DMI-SeptOct 2017 by MeshMix Media

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V O LU M E 1 – I S S U E 2 • S E P T / O C T 2017

W W W. M E S H M I X M E D I A . CO M

Will GST Change

India's Manufacturing Landscape? GST's impact on manufacturing and supply chain: Pains and gains

TC NO: MAHENG14305

IN-EM-2017-Win.indd 1

2/27/2017 10:13:53 AM

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CONTENTS 16

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37 46

38 50

7 8 11

Industry News Kollmorgen

Industry News VDMA

Primer Machine Learning

Industry News Okuma

Industry Report VDMA

Industry News SCHULER Renishaw

36 37 38

Industry News Gleason

14 16

Industry News Nord CII-Karnataka SCHULER

Industry Snapshot Italica

61 62

GST Special Supply Chain

Industry News Grind Master Nord

46 48

Product News Softings

Industry News Hainbauch Danobat

Event Laser World Photonics

Technology Software

Report Czech Republic

Showcase EMAG

Imprint / Company / Advertisers Index

Editor’s Letter Publisher’s Letter Notes From The Field

Product News CGTech Interview DMG MORI Cover Story GST special

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Message | EDITOR’S LETTER

Industry 4.0 is Our Hope

oday the manufacturing world is excited about the Fourth Industrial Revolution or Industry 4.0. The idea, in short, is to create a ‘smart factory’ which will have cyber-physical systems take over from humans to perform automated manufacturing. These smart factories of tomorrow will use technologies like Internet of Things, cognitive computing, additive manufacturing and cloud computing to completely decentralise manufacturing and free us humans to focus on creative tasks like design, research and innovation. It is indeed a noble goal to strive for, and companies such as Siemens and Volkswagen have already begun to take big strides on this path. What does it mean for developing economies like India that have still not been able to implement Industry 3.0 to their benefit? As you know, industry 3.0 is essentially a euphemism for digital manufacturing – that’s where we have automated machine tools that don’t need to be run by mill workers dressed in oil-stained clothes. Instead, they are run by factory operators sitting in front of computer screens. Digital manufacturing or automated manufacturing is still a pipe dream for a majority of factory owners in India. SMEs (Small and Medium Enterprises) that comprise 90 percent of the total industrial units in India and employ 60 million people – the highest after agriculture – still have factory workers use drills, lathes, stamping presses and moulding machines to make goods. Computerisation at these units is limited to ERP systems used for financial accounting and channel management. In short, India’s manufacturing industry is well behind on the third industrial revolution wave. However, counter-intuitively, that is exactly the reason India must pay more attention to the Fourth Industrial Revolution. The other day, I was paid a visit by an SME manufacturer who makes drainage systems for housing apartments. His business is booming. Reason – most of Mumbai’s apartments have drainage systems with designs that are not made for small spaces. You need to put aside an area for drainage in your balcony or other open spaces – which means these areas are out of bounds for other purposes. And Mumbai is known for two things, if nothing else – small spaces and heavy monsoons. This particular manufacturer, who used to supply the old drainage systems, one day had a light-bulb moment when he was parking his car in the basement of a mall. He noticed these shiny, new-age drainage systems installed in the parking lot that merged seamlessly with the floor. These systems, in smaller version could be used in Mumbai’s apartments to replace the whole systems and solve the space issues. The manufacturer, at the first opportunity, rushed to the internet, downloaded the design of the newer drainage systems, ordered components from Alibaba and started manufacturing the new drainage systems which have now become a rage. As I was speaking with this young man, a fresh Mumbai migrant, who sported a Rolex and was excitedly showing me drainage designs on his latest Macbook, I was thinking to myself – ‘Folks, this right here is your Fourth Industrial Revolution.’ Point is, that a big part of India’s manufacturing sector has missed the third industrial revolution. India’s archaic labour laws and sclerotic regulatory and physical infrastructure stem and mar the growth of SMEs – which can’t compete anyway with the Chinese capital and consumer goods might: consider the LED bulb phenomenon, for example. What these SMEs need is a disruptive force – a powerful idea that gives wings to their creative spirit. An idea that uses technology to make things without much dependency on manual labour or physical infrastructure. Additive manufacturing is one such force. So is cloud computing – Internet is easily accessible in India now with big companies competing in this area. The same is true with cognitive computing – we have an abundance of talent in this area. You know where I am going with this – Industry 4.0 could be that disruptive force, the game-changing idea that could take us close to Vision Make in India. There, I said it. What do you think? Let me know your thoughts at editorial@meshmixmedia.com

ANAND PANDEY Editor Meshmix Media

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Message | PUBLISHER’S LETTER

In the wake of GST

any thanks for all the praise, constructive criticism, interest and support we received from you for our launch issue. We have paid good heed to your feedback -- hopefully that is evident in our second issue that rests in your hands. Our inaugural issue was released in mid-July. That was the time when nobody, not even the authorities, had clarity on how GST is going to effect the economy. However, everyone was clear about one thing: the one part of economic activity that GST is going to impact the most, for better or worse, would be operations i.e. manufacturing and supply chain. That was our cue. We knew that our second issue should be able to shine light on the prevailing sentiment, the ground reality and the way forward for the manufacturing industry in the wake of GST. We are proud to say that we have been able to put together a ‘GST Impact special’ that is uniquely informative and insightful. Hope it is of good help to you in your business. Please let us know your feedback. The manufacturing industry is undergoing transformation at a faster clip than ever before. The aim of Dynamic Manufacturing India is to create awareness and encourage innovation and growth in the manufacturing sector, creating a positive environment for emerging technologies. We are also pleased to announce our collaboration with Czech Republic’s Media Max, a leading print and digital media house that specialises in business content. The idea is to bring to you the latest technological developments from Europe, which leads the world in manufacturing research and innovation. The third quarter of 2017 has been a period of reforms and innovations in India as well as worldwide. One of the landmark events has been the EMO Hannover 2017 show, which truly lived up to its motto: Connecting Systems for Intelligent Production. As it does every show, EMO set the pace and the vision of the global manufacturing industry. More than 2,200 international manufacturers from 44 countries including India participated at EMO, making it grand event. Or to quote Carl Martin Welcker, General Commissioner, EMO Hannover 2017, “More business, more international drawing power and more innovations: EMO has once again lived up to its reputation as the leading global tradeshow for the world of metalworking.” A rich array of conferences, seminars and special displays put the spotlight on key topics like industry 4.0, future production scenarios, additive manufacturing, intelligent tools, machine safety, training for factory worker, India’s trade outreach to the U.S. and Mexico, and much more. The entire industry is already looking forward to another promising edition of EMO in the year 2019. We wish everyone all the success and good luck. 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 latest industry updates. Do please write to me at editorial@meshmixmedia.com

PREETI MISHRA Publisher Meshmix Media

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Message | NOTES FROM THE FIELD

PHD for Leaders S

eptember is the month of big conferences and expos in the world of machine tools and manufacturing sector. EMO Hannover 2017, the biggest of them all, took place this month were all the manufacturers who matter were present with their latest products and technologies – we have put together an EMO Special to bring to you a slice of the mega-action. We look forward to your feedback on how useful it was for you and how we can make it better for the next year’s EMO special. This month, I also had a chance to attend the Annual Business Conclave of Narsee Monjee Institute of Management studies (NMIMS), Bengaluru, were the theme was Shifting Horizons. I had the privilege to listen to the different speakers and their views on the India’s current business scenario. One of the many things I recall from the show is an engaging presentation from Mr Prakash Iyer, bestselling author and motivational coach and the former CEO of Mumbai Indians. The biggest thing that stayed with me from this talk was his interpretation of PHD – the one degree that we must earn in order to grow as a leader. PHD as in P for Passion, H for Hunger, D for Discipline. Mr Iyer also talked in detail about character building. He cited the example of a tea bag which gains colour – a euphemism for character – only when it is dipped in hot water: the more number of dips, the deeper the character. In the same way, one’s leadership qualities are forged only under challenging circumstances. In the same vein, a tea bag can be put in any vessel of any shape and it will perform the same task – similarly leaders should be able to excel under any circumstances. And the biggest learning is that it is that the role of a tea bag is to make good tea – a true leader focuses on making his or her environment great not the appreciation that he or she is going to get. This month, Bengaluru also got a new Boeing Engineering Centre. The Union Minister of State for Civil Aviation Mr Jayant sinha inaugurated Boeing’s new facility at the Boeing India Engineering and Technology Center (BIETC). This development follows the opening of Boeing’s Engineering centre in Bengaluru in January 2017. It is a great testament of the faith that Boeing has put in the engineering prowess and talent pool of Bengaluru and India as a destination. I wish the readers a great and successful third quarter and a jubilant festive season. Write to me at advertise@meshmixmedia.com

DINESH MISHRA Senior VP – Strategy Meshmix Media

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Primer | MACHINE LEARNING

Big Data Triggers Appetite for Machine Learning Adoption Progressively larger volumes of data smoothen the path of machine learning for adoption in production operations

rankfurt, 04. September 2017. Between fascination and a slight uneasiness –that’s roughly the sort of subliminal reaction even experts occasionally feel when it comes to the subject of “artificial intelligence”. Autonomous robots, self-driving vehicles or cognitive systems that image the functioning of the human brain and are even able to checkmate a chess grandmaster, may trigger concerns regarding a loss of human control. As a key technology for Industry 4.0, self-learning systems can be expected to find their way into the factories, especially if they are introduced gradually and “in small digestible pieces”, and prove that money can be earned with them. As a sub-category in the field artificial intelligence (AI), it’s primarily machine learning (ML) that’s relevant for industrial manufacturing operations. ML enables systems to understand their surroundings, to plan actions, to respond to impediments, and to communicate with humans. Machines use production data and intelligent algorithms to learn to recognise recurrent patterns and objects autonomously. The learned knowledge can then be applied to unknown and unsorted data. This enables sources of error be identified, processes to be planned and optimised, and forecasts to be drawn up. Machine learning needs Big Data

The hype currently associated with machine learning, although the concept in actuality dates back to the 1980s, is due to the modern-day options for data processing. It was only with the advent of Big Data applications, high–performance computers and gigantic cloud memories that the appropriate infrastructure came into being, used primarily at first by the internet giants. But the industrial sector is following suit. “From the perspective of robotics, we are following very closely what players on the global market like Google and Amazon, with their IT competences and infrastructures, are developing and researching in regard to production technology,” confirms Prof. Jörg Krüger, Head of the Automation

Technology Department at the Fraunhofer Institute for Production Systems and Design Technology (IPK) in Berlin. But the examples from the IT conglomerates cannot be adopted just as they are for industrial applications as well. It’s true than many companies, especially large ones from the automation and control segment, have been infected by the “ML virus”. But in the view of sectoral pundits the use of machine learning in the industrial segment is in many cases still in its infancy. This appraisal should not be obscured by spectacular demonstrations, e.g. when IBM impresses the public with its Watson system in the Cognitive Factory. Or when Festo, with fascinating exhibits like the very recent “elephant’s trunk”, an intelligent bionic handling assistant, answers the question of how people in the factories of tomorrow can interact with their machines simply, efficiently and above all safely. The technology exists. It’s exciting, and stimulates the imagination, but translating it into real products capable of delivering sales and profits will probably take some years yet. SMEs and Start-ups – the ball’s in their court

The fundamental question involved here is whether machine learning is only something for global players and their ideas for a comprehensive concept of a digital factory. Or whether, besides a top-down development thrust by financially potent large companies with their highly competent research and development departments, a bottom-up breakthrough spearheaded by flexible, innovative small and mid-tier enterprises would also be conceivable. “Artificial intelligence is an important issue for the future,” says Dr. Wilfried Schäfer, Executive Director of the VDW (German Machine Tool Builders’ Association) and an organiser of the EMO Hannover 2017 (18 to 23 September), the world’s premier trade fair for the metalworking sector. “So small and mid-tier enterprises should also address the possibilities of machine learning in their production operations, en-

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abling them to derive options in good time for their own development thrust.” For Dr. Cord Winkelmann, Managing Director of Sensosurf in Bremen, things have already been set in motion here on many fronts. “The big companies tend to develop their own solutions, often very complex and comprehensive ones, sometimes spectacular and very effective in terms of marketing,” he comments. “These include a kind of bee swarm flying to and fro, collecting information, exchanging mutual feedback, networking, moving things forward. Digitalisation there is a boardroom issue.” Innovative start-ups can make their own contribution to progressing development. Sensosurf has adopted the slogan “Sensor integration meets machine learning”. Founded in 2016 as a spin-off of the Institute for Microsensors, -Actuators and –Systems (IMSAS) at Bremen University, the company transfers micro-system technologies to the tough environmental conditions encountered in the mechanical engineering sector. These include flanged and pedestal bearings, linear guides and threaded rods. “We’re exploring fields from which so far there had been as yet scanty information or none at all available,” says Dr. Winkelmann. For data evaluation, machine learning is deployed in order to use information on the machines and processes.

Potentials in energy management

Besides the fields of predictive maintenance, condition monitoring and quality management, however, self-learning systems can also progress energy management. At the EMO Hannover 2017, the Munich-based company Gerotor will be premiering its HPS high-power storage system, which is designed to reduce the energy and connection costs involved with the aid of intelligent algorithms. The idea for the product originated with Formula 1, or to be more precise with the KERS (Kinetic Energy Recovery System) used there. The system was imposed upon racing cars at the time for reasons of environmental protection, since it returns to the drive axle energy produced during violent braking manoeuvres, by means of a rotating flywheel system. Gerotor’s founders saw huge potential in “this efficient and at the same time wear-free technology, not only for cars driving round in circles,” as Gerotor’s director Michael Hein colloquially puts it. In the search for an application that likewise involves many and frequent braking and acceleration functions, sometimes within a matter of seconds, they found what they were looking for with machine tools and tool spindles. The advantages of digitalising and networking the power storage system were obvious: “If you’re inside the energy circuit, you’re in the information centre too.” Coupled directly to the line, without requiring a power connection of its own, the new power storage system upgrades the efficiency of the entire line by means of energy recovery, peak smoothing and digitalisation. For this purpose, the system measures all currents and cycles, acquires data and information, improves its own algorithms, and draws conclusions. Whereas with traditional control strategies energy savings of at most 10 to 25 per cent can be achieved, says Michael Hein, users with intelligent strategies ought to achieve about double the savings effect. For Michael Hein, energy management offers a particularly simple and efficient entry route into ML. “Energy systems have to be 100-per-cent predictive,” he emphasises. “We need intelligent control strategies and an infrastructure that re-adjusts itself.”

Strategy of small steps

Large quantities of data are essential for machine learning; without them it’s simply not possible. For swift market penetration, says Dr. Winkelmann, it’s crucial that the information generated pays off from the very first moment. “It’s always the small steps we begin,” he explains. These include data evaluation at the machine, networking the machines with each other, detecting what’s characteristic about what’s happening. “Once you see what data are obtained, evaluated and visualised, you quickly get used to the new insights and the opportunities they offer,” says Dr. Winkelmann. “Measurements trigger an appetite for more.” What proves most persuasive for machinery manufacturers, he says, is that the machine learns to protect itself against operator error. The data obtained can also be used as a defence against unjustified warranty claims, for example. “It’s important to map out migration paths for companies showing how they can introduce the technology of machine learning in small, digestible pieces,” concurs Fraunhofer expert Prof. Krüger. He sees the principal focuses of using ML at machine tool manufacturers as currently centred around the field of condition monitoring. This essentially involves interpreting measured data using pattern detection processes. The knowledge required for detecting process or machine conditions is acquired by the processes of machine learning.

Return on investment is crucial

Author: Cornelia Gewiehs Freelance Journalist Rotenburg

He admits, however, that the concept of machine learning is practically ignored in meetings with customers The crucial consideration is rather the ROI (return on investment): “We sell our products solely by means of the argument that we save more than we cost.” This may in fact be one of the reasons why many companies tend to be rather taciturn when asked about their ML strategies. Machine learning is a means to an end, not a sales argument.

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Industry News | INTERNATIONAL

“Schuler has managed to reinvent the press over and over again”, said BadenWürttemberg’s Minister President Winfried Kretschmann. Picture: Schuler

Schuler Innovation Tower in Göppingen, Germany inaugurated amid leaders Official opening ceremony for Schuler Innovation Tower attended by numerous leading figures from business and politics

ith guests of honor from business and politics, as well as representatives from the city of Göppingen and members of its own staff, Schuler in August,2017, officially inaugurated its new Group headquarters, the Schuler Innovation Tower (S. I. T.). The twelve-story engineering and technology center will provide 750 workspaces with cutting-edge technology, outstanding communication possibilities, and a company restaurant for Schuler employees.

Minister President Kretschmann: prime example of a hidden champion

At the opening ceremony, Baden-Württemberg’s Minister President Winfried Kretschmann stated: “From the exceptional quality of their vocational training, to their commitment to inspiring children and teenagers in the region to take an interest in science and technology, to their activities in the field of corporate social responsibility – Schuler has always been an innovator with an eye to the future. This is also borne out by the new Group

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the Federation of German Industries (BDI), Dieter Kempf, demanded more political backing for small and mid-sized companies: “The fact that Germany is one of the few industrialized nations not to give tax breaks for research and not to provide its companies with a competitive infrastructure is illustrated by numerous international comparisons. Although Germany is ranked the fourth most innovative industrialized nation, it still lags a long way behind the leader Switzerland. And when it comes to digitization, we only just manage 17th place. In other words, politicians need to do their homework so that our small and mid-sized industrial companies can remain the backbone of a strong German economy.” Mayor Till: Göppingenis a reliable partner

“From the Schuler Innovation Tower, we will be driving forward the future challenges of digitization and electromobility,” said Schuler CEO Stefan Klebert. Picture: Schuler

Göppingen’s Mayor Guido Till called Schuler a renowned ambassador and first-class figurehead for Göppingen as a business location. He claimed that the city offered everything companies needed for a successful investment. “We are a reliable partner for our businesses,” declared Till,also with reference to the city’s trade tax rate, which has been unchanged over the last 15 years. “As the mayor of Göppingen, the fact that our ancient city of the Hohenstaufen dynasty is home to such a global player with operations in 40 different countries fills me with pride.” headquarters, the largest investment in the company’s long history. It’s a building that provides plenty of space to work and plenty of freedom to think. And these two aspects are what make Schuler a prime example of a hidden champion from Baden-Württemberg.” CEO Klebert: driving future topics

Schuler’s CEO Stefan Klebert explained: “As the market leader in metal forming, we need excellent employees. And with our new S. I. T., we can offer outstanding working conditions for such good people. The fact that our innovation center was built here in Göppingen is also further proof of the company’s clear commitment to its roots and to Germany as a location for premium technology. From our base in the Schuler Innovation Tower, we will continue to drive the future topics of plant and machine engineering, the digitization of products and company processes, and the field of electro-mobility.” BDI President Kempf: mid-size companies must remain backbone

At the ceremony in Göppingen, the President of

S. I. T. located at “Schuler-Platz 1”

The city of Göppingen’s council and administration had previously decided that the future official address for the Schuler Innovation Tower should be “Schuler-Platz 1” (1, Schuler Square), in order to underline the special bond between city and company. The citizens of Göppingen can experience the Schuler Innovation Tower up close this weekend by registering for a guided tour. The tour will also enable them to enjoy the view from the roof terrace of the 54-meter-tall building. Schuler will also be offering special tours for its own employees on Monday and Tuesday. Work on the interior fittings of Göppingen’s new landmark building, as well as calibration and test runs for its supply systems and amenities (such as the air conditioning system), will be completed in late summer and fall. After that, staff can begin moving into the Group’s new headquarters. The dismantling of Schuler’s old Engineering Building and the creation of new outdoor facilities is due to be completed in 2018.

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Feature | SUCCESS STORY

How Ballbar Diagnostics Improved Airframe Manufacture Without periodic checking and maintenance, CNC machine tools can lose positioning accuracy and introduce errors over time. Machining complex, high-value airframe components, BAE Systems turned to a wireless ballbar system to provide the machine tool diagnostics data it needed to maximise quality and productivity. Background The manufacture of airframe components for modern aircraft demands precision and consistency. With the lifetime expectancy of a component matching that of the aircraft, production quality and reliability are paramount concerns in metal and composite machining processes. BAE Systems, the global defence, aerospace and security company, produces vital airframe components for the Eurofighter Typhoon, a twinengine, canard-delta wing multirole combat aircraft. Entering operational service in 2003, this highly agile aircraft is flown by various air forces around the world. At its state-of-the-art manufacturing facility at Samlesbury Aerodrome near Blackburn in United Kingdom, BAE Systems operates more than 80 CNC machine tools, each tasked with producing a wide range of high-value, short-run airframe components for the Typhoon and other aircraft. Maintaining the performance and throughput of 5-axis machine tools, in order to ensure consistent Picture: Renishaw

part quality, minimise material wastage and maximise manufacturing efficiency, is a key responsibility for the company’s production line staff. Periodic CNC machine tool inspection and calibration checks are therefore vital. For this purpose, BAE Systems had already used Renishaw’s QC10 ballbar machine tool diagnostic system. BAE Systems turned to the second generation wireless system to add greater flexibility and ease of use.

Challenge Irrespective of its type, specification, workload and duty cycle, even the best CNC machine tool may see its positioning accuracy degrade over time and introduce errors if it is not maintained. Wear and tear, damage from collision, incorrect installation, even the influence of foundation-borne vibration and ambient air temperature can all have adverse effects. Identifying a problem with a machine tool after components have been machined can be costly. In the case of BAE Systems’ airframes, a high percentage of components are machined from titanium. This high-strength, lightweight, high temperature and corrosion-resistant metal is high in value and increasingly scarce, with stocks needing to be reserved up to a year in advance. As well as the cost of scrapping high-value material, the loss of CNC machine time caused by machine tool errors can be hard to reclaim. A complex titanium airframe component can typically demand 40 hours of machine time to produce. Repeated production of scrap components can have a severe impact on machine productivity. Of particular interest to BAE Systems’ manufacturing engineers was a machine tool that little-by-little had lost the confidence of machine shop personnel to produce accurate parts. Increasingly failing to produce parts within specification, this

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QC20-W ballbar system If a CNC machine tool’s positioning performance was perfect, then its circular interpolation - in any two-axis combinations - would precisely match a programmed circular path. The QC20-W wireless ballbar provides the means to compare the actual and programmed paths to determine the presence of errors. Containing a high accuracy linear transducer, the telescoping ballbar is located between precision magnetic cups; one mounted on the machine table, the other on the machine tool spindle. In this arrangement the ballbar is able to measure minute variations in radius as the CNC machine tool follows a programmed circular path. Signal processing is carried out within the ballbar and data is transmitted to a PC using a wireless connection. The data gathered is used to calculate overall performance of positional accuracy (circularity and circular deviation) in accordance with international standards and Renishaw’s own standard analysis reports. The ballbar data is displayed in both graphic and numeric formats to further aid machine tool error diagnosis. The ballbar kit includes 50 mm, 150 mm and 300 mm extension bars to cover a wide range of CNC machine tool diagnostic tests. Picture: Renishaw

problematic machine tool was becoming sidelined, and its workload re-routed to other machines. In the face of such challenges, the performance of a CNC machine tool needs regular checking. Maintaining the machine tool’s positioning accuracy is paramount to achieving quality and productivity targets.

Solution To assist with periodic CNC machine tool performance diagnostics, BAE Systems had previously used Renishaw’s QC10 ballbar system to identify specific machine tool performance errors. Moving on to adopt the second generation QC20-W wireless ballbar, the company initiated a site-wide preventative maintenance program to check 60 CNC machine tools on a defined weekly, monthly and annual basis. Through detailed interpretation of the QC20W’s diagnostic data trends across all machine tools, BAE Systems established a dependable go/no-go error margin benchmark, against which all machines’ performance could be quickly checked. Any circularity error in CNC machine positional accuracy greater than 30 µm would demand immediate investigation. The efficiency with which ballbar-trained machine tool operators could run diagnostic checks using the QC20-W meant they could be completed between part production runs with little adverse effect on machine tool throughput. The optimum ratio of ballbar test kits to CNC machine tools was also determined. A ratio of 1:15 was found to accommodate a ballbar leaving site for its annual calibration check, and multiple ballbar checks happening simultaneously across the machine shop.

With the knowledge and experience BAE Systems had gained from applying the QC20-W ballbar to an array of different machine tools, it was in a position to take a much closer look at its one problematic machine tool, which had effectively been removed from service. Using the ballbar, a XY circularity error of 200 μm was observed. Using the ballbar diagnostic software the dominant failure mode was identified as servo mismatch followed by a significant backlash error. The servo mismatch was rectified by BAE Systems maintenance engineers who optimised the X axis drive parameters, using the ballbar as a checking tool to quantify the improvements gained by the various adjustments. Once the servo mismatch had been eliminated there was still a significant error that was diagnosed, again, using the ballbar along with traditional gauge measurements, as X axis ball screw wear. Once the ballscrew had been refurbished and the backlash compensation re-set the machine tool was able to satisfy the XY circularity requirement of 30 μm and returned to error-free service. Jim Walsh, Specialist Manufacturing Engineer, BAE Systems commented, “Making ballbar testing an integral part of machine tool healthchecks has not only helped ensure consistent part conformity, it’s also given us the ability to be able to return a machine tool previously deemed unproductive to full operational service.” He continued, “Using the ballbar’s diagnostic software to automatically interpret results and diagnose errors also means machine operators are effectively freed from having to calculate from first principles what the data really means, where the problem lies and how it can be remedied. This helps save a lot of time in component production.”

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Industry Snapshot | ITALICA

Italica Bets On Tech For Competitive Advantage The company and its leaders have, from generation to generation, endeavoured to provide innovative, durable and superior quality plastic furniture. Its flagship brand, Italica Furniture, is one of the leading brands in the plastic furniture market in India.

P Italica Furniture Factory in Udaipur

IL Italica Lifestyle Limited has been one of the pioneers in the plastic moulded furniture industry. While its manufacturing facility was incorporated in March 1992, the commercial production commenced a year later. The company and its leaders have, from generation to generation, endeavoured to provide innovative, durable and superior quality plastic furniture. Its flagship brand, Italica Furniture, is one of the

leading brands in the plastic furniture market in India. The gamut of products includes plastic chairs, tables, trolley, sun loungers, crates, storage bins, waste bins etc. that have been moulded using cutting-edge technology and advanced manufacturing techniques. These products are made in its environment-friendly industrial unit spread across 18,500 sq.mt. in Udaipur, Rajasthan. Currently, the company owns 10 processing machines which are: SP 300, SP400, SP 600, SP

Italica Production

Italica Factory Overview

Italica Manufacturing Unit

Pictures: PIL Italica Lifestyle Ltd

Key advantages:

Unit spread across

18,500 sq.mt. in Udaipur, Rajasthan.

To produce about 400

metric ton of moulded furniture every month, Italica uses the technique of Injection Moulding process mostly developed indigenously. Italica’s network across North, West and Central India in the states of Rajasthan, Gujarat, Madhya Pradesh, New Delhi, Punjab, Haryana, Uttar Pradesh and Jammu and Kashmir.

800, Ferromatic 660, Italtech 1200, Chinese 760 and Ferromatic 775. To produce about 400 metric ton of moulded furniture every month, Italica uses the technique of Injection Moulding process mostly developed indigenously. With an output of 150 different varieties of furniture for household and industrial purposes, innovation is at the heart of Italica Furniture’s core philosophy and commitment. The company’s investment in employing the latest technologies and machines since inception has drastically improved product quality leading to diversity in its product range at a reduced operational cost. To ensure maximum quality control and keeping up the standard followed by the company through the years, the manufacturing processes are reviewed from time to time, and the testing of every single raw material used for production, packaging and other post moulding activity is carefully undertaken. Italica ensures regular inspection and testing of its finished products which it believes is its key strength to deliver products of highest quality. A team of highly-trained professionals and 110

skilled workers ensure the smooth functioning of its manufacturing unit. Following the approved quality system ISO 9001:2015, the company makes the only CE (‘Conformité Européene’) certified products in India, conforming to globallyrecognised standards of quality. The company has invested an amount of approximately Rs 125 crores in machines and moulds till date. To make sure its manufacturing processes are at par with the competition in the market, Italica plan to extensively and aggressively invest in latest technologies, replacing the old machines and to continue adding newer, stylish products into its portfolio thus establishing a strong presence in every segment of the market. Italica has a strong distribution network across North, West and Central India in the states of Rajasthan, Gujarat, Madhya Pradesh, New Delhi, Punjab, Haryana, Uttar Pradesh and Jammu and Kashmir thus making it one of the largest players in the plastic furniture industry in India. It offers products both in the affordable and the premium categories, catering to all the segments of the society.

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Product News | 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

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.

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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.

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Interview| INNOVATION

Delivering Strength and Agility through Innovation DMG MORI uses groundbreaking technology to help the healthcare industry produce top-quality and cost-effective surgical implants.

Markus Rehm Managing Director DMG MORI’s subsidiary concern Deckel Maho Seebach GmbH

Demographic growth, increases life expectancy and fast breakthroughs in medicine are among the key drivers in the medical technology industry.

he orthopaedic field in particular is witnessing many big leaps: hip and knee prostheses and spinal implants are in demand like never before. Overall, around 180 different products are used in the human body nowadays. Interest in diagnostics and surgical instruments is also growing. It is these areas of innovation that drive innovations at the new DMG MORI’s Medical Excellence Center based in Seebach, Germany. Markus Rehm, the Managing Director of DMG MORI’s subsidiary concern Deckel Maho Seebach GmbH, explains in an interview how DMG MORI supports the manufacturers of medical implants and instruments efficiently and qualitatively.. Mr Rehm, could you tell us about your role in the managing and advancement of DMG MORI’s Medical Excellence Center? Basically, it is part of an initiative where both industry giants as well as smaller companies and suppliers in the medical technology industry work to de-

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Knee and hip prostheses are among the most important orthopaedic products in the medical technology industry.

DMG MORI ensures the efficient, quality-orientated production of complex products for medical applications with innovative CNC technologies.

velop turnkey solutions that enable cost-effective production. To give you an insiderâ&#x20AC;&#x2122;s perspective, the technology experts at the DMG MORI Medical Excellence Center at Deckel Maho Seebach, Germany, are involved early on in the development phase of the products for our customers. So we learn together with the customers and are able to integrate the knowledge gained in the design of our machines and components. This was put to the test impressively during the first Medical Days that took place last June. This was when customers from Germany, Switzerland and Ireland came together to discuss the increase in productivity for medical technology with experts from all the associated fields. Do you see such turnkey solutions gaining importance in the future? That is what we envision. A study undertaken by Avicenne Medical [the leading Paris-headquartered medical devices company] indicates that medical device and technology will grow by 4.4 percent annually in the coming years. This trend will be accompanied by consistent price pressure. Certification issues will also become more acute and will have an impact on production. We aim to overcome such hurdles and ensure that both the high demands on quality and low machining times are met with innovative production solutions. Medical technology is an all important market for DMG MORI. How has this business arm developed in recent years and what are

your expectations for the future. The continuous growth of the market for medical technology has had both challenging and rewarding outcomes for the giants in the field. The production areas are getting ever tighter even while the prices for implants continue to fall. Manufacturers are looking at ways in order to meet these trends. The trend is towards more efficiency on all levels, especially in the production of sophisticated products such as knee and hip prostheses, and spinal implants. What challenges does this entail for DMG MORI as a supplier of technology for production? Medical technology in particular has its own challenges. The technological possibilities are not the limiting factor; it is the high demands in terms of the certification requirements of medical products that determine the process. So far as manufacturing solutions are concerned, it has become more important than ever to integrate digital solutions very early on in the production process. Barcode readers; the measurement and marking of parts as integrated options in CELOS [DMG MORIâ&#x20AC;&#x2122;s CELOS apps allow the user consistent management, documentation and visualisation of order, process and machine data], will both simplify and accelerate documentation and tracking. In addition, automation solutions are gaining in importance. Automated processes include not only unmanned production, but also the reading of pro-

Top products in the medical technology sector: Knee prostheses Hip prostheses Spinal implants Bone plates Surgical instruments

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Interview | INNOVATION Parts such as knee implants made of cobalt-chrome can be manufactured with maximum efficient in 5-axis simultaneous machining on a DMU 40 eVo linear.

grammes, quantities and batch sizes in the production environment as well as feedback to the entire system. Does that also affect the actual operation of the machines? Yes, of course. The App-based user interface CELOS already enables ergonomic and intuitive operation for users. Thanks to its openness, CELOS can also be ideally integrated in the company organisation. Moreover, automation solutions are a great help in many sub-disciplines, because low-manpower production is more cost-efficient. This involves the loading and unloading of single parts and small series in orthopaedics, for example. The focus here is on flexible automations, as it is in the production of medical instruments. An additional challenge in this connection is in the limited production areas, which is why extremely space-saving, integrated automation solutions are called for. The DMG MORI range here includes both pallet and work piece handling systems as well as robotic automations. Of course, high-performance CNC machine tools with the most compact footprint possible remain an essential basis for efficient automation solutions. What are the most attractive series for customers from the medical technology branch? The second Generation NTX 1000 is the most popular model for the 6-sided complete machining of knee and hip prostheses and the 5-axis milling of these parts on the smaller DMU eVo model. The compact MILLTAP 500 machining centre is the

Thanks to its extreme rigidity, high spindle speeds and intelligent cooling system the MILLTAP 700 machines bone plates made of titanium with maximum efficiency – and virtually unmanned as well when equipped with a WH3 workpiece handling system.

With a footprint of just 10 m² the 2nd Generation NTX 1000 from DMG MORI impresses among other things with the 6-sided complete machining of components for hip and knee prostheses.

most productive solution for the manufacture of bone plates while the SPRINT turning machines offer an efficient option in the manufacture of bone screws. However, advanced technologies such as ultrasonic milling and additive manufacturing with powder bed technology are also gaining in importance. With this portfolio we cover a wide range of components in the all-important orthopaedic field. The high demands on quality and the need for shorter machining times are aspects that the medical technology equipment is required to deliver. How do you address these requirements? Complete machining is a commonplace topic in the area. In particular, complex parts such as knee implants made of cobalt-chrome can be manufactured with maximum efficiency in 5-axis simultaneous machining on a DMU 40 eVo linear. High spindle speeds of up to 60,000 rpm and linear drives ensure highest precision, best quality surfaces and maximum dynamics. A pallet handling system boosts productivity even further, even for the lowest quantities.

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Bone screws, among other things, can be produced with maximum efficiency on the automatic turning centres of the SPRINT series.

With spindle speeds of up to 60,000 rpm the HSC 20 linear achieves top surface qualities thus reducing the time and effort required for postprocessing to a minimum.

The LASERTEC 30 SLM enables productive additive production of products for medical applications with powder bed technology.

DMG MORI also advances digitisation in medical technology production, in order to simplify and accelerate documentation and tracking.

What is your answer to complex turn-mill parts? The 2nd Generation NTX 1000 has proved very successful here. The turn-mill centre impresses in the 6-sided complete machining of different components for hip and knee prostheses, for example, and it does so on just 10 m². At least two machines were needed for such applications in the past. What makes the 2nd Generation NTX 1000 so productive? The versatile equipment options enable, among other things, parallel machining of the work pieces using a milling spindle and a bottom turret. The solid machine construction ensures highly accurate machining, while the tool magazine with up to 76 stations contributes to a high degree of flexibility in production.Several automation solutions round off the equipment options. Products made of titanium or a titanium alloy are a hot topic in medical technology. What solutions do you see in this respect? The MILLTAP 700 impresses here with its extreme rigidity, high spindle speeds and intelligent cooling system. Added together these features guarantee shortest machining times and best surface qualities in the production of bone plates. The WH 3 work piece handling system enables low-manpower production. The manufacture of bone screws is carried out under very similar conditions on the automatic turning machines in the SPRINT series. With integrated spindle drives – 10,000 rpm for the main and counter spindles – and a linear drive in the X1-axis the SPRINT 20|8 reduces throughput times to a minimum, as do the two tool slides for maximum 36 tools – including up to ten powered tools, so that even complex components can be produced easily. The extensive DMG MORI product portfolio allows the production of a wide range of components for the medical industry. What do you consider the main focus for your projects in this field? Common focus areas for the machining of orthopaedic products are the bone screws, spinal implants and knee and hip joints where there are high demands placed on accuracy and efficiency. The manufacturing solutions presented at this year’s Medical Days at DECKEL MAHO Seebach showed this quite clearly. Meeting such demands is also the key criterion for the diverse customer projects in the DMG MORI Medical Excellence Center.

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GST Special | COVER STORY

Will GST Change

India's Manufacturing Landscape? GST's impact on manufacturing and supply chain: Pains and gains

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irst, the bad news: Dark clouds of degrowth loom over India’s manufacturing industry. During the first quarter of FY18, the manufacturing growth fell sharply to 1.2% from 10.7% a year ago according to Central Statistics Office (CSO) data. During the period of April-July, IIP (Index of Industrial Production) grew by 1.7 per cent, compared to 6.5 per cent of April-July last year. In short, things look grim as they stand in the manufacturing sector. Now some news that could bring some hope – it’d be too early to call them good news. There are some early signs of revival aided by govt initiatives, global developments such as the recent spurt growth in export volumes and the manufacturing industry’s own inbuilt resilience. Results of the Nikkei India Manufacturing Purchasing Manager’s Index (PMI) survey released in September showed that the manufacturing activity in India rebounded in August rising to 51.2 in August from a 101-month low of 47.9 in July – good but still less than 50 which indicates expansion. “August’s PMI results showed that manufacturers in India recovered quickly from the sharp slump that followed the introduction of the GST,” said Pollyanna De Lima, an IHS Markit economist and the author of the report. The incontestable truth that emerges from all the developments is, that the manufacturing industry needs a much greater push to become the engine of growth and provider of muchneeded jobs that the economy desperately needs. More importantly, for India’s GDP to grow sustainably at 9-10 per cent per annum, it is important that the manufacturing sector must grow steadily at 14-15 per cent per annum over the next three decades. Among all the growth enablers, the government and the industry have for long put their faith in a landmark reform – GST (Goods and Services Tax). After more than a decade of speculation and political tug of war, GST was at last introduced this year on July 1. Manufacturing industry stakeholders are hopeful that GST could be the magic pill that turns the industry around. The MD of the Indian arm of VDMA, a global Mechanical Engineering Association, Rajesh Nath says, “After 17 years of brainstorming and political deliberation and

Metal working industries and machine tool industries supply to every manufacturing sector. Hence the business continues as before; however the uniform tax rate should help the industry to perform better in the long run. Ravi Shankar S, Business Analyst and Consultant Supporting Manufacturing Excellence, Former Managing Director, DMG MORI India.

hurdles, the biggest tax reform in Independent India, the goods and services tax (GST), was finally rolled out on the 1st of July this year. This will surely send out positive signals to the world and the country is going to be seen as a unified market.” He adds that GST will further improve the ease of doing business in India, which could potentially help in making the business environment increasingly conducive. “The first indicators after implementation of GST are positive as tax collections under GST had come to over Rs 93,000 crore in the month of July. This has far exceeded the expectations as this is based on the fact that only 63% of tax assesses had filed their returns.” Further, a joint report by ASSOCHAMEY released in August this year stated that the introduction of GST is exFpected to have the following positive outcomes for the manufacturing sector: Reduced production costs: The cascading effect of the taxes faced by manufacturers on purchase of raw materials and supplies will be eliminated. Smoother supply of goods within the

Key Highlight: The first indicators after implementation of GST are positive as tax collections under GST had come to over Rs 93,000 crore in the month of July.

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GST Special | COVER STORY magnets, says, “Things are moving smoothly than before for us – small vendors who were not inclined to register for VAT and would rather want cash transactions are also now willing to go with GST as it gives them the benefit of input credits.” Ravi Shankar S, Manufacturing Excellence Consultant and former Managing Director DMG MORI India says: “Metal working industries and machine tool industries supply to every manufacturing sector. Hence the business continues as before; however the uniform tax rate should help the industry to perform better in the long run.” After 17 years of brainstorming and political deliberation and hurdles, the biggest tax reform in Independent India, the goods and services tax (GST), was finally rolled out on the 1st of July this year. Rajesh Nath, Managing Director, VDMA India Services Private Limited

Key Highlights: In machine tools business, centralising manufacturing facility at one place is very much important from the point of productivity. Grind Master has been benefitted post GST. Things are moving smoothly than before for us – small vendors who were not inclined to register for VAT and would rather want cash transactions are also now willing to go with GST as it gives them the benefit of input credits

country: Reduced scrutiny at state border checkpoints and lighter compliance norms will lead to cost and time savings, improving supply efficiency by over 60%. Supply chain restructuring: Prior to GST, key logistics decisions such as warehousing and storage were made in order to optimize indirect tax costs, given the arbitrage between VAT rates in different states. GST will cause these decisions to be made keeping in mind business efficiency and locational advantage. Area-based exemptions: Area-based tax exemptions will be discontinued so that the credit chain along GST is not disturbed. While the aforesaid points provide an encouraging overview of GST’s impact, one also needs to understand the prevailing sentiment on the shopfloor, to see how manufacturing industry stakeholders perceive its impact for the near and the long term. To bring in that perspective, Dynamic Manufacturing India spoke with industry thought leaders about all these major implications and then some. Presenting, views from the top. Early View

For one, GST has, without a doubt, widened the tax net and made transactions more streamlined than before. Dhiruj Sarda, Managing Director, East Coast Magnets Private Ltd, a leading maker and supplier of Magnetic Chucks and Holding

Impact On Manufacturing Footprint

The biggest implication of a one-nation one-tax system has to be on the manufacturing footprint of the country, that is, it should enable companies to locate or relocate plants at locations which promise better quality of manufacturing in terms of labour, capital and infrastructure. Will our country’s manufacturing map see any such impact? Industry thought leaders say that, though manufacturing locations could be relocated in the long run, in the immediate turn it doesn’t look imperative especially since many exemption benefits from the earlier tax regime continue. Mr Ravishankar says, “The industries in the SEZs in Industrially backward states are exempt from GST and the exemption is in the form of refund. Hence those industries continue to receive the benefits. The Industry can make rational decisions for the location based on either raw-material availability or market for finished goods as the case may be.” Mohini Kelkar, Managing Director, Grind Master Machines Pvt. Ltd says that “Shifting of manufacturing base within the state is now easier from an administrative point of view as all the units will have one GSTIN. This would save and ease further administration of maintaining separate records and compliance with government authorities. Ms Kelkar affirms that companies in the machine tools industry, including Grind Master, have benefitted post GST: “In machine tools business, centralising manufacturing facility at one place is very much important from the point of productivity. Grind Master has been benefitted post GST.” Sharing the perspective of his industry, Mr Sarda says, “We are in the light engineering sector and hence our choice for location is based more on small vendor support and better infrastructure. This is the reason we expanded

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our operations in SRICITY, Andhra Pradesh for its proximity to Chennai and also extremely good infrastructure in the Industrial area.” However, Asim Behera, Chief Operating Officer-Daifuku India is of the view that it is the distribution network that many companies have begun to deliberate post GST. “Manufacturing set-up is very segment specific -- different segments have different criteria for how they set up their network. Also, many companies have set up manufacturing based on certain tax incentives they would get; thus you see that regions such as Baddi, Rishikesh, etc. have become industrial hubs. GST has not rolled out statutory tax benefits so it really wouldn’t have an impact on manufacturing network, where it will impact is the Distribution network planning. And we are starting to see various Supply Chain Heads discuss more on the distribution network planning.” Mr Nath of VDMA says that, in the long run, we could see a definite impact of GST on India’s economic map. “GST has eliminated taxes on inter-state movement and harmonised the VAT structure across states – except for exempted goods. Border inspections are significantly reduced. That said, GST is expected to result in a significant increase in internal trade — by as much as 30 to 40 per cent, according to some estimates.” He says that there are other economic factors also at play that can significantly alter the economic map of the country by diluting the ‘home market’ effect. “The work of economist Paul Krugman has shown that when the costs of producing a good are lowered with scale in production, there is an incentive to geographically concentrate such production. Particularly so when additionally, there are large benefits in transport costs and production costs by locating the production base near the largest market to minimise transportation costs – which brings in the well-known “home-market” effect. In this setting, a reduction in transport barriers, as is the case with GST, can change the location of production within a country quite dramatically — away from the largest market to low production-cost locations, thus diluting the home-market effect.” Impact on Production Costs

The earlier multi-layered and multi-regional tax regime marred the efficiencies of the manufacturing sector – GST is expected to unlock the sector with reduction in procurement and logistics costs. Mr Nath says: “One of the advantages of GST is reduced cost of production

In many organisations it would be happening that vendors in the last tier would have been shed off or the companies would have reorganised purchases by consolidating with other major vendors. Mohini Kelkar, Managing Director, Grind Master Machines Pvt Ltd

that is expected to be spurred by tax reduction. The subsuming of the entry tax for inter-state transfers is a key reason for reducing cost of goods and services. For example, a supplier of cement from Maharashtra to Karnataka was earlier required to pay entry tax when the supply crossed the interstate border. For Karnataka, the entry tax rate was 5% of the value of the goods. The supplier would pass on this additional cost to the customer, resulting in increase in selling price. With entry tax being subsumed, the supplier need not pay the entry tax rate amount and consequently, not charge the customer this amount either.” He adds that manufacturers need to re-work the prices to be quoted to the customers for each product range and work out the reduction of pricing to comply with the antiprofiteering clause. Mr Sarda concurs that GST has resulted in lower cost of production, “but at the same time a few companies have increased their margins to keep the prices same. We feel that over the next few quarters things will stabilize even more.” Others also advise a wait-and-watch approach. Mr Ravishankar says that presently it is too early for any manufacturer to comprehend and realise the entire cost benefits. Perhaps in the next six months to one year the entire cost impact will be visible. Mr Behera says that some sectors are going to have a lower cost of production whilst other will have a higher cost of production. “I am interested to see how much of this gets passed

Key Highlights: The industries in the SEZs in Industrially backward states are exempt from GST and the exemption is in the form of refund. GST has eliminated taxes on inter-state movement and harmonised the VAT structure across states – except for exempted goods

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GST Special | COVER STORY onto to the consumer,” he says. Ms Kelkar says that for her company, GST will not see reduction in costs because most of the purchases and job work for the company is within one state. “Yes there would be saving due to CST for which credit was not available.” Impact On Vendor Relationships

Key Highlight: When it comes to World bank ranking on ease of doing business India still at 130 out of 190 which is far below. The introduction of GST and successful implementation will be a further step to improve the India’s ranking.

Many Operations Chiefs that we interacted with recently said that the toughest part of GST transition was getting their vendors on to the GST network. Factors such as increased compliance cost and pre-GST inventory destocking adversely impacted vendor relationships for many companies. We asked the sector leaders their experience in this area. Ms Kelkar concurs that GST has impacted vendor relationships, however her company has seen this as an opportunity to strengthen relationships: “In many organisations it would be happening that vendors in the last tier would have been shed off or the companies would have reorganised purchases by consolidating with other major vendors.” But she emphasises that her company has decided not to remove even the smallest vendor. “In the machine tools business, manufactured parts as per design make a lot of difference. Hence, there are many vendors who are in micro and small sector. Out company has strengthened the relationship with these vendors by offering various services like getting them registered under GST, shifting them from manual accounting process to computerised accounting and all possible assistance to be GST Compliant.” Mr Sarda says that “The introduction of GST would have certain impact on vendor management that can’t be ignored. Creating unified credit mechanism across the supply chain till goods or services are consumed entirely is the basic structure of GST. This is only possible when the goods and services are procured from the registered vendor. In order to tackle this, the companies need to engage with their vendors in this sector early so as to understand their readiness for this tax system. Also, any further delay or blunder in depositing GST by the vendors would result into several settlement issues.” Mr Behera agrees that procurement definitely has been impacted but more so in terms of delays due to compliance rather than a paradigm strategy shift. “We continue to use the vendors we have had long term relationships with. For any new vendors, we are looking for them to be GST compliant as a pre-requisite.” Mr Ravishankar said that “Initially there were

After 17 years of brainstorming and political deliberation and hurdles, the biggest tax reform in Independent India, the goods and services tax (GST), was finally rolled out on the 1st of July this year. Asim Behera, Chief Operating Officer, Daifuku India

certain delays which resulted from ensuring that all vendors and customers in the chain are ready with the registration and process. Subsequently more or less all are registered and business process have been proceeding unhindered. Issues may crop up when the returns are filed and if there are differences in the input credit. As said earlier the real issues might get highlighted after few months when the full business cycle gets completed, the refunds are accounted and more so after one full year when the audits are finalised.” Spurt in Contact Manufacturing

Mr Ravishankar makes a prescient point when he says, “With the state levies removed and the check posts abolished, the logistics to a large extent has got simplified. Hence contract manufacturing will get a boost as the decision will be purely based on cost and convenience. In the developed economies like Germany and US, the large corporates focus on design, development, final critical-part manufacturing and assembly; the rest is outsourced.” He adds that the earlier trend in India was to have all manufacturing processes including the raw material procurement and even the manufacturing of machines and tools done in house to ensure that the required knowhow and technology is not available outside. Most of the companies had their own tool rooms. Now the trend is to outsource as many processes as possible to ensure that cost of manufacturing is minimised. Mr Sarda agrees: “Yes, it [boost in contract manufacturing] seems to be a natural progression.

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not be possible, but yes it would give it a push forward. The top reasons we believe for the same are: o A simplified tax structure hence reporting is easier. o Smaller vendors are now getting registered hence their costs come down creating an forward ripple effect for cost reduction. o With increase in contract manufacturing and jobwork outsourcing, GST will help with the simplification of the process and movement of goods.

The introduction of GST would have certain impact on vendor management that can’t be ignored. Creating unified credit mechanism across the supply chain till goods or services are consumed entirely is the basic structure of GST. Dhiruj Sarda, Managing Director, East Coast Magnets Private Limited

Enabler of Mission Make in India

The present dispensation had put up GST as one of the landmark reforms that will help India realize the goals of Mission Make in India. The experts are hopeful but advise rational exuberance. Ms Kelkar says, “It seems that the present Central Govt has really taken up the agenda of “Ease of doing business” in its stride and is working towards achieving the same sincerely. I see it clearly that “Make in India” is not the only campaign rather one of the host of programs taken by the government that would definitely enable Mission of Make In India. GST will prove to be an enabler of Make in India owing to the following reasons: 1) A Simplified Tax Regime i.e. GST would definitely attract foreign investment to India which in turn will be boost ‘Make in India’. 2) With GST, the cascading effects of taxation are removed which will benefit the customer in terms of lowered prices and will eventually present a level playing field to Indian manufacturers 3) The uniformity of tax regime would enable Indian manufacturers to leverage the benefit of markets present in any part of the country which was actually a tough feat in the earlier tax regime. Mr Sarda is also rationally exuberant. He say, “GST itself as an enabler for ‘Make in India’ would

Mr Behera says, “As of now I don’t see a direct link. The real manufacturing enablers are: good utilization of current capacity, easy availability of credit, stable government policies and an optimistic outlook for demand. All of these appear to be going the right way as our internal demands go up; so, Make in India looks more favourable than it has been for a while. Mr Ravishankar says, “When it comes to World bank ranking on ease of doing business India still at 130 out of 190 which is far below. The introduction of GST and successful implementation will be a further step to improve the India’s ranking. Unless this ranking is improved significantly, Mission Make In India will remain a distant dream. Therefore, GST will be and an enabler for Make in India Mission. Both GST and demonetisation efforts from the Government have weighed heavily on the last quarter’s GDP Performance [the GDP growth rate has dropped to 5.7%], but these bold surgical measures by the government are expected to bring up the growth rate to 8% by last quarter.” Mr Nath shares the optimism: “The manufacturing sector in India contributes a mere 16% to the overall GDP. However, the potential to make this a high-growth and high-GDP sector is huge. The “Make in India” campaign makes this possibility real by giving impetus to the sector. Furthermore, it is estimated that India will become the fifth largest manufacturing country in the world by the end of 2020. The introduction of the Goods and Services Tax or GST is expected to be an enabler. One reason is that GST will usher in an era of transaction-based valuation, making calculation of tax much simpler for the manufacturer. The other being that under the new tax laws, manufacturers can claim input tax credit on input goods, which seems to be a positive sign for cash flow. SMEs are keenly observing the time difference between input tax credit and the credit being available,” he concludes.

Key Highlight: The introduction of GST would have certain impact on vendor management that can’t be ignored. Creating unified credit mechanism across the supply chain till goods or services are consumed entirely is the basic structure of GST

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Success Story | KOLLMORGEN

Providing Orientation for Materials Swiss company MEquadrat AG builds test systems with decentralized servo technology from KOLLMORGEN.

The servo motors from the KOLLMORGEN AKM series also travel along on the rotary indexing table. Picture: KOLLMORGEN

aterials with optoelectronic functions are an indispensable part of electrical components today. Users need to know the material´s precise internal molecular structure before the components are installed so that these then work reliably in the application. MEquadrat (ME2) builds test systems for this purpose that are designed as a rotary indexing table. Decentralized servo drives from KOLLMORGEN are placed on the rotary units for positioning the test specimens. Slim, round like a pill, and with clearly defined edges, optoelectronic glass components generally look rather inconspicuous with their milky-white coloration. The minimalist appearance is the result of the manufacturing process in which the eventual components are cut from blocks in large quantities. Processes are required which reveal how the molecular structure has grown in the interior in order to ensure that the bulk material is suitable for installation in the device.

Providing orientation

Inspection systems from ME2 are used for determining the atomic structure of the glass-like materials clearly. The company from the district of Root in Switzerland specializes in test equipment technology. “We build machines that have never been built before,” says Managing Director Stefan Nyffenegger with a smile, before noting that this is why ME2 is always more than happy to start introducing new technologies into machinery construction at a very early stage. This philosophy is reflected currently in a test system driven by decentralized servo drives from KOLLMORGEN´s AKD-N series. “This way we can determine the ideal installation location for the test specimens,” explains the mechatronics engineer. “We know their alignment and behavior precisely once they leave our system,” he adds. The materials go through six test stations via a rotary table for the different measurement procedures. ME2 has placed six servo axes on the rotary table which raise the test specimens after each test step and move them to the next station working together with the rotary motion of the rotary indexing table. “The measurement stations are stationary in the machine, and we have to position the test specimens precisely to two-hundredths of a millimeter with the AKM servo motors,” says Felix Aeschimann, a software architect at ME2. The AKD-N decentralized servo drives drive compact AKM servo motors for this, which are connected in turn as handling axes with ball screws as a linear unit. Everything on one continuous cable

“The great thing about the AKD-N is that we are able to connect it via a loop wiring system. We use just one cable for everything: power, communication and safety engineering,” says Stefan Nyffenegger. Another special feature of the structure for the decentralized servo drive technology is that there is also a slip ring placed between the AKD-C switch cabinet module and the six AKD-N servo drives also rotating on the rotary indexing table, in order to ensure that

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The AKD-C power supply unit (right) supplies the decentralized servo drives. ME2 also uses switch cabinet servo drives from the AKD range to control additional motors outside of the rotary table. Picture: KOLLMORGEN The decentralized AKD-N servo drives are positioned around the machine’s central axis to save space. Picture: KOLLMORGEN

the test unit does not have to reverse and can instead continue traveling endlessly in a circle. The slip ring interrupts the cable connection between the power supply and the servo drives, which provided a new challenge in terms of the safety engineering. Although the combination of AKD-C and AKD-N features the TÜV-certified ‘Safe Torque Off’ (STO) safety function, there is no longer any abatement provided when combined with the interconnected slip ring. Slip Ring Solution with Safety

Author: Diplom-Ingenieur Martin Zimmermann, KAM Switzerland, KOLLMORGEN Switzerland

Slip ring solution with Safety torque off is a crucial function given the daily practice of production employees continuously accessing the machine. This is why KOLLMORGEN developed a TÜV-certified solution working together with slip ring manufacturer Stemmann from the district of Schüttdorf, and was then able to provide these to ME2 as a ready-toinstall drive solution. The slip ring is installed in the central axis of the rotary table and combined with the single-cable connection technology, forms a very slim installation that continues to operate, since the power, communication and safety engineering are looped through to the next device by an AKD-N servo inverter like a string of pearls. The benefit provided by this structure can be seen from the switch cabinet as well as the connection from there to the machine. The ultra-slim circuit groups can barely be seen, which also means there are no problems with cumbersome cable trays or with time-consuming installation processes. ME2´s solution for implementing the machine control unit to the motion control is just as smart. A CompactRIO from National Instruments (NI) with LabVIEW environment is used as the computer center. ME2 uses this system for the actual laboratory processes for precise analysis of the components. “We are the only company in Switzerland that has been able to combine the CompactRIO and LabVIEW with so much motion control,” notes Felix Aeschimann. The NI Alliance Partner links the workflow commands for the motion control via Modbus with

The servo motors from the KOLLMORGEN AKM series also travel along on the rotary indexing table. Picture: KOLLMORGEN

the new KOLLMORGEN Motion Controller PCMM. The LabVIEW connection for the drives via the PCMM is one of the highlights of the engineering partnership between ME2 and KOLLMORGEN. “Manufacturer support is one of the most important factors when we are looking for a supplier that´s right for us,” says Nyffenegger. “We build special solutions, and this always involves challenges that need to be resolved quickly.” The aim is to get systems up and running as quickly as possible, as customers often specify short time frames from development to commissioning. Faster installations mean more time for development

The Swiss company also believes that building the system at the latest possible stage is important following the development and design stages. “We are a small company and so are interested in short pre-financing times. This is why we purchase technology that is as far as possible modular and pre-assembled.” The sales director firmly believes that the cost part for installation and assembly needs to be as low as possible in terms of overall machine costs. “The less we wire up the better. We´re engineers and not electricians. ME2 earns its money from engineering services. That´s why complete systems from one source such as those from KOLLMORGEN are such a benefit to us.”

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Industry News | OKUMA

Esprit delivers solutions for Industry 4.0

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DP Technology is helping factories of the future prepare for the digital transformation that’s taking place in manufacturing, with solutions including digital twinning, digital threads, machineaware manufacturing, knowledge-based machining and cloudenabled databases.

I A representation a digital twin, showing a blend of real life and a virtual simulation of a main shaft being machined on a 5-axis machine. Picture: OKUMA

n order to prepare factories for an increasingly digital future, and to better support Industry 4.0 and smart manufacturing initiatives, DP Technology is focusing on a range of solutions to drive automation in manufacturing. The Esprit CAM System enables manufacturers to streamline their workflows, prevent silos from forming during the manufacturing process, increase tool life and machine utilization, and create greater access to practical knowledge for process improvement. Through the Digital twin technology, Esprit allows users to create a digital twin of their machine tools for programming, optimization and simulation. This virtual machine ensures that whatever happens on screen will also occur on the shop floor. Workpieces and cutting tools are set up virtually, resulting in exacting simulations, greater productivity and better toolpaths for higher quality parts. Digital Thread With Esprit, a digital thread ties together each step of the workflow from CAD design to finished part, ensuring that none of the manufacturing process is siloed. Esprit reads parts’ data from CAD software and creates machine-optimized G-code and setup sheets, which it then passes on to shop floor management, tool data management and enterprise resource planning software. Machine-aware solutions Esprit provides machine-aware CAM programming to increase tool life and reduce cycle times. The CAM system’s Profit Milling and Profit Turning apps represent a fundamental change in the way toolpath is created: most CAM software work from the shape of the parts first and consider the machine last, if at all. Esprit’s machine-aware solutions first consider the machine tool – its axis’ positions and their limits, acceleration, and attainable and requested cutting speeds, allowing users to run machines faster, get a better surface finish on their parts and significantly increase their tool life.

As a result, with machine-aware CAM, programmers make better choices regarding toolpath, without asking the machine tool or cutting tool to exceed their own abilities. Knowledge-based machining Knowledge-based machining, the term for artificial intelligence built directly into a CAM system, makes it possible to significantly cut programming time by capturing best practices, including machining processes and cutting conditions — leaving more time to focus on strategic process improvements and reducing time spent on repetitive tasks. Esprit’s Knowledge Base solution streamlines part programming by automatically selecting the optimum processes — machining cycles, tools and conditions — for part features based on proven best practices. Recording practical knowledge via Knowledge Base is more reliable than leaving it to memory and allows for higher levels of automation through repeatable steps. Because programming is more predictable and consistent, programmers encounter fewer problems and produce higher quality parts. Cloud-enabled machining As shops move to data-driven manufacturing, integration with cloud-based databases, such as Machining Cloud Inc., further facilitates access to knowledge, product data, resources and process controls for machines, cutting tools and work holding. These cloud-enabled databases suggest factory-recommended feeds and speeds for a given cut, let users quickly find the tools they need, and provide continuously updated manufacturer product data, including drawings and models of tools and cutting tool assemblies for simulation. Because information is stored in the cloud, it is always up to date, available on demand and can be accessed anywhere. These solutions will be on display at the company’s booth (Hall 25, Stand D25) at EMO in Hannover, September 18-23, as well as at other industry events around the world.

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Industry News | NORD

Long-life, wash-down drive technology for the beverage industry NORD DRIVESYSTEMS will showcase industry-specific drive solutions at the drinktec exhibition in Munich, Germany to be held from 11 to 15 Sep. 2017

Light-alloy nsd tupH drives optimized for wash-down enable efficient cleaning of plants in the beverage industry. Picture: NORD

he German manufacturer makes on an extensive range of products with a large variety of drive systems featuring aluminium cast housings optimized for wash-down. These lightweight, corrosion-proofed gearboxes, smooth-surface motors, frequency inverters, and motor starters are particularly easy to clean. NORD nsd tupH drives come with effective anticorrosion surface treatment, which is approved for food and drink applications in accordance with FDA title 21 CFR 175.300. The nsd tupH drives are a durable, low-maintenance alternative to stainless steel or coated systems with lower total costs over the long term. Instead of applying a coating,

the nsd tupH treatment hardens and penetrates deep into the alloy surface. Consequently, there is no applied material that could flake off. These drives can even be cleaned with high-pressure steam jets and can be regularly exposed to liquid media without any problems. The nsd tupH drives are fitted with stainless steel standard parts as well as stainless steel output shafts by default. The non-ventilated smooth-surface motors run very quietly and do not actively contribute to spreading germs. They meet current international efficiency levels. Induction motors are available with IE2/high efficiency and IE3/premium efficiency and synchronous motors with IE4/ super premium efficiency.

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Industry News | CII

Karnataka and Tamil Nadu to Collaborate for Better Tomorrow Karnataka Delegation led by LME&I Minister Shri Deshpande Meets Tamil Nadu Industry Delegates

5th September 2017, Chennai: Government of Karnataka aims to leverage technology and manufacturing prowess to attain a position of leadership and excellence in manufacturing and overall industrial development. In this regard, Government of Karnataka in partnership with Confederation of Indian Industry (CII) is organizing Vendor Development and Investors Summit on 23rd and 24th November 2017 at BIEC, Bengaluru. The summit will act as a common platform for CPSUs, SPSUs, Mega and Large units in identifying vendors of their choice in terms of production capacity and quality standards. This meet will also help MSMEs understand the need of the OEMs. In addition, this programme will benefit MSMEs in planning their production and product diversification. More importantly, the Summit will facilitate the participating companies in exploring the investment opportunities in the State of Karnataka and firm up their new/expansion investment proposals with the State Government in terms of project approvals or MOUs. To promote the event among Original Equipment Manufacturers (OEM’s) and MSME’s, Hon’ble Minister for Large & Medium Industries and Infrastructure Development Sri R V Deshpande along with Senior Level officers of Karnataka Government visited Chennai today. During the day the delegation met with some of the key industries from Chennai to invite them to participate in the event and to discuss their interest in expanding their business in Karnataka. During the meetings, Hon’ble Minister discussed with the companies the support and facilitation provided by Government of Karnataka for implementation of their projects in the state. He also invited them to participate in the forthcoming

“Vendor Development & Investors’ Summit 2017” in Bengaluru. In the evening, CII along with Government of Karnataka had organised a Road Show wherein presentation was made on “Manufacturing Eco system of the State” to the large audience present. More than 150 industry representatives and prospective investors participated in during the Road Show. Hon’ble Minster in his address stated that Government is focused on providing momentum for imaging itself as the most industry friendly state in the country. While focusing on the growth, we are taking cautious steps to ensure that the development would not have adverse effects on the environment, people and the ecosystem. He also outlined the potential for investments in various sectors in the state; viz., Aerospace & Defence Equipment Manufacturing, Automobiles, Auto components & Electric Vehicles manufacturing, Biotech, Pharmaceuticals and Medical Devices, Agriculture & Food Processing and Machinery, Textile and Apparels and Innovation & Start-ups among others. D V Prasad, IAS, Additional Chief Secretary to Government Of Karnataka, in his address emphasised on the initiatives undertaken by the state to develop the ecosystem for the overall industrial development; with special focus on the MSME sectors. Deepak Sood, CEO, Invest Karnataka Forum, made a detailed presentation during the Road Show on “Enabling Manufacturing Ecosystem of Karnataka.” Mr. Kamal Bali, Chairman, CII Karnataka & President & MD, Volvo Group India, Mr.M.Ponnuswami, Vice Chairman, CII, Tamil Nadu State Council & Chairman & Managing Director, Pon Pure Chemical India Pvt. Ltd., Mr.L.Krishnan, Past Chairman CII Karnataka and Managing Director, TaeguTec India Pvt. Ltd. and Mr N V Venkatasubramanian Chief Executive L&T Valves were also present in the Road Show.

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Industry News | SCHULER

First spiralpipe produced on a Schulerplant Plant at Tuberías Procarsa in Mexico ready for operation

Tuberías Procarsa, Latin America’s leading producer of carbon steel line pipe, uses the spiral pipe welding system from Schuler into operation and used it to produce the first large-diameter pipe. Picture: SCHULER

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xperts predict that in North America alone, over 10,000 kilometers of new pipeline will be laid per year by 2020. And most of that will be spiral pipes. Tuberías Procarsa, one of the leading manufacturers of steel pipe in Latin America, is equipped for this trend: the company with headquarters in Monclova (Mexico) has put a spiral pipe plant from Schuler into operation and used it to produce large-diameter pipes. The offline spiral pipe plant can produce large-diameter pipes with a diameter of 508 to 2,235 millimeters (20 to 88 inches) and a length of 12 to 24.4 meters. The raw material up to 25.4 millimeter-thick sheet metal band made of highquality steel (up to X100) comes on a hot rolled coil (HRC). The spiral mill forms the diameter and weldsthe spiral pipe within the first step by tack welding. In a further process, the final pipes will be weld by several final welding stands with a submerged arc welding process. An innovation from Schuler is the integrated coil preparation stand. It ensures short changeover times, high occupational safety and an exact 90-degree cut of the beginning of the band. A crane transfer is no longer necessary. All relevant work steps on the spiral millare automated: settings are no longer made manually; instead, setting is done directly on the well-organized control panel and implemented by servo motors. This results in an energy savings of up to 30 percent and short changeover times. At a length of 285 meters, the pipe plant also includes various equipment for inspecting the large-diameter pipes in accordance with the API 5L standard. Ultrasonics, X-rays and water pressurestands are used here. The production capacity of TuberíasProcarsa will be increased by 200,000 tons a year thanks to the Schuler system.

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GST’s Impact On India’s Supply Chain It was the first time post-GST roll out, that a GST Commissioner met with industry representatives and provided clarity on GST-related issue. Even though the govt-industry talk was confidential which can not be shared, we are able to bring you unmissable and useful insights from the conference to help you better negotiate the post-GST world.

n Friday, 04 August, Mumbaibased ASCW Media organized a GST Conference in Mumbai, the first supply chain event in India post-GST implementation that saw government authorities and industry representatives gather at one forum to address GST-implementation related challenges. The Chief Guest of the conference was Shri Sandeep Puri, GST Commissioner (W) Mumbai and his colleagues, who were present all through the conference, and held a 40-minute Q&A session with industry representatives. Their support and contribution made it a landmark event -- one, which is sure to have a far-reaching, galvanizing impact on the operations industry.. The Keynote Presentation was delivered by Prahlad Tanwar, Director – Transport and Logistics, which was followed by a Chief Supply Chain Officer (CSCO) Panel and an industry Q&A session with the Chief Guest and his colleagues. In this feature, we bring to you the highlights of the event that that will give you unmissable insights into how GST will impact the supply chains of companies in the near and the long term. In his Welcome Address, Hon’ble Chief Guest

Shri Sandeep Puri, GST Commissioner (W) Mumbai said: “Logistics and supply chain form the fulcrum of an enterprise. This is the segment through which the Japanese introduced Kaizen and JIT management which were essentially about cost saving and increased efficiency. So I can understand the concern and the anxiety this industry is facing [about GST] because this industry is the first pillar of support. GST, as a concept, is not new. It was introduced in 1954 in the world and today, about 160 countries follow GST. India, we have brought in the dual model of GST – there is the state GST and the Central GST. From one state to the other state, there is the IGST. In your industry, what I find [from the shared questions] is that people have apprehensions about pure services versus pure supply and what is taxable and what is not. We will take up those questions in today’s session. The second area is the reverse charge mechanism (RCM). To those who are not used to the concept, RCM was used round about 2005. The actual issue was that [the transportation industry representatives] said that they are not were adept at keeping books and recordkeeping, so they requested the tax burden to be passed on to the receiver. So that is how the reverse charge

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GST Special | SUPPLY CHAIN mechanism came into being. I thank the organizers of the event to have invited us all and look forward to our interaction.” Road Transportation Cost Could Be Lowered by 15-70% Prahlad Tanwar, Director - Transport & Logistics, KPMG India, in his Keynote Address titled

‘GST’s Impact On Logistics and Supply Chain in India’ said: We as supply chain professionals had been awaiting GST for over half a decade. I’ve to admit that over the last couple of years I had stopped going to events to talk about GST because it became a repetitive process [of talking about the same things]. Now that GST is finally here, we can talk about its real impact. Today I am going to talk about transportation because I believe it will be impacted by GST the most and I am going to highlight some numbers and simulations that highlight that aspect. Let’s take a quick look at pre-GST and post-GST paradigms. Pre-GST, the tax regime discouraged interstate trade, which is encouraged post-GST. Pre-GST, we had different taxes and levies such as excise, VAT, CST on sales, and Service Tax provisions; now we have a tax on “Supplies” where the scope of the term “supply” is wide which includes barter, stock transfer, etc. Pre-GST we had a limited credit regime and now we have a liberal credit regime with limited restrictions. Over the last 5-6 years there were four fundamental questions that we have been constantly asked. The first one is, of course, how can my supply chain be effective and compliant post-GST. As Indians we are very cost conscious and every time you look at the publications we see articles on how GST is going to save costs – it is one of the things we will talk about today. Third is how my supply chain can be remodelled for efficiencies. This is where networking ‘solutioning’ has come into vogue, things like how you can reduce your warehouses from 50 to 32 using geo-code and various supply chain modelling tools. The fourth question is, what is the supply chain operating model with which to realize these opportunities. The template that we use when we are called in to do supply chain remodelling activities comprises six different quadrants. One is your network. This is where we see how it has grown organically and how you can reassess your supply chain. The second one, something that has grown in significance over the years is inventory management– the working capital and related aspects are becoming extremely relevant because of increased volumes of goods transported in India and in terms of exports and imports. Third is procurement – which is my pet subject. I think that that biggest change for supply

GST Commissioner (W) with his team fielding industries queries.

chain managers is going to come from this area. With GST, the biggest challenge is how companies will restructure their contracts for supply chain activities. You may want to work with fewer 3PL players pan India – the challenge is going to be how you structure these RFQs. What are the services you want to outsource, what are the SLAs and KPIs you want around that and as importantly, how do you validate the capabilities of your 3PL. Our view is that in the next 16-18 months, the biggest value in capturing value from a supply chain perspective is how well companies manage procurement of logistics contracts. S&OP planning is the fourth area where all planning processes need to be synced to the new network design. Then we have Geographies and People in terms of alignment of planning, sales and operations to sync up to new network. And lastly we Channel Management where margins and service costs need to be revisited. Road Transportation: Cost Saving Opportunities The first thing you consider when you look at GST is, where is the money being spent in supply chain. According to some of our latest research reports, the total revenue in India for the transport and logistics sector was about $130 billion as of FY16. The biggest spend on logistics is on movement – about 60 to 65 percent. Warehousing is about 23-25 percent. Freight forwarding is 6-7 percent which is more for the EXIM leg, and the value-added services is 7 percent. To give you a context, spend on logistics in any developed part of the world is always less than 50 percent; and value-added services is 20-25 percent. These are the areas where you are going to see a lot of focus in India in the next 10-15 years. It’s important to dwell a bit on transportation

Picture: ASCW

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GST Special | SUPPLY CHAIN

[L-R] Elizabeth Alankara (Moderator), Hemant Sood, Girish Pai, Lt Col Vijay Nair, Laxmana Murthy, Anil Sathe. Picture: ASCW

because the last several years, the emphasis has mostly been on warehousing and rationalising and improving the size and sophistication of warehouses. To give you some context -- you know that in India there is significant modal skew towards Road. Freight movement through Rail is about 32 percent. Fifty years ago, the share of rail in freight movement was 89 percent. If you want to have a robust and efficient economy you have to ensure that Road’s share is less than 50 percent in terms of safety, cost, and of course environmental impact. In India, road offers the path of least resistance. The total road length in India is about 5.5 million km which makes it the second largest road network in the world. The total length of national highways in 2011 was just 71,000 km. In 2016 it increased to 1 lakh km which is only about 2 percent of the total road network in India. The CAGR growth in this time period is very impressive therefore clearly the govt over the last 5-6 years has been cognizant of the fact that we need to develop the highways infrastructure. The length of state highways has increased by only about 0.5 percent in the last 5-6 years. The total capacity [maximum rate of traffic flow] of state highways is about 3 percent – this is glaring because of this 5.5 million km of roads, less than half is paved. Forty percent of all freight in India is moved through only 2 percent of the road network. That is a big challenge. If you look at the growth of commercial traffic including one-ton trucks to 32 tonners, you will find that the total vehicle production and sales has been three times of the development of road networks in India. The good news is that the govt’s earmarked spend has significant increased – from FY 12 the spend has been increasing at a CAGR of 17. Now here is something interesting. According to a [KPMG] research, you will find that the amount of

time that a truck spends in moving on the road is 60-65 percent where check-posts take 20 percent -some states like Maharashtra are better in this aspect than others whereas in states such as Jharkhand and Bihar, there is a significant wastage in the amount of time trucks spend at checkposts of which 5-7 percent is at toll points. The average delay [countrywide] at a check-post ranges from 80 minutes to about 220 minutes for any truck anywhere, reducing asset utilisation and increasing costs. In one day, a truck in India covers approx 200250 km. In a developed economy such as the US or Japan, a truck on an average covers 550 to 600 km. The average speed is 30 to 35 km per hour in India whereas in developed countries it is 60-67 kmph. Now let’s look at how this scenario can change in India post-GST. In the pre-GST scenario, a large company had a central warehouse and then it had a state warehouses. In the post-GST scenario there will be a mother DC, and you will have a strategically located large warehouse, of the size of, say, 1 lakh – 1.5 lakh sq feet. Which means your primary transportation hauls will increase and so will your truckload sizes. You can find the real value of GST here. If you move one-ton truck for a distance of 200 km in a day, the average spend per ton per km is Rs 16. But if you move the same material in a 32 tonner for 200 km, the average spend in Rs 2. Which means there is an exponential benefit of using a larger truck. Further, as your distances will mostly likely increase post-GST because you are shutting down smaller warehouses, you are going to see a significant drop in how much you spend for the same goods. So much against the popular belief, even though the transportation rates will go up, the cost of use will significantly come down. And you will see the real multiplier effect when you won’t just increase your distance, you will also increase the size of trucks. In India, it is estimated that there are a little over a million registered trucks. A majority of those trucks are sub-optimal in terms of size. Because of GST and restructuring of warehousing networks, we are going to see an uptick in larger trucks, and the benefits in road transportation unit costs as one moves up the truck capacity chain could be as much as big as whopping 70 percent. This is where you will see the real value of GST. Warehousing: A Contrarian View I must also do a critical analysis of warehousing with a contrarian view of the theory that exists on warehousing. We outlined four industry verticals, and have evaluated the average size of warehouses for each one of these subsectors. There are two schools of thought – a centralised warehousing approach or a distributor warehousing approach. Keeping in

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mind that GST has been on the horizon for more than 2 decades, companies had already started to migrate to GST-ready warehousing network. Therefore our view is that post-GST the overall impact on warehousing is going to be modest – that we won’t see a major restructuring now. From an implementation perspective, make sure that, whether you are a supply chain manager or a 3PL, make sure that you are using larger trucks. In fact that is already happening as I speak – we see a significant uptick in demand for HCV. ‘Automation Players — Now Is The Time’ The Welcome Address was followed by a CSCO Panel that was premised on Supply Chain Cost Efficiency & Performance Improvement With GST Panellists included Lt Col. Vijay Nair, VP Logistics, Reliance Digital Retail; Laxmana Murthy, VP Group India Logistics, Legrand; Hemant Sood, Value Chain Head, Raymond FMCG; Girish Pai, Director, Natural Ice Creams, and Anil Sathe, Former Sr GM Supply Chain Blue Star. Elizabeth Alankara, Principal Consultant, PwC moderated the discussion. Panel highlights contain trends and forecasts that can help you negotiate the post-GST world with better clarity. Presenting, excerpts: Elizabeth Alankara [Moderator]: What has been happening on the ground in your supply chain in the run up to the GST implementation and post-GST? Laxmana Murthy: I represent the electrical switch gear industry. In terms of preparation our company along with most of the suppliers and had started to work since a long time on transition to GST – therefore we had in a minimum blackout period. For us, nationally all the manufacturing points are aligned. One of the challenges I see is that you get different opinions and interpretations from different consultants that make things complicated. The big concern is that stockists and trading community across India – most of them are still not ready. We have seen across India a huge reduction in inventory to the tune of 30-40 percent. We expected a postGST spurt in sales but that has not happened so far. They would like to normalise in one or two cycles as we begin to see the return credits, etc. The business volumes have been impacted in the short run. The good thing is that the govt has been responsive both post and pre-GST. And imports exports have been simplified. Lt Col. Vijay Nair: The industry had enough time for preparation. That said, there are always that last-minute rush. f you see, most of the GST-related activity – registrations, etc. – happened during the period between the last week of April to the 31st of

Shri Sandeep Puri Commissioner (West), CGST, Mumbai, delivering welcome address

May. The smaller vendors were in doubt and had not had taken the step of registering. Perhaps industry bodies could have played a better role. However, I think a great thing that has happened was that in one month’s time most of them got registered. As regards to the operational aspects, we have been able to transform our network design and have seen our average transportation distance actually came down by about 200 km. In summary, the transportation cost may have gone up, but the reaction time to market has certainly improved. Girish Pai: As a manufacturer, GST has made us more disciplined. Post-GST, our accounts department told us that you need to have your GST number whenever you check into a hotel room. That you even have to have food in a restaurant which is GST-registered [laughter]. I am seeing that GST is entering in all the pages of our balance sheet. Hemant Sood: We started to work on GST preparedness since the last one year and we were ready by May this year. In fact internally we had put together a team comprising of taxation, supply chain and procurement experts which helped in preparedness. The biggest challenge that we have faced is the registration of vendors. The last leg of vendors has still not registered by and large. Must of the vendors started registering in the last week of June which was worrying time for the organisation, however most of them got compliant in the last week, as a result of which we also had a short blackout period which went smoothly. Externally though, we saw a big VUCA world. Most of the retailers in modern trade began to destock and also brought down days of inventory significantly, which has had an impact on the supply chain and production. We had to quickly realign with the demand.

Picture: ASCW

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GST Special | SUPPLY CHAIN Early this year, the industry saw a production slowdown to readjust to the whole new demand pattern, which was the biggest challenge. We are entering the luxury segment and our tax structure has gone up from 14 to 28 percent so half of the profit was wiped out – which has had a high impact on some of the companies. The biggest advantage we have seen is in terms of the costing. Now it’s simple, you have COGS and there is a simple rate [of tax] and you are done. Currently, FMCG industry is still adjusting to a revised demand especially from the modern trade. Most of the general trade retailers are still apprehensive of holding high inventory because they have an impression that they will have to register and all their turnover will be accounted for which they have to pay taxes. Therefore some of them were destocking which is impacting FMCG a lot. For an industry that has been growing by 6 percent annually, perhaps in this quarter I’d say that the growth will be sluggish. Anil Sathe: The biggest challenge that I see is that tax exemptions to industrially-underdeveloped areas will be gone. Manufacturers and supplier in areas like Baddi (HP) are still confused about their tax compliance. Imports have been relatively smoother – but the rest of the supply chain network is taking time so it is early to see the impact. Elizabeth Alankara: How do you see a change in the manufacturing footprint in the post-GST world? Is your industry see a shift of manufacturing bases to locations which may promise better quality, lower cost of manufacturing or labour? Hemant Sood: A lot of manufacturing in FMCG and pharma is located in excise benefit zones such as Jammu, Guwahati and parts of Uttaranchal.

GST Officials Engage With Industry Reps in a First GST Officials interacted with supply chain industry representatives assured them continued support in dealing with GST-related challenges Shri Sandeep Puri Commissioner (West), CGST, Mumbai said that once taxpayers understand the basic concept of GST, they can figure out the answers to most questions themselves. The intention of the govt is – you pay your tax and you take credit for the taxes you have paid. In the earlier tax regime, a lot of people were going out of or going under the ambit, but here is an opportunity to pay the tax and take credit and that’s the theme behind it. The guiding principle is that GST works in the furtherance of your business. Mr Jaishankar Upadhyay, a senior GST official, and a member of Mr Puri’s team said that the GST officials are accessible 24/7 to address GST-related issues. “We run our GST Seva Kendra in our offices. And after office hours you can reach us through our email ID [helpdesk@ gst.gov.in], facebook [https://www.facebook.com/gstsystemsindia/], and Twitter [https://twitter.com/askGST_GoI].

In my earlier assignment I saw that 60 percent of manufacturing was done in Guwahati – so we were sending stocks all the way from Guwahati to Delhi and Mumbai, still we had good benefits. Such a type of manufacturing footprint will continue till the sunset of the excise happens. In that regard, manufacturers need clarity from the government. If the Excise-benefit changes, then we will see a definite disruption in the current manufacturing footprint where it will move closer to the demand centres. And then you will see revaluation of suppliers and contract manufacturers. Geographically speaking, most of the demand comes from the Western and Northern parts of India and you may see more manufacturing moving closer to that part of India. Elizabeth Alankara: Col Nair, Would you be able to through some light on how do you manage consolidated warehouses in your industry? What are the key requirements from a capability point of view in terms of people skills, technologies, etc.? Lt Col. Vijay Nair: Earlierthere was a compulsion that we maintain a warehouse in every state. Now that compulsion is no longer present. Earlier, we could not get into big-ticket automation, which is now going to be possible. Since the GST was always on the cards, we had started to work on moving distribution centres closer to the markets – we have not yet implemented the entire network plan but what we see is that we are going to go for larger warehouses -- we are going to go for large-scale automation. This is certainly going to augment accuracy and the speed of operations. When earlier, large service providers – the MNCs – used to come they used to talk about big things that could never be implemented. I think now is the time. Now with the scales that are come in with large warehouses, automation is a possibility, especially in grocer retail where FMCG’s numbers are very big. From one single warehouse from where destruction will be possible to all the points, automation will be a big driver of that transition. Robotics and even pickto-light, aisle technologies will all come in now. Hemant Sood: I also see the warehousing numbers will go down perhaps by 20-30 percent. This will be governed by two things; one is the proximity to the demand centres, and two, infrastructure. With improvement in infrastructure, I can further reduce my warehouse footprint by 40 percent. Some FMCG companies have reduced the number of warehouses by about 50 percent. This will tend to create new transportation line-hauls. India’s busiest line is DelhiMumbai, which could, as an example, change to Delhi-Hosur. And these kinds of adjustments will happen in the next 12-18 months. Elizabeth Alankara: There are certain industries that talk about postponement strategies where

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you’d locate smaller hubs closer to demand centres. There are certain other industries that are today questioning the very need of warehousing. This is typically the feedback when we speak to CFOs who are constantly at loggerheads with supply chain departments to understand why do we even need a warehouse – can’t we ship directly to manufacturing? Mr Murthy, could you throw some light on why warehouses would not go away and is there a possibility of every looking at shipping directly from manufacturing? Laxmana Murthy: We have a mix of all types that you are mentioning – we have manufacturing units across India starting from South to the Hilly regions in the North. I don’t see an immediate change in the manufacturing strategy. We also have manufacturing units at all excise free zones. From our industry’s perspective – warehousing is going to stay. We have two types of product categories – one of them is custom-made – we have already shifted these production point closer to demand centres. Another after-effect of GST that I want to point out is that we will see a relocation of job opportunities. With relocation of warehouses, we will need more skilled human resources at the new places. The real saving in supply chain, I believe, will come from consolidation in transportation -- when you move from multiple level of transportation to direct line. Two, it will significantly improve my service levels. Three the inventory is going to decrease with the decrease in the number of warehouses. Girish Pai: In our case, we sell ice-cream which is a perishable good, so we don’t require warehouses. We only need them for the [inbound] semi-finished product, raw material and packaging material. For example, we have a signature flavour of tender coconut – the pulp is produced in Mangalore, the packing material is in Gurgaon. Now we are planning warehouses only for the packing material and the semi-finished products in Taloja or somewhere else – though the [Gurgaon] warehouse will exist. Elizabeth Alankara: What are your key asks from the 3PL players – for example, do you prefer assetheavy or asset-light 3PLs? Hemant Sood: If I have a choice, I would lean towards asset-heavy service provider because of better predictability, higher service levels, and more cost benefits. Lt Col. Nair: An asset-heavy 3PL would be preferred because your cash flow is reduced. But from my experience I’ve seen that even an asset heavy provider will not have all his resources deployed to your satisfaction – at times you may find that he may have deployed someone else’s asset for you. So we haven’t seen any significant service improvement when using asset-heavy 3Pls – we have got both asset heavy providers and we have very lean service providers.

Prahlad Tanwar, Director - Transport & Logistics, KPMG India

Elizabeth Alankara: We have seen the emergence of multi-customer sites where there are 2 lakh3 lakh sq ft facilities. And there are talks of up to a million sq feet of warehousing the likes of which you see in the West. These warehouses are shared by customers from different industries, with the benefit of managing peaks and extra buffer space to expand. Would you be comfortable using multicustomer sites? Laxmana Murthy: Ofcourse, as a policy, I will always prefer a multi-client service provider – that’s where there will be a compensating effect – managing demand flux is one of our huge challenges where we see up to 17 percent of our sales during one month. Warehousing service providers should always be able to ramp up at a short notice as you see in places like Singapore. Lt Col. Nair: It varies from one industry to another. In retail, we will definitely want an exclusive facility. But I agree with Mr Murthy – in our industry’s scenario where the growth is absolutely unpredictable, it is very difficult for a 3PL to decide the capacity of a warehouse. But when you enter into a contract – the person who is managing the facility will have the responsibility of looking for additional space. What GST will do is perhaps encourage some big players to enter into this business – then we will have larger warehouses. Today, I don’t think a 3PL singularly holds more than a 2 lakh or 3 lakh sq ft warehouse. Companies like Amazon or large FMCG companies own [or operate on lease] large warehouse up to the size of 7 lakh ft. But you will very rarely see a 3PL managing a large facility independently where he is renting out space to multiple customers. That said, we are primed for this kind of stage and that’s where costs will come down especially for companies that see fluctuating demands.

Picture: ASCW

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Industry News | EVENTS & PROMOTIONS

Hainbuch Maxxos T211:

the hexagonal, superstrong mandrel

211 is a mandrel with hexagonal pyramid shape instead of a round taper, designed with stringent manufacturing requirements and process reliability in mind. Hainbuch has acted in response to demand from specific areas that has been growing year by year. Users are requesting mandrels that deliver higher performance as well as process reliability. The result is called Maxxos. It exceeds even the specified customer requirements and more than this, offers all the advantages of a hexagonal clamping mechanism. The segmented clamping bushing with hexagon inside shape fits perfectly onto the clamping pyramid and enables maximum cutting performance. The lubrication, combined with its tightness ensures a very constant production flow and as a result, achieves maximum reliability. Customers that value process reliability and maximum torque transmission will be delighted with the MaxxosT211.

virtually any dirt getting onto the surfaces. This significantly cuts down the frequency of maintenance times for cleaning and lubrication. Overall, the mandrel has a clamping diameter range of 18 to 100 mm. The clamping areas of each size are designed to overlap. This has the advantage that users can choose from up to three mandrel sizes depending on the clamping diameter. The larger the mandrel is, the greater its stability and rigidity. Smaller mandrels may be able to handle more of the customers smaller workpieces. Users are free to choose the size they want, based on their own judgement and preferences. The aligned, segmented clamping bushings have a minimum concentricity of 0.01 mm and can even be supplied in a high precision version.

Key advantages of T211: I.D. clamping mandrel for

clamping diameters of 18 to 100 mm

Ideal for stringent

manufacturing demands and process reliability

Unique rigidity due to spacious layout of the clamping segments

High transmissible torque and holding forces

Contamination resistant

due to hexagonal pyramid shape

Concentricity < 0.01 mm You can visit Hainbuch will at the EMO 2017 in Hall 3. Booth C72.

also available in high precision version

The Best for Heavy I.D. Clamping

Thanks to the hexagonal pyramid clamp, maximum torque transmission can be achieved. Up to 155 percent more transmissible torque and up to 57 percent higher bending stiffness compared to the classic Mando T211 mandrel. This makes it possible to achieve higher process parameters and consequently improve the yield of finished parts. Greater process reliability is facilitated by the spacious layout between the clamping bushing and the clamping pyramid. Even during the clamping process, this design prevents

Picture: Hainbuch

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Industry News | EVENTS & PROMOTIONS

Danobat showcases focus on digitalisation at EMO

ith an aim to promote its stake in the development of innovative manufacturing solutions and digital value proposition, Danobat, the Spanish machine tool and production systems manufacturer, will have a strong representation at the coming edition of the EMO fair in Hannover. At the event, the company will launch three completely new developments, present its range of redesigned machines for maximum-precision grinding and turning, and will publicise its value-added service offerings. EMO Hannover, one of the most important

fairs for the industrial manufacturing sector in Europe, will serve as the showcase for the company, thatâ&#x20AC;&#x2122;d display in Hall 11, stand C45, solutions designed for carrying out highproductivity grinding and turning processes of great technical complexity. In addition, the company will use this opportunity to share its digital value proposition, comprising in-house technological developments based on industry 4.0 concepts with an aim to advancing the creation of intelligent manufacturing spaces, fitted with interconnected equipment and capable of autonomous operations.

DANOBAT Showcase Expert Solutions

Maximum rigidity

centreless grinding machine, ESTARTA-650 Vertical grinding of medium-sized pieces, VG-800

Internal grinding machine for workpieces of great length, ILD-600 Redesigned machines which carry out high productivity grinding and turning processes, viz: High precision hard turning machine, LT-400 A grinding solution for non-cylindrical shapes and radii, IRD-400 A horizontal development for large workpieces, HG-72 An ultra-precision grinding machine, LG-1000 Digital Solutions Smart HMI: An intuitive interface aiding the operator and facilitating the use of the machinery, thus raising productivity. Data System: A platform for capturing, storing and processing data about the status of the machine Control System: Enables the control, monitoring and supervision of data in high complexity manufacturing lines.

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Technology | SOFTWARE

This graphic depicts the ball end milll vs. circle segment cusp height. Picture: Mastercam

Onward to Better Mold Finishes Advanced cutting tools and complementary CAM toolpaths aim to do for finishing what they have already done for roughing

ithin this decade advanced carbide cutting tools used with constant chipload CNC cutting strategies have dramatically increased material removal rates for roughing of mold cores and cavities. Users report roughing cycle-time savings of 25% to 50% or

more vs. conventional cutting strategies, while achieving dimensions closer to near net shape after roughing for a more favorable impact on subsequent finishing operations. As impressive as these roughing approaches have been, these strategies are rarely used for finishing cycles, which account for the bulk of the machining time required for most mold cores and cavities. More

Jesse Trinque CNC Software, Inc. Tolland, CT

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than anything else, reducing the time it takes to get a core and cavity feature down to the desired surface finish levels will significantly reduce CNC manufacturing costs for molds. For some time, cutting tool manufacturers and CAM vendors have been working together to dramatically reduce machine cycle times when using solid carbide tools for roughing. Now these partnerships are expanding into finish passes where automated CAM toolpaths are driving innovative cutting tool geometry and vise versa. One such example is the support of the new circle segment cutting tools found in Mastercam’sfinish toolpaths. In many cases, this new tool support can dramatically reduce finish cycle times verses the use of more traditional ball endmills.Where these tools and automated cutting strategies can be applied, cycle time reductions ranging from 50% to better than 80% are being achieved routinely and with superior surface finishes. Tool Geometry Makes It Possible

Ball endmills have been the go-to cutting tool for surface finishing for decades. They are easy to program and they can have good reach into tight areas of the part. However, for parts that require a great deal of surfacing, ball endmills are part of the problem rather than the solution when targeting better surface quality along with reduction in machine cycle times.

This steering wheel mold and its manufacturer are benefiting from new circle segment tools and sophisticated dynamic finishing CAM toolpaths. Picture: CNC Software/ Mastercam

Ball endmills must be used with very small stepovers to reduce the size of cusps in the material. To compensate for this staircase effect and achieve the desired surface finish, a proportionally small stepover or stepdown, e.g. typically 3-5% of the tool’s diameter) must be used. This improves the surface finish, but it reduces the amount of surface area engaged by the tool. Thus, the tool must take many passes to achieve the desired finish. The massive number of passes required to finish a part with a ball endmill accounts for why so much time is invested in finishing vs. roughing of cores and cavities. Circle segment cutting tools are designed to allow a small diameter tool to have a large effective cutting radius— many times greater than that allowed by the ball endmill. This design reduces the number of finish passes and the depth of the cusps in the material for a substantially better surface finish while achieving shorter cycle times. The larger cutting radii of these tools (up to 187 times the cutting tools actual diameter) allow extended engagement of the tools with the material and reduce the number of stepdowns required to finish the part. For example, if it takes 30 passes for a ball endmill to finish a set of surfaces, it may take the circle segment tool six passes to do the same work and do it better. In this example, the 80% reduction in the number of passes would translate into a comparable reduction in cycle time for that surface. Software Makes It Work

Over the past two years four different circle segment tool shapes have come to market: Barrel-Shape Oval Form Taper Form Lens Shape Each of these shapes is effective for machining specific types of surface geometries. These surfaces can be straight or have minor undulations and draft angles up to 7°. The tools may be used with3-axis CNC machines, but great care must be taken in defining tool planes to assure accurate finishing results and to ensure the tool is contacting the part in a proper manner. Far better machine cycles are obtained with multiaxis equipment, particularly machines capable of continuous 5-axis machining. When utilizing a machine capable of 3+2 indexing, the ability to apply circle segment tooling vastly improves. Moving to a machine capable of continuous 5-axis machining and the applications for

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applying this technology broadens even further. Fast, responsive controllers with advanced features like high-speed look-ahead are also advantageous. Then there is the CAM software. To take advantage of these tools the programmer/machinist must generate sophisticated programsthat continuously present the tool at a precise angle that is dependent on the slope of surface to be finished and the shape of the tool at any given point in the program. The massive amount of code required to create this type of toolpath makes it impractical, if not impossible, to write these programs manually. To refine this advanced finishing strategy, the circle segment tools and CAM software need to work in sync to coordinate tool definitions and toolpath behaviors, particularly in the 3 + 2 and simultaneous 5-axis machining modes. Better tool library support for these tools was introduced in Mastercam 2017 and the libraries themselves are also compatible with version X9. Circle segment tools can be used within both 3and 5- axis finishing toolpaths that the users are already familiar with. The programmer needs only to load the tool definition into the software from downloadable libraries. Then the machining operation applies

the appropriate tool compensation for ultrahigh efficiency finishing. Proficient multi-axis programmers can also fine-tune parameters to make a good finishing toolpath even more efficient for specific surface requirements. Manufacturing Laboratory Evaluations

During the evaluation process, toolpaths for high-efficiency finishing were tested extensively in the Mastercam Manufacturing Lab. Testing involved cutting an otherworldly, ten-surface demo part designed to provide at least two realistic applications for comparing the performance of each of the four circle segment tool shapes with that of a ball endmill. (See figure 1). It took the ball endmill 100 minutes and 34 seconds to machine all the surfaces in succession. Circle segment tools accomplished the same work in 30 minutes and 34 seconds. This represents an aggregate cycle time reduction of 70%. In all instances, surface finish was demonstrably better. Assessing the Opportunity

What does all this mean to the individual moldmaker? First, it is certainly not time to throw away your ball endmills. There are many surfacing

Circle segment tools and associated toolpaths constitute an emerging technology with much potential for reducing manufacturing costs and lead times for mold makers. Picture: Emuge Corp

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applications where they are still necessary. On the other hand, for some parts and features dramatic finishing cycle reductions achieved with circle segment tools may be able to subtract numerous hours of CNC machining time from the types of cores and cavities you currently machine. Better finishes also lower costs by reducing manual polishing requirements. The evaluation of this new finishing strategy is easier if you already have multi-axis equipment and the CAM software. It is a simple matter to select circle segment tools and insert them into a program you have already run and adjust stepover/

stepdown to achieve a cusp height similar to the one produced by the old ball toolpath. (Minimal changes will also be required to obtain proper tool plane and tool axis control). Then simulate the program with feeds and speeds identical to the ones used previously for the ball endmill. This simple test of time comparisons is likely to be a real eye opener for many mold makers. Circle segment tools and associated toolpaths constitute an emerging technology with so much potential for reducing manufacturing costs and lead times that mold makers cannot afford to overlook them.

A Specialist for Hot Surroundings Infrared temperature sensor with IO-Link from Balluff

he sensor specialist Balluff has developed a new BTS infrared temperature sensor with IO-Link interface and two switching outputs. It can monitor temperatures between 250 and 1250 Â°C even in inaccessible or hazardous areas, detect hot objects in motion and record temperature values - all without contact. This pyrometer in the rugged M30 stainless steel housing with IP67 protection is the first in this form factor to offer a multi-function display with plain text information and automatic display orientation like with a smartphone. In addition to two switching outputs this pyrometer provides an IO-Link interface for remote parameter setting and direct data exchange with the controller or control panel. An analog 4...20 mA output is available as an option. A variety of setting possibilities and functions open up a wide range of applications for the user. Steelworks, foundries, forging, the ceramics industry and glassworks are perfect examples of applications.

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Showcase | EMO HANNOVER 2017

EMAG at EMO Hannover 2017

In the new VL machines for the machining of chucked parts, powerful water-cooled motor spindles with up to 32.4 kW power (at 40% duty cycle) ensure high productivit. Picture: EMAG

Focusing on electric drive systems and the “smart factory”

lectro-mobility and Industry 4.0 – these industrial megatrends will be featured prominently in the EMAG Group booth at the EMO in Hanover from September 18 to 23. EMAG machine manufacturers will showcase their role as ‘facilitators’ of technological change. For example, they will demonstrate complete solutions available for the efficient production of central components of electric drive systems. Exhibition visitors will see several highperformance machines in operation – including world-firsts in the areas of turning operation, laser welding, joining and gear cutting. On its part, the EMAG Group is also accelerating the digitalization of its production technology to establish intelligent factories. The EMO has a dedicated area where customers can test essential Industry 4.0 solutions. The main focus will be on the consistent usability of the software, which continues

to simplify the control, monitoring and analysis of production. The company’s aim to enable a controlled, predictable and monitored production process from start to finish – summarized the message of the EMAG Industry 4.0 presence at the EMO. The manufacturing data of the machines offer many options for perfecting central processes with custom-fit software tools: “MultiMachineMonitor”, for example, enables the control of different machines from a central location by tablet or PC, and fine-tuning of the production process. The “EC Data” software guarantees the traceability of the production process of a workpiece at any time. “MachineStatus” provides a detailed analysis of the machine and the tools during operation. “At the EMO, we will present even more solutions that demonstrate the effectiveness of these combined approaches,” says Rainer Seitz, head of software development & IoT at EMAG. “Standardizing these tools is a high priority for us. We want customers to understand the modules quickly and effortlessly. The main focus of our presentation will be on the simplification of usability.” Promoting E-revolution in Production

The second focus at the EMO also points to the future of industry because EMAG solutions enable the efficient production of many components for hybrid or purely electric drive systems – from rotors and complex differentials to new types of transmission shafts. This process covers the raw part all the way up to the final precision machining. The wide range of technology available within the Group makes this all possible – and their broad range is demonstrated by the machines that EMAG is displaying at the show. For example, the enhanced dual-spindle VL3 DUO vertical turning center is a highly productive solution for gear and engine components up to 150 millimeters in diameter. It only requires a minimum installation space of 24.5 square meters – including the automation system ‘TrackMotion’, chip conveyor and parts storage. Increased productivity is provided by two entirely separate machining areas with

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and endurance precision are significantly higher than industry average. “It’s important to us that the VLC 50 TWIN can be easily interlinked with EMAG hobbing or deburring machines, with the TrackMotion system, for example,” explains Björn Svatek, Sales & Marketing Director, Modular Solutions at EMAG. “With this we can create efficient multi-technology production lines for the complete machining of gears with low non-productive times and high process reliability.” New Degree of Flexibility

The goal of EMAG Industry 4.0 products is a controlled, predictable and monitored production process from start to finish. Picture: EMAG

The world-first ELC 160 HP is the ideal solution for the efficient processing of continually changing batches in the production of gear components.

powerful water-cooled motor spindles up to 32.4 kW power (at 40% duty cycle) and 12-post tool turrets. The matching TrackMotion automation system not only ensures the rapid transportation of parts between the two machining areas, but also flips the parts over between OP 10 and OP 20. The results of this process are a minimization of cycle times, and a significant decrease in unit costs. At the same time, direct distance measuring systems and re-circulating roller guide rails in all linear axes ensure precision and consistent workpiece qualities. Of similar interest is the world premiere of the VLC 50 TWIN turning center for gear components with a diameter of up to 75 millimeters. It has two main spindles in one machining area that are able to process two identical workpieces simultaneously. This results in a massive increase of output quantities and lower unit costs. The diameter and length of the two workpieces can be adjusted independently by the two spindles. This machine equally has direct distance measuring systems and re-circulating roller guide rails. In addition, EMAG uses an innovative linear motor in the X-axis. Its dynamics, repetitive precision

Another global first is the introduction of the ELC 160 HP production solution. This machine is used especially for processing the control gear and clutch body, and combines several process steps into a perfectly timed system viz. joining (press fitting) of the clutch body, induction pre-heating (if required by the material) and connecting the components with a laser beam. Cycle times in some instances are less than 10 seconds because the processes run parallel in four different stations. Furthermore, the ELC 160 HP allows automatic retooling of the fixtures for different gear stages. Due to this feature, the complete set of wheels for a gear can be produced in a one-piece flow, without retooling. “Manufacturers of dual-clutch transmissions or hybrid systems, for examples, are very interested in this technology because the increasing number of gear stages requires new solutions for efficient processing of continually changing batches,” says Dr. Andreas Mootz, Managing Director of EMAG Automation. “This is exactly what we offer with the ELC 160 HP.” In Hall 17, Booth C31, EMAG will demonstrate the entire range of its technological approach: Without exception, these are highly productive and flexible production solutions that can be easily combined into production lines according to demand, and only take up a small space. Setting up new production solutions – for example, for the growing number of electric drive systems – is thus being significantly simplified.

Picture: EMAG

VLC 50 TWIN has two main spindles in one machining area to process two identical workpieces (up to 75 mm in diameter) simultaneously. Picture: EMAG

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Industry News | EVENTS

[Left to Right]: Lighting of Lamp - Mr. Ulrich Ackermann, Managing Director, Foreign Trade division, VDMA Frankfurt , Shri R.V. Deshpande, Honourable Minister for Large & Medium Industries & Infrastructure Development, Government of Karnataka, Mrs. Margit Hellwig-Boette, Consul General, Federal Republic of Germany, Bangalore, Mr. Rajesh Nath, Managing Director, VDMA India.

VDMA Organizes th 6 Mechanical Engineering Summit in Bengaluru India’s Significance for VDMA India is the third-largest sales market in Asia for the German Engineering industry. Presently more than 550 VDMA member companies are engaged with their own business in the Indian market. The Indian office of the German Engineering Federation (VDMA) acts a ‘bridge-head’ between the German and Indian Industry and serves the Indo-German economic relations in the different engineering sectors. The office in Kolkata with regional offices in Mumbai, NCR and a new office in Bangalore promote the activities of the VDMA member companies in India.

[Left to Right]: Release of Special Issue Commemorating 125 years of VDMA - Mr. Ulrich Ackermann, Managing Director, Foreign Trade division, VDMA Frankfurt , Mrs. Margit Hellwig-Boette, Consul General, Federal Republic of Germany, Bangalore, Shri R.V. Deshpande, Honourable Minister for Large & Medium Industries & Infrastructure Development, Government of Karnataka, , Mr. Rajesh Nath, Managing Director, VDMA India

In 2016, the trade between India and Germany grew by 0.7% to €17.42 billion from a figure of nearly €17.29 billion in 2015. Indian imports from Germany experienced a marginal growth of 0.5% over the previous year and amounted to € 9.8 billion. The exports from India to Germany attained a value of € 7.62 billion in 2016. This was an increase of 1% as compared to the year 2015. In 2016, the total import of machinery from Germany reached a volume of € 2.97 billion. This was an increase by 2% compared with the same period of time in the previous year.

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[Left to Right]: Panel Discussion - Mr. Rajesh Mishra, Managing Director, Vulkan Technologies, Mr. Marc Jarrault, Managing Director, Lapp India, Mr. Georg Graf, CEO, Freudenberg Regional Corporate Centre, Mr. Sunil K Gupta, CEO & Managing Director, KION India, Mr. Nitin Vyas, Managing Director, Beumer India, Mr. Rajesh Nath, Managing Director, VDMA India.

he German Engineering Federation (VDMA) organised the 6th VDMA Mechanical Engineering Summit on Friday, 8th September, 2017 at Sheraton Grand Hotel, Bengaluru. VDMA has now been actively promoting knowledge on the benefits of mechanical engineering for 125 years, and with the advent of Industry 4.0, the federation has bigger messages to convey than perhaps at any time in its history. Under the motto “man - machine - progress”, the association addresses important challenges for mankind and the importance of machine and plant construction as a solution provider. VDMA is

a platform that provides its member companies with various networks where they can discuss technological challenges, interdisciplinary issues and many other topics. The 6th Summit was a meeting point for the 500 VDMA member companies in India. Today, the VDMA is the largest industrial association in Europe with around 3,200 member companies, and in Germany alone, machine construction is the largest industrial employer with 1 million employees.

Key Highlights Some of the topics that were covered during the summit were:

Additive Manufacturing -

The Game Changer for the Manufacturing Industry

Digitalization - India Advantage

Business impact of Goods and Services Tax (GST) in the manufacturing industry

Macroeconomic trends and Digitisation

[Left to Right]: Release of VDMA India App - Mr. Ulrich Ackermann, Managing Director, Foreign Trade division, VDMA Frankfurt , Mrs. Margit Hellwig-Boette, Consul General, Federal Republic of Germany, Bangalore, Mr. Rajesh Nath, Managing Director, VDMA India , Shri R.V. Deshpande, Honourable Minister for Large & Medium Industries & Infrastructure Development, Government of Karnataka.

Transparency of key clusters in India

Key sector overview in India

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Industry Report | VDMA

VDMA Business Climate Survey India March – April 2017 The manufacturing sector in March-April this year reported ‘normal’ as well as ‘good’ business climate, says a recently released VDMA industry survey.

DMA recently released for its members the results of a Business Climate Survey it did in Spring this year among 550 top executives of member companies. Presenting, edited excerpts of the survey. The focus of the Indian government as well as the Reserve Bank of India is on maintaining economic and monetary stability and foster the efficiency of the economy through various measures. Reduction of inflation, fiscal deficit, administrative bureaucracy, removal of corruption and black money (as has been seen with demonetisation) and simplification of tax regulations are some of them. Temporarily, these measures have certainly been tempering economic activity. They are, nonetheless, essential in order to enable sustainable growth in the longer run. Especially investment activities, which are currently still very low, are likely to benefit from the measures. A lot more investment is still needed regarding urban infrastructure, traffic ways and transportation systems, as well as overall automation and modernization of the industrial sector. Furthermore, the government must express its will to enhance the meaning of the industrial sector to increase its share in total economic value creation through initiatives like Make in India. Industry Indicators The capital formation growth rose by 2.4% year on year in real terms in the financial year 2016-17 (April 2016 to March 2017) in total. In Q4 (January to March 2017) it decreased by 2.1% For the financial year 2017/18, the panel of

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Current business situation

Current utilization of production/service capaciti

Current business situation

Current utilization of production/service capacities

Percentage share of answers for each option

Percentage share of answers for each option » 47% of the participating

affiliates consider their low current business situation as13% “good”, while 48% of them chose “normal” and 5% “bad”.

bad 5%

high 32% good 47%

professional forecasters which is surveyed bimonthly by the Reserve Bank of India currently expected growth of industrial real value-added by VDMA | India Rep. Office & Dept. of Economic and Statistic Affairs 7.0% (0.9% more than 2016/17). The production index for machinery and equipment rose by 5.5% year-on-year in the financial year 2016/17. In Q4 of the financial year growth was only 1.4%.

VDMA Business Climate Survey India Spring 2017

Number of observations: 154

normal 55%

Source: VDMA Number of observations: 150

Source: VDMA

Representation as balance chart and explanations on balance chart type (1/2) Representation as balance chart and explanations on the balance chart type

Page 8 | June 2017

VDMA | India Rep. Office & Dept. of negative Economicanswers and Statistic Affairs Balance of positive and in percentage points (pp)

» The com

» This exte only

current business situation 42 pp

About the survey current capacity utilization Survey duration: 10 April 2017 - 12 May 2017 19 pp 550 top executives of affiliates of VDMA member companies in India were approached. -20 0 20 40 60 If a member company is active in more than one Number of observations: current business situation: 154, current capacity utilization: 150. mechanical engineering sector, participants were asked to answer for as many of these direction (positive/negative) of a respective sectors as possible. indicator of the business climate rather than Furthermore, participants were asked to the exact distribution of the answer options. provide answers for as many of their companies‘ The balance values in percentage points (pp) in customer industries as possible. the charts are easily derived from the respective 128 participants completed the survey VDMA | India Rep. Office & Dept. of Economic and Statistic Affairs percentage distributions of the answer options (response rate: 23%) as shown in the circle charts. Capacity utilization 154 datasets were prepared concerning ranges from 32 percent to 13 percent. mechanical engineering sectors 222 datasets were prepared concerning Implications derived from the survey customer industries The favourable evaluation of the current business situation is somewhat put into perspective The following results were made available by the results concerning the current capacity to VDMA member companies: utilization. Business climate in India in the Spring of 2017 Here, more than half of the participants stated Figure 1: 47% of the participating affiliates “normal”, whereas the “high” share is 15 percentage consider their current business situation as “good”, points smaller and the “low” share is 8 percentage while 48% of them chose “normal” and 5% “bad”. points larger than the equivalent categories Figure 2: The figure shows utilization of concerning the current business situation. production/service capacities during the period. The prevailing utilization of the respondents’ Reprinted with permission. The article text has production or service capacities is seen as “normal” been edited for brevity. A much more comprehensive by 55%, whereas 32% are operating at high and report is available to all participating companies 13% at low rates of utilization. of the survey. For any questions, please contact Figure 3: The balance charts focus on the rajesh.nath@vdmaindia.org VDMA Business Climate Survey India Spring 2017

VDMA Business Climate Survey India Spring 2017

normal 48%

» The dire resp clim distr 80

100 Source: VDMA

Pictures: VDMA

» Furt clim the the be i dire indic has con cha

Volume 1–Issue 2 S ept/O c t 2 0 1 7

Industry News | GLEASON

Gleason Expands India Presence with New Facility

The expansion affirms Gear solutions leader’s faith in the Indian market

n August 17th and 18th, 2017, Gleason hosted more than 150 customers and business partners for the grand opening of its new 65,000 square foot facility in Aerospace Park, Devanahalli, Bangalore, India. The two day event included a grand opening celebration including a ribbon cutting ceremony and remarks by company executives. This was followed by several product demonstrations among which was the introduction of a new gear finishing cell including a gear hobbing machine and gear shaving machine produced locally by the Gleason India Team. The event concluded with an extensive gear technol-

ogy education program covering a broad range of topics on bevel and cylindrical gear design and manufacturing, gear metrology and the company’s digital manufacturing solutions. Gleason’s first production facility in Bangalore was established in 1996. Since then, Gleason’s presence in India has grown, keeping pace with the country’s remarkable industrial growth. This modern, larger and climate-controlled facility will allow Gleason to provide a wider range of high precision products produced in India for both local and global customers. John J. Perrotti, Gleason President and Chief Executive Officer, said “The investment in this new facility makes an important statement about our belief in the Indian market and its growth potential, but most importantly it is recognition of our confidence in our Gleason Team in India to serve our customers at the highest level.” Products produced at the new Bangalore facility include the Genesis Series Gear Hobbing Machines, the new 200SVP Gear Shaving Machine, remanufacturing of a wide range of Gleason Machines, design and production of certain bevel gear cutting tools and gear shaving cutters as well as sharpening services for bevel and cylindrical gear cutting tools, workholding products and an array of training programs, spare parts, customized service programs and technical support.

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Industry News | GRIND MASTER

Grind Master receives “Aurangabad Best Employer Brand Award”

rind Master recently got the Aurangabad’s Best Employer Brand Award. This Award was hosted by World HRD Congress. Some of the key criteria considered by them included: Combining vision with action with the HR strategy, aligning HR strategy with business strategy, and cultivating competencies for the future to enable building the organization to be future-ready. Mahesh Sahasrabudhe and Sandip Pimple received this Award as Grind Master Employee Engagement Committee Representatives. The company stated that its employee engagement levels are fairly high in keeping with the company’s management philosophy of inclusive growth. Opportunities for vertical growth within Business Units, and horizontal growth enabled by committees and groups motivates team members to excel in performance. There are

Mahesh Sahasrabudhe and Sandip Pimple of Grind Master receiving the award.

intensive training and mentoring programs for everybody with 50 hours per employee per year achieved consistently during the last three years. Further, several initiatives including Sports clubs and CSR activities engage not only employees but also their families, ensuring a vibrant culture for a company which is aspiring to be a global technology leader. Grind Master is an export-oriented company with over 50 percent turnover from exports to countries like China, the USA and the UK. Based in Aurangabad in India, the company has growing business in China which is a major contributor to Grind Master’s global business. Competing with German and Japanese companies in technology, Grind Master has proven its mettle in micro-finishing processes for Crankshafts and Camshafts, accounting for nearly 25 percent of the large market in China for these niche machines.

Volume 1–Issue 2 S ept/O c t 2 0 1 7

Industry News | NORD

It Is Grab-a-wrench Simple Nord delivers drive technology excellence for cooling tunnels and pasteurizers

manufacturer of bespoke machines for the food and beverage industry, US-based mechanical engineering company G.C. Evans has come to appreciate the capable support provided by their drive supplier, Nord Drivesystems. Nord configures reliable, low-maintenance drive units featuring application-specific options. Standstill is a word that smacks of bitter losses to the beverage industry. For drive technology in this sector, high availability and easy maintenance are therefore absolutely essential. David McNamer, manufacturing manager at G.C. Evans Sales & Mfg. Inc., a US-American manufacturer of cooling and heating equipment for the food and beverage industry, explains: “If a beverage pasteurizer were to have a drive failure, you are not only talking about

No bottlenecks in bottle separation – a resilient worm geared motor prevents gridlocks. Picture: NORD

lost product in the unit, but stopping a production line to the tune of potentially hundreds of thousands of dollars per hour. I do not want to worry about our drives and I do not want our customers to either. That is why we choose NORD. In 2008, we decided to give NORD drives a chance, and were in for some very pleasant surprises: Not only were the units less costly than comparable competitors’, but they were really high-quality and well-engineered units. What impressed us the most was the level of service we received from NORD. We are always dealing with a single engineering contact within their company.” Today, NORD drives are used in all G.C. Evans machines. NORD is one of the world’s most experienced gearbox manufacturers with an industry-leading product range featuring variable gear ratios, flexible installation options, and wearfree gearing. NORD configures low-maintenance, sturdy drives for G.C. Evans, implementing application-specific feature options ranging from special gear lubricants to vent plugs that help prevent leakage. Fail-proof and efficient in various machines For two major recent orders, NORD has configured two conveyor drives with very high gear ratios for G.C. Evans. One of these systems, a parallel shaft geared motor, moves 20,000 jam jars, each weighing more than 1 kg, through a cooling tunnel. Its gearbox is configured with a 2,500:1 ratio to achieve an output speed of 0.6 revolutions per minute. This drive system features various special options to meet the hygiene requirements of food processes: a very durable stainless steel finish, a food-grade gear lubricant, a vent plug, and an oil sight glass. The pressure relief vent plug from NORD regulates the air pressure in the gearbox when it heats up and cools down. It prevents the ingress of dust or liquids, which could contaminate the oil and compromise its lubricating properties. This measure enables an extension of the oil change interval. Gaskets, gears, and bearings suffer less wear and tear. Hard-wearing special coating Gear units and motors from NORD are generally

Vo l u m e 1 – Is s u e 2 S ept/O c t 2 0 1 7

The parallel shaft geared motor with an input stage (left) driving the conveyor in the cooling tunnel (right) features a lowmaintenance Gripmaxx bushing. Picture: NORD

designed to withstand harsh environmental conditions. They are effectively sealed against an ingress of moisture and are fitted with corrosionresistant components. The NSD-x3 severe-duty coating, which NORD only offers in the United States, provides extra hard-wearing, long-lasting external corrosion protection for the drives supplied to G.C. Evans. It consists of two primers and a stainless steel (316) saturated silver-gray polyurethane finish. The

A severe-duty coating with four layers of paint ensures scratchresistant corrosion protection. Picture: NORD

solvent-based paint ensures increased durability. Completed by a clear top coat, the coating achieves a very high overall resistance to blows, scratches, heat, moisture, and also to industrial solvents such as lacquer thinner, acetone, gasoline, lubricants, and cutting oils. Sturdy, low-maintenance shaft mounting The second recent project for which NORD supplied a special drive system was a fruit juice pasteurizer with a slow-running conveyor belt: one bottle takes 45 min to pass through the 25 m long machine. The hollow-shaft parallel shaft geared motor is mounted on the machine shaft with a Gripmaxx bushing. The bushings developed by NORD are mounted on the drive shaft simply by means of a few screws, with no need to make any changes to the machine design. Jason Jones, director of engineering at G.C. Evans, explained why this was the optimal mounting method for the pasteurizer: “This roller is removed every few years to service the bearings and for maintenance. A more traditional keyway-secured bushing may be quite problematic, since fretting and corrosion make it very difficult and sometimes expensive to remove. With the Gripmaxx solution from NORD, the hollow bore simply collapses on to the shaft. Removal of the shaft is then grab-a-wrench simple.” While load fluctuations and start/stop or reverse mode operation put strain on keys and can loosen conventional bushings over time, FEMengineered Gripmaxx bushings spread the forces evenly over the entire contact surface. In contrast to standard shrink discs, NORD’s Gripmaxx bushings are available for many different combinations of inner and outer diameter, and therefore require no expensive custom designs.

Volume 1–Issue 2 S ept/O c t 2 0 1 7

Product News | SOFTINGS

Data integration for IoT and Industry 4.0 applications Softing’s new version of the dataFEED OPC Suite allows an easy and secure transfer of data via REST protocols and supports NoSQL databases.

he new version of Softings dataFEED OPC Suite with REST Connector and support for NoSQL databases is now available. The REST Connector, which was already presented as a beta version at this year’s HMI trade show, enables data from automation networks to be integrated into applications supporting REST protocols. Data may originate from a variety of sources including control systems from leading manufacturers such as Siemens, Rockwell, Mitsubishi and B&R as well as OPC UA or OPC Classic servers. Together with. Its second new feature, the support of write access to NoSQL databases such as MongoDB, the dataFEED OPC Suite is ideally suited for IoT and Industry 4.0 applications. REST protocols are used in particular for communication with cloud-based applications, such as the Production Performance Manager of Bosch Software Innovations. NoSQL databases enable high-performance processing of very large amounts of data. They are thus often the basis for advanced

analysis methods (“Big Data Analytics”), which for example can be used for predictive maintenance. “Efficient and reliable provision of production data is a key challenge for the successful implementation of IoT and Industry 4.0 applications,” says Andreas Roeck, Data Integration Product Manager at Softing Industrial. “The dataFEED OPC Suite offers our customers and partners extensive possibilities to implement these requirements for data integration in a simple, flexible and futureproof manner.” Softing’s dataFEED OPC Suite combines a full package of components for OPC and IoT cloud communication within a single product. In addition to the integrated REST interface, the MQTT gateway and OPC UA support enable easy integration of legacy and new controllers into cloud solutions such as Microsoft Azure or IBM Bluemix. The stateof-the-art graphical user interface with intelligent, practice-oriented default settings and intuitive user guidance facilitates system integration and offers maximum usability.

Any representative illustrative image depicting REST protocols and NoSQL databases. Check Google image with the above keywords. Picture: Softings

Vo l u m e 1 – Is s u e 2 S ept/O c t 2 0 1 7

Product News | SCOTT SAFETY

Scott Safety to Raise Silica Exposure Risk Awareness at A+A

leader in the design and manufacturer of innovative respiratory and respiratory protective equipment (RPE), Scott Safety, returns to the A+A trade event in Dusseldorf (17th – 20th October 2017, Dusseldorf, Germany) to showcase their market leading solutions in the areas of construction, silica dust, confined spaces, industrial firefighting and gas detection at Hall 06, Stand G27. A+A is the largest international trade forum for safety, security and health at work. Throughout the event Scott Safety experts will be showcasing cutting-edge technologies and systems that support eye, hearing, head and respiratory protection. Scott will also be presenting an exciting sensory experience, giving visitors the opportunity to try on products in a simulated environment, whilst learning more about them. At this year’s show, Scott Safety will showcase solutions that aim to improve education about

Silica dust is a major occupational safety hazard for workers globally Picture: Scott Safety

worker well-being and work-related illness. Scott Safety is committed to raising awareness about silica dust, where it can be found, how it is created, and how those at risk can protect themselves against its health hazards. John Clement, Marketing Manager, EMEA, at Scott Safety said: “One of the big issues we’re focusing on at present is exposure to silica dust, a major occupational safety hazard. “We are trying to raise awareness about silica dust in its entirety; where you can find it, how it is created, employer responsibility, and how to protect against it, not only with PPE but practical measures that can help to mitigate its effects. In addition at this year’s show we will showcase our wide range of products that cater to workers who may find themselves exposed to silica dust.” Additional keys areas of focus this year include gas detection; portable and fixed, working in confined spaces and industrial firefighting.

Key Highlights Key products exhibiting on the Scott Safety stand also include: The new durable, affordable Duraflow PAPR The lightweight AVIVA half-mask The exciting new Protégé Plus and Protégé SG portable gas detection range Phantom Vision power assisted respirator with improved user experience Scott’s market leading hard hat and bumpcap ranges Scott Sight, the world’s first in-mask thermal intelligence system

Volume 1–Issue 1 J u l y /Au g 2 0 1 7

Industry News | EXPANSION

Sixth edition of LASER World A Great Success LASER World of PHOTONICS INDIA is the only trade fair for the laser and photonics industry in India.

he 6th edition of LASER World exhibition of PHOTONICS INDIA that opened at Pragati Maidan Exhibition Center in New Delhi on September 14 received a grand opening response. The 3-day exhibition was inaugurated by Prof. Ashutosh Sharma, Secretary of Department of Science and Technology, Government of India. “I want to congratulate the team of Messe Muenchen India for organizing an exceptional trade event. We see a high rate of participation not only from laser companies in India but also from USA, UK, Germany, China to name a few. Photonics is an emerging market and possesses a bright future in various sectors such as automotive, agriculture and

Picture: Messe Muenchen

many more.” said Prof. Sharma during the inaugural ceremony on day one. LASER World of PHOTONICS INDIA is the only trade fair for the laser and photonics industry in India. The three-day trade fair is offering an opportunity to manufacturers from various user industries, distributors, government authorities and state corporations to interact and network with exhibitors from across the industry. New Highlight: Additive Manufacturing Technology An exciting array of activities are held at the trade fair. Scientists, industry experts and users can look forward to the Additive Manufacturing

Vo l u m e 1 – Is s u e 1 J u l y /Au g 2 0 1 7

Insight (AMI), an international conference on Additive Manufacturing Technology taking place on the second day, September 15, 2017. It will offer attendees a comprehensive understanding of the state-of-the-art in 3D printing and the latest technological advances in 3D printers and their application for the Indian market. For the first time ever LASER World of PHOTONICS India has set up an Additive Manufacturing Pavilion in hall 7D from 14-16 September to showcase laser-based processing and systems for additive manufacturing in industrial applications. Leading companies such as Capricot Technologies, 3D Systems, Novabeans Prototyping Labs, Redington India Limited, Renishaw Metrology Systems, Shree Rapid Technologies and Stratasys participate in the Additive Manufacturing Pavilion. Bhupinder Singh, CEO of Messe Muenchen India, said: “We are incredibly delighted with the year on year consistent response from our exhibitors as well as interest from new customers. New highlight this year is the Additive Manufacturing pavilion and conference to capture the futuristic 3D printing industry in India.” Special Programs The Laser Safety Forum, the Buyer Seller Forum and the Additive Manufacturing Pavilion attracted a lot of footfalls. The forum covers all aspects of laser safety practice and hazard control wherein the experts shared know-how and provided training

Picture: Messe Muenchen

on the practical applications of laser safety. The Buyer Seller Forum gave a great chance to the buyers and sellers to meet face to face in a beneficial business environment and will continue to add high value by connecting participants to a potential business associate on the next two days. The visitors gained vast information by attending two short courses on Fiber Lasers, Nanophotonics and Nano-Technology, organized by the Institute of Electrical and Electronics Engineers Photonics (IEEE). IEEE Photonics also organized another short course on Optical Fiber and Waveguides on September 15. Spread over 5500 square meters’ area with 160 exhibitors from 13 countries, some of the leading companies at the trade fair are Advanced Photonics, Coherent Laser India, EO Technics, IPG Photonics, Laser Science, Max Photonics, Sahajanand Laser Technology, Scantech Laser, Star Laser, Suresh Indu Lasers and TRUMPF, to name but a few.

Picture: Messe Muenchen

Volume 1–Issue 2 S ept/O c t 2 0 1 7

Report | CZECH REPUBLIC EXPO

Czech Republic Expo to Showcase Make in India India is a partner country at MSV Brno 2017, Central Europe’s largest trade fair. Czech Republic’s export into India reached its historic high in 2016. Czech companies exported goods totalling CZK (Czech Koruna) 15.23 billion ($0.6 billion), improving their CZK 15.09 billion record from 2011. Compared to 2015, export in CZK grew by 13.2 percent (14.1 percent in USD). The turnover of Czech-Indian trade was similarly high, reaching CZK 33.13 billion ($1.5 billion) in 2016.

zech export into India has grown in the last three consecutive years – it experienced the greatest yearon-year growth in 2016. The trend of the last three years confirms that Czech producers and exporters are paying increased attention to the Indian market and are taking advantage of opportunities stemming from the robust growth of the Indian economy, which is currently at over 7 percent of GDP.

Similarly encouraging is the nature of export to India, consisting mainly of products of high added value: car engines, motor vehicle parts and components, lorries, industrial robots, machine tools, machine tool centres, textile machinery, optical devices and various electronic devices. Czech exports into India still have a plenty of room for further growth. The dynamic development of aviation in India and the Indian government’s intention to prepare the ground for increasing the

Vo l u m e 1 – Is s u e 2 S ept/O c t 2 0 1 7

number of domestic air tickets from 70 million in 2015 to 300 million in 2022 presents a tremendous opportunity for suppliers of aviation technology and services. MSV Brno 2017 Once again after five years, India will be a partner country for the largest industrial trade fair in Central Europe – MSV Brno 2017, to be held from 9th to 13th October. “Our Indian partners, including the associated government institutions, have confirmed that in addition to the official participation in the industrial trade fair in Hanover and Moscow, India will once again attend MSV in Brno as a partner country. This is the result of longterm diplomatic negotiations at the government level. We expect and hope that India will present itself in a similar scale and quality as the Chinese pavilion did last year,” said Jiří Kuliš, the managing director of Veletrhy Brno, the organizers of the trade fair. India’s representation at the show will feature EEPC (Engineering Export Promotion Council) which unites over 14,000 small and mediumsized Indian companies. The Indian organisers are planning a joint exhibition where more than one hundred exhibitors from the area of plastics industry, automotive industry, heavy manufacturing, steel production, automation, as

well as information technology will participate. India’s presentation will also focus on promoting foreign investment in line with Mission “Make in India” and promoting the domestic tourist industry in the “Incredible India” promotion campaign. Growing Cooperation For the Czech Republic, India is a major trading partner and one of the priority countries as per the Export Strategy of the Czech Republic 2012– 2020. The volume of import and export between the countries had grown consistently and the presence of Czech companies in the Indian market is on the rise. Aside from Škoda Auto, India has seen investment from companies such as Bonatrans, Likos and others with capital interest in Indian production companies. MSV Brno 2017 is the International Engineering Fair. MSV Brno 2017 is to be held from 9 to 13 Oct 2017 at Brno Exhibition Centre, Brno, Czech Republic. The International Engineering Fair (MSV) is the leading industrial trade fair in Central Europe with annual participation reaching more than 1500 exhibitors and 75000 visitors from 59 countries worldwide. More than a third of the exhibitors are from abroad. All nine of the key specialist sectors of the engineering industry are very well represented.

Byline: This event preview is courtesy Multimedia Project T+T Technika a trh and StreamTech.tv, a Czech publishing house that publishes technical literature. It started more than 25 years ago with a technical industrial montly magazine called T+T Technika a trh. In addition, it publishes CZECH Export, which is produced in several European languages to support mutual trade in Europe. After a natural expansion into the multimedia space, the addition of a web interface, e-mail newsletters and technical videos in the StreamTech. tv project, it has become a multimedia leader in the region. The latest addition to its publishing activities is Project TAIWAN Business, which supports the sale of Taiwanese machinery in Europe and presents Taiwanese companies with current opportunities.

You can find out more at www.technikaatrh.cz

Pictures: MSV Brno 2016

70 Volu m e 1 –Issu e 2 S ept /O c t 2017

COMPANY INDEX A+A 65 ASCW Media 40-45 Avicenne Medical 23 BAE System 16,17 Balluff 53 Big Data 12,13 Blue Star 43 C G tech 20,21 CAM System 21 Capricot Technologies 67 CELOS 23,24 CII 37 CMS Hermle 20 CNC Machine 16,20,21,24 CNC Software Inc 50 Czech Republic 68,69 Daifuku 29,30 Danobat 48 Dassault Systems 20 Deckel Maho 25 DMG Mori 20,22-25 East Coast Magnets Pvt Ltd 28,31 EEPC 69 EMAG 54 EMEA 65 Emo hannover 2017 13,35,46,48,54 Emuge Corp 52 Esprit CAM System 35 Federation of German Industries 15 Fraunhofer Institute 12 G C Evans 62,63 Gerotor 13 Gleason 60 Govt of India 66 Govt of Karnataka 37 Grind Master 28,61 GROB 20 Hainbuch 46 IEEE 67 IHS Markit 27 Industry 4.0 34,35,64,65 Invest Karnataka Forum 37 JIT Management 40 Kaizen 40 Kollmorgen 32,33 KPMG India 41 L & T Valves 37 Laser World of Photonics India 66,67 Lasertec 25 Lt Col 43 Make in India 31,58,69 Manufacturing Excellence Consultant 27,28 Mastercam 50-53 Mazak 20 Mequadrat AG 32 Messe Muenchen 66 MSV Brno 2017 69 Natural Ice Cream 43 Nikkei India 27 NORD Drive System 36,62,63 NoSQL 64 Okuma 34,35 PIL Italica Lifestyle 18,19 Pon Pure Chemical 37 PWC 43 Raymond 43 RBI 58 Reliance Digital Retail 43 Renishaw 16,17 Schuler 14,15,38,39 Scott Safety 65 Sensosurf 13 Siemens PLM 20 Softings 64 Starrag 20 Supply Chain 40-45 Taegutec India 37 V P Group 43 VDMA 17,28,29,56-59 VDW 12 Veletrhy Brno 69 Volvo Group India 37

Vo l u m e 1 – I s s u e 2 M U M B A I

Sept/Oct 2017

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