly building foundation work is no longer necessary. One high-end OEM recently placed an order for another line from Schuler.
70
Volu m e 2 –Issu e 1 J a n/Feb 2018
Vo l u m e 2 – I s s u e 1 J a n / Fe b 2 0 1 8
COMPANY INDEX
IMPRINT
ACDEC 23 AIDAT 20-25 Airbus 31 Apollo Group 63 Ashok Leyland 32,33 ASO International 34 Boeing 31 C G Tech 36,37 Camille Bauer 12 Carl Zeiss 55 CDG India 21 CII 25, 62 CII Tamil Nadu 15 Colibri 47 Cyient 22 Daifuku 27-29 DMG Mori 50-54 Dranetz 14 Dreher 57 Drone Technologies 31 Excon 2017 62 Faro 38-40 Fein 59 FICCI 25 GM Enterprise 64,65 Honda Access 35 HPC Jet Spindle 47 ICEMA 62 Imtex Forming 55 Imtex Preview 56-59 Ingyu 42,43 M Software India 58 M Sheet Metal Solutions 58 Magal 42,43 Make in India 27-29 Marposs 48,49 Maruti 32 Nikkei India 27 Nord 16-19 P3 22 Portescap 44 Power Centre 46 Prajnya 21 Radcam Technologies 41 Renishaw 64-66 Schuler 68 Schunk 45 Siemens 42 Sify 23 SIPCOT Agency 24 SoftBank Venture Funds 21 SSA India 22 Stratasys 30-35 Sunsoft International Inc 21 SuperCads Inc 21 Swan Turbine 39-40 Taiyida 43 TIDCO 23 Unilever 34 VDMA India 27-29 Vergil Technologies 22 Wipro 62
Managing Director / Publisher: Preeti Mishra E: preeti.m@meshmixmedia.com M: +91 9820488203
ADVERTISERS INDEX AMF 3 C G Tech 13 Carl Zeiss 11 Dynamic Manufacturing India 9 Julang 69 Machine Insider 19 Marposs 2 Network 18 72 Radcam 7 Subscription - DMI 67 Zavenir Daubert 71
Editor: Aanand Pandey E: editorial@meshmixmedia.com M: +91 9920155943 Sr. Vice President-Strategy & Sales: Dinesh Mishra advertise@meshmixmedia.com M: +91 9833076669 Creative / Production / Technical: MeshMix Media Team E: creative.meshmix@gmail.com Administration: Sr. Admin Manager: Ekta Jagasia accounts@meshmixmedia.com M: +91 9324595918 Sales & Marketing / Content Supported by: MeshMix Media Private Limited Apna Media Creative / Production - Consultant: Shanmugum Pillai creative@meshmixmedia.com M: +91 9769484725 Place of Publication: Meshmix Media Private Limited # 63, Ruia Park, J. R. Mhatre Road, Juhu, Vile Parle West, Mumbai, Maharashtra – 400049, India Editorial Office: Meshmix Media Private Limited # 1003, 10th Floor, C-Wing, Runwal Pearl, Off Ghodbunder Road, Manpada, Thane West, Maharashtra - 400607, India. Contact: +91 9324240965 CIN No: U74999MH2016PTC287532 Volume 2–Issue 1 Printed by Meshmix Media Private Limited, India Disclaimer: All the content and views expressed in this magazine are those of contributors and appointed agencies from various organizations and brands and is the sole property of the publisher. Reproduction in whole or in parts of text or photography is prohibited without consent of the publisher. Whether published or not, no material will be returned and remains the property of the publishing house, which may produce or reproduce deemed to fit. Advertisement materials are provided by the organizations and brands whose identification is published within the same. Published and Printed by Preeti Mishra on behalf of MeshMix Media Private Limited Printed at Anitha Art Printers, Place: 29/30, Oasis Industrial Estate, Opp Vakola Masjid, Next to Vakola Market, Santacruz (E), Mumbai, Maharashtra- 400 055, India and Published from 63, Ruia Park, J. R. Mhatre Road, Juhu, Vile Parle West, Mumbai, Maharashtra – 400049, India Editor: Aanand Pandey Publishing frequency: 6 times per year
w w w.meshmixmedia.com www.machineinsider.com
8th to 11th February th 8HALL to 11th- February 7D th th 8 to 11 HALL - 7DFebruary
BOOTH NO - 12 HALL - NO 7D - 12 BOOTH BOOTH NO - 12
SCAN TO KNOW MORE SCAN TO KNOW MORE SCAN TO KNOW MORE