EM Apr 2015

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AUTOMOTIVE Advanced Threading Solutions

Innovative Grooving Solutions

A Wide Range of Solutions for the Automotive Industry ABS Systems, Gears, Shafts, Suspension Components, Ball Joints, Bleed Screws and Hydraulic Systems Grooving

Boring

Grooving

Groove Milling

GrooVical

microscope

Mini-V

GM Slot

Micromachining Solutions for Grooving, Boring and Threading in Bores from 1.0 mm

A Complete Range of Solutions for Small Parts Machining

High Precision Tools for Groove Milling

Thread Milling (Inserts)

Thread Milling (Solid Carbide)

For General Grooving Applications with Groove Widths from 0.5 to 6.35mm

Thread Turning

VISIT VARGUS

TM Solid Multi-tooth inserts for high-volume production

Multi-Flute Indexable Thread Milling line for fast machining

VARGUS INDIA

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Multi-function Solid Carbide Thread Milling Tool (drill, thread and chamfer) with Coolant Thru.

Unit Nos. 16 & 20, 1st Floor, Mega Centre | Pune - Nasik Highway, Chakan | Pune - 410501 Tel: +91 21356 54748 | info@vargusindia.com| www.vargusindia.com

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E D I TO R I A L

Developing positive business leads “One thing is certain – manufacturing companies who currently do not have a plan for leveraging nextgeneration technologies, or are not in the process of developing one, risk falling behind their competition”

Manufacturing enterprises, today, must focus on moving faster and making decisions more rapidly in a highly complex and uncertain environment filled with more data, but less insight. It has been observed that, in general, there is not much emphasis on applying lean concepts to information sharing and communications processes on the factory floor, leaving a great deal of process latency still to be removed. Fortunately, mobile devices, social and collaboration technology, and business analytics for the masses can drive continuous improvement / kaizen initiatives forward, helping to streamline factory operations, improve quality, and enhance team coordination for faster problem awareness, understanding, and resolution. Today’s next-generation technology solutions have the potential to transform manufacturing - from improved operational efficiency on the plant floor to new product and service offerings that create stronger customer relationships.

One thing is certain – manufacturing companies who currently do not have a plan for leveraging next-generation technologies, or are not in the process of developing one, risk falling behind their competition.

Realising this, EM has been playing a very important role in its task of capturing and disseminating the right information about advanced technology solutions vis-à-vis market trends, helping you get useful leads and ideas for your technology and business requirements. We would like to invite you to share your knowledge and expertise with us, and develop positive business leads through the magazine.

Happy reading!

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

EDITORIAL ADVISORY BOARD Sonali Kulkarni President & CEO Fanuc India

N K Dhand CMD Micromatic Grinding Technologies

Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant

Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA

Vivek Sharma Managing Director Yamazaki Mazak India

S Ravishankar Managing Director Walter Tools India

Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan Dr P N Rao Professor of Manufacturing Technology Department of Technology University of Northern Iowa, USA

Satish Godbole Vice President, Motion Control Div Siemens Ltd Vineet Seth Managing Director India & Middle East Delcam Plc

Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

EM | Apr 2015

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CONTENTS

Market

Management

Focus

Casting & Forging 10

26

NEWS

40

“UNMANNED OPERATION IN MACHINING FACTORIES WILL BE PREVALENT�

16

Interview with Dr Yoshiharu Inaba, President & CEO, Fanuc Corporation

“MARKET SENTIMENT IS POSITIVE NOW“

Interview with Gautam Ahuja, Managing Director, Dormer Tools India “MARKET OPTIMISM SHOULD SHOW PHYSICAL CHANGES�

Interview with Eswari Prasad, President, MAG India Industrial Automation Systems

The article deals with the factors driving the cost of forging and how companies are adopting the modeling & forging simulations

MANAGEMENT STRATEGIES 34

17

IMPROVING FORGEABILITY, REDUCING COST

ZERO DEFECT & ZERO EFFECT

The article outlines why companies should achieve the zero defect stage in their manufacturing process to ensure maximum productivity

EVENT REPORT 66

MOVING TOWARDS SPECIALISED MACHINES

A post-event report on TIMTOS 2015, held at Taiwan TECHNOLOGY TALK 28

APPLYING SMART BUSINESS SOLUTIONS

The feature discusses the usage of mobile solutions in the manufacturing industry to streamline manufacturing processes

Cover Story 18

BIG DATA APPROACH TO TRACEABILITY

The feature highlights the development of traceability and discusses how manufacturers can leverage the scope of big data approach to achieve manufacturing excellence

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CONTENTS

Technology

Cover image courtesy: Shutterstock & KSPG AG

TEST & MEASUREMENT

AUTOMATION & ROBOTICS 44

Intuitive robot programming

58

The article highlights the software that integrates offline programming, simulation, code generation and path optimisation to make an error-free process

The article highlights Renishaw’s Primo™ twin probe system used by Unimac that increases productivity and quality

Defining & communicating engineering tolerances

60

Shaping product design & manufacturing

The article details on how desktop 3D printers enable users to turn designs into reality MACHINING 56

Machining complex aerospace components

An application story on the recently launched Haas universal machining centre used by KMP

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71

SPECIAL FEATURE 64

52

70

Adopting best practices

The article details the various measures incorporated to maintain a good coolant quality in the systems

The article briefs on the cost benefit of adopting GD&T standards with error-free operations in the manufacturing environment MANUFACTURING IT

New Products

COOLANTS & LUBRICANTS

DIMENSIONING & TOLERANCING 48

Automated on-machine part setting

Going green with veggies

The article overviews the benefits, derived from the usage of vegetable oils for developing environmentally responsible fluids

Hydraulic transfer press; Cloud-enabled digital automated inventory system; Metal 3D printing systems for dental parts; Fully automated boring bar adjustment system Flexible mechatronic parallel gripper; Metal cutting practical application support; Multiple spindle heads; Double-sided insert for multiple application

Columns 07 08 72 72

Editorial Contents Highlights – Next issue Company index

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MARKET | NEWS

Seco Tools inaugurates its new technical centre in Chennai

SKF signs agreement with Volvo Cars

Seco Tools has recently opened its new generation technical centre in SKF has recently signed an agreement to supply Volvo Car Corporation with Chennai. The virtual & practical centre, wheel hub bearing units for their future car lines. Stephane Le-Mounier, is a new kind of facility that combines President, Automotive Market, SKF, said, high quality on-ground training & “Working with Volvo Cars in the development education with global virtual broadcast of solutions that meet their high demands has capacity. This will allow for physical been a successful team effort. Our focus is on events to be run as stand-alone events developing solutions that support high or be combined with local, regional performance and improved energy efficiency. and global online audiences. The new Combined with our global manufacturing and The facility combines high quality centre is equipped with the latest technical support footprint, this was on-ground training & education with state-of-the-art production gear, instrumental in securing the agreement global virtual broadcast capacity including machine tools, CAD/CAM, announced.” SKF’s wheel hub bearing units SKF’s wheel hub bearing tool measuring and setting equipment with low friction grease have been specifically units have been developed combined with the company’s latest high performance cutting tools. The developed to meet Volvo Cars demands on to meet Volvo Cars E-learning modules combined with hands-on trainings, customer specific performance, weight reduction and stiffness, demands component run-offs or new product launches are the application examples contributing to a more comfortable driving of the centre. It will be made available for booking to all of the company experience and lower fuel consumption. SKF is represented in more than industry partners, customers and distributors, while providing a modern, 130 countries and has around 15,000 distributor locations worldwide. high quality platform for metal cutting & industry professionals to discuss Annual sales in 2013 were SEK 63,597 million and the number of employees the global, virtual connectivity without boundaries was 48,401. > MORE@CLICK EM01596 | www.efficientmanufacturing.in

CII West aligns its theme with Make in India

> MORE@CLICK EM01597 | www.efficientmanufacturing.in

FARO® announces its Asia Pacific 3D User Conference 2015

At the first meeting of the CII Western Regional Council 2015-16, Sanjay FARO Technologies recently unveiled the 3rd edition of the annual FARO 3D Kirloskar was elected as the Chairman and user conference for the Asia Pacific region. Catering to 3D documentation Sudhir Mehta was elected as the Deputy communities within various industries, the conference comprises three Chairman of CII - Western Region. “The full-day sessions on theme for CII Western Region for 2015-16 June 2, 2015 in is ‘Enhancing competitiveness to Tokyo; June 26, accelerate growth and create employment’, 2015 in Shanghai the goals of which are closely aligned to and September 4, the Hon’ble Prime Minister’s dream of 2015 in Bengaluru.

‘Make in India’. During the year, the focus “It would be a golden in the western region would be to improve opportunity for the governance, enhance competitiveness and 3D user communities to keep up-to-date with the latest technologies, as According to Sanjay Kirloskar, facilitate ease of doing business to well as to interact and connect with one another, irrespective of the the industry must imbibe the catalyse sustainable and ethical growth in industries they are from,” said Joseph Arezone, MD—Europe, Middle East culture of ‘Zero defect, Zero the region. The industry must imbibe the & Africa and MD, Asia Pacific. Attendees will hear from renowned effect’ culture of ‘Zero defect, Zero effect’. I am professionals and top industry experts about the capabilities and potential confident that together, the industry and of the 3D terrestrial laser scanning technology through keynote addresses, government can and will achieve this dream,” said Kirloskar. Mehta is the power speeches, and case studies of successful implementation. In addition, CMD of Pinnacle Industries, Madhya Pradesh and Kirloskar is the CMD of selected technology solution providers will also be on-site to present their solutions and products in the 3D exhibition segment.

Kirloskar Brothers. > MORE@CLICK EM01598 | www.efficientmanufacturing.in

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> MORE@CLICK EM01599 | www.efficientmanufacturing.in

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MARKET | NEWS

JUNKER group acquires ZEMA

RocTool join hands with Autodesk

The JUNKER group has recently acquired the RocTool has recently opened simplified access to its technologies through Brazilian grinding machine manufacturer ZEMA. a new collaboration with Autodesk Inc and Autodesk Simulation Moldflow With the takeover, the company expands its Insight. “This relationship marks a real strategic change that will make expertise as a complete supplier in the grinding RocTool’s technologies more sector. The customer is now provided with CBN accessible to manufacturers grinding machines, corundum grinding and subcontractors,” said machines and air filters from a single supplier. Stéphane Hersen, President & The company has now secured a qualified CEO, RocTool. The collaboration majority share (more than 75%) in ZEMA, integrates the induction because the company has sophisticated technology developed by RocTool into Autodesk Simulation Moldflow’s flag solutions for grinding with corundum, e.g. for ship simulation tool. RocTool’s Heat and Cool technologies allow mass With the takeover, the machining the flange and journal on crankshafts production of plastic parts with optimum surface quality directly from the company expands its or transmission, turbocharger and cardan mould, without visible weld lines and improved mechanical properties, with expertise as a complete shafts. a reduction in production costs. It also helps with difficult thin wall supplier in the grinding sector Rochus Mayer, CEO, JUNKER Group, said, “Now, mouldings or moulding materials that require very high mould temperatures. we can fulfill any customer needs, open up This collaboration reinforces RocTool’s commitment to allow users of additional markets and supply combined production lines (CBN, corundum).” Autodesk Simulation Moldflow to easily access the added value of RocTool’s ZEMA already supplies global players like Bosch, ThyssenKrupp and Fiat in technologies from April 2015. The “RocTool Ready” concept is a part of the Brazil. JUNKER Group with headquarters in Nordrach, Germany, does have company’s new industrial strategy, which aims to simplify access to a worldwide sales and service network that is continually growing.

RocTool’s well-established premium technologies. > MORE@CLICK EM01600 | www.efficientmanufacturing.in

> MORE@CLICK EM01601 | www.efficientmanufacturing.in

3D printers built with igus products

Indsur Global join hands with Global Industrial Group

With the iglidur I180-PF, igus has recently introduced an advanced filament that is easier to process, which means that real components for real applications can also be easily manufactured and used immediately. After the world’s first tribofilament for 3D printers was premièred at the Hanover Show, the company offers its second filament that has been optimised for friction and wear. “iglidur I180-PF, the new material from our Tribo-expert igus 3D filament range, is even easier to process than offers several the iglidur I170-PF material presented at the components for 3D Hanover Show, because it has a higher elasticity. It printers - from plain is now already available in 1.75 or 3 millimetre bearings and energy diameter,” said Tom Krause, Product Manager— supply systems to iglidur tribo-filaments, igus. The filaments are up friction and wearto 50 times more abrasion-resistant than materials optimised filaments that are traditionally used in 3D printers. The filament and other ‘motion plastics’ products from the company are also suitable for use in 3D printers for axis, e.g. the recently released low-priced solid plastic bearing drylin RJ4MP.

Indsur Global has recently tied up with Global Industrial Group (GIG) of Russia for a long term supply of castings from April 2015. The initial commitment is for order valued at S10 mn, which will be supplied in the next eighteen months. The contract was signed between Yaakov Denis, CEO, GIG Group and Amit Lodha, Director, Indsur Group. Commenting on the occasion, Lodha said, “The tie-up with GIG Group is yet another step that proves our commitment to sustained value creation for our stakeholders and the country. We are proud to support the ‘Make in India’ initiative and are fully committed towards establishing India at the forefront of preferred sourcing destinations, globally.” Denis believes that entering the Russian market is just a small step in a long journey that lies ahead. Speaking on the development, he said, “We look forward to scaling our sourcing in bigger way in line with our long-term growth plans and a mutually beneficial relationship for each of us.”

> MORE@CLICK EM01602 | www.efficientmanufacturing.in

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MARKET | NEWS

EMAG to showcase innovative products at CIMT EMAG will showcase some turning machines for medium & innovative products at the China large batch manufacture of chucked International Machine Tool show to components with a max diameter of be held on April 20-25, in Beijing, 400 mm. It has a uniform basic China. Eldec, a company in the machine construction that always EMAG group will present MIND-M includes integrated pick-up that can be configured to suit a automation. large number of different In addition, the VLC 200 H vertical manufacturing scenarios. It is a hobbing machine, which has highcompact induction hardening performance drives, allowing for the machine, where the designers have use of high speeds on both main combined energy source, cooling VL 2 manufacturing system for chucked components spindle and hob will also be display. unit and processing cell into one Thus, large quantities of gears with complete system, mounted with space-saving effect on a single, compact a diameter of max 200 mm and module 4 can be efficiently dry milled at machine base. shortest cycle times. There will also be the VLC 100 C vertical chamfering The VT series — a manufacturing system optimally suited to the production machine that can be equipped with the technology best suited to the of large batches of shaft components will also be showcased. Its automation individual requirement. Lastly, VLC 100 GT vertical grinder, having a system makes for short chip-to-chip times and low component costs, with combination of turning & grinding technologies will also be showcased. workpiece grippers taking raw parts into the machine and removing the Here, surface areas can be hard-turned before they are finish-machined finish machined components. with external or internal grinding spindles. > MORE@CLICK EM01604 | www.efficientmanufacturing.in The company will also display VL series, consisting of vertical pick-up

PTC India announces new roles for strategic growth

KPIT felicitates the winners of Sparkle 2015

PTC has recently appointed Jaishankar Menon as the Channel Business Director and Sundaram Mallik as the Regional Marketing Manager. In this new role, Menon will oversee PTC’s channel business in India and will be responsible for strategic development and growth of the partner eco-system. With his appointment, the company is looking to expand PTC India’s customer reach across the country. Commenting on this new appointment, Subash Nambiar, Country Manager, India, said, “We are excited about Menon’s new role as a channel business head. His leadership Jaishankar Menon will be key in augmenting our India partner ecohas been appointed as system and increase our business prospects the Channel Business here in the coming years.” Maintaining the Director of PTC, India company’s aggressive focus on the Indian market, the company also announced the appointment of Malik to spearhead the marketing initiatives for India. “With Sundaram’s appointment, we look to strengthen our marketing initiatives and drive awareness about smart connected product technology in India,” said Dr Thomas Roser, VP—International Marketing, PTC.

KPIT has recently announced the winners of Sparkle 2015, a national design and development innovation contest, in association with College of Engineering, Pune (COEP). The contest was aimed at fostering the culture of innovation among science and engineering students by inviting breakthrough ideas to address ongoing challenges in the areas of transportation and energy. The contest received 424 varied ideas from over 1100 students from more than 114 colleges across 17 states of India. In the final round, the shortlisted teams presented ‘proof of concept’ The contest received 424 varied ideas from over 1100 students of their solutions for global issues, from from more than 114 colleges unconventional power generation and hybrid across 17 states of India solutions to intelligent transport systems and driver safety. Ravi Pandit, Co-founder, Chairman & Group CEO, KPIT, said, “Every idea proves that today’s youth has enormous potential to find feasible solutions for many of our existing energy and mobility challenges that matter. We strongly believe in nurturing innovation and sparking creative ideas that benefit society. Sparkle 2015 has enabled students to realise their scientific and technology acumen.”

> MORE@CLICK EM01605 | www.efficientmanufacturing.in

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> MORE@CLICK EM01606 | www.efficientmanufacturing.in

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NEWS | MARKET

India Pavilion in Hannover Messe 2015 to incorporate core sectors of ‘Make in India’ Hannover Messe 2015 will witness a large scale Indian participation by branding the ‘Make in India’ slogan in Germany and other neighbouring European countries By adopting the ‘Make in India’ theme, India is branding strongly in Hannover Messe 2015. Apart from over 100 CEOs from top companies confirming to participate in the fair, more than 300 Indian companies are participating as exhibitors in the fair.

Projecting India’s brand image According to Smt Nirmala Sitharaman, Minister of State for Commerce & Industry (Independent Charge), the Indian Pavilion at Hannover Messe 2015 is being constructed by the Department of Industrial Policy and Promotion (DIPP) to project India’s brand image by incorporating many of the key core sectors of the Indian portfolio forming part of the ‘Make in India’ campaign. The Government has made EEPC India as the lead agency. CII and FICCI are the other partners associated.

At the fair, Hon’ble Prime Minister Narendra Modi would be reaching out the global business and technology leaders on the new initiatives of the Indian Government for doing business in India. To support this, various ministries like the IT, skill development and entrepreneurship, heavy industry, etc, would be hosting seminars on topics relevant to the new government’s initiatives.

Indian participation highlights The ‘Make in India’ initiative to develop and market India to global investors has been decided as the theme for participation. About 300 Indian companies including public sector giants would be participating in the 5–day fair, seeking technology collaborations, business tie-ups and showcasing India’s capabilities in global trade.

EM | Apr 2015

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India will participate at the 10th sectoral core themes of HM 2015 (like energy, wind, industrial automation, industrial supply, etc). Besides IGBS, India will also host 6 seminars to highlight the government’s new initiatives and seeking induction of German technology / investment. Key officials of the concerned ministries of GoI would be involved in seminars like New sunrise in electronics and electricals, Smart Cities the urban challenge, Renewable energy, Strategy for skilling India, Heavy engineering and motion drive & automation, Digital India. Twelve state governments have confirmed participation and the state pavilion, adjacent to the India Pavilion, has been created to display the state profile.

Maharashtra, Andhra Pradesh, Punjab, Gujarat, Rajasthan and UP are separately hosting investments seminars during the fair.

India is hosting the Partner Country Night on April 15, 2015 in which CIM would be inviting participants. ☐ > MORE@CLICK EM01607 | www.efficientmanufacturing.in

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MARKET | INTERVIEW

“Market sentiment is positive now...” ...says Gautam K Ahuja, Managing Director, Dormer Tools India, in an interaction with Megha Roy, while highlighting the Dormer-Pramet App to streamline the manufacturing process and tracing the changes witnessed in the cutting tool industry. Excerpts…

How has the cutting tool technology evolved over the years? turning, milling, parting & grooving, indexable drilling and What are the recent advancements? even boring heads. With such a large range available under one From uncoated carbide days, various types of coatings have roof, the total package of tools is synchronised and synergised evolved over the years leading to greater productivity and for maximum gains for the customer, leading to cost effective enhanced tool life. Different types of multi-layer CVD coatings solutions. and advanced PVD coatings have helped to reduce tool costs significantly for customers. Regularly, new geometries and Do you think the Indian mindset is open to experimenting the grades are being developed, even for difficult-to-machine latest technology changes? Can you brief us on the company’s materials like heat resistant alloys. new product lines & solutions with modular concept?

In milling, there is a constant need to increase productivity, We have recently launched thread milling cutters, tangential face by increasing the depth of cut, and yet provide milling cutters and a positive NF geometry economy with higher number of edges. This for stainless steel machining. Ten versatile has led to the development of Penta cutter of thread milling cutter (J2xx) families have 10 mm depth of cut with 10 edges. In hole been developed with a mix of popular thread making, the drills with newer lip geometries, forms including M, MF, UNC, UNF, G (BSP) coupled with the latest nano coatings help and NPT, with or without internal oil feed. reducing cycle times, while HSS-EPM shark Another important addition is the tangential taps produce accurate threads in minimum mounting of the new robust double-sided time. inserts which ensures rigid clamping. Our new range of inserts will be suitable for large Your company has recently launched an app work-pieces on big castings and forgings for, for the Dormer rotary programme. How does in particular, the power & marine industries. digital technology help in streamlining the For turning, the double-sided positive NF manufacturing process? geometry inserts under the Pramet brand, Digital technology is very helpful since it are available for finishing to medium turning provides all information on the mobile at of stainless steel, low carbon steel and super fingertips. The Dormer-Pramet App is very useful for our alloys. More than 110 variations in insert shapes (C, D, S, T, V customers and dealers. The full product range is available and W), sizes and grades have been developed.

24x7, for selection. We also have the tool selector software for selecting the right tool. The customer can just key in the What is your expectation for the performance of the cutting parameters and the software selects the tool, from a wide tools market in 2015-2016? variety, making it simple. Thus, the manufacturing process of The government has started many initiatives like the ‘Make the customer is steamlined with Dormer-Pramet tools. in India’, which is bound to propel growth in the industry, in the medium term. The interest rate cut regime has also been To implement a complete tooling solution, what are your started by the RBI, which will benefit the auto & housing company’s strategies to ensure cost effective solution for sectors. Thus, the market sentiment is positive. The biggest customers? advantage with India is its inherent demand and hence the Our company has one of the largest range, starting from economy is bound to grow. ☐ HSS to solid carbide in rotating tools, complemented by a > MORE@CLICK EM01608 | www.efficientmanufacturing.in very strong programme in indexable cutting tools covering

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INTERVIEW | MARKET

“Market optimism should show physical changes” Eswari Prasad, President, MAG India Industrial Automation Systems, in this interview with Srimoyee Lahiri, discusses the present scenario of the Indian machine tool industry and outlines the various strategies incorporated to synergise with the changing customer requirements.

With the ‘Make in India’ initiative, how are you synergising your strategies with the business growth?

‘Make in India’ message has already been well received and is pro-manufacturing in the core sectors. There appears some strategy and efforts being put into place to improve the business atmosphere, faster clearances to avoid redtapism. Our company is very conscious of its role in the most potential and technology hungry market. Right from inception in 2007, MAG India has synergised its strategy and catered the best technology and process to make automotive parts for passenger cars and trucks for majority of OEMS from Europe, USA and Japan. The innovation and care for environment has been practically implemented in India with the cooperation of our key customers. A case in point is the magnificent Ford Sanand’s climatically controlled facility, which has started making power train components on our machines equipped with minimum quantity lubrication. MAG’s unique Adapter Plate Concept (patented) makes the system versatile to machine different blocks and heads for engines. This unit is dedicated for export of its product to various destinations.

Please brief us on the company’s new product lines and solutions in the offing?

We believe in “innovate or perish”. Ever since we entered this market, we found it essential to introduce our constantly innovated products in the global market. To name a few, completing the honing operations in single set-up on horizontal machining centres. Two of our key customers have evinced keen interest to introduce in their facilities. We have developed elimination grinding crank shaft by producing in the finish milling process for the crank shafts. The patented Adapter Plate Concept is popular in the Indian market.

How has been the performance of the machine tool industry this year?

The period of 2013-15 was difficult due to the poor untimely decisions taken by the government. Production of commercial vehicles dropped steeply and interest rates rose. With the arrival of the Modi government, there is optimism in the market, which needs to show physical changes. The recent budget presented is evidently pushing the growth in the economy to reach 7 to 7.5%. Though, we see gradual positive results, we have a long way to go. We expect 2016 would be a much better year for the machine tool industry as we see small and medium sized projects have surfaced at an encouraging trend. Machine tool industry in India has learnt to react faster than ever before. There is no reason to worry since the defence and aviation industry is on the up-swing and growth in machinery requirement is imminent. The SMEs are gathering the lost strength and recouping their strategies for the growth.

Tier 1 and 2 will have greater contribution too.

What is the general demand trend witnessed in the Indian machine tool industry?

India has been a blessed country for attracting all the leading automotive producers in the globe. It has been repeatedly proved that cars produced in India are more cost effective than China or Thailand. This brings out lots of credibility in global presence for India. As such, the trend in the demand of machine tools is challenging and only builders with proven track record are automatically selected. The trend in the past was to depend on cheap labour and prolonged time cycle to make parts. This is no longer appropriate to build a strong industry and attain international recognition. India has achieved a milestone in automotive industry. The high potential aerospace and defence industry is now waking up. Thus, machine tool industry is going to be busy looking for appropriate products and processes to take the lead in other sector. ☐

EM | Apr 2015

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Brief us on MAG’s activities in R&D. Our chairman has consistently shown distinct focus in R&D activities to bring in cutting edge products not only for our company but also for other machine builders. 5ME - a part of the MAG business unit, is responsible for R&D activities in the MAG group. Most of our innovative products have found place in leading manufacturing units in the US and Europe, before they are introduced in other markets.

> MORE@CLICK EM01609 | www.efficientmanufacturing.in

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C O V E R S TO R Y

TECHNOLOGY

Image courtesy: Shutterstock

BIG DATA APPROACH TO TRACEABILITY Driving manufacturing excellence

Software technology has advanced to the point where harnessing the big data of a manufacturing enterprise is a practical reality. Leading manufacturers witness initiatives such as traceability, continuous improvement, yield and OEE optimisation, etc. as best handled as a part of true operations-wide big data solution. The article details the development of traceability and discusses how manufacturers can leverage the incredible depth and scope of data approached to achieve world-class manufacturing excellence.

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Jason Spera CEO Aegis Software

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TECHNOLOGY

Product and process traceability was once a requirement of mission-critical or extreme reliability applications and industries alone. Medical, automotive, and aerospace manufacturing have long grappled with achieving traceability to satisfy either regulatory requirements, or to limit potential recalls and the costs and liability associated with them. Over the last decade, these niche and esoteric requirements have become mainstream.

Now, manufacturers in many sectors are expected to provide traceability. It has become a challenge for a large percentage of discrete manufacturers, particularly when manufacturing products include reasonably advanced technologies. The very nature of traceability itself has also evolved. Originally, if serialised products could be recalled against a certain range of component lots the issue was considered solved. This often meant a recall that was broader than it needed to be, but the manufacturer was assured at least that all at-risk products were included, and that was considered acceptable. Today, the situation is very different from both accuracy and a data scope perspective. When a recall occurs, the cost and brand image ramification of any ‘good’ units being recalled is significant. The traceability system must achieve the goal of ensuring absolutely that every faulty unit is identified and recalled, while avoiding the recall of any ‘good’ units unaffected by the problem. Erring on the side of caution resulting in the recall of many additional units is no longer acceptable.

Traceability can no longer be about component batches alone. Now, traceability can provide operator data, showing who was present when a product passed through a specific workstation, process variables from equipment, a chemical or tool used, or even support full forensic-style investigation of all electronic approvals and multi-level confirmations of actions taken on the product. The entire production flow from start to finish, including materials used, tools, operator and machines involved, and every environment variable must be available to provide ‘keys’ against which a group of serialised units can be recalled. Traceability now extends back into the process planning and even to R&D and design via CAD data.

Traditional approach to traceability The typical tools and systems to meet the traceability challenge of the past were most often adopted out of grudging necessity placed upon the manufacturer by the market, regulatory

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C O V E R S TO R Y

agencies, or customers. As such, the approach was often one of ‘do as little as will meet the requirement’. Consequently, systems were bought or built that would satisfy only the specific scope of traceability demanded, and in many cases only on the particular assemblies or products that required it.

This approach answered the immediate need of the company, but failed to achieve anything further. This narrow approach is fraught with missed opportunity. By adopting such a narrow scope and application of traceability, the entire manufacturing culture is trained to see traceability, data acquisition and management as a burden rather than part of the way business is done with inherent benefits. Furthermore, the solution built has to be customised and extended every time the requirements evolve, incurring additional costs and management time.

The biggest lost opportunity is process and manufacturing improvement.

Consider the scope and depth of data available. That information can really drive operational excellence when properly utilised. It can flow back to R&D to improve future designs and it can drive real-time improvement by giving process engineers, operators, and managers a view into the reality of the process. The data set included in modern traceability effectively becomes the definition of ‘Manufacturing Big Data’. When that data is leveraged for more than just answering the traceability challenge, it becomes the most powerful process and product improvement tool imaginable. Traceability should no longer be a primary goal for manufacturers, even if it is a core regulatory, market or customer requirement. The goal should be achieving manufacturing big data across the full scope of operations, and the full depth of product, process, and machinery data. Once manufacturing big data is harnessed, traceability becomes a natural byproduct. More importantly, the analytical and process improvements that come from leveraging this big data are gateways to operational excellence. By having operational excellence via big data as the real corporate goal, traceability ceases to be a burden or cost and becomes part of a valuable culture of improvement that pervades the manufacturing enterprise and drives differentiation and success.

The big data approach to traceability Manufacturing big data is a term used increasingly in manufacturing, but rarely discussed at a tangible level. The

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TECHNOLOGY

The “big data� approach to traceability

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enormity of the concept has to be grasped before discussing engine of operations must run constantly in the background, applications that offer operational excellence and traceability. feeding the flow of materials to production, and the flow of First, consider the scope of manufacturing operations from unused parts back into the warehouse all with precise tracking. when R&D finishes the CAD design and the bill of materials These activities alone yield vast, valuable and critical data sets (BOM) is locked down in PLM and/or ERP. This is the moment within the ‘Manufacturing Big Data’. With materials present at which the readiness of the product configuration is achieved. and correct at each station, the manufacturing process itself can There is a good deal of data involved in the mapping of that begin with the serialisation range and work order information BOM to the associated CAD and revision data. The process, flowing into operations from ERP. quality, test, industrial and manufacturing engineers along The flow of the product begins, and data starts flowing with planners then go to work on that data to transform the in from conveyors, the assembly and process data feeds, the design into a detailed process complete with robotic assembly, operator actions and confirmed presences at each station, inspection, test and process machinery programs. The quality the materials, chemicals and tools consumed or utilised as a plan and route control logic must be developed and laid in. The product entered each station. Vast amounts of information visual assembly instructions for every station of the process can be gathered about every conceivable environmental flow must be designed and digitised along the process. This variable, as well as any entity or material that was added to New Product Introduction (NPI) process yields a lot of data the product in addition to how it was added and by whom. mapped to the CAD design and the BOM including revisions, This data acquisition continues through inspection, repair, people involved and the work output they created. We have test, component replacement, and all the way out to packaging not even reached the factory floor itself and there is already a and shipment. A mountain of context data is gathered. This large body of ‘Manufacturing Big Data’ to store and eventually is ‘Manufacturing Big Data’. And all this data is relationally mine. So, the product is ready to launch into manufacturing linked, connecting back to the CAD data and the BOM. The and the lines are ready to start? Not yet. This is the ‘value add’ product definition itself, embodied in the CAD and BOM, is axis of operations, and without materials being in the right the binding element of that massive mountain of data. place at the right time, manufacturing cannot begin. When the production schedule initiates a build, a hand-off from ERP Where does traceability fit in? materials management in the warehouse to the more granular shop-floor control provided by the Manufacturing Operations When the ‘big data’ is considered, the traceability required by a given regulatory agency, customer, or market is simply Management system must begin.

Organisation of materials into transport orders targeted a forward or reverse query against the data set, or a subset of to the proper process point, the management of local stores, it. When a manufacturing enterprise adopts a Manufacturing kanbans, and even the interception of materials into delivery Operations Management (MOM) system capable of managing or feeder systems and the exact point of use are all needed. All the entire scope of operations as discussed, traceability is no of those functions must be traced down to the part, lot, and longer something an enterprise strives to achieve, it already delivery package so that materials traceability has a record from has it as a natural byproduct of that system. Considered from the incoming loading dock to the point where the material or the inverse perspective, total process, product and materials part is consumed into the product or process. This critical traceability is the essential building block when pursuing

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EM | Apr 2015

The eight pillars of TP

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TECHNOLOGY

When traceability is approached as the end-goal rather than a byproduct of harnessing manufacturing big data, the true cost of the initiative is greater

Image Courtesy: KSPG AG

operational excellence through the use ‘Manufacturing Big Data’.

Benefits of the big data approach to traceability Continuous process improvement: A point-solution to answer a traceability requirement is not typically intended to support process improvement. The data set it generates is meant to satisfy a trace requirement but little else. The big data approach gives the enterprise all the information it needs to leverage data toward process improvement and achieving operational excellence. A big data solution provides this by supporting analytics for managers, engineers and line operators, so they are armed with actionable information to make better decisions. A big data solution also involves automated process interlocking and fail-safing to keep processes from going out of control even when humans fail to detect such conditions. A big data solution provides a view into the entirety of operations that otherwise would be extremely difficult to achieve. Real-time dashboards informing operators of impending issues or process performance, condition-generated reports sent immediately to mobile devices when needed, real-time process interlocking of machines and conveyors based on control conditions, visual quality data collection, repair guidance, diagnostics support, real-time detailed work in process monitoring, predictive process flow analysis, and much more can all be achieved simply and efficiently.

Shifting from the psychology of cost & burden to cultural adoption: A critical factor in the success of any software solution in a manufacturing enterprise is cultural adoption by management and operators. The most powerful and capable software system if considered a burden will rarely succeed.

The perception of burden can be the result of a poor user interface, additional transactional overhead slowing work down, or merely confusion as to why it is even necessary at

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all. All these problems are common with narrow traceability systems. It is not a problem with the big data approach because of the holistic nature of the system and the tangible benefits that go beyond traceability. Adoption of a system to harness all manufacturing data becomes part of the operational culture.

It simply is the way business is done. This perspective evokes more enthusiastic adoption by operators as it is much like switching the entire factory over to a new data system and the old methods no longer exist. Additionally, the big data solution yields visible benefits to management and operators and everyone in between. Dashboards, reports, real-time process interlocking, simplified quality data collection and feedback, real-time detailed work in process monitoring, predictive process flow analysis, etc all give personnel real benefits to their daily work that results in an appreciation of the business’s implementation of such a solution.

Future-proof solution: A point-solution for delivering a specific set of traceability to meet a demand soon requires modification to meet an expanded demand as regulatory requirements evolve, or where a customer demands greater traceability. This never-ending cycle of customisation, costs and delays results in a clumsy and complex solution that is difficult to maintain. The big data approach does not suffer from such issues. It provides an infrastructure to gather all data, and, as requirements evolve, it is simply a matter of querying that data. The solution is inherently gathering the entirety of the data set from the product, process, and materials context of production, or, if deployed incrementally, is architecturally able to add data sources into the system elegantly with little or no customisation.

Lower true cost: When traceability is approached as the endgoal rather than a byproduct of harnessing manufacturing big data, the true cost of the initiative is greater. A point solution offers no additional benefits from which to gain ROI for the system investment. A narrow solution for delivering traceability

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TECHNOLOGY

Image Courtesy: KSPG AG

C O V E R S TO R Y

When approached as a natural byproduct of harnessing manufacturing big data, it becomes a ‘free’ benefit of a system that is yielding analytical and process improvement

essentially incurs only costs by existing as a layer of complexity used only to satisfy an externally imposed requirement. As it has no other benefits for the enterprise, its ROI is based only on answering an external demand for traceability. It may avoid risk, but it creates no benefit and is consequently expensive.

When approached as a natural byproduct of harnessing manufacturing big data, it becomes a ‘free’ benefit of a system that is yielding analytical and process improvement.

Requirements of a manufacturing big data solution Having taken the decision to implement a big data solution as part of an operational excellence initiative, the next step of course is system selection. There are a few key capabilities and business approaches a manufacturer should demand of any MOM vendor to maximise success. First, consider the data model the system sits upon. It is not sufficient for potential vendors to simply state ‘yes we can store that data’ or ‘yes we can acquire that data’. It is important to examine two specific and critical data acquisition and data model issues. First, how does the system go about acquiring data from the industrial automation layer of the factory including robots, conveyors, testers, inspectors, sensors, scanners process equipment, etc?

Does the vendor build customised connectors for every data source, or does the system have a scalable and standards-based data acquisition engine for easy adaptation to the automation layer such that the adapters are productised, consistent and maintainable?

Second, determine if the system actually holds the CAD design data in its data model such that incoming variables are related to elements within the design itself. This is critical to analytics and to data volume efficiency as the storing of the data against the CAD data reduces redundancy. These questions should then lead to another related issue. Once the data is within the system, how is it made useful through alarms, control reactions, dashboards, and reporting? Is the data

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stored in a manner that is meaningful such that reports and dashboards can be made through a graphical user interface without requiring SQL or coding knowledge of the database?

True drag-and-drop construction of real time dashboards and reports is only possible if the structure of the system is designed in such a manner that any incoming data, whether implemented today or four years from now on new machine types, are normalised and stored in a meaningful way. The question simple. If a new machine is connected to the system to acquire its real-time data, is any SQL or coding required to change reporting? The answer should be an unqualified ‘no’.

The scope of the system must also be considered. To properly harness ‘big data for manufacturing’, every activity from the handoff of the CAD data, R&D to the process design and NPI activities, through materials management and then out from the start of manufacture to shipment must be part of the fundamental scope of the system’s coverage. Anything less will yield only a subset of the data needed. The final consideration is not a technical one, but rather the business approach and model of the vendor. Is the vendor providing a ‘core’ of a system that then must be heavily customised to work in your environment? Or, does the vendor have vast stock capability that adapts through configuration to your process, minimising customisation and costs? This customise v/s configure question is the single greatest determining factor in the rollout speed and total cost of the project. A means to truly determine the extent of customisation from a given vendor is to insist on a highly detailed statement of work that defines exactly what the system will and will not provide, and insist the vendor’s quote contains a fixed cost to achieve that functionality. To do otherwise, invites endless customisation and costs as manufacturers discover after the sale that the system, when you realize it, does not actually have the capabilities you believed it would have and customisation is required. ☐ > MORE@CLICK EM01610 | www.efficientmanufacturing.in

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MANAGEMENT | INTERVIEW

“Unmanned operation in machining factories will be prevalent” …says Dr Yoshiharu Inaba, President & CEO, Fanuc Corporation, and Vice Chairman, Japan Machine Tool Builders’ Association, in an interview with Shekhar Jitkar.

While giving an overview on the global business scenario in the manufacturing industry, he shares his optimism about the strong growth of the machine tool industry in Asia in the coming years. Excerpts from the interview…

How is the business scenario for your company in India and globally in the current market situation?

The businesses for our FA (factory automation), robots and robomachines in India are steadily growing and I am quite happy with this situation. There has especially been tremendous growth in the sales of our FA products, which I believe reflects the rapid development of the machine tools industry in India.

Our business overall is successful worldwide, with notable growth in all of our products in FA, robots and robomachines in China. In the American market, there is a steady increase in sales centered on robots. In comparison, the markets in Europe and Japan, while being stable, have room for more growth. The Korean and the Taiwanese markets are also very active now.

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automotive industry, energy production and infrastructure will grow. The Indian market will follow the pattern of the Chinese. In the US, there are innovations in the automotive industry, which focus on more efficient engines and electric vehicles. So, there will be more demand for machine tools as well as FA products.

How do you look at the opportunities and challenges within the industry?

In terms of opportunities, the question would be how to take advantage of the rapid growth in the IT (information technology) industry, represented by smartphones. In this respect, we have not let this opportunity pass us by, and have succeeded in winning a big business.

As for challenges, the networking of entire production EM | Apr 2015

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INTERVIEW | MANAGEMENT

“In the future, intelligent robots with vision sensors will enable loading and unloading to machine tools without human help, and I anticipate that unmanned operation in machining factories will rapidly become prevalent” Dr Yoshiharu Inaba

systems as dictated by Industry 4.0 of Germany, is surfacing as a new issue, but Fanuc is making firm progress in preparing to meet such challenges.

What is your approach towards focus on R&D and innovation strategies?

Approximately one third of our employees engage in research and development, and I expect this percentage to increase. We are also planning a substantial expansion of our laboratories in order to speed up development and enhance the reliability of our products.

As one of the leading manufacturers of factory automation and robots, what is your strategy for automating your factories?

Our manufacturing facilities are located exclusively in Japan.

As a company, a manufacturer of factory automation and robots, we must prove that the use of robots reduces costs and that also companies in high-wage countries can flourish in the international competition. We employ the latest technologies for automation and robotisation in our own factories. By doing so, we are able to assess new technologies in our factories before shipping them to actual markets, and minimise production costs by constantly making full use of state-of-the-art automation technologies.

There was a news recently about global collaboration between Fanuc Corporation and Rockwell Automation on Integrated Manufacturing Solutions. Can you brief us more on this?

Fanuc is basically a manufacturer of standalone units, consisting of CNCs, robots and robomachines. Fanuc had already been offering flexible open interfaces to complementary automation systems globally. On the other hand, Rockwell Automation is a manufacturer that is strong in developing systems such as PLCs and factory management software. By combining our areas of expertise, we are able to provide to our customers with a more seamless and integrated manufacturing solution. The two

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companies have expanded their initial collaboration, which started four years ago, in the CNC and Logix programmable automation controller (Logix PAC) environments with further integration of robotics, robomachines and enterprise software products. The effort will have an initial impact on applications in the automotive industry, where customers can experience benefits of a preferred integration plug-and-play automation and information solution. Fanuc and Rockwell Automation will strengthen the relationship and shall continue to develop solutions that will satisfy our customers.

Can you comment on the trends in CNC & robotics – technology & customer needs?

Loading and unloading of CNC machine tools are presently being conducted by human beings. That is why despite machine tools being able to operate automatically by themselves, there has not been much progress in reducing the number of human workers in machining factories or making such factories unmanned. In the future, intelligent robots with vision sensors will enable loading and unloading to machine tools without human help, and I anticipate that unmanned operation in machining factories will rapidly become prevalent.

How do you look at the demand trends globally in the manufacturing sector, in general?

The world’s population continues to grow and the average level of our lives continues to rise. From this, I expect that overall demands will continue to increase throughout the world, such as in daily necessities and building of infrastructure. This will continue to boost demands in the manufacturing industry which support such demands.

What are your diversification & expansion plans for India and globally?

As we have been doing up to now, we shall actively dig up demands for automation and robotisation of factories to contribute to the manufacturing industry in India. ☐ > MORE@CLICK EM01611 | www.efficientmanufacturing.in

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T E C H N O L O G Y | TA L K

Applying smart business solutions

I M A G E C O U RT E S Y: Shutterstock

In today’s fluctuating business environment, manufacturers are always juggling to maintain profitability. This can be done by adopting lean manufacturing techniques to eliminate waste at every stage of the manufacturing process. As such, mobile solutions for shop floors can be an effective tool to streamline manufacturing processes. This leads to more effective utilisation of work force, machines and materials.

Currently, with the help of smart technologies in the industrial landscape, the use of smartphone and tablets is encouraging the growth of applications designed for them.

The manufacturing applications designed, are now being used to implement business strategies, such as lean manufacturing and supply-chain management. Such applications installed for manufacturing facilities not only fastens decision making, but also improves communication and workflow. A few examples of companies adopting such applications include CAM2

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With rapid evolution of technology, manufacturing industry witnesses a technology-savvy business strategy, which includes applying mobile solutions for shop floors, which can be an effective tool to streamline manufacturing processes. The feature highlights the manufacturing applications that are used today to implement lean manufacturing and supplychain management.

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

Measure 10 from Faro; CoolanTool™ from Quaker Chemicals; Robot Studio Online from ABB and Swivel Optimiser from Schunk.

Why smart applications?

It goes without saying that mobility is pre-requisite for manufacturers. It is one such technology that allows people to access information while “on the go” and at the same time, ensuring efficient decision making. The mobile applications deployed on smart phones and tablet enables integration with various IT systems to provide means of increased visibility, which in turn leads to speed up effective decision making. It also helps manufacturers address productivity and visibility.

However, companies using such apps should have proper IT training to be exposed to programming languages, such as

EM | Apr 2015

3/31/2015 6:03:10 PM 3/31/2015 6:46:58 PM

KNOW WHAT’S HAPPENING

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SCHUNK SWIVEL OPTIMISER The SCHUNK Swivel Optimiser is the first app worldwide for adjusting pneumatic rotary units. It allows fast and easy calculation of the optimal pressure and shock absorber parameters for every individual rotation process. One can upload the app to a normal smartphone, mount the smartphone at any position on the setup, select the corresponding rotary unit in the app and activate the rotary movement in the system controller. During the rotary movement, the app compares the actual parameters with optimal values, calculates the necessary corrections for the pressure and shock absorber stroke and recommends in detail the changes that need to made to the valve or the stroke adjustment. It takes only a few measurement runs to set and verify the optimal parameters for the rotary unit.

RITTAL RITHERM CLIMATE CONTROL

Objective-C for iOS or Java for Android. Regarding security, when apps are implemented, personal devices are integrated with the company’s network, adding another network portal that may be vulnerable to virtual intruders. As such, employers need to be concerned about employees losing personal devices containing company data. The potential for malware infecting the corporate network through smartphones and tablets is yet another concern.

Next generation mobility-based solutions According to a recent survey by L&T Infotech, the key drivers for mobility on the shop floor are productivity, visibility and process improvement. For most manufacturers, the initial drive for implementing mobility on the shop floor comes from the need to increase productivity of its workforce. Applications that facilitate significant time-saving techniques for end users find high rates of adoption in the manufacturing industry.

Typical examples of such applications are the one which automate paperbound processes, remove errors due to manual data entry, allow quick access to job-specific instructions and perform approvals and submissions. The other significant drive for mobility is propelled by the increasing need of managers and key decision makers to access mission critical information on the go. In the complex global supply chains, the need to monitor production data is of equal importance for both internal and external stakeholders in the supply chain.

Mobile applications that provide easy access to critical production data like WIP (Work in Progress) status, scrap and rework rate, machine performance, inventory levels, etc can facilitate faster decision making and better co-ordination among various stakeholders of the manufacturing supply

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RiTherm smartphone app carries out enclosure climate control calculations on the move. For project-planning, the optimum climate control solution can be done in 5 easy steps: project title (reference line for e-mail), parameter, enclosure, selection and recommendation. The app for Android and iPhones handles the time-consuming process of calculating climate control requirements for individual enclosure assemblies. With its fast selection feature, the app provides a compact variant of the full software version “Therm 6.2”. As such, the result can be sent quickly and easily as an e-mail. A user-friendly interface guides the operator to the most suitable, correctly dimensioned climate control component using the typical smartphone controls.

chain.

When it comes to lean manufacturing, the next generation of mobility based solutions can be used to optimise existing manufacturing practices to eliminate waste at every stage of the production process. Mobility-based solutions can be used to enhance operational efficiency by better utilisation of man, machine and materials. So, manufacturing executives are becoming proactive in protecting against plant downtime with better maintenance practices.

Bertil Thorvaldsson, Global Product Manager—Software Products, Robotics Business Area, ABB, believes that with evolution, technology breakthrough is taking centre stage, and it’s the same in the manufacturing arena. “Our company has come up with Robot Studio online that operates on several robotic simulation and has an action plan that includes backup,

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update, re-date, re-start and set time. It has a remote support and comes in tab and holding device,” he said.

Speaking on the risk & safety measures in manufacturing facilities, connecting robots to clouds, connecting all robots internally and wireless devices connected to robots are some suggested measures.

Smart App in manufacturing Success in the manufacturing sector depends on optimising workflow. Market conditions change as companies develop new lean production methods, invest in R&D, grow more globally dispersed supply chains and refine product lifecycle management processes. Smart business solutions can help by changing the way one shares and works with digital information.

So, one can communicate effectively with teams and suppliers in the same facility or around the world. In addition, being aware of the application adds to functionality and connectivity of the manufacturing system. This is time saving as one has to spend less time on the shop floor and more time on the virtual floor. “For updating system and investment on cloud segment, the remote service provided by ABB is box-retrofitted to robots and also useful for control system. The main USP of our device is the hacking virus that acts as a safety or licensing technology.

It also has a virtual simulation that connects various devices,” added Thorvaldsson.

According to research from Micromanufcaturing, there are three main options for companies that want to implement a mobile app: develop one internally, have a developer write one or purchase an off-the-shelf solution that can be customised.

The next big decision is whether to use “native” apps designed for different smartphone operating systems (such as Android, iOS or Blackberry) or a web-based application.

The need to adopt smart applications in the manufacturing facilities accounts to integration with machines and plant

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Faro’s CAM2 Measure 10 is the the company’s all-in-one metrology software for users that are looking for a single, complete solution for probing and scanning tasks, without the need of any additional software. Designed with inspection in mind, it can be used in combination with a Faro scanning device, such as the Faro ScanArm, providing state-of-the-art functionalities for CAD-toPart analysis. The software is perfectly suited for tasks such as the inspection of free and complex forms and even soft or flexible materials that are difficult to inspect with a tactile system.

With this, Apple App, iPhone, iPod Touch and iPad owners can communicate with their CAM2 Measure 10 via WLAN and thus conduct remote measurement.

QUAKER CHEMICAL’S COOLANTOOL™ CoolanTool™ is the first mobile app to facilitate the monitoring processes for metalworking fluids, and organise information.

It can be registered in the CNC machines and track of coolant concentration can be kept. pH values are displayed in graphs. A complete troubleshooting guide for quick and easy problem solving is also included. The features include monitoring pH and concentration for fluid condition, tracking results graphically, exporting data to MS Excel and calculating machine consumption, troubleshooting tool, which is available in English, Chinese, French, German and Russian. The benefits include recording results digitally in one place, illustrating control of chemicals to the local health & safety executive and conducting analysis and performance comparisons across multiple machines.

automation, security & interference concerns and converting paper-based plant logs into electronic log books. Thus, using such technology simplifies data visualisation, embed sensors, receive real-time information, mobility and cloud deployment.

This will let the manufacturers achieve a higher customer satisfaction, service innovation and profitability, thereby evolving from smart manufacturing to manufacturing smart! ☐ > MORE@CLICK EM01612 | www.efficientmanufacturing.in

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M A N A G E M E N T | S T R AT E G I E S

ZERO DEFECT & ZERO EFFECT To achieve zero defect stage, it is important to select the right tools and techniques. Its application, together with the monitoring of critical parameters for sustenance of results achieved plays a vital role. The article highlights why companies should achieve the zero defect stage in their manufacturing process to ensure maximum productivity Addressing the nation on India’s 68th Independence Day, Hon’ble Prime Minister Narendra Modi has thrown a gauntlet to the Indian manufacturing sector for manufacturing goods in the country with zero defect, as well as ensuring that the goods have a zero effect on the environment. “We should manufacture goods in such a way that they carry zero defect and our exported goods are never returned to us. We should manufacture goods with zero effect so that they should not

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M Hariharan, Director, Savoir Faire Management Services hari@sfalignment.com

S Vasudevan, Vice President – Operations, Savoir Faire Management Services vasudevan@sfalignment.com

have a negative impact on the environment,” he said.

Every kind of economic activity undertaken for the development of economy and society will use some kind of resources and have some impact on the environment. Therefore, it is necessary to evolve innovative ways to reduce the consumption of natural resources and develop solutions leading to sustainability of energy use and protection of global environment. As a matter of fact, any kind of development that

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S T R AT E G I E S | M A N A G E M E N T

is directed towards the development of economy and the society at large, aims at enhancing the quality of life of the people. It cannot be fulfilled if the environment within which the society exists is deteriorating.

On such tough economic backdrop for business, the urge of ‘Zero Effect & Zero Defect’ from the Prime Minister is an open challenge and a motivational statement as well.

Zero defect ensures greater productivity Zero defect has nothing to do with being perfect. It is a process to perform to the customer requirements that have been agreed upon, and do it right every time. It means conformance to the requirements, be it customer specifications or functional requirements. It is a process to attain the objective through rules, specifications and standards. Adopting such process is always cheaper and more efficient to do things right

the first time and productivity is a result of that.

In fact, Zero Defects Accepted is a proper way of quoting.

The idea is that no defect that is found should be passed on to the next station in the progress. This means, not only to pass no defect knowingly to the consumer, but also to pass no defect knowingly to anybody downstream. It is one of the eight zeros Toyota strives for (defect, lot size, setup, breakdown, handling, lead time, surging). With relentless pursuit of zero, the company has improved their quality much more than anyone else, as referred in Figure 1.

Many questions come to our mind like, Is Zero Defects possible? Is Zero Defects a myth or a reality? What is the cost of doing it? Many companies, irrespective of size, resigned to the fact that the concept of achieving Zero Defect is not possible. Some value is kept in the mind, which is considered acceptable and it is only the variations over and above this that are discussed in the meetings. While they do discuss the Advt

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Atlantic Lubricants & Specialities Pvt. Ltd. 301, Ketan Apts., 233, R.B. Mehta Marg Ghatkopar East, Mumbai 400 077 Tel: + 91 22 2501 1960/2501 1961 Fax: + 91 22 2501 1928

Motul 119, boulevard Félix Faure 93300 Aubervilliers - France Tél.: +33.1.48.11.70.30 35 Fax.: +33.1.48.11.70.38

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M A N A G E M E N T | S T R AT E G I E S

Figure 1: Power of zero Figure 2: Path towards Zero Defect

reduction of defects, seldom the discussion is towards Zero.

Going back to the three questions, from a TPM perspective, it is possible. It is definitely not a myth and is not expensive. It is real and it is possible to achieve, if the basic concepts of man, machine, material and method (4M condition) is understood and followed to the core. Not an easy one; but not difficult either. The attempt and focus is the key. For a moment, pause to think, shall we be comfortable boarding a plane that boasts of Six Sigma Quality – “We are a 3.4 ppm defect company, we have flown 1 million trips without an incident!”

To achieve the Zero defect, it is very important to select the right tools and techniques, its application together with the monitoring of critical parameters for sustenance of the results achieved play a great role. Of course, people’s involvement in the whole process is a vital success factor too.

How to prevent zero defects?

It is not possible to achieve the zero defect status overnight.

It is not a short term activity. The steps taken towards it should be firmly grounded and activities should be taken forward. A good strategically drawn out process, meticulously followed will lead to the goal. The generalised path towards Zero Defect is shown in Figure 2.

The zero effect Manufacturers have many reasons to reduce their environmental impact, yet many are missing the substantial

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opportunities to become greener without having to make significant investments. There is an increasing consensus that some human activities have harmful side effects that has an impact to the environment. Manufacturing activities are a particularly significant source of environmental impact because many processes are energy intensive. Industrial activities drive approximately 27% of the global CO2 emissions directly.

Printing fewer pages or switching to low energy lighting are some admirable steps, but as long as manufacturing companies fail to target their core operations, they can only hope to achieve small improvements. Energy consumed directly during the manufacturing process accounts for nearly 90% of the CO2 emissions through production alone. Many companies are concerned that significant changes to production techniques will be needed in order to reduce the overall emissions. These changes, they feel, will be extremely expensive to implement, or will have unacceptable impact on quality, flexibility or productivity.

On the contrary, significant portion of energy consumption in many manufacturing operations comes not from what is being done (the process), but in the way it is being done (the management). Simple operational changes designed to maximise energy efficiency can cut the overall consumption by as much as 15%, with no or little capital investment.

Alignment of lean & green initiatives In fact, many standard lean practices improve energy

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M A N A G E M E N T | S T R AT E G I E S

IMPACT MATRIX ON ZERO EFFECT (GREEN) VS LEAN Types of wastes

Definition

Example

Defect

High Process energy consumption

Machines consume more power to make up good units

Over Production

Producing Excess energy (Input energy that is unused)

Heating of empty ovens

Waiting

Consuming energy while production is stopped

Unused conveyor belts running, furnace heating

Employee Creativity

Failure to identify energy waste

Employees not involved in energy saving initiative

Transportation

Inefficient Transmission of Energy

Redundant Compressor Air network

Inventory

Stored goods use / lose energy

Food processing in Cold freezers

Motion (Inefficient Processes )

Energy inefficient processes

Motor running below optimum

Rework / Extra Processing

Additional unnecessary consumption of energy

Additional time of rework, changes in upstream processes

efficiency as a side effect. The wastes that lean processes reduce include defect, overproduction, transportation, inventory, waiting and extra processing, (and even movement) for example, all have associated energy consumption that will disappear as those wastes are eliminated. Similarly, the idle equipment consumes considerable energy, waiting for production. Overall Equipment Effectiveness (OEE) will also reduce CO2 production by improving availability. It also maximises the production when the equipment is fully engaged.

Most of the methods address the impact on ZED.

Why should SMEs focus on Zero Defect & Zero Effect?

According to a management consulting firm McKinsey & Co, India’s manufacturing sector could reach $ 1 trillion by 2025. This could be achieved on the back of the continually growing demand in the country. Up to 90 million domestic jobs could be created by 2025, with the manufacturing sector contributing to about 25–30% of India’s gross domestic product (GDP).

While there’s no doubt that lean manufacturing will result in lower material and labour costs and greater production revenues, there is less discussion about the benefits of lean in relation to green manufacturing. With fast eroding, limited resources at our disposal, and with lower capability to withstand the shocks of resource scarcity, it is imperative for the SMEs to focus on ZED. They need to do more and more

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with less and less. Knee jerk reaction of retrenchment can give a blip of performance in the short term. However, in the longer run, only efforts like ZED can help us to survive.

Conclusion So, if we look at this picture, the Prime Minister’s urge looks like a well-timed challenge for the manufacturing segment. However, to capture these opportunities, manufacturing SMEs in the manufacturing industry holds great amount of expectations.

It is known to everyone that the economic condition of the Indian manufacturing industry is not so glossy. On the contrary, manufacturers are even struggling to survive. The list of challenges that the manufacturing segment is facing is huge.

For example, increasing raw material cost, ever growing prices of industrial land, non-availability of labour and delayed payments. A large chunk of manufacturers in India even believe that globalisation is a myth for them and they consider global opportunities as a threat to their domestic business.

However, no one can rule out the global opportunities, which are knocking the doors of Indian economy. But, to capitalise this global opportunity, Indian entrepreneurs must have to achieve manufacturing excellence and have to carefully work upon competitive enhancement for their respective business through zero defect and zero effect, which will allow them to surge forward. ☐ > MORE@CLICK EM01613 | www.efficientmanufacturing.in

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CASTING & FORGING | FOCUS

I M A G E C O U RT E S Y: Kirex Techno

IMPROVING FORGEABILITY, REDUCING COST Forged parts are widely used in mechanisms and machines wherever a component requires high strength. The article deals with the factors that drive the cost of forging and how companies are adopting the modeling and forging simulations to improve forgeability and minimise development time.

Today, systematically designed forging processes are being performed in controlled presses and hammers to produce forged shapes with a high degree of dimensional accuracy and structural integrity. Forgings range in size from very small, weighing only a few grams to component products weighed in tonnes. The term forging is applied to several processes in which a piece of metal is shaped to the desired form by plastic deformation of a simple starting form such as bar, billet, bloom or ingot. The energy that causes deformation is applied by a hammer, press, upsetter or

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ring roller, either alone or in combination. The shape is imparted by the tools that contact the workpiece and by careful control of the applied energy.

Advantages of forging The advantages of forging for engineered products have been realised in a wide range of industries and situations, for example, a steering arm made from a three piece weldment created

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FOCUS | CASTING & FORGING

processing characteristics, or “forgeability”; ongoing manufacturing development in forging processes is increasing the industry’s understanding of the mechanics of the forging process. As a result, production rates are being increased, costs reduced, and many companies are producing shapes and forms that are much closer to net shape than were considered practical a few years ago. Forging companies are utilising state-of-the-art systems to control critical processes. As process variables are reduced, dimensional precision is improved, and costly chipmaking operations are eliminated. CAD/CAM is being used throughout the design and production processes to improve dimensional accuracy of forgings while reducing lead times. The industry is also adopting rapid prototyping techniques to an increasing extent. Modeling and forging simulations, such as flow simulations and thermal simulations, are being used by some forging companies to minimise development time. Fast tool change capability facilitates the preplanned replacement of die inserts in long production runs, and reduces changeover time for shorter runs, such as those required with just-in-time delivery schedules.

Cost factor

problems in manufacturing, it was converted to a one piece impression die hot forging at a 13% reduction in weight and reduced manufacturing cost. Also, when a cast hub for a large power shovel in a coal field failed, causing an estimated downtime of four to six weeks at a cost of $4000 per hour, the hub was slightly redesigned as an open die forging and was produced in two working days. A manufacturer of huge rotary kilns doesn’t require to be replaced with the riding tires over the life of the product since the tires are made from rolled rings. A manufacturer of hand tools, which operate under high impact and high fatigue, specifies cold forgings made to net shape.

These are just a few selected documented success stories from the purchasers and designers who specify forgings.

Ongoing improvements The forging industry is keeping pace with other metal forming processes through continuous progress in many areas.

Alloys are being developed and refined to improve their

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The actual cost of a forging can be determined only by obtaining a cost analysis from a reputable forging producer. The designer should be aware of the factors that drive the cost of a forging. Five categories of cost drivers that should be considered are material cost; tooling cost; manufacturing cost and secondary (value added) operations.

Material cost: Material cost is the cost to purchase and process enough material to ship the product. The amount of material purchased must include the amount in the end product plus “engineered” scrap. The raw material for forging is bars, billets, blooms or ingots. Forging alloys purchased in these forms are equivalent in cost to similar alloys used for castings, bar or plate stock. There are five primary sources of engineered scrap in forging: punch-outs, flash, other discards, material losses from furnace heating and machining allowance.

These include open die forgings with the greatest amount of machining allowance of the forging processes. The process does not produce flash, but there are generally discards from either or both ends of the forging. Impression die and upset processes require less finish allowance, but usually generate flash. Net or near-net impression die forgings eliminate most or all finish allowance, and are sometimes flashless. Near-net forgings also have lower draft angles, and thus embody less material in the end product. Ring rolling uses preforms, which are disks with the centres pierced out. The process produces no flash and requires

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I M A G E CO URT ES Y: Kirex Techno

Relatively small components that are rotationally symmetrical or axisymmetric, require high strength and high precision, and are produced in larger quantities are candidates for cold forging

few, if any, finish machining operations. Cold forging generally produces no flash and very close dimensional tolerances.

Tooling costs: Tooling preparations cost quoted by forgers generally include the cost of designing and manufacturing the tools used to produce the forging. It also includes the cost of special gauges and fixtures. Tooling cost varies with a number of factors, the most important being the forging process. t Open die: Open die forgings are made with standard “V�, swage or flat dies. Tooling cost is not significant. t Impression die: Tooling cost is usually significant in impression die forgings. It includes one or more impressions (preform, blocker, finisher or other impressions), sometimes preforming rolls, edger or fullering impressions, and usually trim dies. The cost of manufacturing the impression dies is driven by the size and complexity of the forging. Trim die cost is driven by the size of the forging and the complexity of the geometry. Press tooling can differ significantly from hammer tooling due to features such as knockouts, strippers and master tool holders. Die wear necessitates periodic maintenance, resinks, and ultimately replacement of the dies. Die wear varies with the alloy being forged with the harder alloys causing faster die wear. This tendency can be reduced by proper adjustments to product design. t Rolled rings: Tooling cost, including manufacturing, maintenance and replacement for rolled rings, is compared with the impression die process. There is virtually no tooling cost for plain rectangular section rings. However, shaped rollers are required to roll rings that have inside or outside contours. Rolls for forming inside contours (mandrel) cost substantially less than rolls for outside contours (main rolls).

Profiled ring rolling also requires dies for the preforming operation. They are less costly than those used for the impression die process, but must be recognised. t Cold forging: Tooling cost for cold forgings is typically five

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to ten times as much as for equivalent hot impression die forgings when also considering the automation that typically accompanies cold forging processes. But tool life in cold forging is much greater. In many cases, a sequence of operations is used requiring several dies, so that quantities are typically very high. Tool cost can be reduced when similar parts can share common tool details.

Manufacturing cost: Manufacturing cost includes the cost of labour plus the cost of purchasing, maintaining and operating the required machinery and material handling equipment. A portion of these costs is charged to each forging produced. In most cases it also includes the cost of maintaining and replacing the forging tools. Machinery typically includes saws, shears, furnaces, preforming equipment, the forging press or hammer with its associated controls and trim presses. Material handling equipment typically includes cranes, lift trucks, conveyors, etc.

Manufacturing cost is driven by the number of operations required to produce the forging and the cost of each cost centre.

Each cost centre is assigned an hourly operating cost, which is divided by the number of pieces produced per hour to arrive at the cost charged to the forging. For example, when forging micro-alloyed steels, which are used to eliminate heat treating, the cost of using special cooling conveyors will be included. The total manufacturing cost is the sum of the costs of the individual operations.

Processing cost can be reduced by designing the forging to facilitate metal flow in the die and reduce forging pressures. This usually involves modifying sharp details to provide larger radii.

In some cases it may be possible to use a smaller forging press with a lower hourly operating cost that produces more parts per hour. Lower forging pressures also tend to reduce tool maintenance and replacement cost, which is usually a part of the quoted piece price.

Secondary operations: Secondary operations are those required

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FOCUS | CASTING & FORGING

The wide range of alloys and sizes, combined with excellent mechanical and physical properties has made forgings the design choice for nearly all product areas. The most common are shown in Table 1

COMMON APPLICATIONS FOR FORGINGS t "FSPTQBDF Aircraft engines, airframe and auxiliary equipment

t Mechanical power transmission: equipment, incl. bearings

t Guided missiles and space vehicles

t Off-highway, equipment (construction, mining and materials handling

t "VUPNPUJWF Passenger cars trucks, busses and trailers, motorcycles and bicycles

t Ordinance and accessories

t Bearings, ball and roller

t Oil field machinery and equipment

t Electric power generation/ transmission

t Pipeline fittings

t *OEVTUSJBM BOE DPNNFSDJBM: Machinery and equipment

t Plumbing fixtures, valves and fittings

t Hand tools

t Pumps and compressors

t Industrial tools

t Railroad equipment and spikes

t Internal combustion engines

t Rolling, drawing and extruding equipment and tools for nonferrous metals

t Metalworking and special industry machinery

t Ship and boat building and repairs

t Steel works, rolling and finishing mills

t Special industry machinery t Steam engines and turbines

to bring the forging to the required shape, precision, mechanical properties or surface finish. These operations include heat treatment; cold coining; straightening; machining; nondestructive testing; vibratory finishing; shot blasting and coatings such as paint and powder coat.

In some cases, special packaging is specified for purposes such as protecting during shipment or positioning uniformly to facilitate assembly. Secondary operations must be factored into the design of the forging so that processing requirements can be recognised in the design.

The costs associated with some secondary operations are traded off against tooling and processing costs. For example, it may be possible to produce a forging by developing the rough shape as an open die forging, or in a blocker die, and finish machining to develop the required precision. Or, finish machining cost may be reduced at increased tooling and processing cost by forging to more detail and closer precision using multiple operations. The decision is usually driven by the number of machining operations required, production quantities and raw material cost. Lower forging pressures also tend to reduce tool maintenance and replacement cost, which is usually a part of the quoted piece price.

Process trade-offs When a product that has been traditionally made by some other process is being designed for forging, or when an existing product is being redesigned for forging, the design must focus on the function that is to be performed and avoid the tendency merely to replicate the former shape.

Designing for function, rather than form, will enable the

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designer to realise the full benefits of forging. It will help, in many cases, to avoid costly overdesign. As noted above, in functional design the various features of the forging are tailored to the mechanical requirements of each feature. The end product contains the minimum amount of material, minimising weight and reducing cost. The stamping mentioned below would have a constant thickness while the forging thickness could be varied to develop less weight for essentially the same part.

In most design programs, more than one manufacturing process may be employed, but one process will be optimum.

Therefore, identifying the optimum process is a critical step in a the development of a product.

A second factor, often overlooked, is the profound effect of the manufacturing process on the shape of a product. For example, the features of a steel stamping are essentially uniform in thickness because the stamping is made from sheet stock of uniform thickness. A forging that performs the same function can have varying thicknesses tailored to the mechanical requirements of each feature. A weldment often requires special built-up features at joints, such as flanges and bevels, to develop adequate weld strength. A forging is a monolithic structure, and does not need tho se features.

In both categories, the finished forgings often weigh less than the part being replaced.

A third factor is the opportunity to combine two or more parts that are being separately manufactured and assembled.

Often, substantial cost savings and product improvement can be realised by redesigning into one forging. �

Courtesy: Forging Industry Association > MORE@CLICK EM01614 | www.efficientmanufacturing.in

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I M A G E C O U RT ES Y : Jabez Technologies

A U TO M AT I O N & R O B OT I C S | T E C H N O L O G Y

Intuitive Robot Programming Robots are flexible tools for aircraft manufacturing and assembly.

Their full potential, however, can be limited by the challenges of programming a robot in a CAD/CAM environment. This article highlights the software that integrates offline programming, simulation, code generation, and path optimisation which makes the process seamless and error-free.

Robots are poised to transform the aerospace industry the way they revolutionised automotive assembly in the late 1970s and 1980s. Increased productivity and cost savings are fueling the move towards flexible robotic automation.

Unlike their land-bound cousins, aircrafts have key differences that defy the automation paradigm. Aerospace manufacturing tolerances are much tighter, while the subassemblies tend to be significantly larger and heavier.

Compared to automotive, aircraft production volumes are much lower, while the life expectancy of commercial aircraft is measured in decades, not years.

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Tanya M Anandan Freelance technical writer

Global demand for aircraft is rising, straining current manufacturing resources. The Advanced Manufacturing Research Centre with Boeing (AMRC) is on the frontlines of this industry trend.

“Sales of commercial aircraft are increasing. The majority of manufacturers have pushed their production capacity to the absolute limit and further capital investments are needed to reach the targeted rate. For some platforms we’re working on, this might be up to 60 aircraft a month, which is an incredible amount. So a step change in manufacturing is needed,” says Ben Morgan, Head — Integrated Manufacturing Group,

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T E C H N O L O G Y | A U TO M AT I O N & R O B OT I C S

Global demand for aircraft is rising, straining current manufacturing resources

AMRC. That step change is coming in the form of flexible robotic automation. Ushering the robots’ foray was the advent of composites in aircraft component manufacturing.

Rise of aerospace composites According to a study by market research firm Lucintel, the global aerospace composites market is expected to reach $112 billion annually by 2017, with a compound annual growth rate of 5.3% (Source: CompositesWorld). Composites typically weigh 20% less than aluminium and have a longer life span than traditional metallic materials. Credited for higher strength-to-weight ratios, better fuel efficiency and longer service intervals, composite aircraft materials are vital to the aerospace industry.

The composites revolution helped extend the jet way to robots. Robotic machining and material removal is increasingly being used in non-metallic and metallic applications, including milling, drilling, surfacing, riveting, waterjet cutting and trimming of composite skins and components for large commercial aircraft.

Prime for robotic machining For years, robots were peering over the shoulders of their computer numerically controlled counterparts. Now, the focus has shifted. “With advances in robotics over the last 10 years, serial-arm devices are becoming a more feasible option,” says Morgan. “There’s been a boom in interest in robotic trimming, routing and machining. By developing concept robotic trimming systems and the facility we have at the AMRC, we are starting to prove to high-end automotive and aerospace manufacturers that flexible cells are an alternative to some of the traditional, expensive CNC machine tools.”

The AMRC was established in 2001 as collaboration between the University of Sheffield and Boeing. Located in a sprawling high-tech industrial park in Sheffield, England, it employs more than 400 researchers and engineers focused on

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modernising manufacturing by testing and proving different technologies, and has more than 100 member companies ranging from global aerospace giants to local small businesses.

“We are talking maybe $15 million for some of the big CNC machines that are being used to manufacture these aerospace parts,” says Morgan. “For a robotic cell we would probably be looking at a couple of hundred thousand dollars.”

The cost of deploying robots continues to decline, while their rigidity and accuracy is improving. Robotic technology can now compete for a broad range of aerospace applications previously limited to custom machinery, including one-up assembly, drilling and filling, automated tape lay-up (ATL), and automated fibre placement (AFP).

Robot programming the hard way Most top-tier aerospace suppliers recognise the advantages of deploying robots for their subassembly operations and have even earmarked annual budgets for robotisation. But for some, robot programming is the quagmire. Singularity, calibration, collisions, reach limitations, and motion granularity are uniquely complex to robotic systems and can make programming robots for machining operations particularly cumbersome. Navigating around the errors can be timeconsuming. Companies accustomed to using CNC machine tools get stuck when they try to deploy a robot for the first time. They often try to use the robot manufacturer’s software for programming. However, this software is typically intended for simulation purposes, not programming. In a simulation environment you can see the error, but the difficulty lies in identifying the cause and how to fix it.

A different approach is the use of CAD/CAM point converters, which create robot trajectories for different types of applications. The point converters tend to do a quick and inexpensive conversion to a robotic system, but there is no way to validate kinematics and check for errors. The main problem with these methods is the lack of a path optimisation tool.

Once the program is applied to the robot, there may be a

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A U TO M AT I O N & R O B OT I C S | T E C H N O L O G Y

Sogerma Composites Aquitaine tools aeronautic composite parts in small quantities

lengthy prove-out period. “When we decided to buy a new solution to tool composite parts with a robot, we could not have imagined how different the robotics world was from our traditional CNC machine world,” says Eddy Coubard, CAD/ CAM Production Engineering Manager at Sogerma Composites Aquitaine. “New vocabulary, a new working method and new problems, it was a challenge.” Celebrating its 30th anniversary, Sogerma Composites Aquitaine is a wholly owned subsidiary of Sogerma Group, and is based in France with 475 production and R&D personnel supporting more than 100 major suppliers in Europe and around the world with high-performance composite material products. “We tool aeronautic composite parts in small quantities, which means we have to get the robot programming right the first time,” says Coubard. “Otherwise, our costs increase dramatically.”

“The first robotic software we tried was not efficient at all,” he says. “It required making the tool path in CAD/CAM software and writing a kind of G-code with a post-processor, then reading this G-code on a simulator, only to realise that most of the time there were errors. Then, we had to go back to the CAD/CAM software and write the robot code through another post-processor.” This is the typical scenario. A company acquires a robot, tries to deploy it for a machining operation, only to realise that they don’t have the proper software for the job.

CAD/CAM-based robot programming Considering the robot programming software upfront is a better strategy. This should be done either at the time of robot system acquisition, or even prior to the purchase. CAD/CAM software specifically designed for programming robots addresses issues with singularity, collisions, joint limits, reach issues and wrist flips. The right software should automatically

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calculate and optimise robot trajectories, seamlessly integrate external axes, and provide instant visual feedback. It should be easy to use, even for operators new to robotics. The software should also support offline programming, without interrupting production on the shop floor other than for the final test and fine-tuning. Changeovers then become a parallel, rather than a sequential operation. The latest version of Jabez Technologies’ Robotmaster® software streamlines programming, simulation, code generation and path optimisation into one integrated solution. All major robot models are supported. “A robot can be a difficult device to manage,” says Chahe Bakmazjian, President, Jabez Technologies. “It consists of six rotary joints stacked one on top of the other, so it’s very difficult to anticipate errors. Usually you encounter the error when it happens. There is no warning,” he says.

“Aircraft manufacturers often put large robotic systems in place, but they’re only exploiting them to a limited area where they know they can avoid errors,” says Bakmazjian. “Any time they want to go outside those areas, it becomes very restrictive.”

Composites Aquitaine’s Coubard says that by replacing their old software their programming time was reduced by two to three times. “Robotmaster allows us to work in the same way we used our CNC machines to tool parts,” he says. “Since Robotmaster also interfaces with Mastercam® software, we were able to quickly and easily perform full 7-axis milling and drilling.”

Coubard says that they are using Robotmaster to program a rail-mounted 6-axis robot. The applications include tooling thermal protection parts made of glass fibre for the Airbus A330 airliner and honeycomb for the Airbus Super-Puma MK II helicopter. “With Robotmaster we’re able to embrace the world of robotics. Now we can tool our composite parts in the same easy way we used to tool them with the CNC machine,”

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T E C H N O L O G Y | A U TO M AT I O N & R O B OT I C S

says Coubard. “In fact, the new simulation feature is so powerful that we have yet to exploit all of its capabilities.”

Without Robotmaster, Coubard says they would have most likely abandoned robotics and gone back to old CNC machining methods.

Error-free programming At the AMRC, Morgan’s group uses robotics and metrology to develop new methods for assembling complex products for aerospace and other high-value industries. “We have been working with Robotmaster for the last three years,” says Morgan. “The software has allowed our operators and engineers to quickly and effectively reprogram the cell, as well as optimise the machine path. It has great flexibility and control.”

“Using this software lends itself to the research environment in particular, because our range of work and part variability,” says Morgan. “We don’t manufacture anything here, so often we end up doing one, two, or three parts and then we’ll move

on to another part. But the aerospace sector itself is demanding re-configurability as well, so we’re meeting that requirement with Robotmaster.” Operators report that the software works 100% of the time – the first time – without the need for manual teaching intervention or touch-up. It’s error-free robot programming without the complexity. So easy, even a newbie can use it.

Conclusion After coupling a flexible robot with an advanced software solution, one is free to exploit the entire robot workspace.

What first appeared as a liability of an over determined system with various ways to reach the same point has now become an opportunity given sophisticated path optimisation tools.

Robots have proven their airworthiness. They just need the right software to realise their full potential. ☐ Courtesy: Jabez Technologies www.robotmaster.com > MORE@CLICK EM01615 | www.efficientmanufacturing.in

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Defining & communicating engineering tolerances Design standards such as ASME 14.5 Y and ISO provide a universal language for designers, machinists and inspectors to communicate.

Geometric dimensioning and tolerancing (GD&T) conventions facilitates this communication by clearly specifying when, where and by how much each dimension is allowed to vary, with particular emphasis on allowances for material to material mating surfaces.

The feature highlights the cost benefit of adopting GD&T standards with error-free operations in the manufacturing environment.

Geometric dimensioning and tolerancing (GD&T) is an international language used on drawings to accurately describe a part. It is a system for defining and communicating engineering tolerances. The language consists of a well defined set of symbols, rules, definitions, and conventions that can be used to describe the size, form, orientation, and location of part features.

Production uses the language to interpret the design intent, and inspection looks to the language to determine set-up. By providing uniformity in drawing specifications and

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Maria Jerin Features Writer maria.jerin@publish-industry.net

interpretation, GD&T reduces controversy, guesswork and assumptions throughout the manufacturing process.

Speaking on this, M Krishnamoorthy, Director-Training, IMTMA Technology Centre, says, the basic definition of a part starts with its drawing and unambiguous representation in drawing is very important to avoid disastrous effects during production and assembly stages. “GD&T is a new tool that eliminates such ambiguities and brings out the designer’s intent very clearly in the engineering drawings.�

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T E C H N O L O G Y | G E O M E T R I C D I M E N S I O N I N G & TO L E R A N C I N G

The correct & incorrect OEM paper details the 7 deadly sins of dimensioning and tolerancing

In today’s modern and technically advanced design, engineering and manufacturing world, effective and accurate communication is required to ensure successful end products.

Suggesting the same, Krishnamoorthy says, “Globally the US based companies started adopting the GD&T practices in the engineering drawing that is followed by other countries.

Currently, ASME Y14.5M is the accepted standard and ISO based in Europe have an equivalent standard. In India the awareness is catching up. Here the challenge is to bring all the industries to the common level of understanding and to nullify any knowledge gap existing in this field of GD&T. For example, OEMs have higher level of understanding and as the scale comes down to tier 1 & tier 2, the level of understanding is not in the same manner. So thereby, the end results of savings in production are not achieved. Adopting GD&T reduces the cost of manufacturing & inspection and it will ensure the trouble-free assembly of components across the entire downstream of the design to the other functions of engineering or planning, then production, assembly, and inspection, finally dispatch.”

Mechanical components need their own spec system that is repeatable, clear and not overly restrictive. The recent revision of the American Standard, ASME Y14.5M-1994, is fast becoming the spec system of choice for mechanical components by today’s OEMs. It is 90% compatible with the GD&T sections of the ISO standards, bringing OEMs more in step with the global manufacturing scene. Effective Training Inc, leading training provider in the field of GD&T, shares 7 deadly sins to be avoided while dimensioning and also shares the advantages that add up to significant savings in production by using GD&T.

7 deadly sins of dimensioning and tolerancing Unfortunately, dimensioning rules are violated frequently.

These errors have appeared so often, and for so long, they are accepted without question by many drawing makers and users.

These errors or deadly sins generally fall into seven categories.

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Improper use of the word “thru”: This is a dangerous word, unless it is used with absolute precision. It means only one thing; namely, “all the way through”. If through is not the intent, it is best to specify a depth.

Improper use of the word “central”: The question to ask before using this word is: Central to what? It may relate to any of several diameters. When using the word central, include a frame of reference or the dimension will just float on the drawing.

Unnecessarily tight title block tolerances: To produce prints quickly, some designers use tight title block tolerances, so fewer exceptions have to be thought through and noted elsewhere on the print. Manufacturing eventually bears the brunt of these false goals. People work harder than necessary, time and effort are wasted, and more deviations are asked for. Engineering time is consumed processing print-change requests.

Use of esoteric notes: Many situations handled using notes would be better handled using geometric tolerances to eliminate any ambiguity.

Imaginary dimensions: A dimension—for example, from a hole centre line to an undefined vertical line—cannot be measured during part inspection. With GD&T, the dimension would be from the hole centre line to a defined plane.

Dimensions without tolerances: These usually occur when there are many basic dimensions. A tolerance—for instance, for location—should be included with every basic dimension.

Missing dimensions: This seldom happens with principal or obvious dimensions, but can when components are not thoroughly documented. Missing dimensions are particularly dangerous because inspectors are trained to inspect what is on the drawing, not what is missing. Missing dimensions may go undetected for years until there is a warranty problem or lawsuit.

GD&T violations cause many problems. For instance, if a company uses drawings to decide what machines will be needed and what production rates will be, they may calculate product costs incorrectly. Violations can also extend product cycle time

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G E O M E T R I C D I M E N S I O N I N G & TO L E R A N C I N G | T E C H N O L O G Y

Comparison between GD&T and coordinate tolerancing

by causing manufacturing to tool up with the incorrect equipment. Errors may force manufacturing to guess at the designer’s intent, and a finished product may function poorly.

Eliminating tolerancing errors can help a company decrease scrap, rework, changes, confusion, and downtime. To eliminate GD&Ts seven deadly sins, a company needs a combination of training, feedback, and quality audits.

tolerance on parts, the process will be more capable, reducing manufacturing costs.

Bonus tolerance: In addition to the tolerance gained from using round zones, GD&T allows a “bonus” tolerance under certain conditions. This bonus tolerance is gained by using the MMC (Maximum Material Condition) modifier, as indicated by Arrow B in Figure 1. The MMC modifier allows a hole to have additional tolerance when it is produced larger than its minimum size. This is a win-win situation for the OEM because Cost benefits engineering can be assured that the part will assemble when the Because of the lack of studies demonstrating the cost benefits holes are the smallest, and manufacturing can have additional of GD&T, many upper management people, especially those tolerance when the holes are larger than their minimum size. In without engineering backgrounds, lack the understanding coordinate tolerancing, the tolerance zone is always fixed in needed to estimate actual savings. Consequently, they may be size (Figure 2, Arrow A), at all hole conditions. This results in a reluctant to fund GD&T training programs. The benefits of number of functional parts being scrapped and a more stringent using GD&T to specify mechanical parts can readily be condition for manufacturing. demonstrated when we compare GD&T to coordinate Inspection: GD&T’s datum system clearly communicates one dimensioning, which has been in use for over 150 years. The set-up for inspection. Datums are theoretical planes, points, or advantages that add up to significant savings in production axes, and are simulated by the inspection equipment. The include: symbol used to specify a datum feature is shown on Figure 1, Functional dimensioning: The design philosophy of GD&T is Arrows C. These symbols denote which part surfaces touch the that of functional dimensioning, which means that a part is gaging equipment during inspection. Datum features are defined by how it functions in the final product. Instead of selected on the basis of part function and assembly requirements; copying a tolerance from an existing drawing, the designer they are often the features that mount and locate the part in its bases the tolerance on part function; this allows the maximum assembly. Datum reference letters are specified (as shown in amount of tolerance to produce the part. When properly applied, Figure 1, Arrows D) inside the geometric controls and denote functional dimensioning can often double or triple the amount the sequence in which the part surfaces contact the gaging of tolerance on many component dimensions, which reduces equipment. This sequence is needed in order to have multiple manufacturing costs. With coordinate dimensioning, tolerance inspectors set up the part in an identical manner. In coordinate zones are not related to functional requirements. dimensioning datums are implied, allowing choices for set-up Round tolerance: GD&T allows round tolerance zones. In when inspecting the part. Different inspectors may get different Figure 1, Arrow A points to a GD&T symbol which specifies a results; some good parts may be scrapped and some bad parts round tolerance zone (for the mount holes). The zones are may be accepted. specified by coordinate dimensioning (Figure 2, Arrow A). Assembly problems: GD&T reduces assembly problems. Since Round tolerance zones allow for 57% more tolerance than the inspection process with GD&T ensures the at parts will square zones, resulting in more usable parts. By allowing more assembly properly, assembly methods no longer need to be

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T E C H N O L O G Y | G E O M E T R I C D I M E N S I O N I N G & TO L E R A N C I N G

addressed by the guy on the assembly line with a two-by-four ISO standards rigorously document the interpretation of each and a hammer. The inspection process with GD&T ensures that GD&T symbol and concept. On the other hand, coordinate OEMs can use competitive souring or obtain multiple sources tolerancing is like folklore; it’s not well documented, even for the same part, resulting in increased profitability. though it has been around for 150 years. Producing parts to Statistical process control (SPC): In the area of inspection, GD&T’s documented standards assures the OEM that parts will GD&T supports the use of SPC. GD&T’s Datum system provides be accepted by the customer. Fewer replacement parts will be the repeatable part measurements that are necessary for making needed and recalls can be avoided, saving time and money. a meaningful SPC chart. With coordinate tolerancing, SPC data may include assumptions, which reduces the accuracy of the Conclusion data. The use of the profile control is another example of how As the makers of CAD design software have integrated GD&T supports SPC. The profile control helps in two ways: (1) It establishes a mathematically defined tolerance zone, and it powerful GD&T functionality into their programs, dimensioning relates the measurement to datums. When coordinate and tolerancing of complex part designs has become easier. tolerancing is used, the precise tolerance zone definition simply “Many of today’s CAD systems have GD&T capabilities, but the doesn’t exist. For example, try to define the size and location of operator must still understand GD&T in order to use it the radius (Arrow B) in Figure 2. (2) Because the datum system effectively,” says Krishnamoorthy. On a concluding note, he and profile control allows SPC data to be more accurate, needless says, “In the competitive industrial scenario prevailing today, changes in the manufacturing process are avoided, regarding engineers need to understand clearly and adopt the concept of GD&T in all the stages viz, design, manufacturing as well as the OEM with time and cost savings.

International standards: GD&T is supported by national and inspection.” ☐ international standards. ASME Y14.5M-1994 and a series of > MORE@CLICK EM01616 | www.EfficientManufacturing.in

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M A N U FA C T U R I N G I T | T E C H N O L O G Y

Shaping product design & manufacturing This article details on how desktop 3D printers enable users to turn designs into reality.

Through case studies and expert perspectives, readers will learn about applications in the specific areas which include making ideas tangible in the conceptual design stage; preparing functional prototypes; crafting jigs and fixtures for manufacturing and creating custom enduse parts.

In the span of a past few decades, 3D printing has gone from being the stuff of science fiction to a valuable driver of real-life product design and manufacturing. Today, the technology is helping companies in a wide range of industries to realise their design ideas at every stage, from concept to end-use parts—while being cost-effective. The diversity of 3D printers available in the marketplace now makes it possible for SMEs to implement this paradigm-shifting technology. Product engineers and tooling manufacturers, in particular, have much to gain from the efficiencies that in-house 3D printing can

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create. Generating inexpensive, yet highly accurate prototypes early in the design process allows manufacturers and engineers to check form, fit, and function without committing significant resources. They can rapidly gauge customer response to an item, adjust the design and produce multiple iterations to compare alternatives. They can even quickly craft end-use parts that are customised for a particular job without any delay.

Manufacturing professionals are no longer limited to massive 3D printers that are both expensive and unsuitable for an office environment. Today’s affordable, compact units, exemplified

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Worxsimple uses 3D-printed parts, such as the yellow point guard shown here, in prototyping and end-use applications

by the Mojo and uPrint lines of desktop 3D printers, are expanding 3D printing capabilities and increasing the availability of high-quality prototypes and parts.

Making a real impact in the real world To illustrate how owning a 3D printer can improve business workflows, we will explore how two different companies Worxsimple and Redshield Technology have utilised their 3D printers to enhance manufacturing processes. Based in Sandy, Utah, Worxsimple, LLC is an original equipment manufacturer of custom medical parts and equipment. The company’s engineers create prototypes and test fixtures on their 3D printers. To meet their various needs, Worxsimple uses three Stratasys 3D printers: the Mojo, uPrint, and Objet®30 Pro™.

Both the Mojo and uPrint employ FDM technology, which crafts extremely durable parts by extruding thermoplastic. In contrast, the Objet30 Pro features PolyJet™ technology, which operates in a similar fashion to an inkjet printer (instead of jetting ink, it jets layers of photopolymer resin that is cured with UV light) is useful for parts that require fine feature detail.

David Baker, Owner of Worxsimple, says, “We had the Mojo first which was always full and we could never really get in all the print jobs that were in queue. That spurred the purchase of the uPrint. Soon after that, we realised the need for a printer with enhanced surface texturing and accuracy that was satisfied with the Objet30 Pro. Having all three printers have been pretty beneficial in the machine design business because we can build pretty much anything we want.”

The second company, Redshield Technology, is an agricultural machinery manufacturer based in North Liberty,

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Iowa. Using the uPrint SE Plus®, its designers created 3D printed parts for sensor brackets, computer module housing and exterior trim pieces for machines that test soil composition.

Because Redshield Technology is a start-up with a limited budget, owner Stacey Schildroth was very concerned about the cost of producing parts. Owning a 3D printer seemed to be the logical answer. “With the 3D printer, we have more control of profitability,” she explains. “We can print as many parts as needed. We avoid the downtime that outsourcing would have involved. And we are able to maintain better quality control, since it is now in-house. Having our own 3D printer improves the bottomline dramatically, as it pays for itself so much faster than going to an outside party,” she added.

Turning conceptual designs into tangible models Producing realistic physical models by traditional methods is time consuming, but the models are a necessity if clients are to fully comprehend a project’s design intent. With in-house 3D printing, professional models can be created very quickly to demonstrate designs, illustrate assemblies and identify potential problems before resources are invested in tooling and production. “For Worxsimple, buying a 3D printer was a leap of faith,” says Baker. He explains that although he was very excited from the start about incorporating a 3D printer into his workflow, he was somewhat overwhelmed by the range of possibilities. However, he quickly realised the breadth of what he was able to do with the technology and how it would fit in with his company’s business process.

For Redshield Technology, which is still in the startup phase, the focus is on keeping costs minimal which includes

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Each part produced on a 3D printer can be uniquely identified with its own rev control number

maintaining a small inventory. Since it takes only a few hours to create a new part with the uPrint 3D Printer, workers can create parts on a just-in-time basis. This speed also helps them turn around orders rapidly; workers can fully assemble a soiltesting machine in less than a day. Schildroth explains that Redshield also seeks to control costs by making each CAD model as accurate and complete as possible before it’s sent to the 3D printer, so reprints won’t be needed. “However, from that point on, the printer is always involved from the first prototype to production parts that go on the final assemblies shipped to the customers,” she added.

Preparing functional prototypes Physical models are also important tools for testing a product’s accuracy and viability. Unfortunately, when outsourcing the creation of such a model, manufacturers can’t be certain that the fit, strength and texture will be right. In addition, long turnaround times may lead to delayed projects and the loss of business and profitability. An in-house 3D printer enables companies to evaluate performance and finetune products without committing to production tooling. “It’s very cost-effective for us to do our initial bids this way,” explains Baker. “We can push ‘Print’ on any of our 3D printers and go home and come back the next morning and put our parts together. They look great and are very pleasing to the eye, and perform as well as any machined part in a low-stress situation.” He noted that one particularly useful benefit of prototyping with a 3D printer is that it eliminates errors due to version-control issues. “We have a lot of scrap parts and if you are going through a lot of changeovers, or you are still redesigning your machine with very minute differences between the parts, you can accidentally put the wrong part in the final device,” he explains. “With the rev control (number printed) on the part, that really saves us a lot of headaches later

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on down the road.”

Schildroth also believes that the uPrint has helped improve Redshield Technology’s prototyping significantly, and observes that the 3D printer really pays off when time is critical. “We were in a situation last spring where we needed to deliver a prototype to a customer that was evaluating our machine for a possible purchase. Unfortunately, we found an error in the design only days before delivery. We were able to redesign the part, get it printed on the uPrint SE Plus, and assemble it to our machine without missing our delivery date. We would never have been able to do that if the 3D printer weren’t in-house,” she added. As other Stratasys customers like Digi, Oreck and Thogus / rp+m have shown, financial justification of a new 3D printer based solely on jigs and fixtures can be quite easy and the outcome quite profitable. The important elements of these justifications are to equate the ease and simplicity of AM with more fixtures put into service. Then carry the savings out to the production floor to calculate labour reduction and profit gains from getting product on the shelves sooner.

Crafting jigs & fixtures Custom-made tooling and fixtures can be produced as needed on a 3D printer, improving a company’s ability to respond to customer demand. Strong, durable jigs and fixtures can be created in one night instead of weeks. “We bought [the Mojo] primarily to do prototyping for our fixturing that goes into our final machines,” says Baker. “We would do some development work and test them on the machines, and then later on we would convert to a stainless steel part or aluminium part before we finally shipped it. As we started working with Mojo, we found out how accurate and how reliable the parts were that came off of it. We started using it for more brackets and even more special widgets that we would ship with the final product to our customers.” Printing out components

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T E C H N O L O G Y | M A N U FA C T U R I N G I T

overnight and using them the next day provides substantial time savings, he notes: “You’re cutting days and weeks out of the lead time for building machines.”

Creating end-use parts A 3D printer can speed up the tooling process — but it can also enable manufacturers to skip it completely. Both Mojo and uPrint utilise production-grade thermoplastics for their models, so users can simply print end-use parts directly from CAD files. “Since we sell a high-value, low-volume product, we utilise parts off the uPrint SE Plus for both prototyping and production,” says Schildroth. “It saved us from having to invest in high-volume tooling, and we can change the design immediately, if needed. Our customers are really surprised that we can create our machines in-house using a 3D printer.

They are impressed with the level of detail involved, the quality of the parts, and the durability. If we don’t tell them that the parts are made on a 3D printer, they would have no idea.” “If everybody feels very good about it and is very positive about a machine that you are building, then they will go that extra mile to make sure that it’ll work,” says Baker. “I think 3D printing really lends itself to making something that’s very aesthetically pleasing. The curves of the devices, the curves of the parts, it really improves the look of a machine.”

The most important aspect of uPrint, believes Schildroth, is that it dependably produces quality parts. “We looked at less expensive ‘prosumer’ models,” she says, “but it seemed that you were forever tweaking and adjusting them to get good parts out. This is our business and we can’t afford the time to print multiple parts before we get a good one. With the uPrint SE Plus we can send the design to the printer and rely on good parts being built.” ☐ Courtesy: Stratasys www.stratasys.com > MORE@CLICK EM01617 | www.efficientmanufacturing.in

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M A C H I N I N G | A P P L I C AT I O N

Machining complex aerospace components Today, machine shops need a cost-effective solution for cutting tough, difficult-to-machine materials for the large aerospace companies. The article highlights the use of recently launched Haas universal machining centre by the French company KMP, where an automated UMC-750 simplifies machining complex aerospace components in titanium for Airbus.

In southwest France, The Airbus Group dominates the industrial landscape. Along with an extensive supply chain in the Toulouse area, the company is single-handedly responsible for a good deal of the region’s economy. In fact, in 2011, when the company was planning a major manufacturing programme, entrepreneurs Sébastien and Sonia Korczak decided to establish their own subcontract machining facility, KMP, with the intention of servicing the large number of tier-2 and tier-3 aerospace companies in the area.

“Before we opted for Haas, we were told by other machine tool suppliers that they weren’t up to the job of cutting hard materials,” says Sébastien. “In fact, it turns out they didn’t want us to know that Haas machines can be pushed day and night cutting tough materials, and will not let anbody down. They

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are so easy to use that one of my operators learnt the control in just a day; even my 11-year-old son can run the machines!”

The ideal solution With no established contacts in the aerospace supply sector, KMP’s first six months were far from plain sailing. But, knocking on the doors of large aerospace supply chain companies eventually led to a hand full of orders, which the company machined using a pre-owned Haas VF-2 vertical machining centre with a Haas TR160 two-axis (rotating/tilting) trunnion table.

According to Sebastian, Haas has a big brand presence in the market in Europe. “Since we’d had a good experience with

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A P P L I C AT I O N | M A C H I N I N G

An operator at KMP loads the tower with billets, presses the button, and walks away, returning to find a completed batch of precision parts

our used VF-2, we felt compelled to find out more about their machines. Other machine tool suppliers said Haas machines were only good for aluminium and plastics, but to me, their derisory comments hinted that there was a hidden truth they did not want us to know about. Initially, we wanted a 5-axis machine to differentiate ourselves from three main competitors we had identified in the market. But, we needed to find a good machine at a good price, and we couldn’t afford to buy a new one. The pre-owned Haas VF-2 proved to be the ideal solution.

It has a very big program storage capacity, which allows us to use sophisticated machining strategies,” he said.

customer approved the part when they were delivered as “right first time.”

Around-the-clock machining

Around 80% of components at KMP are produced from titanium – a notoriously tough and difficult-to-machine alloy for the aerospace and motorsport industry. Many of the components are highly complex, featuring freeform surfaces, inclined faces, angled through-holes and irregularly shaped bosses. Sometimes, 80-90% of the original billet is machined away. Titanium has proved to be useful for the Haas machines.

Thanks to automation, one of the UMC-750 machines runs High-precision machines around the clock cutting titanium work pieces.

Such was KMP’s initial success that within six months, the The Eco-Tower 60 from Lang Technik offers a simple and company had swapped the VF-2 for a Haas VM-2 vertical advantageous introduction to automation, typically for batch machining centre complete with a more powerful spindle, sizes up to 60 off. An operator at KMP loads the tower with followed shortly after by a Haas DT-1 drill/tap centre. However, billets, presses the button, and walks away, returning to find a the most recent purchases at KMP are two Haas UMC-750 five- completed batch of precision parts. “Communication with the axis machining centres, one of which is robot-loaded and UMC-750 is very straightforward and was facilitated by a Haas typically runs all night. KMP was, in fact, the first company in technician in no time,” adds Sébastien.

France to install a UMC-750.

KMP aims to continue growing by finding customers who “We shopped around, but with a weight of 8 tonne, the need precise parts made in tough materials and larger volumes.

UMC-750 appeared to us to have the mass we were going to But the company is in competition with local companies, as need to cut tough materials,” says Sébastien. “We had the well as rivals operating in lower-cost economies, such as opportunity to see the UMC-750 without the cover and were Romania and Tunisia. reassured by the sturdy, rigid machine frame. Also, we have Sébastien further believes that the company has to be well great confidence in the Haas control. In fact, the UMC-750 is organised and structured, with an attractive hourly rate, in supplied as standard with some essential macros for five-axis order to compete. “This means the price and running costs of machining, specifically for the dynamic repositioning of parts.” UMC-750 machines are a huge advantage, and we can build on As per Sébastien, the machine’s precision is another that. Now, we feel confident enough to hire more employees differentiating feature that has helped overcome many and buy more Haas machine tools, especially universal component issues at KMP. For instance, one particular part machines,” he said. ☐ required holes drilled to a tolerance of ±3 µm. The holes were Courtesy: Haas Automation > MORE@CLICK EM01618 | www.efficientmanufacturing.in generated using helical interpolation on the UMC-750, and the

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T E S T & M E A S U R E M E N T | A P P L I C AT I O N

Automated on-machine part setting It is important to increase machine utilisation time and eliminate manual setting errors, thereby improving accuracy and part conformance in the manufacturing plant. The article deals with Renishaw’s Primo™ twin probe system, used by Unimac to design on-machine part setting, part inspection and tool setting that increases productivity, improves quality and boosts profit Pune-based Universal Manufacturing Company (Unimac) has consistently reduced inspection time by 90% over four months after installing a Primo™ twin probe system, designed for machine part setting, part inspection and tool setting.

Unimac manufactures components for railway engines, power generation plants, cement manufacturing plants, and other heavy engineering applications. For the company, maintaining accuracy of 15-20 microns on large parts is vital.

A major challenge for the company has been the inspection of large parts during the manufacturing process. According to Ashok Mungale, Director, Unimac, the issue was resolved five months back when Renishaw’s Primo system was installed on the machine, based on the application requirements. “The on machine probe is not only easy to use, but performance driven, which has resulted in increased machine utilisation time.

Renishaw has truly been instrumental in our growth by providing an outstanding probing system that helped shorten our cycle time.”

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Innovative probing The Primo twin probe system consists of a radio part setter and a radio 3D tool setter. It enables automated on-machine part setting, part inspection and tool setting, that helps to eliminate manual setting errors, improve accuracy and part conformance, whilst reducing the non-productive time and scrap. All of these increases productivity, improves quality and boosts profits. The probe system is straightforward to install and use, and represents a low initial financial outlay. It also has an exclusive, enhanced warranty to offer users peace of mind.

Increasing productivity It is so easy to use the Primo system that at Unimac, its installation and evaluation were completed on the same day.

The Primo GoProbe training kit and pocket guide make it very quick to learn and implement the system. A key benefit is that

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A P P L I C AT I O N | T E S T & M E A S U R E M E N T

The Primo twin probe system enables inspection to take place on machine, removing the need to breakdown and move the part, and reset it once it has been inspected

there is no need for extensive G-code knowledge. Simple, single line commands are used instead of multiple lines of code, removing the necessity for any special training.

Ashok Mungale started Unimac in 1987, after purchasing a second-hand machine from Germany for manufacturing components needed in sugar and cement plants. He later switched to manufacturing general engineering components.

Currently, the company manufactures large precision parts used for railway engines, power generation plants, cement manufacturing plants and other heavy engineering applications.

The company has its own tool room, horizontal boring machines, floor boring machines, HMCs and VMCs. One of the VMCs has a bed size of 4.5 m x 2.75 m.

Optimising throughput

Making a difference

Building trust

Unimac manufactures precision components, such as turbo chargers that are used in railway engines and one-off single components, for its customers. Before the Primo system was installed, the cycle time for machining a turbo charger housing was 46 hours. During this process, at the semi-finished stage, the part would be taken to an inspection facility to be checked for flatness, squareness, parallelism and positional accuracy.

The part would then be brought back to the machine, and have to be realigned and set before further machining could take place. This process would take three hours and have to be carried out twice, meaning that the machine lay idle for six hours during each manufacturing cycle. In this manual process, part setting itself takes 30 minutes.

The Primo twin probe system enables inspection to take place on machine, removing the need to breakdown and move the part, and reset it once it has been inspected. Now at Unimac, the new process takes just 30 minutes. It has reduced inspection time by 90%, reduced cycle time by 12% and led to a very fast return on investment (ROI) in just four months.

The company first heard about Renishaw when ten years ago it purchased its CMM, which came fitted with a Renishaw probe. Following this, the company formed a relationship with Renishaw, and received regular updates about new product developments. Renishaw engineers analysed all of the machining applications at Unimac thoroughly, and offered best practice advice and guidance on which Renishaw products would be most suitable for Unimac’s needs. The Primo system is the company’s first machine tool probe.

Speaking on reliability, Mungale concluded, “Since we were convinced with the sales, service and application aspects of Renishaw, we installed its telescoping ballbar to help maintain machine accuracy. After this, it was easy to ascertain whether the fault was during machining and the errors could then be eliminated. Results from the ballbar are always perfect, so a mutual trust has developed between Renishaw and us”. ☐

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According to Mungale, after installing the Primo system, the manpower cost, material handling costs, material equipment and power consumption charges are saved. As such, no additional investment is required. “This gives flexibility to the manufacturing unit in accepting orders for any size and for segments such as the machine tool industry. The manual analysis of results is also avoided, as the data is available on the same controller,” he said.

He further added, “The Primo system combines part set up, part inspection and tool setting capabilities in one system. So, there is no need to source the separate items.”

Courtesy: Renishaw > MORE@CLICK EM01619 | www.efficientmanufacturing.in

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COOLANTS & LUBRICANTS | TECHNOLOGY

ADOPTING BEST PRACTICES In a typical plant, metalworking systems are never completely sterile and fluids are continually “under attack” by biological organisms from a myriad of sources. This article presented in a two-part series, details the various measures incorporated to maintain a good coolant quality in the systems, while managing and taking care of fluids.

As Benjamin Franklin said, an ounce of prevention is worth concentration fluctuates significantly, its performance can also a pound of cure. This certainly applies to coolant quality. change dramatically. Products are designed to perform at an Maintaining good coolant quality in the systems is a culture—a optimal concentration; otherwise, their performance attributes, proactive way of thinking. Some companies do it very well and such as tool life, corrosion protection, bio-resistance, cooling, reap the quality, cost and productivity benefits. Others do a chip handling, oil rejection, and applied cost are diminished. very poor job and suffer the consequences, consistently chasing Tramp oil removal is essential for two reasons: It eliminates a problems they could have avoided with the help of best “food source” for bacteria, and the oil is collected and recycled practices. for other operations or for general reclaim. Both of these approaches save time and money.

Volume control helps maintaining a properly equalised Saving time and money system: Making sure that the correct amount of fluid is being Quaker Chemical utilises the principal of sharing best used according to the design specifications helps minimising practices, saving the customer time and money. When it comes foam generation, often through longer residence times, to managing systems and taking care of fluids, some standard premature pump failures and pump cavitation. Proper level best practices that can be incorporated are as follows: control can also help identify leaks in the system or other Concentration control is your No.1 priority: When a product’s mechanisms that result in the loss of fluids from the system.

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TECHNOLOGY | COOLANTS & LUBRICANTS

TECHNOLOGY | COOLANTS & LUBRICANTS

Maintaining good water quality can prevent problems with large central systems: If water of known poor quality is added as make-up, systems gradually increase in hardness, chlorides and sulfates from their starting values. To keep the system at a reasonable contaminate level, use a mix of city water and reverse osmosis (RO) or de-ionised water in the system for the make-up. Otherwise, one might run into typical problems, such as splitting of the emulsion, poor lubrication, and rusting of parts (like steel or cast iron).

Biological control in metalworking fluids prevents the generation of micro-organisms-bacteria and fungi - which many people call “bugs.” Bacteria live and grow in the metalworking fluid and can consume portions of the fluid.

“Monday morning odour”- that rotten egg smell, which contains hydrogen sulfide (H2S), is mainly created by sulfate reducing bacteria (SRBs). SRBs grow in areas where there is no oxygen. If the sump has remained stagnant over the weekend, that following Monday morning when the machine tool pump is turned on, oxygen is again incorporated into the fluid. When the SRBs are exposed to the oxygen, they begin to die and emit H2S, which is that rotten egg odour.

Other effects of bacterial growth besides odour are numerous and can include corrosion effects from acidic components produced by bacteria, health effects, dermatitis and eventual physical breakdown of the emulsion. Without biological control, the bacteria will continue to grow. And not just a little. An entire population of some common metalworking fluid bacteria can double approximately every 20 minutes. So, if one starts with 1,000 bacteria at time zero, in 8 hours he would have nearly 17 billion bacteria!

Fungus, yeast and mould tend to live around the fluid, not so much in it. Fungus smells like “wet dog” or a “musty locker room,” and lives in the soil and air. For instance, if the plant is located near a farm, fungal problems can show up in the spring when new crops are planted and at harvest time in the fall, because the soil is churned and loads of micro-organisms are dispersed into the air.

If fungus shows up in the fluid, one can bet it exists somewhere else. It tends to proliferate in splash areas where the coolant sits without agitation, and is more of a physical problem, creating films and mats of growth that can plug coolant nozzles, filters and fluid lines. Given enough time, these mats and films will coat the walls of coolant flumes in the below-ground trenches. Sites use different tests to determine the amount of

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COOLANTS & LUBRICANTS | TECHNOLOGY

Biological control in metalworking fluids prevents the generation of microorganisms-bacteria and fungi

biological activity in their fluids. One of the most widely used plant?” The questions come down to this: “Is it possible to measurements is Biosticks. predict bio-stability?”

Maintaining the supplier’s recommendations: Maintaining The answer is yes. But it’s a complex issue predicated on a recommendations from the suppliers, such as, concentration, number of variables. A truly bio-stable product relies not only pH control, minimising contamination and sustaining good on the inherent characteristics of the product, but also on good maintenance practices is essential. maintenance practices and adherence to recommended Mist collectors: Mist collectors have been an issue when it parameters. A long fluid life is always desired by the customer; comes to high metalworking fluid usage. They can cause higher however, changes in product chemistry over time must be use and should be monitored for fluid loss and be tracked like considered. other chemicals at the facility. Meters can measure the amount Metalworking systems are continually “under attack” by of fluid lost due to the collector. organisms. Bio-stable fluids are designed to resist microbial Filter equipment: This removes oils, debris and fines from the attack from bacteria, fungi/yeast and mycobacteria. However, fluid in the system, aiding in optimising fluid cleanliness, in a typical plant, metalworking systems are never completely protecting pumps from premature failure, maintaining an sterile and fluids are continually “under attack” by biological acceptable surface quality, and preventing re-deposition of organisms from a myriad of sources. It is a common practice to particulates on the surface that can initiate corrosion. allow small amounts of microbial growth. This growth has to Collectively, this helps maintain the longevity and consistent be monitored closely because it can rapidly become out of performance of the metalworking fluid. control and require treatment with a biocide.

Control plans: This can be incorporated to monitor and control all these constantly changing variables. Use control plan Approaches to designing a bio-stable fluid documents as a tool to set the limits within which the process There are a number of approaches to develop a biostable should operate; to list specific process activities; and to state the variables or risks affecting them, as well as their specifications fluid. A common method is to add an approved biocide into the neat (undiluted, as received) metalworking formulation. and corrective action steps.

Data collection: Data collection is crucial for process control With this approach, each time one adds concentrate to the and successful program. One should regularly collect process systems, he is providing a “dose” of biocide. Another approach information and record it in a central location. Then, this data is to incorporate ingredients into the metalworking fluids that can be used as an early warning detection system, and produce an environment that is inhospitable to microbial incorporate it as a decision making tool to assist with making growth. Significant research has to be done to determine what kind of functional raw materials will provide this environment. educated and low-risk decisions.

Finally, designing a fluid that equilibrates in the system at a pH between 9-9.5 will aid in bio control. All three approaches may Maintaining bio-stability in metalworking fluids be used in one fluid. ☐ Metalworking customers often ask: “Is there a metalworking Part 2 of the article will apear in the next issue fluid that is truly bio-stable-one that will never require the use Courtesy: Quaker Chemicals of post-added biocides?” “How do I know that particular bio> MORE@CLICK EM01620 | www.EfficientManufacturing.in stable fluid will maintain its stability in my manufacturing

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S P E C I A L F E AT U R E | G R E E N M A C H I N I N G

Going green with veggies The article outlines the various benefits derived with the usage of vegetable oils and the latest renewable resource additives in combination with effective microbial control chemistry. This has led to the development of highly performance driven, effective and environmentally responsible fluids.

At present nearly all metal cutting machines in the industry working with cutting fluids use products containing mineral oil. The recent years have seen a dramatic increase in prices of petroleum products, owing to the weakening of rupee and the demand—supply situation. Metal working fluids (MWF) are the raw materials, which are majorly dependent on petroleum derivate, have taken a direct hit forcing suppliers to increase their prices over 15-20% in a short span of time.

Considering the uncertainty of petroleum product prices and supply side constraints, MWF manufacturers are constantly trying to reduce dependency on petroleum. This has led to

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Vrushal Phadnis Director Taurlube Petrochemicals vrushal.phadnis@taurlube.com

various developments in synthetic products that fulfil the requirements of lubrication, corrosion prevention and dissipation of heat from the tool and work piece.

Vegetable oils for faster machining A parallel line of development is in the field of renewable & bio-based products that are reasonably stable in product costing & supply, i.e. products derived from vegetable oils.

Vegetable oils, owing to their high polar properties adhere better to metal surfaces, thereby creating a more durable

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G R E E N M A C H I N I N G | S P E C I A L F E AT U R E

Vegetable oil maintaining a more durable film is able to withstand high cutting speeds, without overheating of the component or tool, thereby facilitating faster machining of these metals and improving production numbers

lubricating film than conventionally used mineral oil based products.

The basis for the high lubricity lies in the very structure of the molecules of vegetable oils. Molecules of the vegetable oils are heavy, long and have dual polarity, which implies that each molecule of oil has opposite electrical charge at its ends. These bi-polar molecules have great affinity towards metal surfaces, which have a natural & inherent ionic charge on their surfaces.

This results in the formation of a strong, durable and homogeneous layer of oil over the metal surface that is able to withstand high cutting forces without rupturing, thus, enhancing the insert life during metal cutting operations.

Mineral oil, on the other hand, don’t have polar properties.

These form a film of layer on the metal surface which is weaker in nature, and can rupture easily. Thus, in order to make mineral oil based film exert higher forces, it is required to induce strength to the film using Extreme Pressure (EP) additives.

A comparative study conducted at a manufacturer of aluminium & steel parts revealed an increase in the life of carbide inserts by over 35% [350 components / insert edge] using vegetable oil based fluids, compared to a good quality mineral oil based fluid [260 components / insert edge] used in the same machining conditions.

Hard to cut metals such as stainless steel and titanium used in aerospace and dental industry, which require higher cutting forces and speeds often face the issue of overheating & inadequate insert life, putting a limitation of machine speed feeds. Vegetable oil maintaining a more durable film is able to withstand high cutting speeds, without overheating of the

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component or tool, thereby facilitating faster machining of these metals and improving production numbers.

Benefits A very useful feature of vegetable oils is their flash point.

Vegetable oil has a significantly higher flash point which leads to lower evaporation losses and lower oxidation, leading to less smoke formation during metal cutting operations. Typically, a mineral oil based neat cutting fluid having viscosity of 22 cSt has a flash point of 170 - 1800 C. A particular type of vegetable oil based neat cutting fluid having the same viscosity will exhibit a flash point of over 2400 C. This ensures higher fire safety, lower oil consumption and cleaner working environment.

Toxicity levels of vegetable oil based products are low, thus increasing the operator health and skin compatibility. The heavy molecular structure of vegetable oils also results in lower mist formation during machining, leading to a safe and cleaner working environment. Common sources for extraction of vegetable oil for use in cutting fluids include sunflower, rapeseed, soya bean, etc. Life Cycle Analysis (LCA) of vegetable oil based cutting fluids shows that the environmental impact of the production, use and disposal of these products is far less than that of mineral oil based products. Vegetable oils have higher organic content and are easy to treat for disposal and lead to lesser Chemical Oxygen Demand (COD) and Biological Oxygen Demand (BOD) in Effluent Treatment Plants (ETPs). � > MORE@CLICK EM01621 | www.efficientmanufacturing.in

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event | REPORT

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HIGHLIGHTS

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ith 47,033 attendees, 7,130 overseas and W 294 from India Under the theme of “Smart Automation Practices”, a total of 5,411 booths at the exhibition Around 1,015 exhibitors, 298 foreign, 717 from Taiwan Participation from 16 schools with 40 groups for empowering future industry dynamics Thirty feature seminars, including Smart Factory Technology Forum, High efficiency machining technique for aerospace industry T he 12th Taiwan Machine Tools Industry Awards for excellence in research and innovation P articipation from countries like China, Japan, Korea, India, Thailand, USA, Turkey, Singapore, Argentina, Vietnam, Germany & Switzerland T he exhibition witnessed trends like robot development, unlocking big data, digital manufacturing, smart manufacturing and laser & electric technology

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Moving towards specialised machines Focussing on smart machining solutions to enable greater productivity in the manufacturing industry, TIMTOS 2015 displayed a host of automated products and high-precision machine tools that served as an interactive platform for global manufacturers in the machine tool industry. A post event report…

Today, Taiwan is recognised as a major machine tool manufacturer across the globe. The 25th Taipei International Machine Tool Show, held on March 3-8, 2015 at the Taipei World Trade Centre (TWTC) Exhibition Hall, EXPO Dome and Nangang Exhibition Hall, demonstrated the increase in demand in the domestic and foreign markets in the Taiwan machine tool industry. Organised by the Taiwan External Trade Development Council (TAITRA) and Taiwan Association

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

of Machinery Industry (TAMI), the biennial exhibition witnessed a total of 7,130 foreign buyers, marking an increase of 8.3% on the previous show held in 2013. “The exhibition hosted 1,015 exhibitors spread across 5,411 booths, including 260 foreign manufacturers from 18 countries. Marking the debut of a host of automated products, the show highlighted the underlying automation of Industry 4.0,” said John Hsu, Chairman, TAMI.

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REPORT | EVENT

investigation and diversified product strategy. According to Yih Jyh Kang, Executive Director, TAITRA, one of the major highlights of the exhibition was the Taiwan Controller Appliance Pavillion. “The pavilion features three Taiwan-based controller makers - Syntech Technology, Delta and AdvantechLNC with six local machine tool manufacturers to showcase the advanced applications of CNC machine tools, such as cell phone case processing and dental implant processing.”

Trends dominating TIMTOS Robot development: China together with the ASEAN, currently looks for automation solutions. In anticipating this, many Taiwan machine tool suppliers have already set up a robot division of theirs or even transformed themselves into robotics suppliers. Companies like HIWIN and Fanuc displayed some of their robots at TIMTOS. Also, Delta Industrial Automation’s new SCARA robot DRS40L with high speed and precision has been applied to the company’s plant for enhancing productivity and lowering manpower costs.

Unlocking big data: To meet the challenges of the fluctuating market landscape, Taiwan-based manufacturers are aligning data analysis initiatives with the business performance goals. According to reports, cloud and big data technologies help aggregate data set across disparate functions Highlights to overcome data silos. TIMTOS saw companies diverting their The six-day event attracted a total footfall of 47,033 visitors, IT spent towards setting up specialised data optimisation widely catered to the future of the Taiwan machine tool laboratories, and traditional factory floor data analysing tools development. The seminars & conferences during the making way for faster & smarter product lifecycle management exhibition included the Mitsubishi new generation CNC applications. product presentation; new vision for manufacture-smart Digital manufacturing: With the latest technology factory technology forum, trends in machine tools and advancements, integrating PLM with shop floor applications resulting challenges for linear drive systems, 3D fibre laser enables the exchange of information between design & tube cutting technology, high effiecncy machining technique manufacturing groups. As such, digital tools enable the local for the aerospace industry, fibre laser apllications & trends and makers to take on the increasingly challenging global market.

5-axis machine focus on aircraft & automotive industry.

To assist local manufacturers to go upmarket to fend off cutThe exhibitors, on the other hand, focussed on the latest throat competition, the Industrial Development Bureau under advances and technologies and industry trends, such as Ministry of Economic Affairs proposed a three-year project to industry market development and machine tool intelligence. boost growth and development of traditional Taiwanese Currently, the machine tool industry in Taiwan faces industries. The exhibition saw many local companies competition from Japan and Germany in the high-end market, concentrating on PLM to ensure informative-driven decisions and China in the low-end market. For a greater market share, at every stage in the product lifecycle.

Taiwanese producers have been quickly adjusting to changing Solution-based products: TIMTOS focussed on solutiondemands and have identified niche markets through intensive based products. In this regard, Wele Mechatronic focussed on

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Considering the global market uncertainty, Taiwanese manufacturers have upgraded themselves with blooming trends such as Industry 4.0, intelligent & smart manufacturing systems

manufacturing time saving machines with unique technology.

The vertical multi-tasking turning centre’s (which claims to be 50% more efficient than Japan machines) USP is zero breakage with special control in ASS. SEYI, an application & solution provider company integrates machines with different automation, thus enabling solution-based products for customers. On the other hand, PMI Linear Motion Systems has products like cooling nut system that shortens the warmup time of machines and maintains the performance of lubrication grease and ground ballscrews with rotary nuts that can be used in gantry type machining centre.

According to Brian Chen, Project Manager—Industrial Motion System, Delta Electronics, the company provides machine tool solution with industrial robot solution and peripheral solution. “Machine business has become quite competitive. So, the products need to offer customised solutions for customers. In this context, high performance spindle motors is important,” he said.

Smart manufacturing: As per Alan Lu, Chairman— Machine Tool Committee, TAMI, the depreciation of Japanese Yen has greatly left an impact on the Taiwanese manufacturers.

“Taiwan’s investment in the machinery equipment is made by the sectors that require advanced technology, such as energy, aerospace and automobiles. Using smart machining processes and developing Industry 4.0 through collaborating with R&D is taking the centre stage for local manufacturing.”

TIMTOS witnessed a host of companies displaying smart manufacturing practices. Bryan Chen, Chairman & CEO, YCM, believes that the company adopts integrated manufacturing model to practice best machine tools, from casting, assembly, inspection and shipment. The company has established “Smart Automation Development Dept” to integrate smart control interfaces into machine tools. In addition, Delta Industrial Automation displayed 10 high-end integrated machine tool solutions, including a high-speed tapping machine, dental

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milling machine, vertical machining centre and tool turrets solution.

Laser & electric technology: TIMTOS saw many Taiwanese suppliers putting their R&D emphasis on key components, including servo motors and controllers, which is expected to enhance the R&D capabilities. Many Taiwan-based controller manufacturers have launched all electric control systems and have been using laser technology that accounts for 30% better efficiency than traditional presses, thus, boosting the demand for newer machines.

Inviting students: To cultivate future knowledge on the industry dynamics, TIMTOS invited several student groups to understand the major machinery verticals of the industry.

Around 16 schools participated in the show. The exhibition saw industry stalwarts explaining the required items catering to the different markets in the world. This helped the students to get an insight of the machine tool industry.

Overviewing the industry Considering the global market uncertainty, Taiwanese manufacturers have upgraded themselves with blooming trends such as Industry 4.0, intelligent & smart manufacturing systems, along with adequately equipping their plants to keep abreast of the latest technologies. Taiwan has also developed significant strength in the production of machine tool components. As far as technological innovations are concerned, the country is heading towards technological independence & manufacturing intelligence. The industry has already made great progress in the development of controllers and other key components, such as AB shafts and C shafts for direct drive motors and has, thus, freed itself from depending on foreign suppliers. Recent technological innovations have given rise to many potential end-user markets, and with it, new opportunities and challenges for the industry.

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REPORT | EVENT

INDUSTRY SPEAK “Taiwan Controller Appliance Pavillion features three Taiwan-based controller makers- Syntech Technology, Delta and advanced LNC with six local machine tool manufacturers to showcase the advanced applications of CNC machine tools.”

Yih Jyh Kang, Executive Director, TAITRA

“Using smart machining processes and developing Industry 4.0 through collaborating with R&D is taking the centre stage for local manufacturing.”

Alan Lu, Chairman—Machine Tool Committee, TAMI

““TIMTOS is about high-precision machines. Such machine should be followed in the Indian market too.”

T Venkatesan, DGM—Projects, S&T Engineers

“TIMTOS had more 5-axis machines with higher technology finish, which showcases the technology advancement.”

Indradev Babu, MD, UCAM

Export orders: The total export value of Taiwan machine tool industry early this year went up to $3.75 billion, which is 5.8% growth on the same period last year. In terms of exports, Mainland China ranked first with the value of $1.2 billion, accounting to 32.4% on the total number, an increase of 7.3% compared to the same period last year. The US came second with an export value of $414 million, with 11.1% of the tool and a 3% increase compared to the same period last year. This is followed by Turkey with 15.8% surge, Germany with 8.9% rise. The Netherland with 17.9% hike and Russia with 8.8% increase.

Import value: As per reports of Jan-Dec 2014, in terms of import for the Taiwan machine tool industry, Japan accounts for 52.9% with a YOY of 18.8%. Germany comes next with 12.6%, followed by China with 8.2%, Switzerland with 5.4%, USA with 3.7%, South Korea with 3.1%, Singapore with 2.4%, Thailand with 2.3%, Italy with 1.8%, Czech Republic with 1.5% and other countries accounting for a total of 6.2% import value.

International participation The exhibition witnessed 717 domestic exhibitors and 298 foreign exhibitors, with a total of 7,130 foreign visitors. A major highlight was the German and Swiss Pavilion in the show. The German pavilion featured eight German companies exhibiting and promoting innovative products. It hosted seminars on topics such as ETEL torque motor and TS 460 touch probe. On the other hand, the Swiss pavilion, comprising 105 booths displayed a wide spectrum of technologies in grinding, milling, sharpening, turning, jig boring, electrical discharge machining, gear cutting and forming. The main focus of the pavilion was to demonstrate the Taiwan metal manufacturing companies innovative and flexible solutions in the product process.

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Presence of India According to CC Wang, President, TAMI, Taiwan’s machine tool sales in India has improved to 12.6%, as compared to the last year. “Our machine tool sale in India is around $100 million. There are around 1,000 Indian buyers in Taiwan and a few factories are located in India too. However, India had a booming market in the past, but in the last few years, the growth has slowed down,” he opined.

Indradev Babu, MD, UCAM, believes that the exhibition witnessed more integration in machines. “This year, TIMTOS had more 5-axis machines with higher technology finish, which showcases the technology advancement.” Speaking on the use of advanced technology in today’s world, T Venkatesan, DGM—Projects, S&T Engineers, suggests that since Germany has a rigid market and Japan has an expensive market, the Taiwanese market is well suited for India, mainly for costcutting. “TIMTOS is about high-precision machines. Such machine should be followed in the Indian market too. For example, some machines have a magnetic base technology, which minimises the wear-and-tear of the machines,” he said.

Given that with the ‘Make in India’ initiative in the milieu, the Indian market is trying to meet the global standards.

Highlighting this, K G Advani, Chief Executive, Chmer EDM, said, “Taiwan-based products are a value for money. These are well-accepted in the Indian market. For the latest multi-axis & solution-based products and for adopting smart manufacturing techniques, it adds value to the Indian market too.” With a total number of 294 visitors from India, the exhibition had two Indian exhibitors Pragati Automation and Fenwick and Ravi.

TIMTOS 2017, scheduled on March 7 to 12, 2017, is expected to scale new peaks to deliver huge prospects across the machine tool industry, thus, developing smart manufcaturing practices. ☐ > MORE@CLICK EM01622 | www.efficientmanufacturing.in

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TECHNOLOGY | NEWS

Hydraulic transfer press

Cloud-enabled digital automated inventory system

Dees Hydraulic has developed HD-FASTech technology for the stamping industry. The HD-FASTech hydraulic machine completely solve conventional deep-drawing's low efficiency and elevated from 3 SPM to 5-8 SPM, which greatly improve production efficiency. By using single acting cylinders for lifting and pressing, the company effectively prevented unnecessary scratching of cylinder during off-center forming.

With the unique design of cylinder cover, maintenance or servicing is performed at ease without removal of entire cylinder, thus, saving precise HD-FASTech hydraulic machine time. The slide return mechanism ultilises the company’s proprietary design, by using lifting bars and individual cylinders, slide falling is thus prevented. The company has also integrated the patented pipe bursting slide locking protection circuit for protection of workers and tooling during forming. If pipe or rubber hose bursts, the hydraulic circuit senses a loose in pressure which will lock the slide from sudden downward drop.

Kennametal has launched a new service offering combining its vending solution, ToolBOSS™ and its cloud-enabled digital tooling and process knowledge vehicle NOVO™. Manufacturing’s unrelenting pressure to remain competitive and control costs combined with the widening skills gap are shaping the present and future of how Integrating ToolBOSS with NOVO customers operate and manage machine shops optimises both process planning today. Recent research indicates up to 70% of and shop-floor operations manufacturing executives are focusing on plant-floor data initiatives to drive operational and business excellence, faster time to market, and immediate access to data from machines on the factory floor. The company’s ToolBOSS with NOVO was inspired by the needs of machining customers seeking seamless real-time integration of their enterprise engineering systems (CAD/CAM systems) with their production floor. This makes plans and budgets more time- and cost-efficient. ToolBOSS users on the cloud with the latest software version can now use NOVO™ to see if an item proposed for a process plan is already available in their ToolBOSS inventory.

Dees Hydraulic Industrial | Taiwan Email: sales@spc.com.tw | Tel: +886-2-2601 8661

Kennametal India | Bangalore Email: bangalore.information@kennametal.com | Tel: +91-80-22198444

> MORE@CLICK EM01623 | www.efficientmanufacturing.in

> MORE@CLICK EM01624 | www.efficientmanufacturing.in

Metal 3D printing systems for dental parts

Fully automated boring bar adjustment system

Renishaw is offering its AM250 metal 3D printing machine fully optimised for producing dental parts. The metal 3D printing systems will not require further adjustment to achieve the production of high quality frameworks. To further enhance this offering the company will also supply cobalt chrome powder that can be used in the manufacture of dental frameworks. Suitable for 3D printing of a large variety of metal dental devices, the optimised AM250 is a AM250 Plus plac high volume 3D printing machine specifically aimed at the dental market. Fine tuned to the intricacies and challenges of dental devices, it is a popular alternative for those aiming to reduce the costs associated with milling operations and can replace traditional wax casting techniques by building dental frameworks from STL data as part of a digital workflow. The company has conducted its development with an emphasis on accuracy and quality of frameworks, quality and traceability of raw materials, and speed and reliability of manufacture. The key aim is to allow a rapid return on investment for its customers.

Rigibore has developed Active Edge, a completely automated and closed loop boring bar adjustment system. Measuring the bore size in process using a probing device and feeding the measurement data back to the machine, the ActiveEdge system can make decisions to make a compensation adjustment for wear. Once this decision is made by the supplied sub-routines, the control can relay instructions by addressed radio to the battery powered ActiveEdge tool. On receiving the instruction from the machine, the ActiveEdge tool, which can be situated anywhere on the machine, Active Edge boring bar powers the servo motor built into a adjustment system precision customer replaceable cartridge, making accurate, micron level adjustment without human intervention. The tools can also be easily adjusted by a remote control, the 3T Adjuster, and the automatic boring adjustments are captured for future analysis through supplied ActiveNET software. The Active Edge system, improves the overall safety by preventing operators from adjusting tools in the machine envelope.

Renishaw | Pune Email: samina.khalid@renishaw.com | Tel: +91-90-4900-1589

Rigibore India | Bangalore Email: lalit@rigibore-india.com | Tel: +91-80-41253035

> MORE@CLICK EM01625 | www.efficientmanufacturing.in

> MORE@CLICK EM01626 | www.efficientmanufacturing.in

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NEWS | TECHNOLOGY

Flexible mechatronic parallel gripper

Metal cutting practical application support

Schunk has introduced EGL 70 flexible mechatronic parallel gripper with variable gripping force between 50-600 N for industrial applications. Since the finger position, closing speed, and gripping force are freely programmable within a maximum stroke of 48 mm per finger, diverse components with a weight of up to 3 kg can be precisely handled in force-fit gripping. The gripper fingers can be prepositioned to reduce cycle times. The entire control and power electronics of the EGL are integrated to save space and to allow decentral operation and even mobile use, thanks to the 24 V EGL enables flexible DC operating voltage. Since the EGL fulfills and efficient industrial standards and the basic version is handling processes connected only by means of industrial connectors, installation time is reduced to a minimum. It is compatible with the world’s most extensive standardised line of modules for gripper systems from the company. It is ideal for diverse applications in the field of industrial assembly technology, mechanical engineering, and lab automation.

Seco has recently introduced four metal cutting books in a new series called ‘Metal Cutting – Best Practices.’ These books cover current trends and techniques in metal cutting and will be published throughout 2015. This new series complements the company’s previously published books on metal cutting. In 2012, the company first partnered with professor ‘Metal Cutting – Theories in Ståhl to translate his book entitled ‘Metal Practice’ published in 2014 Cutting – Theories and Models’ from Swedish into English. This comprehensive book is included in the company’s STEP (Seco Technical Education Programmes) package and used by numerous professors in universities throughout the world. The release of “Metal Cutting – Best Practices” offers another layer to how the company presents information to customers, others in the manufacturing sector and the academic world. It is extremely practical and based on years of experience manufacturing cutting tools and applying them in various applications in customers’ shops.

Schunk Intec India | Bangalore Email: rakhi.singh@in.schunk.com | Tel: +91-80-4053-8999

Seco Tools India | Pune Email: seco.india@secotools.com | Tel: +91-02137-667300

> MORE@CLICK EM01627 | www.efficientmanufacturing.in

> MORE@CLICK EM01628 | www.efficientmanufacturing.in

Multiple spindle heads

Double-sided insert for multiple application

Suhner has introduced POLYdrill multiple spindle heads that combines modern design features with high drilling performance in a very compact product envelope size. Over the years, the program range for POLYdrill multiple spindle heads has been consistently up-dated and expanded. A substantial gain in productivity and output can be achieved through the application of standard simultaneous multi-operation components at POLYdrill multiple spindle heads relatively low investment cost. With the new line, the company is now offering adjustable multiple spindle heads for 2, 3 and 4 spindles in 6 different capacity classifications. Including custom made application specific fixed spacing heads with up to 144 spindles – an enormous increase in productivity. In addition to multiple spindle heads, the company offers a variety of different other POLYdrill components including angle heads for drilling, tapping and milling operations as well as back facing heads for drilling and countersinking operations.

TaeguTec has launched a new compact four corners double-sided insert– the 4NKT 6 mm inserts for end mills, face mills and modular cutters. The 90 degree entering angle insert, despite the double sided design, is suitable for high ramp down angle applications. Its high positive geometry generates low cutting force while the cross edge insert geometry prevents unexpected insert failure. The increased insert thickness and high strength, combined with the cutter’s wide bottom for improved clamping, enables excellent high stability and productive machining. Furthermore, 4NKT 6 mm insert the 4NKT’s smaller 6 mm size compared to the 11 mm and 16 mm sizes increases the number of teeth on the cutter which is not only good for machining small components but also makes it a finer pitch tool that increases productivity.

The new line of cutters is offered as end mills (D16- 40 mm), modular types (D16- 40 mm) and face mill types (D32- 63 mm). All cutters include an internal coolant delivery system for efficient chip evacuation that prevents built-up-edges.

Suhner India | Bangalore Email: automation.in@suhner.com | Tel: +91-80-2783-1108

TaeguTec India | Bangalore Email: indira@taegutec-india.com | Tel: +91-98-8667-6473

> MORE@CLICK EM01629 | www.efficientmanufacturing.in

> MORE@CLICK EM01630 | www.efficientmanufacturing.in

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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T

Highlights - May 2015 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net

» Composite machining Composite parts are finish machined by way of turning, milling, slitting, drilling, routing, etc. However, our knowledge of machining conventional materials like aluminium, steel or cast iron cannot be directly applied since the basics of machining action and machineability of composites completely differ. Associated critical aspects must be carefully considered for successfully machining composites and the machine tool employed should accordingly be constructed. The next issue will highlight these trends.

» Power presses Power presses are dangerous machines which have caused many accidents over the years. The causes include poor maintenance of the press, its safeguards and its control system. The next issue will provide information on the safe usage of power presses. » Industrial parts cleaning Owing to the constantly increasing requirements in terms of efficiency, quality and environmental protection, the cleaning of industrial parts has become absolutely essential in manufacturing processes.

A successful cleaning process requires careful selection of both the cleaning chemistry and equipment. Cleaning process is influenced by various factors viz. manufacturing process, cleaning media, surrounding conditions, work-piece quality, parts handling, testing process, etc. The next issue will highlight various solutions in industrial parts cleaning.

» Design of Experiments Design of Experiments (DoE) is one of the most successful structured approaches in understanding the real life issues in manufacturing and identifying the critical factors and interactions in causing the issue. DoE saves considerable time & efforts in trouble shooting, identifying quality inputs and in rectifying the total system. The next issue will provide overview of various approaches like factorial, fractional factorial DoE, benefits of applying, and practical applications in designing a robust product/process.

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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 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

COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Aegis Software. . . . . . . . . . . . . . . . . . . . . . 18 Altair Engineering India . . . . . . . . . . Back Cover Blaser Swisslube . . . . . . . . . . . . . . . . . . . . 25 Chmer EDM. . . . . . . . . . . . . . . . . . . . . . . . 66 CII West . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Comsol Multiphysics . . . . . . . . . . . . . . . . . . 23 Dees Hydraulic Industrial . . . . . . . . . . . . 61, 70 Delta Electronics. . . . . . . . . . . . . . . . . . . . . 66 Dormer Tools India . . . . . . . . . . . . . . . . . . . 16 EMAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fanuc Corporation . . . . . . . . . . . . . . . . . . . 26 Faro . . . . . . . . . . . . . . . . . . . . . . . 10, 28, 39 Flir Systems. . . . . . . . . . . . . . . . . . . . . . . . 29 Forging Industry Association . . . . . . . . . . . . . 40 Haas Automation . . . . . . . . . . . . . . . . . . . . 56 Hannover Messe . . . . . . . . . . . . . . . . . . . . 15 Hong Ji Precision Machinery . . . . . . . . . . . . 37 Hyundai WIA India. . . . . . . . . . . . . . . . . . . . 21

Features Writer Maria Jerin maria.jerin@publish-industry.net

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page igus . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 31 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . 33, 48 Indsur Global . . . . . . . . . . . . . . . . . . . . . . . 12 Jabez Technologies . . . . . . . . . . . . . . . . . . 44 Junker . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Jyoti CNC Automation . . . . . . . . . . . . . . . . . . 3 Kennametal . . . . . . . . . . . . . . . . . . . . . . . . 70 Korloy India . . . . . . . . . . . . . . . . . . . . . . . . 11 KPIT Technologies. . . . . . . . . . . . . . . . . . . . 14 MAG India Industrial Automation Systems. . . . 17 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 63 Mitsubishi Heavy Industries. . . . . . . . . . . . . . . 2 MMC Hardmetal . . . . . . . . . . . . . . . . . . . . . 13 MotulTech India . . . . . . . . . . . . . . . . . . . . . 35 PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Quaker Chemicals . . . . . . . . . . . . . . . . 28, 60 Renishaw . . . . . . . . . . . . . . . . . . . 47, 58, 70 Rigibore . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Rittal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Name . . . . . . . . . . . . . . . . . . . . . . . . . Page RocTool . . . . . . . . . . . . . . . . . . . . . . . . . . 12 S&T Engineers. . . . . . . . . . . . . . . . . . . . . . 66 Savoir Faire Management Services . . . . . . . . 34 Schunk Intec India . . . . . . . . .Front Inside Cover Seco Tools. . . . . . . . . . . . . . . . . . . . . . 10, 71 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Stratasys India . . . . . . . . . . . . . . . . . . . . 1, 52 Suhner India . . . . . . . . . . . . . . . . . . . . 51, 71 TaeguTec India. . . . . . . . . Back Inside Cover, 71 TAITRA . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Taiwan Diamond Industrial Co . . . . . . . . . . . . 55 TAMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Taurlube Petrochemicals . . . . . . . . . . . . . . . 64 UCAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Vargus India . . . . . . . . . . . . . . . . . . . . . . . . 6 Yeong Chin Machinery Industries . . . . . . . . . 66 YG1 Cutting Tools . . . . . . . . . . . . . . . . . . . .4,5

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

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