EM Sep 2014 by publish-industry India

www.efficientmanufacturing.in

EFFICIENT MANUFACTURING

TOTAL PRODUCTIVE MAINTENANCE

Whatâ&#x20AC;&#x2122;s missing from your lean initiative?

FOCUS H ydraulics & pneumatics

P. 44

www.efficientmanufacturing.in

SPECIAL FEATURE Additive manufacturing

P. 80

EM - Interview Aravind Melligeri

Chairman & CEO, Aequs (p.34)

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e d i to r i a l

Productivity at its best!!!

â&#x20AC;&#x153;A number of manufacturers in India have launched productivity improvement initiatives in terms of adapting highly productive manufacturing solutions through superior machining processes, lean manufacturing practices, advanced automation technologies, efficient machines and most importantly, highly motivated manpowerâ&#x20AC;?

It has been observed that companies which take steps to increase productivity in all the areas of manufacturing operations could unlock significant value, minimising costs while establishing greater operational stability, resulting into a sustainable competitive excellence. Achieving a significant improvement in productivity is a journey that requires sustained efforts by the entire manufacturing value chain, embracing several disciplines both technical and managerial. It needs committed professionals to search for ways to improve productivity in their operations and to implement these measures consistently. A number of manufacturers in India have launched productivity improvement initiatives in terms of adapting highly productive manufacturing solutions through superior machining processes, lean manufacturing practices, advanced automation technologies, efficient machines and most importantly, highly motivated manpower. The recent Productivity Summit by IMTMA affirmed the productivity movement in the Indian metalworking industry. This event showcased selected productivity projects which have excelled in achieving superior performance through sustained productivity improvements. The participantsâ&#x20AC;&#x2122; focus areas were quite varied, from process/layout modification, cellular manufacturing, machine reconditioning, autonomous maintenance to production automation, low cost automation, redistribution of machining operations, various quality tools and TQM, Kaizen & Poka Yoke, product design changes, better visual displays & ergonomic improvements, elimination of non value adding activities, cycle time reduction, and reduced energy consumption. We, at EM, have been quite successful so far in bringing you a comprehensive overview of the multi-faceted developments in the manufacturing sector, pertinent to the above mentioned areas, helping you achieve the required competitive excellence. Continuing the trend, I am happy to present you this issue, again packed with lots of interesting and thought-provoking features that will keep you engaged. Happy reading!

Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net

editorial advisory board Sonali Kulkarni President & CEO Fanuc India

S Ravishankar Dy Managing Director Yamazaki Mazak India

Satish Godbole Vice President, Motion Control Div Siemens Ltd

Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant

N K Dhand CMD Micromatic Grinding Technologies

Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan

Vineet Seth Managing Director India & Middle East Delcam Plc

Dr P N Rao Professor of Manufacturing Technology Dr K Subramanian Department of Technology President, STIMS Institute, USA University of Northern Iowa, USA Training Advisor, IMTMA Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

EM | Sep 2014

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CONTENTS

Market

Management

Focus

Cover Story 10 NEWS

28 TOTAL PRODUCTIVE MAINTENANCE

44 Moving toward function integration

The article discusses the benefits of adopting TPM for continuous machine reliability

16 “Bringing in technology & competence together”

Interview with Tosher Hormusjee, Director, G W Precision Tools India

Hydraulics & Pneumatics An article on function integration in electrical & pneumatic subsystems for increased reliability and reduced interfaces

34 “Need to ensure seamless quality production”

Interview with Aravind Melligeri, Chairman & CEO, Aequs

20 “Investing our operational capabilities in India”

Interview with Dr Jörg Matthias Grossmann, Regional Representative India, Freudenberg Group and Executive VP & CFO, Freudenberg Chemical Specialities SE & Co KG

COMPANY PROFILE

38 Creating the best in tightening technologies

A facility visit of Desoutter Industrial Tools, Pune 40 Creating business through NPD

22 “Growth is the only option”

Interview with Chetan Tamboli, Chairman, CII (WR) and Chairman & MD, Steelcast

The feature discusses the changing dynamics of new product development as per market trends

Market

EVENT REPORT

87 Increasing technology intensity

A post event report on the West Tech Summit 2014 held at Pune

TRENDS

24 Machine tool industry dynamics

90 Platform for global manufacturing

A read on Industry 4.0 & increased efficiency, influencing machine tool industry’s investment decisions

innovation

A pre-show report on 3rd Taiwan International Machine Tool Show 2014

MORE TOUCH. MORE PC. MORE POWER. www.br-automation.com/multitouch

Phone: +91-20-41478999

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Email: sales.in@br-automation.com

9/5/2014 4:45:41 PM

CONTENTS

Advt

Technology

C O V E R I M A G E C O U R T E S Y: S H U T T E R S TO C K

TEST & MEASUREMENT 50

Tool breakage detection for camshafts

MACHINING 70

A feature on the accuracy of precision machines for increased customer demand & current production environment

An application story on the use of Renishaw’s tool breakage detection system by Ducati 54

Collaborative automotive engineering

An application story on the use of FaroArm by Mitsubishi Motor Corporation

Precision engineering

WELDING

Effective production processes

The article highlights integrated solutions developed for the application of processes with high output rates

New Products 93

TOOLING & WORKHOLDING 56

Myth buster for chucking applications

CONDITION MONITORING & MAINTENANCE

Milling in a new dimension

The feature highlights common misconceptions regarding 3-jaw power chucks & suggests relevant solutions

The feature deals with telescopic covers from Tsubaki Kabelschlepp, which covers reliable protection from cables & guide ways

AUTOMATION & CONTROL 60

Convergence revolution in production

New age modular mechanical designing

SPECIAL FEATURE

The truth about speed

A read into the decisive impact of cleaning on quality & costs in MRO processes

An article on multiple intelligent manufacturing disciplines merging into seamless barrier-free communication 66

An application story on the use of B&R’s safety technology by ELB-Schliff for grinding machinery

Cleaning mechanism

The article discusses the considerations manufacturers should give to speed while selecting the right 3D printing technology

5-axis coordinate milling & drilling machine; Code readers with innovative polarisation filter; High-speed turning grade on steel machining applications; Soft PLC solution Indexable inserts with positive geometry; Software with advanced CMM-type capabilities; Crossbar robots; Schunk pneumatic selfcontained power chuck Jetstream tooling with multiple enhancements; Colour vision sensor; Modular belt conveyor; Contact cooled rotary screw air compressor

Columns 07 08 96 96

ditorial E C ontents Highlights – Next issue C ompany index Advt

content Sep 2014.indd 9

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market | news

Aequs lays foundation of automotive component plant Aequs recently laid the foundation for a new state-of-art automotive inefficiencies. “With India having emerged as a major auto component components plant at its 250 acre Aequs SEZ, Belgaum. The new automotive procurement hub for global OEM players, there is a rising thrust on plant will add machining capacity technology innovation and cost of over 1,00,000 hours annually optimisation for manufacturers. and will support the company’s Most leading auto manufacturers of rapid expansion plans in the US the world outsource their component and European markets in 2014. manufacturing to India. By 2020, The company aims to increase India’s exports from this industry is its revenues from the automotive expected to reach US$ 40 billion, business to US$ 30 million by from the current US$ 12 billion,” 2020 and is scouting to establish said Aravind Melligeri, Chairman & joint ventures to add to its CEO, Aequs. capabilities in this vertical. The integration of the automotive The new plant, which is expected The new automotive plant will add machining capacity of over 1,00,000 hours annually manufacturing facility into the to be operational from March company also enables it to take 2015 also expects to further strengthen the company’s emergence in the advantage of central and state government incentives such as tax holiday last few years among the few Indian companies in the automotive on corporate income for 15 years, VAT and others. The company’s component manufacturing space to provide a ‘manufacturing ecosystem automotive customers include global majors such as Bosch, Jacobs Vehicle model’. Here, the interconnected processes in the manufacturing value Systems and Bosch Rexroth. It is one of the preferred partners for Bosch in stream such as forging, machining, heat treatment and grinding are India and has provided zero defect delivery to the auto major for over six > MORE@CLICK EM01291 | www.efficientmanufacturing.in delivered at the same location, thereby minimising supply chain years now.

Altem Technologies wins India SME 100 Award Altem Technologies, a Bengaluru-based 3D printing company was awarded with India’s prestigious India SME 100 Award for 2013-14 in IT/ITeS segment. Speaking the milestone moment, Prasad Rodagi, Founder Director – Altem Technologies, said, “We’re elated on Altem being chosen among the top 100 SMEs in the country. We believe that the company’s efforts to promote and educate people about 3D technology through efforts like www.printmyCAD. com, an experience platform for 3D printing, was one of the factors behind this success.” Sharath Chandra, Director - Sales, Prasad Rodagi, Founder Director, Altem Technologies, said, “The wide Altem Technologies, receiving the range of applications of 3D printing award for the IT/ITeS segment technology can soon be predominant in various fields such as consumer goods, electronics, engineering, medical equipment, automobile, architecture, aerospace, defense, education, etc. We hope we can continue to build this industry and contribute to the development of manufacturing and design in India with 3D printing.” > MORE@CLICK EM01292 | www.efficientmanufacturing.in

Market News Sep-14.indd 10

Intelligent monitoring of machinery B&R will present its advanced technologies at the EUROBLECH exhibition scheduled on October 21-25, 2014 in Hannover, Germany. The intelligent monitoring of machinery and plant states means reduced downtime in metalworking enterprises as well as the prevention of damage caused by unexpected defects, resulting in increased machine output and improved product quality. The latest solutions inspired by the vision of “Industry 4.0” will also be on display at the booth. By combining CNC, robotics The latest solutions inspired by the and general control tasks on a vision of “Industry 4.0” will be on single hardware platform, the display at the booth solution from B&R already has what it takes to overcome this challenge. At the expo, B&R’s comprehensive Automation Studio Engineering Environment - a tool that presides over the entire machine lifecycle and considerably simplifies engineering processes all along the way, will also be highlighted. > MORE@CLICK EM01293 | www.efficientmanufacturing.in

EM | Sep 2014

9/5/2014 1:31:47 PM

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market | news

Tatas to set up aircraft manufacturing unit with Ruag

Tech Mahindra signs agreement with Wichita State University

Tata Group with Swiss aerospace and defence firm Ruag Aviation is setting up an aircraft manufacturing facility in Hyderabad. For Tata Group, this will be the fourth venture in the sector. The factory will be manufacturing cabins and wings in the first phase. Tata Advanced Systems The factory will be manufacturing cabins and now makes helicopter wings in the first phase cabins for the USbased Sikorsky Aircraft. It has two more facilities in joint venture with Lockheed Martin and Sikorsky and one on its own. In November 2010, Tata Group announced it plans to make Hyderabad a hub of its aerospace and defence investments. K Chandrasekhar Rao, Telangana Chief Minister laid the foundation stone for the project of Tata-Ruag joint venture. In three years, the venture is expected to manufacture the 19-seater Dornier 228 aircraft.

Tech Mahindra recently signed a Memorandum of Understanding with Wichita State University, a state educational institution in Kansas, the US, in the areas of aerospace engineering, composites, advanced materials and structural testing, certification, IT and automotive testing. The company would gain access to the university’s extensive research and test lab capabilities and have the opportunity to train students before they enter the workforce. It also plans to invest in equipping the The company would gain access to engineering talent available in the the university’s extensive research region to enhance their employability and test lab capabilities in the Wichita aerospace community. This investment will help provide end-to-end solutions from design, to testing and certification for global aerospace and automotive customers. The collaboration will ensure the company’s local pool of trained aerospace, IT and automotive engineers available to service their global network of clients and will also facilitate cooperative initiatives in innovation and R&D projects.

> MORE@CLICK EM01294 | www.efficientmanufacturing.in

> MORE@CLICK EM01295 | www.efficientmanufacturing.in

World’s largest scooter plant in Gujarat

Innovation Excellence Awards for KBL

Honda Motors is setting up the world’s largest scooter plant in Gujarat to roll out ` 12 lakh units annually and achieve leadership position in the Indian 2-wheeler market. The ever-rising demand for scooters that has far outstripped supply has prompted the company to set up its first dedicated scooter plant in Ahmedabad. “Even as we have more than doubled our scooter capacity in India, The ever-rising demand for scooters that we have not been able to has far outstripped supply match up the demand,” said YS Guleria, VP—Marketing & Sales, Honda Motors. “While scooter production has trebled in the past decade, we still have a backlog of 60,000 scooters that should multiply in the festive months ahead,” he added. The company would also spend ` 1,100 crore on the new plant in Ahmedabad and expand its range with a few more offerings.

Kirloskar Brothers Limited (KBL) was recently awarded ASSOCHAM’s 3rd Innovation Excellence Awards 2014. The company’s all-women Coimbatore plant won the ‘gold award’ for its advancement in science and technology. Dr RV Raj Kuumar, Divisional Head - Coimbatore plant, KBL, received it from Lt Gen Anil Chait, Ministry of Defence, at the national ASSOCHAM India summit in Delhi. The award is a recognition to the efforts made by KBL’s all women Coimbatore plant that was established in 2011. “In less than three years of its establishment, GreenCo rated KBL’s Coimbatore plant has conferred many significant national awards,” said Raj Kuumar. Since its Dr RV Raj Kuumar, Divisional HeadCoimbatore plant, KBL, receives establishment, the workers at the plant the award took 60 seconds to assemble a pump. The female associates have significantly reduced this time to 17.25 seconds in April 2014 that has tripled the plant production to 34,000 pumps per line per month. The plant has set another benchmark and bagged a prestigious award by the Limca Book of Records for its project ‘Mahila Mission 20.’

> MORE@CLICK EM01296 | www.efficientmanufacturing.in

Market News Sep-14.indd 12

> MORE@CLICK EM01297 | www.efficientmanufacturing.in

EM | Sep 2014

9/5/2014 1:31:54 PM

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market | news

EMTE-EASTPO 2014 concludes on a positive note The first EMTE-EASTPO 2014 recently concluded at Shanghai, China. Nearly spur greater cooperation between machine tool makers and users,” said 650 international manufacturers from 24 countries showcased their Filip Geerts, Director General, CECIMO. The exhibition also welcomed innovative machinery to over 47,000 visitors. several overseas delegations including the “We are pleased with the first EMTE-EASTPO Ludhiana Machine Tool Manufacturers exhibition - a high quality showcase of Association, India and groups from the innovative technology and practical solutions Philippines: Philippine Die and Mould presented by leading names from around the Association (PDMA), Metalworking Industries world,” said Dr Frank Brinken, Chairman, Association of the Philippines (MIAP) and Economic Committee, CECIMO. The joint Metals Industries Research Development exhibition saw the successful staging of Centre (MIRC). Philip Ang, President, Philippine several knowledge-sharing activities and Die and Mould Association, commented, “At technical seminars. EMTE-EASTPO, we were able to see a wide The EMTE-EASTPO CEO summit was one of Buyers from India, Japan, Korea and SouthEast Asia made up variety of machinery and technologies for the the key activities held in conjunction with the the majority of international visitors at EMTE-EASTPO 2014 manufacturing industry and was a great exhibition. It attracted nearly 100 participants sourcing platform.” to learn and exchange ideas with a panel of distinguished speakers led by Other activities included a dialogue on robotics & metal processing machine keynote presenter, Dr Fritz Klocke, Professor & Director, of Laboratory for tool technology integration and application, summit on the 1st EU-China machine tools and Production Engineering (WZL) of RWTH Aachen University machine tool industry capital and technical cooperation summit and a (Germany). “We are privileged to have the presence of many machine tool series of technology seminars led by the Shanghai Mechanical Engineering experts and leading industry end-users to discuss ‘profitable growth Society. > MORE@CLICK EM01298 | www.efficientmanufacturing.in through state-of-the-art manufacturing’. We hope that the discussions will

MathWorks introduces Simulink Real-Time MathWorks has recently announced the introduction of Simulink Real-Time into the Simulink product family. It enables engineers to build, test and run real-time applications from Simulink models on dedicated target computer hardware connected to their physical systems, Combining the functionality of xPC Target and xPC providing a complete Target Embedded Option, Simulink Real-Time supports end-to-end real-time real-time simulation simulation and testing solution. Combining the functionality of xPC target and xPC target embedded option, it supports real-time simulation and testing including rapid control prototyping, DSP, vision system prototyping, and hardware-in-the-loop (HIL) simulation. With this introduction, engineers can extend their Simulink models with driver blocks, automatically generate real-time applications, define instrumentation and perform interactive or automated runs on a dedicated target computer equipped with a real-time kernel, multicore CPU, I/O and protocol interfaces and FPGAs. > MORE@CLICK EM01299 | www.efficientmanufacturing.in

Market News Sep-14.indd 14

EEPC India & Hannover Milano Fairs join hands Engineering Export Promotion Council India (EEPC INDIA) has recently signed a cooperation agreement with Hannover Milano Fairs India Pvt Ltd (HMFI) to organise India Engineering Sourcing Show – Industrial Supply India by Bhaskar Sarkar, ED & Secretary, EEPC India and Wolfgang Pech, Global VP, Deutsche Messe AG in the presence of Ravi Capoor, Joint Secretary, Ministry of Commerce & Industry, Government of India. “The government under the leadership of Prime Minister, Narendra The partnership is set to explore new avenues of growth for the Indian Modi, is keen on supporting the industry engineering sector efforts to reach out to more and more parts of the world and this agreement has come at a right time. IESS will also provide an opportune platform to the Indian MSME sector to reach out to the global buyers,” said Capoor. The partnership is set to explore new avenues of growth for the Indian engineering expertise to the world, through various joint activities. “This cooperation will explore new business opportunities for Indian manufacturing sector from international buyer delegations visiting the show,” said Pech. > MORE@CLICK EM01300 | www.efficientmanufacturing.in

EM | Sep 2014

9/5/2014 1:31:58 PM

news | market

The UK Deputy Prime Minister announces Renishaw investment in India

Keeping at par with the AM technical centre locations in the UK, USA, Canada, Germany & China; Renishaw will now set up its first Indian additive manufacturing technical centre in Pune Nick Clegg, Deputy Prime Minister, UK, recently announced a new investment in 3D printing by Renishaw—its first Indian additive manufacturing (metal 3D printing) technical centre in Pune on the final day of a trade delegation he has led to India. Additive manufacturing, often referred to as metal 3D printing, is widely recognised as a potentially transformational manufacturing technology.

The technical centre Forming part of the company’s continuing investment in development, manufacture and application of additive manufacturing technologies, the new centre also maintains the company’s long term commitment to the Indian market. It will sit alongside Renishaw’s existing key strategic AM technical centre locations in the UK, USA, Canada, Germany & China, with additional centres also planned for other key markets. To mark the announcement of the new technical centre, Rhydian Pountney, Director - Indian Sales & Marketing Operations, Renishaw, presented Clegg with a 3D printed titanium scale replica of the company’s 19th century headquarters building in Gloucestershire. “The thrust of the additive manufacturing technical centres is to create a platform to work in close partnership with our customers to help them realise the benefits of AM in their products and manufacturing processes. Our new Indian AM technical centre will be

EM | Sep 2014

Market News Sep-14.indd 15

equipped with the latest products and will be staffed by our knowledgeable local team who are well versed in service, applications and process engineering,” said Pountney.

Strengthening the links The Pune facility, which will house the new technical centre, already forms an important role in the company’s overall manufacturing and procurement strategy, and also houses a large group of the company’s software engineers, many of whom are directly contributing to the additive manufacturing product line. Clegg added, “This major trade mission marks a turning point in the relationship between India and the UK. Our links with India are among the strongest we have with any country, and the openness to trade and investment promised by the Prime Minister Modi drives us closer still to the new special relationship we have been aiming for since 2010. Strong British companies like Renishaw will be vital to these efforts to create a stronger economy with a new special relationship with India.” Renishaw believes that successful adoption of AM technologies into mainstream manufacturing depends on a number of factors including design for process, applications engineering, knowledge sharing, process development, materials science and production engineering disciplines. ☐ > MORE@CLICK EM01301 | www.efficientmanufacturing.in

9/5/2014 1:31:59 PM

market | interview

“Bringing in technology & competence together” Tosher Hormusjee, Director, GW Precision Tools India, highlights the upcoming technology and demand trends in the Indian manufacturing sector, in an interview with Sumedha Mahorey What is the USP of GUSTI, the new project that you are working We have learnt that projects have not succeeded as per the on currently? plan due to deficiencies not correctable after 90% project At the moment, technology excellence centre is not available implementation. In any project or venture, there has to be a in India. With GUSTI, we are planning to bring in world-class clear understanding that the end product has to be looked at technology and use that technology to build our competence, in totality, considering the macro environment. with the help of industry-academia interface. A run-off from Also, in terms of procurement, today, no company is able this will be skill development. The focus of the project will be to manufacture each and every nut, bolt & screw of its product. on competence building among post graduate engineers. In We are now looking at companies not making components but India, more than half a million engineers pass out every year. sub-assemblies. As part of GUSTI’s incubation facilities, we Of which, not even 5% enter the engineering sector. This is have been very lucky to have two ready-made facilities available a huge loss for the industry. There is no competence without immediately. So, manufacturers can bring their machines and technology and no technology without begin functioning. In the present times, there competence. Thus, the idea is to bring in is no casual attitude in manufacturing. It’s technology and competence together to arrive clearly step-up or step-out. We have to look at total solutions. at the future of manufacturing, the future of GUSTI’s centre will be capable of servicing being able to produce the highest quality, at any number of tech parks that are coming up in the lowest price. the vicinity or at a distance. It will help Indian manufacturing sector be globally competent Which trend lines have been identified in terms in terms of productivity, quality and more of demand & technology requirements? importantly, help generate innovation & On the demand side, aerospace is definitely entrepreneurship. This technology excellence the first thrust sector. Secondly, locomotive centre will be hungry for all kinds of technologies will be the key driver in terms of technologies, both to upgrade existing or to urban mobility, interstate mobility and crossbring in brand new technologies. country mobility. Thus, the highest volume game will be played in locomotive. Are you seeking support from the government, machine tool On the tooling technology front, the industry is concentrating builders & other competitive players in the market for GUSTI? on solid carbide. There is also huge potential in diamond tools, We have in principle support from many machine builders and especially polycrystalline diamonds, as the newer materials technology companies. We are also in discussion with more are largely aluminium. than 4 MNCs as well as family-owned companies to join us Carbon fibre will be another new material where many and put their technology forward. From the government side, developments can be anticipated. Additive machining, both in we definitely need support, as this is not a financially viable terms of buildup of carbon fibre or laser welding or 3D printing model. The government should understand that this is an is another technology trend. The technology that is currently investment that they will have to make. The government has available and is absolutely non-existent in the country is always been trying to initiate such projects on its own; but has conventional machining, combined with additive machining. never succeeded. Thus, removal of material, adding material wherever needed and then machining it, is going to be the future. ☐ How is the shop floor learnings from GW Precision being > MORE@CLICK EM01302 | www.efficientmanufacturing.in imbibed in GUSTI?

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c o v e r s to r y MMAANNAAGGEEMMEENNTT

Image courtesy: SHUTTERSTOCK

Total Productive Maintenance What’s missing from your lean initiative?

Zero equipment breakdowns…yes, have you been able to achieve it? Most business owners and general managers today recognise just how critically important proper equipment maintenance is, particularly in an asset-oriented work environment. Yet, in the context of lean initiatives, debates crop up regarding the role of preventive and predictive maintenance versus Total Productive Maintenance (TPM). Are preventive and predictive maintenance tactics sufficient? Isn’t TPM a separate initiative, a secondary consideration, or just plain extraneous to a primary lean implementation? Or, should lean and TPM be interconnected? Let’s find out… 28

Coverstory_Sep_2014.indd 28

Michael Kuta Managing Partner Productivity Inc, USA mkuta@productivityinc.com

EM | Sep 2014

9/11/2014 12:04:22 PM

MANaGEMENT

In too many companies, equipment initiatives stop with preventive and predictive maintenance. TPM is a capability built on total asset reliability—and total employee involvement. More than traditional preventive maintenance, it is a systematic, data-driven process that fosters an efficient partnership between production, maintenance, and engineering, and that engages those closest to the work. It results in an organisation’s ability to transition from reactive to proactive maintenance and to create low cost, even free capacity. More importantly, TPM has a dramatic impact on the organisational culture, overall operations—and the bottom line. It frees up valuable production capacity without the drain of capital investment. The direct and measureable results are better performance, increased capacity, improved quality, decreased scrap and waste, and increased reliability & efficiency. Without TPM, achieving lean flow is not possible; therefore TPM should be an integral part of any lean transformation.

The origin of TPM TPM evolved as an offshoot of Total Quality Management (TQM), when the problems of plant maintenance were examined as a part of TQM programmes. At the time, preventive maintenance (PM) had been considered the major component of a traditional maintenance programme. In attempts to improve production, maintenance schedules designed to keep machines operational were often revved up to the point of over-servicing. Yet, there was little or no involvement of the machine operator in the maintenance programme, and maintenance personnel had little training beyond the (often inadequate) contents of maintenance manuals. The need to go further than conventional scheduled maintenance as a method of improving productivity and product quality was quickly recognised by companies who committed to TQM. As they kept raising the production bar, they demanded better and better machine reliability, and began to see reliability as the key to greater efficiency and higher productivity.

TPM in a nutshell In essence, TPM is a strategy that empowers employees

EM | Sep 2014

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COV E R STORY

by enlisting equipment operators to participate actively in the design, selection, correction, and maintenance of equipment. The objective: to ensure that every machine or production process is always able to perform its required tasks without interrupting or slowing down defect-free production. Operators share “ownership” for the equipment with which they work. TPM is viewed as “beginning-to-end maintenance” that is critically important to business success. Downtime for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. It is no longer simply squeezed in whenever there is a break in material flow. The goal is to hold emergency and unscheduled maintenance to a minimum. A fair analogy would go something like changing your car’s oil regularly is “preventive maintenance”; analysing the oil would be “predictive maintenance”; knowing the engine and understanding what keeps it running smoothly would be “autonomous maintenance”; performing all of the above is TPM.

Why TPM? You cannot truly become lean or sustain lean gains without adopting a lean equipment management strategy that fosters and enables continuous machine reliability. Like lean, TPM is not a “program.” Rather, it is a step-by-step, systematic, strategic process that aims to achieve at least 90% equipment availability and 95% equipment performance. It involves the entire organisation and is the foundation upon which lean is built. Many managers find this counterintuitive, because they have been taught to believe that the production schedule drives the maintenance schedule. In fact, the opposite is true. Equipment is the bloodline of production. It needs to be kept in a constant state of order rather than being repaired only when needed. Planned downtime costs a company a mere 10% of what it costs for an unplanned breakdown. That can add up to sizeable savings in every plant over the course of a year. Unfortunately, in many companies TPM is viewed as a separate initiative that is optional in a lean environment. In others, managers haven’t yet recognised the symbiotic relationship

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c o v e r s to r y

MANAGEMENT

The eight pillars of TPM

between lean and TPM, and think they need to choose between the two. But the true objective of the lean/TPM partnership is the implementation of a total process that impacts virtually every aspect of operations and daily work.

It’s not just for the maintenance department Lean and TPM, and the transformation they can achieve together, require a vision that is shared by the entire employee community, one that can be turned into concrete and measurable objectives and that connects to all improvement activities throughout the entire organisation. For example, human resources play its part by recognising the need for more extensive training of employees on equipment monitoring and autonomous maintenance, while accounting must appreciate the importance of allocating additional funds for the purchase of the proper equipment and parts. Also, quality department staff must connect directly with the maintenance manager so that both sides grasp the relationship between reliable equipment and a quality product. And, production personnel learn to take ownership of their equipment, perform autonomous maintenance routines, and participate in the design processes for new equipment.

More on the “Total” in TPM Traditional maintenance puts responsibility to react to problems primarily on the shoulders of the maintenance department. TPM, on the other hand, creates a shared and proactive responsibility for equipment, encouraging greater involvement by plant floor workers. In the right environment, this approach can be extremely effective in improving productivity (increasing uptime, reducing cycle times, and

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eliminating defects). TPM trains the people—not just the maintenance people but also machine operators and others— to play an active role with equipment. Effective TPM comprises a wide range of elements that take an organisation way beyond simple preventive or predictive maintenance. Through early equipment management, team members develop an important understanding of how the design and manufacture of equipment can help make it easier to operate, simpler to maintain, and right-sized for its purpose. The people who operate the equipment are involved in helping to reduce the complexity of real-time operation. By understanding the concept of maintenance improvement, team members evolve from a reactive to a proactive position. They analyse breakdowns to better reveal machine weaknesses. They learn to modify equipment and manage replacement parts to improve operator maintainability. And, they map out a planned maintenance schedules for longer service life. The long-term value of committing to a comprehensive training programme ensures that people at all levels have the skills, and just as importantly the awareness, to support TPM effectively. The adoption of an autonomous maintenance programme instills an “operator-based care” philosophy, transferring basic equipment care responsibilities from maintenance staff to equipment operators. This frees up key maintenance employees to handle more specialised activities such as major overhauls, machine upgrades, predictive maintenance, and new equipment planning. At the same time, autonomous maintenance encourages a strong relationship between TPM and the efficiencies of 5S programmes. A quality maintenance strategy commits the organisation to efforts that ensure equipment is maintained effectively throughout the entire production process. The objective is

EM | Sep 2014

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c o v e r s to r y

MANAGEMENT

Effective TPM comprises a wide range of elements that take an organisation way beyond simple preventive or predictive maintenance

to eliminate defects—beginning with basic materials and continuing right on through to the finished product. This might include monitoring very specific machine features such as temperature, pressure, flow, and equipment flexibility. Finally, TPM enables companies to get the most out of their machines by accurately measuring overall equipment effectiveness. Companies will thus, have the ability to determine the actual contribution of each piece of equipment as a percentage of its potential to add value to the overall operations. There may be no better example of implementing true “productive maintenance.”

Next steps for initiating or reviving a TPM rollout Developing a strategy to establish TPM and integrate it as part of a lean transformation begins with analysing and understanding the key areas that need to be improved throughout the operations. That involves establishing revenue goals, performing value stream analysis, creating key lean initiatives, identifying and sharing responsibilities for action items, and laying down milestones and rollout plans. Companies need to begin by asking fundamental business questions like how does their organisation make money. How does it spend money? What drives profits, revenues, and margins? Where is the improvement focus? How to get all employees more actively involved? The last item may be the most critical. Lean and TPM will have a profound and lasting effect on a company’s culture by emphasising the role of employees in virtually every step of the production and maintenance process. Successful TPM requires a mindset of commitment, an enterprise-wide strategy, recognition of what’s at stake, and an

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end goal of “world class status” for the organisation. The initial steps that should be considered include committing top management to full support of TPM; generating a detailed implementation plan and roadmap; putting in place autonomous maintenance for all operators; adopting a datadriven philosophy; creating a partnership between production, maintenance, and engineering; and instituting a “no blame” environment focused on root causes of problems.

Key takeaways These five key points capture the high-level view of TPM, what makes it tick, and its importance for your organisation: • TPM impacts your organisation’s total operational process. • It is designed to build and strengthen the capabilities of your people, your processes, and your equipment in order to maximise asset reliability and, ultimately, company profits. • TPM cuts deeper than preventive and predictive maintenance routines, works hand-in-hand with your lean strategy, and is fundamental to achieving true flow. • Without the proactive commitment and the everyday involvement of your workforce, TPM (like lean) is unsustainable. • TPM transformations yield dramatic improvements in how employees perform their jobs, in the relationship between employees and management, and in their ability to work in teams and react positively to change. ☐ Courtesy: © Productivity Inc. Reprinted with permission of Productivity, Inc, USA, a leading firm providing consulting and training on lean and TPM practices for more than 30 years. www.productivityinc.com > MORE@CLICK EM01306 | www.efficientmanufacturing.in

EM | Sep 2014

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S p e c i a l f e at u r e | A d d i t i v e M a n u fa c t u r i n g

The truth about speed What product designers and manufacturers really want today is an efficient process: one that has few bottlenecks, lots of automation and rapid response. To find that efficiency, one must understand their operations and learn the truth about 3D printer process time and overall speed. Speed is a fundamental advantage of 3D printing (or additive manufacturing) that is critical in the race to bring new products to market. When asked, most of all those performing 3D printing will say speed is important. But how fast is fast enough, and how is speed measured? In reality, speed is a relative measure, and when it comes to 3D printing, it is throttled by many variables. To lump technologies in “fastest” and “slowest” buckets is misleading. While some generalisations are fitting, few hold true when considering the entire speed picture. And the perception of speed — as a print head zips across a powder bed or a laser dances along a vat or an extrusion head methodically works its way around a part — may lead you to the wrong conclusion. The right conclusion considers the total process time, degree of automation, settings that throttle speed and change in build

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Rob Winker Senior Application Engineer Stratasys Inc info@stratasys.com

speed over time. And it pairs this information with the desired mode of operation. What product designers and manufacturers really want is an efficient process: one that has few bottlenecks, lots of automation and rapid response. To find that efficiency, understand your operations and learn the truth about 3D printer process time.

The whole process Build time — the time a part spends in the machine — is the most cited measure of process speed. But it is just one component of the elapsed time for part completion. The tortoise and hare fable offers a good comparison for 3D printers. A quick dash does not mean that the hare crosses the finish line first, because that sprint does not cover the entire

EM | Sep 2014

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A d d i t i v e M a n u fa c t u r i n g | S P E CIAL F E ATUR E

Figure 1: To measure speed, you must clock the entire 3D printing process, including file preparation, system preparation, part building, post build machine operations and postprocessing for parts

distance. In this analogy, build time is just one leg of a much longer race to deliver parts. The 3D printing process has many phases, including file preparation, system preparation, part building, post build machine operations and post-processing for parts. To measure speed, you must clock the entire process: Start the timer the moment you receive an STL file, and stop it when the part is ready for use. As shown in Figure 1, a four hour build plus additional required steps can result in a 12-hour overall process. Conversely, an eight hour build plus other required steps can result in only a 10-hour process. So the process with a slower build stage could be the overall faster process. On the front end, the time to create a job â&#x20AC;&#x201D; orienting, supporting, slicing and applying build styles â&#x20AC;&#x201D; will vary, especially if stock build styles do not apply. But the big surprise to many is how much time may be needed to prepare the machine, load or swap materials and warm-up the machine, especially if from a cold start. Before kicking off a job, you might need to wait anywhere from a few minutes to several hours. On the back end, after the build finishes, two factors come to play: post-build idle and post-processing. After a part is built, depending on the process, parts may have to drain, binders may need time to harden or chambers may have to cool. These delays vary from no time to many hours. For some technologies, build time is effectively doubled because parts have to cool for nearly as long as they were building. Once you can handle the parts, itâ&#x20AC;&#x2122;s time to postprocess them. Every technology requires some form of postprocessing, and the time to complete this step varies widely. For an accurate sense of delivery speed, you need an understanding of the actions needed. Depending on the process, these steps might include cleaning, post-curing, depowdering, de-cubing, support removal, infiltration sanding or other steps.

Automated or manual For those who are resource-thin, also consider the impact of labour-dependent processes on delivery time. What delays will occur if personnel are not ready and waiting? And how

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much time will they need to complete the action? For every manual step, without resources ready, delivery time can swell. This can become a critical factor and a bottleneck to delivery. The advantages of automation are most notable in the post processing phase. For example, a 3D printing technology that spits out dozens of small, highly detailed parts in a few hours may have delivery time measured in days if each part requires more than a few minutes for support removal and finishing. This scenario becomes even more burdensome and timelagged if a skilled technician is needed. For example, removing supports made of the same material as the part is not a job for an unskilled staffer. It takes an experienced hand and keen eye to discern where the part stops and supports begin. If your resources are so thin that you will be doing all this post processing yourself, you have to consider whether you have the time to take on this work.

Build time variance Build time is a function of many variables, some that you select and others that are fixed. In the fixed category, consider the details of the parts. It is widely known that the height of the part drives time: For every technology, the taller the part, the longer the build time. But many overlook other factors, such as material volume, surface area and part footprint and configuration. Each might add hours to build time. There are too many factors to cover, and they vary for each technology. To learn the truth about speed, you should discover what affects time and how that translates to your parts. Note: Be cautious. Those who want to sell you a system know what increases time, and they may attempt to redirect you to a part with the fastest build speed. Some of the variable elements of build time come from the build styles you will use. Do you want high resolution, smooth surfaces, solid parts and the best mechanical properties? Those will take more time. The only way to fully understand this component of speed is to discuss the part qualities you will need, match them with a technology and ask for an estimate of the resulting build time. Take FDM as an example. With the high-end systems, the software offers

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S p e c i a l f e at u r e | A d d i t i v e M a n u fa c t u r i n g

Figure 2: With the high-end systems, the software offers control over slice thickness, extrusion diameter and the number of contours (boundaries of each layer profile). Altering any one of these variables will change the build time

control over slice thickness, extrusion diameter and the number of contours (boundaries of each layer profile). Altering any one of these variables will change the build time. Another FDM example is the fill style. If you opt for a sparse fill — solid boundaries with an internal lattice — you can reduce build times by as much as 60%. See Figure 2. The two remaining user-selected variables that affect time are part batching and part orientation. If you plan to hold postponed builds until you have amassed as many parts as possible, you will want to understand the effect on time. Likewise, if you will build individual parts as needed, find out how that affects time. Some technologies are fastest on single part builds while others require multi-part batches to realise the fastest times. Part orientation has a direct effect on part quality as well as time. As stated previously, taller parts take longer to build. But recognise that orientation is not always at an operator’s discretion. Most 3D printing technologies put their materials through a state change, such as from liquid to solid, which induces stress. Some cope with residual stress better than others. For those that may twist, warp or curl, the shortest part dimension may not be an option for the Z-axis of the build, so you may be forced to build the part in a different orientation. This makes claims of half-inch per hour rates, or similar, misleading. For example, a long, flat part may have to be built on edge to keep the part from warping. Due to this change in build orientation, what could have been a one-inch tall build (one hour) becomes a four–inch tall build (eight hours).

Time’s effect on speed Also like the tortoise and hare, some 3D printing technologies start off fast when the machine is fresh and new but slow down as their components age. Others may have a slower, but consistent, process speed over the life of the machine. For example, laser based processes may see increased build times as power output declines. Less energy means more time. Another example of the ravages of time is aging materials,

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which is especially true with systems that reuse materials by regularly combining new and used. Material that surrounds parts as they are building has been exposed to energy, heat and moisture, all which can change the reaction properties. So a one-year-old bed of powder may take longer to solidify into the part you desire than it did when the material was fresh.

Time buckets While it is comforting to know that a technology can deliver in a hurry when emergencies occur, the truth is that you will likely fall into a pattern of 3D printer operation. For example, you may hold jobs until the end of the day to make sure that all the day’s parts make it into the overnight build run with the goal of having usable parts first thing in the morning. If you believe that you would fall into this pattern of use, then the difference between a four-hour build and a 10-hour build is not very important. Both options will be ready with parts when you walk in the next day. Now, the differentiating factor becomes how long it takes to post-process those parts. In general, 3D printer users typically fall into one of three build patterns: four-hour cycles (half a workday), eight-hour cycles (full workday), and overnight cycles. So the question of speed should be whether or not your typical parts can be completed in your anticipated operational mode. Before settling for a fast build with moderately acceptable properties, consider what approach will be your most likely. As you can see, there are far too many variables to declare any technology the fastest for all parts. There are too many factors to definitively state which is the tortoise and which is the hare. The truth is that you need to know your operations, your parts and your requirements before measuring speed. And of course, remember that an inferior part done quickly can never outperform a superior part completed in a bit more time. Build speed should be just one of the many considerations in your selection of the right 3D printing technology. ☐ > MORE@CLICK EM01320 | www.efficientmanufacturing.in

EM | Sep 2014

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JIMTOF2014_1_out.pdf

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Features of Many opportunities for business deals, with a number of visitors who are involved in the purchase of products

Overwhelming ability to attract visitors mainly consisting of people involved in manufacturing Visitor trends at JIMTOF of recent years 150,000

130,000

142,408 130,908

Government office / School 5.3%

Trading company / Agent 16.5%

100,000

Metal products 28.2%

Other manufactures 6.8%

50,000

General machines 16.4%

Automobile and Parts 7.2% 2006

Others 3.3%

2008 2010

2012 2014 Expectation

Keeping ‘Over 100,000 visitors’

Manufacturing industry 74.8%

Electric machines 8.7% Steel / Nonferrous 7.7%

Over 70% from Manufacturing industry

The trade fair that is among the first in the world to show cutting-edge technologies High satisfaction level from visitors

Dissatisfied 0.6%

Worse than expected 6.9%

Dissatisfied

Worse than expected 4.0%

0.5%

More than expected 20.1%

CMY

Type of Occupation of JIMTOF2012 Visitors University, Research institution, Others 4.9%

University, Research institution, Others 12.8%

128,674

114,558

Type of business of JIMTOF2012 Visitors

Overseas

Domestic

More than expected 38.3%

Sales, Management etc 28.6%

Sales, Management etc 19.0%

Domestic

Overseas

Involved in the Purchase

(Executive, Responsible for Purchasing, Technology sector)

58.6%

76.1%

Concurrent Programs Lectures and seminars In addition to the International Machine Tool Engineers' Conference (IMEC), which focuses on the trend of cutting-edge technologies, current information on manufacturing will be offered with authorities and pioneers in various industries as lecturers.

Exhibitions by organizers As expected 57.2%

As expected 72.4%

Through exhibitions as well as demonstrations given by skilled people who are active in the field of Mono-Zukuri, the power of Mono-Zukuri will be introduced.

Result of JIMTOF2012 DATA

Voices of JIMTOF2012 Exhibitors How many of your goals did you achieve? Achieved none 3.2%

Others 2.0%

Would you like to join the JIMTOF2014? Not sure

7.2%

Would not like

0.6%

Others

1.6%

Achieved all

35.3%

Achieved partly

Would like to join

59.6%

90.6%

Visitors ………………………… 128,674 (Overseas visitors: 8,347) Exhibitors ……………………… 815 (Overseas Exhibitors: 237) including co-exhibitors and represented companies

Exhibition scale ……………… 5,092booths (45,828m2) Conferences & Seminars …… 30sessions Exhibitors Workshops………… 37sessions International associations …… 14 University & institution for IMEC poster sessions ……………………………… 38organizations / 59sessions Catalogue exhibit

…………… 29

≪Media Coverage≫ Japanese: 781 As one of the world's leading trade shows of machine tools, JIMTOF also attracts a number of buyers from emerging countries. Thus, a very good outcome can be expected in developing markets in emerging countries.

JIMTOF is a highly important trade fair to us as well as many other companies in our country.

While we participate in many trade shows, JIMTOF is special. We put the highest priority on contents to be presented in the trade show. We also develop new products to be presented at JIMTOF.

Overseas: 86

Total: 867

JIMTOF2014_4_out.pdf

CMY

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REPORT | event

Increasing technology intensity The two-day West Tech Summit 2014, organised by Confederation of Indian Industry (CII) at Pune, provided a platform for policy dialogue on creating a robust ecosystem and strengthening enablers for increasing investment, technology intensity in products & services and updating the stakeholders with latest technology. A post event report… Greater consideration has been given in recent years to the role of technology deployment in promoting business competitiveness and societal development. Technology and innovation form two established engines of growth in the global knowledge economy. Thus, diffusion of technologies form an integral part of the developmental agenda of the country. With this objective, CII recently organised “West Tech Summit 2014 Technology Summit & Platform” at Pune. The focus sectors of the summit were industrial & automotive manufacturing,

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defence, IT & ITeS and agriculture. Speaking during the inaugural session, Chetan Tamboli, Chairman, CII (WR) & Chairman & Managing Director, Steelcast, said “Technology plays the key role in finding appropriate solutions to challenges. At the same time, technology plays a major role in economic growth and employment generation through technologically superior industry sector investing in and operating from the state. India’s priority should be to build a technology sustainable future. With India’s edge in terms of human capital,

Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net

knowledge, technological genius, and a sense of social responsibility, there is every opportunity for this to happen”. Western Region India contributes more than 25% to GDP of India. Industrialised and services sector together contribute about 85% of the region’s domestic product. Agriculture and allied activities sector contributes 15% to the region’s income, said Sanjay Kirloskar, Deputy Chairman, CII Western Region & Chairman & Managing Director, Kirloskar Brothers. Dr Naushad Forbes, Vice President,

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event | REPORT

Sanjay Kirloskar, Deputy Chairman, CII Western Region & Chairman & MD, Kirloskar Brothers, addressing the inaugural session

CII & Director, Forbes Marshall, said that Pune Zonal Council & Chairperson, the test of good technology should be Thermax, said that “Technology and economical. Self-reliance is a virtue and growth are interwoven and can create there must be focus on building tremendous opportunity for a nation. competence. Technology is a tool of The role of technology in the economic development. He also stressed on having development and innovative technologies an innovation matrix which evaluates is boastful. She added that for innovation technology impact and the percentage & technology to flourish, the most important is to set the right culture value added by the new product. Industry has become competitive on within an organisation for the innovation quality, cost and delivery, said Vikram to flourish. Kirloskar, Vice Chairman, Toyota Kirloskar Motor. While focusing on Session highlights innovation, he said that innovations have to be scaled up and should be scalable. The first plenary session on day 1 was He also added that the development of held on the topic “Strengthening a technology is dependent on the knowledge ecosystem through superior management structure. In the beginning, technology solutions”. This was followed a clear definition of who the customer is by a panel discussion to provide a and what are his requirements are perspective on how technology plays a important for management of technology key role in building and strengthening of & innovation. knowledge ecosystem. Moderator for the Ajay Shankar, Member Secretary, session was Dr Naushad Forbes, Vice National Manufacturing Competitiveness President, CII & Director, Forbes Council, while highlighting the defence Marshall and the presenters were sector, said that if the private sector Vikramaditya Ugra, Deputy General partners with the government, the needs Manager and Regional Head, Exportof the armed forces in terms of technology, Import Bank of India; Dr Ganesh R&D, components, etc can be sufficed. Natarajan, Chair, CII National Knowledge The time has come when the government Committee and Vice Chairman & CEO, and the private sector can forge an Zensar Technologies; Dr Arup Basu, Vice Chairman, CII Maharashtra State Council alliance. Meher Pudumjee, Chairperson CII & President, New Business & Innovation

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Centre, Tata Chemicals; Anil Goel, Vicechairman, CII Pune Zonal Council & Chairman, DuroShox and Rashmi Urdhwareshe, Director, Automotive Research Association of India. This was followed by an industry leaders’ panel discussion on IT & ITeS on the topic “The Internet of Things and its Application (M2M)”. The discussion focused on M2M which is considered an integral part of the Internet of Things and brings several benefits to the industry and business. The panel discussion explored how IoT and its application have changed the outlook of the industry and the way business is done. CII Pune Panel on IT & ITeS and PwC, then, launched the cloud computing discussion paper for the education, automotive and IT & ITeS sector. The session-II of day 1 was focused on modernisation and indigenisation of the Indian defence sector. This session gave a perspective on committing to selfreliance and indigenisation of Indian defence sector. The session chairman was Venkatesh Parlikar, Associate Director, R&DE (Engineering), DRDO, Ministry of Defence, Government of India. The first presenter was Prashant Rojatkar, Associate Director, Armament Research & Development, Establishment (ARDE), Ministry of Defence, Government of

EM | Sep 2014

9/5/2014 2:58:38 PM

REPORT | event

India who presented on “Challenges in production of indigenously developed artillery rockets”, followed by a case study on self-reliance in defence sector by Rajinder Bhatia, Executive Vice President & CEO, Bharat Forge. Next presentation was on “Development of indigenised products and technologies in the defence sector” by B K Kalra, General Manager and Head, L&T Strategic Systems, Larsen & Toubro, followed by presentation by Vishal Verma, President & CFO, Hindustan Semiconductor Manufacturing Corporation. Day 2 began with a session on automotive & industrial manufacturing titled “World-class technologies for sustainable growth of automotive industry”. The session provided insights into the latest developments in automotive technology & transformational trends in sustainability. The session chairman was Sudhir Mehta, Past Chairman, CII MP State Council, Director - Force Motors, MD - Pinnacle Industries, & Vice Chairman - Caveo Pinnacle India. Next presentation was on “Key technology drivers that will (re)shape the automotive Industry” by Ravi Pandit, Co-founder, Chairman & Group CEO, KPIT Technologies and by Dr Shrihari Mandaogane, Head - Total Quality Management, Tata Motors. Another presentation on “Industry 4.0 in manufacturing” was presented jointly by Nitin Nair, Head, Automotive Vertical, Siemens and Gautam Dutta, Director – Marketing, Siemens PLM Software. The last presentation of the session was on “The Importance of design in hi-tech manufacturing” by Geetika Kambli, Managing Partner, Future Factory LLP. The two-day West Tech Summit 2014 provided a platform for policy dialogue on creating a robust ecosystem and strengthening enablers for increasing investment, creating knowledge

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ecosystem in the states, increasing technology intensity in products and services, knowledge sharing, trading, business to business dialogues and

updating the stakeholders with latest technology trends in focus sectors. ☐ > MORE@CLICK EM01321 www.efficientmanufacturing.in

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Platform for global manufacturing innovation The 3rd Taiwan International Machine Tool Show 2014 (TMTS 2014), which will be held on November 5-9, 2014, at Taichung, expects a host of exhibitors and buyers revolving around the theme of global manufacturing innovation. EM was a part of the pre-show conference at Taiwan. A report… The 3rd Taiwan International Machine Tool Show 2014 (TMTS 2014) will be held on November 5-9, 2014, at the Greater Taichung International Expo Centre (GTIEC), Taiwan. The event, hosted by Taiwan Machine Tool & Accessory Builders’ Association (TMBA), provides a significant platform for a host of global machine tool manufacturers and consumers. The preshow conference was inaugurated by Jui-Hsiung Yen, Vice Chairman, TMBA. “TMTS is the largest machine tool show in Taiwan showcasing a platform for the global tool industry. In 2014, the exhibition will witness 45% increase in terms of exhibitors and 56% increase in exhibiting all types of high precision machine tools, components, accessories, tools and automation equipment. Overall, it will be a high quality service exhibition,” he said. According to Chin-Kun Yu, Vice President, TMBA, 90% of the machine tool industry of Taiwan includes small to medium enterprises. “All companies manufacture a complete range of machine tool value chain—from castings to high precision

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Megha Roy Features Writer megha.roy@publish-industry.net

components and accessories.” Elaborating on this year’s show, Carl Huang, Secretary General, TMBA, said, “In 2010, the exhibition had attracted 243 exhibitors spread across 1282 booths. This rose to 475 exhibitors and 2419 booths in 2012, and in 2014, 650 exhibitors have already booked 3700 booths.”

Highlights The exhibition will be divided under two themes of 5-axis machine tool cutting application and servitisation in manufacturing. Governmental units, Industrial Technology Research Institute (ITRI) and Precision Machinery Research & Development Center (PMC), will take the chance to display R&D performance of controllers in different applications. In addition, Central Taiwan Science Park and The German Trade Office have invited member companies for joint exhibition, planning to present professional subjects respectively.

EM | Sep 2014

9/6/2014 12:27:06 PM

REPORT | event

In addition to this, many exhibitors will showcase cutting performance and related applications of 5-axis machine tool during the show. Moreover, there will be series of presentations to introduce how to implement manufacturing service in the machine tool industry accompanied with a number of technical seminars and conferences discussing the growth of the global manufacturing industry. To provide optimal service for visitors and buyers from all over the world, the organisers also offer events such as product release, purchasing conference, factory visit and a free city tour.

Taiwan machine tool industry witnesses an increase in export The Taiwanese machine tool industry focuses on the automotive industry and 3C industry, with middle class technology and the mid-priced products. The exports of the Taiwan machine tool in the first half of 2014 were USD 1.81 billion, up 4.9% YoY. Exports in June 2014 were USD 0.352 billion, an increase of 8.1% MoM and a rise of 13.2% YoY. As the economic forecast has been showing positive signs in Europe and USA, wearable gadgets have become popular and commercial opportunity of Internet of Things (IoT) is highly expected, in turn contributing to Taiwan’s expanding export performance. According to custom statistics published by Directorate General of Customs and Department of Statistics and analysed by Taiwan Machine Tool & Accessory Builders’ Association (TMBA), Taiwan’s top exporting areas of machine tools are China (including Hong Kong), USA, Thailand, Turkey, Germany, Korea, The Netherlands, Russia, Indonesia, Malaysia and India.

lathes and supplies CNC machine tools and plastic injection moulding machines. In 2014, the main products manufactured by the company include horizontal turning lathes (80-100 sets/ month), vertical turning lathes (5-10 sets/month), multi-tasking + HMC (5-10 sets/m and meehanite castings (1200 tonne/ month). For the TMTS exhibition, the company will have 6 exhibits including 3 new models like Vturn-Q200T2Y2, Vturn-45/325 and Vcenter-H630HD. Leadwell, Fair Friend Group (FFG): The company manufactures its machines locally, except the CNC machine tools, which is imported from overseas. The company’s business is divided into machine tool division, PCB division, green energy division and industry equipment division. Here, vendors concentrate in supplying 80% of the machine parts while the company produces only 20% of the materials. It has a representation in India too.

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Exhibition zones In order to have a better access to the suppliers and their products, the organisers of TMTS 2014 have planned the exhibition into five pavilions: • Metal cutting machine tools • Metal forming machine tools • Components / parts / tools / toolholding & workholding devices / accessories / software / inspecting, measuring and testing equipment • Automation & robotics / hydraulic & Pneumatic Components • International associations & media area

Participating companies Victor Taichung Machinery: It manufactures conventional

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Exhibitors will showcase cutting performance and related applications of 5 axis machine tools during the show

Kao Ming Machinery Industrial Co Ltd: Having main markets across USA, Europe, Asia, China & Taiwan; the company specialises in double-column machine 180 units/year and EP series 6 units/year and G series 6 units/year. According to Tim Chang, General Manager, Kao Ming Machinery Industrial Co Ltd, this is the first factory producing big machines. Its product range includes moving gantry plano machining centre, high speed double-column machine, high speed vertical double column machine, five-face machining centre, vertical machining centre and radial drills, while double-column series remains the speciality. It has two representatives in India including Mumbai and Bengaluru. At the TMTS exhibition, the company will showcase the largest machine weighing 2000 tonne. Quaser Machine Tools Inc: It uses technology like thermal control, thermal compensation and thermal solution for manufacturing its 5-axis application. The company will be displaying high speed spindle at the TMTS exhibition. As far as the supply chain is concerned, all parts are manufactured within 30 km distance and caters to Japan and Europe. The main product range comprises VMCs and HMCs multi-face machining centres. Chemer EDM: The comp3any has a global presence and mostly produces linear motor drivers and CNC machines. The main advantages of applying linear motor systems include high machining speed, high response, high follow-up performance and low friction of axis movement. It has 90 marketing agencies in 55 countries including India. Also, 90% of the controls are manufactured in-house and has 40 engineers in its R&D department. The recent development from the company is its flagship wire EDM Q4025L and automatic wire threader. YCM - Yeong Chin Machinery Industries: Specialising in machine tool manufacturing, YCM is the first company to design and implement 5-axis technology in Taiwan. Spread over a factory area of 164160 m2, every manufacturing component is produced in-house. The company not only manufactures its own spindles, but also has its R&D and spindle department at

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its technology centre. It will be displaying a total of 20 pallets of machines at the exhibition. Tongtai Machine & Tool Company: The company manufacturers products like casting beds, columns, headstocks and gear boxes using in-house machining equipment like 5-dimension machining centres, vertical milling machines, horizontal boring and CNC lathes. Machining centre / CNC lathe / PCB drilling machine are some of the main products of the company. It will display its aerospace technology at TMTS 2014.

Investing in India Considering the Indian market in terms of global manufacturing, most industrial giants are keen towards investing in India. But, owing to cost-cutting initiatives prevalent among the Indian manufacturing companies, global establishments are hesitant towards investing or setting up units in India as compared to other Asian countries like China and Japan. “India has a huge potential of skilled manpower. But, when it comes to expansion, it becomes a difficult market to invest. However, with the arrival of the new government, we hope the market scenario to change and attract global manufacturers on a large scale,” said Tim Chang, General Manager, Kao Ming Machinery Industrial. According to Rock Liao, President, Quaser Machine Tools Inc, India has a different market altogether. “We set up our establishments depending on the market scenario of the particular place. Though we have no plans to focus on the Indian market currently, we expect to witness some expansion plans in the near future.” Speaking on the Indian market opportunities, Jui-Hsiung Yen, Vice Chairman, TMBA, believes that India has a powerful manufacturing industry. “We hope to witness an increase in the number of Indian buyers. We also look forward to communicate more with the Indian market in the near future.” ☐ > MORE@CLICK EM01322 | www.efficientmanufacturing.in

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news | technology

5-axis coordinate milling & drilling machine

Code readers with innovative polarisation filter

Worldwide Industrial Machinery has developed a 5-axis coordinate advanced milling and drilling machine (CAMDER), suitable for automotive mould & complex machine components. It is based on horizontal deep hole drilling machine with CNC rotary table and spindle tilting function design concept. With the advanced design, it can interchange from a milling function to a drilling function in a very short time. X, Y, Z & W axes are all using a high precision linear The spindle power is 22 kW, can be guide and ball screw, with high use in gun drilling and more efficient rigidity and accuracy. The ejector drilling system maximum loading capacity is 30 tonne with dual servo motor to eliminate the backlash. Furthermore, each rotary axis is equipped with round linear scale to ensure the accuracy of the angle. The spindle power is 22 kW, can be used in gun drilling and more efficient ejector drilling system. Maximum spindle speed is 4000 rpm. X, Y, Z maximum cutting speed is 8 m/min with AICCII function for complex machining.

With the OPC120 Series code readers, Pepperl+Fuchs has offered stationary readers for detecting and decoding 1-D and 2-D codes, such as barcodes and data matrix codes. The housing may be only 70 mm wide, 70 mm high and 54 mm deep, but contains a CMOS imager, an LED flash, and a control interface. The OPC120 W design can be used in many standard tasks that have normal reading The OPC120 W design can be speed requirements. The OPC120P is the "high-end" design, reaching used in many standard tasks high reading speeds of 100 that have normal reading speed readings/s or tape speeds of up to requirements 10 m/s. It is equipped with unique polarisation filter technology that prevents faulty readings in these and similar scenarios. This technology eliminates harmful reflections and enables more reliable readings to be taken, even if codes are located on highly reflective surfaces such as metals, plastics, and printed circuit boards, or on film.

> MORE@CLICK EM01323 | www.efficientmanufacturing.in

High-speed turning grade on steel machining applications TaeguTec has expanded the range of its life+ line with the addition of the TT8105 grade for high-speed turning on steel machining applications. Because of its special coating technology, the new addition to the life+ line grants excellent wear resistance while also guaranteeing stable and long tool life. The TT8105 gets an extra boost with the addition of the GoldRush treatment, a special coating that enables better surface roughness and high durability. These new grades have excellent wear resistance, are stable in high-feed and speed The TT8105 gets an extra boost with the machining conditions, and are an addition of the GoldRush treatment, a ideal choice for professional and special coating that enables better surface amateur machinists who aim to roughness and high durability achieve excellent surface roughness while minimising build-up-edges. During several tests of the new TT8105 life+ coating, it was found that tool life in addition to wear resistance improved significantly. One example was done during the machining test of a guide cover made from alloy steel. > MORE@CLICK EM01325 | www.efficientmanufacturing.in

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> MORE@CLICK EM01324 | www.efficientmanufacturing.in

Soft PLC solution COPALP has recently upgraded its core product, the IEC 61131-3 soft PLC Straton, to include full POWERLINK support. For COPALP, integrating open-POWERLINK, the open source POWERLINK stack paves the way to greater flexibility, especially since the open COPALPâ&#x20AC;&#x2122;s Straton features full standard does not require POWERLINK support, including the direct a specific Ethernet import of POWERLINK configurations controller. created in openCONFIGURATOR The integration also addresses growing demand in markets where deterministic Ethernet protocol has become the standard, such as China. Stratonâ&#x20AC;&#x2122;s ability to communicate via POWERLINK makes it easier to integrate B&R X20 and X67 I/O systems, addressing the needs of both machine manufacturers and process automation applications. In combination with the IEC 61850 tools included in Straton, it also opens up a host of new opportunities for the power industry. > MORE@CLICK EM01326 | www.efficientmanufacturing.in

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technology | news

Indexable inserts with positive geometry Walter AG has expanded its Tiger•tec Silver® range with three efficient, positive, steel cutting geometries — an often underestimated insert type, which shows its full potential with low cutting pressures and on small diameters. The three new ISO P geometries with a positive basic shape are called FP4, MP4 and RP4, and have been added to the tool range of the Tübingen-based specialist. The indexable inserts for steel machining are available in the proven WPP10S, WPP20S and WPP30S Tiger•tec Silver® cutting grades. FP4 (F=finishing) is optimised for finishing steel and achieves the best surface finish quality and chip control for exact precision machining. MP4 Walter FP4 for finishing, MP4 for (M=medium) for mid-range steel medium machining and RP4 for machining is the universal design of roughing with positive indexable inserts the three new inserts and is particularly well suited to machining long-chipping materials, such as St37 structural steel or other low-carbon steels. The geometry is available with two clearance angles (7° and 11°), as well as in a precision-sintered and a precision-ground design. The clearance angle of 11° enables machining of smaller diameters. > MORE@CLICK EM01331 | www.efficientmanufacturing.in

Software with advanced CMM-type capabilities Renishaw has introduced a range of process control solutions that help tackle the increasing drive to lean manufacturing, from new technologies for preprocess machine calibration, to on-line and off-line post-process measurement. The new OMV Pro software includes advanced CMM-type capabilities with an extended range of geometric dimensioning and tolerancing (GD&T) functionality, plus the ability to work with multiple alignments in The new OMV Pro software includes more a single program, an advantage in advanced CMM-type capabilities with an working with multi-axis machine extended range of geometric dimensioning tools. The software includes and tolerancing (GD&T) functionality simulation capability, an intuitive graphical interface and crystal-clear reporting format that make it accessible to shop-floor staff. OMV Pro’s GD&T measurement wizard helps users create standardised report elements based on internationally recognised symbols, allowing operators to compare part measurement results on the machine with those on the manufacturing drawing. > MORE@CLICK EM01332 | www.efficientmanufacturing.in

Crossbar robots

Pneumatic self-contained power chuck

Schuler’s crossbar robots are used to transfer parts from one stage of a press line to the next. They can remove up to four parts at a time from the die, change their orientation where necessary, and place them directly into the next die. The robot is based on a six-axis industrial robot, to which engineers have added The robot is based on a six-axis industrial robot, to which engineers have added a further two axes. These represent the hand of the further two axes robot arm and the horizontal drive, thus, greatly increasing maneuverability, flexibility and output. And thanks to its process data interface, the new robot is already well prepared for the Industry 4.0 era. Its intelligent networking capabilities turn it into an analysis tool which can monitor processes and report any errors which may occur and plays a decisive role in securing high and consistent productivity – forming an ideal bridge into the future for press lines.

Schunk’s ROTA TB2 pneumatic self-contained power chuck has set a new standard in the machining of rods and pipes for the oil industry, mining and construction sectors. The ROTA TB2 has an extremely large through-hole of up to 560 mm. With an air pressure of 6 bar it is already possible to achieve very high clamping forces of up to 280 kN, which can easily be adapted to the particular task. An anti-corrosive coating applied to the most important functional components of the power chuck significantly increases the service life. The The ROTA TB2 has an extremely large base jaw guidance is equipped through-hole of up to 560 mm with a special seal to prevent penetration of contamination, dust and chips, therefore reducing maintenance costs. The design and the guidance of the base jaws have been optimised for minimal loss of centrifugal force even at high rotational speeds. To increase the cycle rate in the machining of pipes and rods, it features a double acting check valve with extra large channel bores, which speeds up the clamping process considerably.

> MORE@CLICK EM01333 | www.efficientmanufacturing.in

> MORE@CLICK EM01334 | www.efficientmanufacturing.in

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news | technology

Jetstream tooling with multiple enhancements Seco Tools has recently improved the productivity and process safety of its line of jetstream tooling products through multiple enhancements, including a new lever clamping design and optional roughing inducer. These extras further increase the performance levels of jetstream tooling, enabling manufacturers to attain higher productivity and part quality by removing heat from turning applications. A lever clamping design replaces the original pin-clamping A lever clamping design replaces the system for negative inserts to establish original pin-clamping systems for several new advantages, including negative inserts to establish several better indexing accuracy and prevention of insert movement under new advantages high loads in roughing applications. On shanked toolholders equipped with jetstream tooling duo, an additional coolant outlet underneath the holder directs a jet to the secondary heat zone just below the cutting edge. This boosts cooling efficiency and part quality. Additionally, an optional roughing inducer can be ordered separately to adapt the coolant jets for larger depths of cut and higher feed rates. > MORE@CLICK EM01327 | www.efficientmanufacturing.in

Colour vision sensor Cognex Corporation has introduced the Checker 4G7C, an easy-to-use colour vision sensor that distinguishes parts by colour. It delivers 376 x 240 inspection resolution with Ethernet support for industrial protocols and high-intensity white LED illumination for the detection and inspection of parts and features at up to 800 parts per minute. As part of its product line, Checker 4G7C includes the patented internal trigger Checker 4G7C delivers 376 x 240 technology which provides several key inspection resolution with Ethernet advantages that does not require support for industrial protocols additional sensors to determine if a part is and high-intensity white LED present; detects parts by locating a illumination for the detection and feature on a part and tracks parts along inspection of parts and features at the production line without requiring up to 800 parts per minute precise part handling. In addition to the new ability to inspect parts for colour, the sensor provides features that the product line is known for including flexible optics, ease of setup, ability to add unlimited sensor tools to a job and intelligent pass/fail logic based outputs. > MORE@CLICK EM01328 | www.efficientmanufacturing.in

Modular belt conveyor

Contact cooled rotary screw air compressor

Dorner has launched the 3200 series platform, giving customers more options by adding flexibility to serve a greater range of markets, including industrial, packaging and assembly. The modular belt conveyor includes many of the features of the company’s other heavier-duty platforms, but also has new designs to enhance efficiency and performance. Its features include flat side tail design for ease of machine interface, capability for up to four curve modules, improved curve conveyor capacity up to Its features include flat side tail design 200 per cent, curvevbelt speed for ease of machine interface, capability capacity to 400 feet per minute, for up to four curve modules, improved straight nosebar drive size curve conveyor capacity up to 200 per reduced by 50 per cent – fits cent and curvevbelt speed capacity to into frame height, and weighted 400 feet per minute belt take-up module on curves reduces product maintenance.

Ingersoll Rand has launched Evolution™ - a brand of contact cooled rotary screw air compressor. The new Evolution™ brand has been designed specifically to meet industry requirements while delivering energy efficient performance. It offers a wide network of certified and well trained technicians and engineers capable of supporting customers with cost effective service solutions that will help keep their compressed air system at peak performance. This range of compressors is designed with the latest technology providing prominent benefits including more CFM/kW that provides more air flow (CFM) with less This range of compressors power consumption (kW); low is designed with the latest maintenance cost that increases the life technology providing of the compressor and long life ultraprominent benefits including coolant that increases productivity and more CFM/kW that provides efficiency of air end. It is a one stop more air flow (CFM) with less solution with refrigerant air dryer, air filter power consumption (kW) and receiver that provides moisture-free air to enhance the life of end equipment.

> MORE@CLICK EM01329 | www.efficientmanufacturing.in

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> MORE@CLICK EM01330 | www.efficientmanufacturing.in

9/5/2014 5:55:28 PM

h i g h l i g h t s | c o m pa n y i n d e x | Im p r i n t

Highlights - October 2014 impRINT Publisher / Chief Editor  Shekhar Jitkar shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net

»»Cutting tools Cutting tool technology is evolving rapidly to respond to changing demands and more challenging workpiece materials. Cutting tool technology has advanced dramatically, and the right choice of tooling today can fundamentally transform the process. The coming issue would provide an in-depth know-how on how cutting tools lead to greater productivity and efficiency.

»»Coolants & lubricants With an urgency in improving efficiency, companies are constantly working on increasing cutting performance by using better lubricants in coolants and cutting oils. With market dynamics changing it has created more demand for new generation coolants. In such a scenario, maintaining a coolant to increase its longevity becomes indispensable. »»Machining centres Multi-functional machine tools have been around long enough in various configurations for manufacturers to appreciate their potential for cost saving, and productivity. Elaborating on the trends in machining centres, the upcoming issue takes a look at how ‘doing more with less’ is aptly becoming the mantra today in machining.

»»Industrial maintenance Maintenance is a complex process that is triggered by planned periodic repair, equipment breakdown or deterioration indicated by a monitored parameter. This process requires planning, scheduling, monitoring, quality assurance and deployment of necessary resources. The next issue of EM highlights aspects such as maintaining a competitive advantage with existing assets; improving & ensuring performance of existing/new assets; increasing productivity and reducing downtime, etc.

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Advertising Sales  Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany)  Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout  Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net

company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Ace Micromatic Group . . . Back Inside Cover, 56 Aequs . . . . . . . . . . . . . . . . . . . . . . . . 10, 34 Altem Technologies . . . . . . . . . . . . . . . . . . 10 Autogrip Machinery Co . . . . . . . . . . . . . . . 89 B&R Industrial Automation . . Cover, 8, 9, 10, 66 Benign Enterprises . . . . . . . . . . . . . . . . . 36,37 Blaser Swisslube . . . . . . . . . . . . . . . . . . . . 43 BMGI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 CECIMO . . . . . . . . . . . . . . . . . . . . . . . . . . 14 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Cognex Corporation . . . . . . . . . . . . . . . . . . 95 Comsol Multiphysics . . . . . . . . . . . . . . . . . 13 Copalp . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Dees Hydraulic Industrial Co . . . . . . . . . . . . 59 Desoutter Industrial Tools India . . . . . . . . . . . 38 Diamond Metals . . . . . . . . . . . . . . . . . . . . 75 Dormer Tools India . . . . . . . . . . . . . . . . . . 53 Dorner . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 EEPC India . . . . . . . . . . . . . . . . . . . . . . . . 14 EMAG India . . . . . . . . . . . . . . . . . . . . . 11, 74 Faro . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Fatty Tuna India . . . . . . . . . . . . . . . . . . . . . 70 Festo Controls . . . . . . . . . . . . . . . . . . 33, 44

Features Writer Megha Roy megha.roy@publish-industry.net

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Freudenberg . . . . . . . . . . . . . . . . . . . . . . . 20 Gifu Enterprises . . . . . . . . . . . . . . . . . . . . . . 4 GW Precision . . . . . . . . . . . . . . . . . . . . . . 16 Haas Automation . . . . . . . . . . . . . . . . . . . . 1 HG Technology Co . . . . . . . . . . . . . . . . . . 41 Honda Motors . . . . . . . . . . . . . . . . . . . . . . 12 Hyundai WIA India . . . . . . . . . . . . . . . . . . . 21 Ifm electronic India . . . . . . . . . . . . . . . . . . 65 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Ingersoll Rand . . . . . . . . . . . . . . . . . . 27, 95 Italian Technology Center . . . . . . . . . . . . . . 69 Jainnher Machine Co . . . . . . . . . . . . . . . . 67 JMTBA . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Jyoti CNC Automation . . . . . . . . . . . . . . . . . 5 Kabelschlepp . . . . . . . . . . . . . . . . . . . . . . 76 Kim Union Industrial . . . . . . . . . . . . . . . . . 91 Kirloskar Brothers Limited . . . . . . . . . . . . . . 12 Komet Precision Tools India . . . . . Front Gate Fold Lico Machinery Company . . . . . . . . . . . . . 55 MathWorks . . . . . . . . . . . . . . . . . . . . . . . . 14 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 6 Mitsubishi Heavy Industries . . . . . . . . . . . . . . 2 MMI India . . . . . . . . . . . . . . . . . . . . . . . . 23

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page MotulTech India . . . . . . . . . . . . . . . . . . . . 25 Omron Automation . . . . . . . . . . . . . . . . . . . . 3 part2clean . . . . . . . . . . . . . . . . . . . . . . . . 78 Pepperl + Fuchs . . . . . . . . . . . . . . . . . . . . 93 Renishaw . . . . . . . . . . . . . . . . . . . 15, 50, 94 Rockwell Automation . . . . . . . . . . . . . . . . . 60 Rollomatic India . . . . . . . . . . . . . . . . . . . . 63 Royal Precision Tools Corporation . . . . . . . . 51 Schuler . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Schunk Intec India . . . . . . Front Inside Cover, 94 Seco Tools . . . . . . . . . . . . . . . . . . . . . 47, 95 Steelcast . . . . . . . . . . . . . . . . . . . . . . . . . 22 Stratasys . . . . . . . . . . . . . . . . . . . . . . . . . 80 TaeguTec . . . . . . . . . . . . . . . . . . . . . . . . . 93 Taiwan Machine Tool . . . . . . . . . . . . . . . . . 31 Taiwan Takisawa Technology . . . . . . . . . . . . 49 Tata Group . . . . . . . . . . . . . . . . . . . . . . . . 12 Tech Mahindra . . . . . . . . . . . . . . . . . . . . . 12 TMBA . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Vargus India . . . . . . . . . . . . . . . . . . . . . . 61 Walter Tools . . . . . . . . . . . . . . Back Cover, 94 Worldwide Industrial Machinery Ltd . . . . 17, 93 YG Cutting Tools Corporation . . . . . . . . . 18, 19

Editorial & Business Office  publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752 Board of Directors  Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor)  Subscription  Cover Price: `100 Annual Subscription Price: `1000 em.india@publish-industry.net Tel: +91-20-6451 5754 Printing  Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting  The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.efficientmanufacturing.in

EM | Sep 2014

9/5/2014 5:41:27 PM

Page _Ace Micromatic 210X273.pdf

CMY

9/2/2014

6:59:56 PM

Back Cover Walter new_210X273.pdf

8/27/2014

4:57:39 PM

RNI No.: MAHENG/2010/34603

Watch trailer:

CMY

MORE FORCE, MORE STAMINA, MORE BITE. Tiger·tec® Silver turning inserts for ISO P, ISO K and ISO M materials New cutting materials and new geometries – coming together to increase performance by up to 75 %. Based on the unique wear resistance and toughness, it is possible to predict what these cutting materials can endure. This is made possible by a new, patented aluminium oxide coating, which, in conjunction with the Tiger·tec® Silver procedure that is recognised worldwide, adds a whole new dimension to machining. Tiger·tec® Silver – because process reliability deserves more bite.

Walter Tools India Pvt. Ltd. India Land Industrial Park, S No. 234, 235 & 245, Hinjewadi, Phase I, Pune 411 057 Tel.: +91 20 30457300 service.in@walter-tools.com www.walter-tools.com

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