For over 50 years
LEADERS of INNOVATION Back then
and NOW
The first triangular Laydown Threading Insert | 1975
The first indexable Thread Milling System | 19 85
| 2016 AN D B E YO N D
Advanced Threading Solutions
Innovative Grooving & Turning Solutions
TMSD
microscope
Thread Mill for Deep Holes
For Gear, Spline & Rack Manufacturing
Micro Tools for Small Bores
Inserts now available in full profile and conical profiles
Gear Milling Solutions are now available as standard
Expanded line of Inserts for every Boring Application
The Microscope line offers extended range of single-ended inserts and a full range of tool holders with a simple clamping system.
A multi-flute, highly productive and economical solution for milling threads in deep holes
To see the full range of VARGUS innovations visit: w w w.vargusindia.com VARGUS INDIA
Unit Nos. 16 & 20, 1st Floor Mega Centre
Pune - Nasik Highway, Chakan, Pune - 410501
Tel: +91 21356 54748 info@vargusindia.com
VARGUS Ltd.
mrktg@vargus.com www.vargus.com
E D I TO R I A L
E D I TO R I A L
A better outlook The business confidence in Indian industry has increased to 57.20 in the second quarter of 2016 from 54.10 in the first quarter of 2016, according to CII. India has been an attractive hub for foreign investments in the manufacturing sector. Several mobile phone, luxury and automobile brands, among others, have set up or are looking to establish their manufacturing bases in the country. With impetus on developing industrial corridors and smart cities, the Government of India aims to ensure holistic development of the nation. Furthermore, the government has an ambitious plan to locally manufacture as many as 181 products. The move could help infrastructure sectors such as power, oil and gas, and automobile manufacturing that require large capital expenditure and revive the Rs 1,85,000 crore Indian capital goods business. With this, the industry has a better outlook for the future with an increased confidence level, though with a cautious optimism. Although the outlook on capacity and workforce addition in the sector is not very optimistic, companies plan to spend more on R&D, new product or service introductions, facilities/ geographic expansion, and marketing. Just to give an example, in the Management Interview in this issue, Kishore Jayaraman, President, Rolls-Royce India & South Asia, shares his company’s plans to hire about 1600 engineers in its various upcoming facilities. Also, with the current spend on procurement at around $40 m (2016), Rolls-Royce has set a target of procurement spend of around $200 m by 2020 and doubling the supplier base in 2017. Sounds interesting? Have a look at the feature for more details. Happy reading!
EDITORIAL ADVISORY BOARD
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Raghavendra Rao Senior 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
Dr N Ravichandran Former Executive Director Lucas-TVS Chief Mentor, UCAL Fuel Systems
N K Dhand CMD, Micromatic Grinding Technologies
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA Sonali Kulkarni President & CEO Fanuc India Dr Wilfried Aulbur Managing Partner Roland Berger Pvt Ltd S Ravishankar Consultant
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Aug 2016
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CONTENTS
Market
Management
10
NEWS
14
“Making the right tooling solution available�
INTERVIEW 24
“Abrasive application is truly engineering�
Interview with Ashok Kocheril, Chief Executive Officer, Suhner India EVENT REPORT 66
Connecting the physical and digital...
A post-event report on the recently concluded Liveworx 2016 by PTC, at Boston, Massachusetts, USA EVENT PREVIEW 72
Next wave of factory revolution
An event preview of TMTS 2016 to be held at Taichung, Taiwan
METAL CUTTING TECHNOLOGIES
“Embracing opportunities to co-develop and co-manufacture in India�
30
Interview with Kishore Jayaraman, President, Rolls Royce India & South Asia
Interview with Puneet Kapoor, Managing Director, GĂźhring India 16
Focus
ROUND-TABLE 26
Hitting the point of disruption
Role of cryogenics in machining processes
A read on the sustainable machining processes, using cryogenic conditions and gaining higher performances, lower environmental and health influences, increased safety, etc
The feature explains how disruptive innovation is altering the manufacturing landscape and evaluates few trends hitting the point of disruption
18
COVER STORY Software selection for manufacturing organisations
The feature explores some common business challenges faced by today’s manufacturing organisations, how the right software addresses these challenges, and posits a number of key selection factors that will optimise ROI
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EM | Aug 2015
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CONTENTS
Technology
New Products AUTOMATION & CONTROL 36
40
Modernising the automation systems
TEST & MEASUREMENT 54
Better accuracy – key for quality performance
The article helps determine how to modernise using a total systems approach or individual component replacement strategy with minimal disruption
The article focuses on the application of laser system and a telescoping ballbar system, analysing how it can aid the tooling sector by saving time, money, reduce scrap and achieve accuracy
Towards complete automation systems
EDUCATION & TRAINING 58
The feature explains how the interaction between the control functions for automation & safety is the key to success
Bridging the gap…
A read on how embracing the latest technologies harnesses the students and working professionals to develop robust, appealing and competitive products
MOTORS & DRIVES 44
Driving energy efficiency
An application story on how Emerson’s drive and motor solution has helped to cut extruder energy usage by 9%, thus, improving the production process WORKHOLDING & FIXTURING 48
Upgrading production capacity
SPECIAL FEATURE 62
Changing economics of marketing mantras
The feature traces the evolution of the marketing strategies as well as focuses on the latest marketing trends in the machine tools sector
77 Industrial Ethernet, I/O system; Drilling tools; Milling cutter; Deep-hole drilling machine; 78 Plastic strain wave gearing for robots; Replaceable head drill; Optical incremental encoder; Modular assembly systems; 79 Solid-carbide end mills; High precision machines; Indexable holemaking platform; Absolute encoder
Columns 07 08 76 80 80
Editorial Contents Tech talk Highlights – Next issue Company index
The feature focuses how the jaw quick-change system significantly reduces the set-up time, thereby, increasing productivity
EM | Aug 2015
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MARKET | NEWS
ExxonMobil partners with Micromatic Machine Tools
CCIMT to be held in November 2016
ExxonMobil Lubricants has recently announced its partnership as the official lubricant partner for Micromatic Machine Tools. Speaking on the partnership, Glen Sharkowicz, Industrial Lubricants Marketing Manager— Asia Pacific, ExxonMobil Fuels & Lubricants, said, “Our collaboration with EBs has led to the development of advanced high performance lubricant solutions that our customers can rely on. This partnership will help us push the boundaries of lubrication formulation and performance.” The collaboration will see Mobil This partnership will help us push the Industrial Lubricants support boundaries of lubrication formulation Micromatic Machine Tools with and performance their advanced range of industrial lubricant products and services, backed by the leadership and expertise from the company. As per TK Ramesh, CEO, Micromatic Machine Tools, “ExxonMobil’s team has used its application expertise and enabled partners like us to improve product performance and efficiency of our machines. We look to leverage our collective knowledge to bring improved productivity to our customers and use the expertise of Mobil in promoting the right disposal methodology for used fluids in line with promoting green environment.”
The Association for Manufacturing Technology along with the China Machine Tool and Tool Builders’ Association (CMTBA) have recently announced the launch of the China Chongqing International Machine Tool Show (CCIMT) to be held on November 13-16, 2017, at the Chongqing International Expo Centre, Yubei district, Chongqing, China. The exhibition will showcase the latest in manufacturing technology and bring buyers and sellers together from across the world to the market of Chongqing and southwest China. With an expanding manufacturing base of domestic companies plus more than 250 Fortune 500 multinationals, Chongqing has established itself as an innovation centre for high technology. Chongqing’s economic growth was 11% in 2015, the fastest growth among 31 provinces in China. As per Douglas Woods, President, AMT, “We are thrilled to partner with CMTBA to create a world-class manufacturing technology event in the robust industrial city of Chongqing. Our combined research recognises that Chongqing is a major production hub, and in the past decade, we have seen more than 2,000 companies emerge.”
DesignTech hosted technology seminar
EMO Hanover 2017 will focus on digitisation
DesignTech Systems recently organised a one-day technology seminar titled ‘Vision: Product excellence through technology impetus’ at Kolkata. The aim of this event was to showcase the latest and most advanced technologies in product design, analysis, validation and manufacturing to help companies build better products faster, cheaper and better than before. Using these technologies, the companies can not The event demonstrated technologies only achieve their product design & for every stage of product lifecycle manufacturing objectives, but through PLM solutions, they can also set-up well streamlined & optimised work processes to attain maximum efficiency. Eminent industry speakers from L&T Constructions and MSME Tool Room Kolkata, shared their experiences and benefits that they have derived by using Altair CAE solutions and Siemens PLM software, respectively. At the event, DesignTech also demonstrated technologies for every stage of product lifecycle, starting from concept development, 3D modeling and validation, product design analysis and simulation, rapid prototyping, alternative production technologies, digital manufacturing for plant simulation, to PLM for managing and optimising the entire product design and development data and processes.
EMO Hannover 2017, a premier trade fair for the metalworking sector, which will take place on September 18-23, 2017, will focus on digitisation within Industry 4.0. According to Carl Martin Welcker, General Commissioner, EMO, “Entrepreneurs all over the world are progressing the digitisation and networking of their products because they see this as the next quantum leap forward in development.” The fair is an international shop window for production technology, and a suitable As per Welcker, the event is platform for users to find solutions a platform for users to find for their increasingly multi-faceted solutions for their increasingly requirements. “Users want holistic multi-faceted needs solutions that can be coherently imaged in a single system. These require thorough comprehension of the processes in place at our customers’ facilities and of the complex technologies featured in our machines. Where the individual vendors currently stand will be revealed at the fair,” added Welcker. In 2017, EMO Hannover will once again be the meeting point for the global world of the machine tool industry.
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EM | Aug 2016
NEWS | MARKET
EuroBLECH 2016 presents online competition
AMTEX 2016 concludes on a positive note
EuroBLECH 2016, the 24th international sheet metal working technology exhibition to be held on October 25–29, 2016, at Germany, will be presenting the second edition of its online competition titled, ‘The new generation of sheet metal working’. The competition will reward six organisations or individuals in the sheet metal working industry. The competition categories focus on the recent developments & trends in the sheet metal working industry. Factory of the Future will reward organisations for clever The competition will reward six implementation of smart organisations or individuals in the manufacturing methods. Women sheet metal working industry and Innovations will focus on cutting-edge projects and accomplishments by women in sheet metal working. The best university projects in science & engineering involving sheet metal technology will compete in Academic Excellence. Original Design is open to companies producing unusual products made from sheet metal. The Young Generation is seeking for outstanding performance of junior employees and young inventors, and Clean Technology will reward eco-friendly solutions and sustainable manufacturing methods.
AMTEX 2016 has recently concluded its 11th edition of the machine tools exhibition at New Delhi. Experts from the machine tool and manufacturing industry in India as well as global participants from China, Germany, Japan, Korea, Singapore, Taiwan and Turkey marked their presence at the four-day expo. The exhibition was inaugurated by Rishi Kapoor, GM, Meiban Engineering; Hiroaki Kiriyama, Muratec Engineering; Cyril Pereira, MD, Reed Triune Exhibitions and Mohammed Shakeeb, Director, Reed Triune Exhibitions, along with Michael The event acted as a platform for Mandl, CEO, Reed Exhibitions exhibitors to present new technologies India; T K Ramesh, CEO, Micromatic Machine Tools; Terrence Miranda, Country Head, Haas India and Maulik Patel, Executive Director, Sahajanand Laser Technology. On the sidelines of the event, Frost & Sullivan unveiled its exclusive white paper themed Smart & Sustainable Manufacturing—Changing era of Indian manufacturing, in partnership with AMTEX, followed by a series of conference sessions led by industry experts. A major participation was seen by companies like Ace Micromatic, Jyoti CNC Automation, Mitsubishi Electric India, Meiban (Meiban Engineering Technology), etc.
Geometric releases tolerance-based machining
Emerging Technology Center at IMTS 2016
Geometric Limited has recently announced the availability of a revolutionary new technology that uses SOLIDWORKS 3D DimXpert and Model Based Definition (MBD) 3D dimensions and annotations to automate the programming process for CNC machined components. Aligning with industry initiatives, such as smart manufacturing and Industry 4.0 for advanced manufacturing, CAMWorks has been uniquely structured to realise the benefits of automated CNC program generation based on tolerance, surface finish and other annotations in SOLIDWORKS 3D parts. This functionality is possible due to CAMWorks’ ability to extract manufacturing features like pockets, bosses, holes, etc CAMWorks has been structured to and automatically create tool realise the benefits of automated paths based on an internal CNC program generation knowledge base of user definable tools, feeds, speeds, and strategies. Speaking on this, Jim Foster, VP— Channel Marketing & Sales, Geometric, said, “CAMWorks with tolerancebased machining will save 70% to 90% of the typical times involved, when using traditional CNC software to prepare parts and assemblies for machining. For many of our product manufacturing customers, the competitive advantage this technology offers is significant.”
The upcoming IMTS to be held on September 12–17, 2016, will witness AMT featuring Additive Manufacturing, smart manufacturing and integrated energies in its Emerging Technology Center (ETC). AMT created the ETC as a showcase for current and near-future state-of-the-art manufacturing technologies. Premier exhibits at IMTS 2016 include three proof of concept Additive Manufacturing (3D printed) displaying additive bionic human, showing additive-manufactured medical implants and body parts; AMIE (Additive Manufacturing Integrated Energy) project from the Department of Energy’s (DOE) Oak Ridge National Laboratory (ORNL) The 3D printed car and solar-powered demonstrating rapid 3D printed house are built with innovation through Additive advanced composites Manufacturing to connect a natural gas-powered hybrid electric vehicle to a high-performance building that produces, consumes and stores renewable energy and an all-electric Shelby Cobra replica and a 1952 Willys Army Jeep reproduction. As per Peter R Eelman, VP—Exhibitions & Business Development, AMT, “The ETC is worldrenowned for showcasing projects and disruptive technologies that were previously known to only a few. We want the ETC to challenge pre-conceived notions of how manufacturing performs at its best.”
EM | Aug 2016
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MARKET | NEWS
KEPL felicitated by CII for Kaizen practices
LANXESS makes Honda’s FCV zero emission vehicle lighter
Kirloskar Ebara Pumps Limited (KEPL) has recently been awarded the runners-up trophy at the Kaizen competition organised by CII, Western Region at Pune. Commenting at the occasion, S S Katare, Plant Head, KEPL, said, “We started this journey in April 2013, by introducing innovative schemes for challenging workforce towards implementing KEPL was awarded the trophy for training this process. We, now, operators who implement Kaizen & maintain SOP have trained operators who implement this process, maintain SOP, which is frequently audited for sustenance.” The event also witnessed Team MSD (machine shop department) from the KEPL state-of-the-art manufacturing facility at Kirloskarvadi, who presented their case study on ‘Reduction in line organisation loss by enhancing machine capacity of keyway broaching machine and improving broach utilisation’ under large scale industries category. The case study started with an introduction of KEPL, introduction of Gemba, followed by problem definition, selection of Kaizen theme, root cause analysis, Kaizen idea, implementation and horizontal deployment.
LANXESS has been recently featured in FCV (fuel cell vehicle) Clarity Fuel Cell, the latest model of hydrogen electric vehicle from Honda Motor Co, which has been introduced in the market. Using Tepex’s continuous and long-fibre reinforced thermoplastic composites with PA 6 matrix from LANXESS subsidiary Bond-Laminates, in combination with Durethan, a PA 6 high-tech plastic grade from LANXESS, Honda has introduced the world’s first development of hybrid-molded rear bumper beam in the model using one-shot moulding technology enabled by LANXESS. Speaking on the occasion, Martin Klocke, Head— Technical Marketing & Business Development, Tepex Auto in High Using Tepex’s continuous and Performance Materials Business long-fibre reinforced thermoplastic unit at LANXESS, said, “It is our composites, Honda has introduced great honour to feature our light hybrid-molded rear bumper beam weight solution with our Tepex and Durethan in Honda’s latest model of FCV.” As per Deniz Guerkan, Manager—Technical Marketing & Business Development, Tepex Auto in the High Performance Materials Business unit at LANXESS, Hong Kong, Tepex is a light yet strong stateof-the-art composite material made from a thermoplastic matrix and continuous fibre reinforcements.
Mitsubishi Elevator India launches new plant at Vemgal
Italian industry witnessed upward trend
Mitsubishi Elevator India has recently launched its new plant in Vemgal near Bengaluru. Spread over an area of 89,000 sq mt, the facility with floor space of 25,400 sq mt and manufacturing capacity of 5,000 units annually, has the capability to expand production in the future. The first elevator is scheduled to be delivered in December 2016. By producing locally, Mitsubishi Elevator India expects to strengthen the product competitiveness in terms of price and cut down on delivery time by focusing on its NEXIEZ-LITE elevator model for low to midrise buildings in the Indian market. Special emphasis will be placed on the efficient integration of sales, manufacturing, installation and maintenance. According to Iwao Oda, MD, Mitsubishi Elevator India, “Through the launch, we As per Oda, MD, Mitsubishi Elevator will directly cater to the India, the company emphasises safety emerging elevator market, & quality of products in India which is now the world’s second largest after China. The company emphasises on the safety and quality of all the products. It will be a collaborative effort of Japanese technology with trained Japanese personnel.”
UCIMU-SISTEMI PER PRODURRE recently concluded the annual members’ meeting. Speaking on the ocasion, Luigi Galdabini, President of the Meeting, confirmed the Italian industry’s fourth position in the world ranking of manufacturers and its third place in the ranking of exporters. “The 2015 data processed by the Studies Dept of UCIMU certainly show a positive picture of the Italian machine tool industry. The export growth, added to the recovery of domestic consumption, surely makes up an excellent outcome. However, this doesn’t mean that all problems are over. Beyond the instability conditions of the situation in which we are working, what should Massimo Carboniero is the new worry us more is the situation of the President of UCIMU Italian manufacturing industry, whose competitiveness has strongly stepped back in the last few years due to the recession.The meeting coincided with the appointment of the Association’s changed positions. Appointed to succeed Luigi Galdabini as the President of UCIMU is Massimo Carboniero, General Manager & co-owner of OMERA.
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EM | Aug 2016
MARKET | INTERVIEW
“Making the right tooling solution available” …says Puneet Kapoor, Managing Director, Gühring India, in this interaction with Maria Jerin, while discussing his company’s plans in expanding the market presence in India. He also details the key emerging applications driving the growth of tooling industry. Excerpts... As per recent reports, global market for metal cutting tools is projected to reach US$ 10.8 billion by 2020. What are the key emerging applications driving this growth trend? Over recent years, the requirement for adopting higher productivity practices is being felt everywhere, and, in turn, being implemented at many places. This naturally has increased the demand for better and accurate tooling solutions to be run on machines, ranging from a simple CNC machine to high capacity machining centre. Emphasis is being given to innovation and technology development resulting in more fuel efficient engines being made with tougher and lighter materials giving out higher horse powers. The life span of an automobile model has also decreased resulting in increased pressure on automobile companies to bring out newer models at a faster rate, which has propelled the demand for better and sophisticated tools and tool materials for these new and challenging applications. Given that rising automobile production spurs opportunities for metal cutting tools, how do you see the automobile segment’s current market potential and demand trends in India? Automotive companies in India are right now gearing up for the festive season and the new GST regime. Even though the automotive sales in India are showing slow signs of growth, increased exports have helped in maintaining the production levels. As per the latest June 2016 YOY comparison with respect to 2015 from SIAM (Society of Indian Automobile Manufacturers), the figures reflect the mixed sentiments prevailing in the market. A key strategy in achieving higher output in less time is to drive production lead-times at a lower rate. What role does cutting tools play to meet this requirement and how is your company customising its product solutions? Cutting tools play a pivotal role in deciding the productivity, output quality and cost per component of a shop floor.
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Implementation of advanced tooling concepts like high feed reaming, HPC/HSC milling, combination tools and synchronised tapping help in reducing cycle time and reduction of component scrap rate. With our expertise in tooling industry, we have come up with new products including HSK Taper, RF 100 Diver for versatile combination of operations, HR 500 reamers for high feed reaming, HPC milling cutter for burr-free machining of components, tools & holders for MQL technology, etc. There is a rising trend witnessed in leveraging digital platforms for better tool management. What are your company’s initiatives on this front? We offer complete digitalisation of the tool rooms in machine shops through our innovative tool dispensing systems and tool management software. Gühring’s tool dispensing system enables storing a large number of compact tools in a very small space and very securely providing complete control over the withdrawal of goods. In addition to the tool or stock management, Gühring’s Tool Management Software (GTMS) modules provide the possibility of quickly finding and evaluating hidden process costs, identifying bottlenecks in the production and increasing productivity via specific counter measures. What are your company’s latest offerings for the Indian market? How do you plan to expand your market presence in India? Few of our advanced tool types, which were released in India include RF 100 DIVER end mills, HR 500 reamers, HPC milling cutter and GuhroSYNC holder. We believe in treating customers as our business partners and growing with the customer. We plan to expand our business by making available to our customers, the right tooling solution at the right price with right service at the right time to make a mark in their productivity requirement, irrespective of the customer being small or big. ☐
EM | Aug 2016
MARKET | INTERVIEW
“Abrasive application is truly ‘engineering’” …says Ashok Kocheril, Chief Executive Officer, Suhner India, in this interaction with Maria Jerin. He discusses recent advancements in the manufacturing industry and his company’s business potential for the Indian market. Excerpts... What are the recent advancements witnessed in the manufacturing industry today? What are the key factors that are accounting for growth? The recent advancement of 3D printing has brought down the prototyping timelines dramatically. Companies, particularly for products where structural demands are minimal, are seriously pursuing 3D printing as a viable manufacturing technology. The cost of 3D printing has been coming down significantly and this could turn out to be a disruptive technology. The use of robots in conventional manufacturing space is another advancement that has been in vogue recently. Whilst these advancements have been on the anvil, there is a growing demand for transportation, particularly in India, where the GDP is growing at 7.4%. Also, the ‘Make in India’ program is gaining some traction and the manufacturing sector is seeing buoyancy. Out of Suhner’s various business units, which ones do you think have a major potential in India? We see great potential in both the abrasive and automation division. The processes involving abrasives are still considered as an unskilled job in many industries, whereas the field of abrasive application is truly ‘engineering’. We conduct customer education programmes in several locations to bring them up-to-date on the contemporary practices, as well as industry-specific solutions developed in our Abrasive Academy in Switzerland. In the machining space, where our automation division is operating, the cost per component can be reduced by using large volume special purpose machines. We are seeing a healthy traction in this domain and we expect higher business volumes. As per the recent global reports, the automotive segment accounts for the largest market share in the abrasive market. What is your take on this? It is a given fact that automotive segment has major share for abrasives. In this domain, we deliver high-quality surface finish in various metals (ferrous and non-ferrous) as well as non-metals such as composites. As more and more marquee
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automobiles are being produced in India, the need for exacting finishes is on the increase. The local brands also try and emulate the global marquee brands, thereby, taking the abrasive technology in the industry one notch up. Your company has launched a new series of products used with robots. Can you elaborate on this? We witness customer’s requirements from the automation and abrasives angle. In many companies, the manufacturing lines are set-up first to do the machining operations (where our automation spindles are used) and then a deburring station to remove the burrs using abrasives. We have developed a series of tools that can work with robots, so that the robot station is able to complete all operations, including the abrasive related ones, in one go. We have addressed several perennial issues of the industry, related to deburring, in doing so. We also successfully developed robot solutions for polishing of various aircraft components, to the very exacting standards of the aerospace industry. We believe that the robot-based solutions will become widely used in India in the next 2 to 5 years. How do you strategise your company’s business model keeping in mind the price sensitive Indian market for SMEs? Price-sensitive is not the right term to describe the SME phenomenon. In reality, the SMEs are concerned with the cost per piece and, therefore, the ROI. So, we focus on the cost per component to the customer and also highlight the hidden cost of using poor quality tools and spindles. How do you see your company’s growth in the near future? What are your future plans for the Indian market? In the Indian market, we intent to grow our abrasive, automation and transmission divisions. The use of robot solution is bound to increase in India, and when that happens, we are ready for the market. In the transmission division, we expect to bring in the flocked shafts that are used in the power seats and the sunroofs of automobiles, to the Indian market. ☐
EM | Aug 2016
High Performance Cutting Tools
INDIA’S LARGEST BURR MANUFACTURER
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C O V E R S TO R Y | T E C H N O L O G Y
Im ag es co ur te sy : Sh ut te rs to ck
SOFTWARE SELECTION FOR MANUFACTURING ORGANISATIONS Targeting ROI optimisation
The nature of technological innovation and prevalence of economic uncertainty have transformed the environment for manufacturers from one that was rather slow-moving and monolithic to today’s fast-paced, hypercompetitive, time-sensitive, customer-demanding, increasingly nuanced global commercial ecosystem. The cover story explores some common business challenges faced by today’s manufacturing and high-tech organisations, how the right software addresses these challenges, and posits a number of key selection factors that will optimise ROI on software investment for those in the sector.
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EM | Aug 2016
TECHNOLOGY
Keeping risk at bay, and identifying and seizing opportunity are traits of companies that thrive in this difficult environment and steer a steady course in seas where potential crisis lurks. In our digital, data-driven world, software—particularly enterprise resource planning (ERP) software—is one of the principal tools organisations leverage to keep the enterprise ship sailing boldly forward. Because these systems are central to today’s enterprise operations, their selection must confirm that the features and functionality they provide take into account the rapidly changing nature of global manufacturing and help address the challenges that poses.
Common business challenges Compliance issues: Regulations and regulatory compliance are particularly important in the manufacturing sector. For example, according to the National Association of Manufacturers, the average manufacturing firm in the United States pays nearly twice the compliance costs of the average US firm; small manufacturers pay nearly three times as much as the average. Additionally, as global trade increases, international standards take on greater importance. These can range from multiple ISO standards to directives that have been introduced by the European Union (EU) that are moving toward global recognition as de facto or de jure international standards. In certain vertical sectors, such as medical device manufacturing, validation processes are critical. Keeping compliance with such regulations is an ongoing concern for manufacturers,
EM | Aug 2016
C O V E R S TO R Y
not only from an adherence perspective, but also from a cost of documentation perspective. Rising margin pressures: Regardless of the specific sector, margins for manufacturers are being squeezed from multiple directions. In developed markets, top-line growth has slowed or declined, whereas in emerging markets, margins are threatened by rising labour costs, more expensive commodities, and cost of distribution. As such, manufacturers need more granular information on what margins are being made when they’re taking or closing orders. If margins change based on a supplier’s increasing costs, the manufacturer needs to be made aware of that proactively, as it happens, so that action can be taken in response. Greater visibility & more granular information: Today’s manufacturers want to know how much time and effort— specifically and from where—have gone into designing a new product. How much time (and money) was spent with a customer working on a product design? How much did we budget? What resources have been used so far? How many can we expect to use? This process can entail anything from finance doing credit checks to engineers doing drawings to prototype production to manufacturing set-up. Visibility of the time/expense plan is increasingly crucial for many manufacturers and granular detail is key. Consumer demand: Many manufacturers now must account for individual consumers as well as traditional industrial customers. This trend is particularly growing in the environmental arena, where consumers are demanding verification that what they are purchasing has been manufactured in a sustainable way. Increasingly, it’s important
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C O V E R S TO R Y
TECHNOLOGY
The concept of manufacturing agility involves the development of manufacturing capabilities to achieve sustained competitive advantage in an unpredictable environment
for manufacturers to have eco-footprint information within their systems to report their carbon footprint, recyclable packaging used, etc. This information needs to be reportable internally, to shareholders, and more and more to the public at large. Standardisation: Particularly as operations extend across disparate locations or geographical borders, manufacturers and high-tech organisations are looking for ways to standardise their business processes across multiple sites for consistency and cost reduction factors. This need extends from design to production to service, and applies to smaller manufacturers (e.g. a company building a product at two different local sites) as well as to global enterprises that may manufacture in one country and assemble in another. Disruptive innovations: Disruptive innovations are those that help create new markets and value networks, eventually disrupting an existing market and value network (over a few years or decades), and displacing earlier technologies. When new technologies emerge, the decline of industries is neither rapid nor immediate; but successful manufacturers understand that growth demands innovation, and innovation in the sector cannot occur without embracing technologicallyadvanced manufacturing capabilities. Perhaps the most visible of today’s disruptive technologies is additive manufacturing, also known as 3D printing. In the future, smaller, highly specialised 3D printing companies will emerge to serve a local area on demand. So instead of manufacturers buying components such as spare parts and having them shipped from afar, or buying a machine and putting it into the warehouse and taking up stock and cost from a financial point of view, they could wait until a part failed, send a
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command, and have it printed on demand within hours. The Internet of Things (IoT) is another development moving rapidly from the consumer venue to manufacturing. Sensors are being embedded to provide machine-to-machine communications for applications, such as remote monitoring and control, enabling manufacturers to get information and act upon it remotely. This is speeding maintenance, while driving down costs.
How the right software addresses business challenges? The right business software supports manufacturing’s ability to meet emerging challenges and respond to constant change by providing the foundation for enterprise agility. The concept of manufacturing agility involves the development of manufacturing capabilities to achieve sustained competitive advantage in an unpredictable environment. Agility is the product of three foundational blocks—vision, knowledge, and flexibility—that effectively designed and developed software facilitates across the business. Vision is the ability to link business strategy and growth aspirations to technology investment, and to make informed decisions that prove effective over time; knowledge is the ability to identify, understand, and predict new sources of threat or opportunity across quotidian business operations and projects and flexibility is the ability to take action rapidly when things happen, expectedly or unexpectedly, founded on technology that makes rapid and responsive change possible.
EM | Aug 2016
C O V E R S TO R Y
TECHNOLOGY
Data-driven decision-making is central to enterprise operations, but the proliferation of data can be overwhelming for users
10 key questions to ask when selecting enterprise software 1 Does the software support rapid business change? An organisation’s software should help it plan for change. Change is constant and the most dominant characteristic of today’s business environment, so the ability to plan for the unknown makes it possible for agile companies to thrive. Long-term planning is not about being able to predict every future, but being able to respond fast and smartly enough to capitalise on change. Effective software facilitates the ability to change. 2 Does the software provide essential access to data? Data-driven decision-making is central to enterprise operations, but the proliferation of data can be overwhelming for users. Well-designed software delivers data to users in ways they can use it, wherever they are, whenever they need it, without delay or variation. Having data in a single place, accessible from any device, is key. 3 Does the software allow for future growth? The boundaries between manufacturing and distributing organisations have been slowly disappearing; more manufacturing companies have been distributing and servicing their products, which has led to tighter integration of ERP, CRM, and supply chain management (SCM) solutions. Many companies that today are manufacturing only may be looking to add service as part of their portfolios. These companies are served by software that meets their current need, but also has the capability to handle future development in the system. 4 Is the software appealing to today’s generation of workers? As the manufacturing workforce ages, a younger generation is coming into the sector. The longstanding perception of manufacturing as a smokestack environment
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(i.e. dirty, greasy, unhealthy) is giving way to the reality of high-tech manufacturing, much more appealing to those that grew up in the digital age. When younger people come into manufacturing, they don’t want to work with a greenscreen application; they want something that they are familiar with (i.e. graphic sophistication, touchscreens, apps to download onto a phone). 5 Is the software usable in today’s changing work environment? Related to the question above, usability speaks to the way work is done differently today, which is something influenced by the younger generation, but certainly not limited to them. Increasingly, the workplace is where we happen to be, which may not be within the “four walls” of the organisation. This has certain implications for software. Is it mobile? Can it be accessed and comprehended by sophisticated and casual users on multiple devices: laptops, tablets, smartphones and, in the coming years, wearable technology like watches? Does it provide role-based portals and interfaces? Is it intuitive to anyone who sits in front of it? 6 Is the software’s CRM discrete or embedded? Customer relationship management is increasingly important in today’s manufacturing market, and nearly all software providers will have CRM as a separate but integrated package. But it’s still in a separate world. This becomes an issue when manufacturers set up more complex relationships (e.g. from opportunity to sales to contract delivery), which typically requires integration work. Further, there are user experience issues, including not being able to drill through CRM all the way to the back office, and not from the back office into CRM. When CRM is embedded in the enterprise software, those issues are taken off the table. There is no need for integration work. Users can now drill through in both directions, which can be an important advantage.
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TECHNOLOGY
7 Does the software provide deployment options? Single instance, on-premise enterprise systems are rapidly being relegated to the past as hybrid models continue to grow toward the norm. Whereas the majority of those hybrids are a combination of core and point solutions (onpremise) from multiple vendors, increasingly manufacturers will use cloud-based point solutions as an essential part of the hybrid approach. This is inevitable, particularly as manufacturing operations take on global scope. Does your software provide real deployment flexibility? 8 Does the software speed execution of tasks? While provision of real-time data is increasingly a given for enterprise software, is this translating into faster execution of essential work? Software should enable companies to have information they can believe and trust, in one system, so when they print out a trial balance, they believe the numbers generated. There shouldn’t be a need to wait for information (e.g. for production to indicate how much WIP they have, or accounting to report accruals). Real real-time data is often overlooked these days, because companies are not used to it; but it’s still a shock when a company tells you it takes a week to do a month’s end report. 9 How broad and deep is the software solution? Can the software system phase out the use of multiple systems, eliminating undue complexity and cost? Today, many manufacturers are multi-modal: some products are made to order, some made to stock, some engineered to order, some assembled to order, and some configured to order. Can your software handle all these approaches? If you set an approach today, do you have the ability to easily change over in a week’s, month’s, or years’ time? A broad
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C O V E R S TO R Y
and deep solution will provide this capability. 10 Customisation or configuration? Is the software easy to modify? Because change will make it likely for a company to want to modify its software over time, how easy and how costly will it be to make that change? Best systems enable users to add their own fields, events, and so on without having to go back to the software provider for customisation. Configuration is part of the functionality out of the box and easy-to-do, not part of an upgrade or requiring additional costs.
Consider independent assessment Finally, companies are well served by looking to respected analysts who assess the status of software providers. Of those who study enterprise software and systems, the best known and perhaps most highly respected is Stamford, Connecticut-based Gartner. Gartner’s “Magic Quadrant for Single-Instance ERP for Product-Centric Midmarket Companies” focuses on ERP systems that support a single-instance strategy for multientity midmarket and upper-midmarket companies. Companies are evaluated on multiple aspects of two parameters (ability to execute and completeness of vision), then mapped in an X-Y grid to create a quadrant: niche players (low on both parameters), challengers (high on ability to execute, low on completeness of vision), visionaries (low on ability to execute, high on completeness of vision), and leaders (high on both parameters). Of the 10 companies evaluated, two were leaders. IFS Applications is one of the leaders. ☐ Courtesy: IFS
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MANAGEMENT | INTERVIEW
Embracing opportunities to co-develop & comanufacture in India …says Kishore Jayaraman, President, RollsRoyce India & South Asia, in this interview with Shekhar Jitkar. He expresses his optimism on the growth potential & opportunities in India and discusses how Rolls-Royce can play a role in India’s indigenisation ambitions with the right strategic partners. Excerpts… Rolls-Royce has been a partner to the Indian Armed Forces since 1932. Going forward, how are you planning to strengthen this partnership in future, so as to help India in its vision to become a global hub for aerospace design, development and manufacturing? Rolls-Royce is deeply embedded in India as an investor, a high skills employer and as a supplier of power systems across all our five businesses: civil aerospace, defence aerospace, marine, civil nuclear and power systems. Presently, we are working towards the indigenisation of the Indian defence industry by exploring strong partnerships with companies who share our goals. We are already leveraging the vast engineering talent pool and playing a leading role in the government’s ‘Make in India’ initiative. In terms of design, development and supply chain capability, we have announced the recruitment of 500 people in Bengaluru by 2017. These people will undertake aerospace engineering for customers in the region as well as support for Rolls-Royce’s regional supplier base. We have plans to hire around 100 engineers at our upcoming Engineering centre in Pune by this year. In
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addition, more than 1000 engineers, through our partnership with QuEST & TCS, work at Rolls-Royce managed engineering centres in Bengaluru. In terms of manufacturing, International Aerospace Manufacturing Pvt Ltd (IAMPL) is now at full production, employing over 120 people for a wide range of engine programs including the Trent XWB. Today, we are already nurturing skills, developing local supplier base and building capabilities, and are well positioned to cater to the future growth opportunities available in India and South Asia. Looking to the future, we are ready to eventually embrace opportunities to co-develop and co-manufacture for the aerospace sector with the right Indian strategic partners and keen to play a role in India’s indigenisation ambitions. Tell us more about the operations of IAMPL, Rolls-Royce’s joint venture with HAL. IAMPL has been built with an investment of over US$25 million, the 4500 sq mt production facility manufactures critical engine components such as compressor shrouds and cones for Rolls-Royce gas turbines – both for new production
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INTERVIEW | MANAGEMENT
“With the current spend on procurement around $40 m (2016), Rolls-Royce has set a target of procurement spend of around $200 m by 2020” Kishore Jayaraman
and aftermarket use. It is one of the first tier one suppliers in India for civil gas turbines, commonly known as jet engines, for any major foreign OEM. IAMPL is a benchmark manufacturing facility within the Rolls-Royce gas turbine supply chain, operating the latest technologies to the highest levels of aerospace compliance. It also has five NADCAP approvals for special processes. Its manufacturing portfolio covers approximately 140 different compressor parts for Rolls-Royce Trent and RB211 engines. Our relationship with HAL is one of the longest in the industry and we hope that our relationship will grow from strength to strength. Who are the partners/suppliers in India that Rolls-Royce has tied up with for production facility creation? India has a robust and competent industrial ecosystem that is capable of manufacturing components and sub-systems that require a high-level of precision. Stronger economic growth, more favourable offset policies, cost advantages, and a robust talent pool have further increased the aerospace suppliers’ base in the country. We firmly believe in leveraging India’s competencies to support the ‘Make in India’ initiative. Our biggest partnership is with HAL (IAMPL), and we intend to grow the JV partnership with a focus on opportunities to collaborate on co-development. With the current spend on procurement around $40 m (2016), Rolls-Royce has set a target of procurement spend of around $200 m by 2020. Other Indian suppliers include Bharat Forge, Godrej & Boyce and TASL (Tata Advance Systems Ltd). Currently with 3 tier-I suppliers in 2015, we are working on doubling the supplier base in 2017. Tell us more about Rolls Royce’s India Open Innovation Programme (IOiN-RR) for SMEs. How is the progress and response? Rolls-Royce is committed to innovation. We continually innovate to remain competitive and most importantly, we ensure that innovation is relevant to our customers’ needs. We believe that India is home to some of the most innovative small and medium sized companies. Being a key entrepreneurial nation, the Open Innovation Programme was launched in India in 2013. Being the pilot programme, we received a tremendous response from thousands of
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companies in India. We received some game-changing ideas from Indian companies for the challenges shared by us. This involves farming out various problems faced by the firm to Indian companies and getting them to come up with unique solutions. We are trying to see how we can take the winning solution and give them the opportunity to integrate into RollsRoyce global operations through a collaborative relationship with the company. How is Rolls-Royce positioned today to cater to the future growth opportunities available in India? As India gets ready to move on its growth path, we will continue to support the country with our powerful portfolio of products and services and the right combination of experience and advanced technologies. India as a market represents a host of significant opportunities across all sectors in which we operate – India’s defence budget allocation is estimated to touch $620 billion by 2022 as per FICCI. The civil aerospace market is growing at a double-digit pace. There is a huge energy deficit with large eventual opportunities for the gas distribution, distributed power generation and nuclear sectors despite short term challenges. The marine sector has been designated a strategic industry, though also facing immediate challenges. India also offers the Group very significant supply side advantages due to cost-competitive, worldclass IT and BPO industries and growing engineering and manufacturing capabilities. In the short term, we will look at increasing our supply chain base. We are working towards introducing Indian supply chain to more complex commodities like complex fabs, pipes (installations SCU) and mainline shafts (rotatives SCU) as well as introducing new commodities such as: external brackets, casings, wire harnesses, castings, stub shafts/blisks. In the long-term, we will continue to build on our legacy here and identify opportunities to codevelop and co-manufacture through partnerships and collaborations with Indian companies. We can significantly increase value to the Group from these activities, while playing a greater role in growing our engineering pool, developing local advanced manufacturing capabilities and a strong supply chain base, thereby, making ourselves more relevant in the country. ☐
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R O U N D - TA B L E | M A N A G E M E N T
Hitting the point of disruption For industries across, it has become imperative to contemplate disruptive innovations in the market. These are trends that will craft utterly new industries and, in most cases, displace others in the process. The round-table feature explains how disruptive innovation is altering the manufacturing landscape and evaluates few trends hitting the point of disruption. As per recent reports from PwC, there has been a significant adoption in advanced manufacturing technology— especially Additive Manufacturing or 3D printing. The survey conceals that new technology is now stirring to up-end established markets as costs plunge and quality & performance rise. Alongside traditional manufacturing, there has been a rising wave of innovation with the capacity to transform existing markets and value networks. Sharing insights on this are Rajiv Bajaj, Managing Director—India, Stratasys AP; Sanjeev Baitmangalkar, Strategy & Lean Management Consultant, Stratmann Consulting and Dr Vishwas Puttige, R&D OSD, Ace Manufacturing Systems.
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Megha Roy Senior Features Writer megha.roy@publish-industry.net
Innovation becoming disruptive Innovation is not adequate to be considered disruptive – there needs to be a cost benefit before any new technology can obligate a momentous impression. Only when the value of a technology surpasses the value of a competing market does it officially become what we can call a disruptive trend. Conventionally, disruption and innovation doesn’t go handin-hand. But, today the manufacturing industry is witnessing disruptive innovation as a major trend. Speaking on this, Bajaj says, “3D printing or Additive Manufacturing has been one of the solutions that meet most the requirements that
EM | Aug 2016
M A N A G E M E N T | R O U N D - TA B L E
“3D printing is not here to destroy; it challenges the inherent ideas and existing workflows” Rajiv Bajaj, Managing Director—India, Stratasys AP
the industrial sector is looking for, while it happens to be an innovation that streamlines or disrupt the design and manufacturing cycle.” Furthermore, Dr Puttige explains that this innovation has to be accepted by manufacturers and users, if not their existence itself maybe unsure. “To be able to grow in a dynamic scenario, it is not just sufficient to accept the change, but also adapt products or services suitable to the newer trends,” he opines. Today, as 3D printing becomes more accessible on a global scale, consumers have begun to innovate across a diverse range of industries. As a result, the process of Additive Manufacturing is beginning to create industry disruptions. Speaking on this, Bajaj highlights, “There have been many case studies where 3D printing works hand-inhand with conventional fabrication within the industrial environment. This helps manufacturers and factory owners maximise their productivity with the best mix of solutions according to their business nature and needs.” However, the problem with conflating a disruptive innovation with any breakthrough that changes an industry’s competitive patterns is that different types of innovation required different strategic approaches. Emplacing this, Baitmangalkar considers that with multiple manufacturers for the same product, it has become necessary to produce an innovative idea to survive and grow. “When ideas are galore, we will see market creating innovations that add to growth and jobs, else, we will see either sustaining or efficiency innovations that are either replicative in nature or the ones that either take away or do not add jobs. There can be no disruption without innovation,” he says.
Digital manufacturing era Disruptive innovation not only hails technological advances, but also changes the market scenario. Considering the volatile manufacturing industry, whether innovation will make an impact or not is debatable. When asked, Bajaj
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asserts that change is at an early stage and the market will continue to evolve with the constant technological advancement and unleashed imagination from users. Considering 3D printing, he points out that as technology evolves and advances, 3D printing has more far-reaching impact than when it first started. He further explains that combining increased awareness and continuous knowledge transfer, some changes have been witnessed in the manufacturing sector, namely the rise of a digital manufacturing era, where economies of scale matter less and increasing manufacturers adopt low-volume or customised manufacturing to cater to customers’ unique requests. The primary focus of information technology has been on driving improvements in business efficiency. As per Dr Puttige, the digital era has uprooted the entire manual paper-based activities. “The LED technology has eradicated many conventional industries. The smart phones also have removed the need for a lot of essential utilities, which were otherwise used as standalone devices. Some of the other areas in manufacturing include near-net shape manufacturing, Additive Manufacturing, low-pressure die casting, carbon fibre and other composites in place of metals,” he avers. A disruptive innovator transforms existing markets and creates new ones by playing the innovation game, thereby, changing the business model in a fundamentally different way. Explaining this, Baitmangalkar lists a few examples— “Disruptions gives a more convenient alternate form of doing business in terms of efficiency innovation, such as e-commerce, advertising on search engines, data analytics; efficiency innovation that has disrupted conventional business models by re-imagining a new business model such as Uber, OLA, Airbnb and Fracking has shifted business dynamics making the product more accessible, affordable and easier to get and sustaining innovations, such as electric or hybrid vehicles, new age battery technology is on the way to disrupt the internal combustion engine and the fossil fuel industry.”
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R O U N D - TA B L E | M A N A G E M E N T
“It is not just sufficient to accept change, but also adapt products or services suitable to newer trends” Dr Vishwas Puttige, R&D OSD, Ace Manufacturing Systems
“Disruptive innovation will result in major changes, but they do not often rely on technological breakthroughs” Sanjeev Baitmangalkar, Strategy & Lean Management Consultant, Stratmann Consulting
Disruption is not destruction It’s quite debated that perhaps even more important than what 3D printing can build is what it can destroy. Conversing on this, Bajaj says, “3D printing is not here to destroy. While technology enables users to build tangible models and parts, it also challenges inherent ideas and existing workflows. Instead of making things through subtractive fabrication methods or handcrafting, things can be made more efficiently, with fewer materials and in shorter time. With such change in the way things can be made, more possibilities and opportunities arise for designers and manufacturers.” Dr Puttige believes that Additive Manufacturing is a form of disruptive technology, which can disrupt the conventional subtractive manufacturing to a certain extent. However, he further believes that there are certain constrains to this which may make them only to reduce the need for the conventional technology of manufacturing. “With the increase in demand for smaller batches of manufacturing and customisation, there is a growing need for Additive Manufacturing,” he says. Today, with Additive Manufacturing, many assemblies of parts can be produced in one print. This will reduce the number of conventional part count. It saves on manufacturing parts individually and assembling them, while improving quality and productivity. So, Baitmangalkar opines that 3D printing will not destroy anything, instead it will add better value. “When disruption or a new idea comes, it is very important to run with it, embrace the change rather than resist it. When manufacturers don’t change in response to disruption, they self-destruct, and they don’t have the advantage of being the first mover either,” he adds.
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Coping up with current technical advancements… Disruptive innovation is now becoming a very real part of the manufacturing industry and this has important implications for how we think about technical education and the education of skilled labour as well. Bajaj believes to stay tuned to the latest development in technology. “It may be wise for organisations to join technology workshops or seminars on a regular basis, or stay alert to the leading providers of the solutions that they are interested in,” he opines. Taking the idea further, Dr Puttige believes that new technology could be in products, materials or processes. “This will provide a value proposition and an edge over competition. Invariably, the trends are observed emerging at some of the advanced research institutes, displayed at exhibitions, or can originate from customer interactions,” he adds further. As manufacturing has evolved significantly over the past years, so too have the innovations that resulted from developments in the technology landscape. To conclude, Baitmangalkar says, “Disruptive innovation will result in major changes, but they do not often rely on technological breakthroughs. The technology many times by itself may be trivial. Barriers to consumption come in different forms— skills, accessibility to solution, money, laws, cost, necessity, affordability, service and support, etc. Once you find that constraint in consumption, target that job to be done, thinking how you can play that innovation game differently. Remember, it’s not about doing it better; it’s about making it better, simpler, cheaper and more affordable.” ☐
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M E TA L C U T T I N G T E C H N O L O G I E S | F O C U S
Images courtesy: 5ME
Role of cryogenics in machining processes In recent years, researches have proved that cryogenic machining technology has a high potential to cut costs and improve competitiveness over conventional machining processes. A read on the sustainable machining processes, using cryogenic conditions and gaining higher performances, lower environmental and health influences, increased safety, etc. Franci Pušavec University of Ljubljana Faculty of Mechanical Engineering Ljubljana, Slovenia
Antun Stoić J J Strossmayer University of Osijek Faculty of Mechanical Engineering Slavonski Brod, Croatia
Sustainability – according to definition, is the development that meets the needs of the present, without compromising the ability of future generations to meet their own needs. For fulfilling this definition’s aim, the ideas have to be implemented in all the fields and levels of production and in this way, contribute to the idea of global sustainability.
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Janez Kopač University of Ljubljana, Slovenia Faculty of Mechanical Engineering Ljubljana, Slovenia
At the moment, the manufacturing industry is under increasing pressure of financial crisis, new sustainable development regulations, supply-chain and customer demands. One way to gain an advantage in this situation is to focus on competitive sustainable manufacturing (CSM). CSM has the dimension of economy, ecology, sociology and
EM | Aug 2016
F O C U S | M E TA L C U T T I N G T E C H N O L O G I E S
Cryogenic machining is proposed as alternative ahead of conventional machining processes to achieve sustainability
technology and calls for practices and decisions that will assure high-adding-value solutions. The global environmental problems caused by the consumption of natural resources and the pollution resulting from the life of technical products, have led to increasing political pressure and stronger EU regulations being applied to both the manufacturers and users of such products. The industries involved in production are additionally under economic pressure, and are attempting to compensate for increasing costs and create added value for their products. The adoption of sustainable development in production offers industry a cost effective route for improving economic, environmental, and social performance (i.e. the three pillars of sustainability).
Industrial needs Heat resistant alloys (high-temp alloys) with high-melting temperatures are nowadays important materials used in the manufacture of aero-engine components. These super-alloys can be grouped into four major categories: nickel-based alloys; cobalt-based alloys; iron-based alloys (e.g. high chromium stainless steel), titanium alloys and tungsten. The ability to retain high mechanical and chemical properties at elevated temperatures makes super-alloys ideal materials for use in both rotating and stationary components in the hot end of jet engines. The components produced with superalloys are smaller and lighter than those made from conventional steel. This results in significant fuel savings and, therefore, a reduction in environmental pollution. Super-alloy materials are also used by the chemical,
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medical and structural/construction industries in applications requiring extraordinarily high temperature properties and/or corrosion resistance. Power plants and the aerospace industry use higher proportions of machined components made from super-alloys, such as turbine engine components. The machining of nickel-based, tungsten, and titanium-based alloys and other high-tech materials are very expensive because of their high-temperature properties as well as their ability to retain a high strength-to-weight ratio, which are essential for the economic exploitation of aerospace engines. However, these properties, on the other hand, lead to shorter tool-life, which significantly increases tooling waste and machining costs. It is envisaged that the aerospace sector will witness a doubling of the aircraft fleet over the next 20 years in response to the replacement of older aircraft and growth opportunities. Therefore, the same trend of development/usage is indirectly expected in innovative machining/production systems, which additionally prove the high potential for innovative sustainability-oriented machining processes. The fact that the volume of aerospace-alloy usage is continually increasing has resulted in huge pressure to reduce machining cost by developing efficient technologies. From the initial investigations it is possible to state that innovative sustainable machining process (cryogenic machining, high pressure jet assisted machining, etc), in combination with appropriate tool material(s) and technology, has resulted in enhanced performance when machining aerospace (hard-to-machine) alloys. Conventional cooling lubrication fluids (CLFs) in these
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M E TA L C U T T I N G T E C H N O L O G I E S | F O C U S
Cryogenic machining presents a method of cooling the cutting tool and/or part during the machining process
applications are not as effective as the proposed alternatives in terms of decreasing the cutting temperature and improving environmental sustainability. In some cases, they even cannot fulfill the machining or final part requirements related to its functionality. Additionally, one of the most fundamental concerns is the use of CLFs, which has a direct influence on the environment, performance of machined surface and machining economics. In reality, there are always some losses of CLF in the production process. This occurs through vaporisation, the loss with chips and parts as they leave the machine tool, the loss of machine components such as handling devices, as well as through leakage. Taking into account that up to 30% of the annual total CLF consumption can be lost from the system by the above means, it becomes clear that technologies employing CLFs are unsustainable, and by avoiding of their usage through applying dry, near-dry, etc machining alternatives, there would be a huge process gain from the sustainability point of view. With regard to this, cryogenic machining is proposed as alternative ahead of conventional machining processes.
Cryogenics Cryogenics is the field related to technology at deep freezing temperatures. Traditionally, the field of cryogenics is taken to start at temperatures below 120 K (~ – 150 °C). The definition includes the more common cryogenics such as helium, hydrogen, neon, nitrogen, oxygen, argon, krypton, xenon, methane, ethane, and propane. Carbon dioxide is commonly added to the list even though a pressure
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over 50 kPa is required to maintain it in liquid form. Even the term ‘cryogenics’ seem like an esoteric field, it plays a major role in modern industry and science. Some of the applications are – air separation plants for breaking it down into its components for industrial and medical uses, liquefied helium has become unavoidable cooling element of magnetic resonance imaging systems in modern hospitals, in space technology, where cryogenics are through the liquefied hydrogen and oxygen used as fuels, food freezing and cooling, purging and blanketing, etc. The application of cryogenic fluid to cool the metal cutting process started as early as the 1950s. The cryogenic fluids used were CO 2, freon, or solvenlene. They were sprayed in the general cutting area or were applied to the workpiece before cutting in a prechill. This method, however, consumed excessive amounts of cryogenic fluid and had no lubrication effect. Additionally, this reflects high costs and present high complexity in delivering of cryo fluid to the cutting zone. Today, the process of liquefaction and storage system becomes more affordable, and there is a need to develop and rise the cryogenic machining on an industrial level.
Cryogenic machining Cryogenic machining presents a method of cooling the cutting tool and/or part during the machining process. More specifically, it relates to delivering of cryogenic CLF (instead of an oil-based CLF) to the local cutting region of the cutting tool, which is exposed to the highest temperature during the machining process, or to the part in order to
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M E TA L C U T T I N G T E C H N O L O G I E S | F O C U S
Using cryogenic coolant in machining process, eliminates disposal costs related to CLF usage
change the material characteristics and improve machining process performance. Generally, nitrogen fluid is used as the cryogenic coolant. Using it in machining process, when delivered to the cutting zone, it immediately evaporates and returns back to the atmosphere, leaving no residue to contaminate the part, chips, machine tool, or operator. Thus, it is eliminating disposal costs related to CLF usage. This represents completely clean process in contrast to conventional oilbased CLFs. Potential benefits of cryogenic machining includes sustainable machining methods (cleaner, safer, environment friendly, more health acceptable, etc) to eliminate numerous costs associated with conventional cutting fluids and cleanup operations. It also increases material removal rate without increase in worn tool and tool change over costs, thereby, increasing productivity. It increases tool life due to lower abrasion and chemical wear. Additional benefits include machining of hard parts and hard-to-machine alloys, which in the past, could have been produced only via expensive grinding operations; surface roughness of machined workpiece improvement; produced parts quality improvement by preventing mechanical and chemical degradation of machined surface. It also enables potentially lower investment costs due to reduction in number of machine tools required and improvement of manufacturing flexibility for reduced production times & high output, etc. All these benefits occur due to lower cutting temperatures in cutting zone, improvement of chip breakability, decreased BUE formation probability, decrease of burr appearance probability, inert environment assurance, no oil-based
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emulsion used, no additional processes needed, liquid nitrogen specifications and changes in material characteristics at lower temperatures, etc.
Towards sustainability‌ The role of cryogenics is pointing out the reasons and needs for practices in the field of sustainable development on all levels and fields, even machining process, for assuring our common goal of global sustainability. The focus is on novel machining technologies that are meeting environmental and social regulation, while still being competitive. Additionally, the main pillars of sustainability are under the scope, i.e. reduced energy consumption, prolongation of tool-life, improved final product functionalities through improved machined surface integrity, etc. Experimental analysis shows that as an alternative to cost infectivity, health and environmental problems of plastic infiltrant machining procedure, cryogenic machining can be used for machining of porous tungsten for dispenser cathodes. Cryogenic machining is able to keep unsmeared surface — keeps open pore structure that satisfies the industry standard. This accomplishment has never been achieved with using of any other cooling/lubrication techniques. As a result, it can be claimed that cryogenic machining as sustainable machining alternative can essentially provide: (i) improved environmental friendliness, (ii) reduced cost, (iii) reduced energy consumption, (iv) reduced waste and more effective waste management, (v) enhanced operational safety, and (vi) improved personnel health. â˜?
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A U TO M AT I O N & C O N T R O L | T E C H N O L O G Y
Modernising the automation systems Outdated or insufficient automation systems and components can compromise competitiveness, yet many manufacturers fear the modernisation process. The article helps determining how to modernise using a total systems approach or individual component replacement strategy with minimal disruption. Downtime is often a symptom of poor diagnostic capabilities. Many existing systems do not provide the type of transparency that plants need for predictive maintenance. This same level of transparency is also necessary for effective energy management and optimal plant utilisation. Less-advanced automation systems also tend to be inflexible and cannot adapt to rapid shifts in customer demands. For instance, if a manufacturer can’t change over quickly to meet demand for a new sales order, it could face production and delivery delays. This lack of flexibility also makes it difficult to capitalise on new business opportunities. Less advanced existing systems may have reached maximum capacity or would require a significant investment to add capacity.
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While it may seem like the least painful route is to upgrade components from a current vendor, it may not be the best option for manufacturers. Many vendors have dead-ended or are phasing out legacy hardware, and no spare parts are available. If parts are available, they might come at a premium. As parts reach obsolescence, often times manufacturers will dramatically increase the price. Once the parts are completely phased out, private sellers may step in and sell them at an even higher cost. So, a processor that originally cost $4,000 eight years ago could be upwards of $50,000 today. Some vendors may offer more advanced versions of obsolete parts, but manufacturers may still need to convert their code to new programming software.
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T E C H N O L O G Y | A U TO M AT I O N & C O N T R O L
Manufacturers have two options when deciding to modernise their production: a total systems approach or individual component replacement.
A total systems approach One of the replacement options available to manufacturers is a total systems replacement. This approach is suitable for manufacturers that want the full benefits of totally integrated automation – a necessary step to integrating your entire value chain, from design and engineering, to sales, production and service. Automation platforms based on an open system architecture offer maximum interoperability across all automation components. An integrated system ties the control system to key features such as: Diagnostics: Users don’t have to continually interrogate the system to obtain performance data. For example, if a plant experiences a supply voltage loss or overruns its current limit settings, the built-in module—with no additional programming required—will automatically report the information back to the controller. Security: This includes protective features in the actual hardware, not just the network. In the event that network
security levels are breached, security at the controller levels adds another layer of protection. Plants can establish up to four levels of secure access with encrypted passwords. Safety: Safety is often overlooked in automation systems and has become an increasing concern in industrial facilities. Like integrated security features, the highest-performing automation systems include safety functionality in all the components, saving end users from additional programming requirements with add-on safety controllers. Automated validation also reduces bandwidth utilisation across the network at each individual module. A totally integrated approach is also ideal for manufacturers that are seeking additional production flexibility. Systems built on a single engineering framework allow plants to make on-demand changes to line volume, for instance, without rewriting code. That same common platform also improves engineering efficiency, thereby, lowering design costs. With a centralised portal, or project management tool, an engineer can view the entire line and all the devices operating on that line. The engineer can then make changes much more quickly to any issues that may impact communications or overall performance. This can result in savings of up to 30% in engineering time.
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EM | Aug 2016
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A U TO M AT I O N & C O N T R O L | T E C H N O L O G Y
Manufacturers have two options when deciding to modernise their production: a total systems approach or individual component replacement
Individual component replacement Total replacement may not be feasible for a variety of reasons, including significant investments in existing systems. Still, outdated or underperforming controllers and other critical components can negatively impact competitiveness. Manufacturers should seek advanced automation components that can easily integrate with existing systems, while providing additional functionality. A few examples of the integration features that are important when replacing individual components include: ■ Easy integration with existing assets. Native PROFINET, PROFIBUS, Modbus, Modbus TCP, TCP/IP and Open Ethernet protocols enable connections to existing controllers so that plants can share data via EtherNet/IP without any code modifications to installed controllers. ■ Flexibility to support various network protocols, including PROFINET and EtherNet/IP. For example, modular, threepiece drives with multiple network compatibility allow users to replace the power module when it fails, instead of the entire control unit. This eliminates the need for network set-up after replacement. ■ Easy-to-configure hardware and software, including add-on instructions for easy insertion.
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High-performance automation components, such as drives and controllers, also should have built-in safety, diagnostics and communications functions to make integration with existing infrastructure even more seamless.
Doing nothing is not an option Manufacturers have installation options when it comes to modernising their automation systems with minimal downtime and effort. The risk of doing nothing, though, is significant. Considering that 40% of manufacturers have little to no visibility into real-time status, the 2015 Siemens Automation Summit witnessed a keynote address from Raj Batra, President—Digital Factory Division, Siemens. Batra explained, “Thirty percent spend as much as four hours a day searching for equipment and products on the plant floor, and 50% only become aware of a problem after a breakdown occurs.” Automation solutions that provide system-wide transparency help plants avoid reactive maintenance and other inefficiencies that impact productivity. They also enable more informed decisions leading to greater flexibility and competitiveness. ☐ Courtesy: Siemens
EM | Aug 2016
A U TO M AT I O N & C O N T R O L | T E C H N O L O G Y
Towards complete automation systems Machine builders need appropriate & customised control concepts to meet rising demands on productivity and plant & machine availability. Interaction between the control functions for automation and safety are the key to success. Simpler, more flexible, more productive, more efficient, as the demands on plant and machinery rise, so too does the level of automation. And control technology has a key role. It is the playmaker; it processes the digital and analogue signals from the sensors and input devices, sends them to actuators, drives and control devices and keeps the plant running. The processes required to do this are becoming increasingly complex. The number of relationships within a machine is rising and the level of networking is also growing. This creates additional challenges in terms of handling. At the same time, in many sectors, people are moving ever closer to the process, to fit and set up machinery for example. Where man-machine interaction is as close as possible, it can help to improve plant availability and therefore increase productivity. Accordingly, safe automation is becoming increasingly important within the whole automation concept.
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Standardising safety The determining factor when selecting the appropriate safety system is the plant’s function range. For example, by their very nature, standalone machines have fewer safety functions than interlinked machines and does not need an overriding safety function, such as a safety area shutdown. Configurable control systems are particularly suitable for this type of application. One classic application area is series machine building. In this case, manufacturers are often forced to use prescribed or country-specific machine control systems. Slight changes are continually needed to the automation concept. Openness is, therefore, essential. As the Pilz configurable control systems PNOZmulti support all common fieldbus and Ethernet-based communication systems, for example, machine operators
EM | Aug 2016
A U TO M AT I O N & C O N T R O L | T E C H N O L O G Y
With intelligent & safe control architectures, users have the freedom they need for customised implementation of the safety requirements
can choose the operational control system that best suits their individual needs and don’t need to worry about how safety is connected. Both manufacturers and users benefit from this standardisation of safety, in terms of troubleshooting, machine design and training.
Safety and automation in one system Dynamic safety concepts, such as different operating modes or torque monitoring based on the position of one or more axes, will continue to find their way into the control architecture in future. Increasingly, that requires more complex relationships with the individual elements in the overall process chain. Machine data – whether for automation or safety – must be capable of being processed together. The trend is for automation and safety functions to use a common control architecture – or even to functionally merge the two areas that have previously always been separate. Hybrid designs are catching on, especially in distributed systems to minimise cabling complexity and interface problems, for example. Machine tools are one example. Safe CNC or motion controllers, for example, record safety-related information such as linear speed, rotational speed or standstill at the various axes directly via their integrated encoder systems, passing the information on to safety control systems for safe evaluation. In this case, they not only process local safety functions, but also record and forward signals, for monitoring end positions for example. Just one common periphery system is needed for the important controlrelated process signals as automation I/Os and the I/Os for the safety functions. Thanks to the openness of the safety control system, additional encoder systems, interface problems or adapter solutions are consigned to the past. Here, Pilz offers the control systems PSSuniversal multi.
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Distributing intelligence Both PSSuniversal multi and PSSuniversal PLC are control systems in the automation system PSS 4000 from Pilz. The central idea of PSS 4000 is to merge automation and safety. Process or control data, failsafe data and diagnostic information are exchanged and synchronised via the Ethernet-based SafetyNET p. For the control function, therefore, it makes no difference where the respective program section is processed. All network subscribers are configured, programmed and diagnosed this way. So for all control tasks, the user maintains a centralised view of distributed systems. If the intelligence is distributed in the machine components, the benefits can be seen in greater availability due to local error reactions and higher productivity as a result of shorter reaction times across the whole system. Dividing the intelligence into smaller machine components also leads to improved scalability. Such multi-master automation structures result in largely standalone cell control systems, which can interact within the network. So PSS 4000 enables the mechatronic approach to be transferred to the control level, which is a key step towards Industry 4.0. Plants can be broken down into manageable, independently functioning units. As a result, the cost of engineering, commissioning and maintenance is significantly reduced. If plants are thought out and designed mechatronically, the system and hardware can be developed in parallel, for example. To date, software development is only started once the machine specification has been established. Subsequent changes or expansions to functions are very difficult retrospectively because the program as it stands accesses the hardware directly. The degree of standardisation of elements of plant and machinery also rises, allowing them to be adapted rapidly and flexibly to changing customer requirements. ☐ Courtesy: Pilz
EM | Aug 2016
M OTO R S & D R I V E S | T E C H N O L O G Y
Driving energy efficiency An application story on how drive and motor solution from Emerson helped Stål & Plast to cut extruder energy usage by 9%, thereby, improving the production processes The prospect of improved energy efficiency, increased operational reliability and lower maintenance costs appeals to any business. It was these three factors, which ensured Emerson was able to help Stål & Plast, a Danish extrusion specialist, improve its production processes by replacing three worn-out DC electric motors with energy-friendly Dyneo PM motors and a Unidrive M variable speed drive at the company’s extruder plant. The annual energy savings have been calculated at an average of 9% or 90,000 kWh, which is particularly interesting in the long term, keeping in mind that over 10
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years, 95% of the total costs of an electric motor is directly related to the energy consumption. Stål & Plast A/S, which is located right in the heart of Denmark, manufactures bench tray systems that are used in greenhouses and nurseries worldwide. The raw plates are manufactured at a modern co-extrusion plant operated by three extruder motors, one 175 kW motor and two 71 kW motors. The extruder plant’s three worn-out DC motors were due for extensive reconditioning or alternatively an expensive and time-consuming replacement, as new DC motors would have to be made to order.
EM | Aug 2016
M OTO R S & D R I V E S | T E C H N O L O G Y
Drive and motor solution cuts extruder energy usage by 9% for the Danish extrusion specialist
Extruder plant upgradation As the DC technology is expensive and outdated in terms of energy consumption and moreover associated with high operation and maintenance costs, Jacob Braa Sørensen, Managing Director, Stål & Plast, in consultation with Emerson Industrial Automation, decided to upgrade the extruder plant by purchasing highly efficient Dyneo PM motors from Leroy Somer, which are controlled by a Control Techniques Unidrive M700 variable speed drive. One of the aspects that mattered most to Stål & Plast A/S was that Emerson was the only supplier that could offer to replace the motors and the controls as a total project for which they would assume full responsibility. The replacement took place in collaboration with the service partners Lindpro as the professional installer and automation provider for the project, and Ølgod Elektro, which routinely handled commissioning and running-in. Stål & Plast A/S manufactures a broad range of topquality bench tray systems, which are used in greenhouses and nurseries worldwide. The tray systems are manufactured on a fully automated vacuum forming machine. The company manufactures its raw plates on a modern co-extruder that makes it possible to manufacture the plates in three layers.
Choosing PM technology For Stål & Plast A/S, the main reason for choosing a motor technology with permanent magnets was, first of all, the long-term energy savings on power consumption, but also the higher operating torque, the operational reliability of PM technology and the very low maintenance costs compared with DC technology. Calculations showed that Stål & Plast could reduce the
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annual energy consumption of the three motors by an average of 9%. The extruder accounts for 75% of the plant’s total energy costs, of which most is consumed by the extruder motors. Over a period of 10 years, 95% of the total costs of an electric motor are directly attributable to the energy consumption, whereas the purchase price and the maintenance costs represent as little as 5% of the total costs of the investment when choosing the Dyneo PM motor technology from Emerson. Since 1984, Stål & Plast A/S has manufactured Ebb/Flow products in high impact polystyrene, which is sold by a worldwide network of distributors. The distributors are typically nursery construction companies that install the tray systems as part of a total project purchased by a nursery.
Optimising production process Over the years, the tray systems have been thoroughly tested against common fertilisers, temperature impact, UV radiation and normal daily wear and tear in a modern greenhouse. This know-how is used to improve and optimise the products on an ongoing basis. The tray systems are produced on modern fully automated vacuum forming machines that are optimised for the production of Ebb/Flow products. The production plants are primarily operated by robots and monitored by trained staff with years of experience. The company manufactures its raw plates on a modern co-extruder that makes it possible to manufacture the plates in three layers. As a result, the finished trays can be manufactured in accordance with the customer’s exact requirements and with all the desired characteristics. ☐ Courtesy: Emerson
EM | Aug 2016
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W O R K H O L D I N G & F I X T U R E S | A P P L I C AT I O N
Upgrading production capacity The constant pursuit to optimise quality, deliverability and costs by the manufacturing sector often brings the focus on processes, systems, materials and employees. The article highlights how the jaw quick-change system significantly reduces set-up time, thereby, increasing productivity. A visit to STIEBER GmbH in Heidelberg shows that small investments can achieve significant effects in production. In association with the affiliated companies— Formsprag and Marland, STIEBER is a world market leader for freewheels and escapement mechanisms. As part of the ALTRA Industrial Motion Group, a worldwide leading manufacturer of mechanical drive elements, STIEBER uses the ALTRA Business System (ABS). The system’s integrated approach aims to optimise quality, deliverability and costs, with the result of maximum possible customer satisfaction.
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In pursuit of this goal, the focus is equally on processes, systems, materials and employees. The main motivating forces are Kaizen and the continuous improvement process.
Higher flexibility and lower costs What, at first, sounds theoretical quickly becomes concrete, when one takes a look at the soft machining department at STIEBER. During a Kaizen event with the ALTRA group management at STIEBER in Heidelberg,
EM | Jul 2016
W O R K H O L D I N G & F I X T U R E S | A P P L I C AT I O N
The jaw quick-change system was particularly developed for conventional lathe chucks with bolt-on jaws
Andreas Sandmaier, who is responsible for production controlling, transformed the heretofore conventionally organised soft machining department into a cell production system in which the workpiece passes through all stations of the cell directly, i.e. without lengthy waiting times. “Instead of receiving prepared blanks for sawing, our machining now starts with sawing of the pre-machined part and ends shortly afterwards with the completed part,” Sandmaier explains. The result is impressive: this procedure reduced the processing times by two to three weeks. Short-term orders can be produced with much higher flexibility. “Today we can respond to customer requirements much more quickly, and the throughput of parts has increased significantly, without putting stress on the employees,” the specially trained Kaizen leader confirms. He and his team were actively involved in the process from the very beginning. “Such a solution requires people who understand and also accept the principle.” Basically, it was a matter of streamlining the organisation and eliminating wastefulness wherever possible. The required machines were arranged to minimise the distances between the stations; all machining programmes were merged; all required tools are now on shadow boards directly at the location of the machine. While one employee operates the machines, the other sets up the next job. The team recognised early on that the set-up times on the two lathes slow down the process considerably. “There are days when the early shift has to change the set-up six times. That takes between 15 and 20 minutes each time,” Sandmaier summarises. If covers are machined in quantities between five and twelve, the number of set-up processes is
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even higher. The first step was to equip all existing jaws with bolts and T-nuts, to allow faster changing. “That saves a few minutes, but in the end, each set-up process still takes 12 to 15 minutes.”
One hour of set-up time saved per day The SCHUNK PRONTO jaw quick-change system finally provided the solution. “We were still in the middle of reorganising when the new change system was launched,” the team leader relates. The first test series already resulted in significant savings potentials. The standard system was further optimised and today, his team needs only two to a maximum of five minutes to change from one product to another. Due to the parts spectrum, usually only the clamping attachments have to be changed, which takes only a few minutes. The savings in set-up times for each lathe add up to at least one hour per day, according to Andreas Sandmaier. “The system increases the productivity on our existing lathes by 10 to 15 per cent, without the necessity for extensive investments. With one small step, we have made huge progress.” The jaw quick-change system was particularly developed for conventional lathe chucks with bolt-on jaws. It reduces the absolute set-up time for a complete jaw set to only 30 seconds, which is about 95% less than with conventional solutions. It combines serrated supporting jaws (1/16" x 90° or 1.5 mm x 60°) with special quick-change inserts, which allows expansion of the clamping diameter within seconds by up to 55 mm on soft jaws and by up to 45 mm on claw jaws, without having to move the base jaw. That is eight
EM | Jul 2016
W O R K H O L D I N G & F I X T U R E S | A P P L I C AT I O N
times more than what was achieved with conventional power chucks. All that is necessary for fast jaw change with repeat accuracy is to loosen the interchangeable insert with an Allen key, remove the insert and replace it with another one. This eliminates the risk of incorrect positioning. In locked state, six-sided form-fit clamping ensures maximum process stability and enables high force and torque transfer. Different supporting jaw variants are available for small, medium, and large clamping areas, depending on the particular application. As top jaws, the innovative family-owned company offers hard claw inserts for different diameters and clamping ranges as well as soft interchangeable inserts for finished part machining. Once they have been turned out, the latter can be reused again and again on the system. The clamping depth is variable with the workpiece stop. An adjusting sleeve facilitates the jaw change.
Complete line of quick-change jaws The jaw quick-change system can be retrofitted on all fine serrated lathe chucks of the sizes – 200, 250, and 315,
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regardless of the manufacturer. The modular design of the components allows the individual and, therefore, very economical combination of the single components. This also means that the interchangeable inserts are compatible with all supporting jaws; only their position varies. A specially developed set-up cart provides for orderly storage and fast accessibility of all claw inserts, soft interchangeable inserts, supporting jaws with mounted bolts and T-nuts, as well as the adjusting sleeves. A clearly structured table book enables fast selection and mounting of the single components. Provisions were even made for storage in the machine: all parts can be transported on a tray and positioned for mounting directly within the machine by means of a quickacting connector. This system is especially advantageous when it is necessary to increase the productivity of existing lathes. “Instead of replacing our existing lathe chucks with quickchange chucks, investing in the jaw quick-change system is a better idea as it helps shorten set-up times significantly,” Sandmaier ascertains. ☐ Courtesy: Schunk
EM | Jul 2016
TEST & MEASUREMENT | TECHNOLOGY
Better accuracy – key for quality performance Accuracy and on-time delivery are key requirements for the tooling industry. The article highlights the application of a laser system and a telescoping ballbar system, analysing how it can aid the tooling sector by saving time, money, reduce scrap and achieve a high level of accuracy. Godrej, a household name in the Indian market, has international presence in The Netherlands, Saudi Arabia, the UAE, Oman, China, Vietnam, Malaysia and Singapore. Founded in 1935 as a captive tool room, the Godrej Tooling Division commenced commercial operations in 1993 and manufactures press tools, die casts and special-purpose machines, jigs and fixtures. With revenues exceeding ` 1.2 billion, the company caters to the tooling needs of Toyota, TATA, Honda, GM, Maruti Suzuki and Siemens, amongst others.
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Godrej, India’s largest tooling solution provider, has unsurpassed capabilities in the manufacture of complex dies, with 15-20% of its products being exported around the world. As part of its Total Productive Maintenance (TPM) initiative, Godrej follows PQCDSM (Productivity, Quality, Cost, Delivery, Safety, and Morale) and Kaizen guidelines. The main objectives of its TPM initiative are to reduce down time to zero and ensure on-time deliveries. Therefore, maintaining the accuracy of its equipment, including CNC and EDM machines, with high precision calibration equipment is essential.
EM | Aug 2016
TEST & MEASUREMENT | TECHNOLOGY
Die and mould customers choose Godrej because of the long life span of its dies resulting from their tightly controlled quality parameters
Precision is key In the early days, Godrej’s evaluation of accuracy was difficult to obtain. National Aerospace Standard NAS979 tests (standardised cutting tests for CNC milling machines) were performed by a highly skilled expert as part of machines commissioning. These tests were problematic and timeconsuming to carry out. In 1996, Godrej purchased Renishaw’s ML10 laser system after hearing about the quality of the product and was impressed with its accuracy and reliability. Furthermore, Godrej was surprised how simple it was to use and avoided expensive errors common in the NAS test. Although the ML10 only measured 9 parameters, as compared to 13 in NAS tests, the improvement in results quality was more important than the parameters left undiagnosed. The data reading was instant and easy to analyse. Godrej soon realised that the Renishaw laser system would save time, money and reduce scrap. Its accuracy prompted Godrej customers to specifically request ML10 certification. “The product is rugged and stable. There has never been an instance of product failure,” shared S M Nayak, Senior General Manager, Godrej Tooling Division. Godrej has since upgraded to Renishaw’s XL-80 laser system designed with simplicity and ease of use in mind, reducing the need for a highly skilled expert. “We requested training from Renishaw which was completed in a week. They have an immediate response time,” shared Nayak. The XL-80 laser measurement system offers high performance calibration for motion systems, including CMMs and machine tools.
Meeting new challenges As a part of its expansion, Godrej Machine Tools purchased multiple CNC machines in its tooling division. This posed new challenges as the machines needed to be tested for additional parameters like circular interpolation
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and drive tuning. Godrej found a solution in the QC20-W telescoping ballbar system by Renishaw, which identifies machine errors easily with a high degree of accuracy. It directly determines servo mismatch, geometric accuracy, squareness, positional errors and reversal spikes in all 3 planes (xy-yz-zx). The adoption of QC20-W ballbar, testing Godrej’s down time and rejection rates, have reduced to 5%.
Delivering results In the tooling industry, quality parameters are critical and customers expect a product life span of 10 years. Through its adherence to the highest quality & accuracy standards, Godrej has been able to deliver products with a life span of 1,25,000 cycles, far ahead of the industry norm of 50,000 cycles. Godrej’s customers in defence, aerospace and nuclear application industries request audits during the manufacturing process to ensure quality measures are being maintained and insist on seeing ballbar certificates for the machines. Nayak elaborates, “Godrej has improved its quality norms, boost inhouse capabilities, competence and confidence and has also reduced costs with the help of Renishaw products.”
Beyond savings to revenue generation Die and mould customers choose Godrej because of the long life span of its dies resulting from their tightly controlled quality parameters. The customer demand for high quality and precision measurement prompted the company to provide laser and ballbar certifications. Now, Godrej offers calibration services to others, generating an additional revenue stream. Godrej’s manufacturing facility is equipped with state-of-theart CNC, EDMs and jig boring machines. Nayak states, “High precision calibration of these machines with a Renishaw laser or ballbar is key to quality and reliable performance.” ☐ Courtesy: Renishaw
EM | Aug 2016
E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y
Bridging the gap… To make fresh graduates competent with international industry standards, organisations, today, are doing away with the traditional approaches of building products. Rather, they have now embraced latest technologies and harnessed their advantages to develop robust, appealing and competitive products—not only for students, but even for working professionals. Several renowned studies have indicated that less than 25% of engineering graduates in India are actually employable. India sees one of the highest numbers of engineers graduating every year and the fact that around 75% of them will not find a good job is very concerning. With rapid evolvement in technology, and new knowledge creation, the education imparted to students at their engineering colleges becomes obsolete and barely finds relevance in the industry outside. In today’s highly competitive environment, the industry looks for trained manpower that would start contributing to their company’s growth objectives at the earliest. Bridging this gap is imperative, if we are to increase the absorption rate of the freshly passed out engineering graduates in the industry.
Industry – institute collaboration In a strictly academic environment, it is difficult for the
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Prashant Deshpande Sr Business Manager— Education and Trainings DesignTech CAD Academy
students to comprehend the nature and magnitude of work that takes place in the industry. Also, the knowledge that students are imparted in their academic institutes is limited and does not cover the entire scope of work that companies execute regularly, which furthermore keeps students oblivious about the industry working knowledge. Industryinstitute collaboration makes for a perfect approach to help students get a glimpse of industry work scenario and gives them an exposure of the detailed operational understanding within a company or an industry. Siemens PLM Software, in association with DesignTech Systems, has established 11 centres of excellence in various cities in Gujarat. These centres, each dedicated to a specific domain such as automotive, aerospace and defence, industrial machinery, etc, contain a set-up of the latest and most advanced technologies in product design, engineering, automation and manufacturing. This gives students the exposure to the
EM | Aug 2016
T E C H N O L O G Y | E D U C AT I O N & T R A I N I N G
DesignTech CAD Academy student Nilesh Kurade designed F1 Car in NX CAD
contemporary technologies being used in the industry, which not only helps students update and upgrade their knowledge, but also increases their chances of initiating a bright career with a good company.
working out policies for ease of doing business—these initiatives are providing a major thrust to the manufacturing sector which is expected to boom manifold. This will further expand and create new career opportunities.
Capitalising new opportunities
Addressing the skill gap
With the advent of new technologies, processes and workflows in manufacturing, students can now capitalise on new opportunities created in this area of work. Cuttingedge technologies, processes and certifications that are used in the manufacturing set-ups that include computer-aided designing, computer-aided manufacturing, plant simulation and digital manufacturing, Additive Manufacturing, PLM, inventory management, quality control, six sigma now help students have multiple new career avenues to choose from. With new collaborative and self-managing manufacturing systems being researched upon through IoT, the operational functions in the manufacturing set-ups is expected to change radically. Industry 4.0 is going to be the Next Big Thing that is going to revolutionise the way manufacturing machines and systems have been operating. After the Assembly Lines invention at Ford manufacturing that brought about the new age industrial revolution, Industry 4.0 will bring in amounts of investments being made into this research area. With the Government’s focus on ‘Make in India’ initiatives, the manufacturing sector in India has got an exponential boost, thus, creating many job opportunities. Students need to make the most of this, and work on gaining relevant knowledge to be a part of this growth engine. Greater foreign investments, emphasis on skill development,
Traditionally engineering projects and internships were bridging this skill gap. Through internships, students would gain an understanding on industry’s working environment and processes. They would also develop deep understanding about the company’s operations, while working closely within or with the companies, or professionals for their engineering projects. But this understanding is limited as internships, at the most, last not more than 3 months. Also, the knowledge that students acquire is limited to the extent of the scope of the project. Engineering colleges and institutes, and other private training institutes have to make consistent efforts in upgrading their courseware, teaching techniques to include the knowledge of the latest advances in their field. Also, live scenario projects and arranging industry seminars from industry experts is another way of introducing students to the outside world of industry. Establishing centres of excellence is the new approach to make students familiar with the latest technologies that the industry is using. The knowledge that students possess should be congruent to the industry applications. Redundant knowledge will never help students get a realistic picture of an industry’s working dynamics. Therefore, industryacademia collaborations is the best and the most straightforward way to bridge the gap.
EM | Aug 2016
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E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y
At par with latest trends The highly competitive “one world one market” scenario has necessitated the research agencies and companies’ R&D departments to invest heavily into bringing new technologies to augment product innovation, optimise development costs & time, while bettering product quality and gaining manufacturing efficiency. Consistent efforts in the development of modern technology have resulted in incremental evolution of tech solutions. Technologies now become obsolete and/or redundant in a matter of months. Hypothetically, if an engineering student was introduced to a certain technology in his first year, it would not be an exaggeration to say that this technology would be nearing its descent or would have already begun its descent in terms of its applications and use by the time that student passes out of the engineering college in the fourth year. If professionals want to continue their growth trajectory, they have to constantly
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invest in gaining new knowledge and keeping themselves abreast with the latest technologies and processes. In mechanical engineering, for example, there are a plethora of new technologies besides CAD and CAM solutions that have made their way in the industry, becoming an integral part of their processes in the last couple of years. Also, companies are now done away with the traditional approaches of building products. They have now embraced these latest technologies and harnessed their advantages to develop robust, appealing and competitive products—not only for students, but even for working professionals. If they want to retain their position and place within the company and experience consistent growth in their career may have to be abreast. Reading about new innovations, upgrading their knowledge, acquiring training to get deeper understanding about their applications, strengths, and usage is a must for their professional growth. Only then will they be able to contribute to ensure sustainable growth for their company and themselves. ☐
EM | Aug 2016
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M A R K E T I N G M A N A G E M E N T | S P E C I A L F E AT U R E
Changing economics of marketing mantras The article traces the evolution as well as the latest marketing trends and strategies in the machine tools sector, while discussing the importance of providing customised service packages to customers, who are increasingly looking for turnkey solutions in the global market There was a time when very few companies catered to the machine tool sector in India. HMT and Cooper had a monopoly here and there was no marketing involved as it was more a seller’s market. Subsequently, there was an invasion from foreign brands, especially from Germany, Japan and USA. Most had Indian agents who acted as middlemen and there was proxy-marketing involved due to which customers had no trust in them. They also failed to provide after-sales service. In the meantime, low-cost local manufacturers started making standard machines with their own sales and marketing network. After the liberalisation policy was passed in India in 1991, foreign brands started to establish their local offices in India. Globally, the European machine tool sector got consolidated and many of them migrated to the Far East.
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Suchi Adhikari Sub-editor & Correspondent suchi.adhikari@publish-industry.net
Key issues in machine tools marketing Today, across industries, there have been several key issues witnessed, in regards to the machine tools marketing sector in India. While the challenges are many, Avinash Khare, Head – Technology Centre, Indian Machine Tool Manufacturers’ Association, opines that Indian manufacturers are inclined in making standard machines more, rather than customising them for specific requirements, because customers look for turnkey solutions. He further added, “Customers today are not only looking for efficient machines, but also want service packages. However, Indian manufacturers are not providing this solution – they are just selling basic machinery.”
EM | Aug 2016
S P E C I A L F E AT U R E | M a r k e t i n g M a n a g e m e n t
Another issue is quality. Khare explains that the quality of paint, aggregates, etc is low due to which Indian machinery looks old and ages very fast. Furthermore, “There is a lack of process discipline which accumulates into poor reliability of products,” he says. Thirdly, the approach of customers in India may often act as a hindrance. “They are not ready to bear the expense of excellence coming from Indian companies, while the partiality remains for foreign brands,” elaborates Khare. So, a solution for this is to educate customers and set bench-marking and proving exercises which will challenge customers’ perceptions.
priorities of the customer. “We need to recognise a customer’s individuality – they are not all the same, so they should not be treated the same. There are positive customers who tend to see what’s there and negative customers who tend to see what’s missing. It is important to recognise this differentiation in customers before making a pitch to them,” elaborates Ramesh. Navalgundkar also emphasises on the importance of providing customised service to customers where their convenience is taken care of. “Providing a single point of contact for after-sales service and giving warranty of service are some of the ways in which a customised deal can be given,” he explains.
Customer-centric marketing
Theory in buying behaviour
The market has evolved over the years and customers today are looking for a complete solution package. They are demanding reduced costs, improved quality and meeting timelines. “Hence, the solution they need is not just a machine but a service package that will aid in meeting these demands. This needs a change in the thought process and engineers have to evolve their strategy so as to meet this demand,” says Dattatraya Navalgundkar, General Manager — Organisation Strategy, Kirloskar Pneumatic Co Ltd. T K Ramesh, Chief Executive Officer, Micromatic Machine Tools Pvt Ltd, also suggests that the marketing strategy implemented by the sales engineer is of prime importance. He opines that the sales engineer must learn to be good at maintaining relationships with customers. “Selling does not work on logic. The cerebral and emotional quotient of customers must be taken into account,” he says. Additionally, the sales engineer must also know and study their business thoroughly.
Ramesh has categorised buying behaviour of customers into five different stages and it is called Maslow’s Motivation Theory in Buying Behaviour. The following are the five stages: t Psychological: This group includes companies who cater to first-time buyers who have budget constraints t Security: This group includes companies who are looking for repeat buyers and are looking to expand their business. t Belonging: This group segments those companies who are looking to make an entry into a band or group. For instance, a car manufacturer moves on from basic cars to luxury cars. t Esteem: This group of companies are looking to better themselves on a quality-cost-delivery basis. t Self actualisation: These companies are the leaders of the industry. Thus, the sales engineer needs to identify which of these five categories his customer belongs to and then modify his sales strategy accordingly so that the pitch will be more customised.
Psychology of selling Thus, it is crucial to understand a customer’s desires, fears and motivation. Without this understanding, we can only guess as to why they do or don’t do what they are supposed to do, which is buy from us. Hence, it is important to analyse the human mind so that the sales engineer can pitch to the customer keeping in mind the mindset and
EM | Aug 2016
Personality styles overview Ramesh further elaborates on differing customer personalities and the approach that the sales engineer must adopt towards them through the following:
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M A R K E T I N G M A N A G E M E N T | S P E C I A L F E AT U R E
Ramesh’s take on balancing traits ANALYTICAL CUSTOMER SALESMAN
DRIVER CUSTOMER SALESMAN
Critical Indecisive Moralistic Stuffy Exacting
Domineering Pushy Harsh Severe Blunt
Industrious Serious Orderly Vigilant Persistent
Determined Single-minded Thorough Decisive Efficient
AMIABLE CUSTOMER YOU
EXPRESSIVE CUSTOMER YOU
Comforting Retiring Awkward Dependent Ingratiating
Manipulative Undisciplined Hysterical Reactive Excitable
Agreeable Dependable Supportive Willing Concerned
Talkative Dynamic Personable Enthusiastic Stimulating
t
Driver and analytical customers: These types of customers try to control the process and give specifications. In order to deal with them, the sales engineer should ask them relevant questions such as why they need that specification. This gives the perception that the salesman is trying to aid them in their process of control. Another thumb rule to have is to not to tell or instruct these types of customers but to ask questions. t Amiable and expressive customers: These categories of customers are emotive and expressive. The salesman can tell and instruct them regarding their service because they will listen and get convinced. The sales engineer’s ability to read these signals and personalities is crucial for successful and persistent success in sales.
Stay lean, stay fit Specifically, in machine tools, repeat business comes when one learns how to manage the customer after the sales is over. “It becomes the sales engineer’s responsibility to make the customer successful after your product has been sold to them,” emphasises Ramesh. That is why after-sales service is important which includes tending to their calls, service request, etc. Previously, volume growth was the focus with the mindset that more the turnover, more the business. “However, now, the business paradigm has shifted to staying lean and staying fit which means that there are more versatile products with less volume,” says Khare. Earlier, mass production of machines was needed but products today need to offer economy with flexibility and configurability of machines. This also means integration of technologies on all platforms and building multi-purpose machines. For instance,
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customers now demand an EDM which can also do milling, induction hardening, grinding, etc. Thus, strong research and development is required specifically in India as such versatile machines are not being manufactured here.
The Indian advantage On the global platform, European and Japanese companies are showcasing premium technology, integrated technology product and multi-purpose products whereas Chinese companies are thriving mostly on low cost products. “However, Chinese manufactured products are not very trusted globally. India can use this to its advantage and pitch in by making bold marketing strides. Our trust factor globally is more than that of China and we also have a language advantage in terms of being well versed in English. We need to build offices and a strong presence globally and target the rest of the world (excluding Far East countries) where our products would be cheaper than the Western products and better in quality than the Chinese products,” suggests Khare. Furthermore, Indian machine tool manufacturers must adhere to global standards and should not compromise on quality, standards and other important parameters. “With the latest advancements in Industry 4.0 which talks about human-machine interaction, Indian manufacturers need to get actively engaged in this revolution and provide remote monitoring of machines and proactive support to customers,” says Navalgundkar. Finally, the value perception created in customer’s mind goes a long way and providing exceptional after-sales service is key. “Creating schedules and recording data of all the processes involved to showcase value only happens after sales. This is the seed to grow the orchard,” concludes Ramesh. ☐
EM | Aug 2016
EVENT | REPORT
Connecting the physical and digital... Barriers to technology, affordability and implementation are crumbling, and more companies are embracing the paybacks of connectivity, data collection and analysis. With subsequent tracks and breakout sessions, PTC recently concluded Liveworx 2016, at Boston, Massachusetts, USA. The IoT event also witnessed rapid integration of the company’s recent acquisitions with other elements of their product portfolio. A post-event report… It’s much talked about as ‘Made in China 2025’ in China; as ‘Industrial Internet of Things’ in North America and as ‘Industry 4.0’ in Europe. Lately, there’s been a natural gravitation to the realm of IoT not only in the western world, but also across the Indian landscape. Universally, IoT stimulates a heightened level of cognizance about a platform from which to monitor the reactions to the varying circumstances. Very analogous to the internet itself, IoT enables a myriad of applications, ranging from micro to macro, and from the trivial
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Megha Roy Senior Features Writer megha.roy@publish-industry.net
to critical. Today, from healthcare to smart homes to now smart cities, there are different sectors that are being touched by the IoT with the Indian government’s ‘Make in India’ wave. With an effort to crack IoT from a concept to reality phase, PTC recently concluded LiveWorx 2016 at Boston, Massachusetts, USA. The business event on IoT featured industry leaders, pioneering technology and real-world application, highlighting the potentials of the technology. Today, the blend of the physical and digital world is the new
EM | Aug 2016
REPORT | EVENT
Underlining the amalgamation of the physical and digital eras, Jim Heppelmann, President & CEO, PTC, explained that IoT is a game changing innovation
reality, which creates state-of-the-art opportunities for innovation. Keeping this in backdrop, the four-day event was an eye opener to the businesses gaining a competitive edge in the marketplace. Attendees included professional who design, manufacture and service today’s products, as well as those who develop the applications and experiences that will unleash the future potential.
Merging the two worlds With a footfall of around 4000 people, LiveWorx 2016 hosted 200 breakout sessions and presentations from business leaders, sharing the challenges and successes on an extensive range of IoT topics in a series of content tracks for design, development, manufacturing, and service. It also witnessed the unveiling of the brand’s new logo with X’tropolis, an expo hall where attendees experienced hands-on demonstrations of IoT and Augmented Reality technologies. Keynote presentations from the greatest of visionaries and industry stalwarts were delivered at the technology-driven conference that was moderated by David Pogue, Yahoo Tech Founder & Industry Writer. “We are becoming the citizens of new world” he said, while he summarised the consequence of IoT and discussed a roadmap for business leaders. Underlining the amalgamation of the physical and digital eras, Jim Heppelmann, President & CEO, PTC, kicked off Day 1. In his keynote session, he averred that the DNA of the product—physical products, now communicates to the cloud environment. “The concept of digital product cloud changes manufacturing operations, design, service & sales, and business sectors, and IoT is a game changing innovation.” Taking the discussion forward, Heppelmann was later joined by Terri Lewis, Director—Sales & Technology, Caterpillar, to present on IoT combined with Augmented Reality & Virtual Reality. He discussed the business benefits of
EM | Aug 2016
AR and VR, and included Analytics as a critical component of the IoT platform. Speaking on the dynamics of Analytics, Erich Von Gemron, Vice President—R&D, Flowserve, explained how the company demonstrates Analytics to their customers.
IoT—the evolutionary journey The next keynote session was addressed on the topic ‘The power of Platform’, jointly presented by Rob Gremley, Group President—Technology Platform Group, PTC; Jay Wright, President & General Manager—Vuforia Technology, PTC; Joe Biron, SVP—ThingWorx Technology, PTC and Mike Campbell, EVP—Vuforia Technology, PTC. While Gremley discussed how solutions are developed by PTC, he explained that a platform enables developing and operating a solution or technology easily, by putting across the right tools for all applications. Sharing the augmented reality experiences was Wright, as he discussed the platform capabilities of Vuforia™ Studio Enterprise – a powerful new tool for authoring and publishing Augmented Reality experiences for the enterprise. The Enterprise was officially launched by Campbell at the event, wherein, he discussed its integration with ThingWorx and emphasised the newer capabilities to break the physical and digital world. Lastly, Biron emphasised that connecting things is the most fundamental aspect of IoT. While discussing its applications, he highlighted its connection with Kepware ThingWorx that leverages the right combination of best-of-breed components from ThingWorx and the 3rd party device clouds to suit their specific goals, environment and needs. This was followed by another interesting keynote session on the journey of transformation, where Craig Hayman, Group President—IoT Solutions Group, PTC, explained the fundamentals of a business cycle. According to Hayman, digital engineering services are grabbing eyeballs today. “The relation
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EVENT | REPORT
Very analogous to the internet itself, IoT enables a myriad of applications, ranging from micro to macro, and from the trivial to critical
between suppliers & customers are changing, and, therefore, we have to focus on how a company can become agile,” he said. Speaking further on agile engineering, Joe Justice, President of Scrum in Hardware, Scrum Inc, briefed the attendees on PTC AgileWorx. “Similar to engineering teams, PTC AgileWorx is designed around products, not projects. It links to ALM, PLM and CAD systems of record used every day,” he added. The keynote also witnessed discussions by Kevin Bollom, Vice President—Building Services, Trane, and Howard Heppelmann, Divisional GM—Manufacturing Solutions, PTC. Moving ahead, Pogue also hosted an interactive session with Adam Savage and Jamie Hyneman from MythBusters, the Discovery Channel TV show, where the duo shared their unique perspectives in the areas of innovation and collaboration.
Future advancement of IoT Digital agility is certainly gaining paramount importance with time, and Deloitte, a leading systems integrator, created Deloitte Digital, which they claim is a unique combination of strategy, creativity and technology. Focussing on this, began the first keynote session of Day 2 on ‘IoT: From sensing to doing’ by Robert Schmid, Chief IoT Technologist, Global Leader, Deloitte, where Schmid explained the IoT value proposition and touched upon tech trend 2016—greenfield vs brownfield. “Creating a digital consultancy is the need-of-thehour. Our digital reference architecture comprises of an ecosystem to create, communicate, aggregate, analyse and act,” he addressed. Furthermore, he explained the concept of vertical vs horizontal IoT applications with industry-specific statistics and concluded his session with a pep talk on the human side of IoT. Next, Colin Angle, Chairman, CEO & Co-Founder, iRobot, presented on ‘Robots and the Internet of Things’, where he discussed how the applications of robots are becoming widespread in the household applications for creating smart and connected homes. “To meet the market trends, we follow
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the trial & error method and, thereby, earn the right measure to adopt the required feature,” he discussed. No doubt digital technologies are fundamental to secure a robust and globally competitive industrial base in future. Speaking on transforming the global manufacturing industry was Eric Schaeffer, Senior Managing Director, Accenture. Schaeffer spoke on ‘The Rise of the Digital Enterprise’, and opined that the future evolution of IoT is likely to have four phases—Phase 1 and 2, with numerous options and Phase 3 and 4, with structural changes for long term. Day 2 concluded with an interactive panel discussion on the disruptive impact of IoT, where panellists Heppelmann, Angle and Prof Michael Porter, Harvard Business School, discussed the key takeaways of IoT research, its areas of applications, research collaboration topics, required collaborations, accelerating impact of IoT, etc. However, the highlight of the event featured Hollywood actor Joseph Gordon Levit, speaking for his company, Hit record, an online collaborative production house that helps in producing films or music by letting the creators collaborate and add value in the process of production.
Tracks for fabricating future In an attempt to connect every engineer, entrepreneur, maker and inventor, Liveworx 2016, simultaneously hosted four tracks on Design, Develop, Manufacture and Service. While the Design track witnessed design leaders, from engineering to retail and product development to learn how to tap into connected devices and harness the data produced to reduce rework costs & improve development costs, collaboration, and time-to-market; the track on Develop focussed on application & solution development leaders exploring latest technologies, IoT coding approaches, realworld applications and development management approaches. The Manufacture track concentrated on making production smoother by driving production efficiency, improving quality & performance and reducing risk. The track on Service hosted
EM | Aug 2016
EVENT | REPORT
service leaders, learning to harness the power of IoT to reduce service time/costs and increase efficiency.
Vuforia™ Studio Enterprise Though Augmented Reality is a fast-growing technology segment in the enterprise, its adoption is hindered by a lack of tools for content authors that can leverage existing 3D assets. Providing a solution for the same, LiveWorx 2016 also witnessed Vuforia Studio that addresses this challenge and enables development of new experiences for creating, operating and servicing connected products. Originally announced as Project ThingX, Vuforia Studio Enterprise is seamlessly integrated with PTC’s Creo® 3D CAD visualisation and illustration software and ThingWorx® Internet of Things (IoT) platform to quickly and easily add an Augmented Reality component to connected things – from manufacturing and factory equipment to solar panels and medical devices. According to Heppelmann, “Available as part of the Vuforia Studio Pilot Program, it ushers in the era of Augmented Reality for the enterprise by delivering a set of components that allows, practically anyone, to create an augmented experience, with no coding knowledge required.”
Key takeaways… Overall, the strong customer stories highlighted at LiveWorx 2016, demonstrated stories and product enhancements to get customers and prospects to take that new look, buy, implement, and achieve the desired returns. Also, PTC’s rebranding emphasised the paradox of physical and digital, summarising their strategy to support customers developing smart and connected products. According to experts, the company’s strength in industrial equipment design is a good fit for the industrial internet requirements of that segment, and many others. LiveWorx 2017 will be hosted on May 22—25, 2017, at Boston, Massachusetts, USA. ☐
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EM | Aug 2016
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EVENT | PREVIEW
Next wave of factory revolution Underlining the tagline ‘Exhibition integrated with manufacturing supply chain’, the 4th edition of Taiwan International Machine Tool Show (TMTS 2016) is to be held on November 23-27, 2016, at Taichung. EM was a part of the preshow conference recently held at Taiwan. A pre-event report… Globally, across manufacturing companies, Industry 4.0 technologies have developed in leaps and bounds, and when it comes to manufacturing industry, it goes without saying that Taiwan is climbing the ladder at a rapid pace. Starting from computer simulation technique to intelligent production lines and integrated smart systems for factories, major trends are witnessed to meet future requirements. Focussing on this, Taiwan Machine Tool & Accessory Builders’ Association (TMBA) recently organised a pre-show conference for the upcoming Taiwan International Machine Tool Show (TMTS 2016). The conference gave a glimpse of the future
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Maria Jerin Features Writer maria.jerin@publish-industry.net
technologies to be showcased at the main exhibition on November 23-27, 2016. Present at the inauguration of the conference were Jui-Hsiung Yen, Vice Chairman, TMBA; Chin-Kun Yu, Vice Chairman, TMBA, along with Chia-Lung Lin, Mayor of Taichung City Government. Speaking on the scale of fourth edition of TMTS, Yen emphasised, “TMTS has increased from 1,200 booths to more than 4,000 booths in seven years.” According to Yu, “More than 744 companies and 4,133 booths have applied to attend TMTS. However, due to space limitations, the exhibition area will be 78,000 sq mt with 4,000 booths,
EM | Aug 2016
PREVIEW | EVENT
Keyarrow professionals explained the OPL (One Point Lesson) strategy followed in their company to reduce the lead time in the delivery line
exhibiting all types of high precision machine tools, components, accessories, tools and automation equipment. There is an 8% increase in the overall scale and exhibitor number, when compared to the last edition in 2014.”
Highlights TMTS 2016 is themed with ‘Activating Intelligent Manufacturing: Heading towards Industry 4.0’ to express the achievement of related advanced products, including sensing technology, machine-to-machine (M2M), data driven decision making, robot-controlled manufacturing, human-robot collaboration, and intelligent control of flexible (customed) manufacturing system, etc. To be held at Taichung, the exhibition takes advantage of being close to the sales market and easy transportation, thereby, expecting to attract over 75,000 visitors. “The order amount is expected to be over US$ 250 million with transaction size surpassing the last show,” noted Yu. “To provide optimal service for visitors and buyers from all over the world, there will be series of events, such as new product release, purchasing conference, factory visit and free city tour,” he added.
Machine tool industry performance Taiwan machine tool industry reached US$ 4,167 million of product value in 2015, and is ranked 7 th in the world. Highlighting this, Yen said, “Focused on the export market, 80% of exports to 138 countries all over the world, make Taiwan as the 4 th export country of machine tools in the world.” According to the recent reports, the top 10 export areas of machine tools at the first quarter of 2016 are as follows: China (including Hong Kong), USA, Turkey, Germany, Thailand, The Netherlands, Vietnam, India, Japan
EM | Aug 2016
and Korea. Also, Taiwan is ranked 15 th by import value, and 9 th by consumption value in the world. Speaking about export market, in the first quarter of 2016, China was still the biggest export market of Taiwan machine tool accessory with an export value of US$ 105 million, followed by Japan with US$ 22 million, and USA, Germany, Korea, India, Italy, Thailand, Turkey, and Malaysia. For imports, Japan is the main import country with an import value of US$ 17.67 million and share of 35.2%, followed by China (including Hong Kong) with US$ 13.64 million, and Germany, Italy, Switzerland, USA, UK, France, Korea and Sweden.
Across the industry cluster There are more than 1600 manufacturers in Taiwan machine tool supply chain, and nearly 90% of these manufacturers are located in the Greater Taichung area. “Taichung is not only a major base in global machine tool manufacturing, but also a major consuming market in machine tools and other mechanical equipment,” noted Yu. As part of the pre-show conference, TMBA also hosted facility visits across the city to witness Taiwan machine tool companies’ developments across the manufacturing industry. The following section discusses about the companies visited: Keyarrow: The company is a specialised manufacturer of machine components, whose main products are bellows, bellows with lamella, telescopic covers, chip conveyors and machine guards system. The company implemented KAPS (Keyarrow Production System), based on ‘5S+TPM’, following the spirit of TPS (Toyota Production System). OPL (One Point Lesson) is another strategy followed by the company to reduce the lead time in the delivery line. With this, the company delivered components for 6,500 machines within 45 days for its business order in China.
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EVENT | PREVIEW
A Tongtai professional explained the product application that are produced with Additive Manufacturing machine
Hartford Motors: As a professional machining centre manufacturer, the company manufactures everything from casting irons to shipment so that all procedures are completed in-house. It has sold over 4,600 machining centres globally, resulting in over 37,000 satisfied customers. At TMTS 2016, the company will be showcasing 5-axis machining centre 5BC, 5A series for best machining performance in the aerospace industry. 5A series has both 5-axis and 4+1 axis machining centre for selection. The unique design of 3 axes thermal growth control system on 5-axis means thermal deformation problem is not an issue and making axis accuracy stable. For high precision large aerospace components and difficult to machine materials, 5BC series provides a solution with the 5-axis double column machining centre. Posa Machinery: The company’s product range includes lathe spindles, machining centre spindles, grinder spindles and boring machine spindles. Due to the global customers’ needs of energy saving, high quality and high efficiency, the company developed built-in spindle for CNC lathes. Integrated design allows smaller spindle with low vibration and noise and easy maintenance. With the concept of intelligent design, built-in spindles detect inner temperature and vibration. Because of the detect sensors, the efficiency and lifetime of spindles are improved. The company markets its products globally, including China, USA, Germany, Japan, India, Indonesia, Brazil, Turkey, Singapore, Malaysia, etc. HIWIN Technologies: The company is specialised in manufacturing motion control and system technology. It supplies precision critical components to many hi-tech industries for machine tools, medical equipment, material handling, automotive, and energy saving industry. The company has also opened a new page of intelligent automation by robots. It has launched a robot series from multi-axis robots
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(6-axis robot, SCARA Robot, Delta Robot, Wafer Robot) to medical robots (Robotic Gait Training System, Hygiene System and Robotic Endoscope Holder) that provide a friendly working environment and a better life to human society. Goodway Machine Tool Group: The company’s marketing networks have been covering 45 nations and regions, and creating a well-known image in Japan, Germany, Italy, China, USA, Turkey, Bulgaria and ASEAN. Its customers mainly focus on automobiles, dies & moulds, energy, electronics and medical equipment. Meanwhile, along with development of aerospace sector, the advanced multi-axis machines of the group have high acceptability in the global market. Nowadays, along with the trends of Industrial 4.0, the GOODWAY GROUP has been putting lots of efforts, developing intelligent software system and automatic equipment to meet future requirements. GSA Technology: As a professional CNC rotary table manufacturer in Taiwan, the company spends huge investment on importing superior machining equipment and inspection facilities from Germany and Japan to ensure quality. The company produces mainly CNC rotary tables and CNC turrets. It has a joint-venture factory in India. The selfdeveloped product—with high torque, high accuracy, zero backlash and lengthy lifetime, is able to compete with European machine tools manufacturers. Litz Hitech: Specialised in manufacturing CNC vertical machining centres, CNC horizontal machining centres, CNC turning centres, double-column machining centres and 5-axis high-precision machines, the company is a part of M-Team alliance, that brings machine tool products of high performance, most applicable to the defence and aerospace industry. At TMTS 2016, it will feature the concept of ‘do-in-one’ by exhibiting 5-axis and turning and milling compound machines, which can achieve high accuracy and high efficiency machining with the capabilities of one-time loading and clamping, multi-
EM | Aug 2016
PREVIEW | EVENT
faces production and process intensification, leading to high ROI by reducing the delivery time. The exhibition also sees the debut of LITZ turning and milling machine, TM-2500. FEMCO: A multi-divisional steel manufacturing company operating in diversified commercial industries, its machine tool brand FATEK (Factory Automation Technology) designs, manufactures, sells & distributes a full line of CNC machine tools including CNC lathes, CNC vertical lathes, CNC horizontal boring mills, CNC wheel turning machines and CNC housing type plano mills. At TMTS 2016, the company will display automatic virtual metrology system (AVM) for wheel automation line coping with upcoming trend of Industry 4.0. As emphasised by David Chuang, Chairman, FEMCO, the precision outcome from the AVM system even receives an almost equally high result as from the CMM. The company has its Indian subsidiary based in Pune to meet the demand of Indian market. Tongtai Machine & Tool: Specialised in producing customised machine tools, machining centre, CNC lathe and PCB drilling machine, the company manages the entire machine manufacturing process from choosing appropriate machine model to constructing that machine and assuring its high performance. It has established ‘Tongtai Technical Application Center’ (T-TAC) to provide advanced machining technologies, machining solutions as well as trial tests to customers. During TMTS 2016, the company will exhibit 6 machines including VTX-7 (CNC milling and tapping centre), VP-8 (Vertical Machining centre), VC-610 (Vertical Machining Centre for high speed contouring), MT-2000 (CNC lathe), TD-2000Y (Multi-tasking turning centre) and SH-4000P (horizontal machining centre). The company also has developed ‘PFB additive manufacturing equipment AM250’ for which it is rewarded with 24th Taiwan Excellence Award. It has set-up new business in India and Iran.
EM | Aug 2016
You Ji Machine Industrial: Specialised in manufacturing CNC vertical lathe, CNC horizontal lathe, CNC horizontal machining centre and CNC aluminium wheel NC, the company sells its products in India through Cosmos Impex’s imported machine division. It has developed horizontal floor type milling and boring machine as well as double column 5 faces machining centre. It has launched 130 mm and 150 mm spindle quill diameter horizontal boring machine to local and foreign markets covering Asian, European and South American countries. Its machines are majorly used by automotive and aerospace companies. ☐
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T E C H | TA L K
Coolants - what is it and why is it used?
In a typical machining operation, two-thirds of the heat is generated as a by-product of shearing off the workpiece material. The other one-third is created by the friction of the chip sliding over the cutting tool. High temperature in the tool results in rapid tool wear, and high temperature in the workpiece can change its metallurgical characteristics and hardness, create unwanted thermal expansion, or lead to unwanted chemical reactions such as oxidation. This is why the tool and workpiece must be kept cool by using a coolant. 80% of the heat generated is carried away by chips and coolants take away the rest. Coolants also act as a lubricants, reducing the friction between the tool and workpiece that generates heat. The lubrication also prevents built-up edge. Types of coolants There are various kinds of coolants: oil, oil-water emulsion, aerosols (mists), and air or other gases. They may be made from petroleum, plant oils, water, compressed air and compressed CO2. The most popular coolant is an emulsion of water and mineral oil. Water is a good conductor of heat but cannot be used directly as a coolant because it boils quickly, promotes rusting of machine parts, and is not a great lubricant. Mineral oil is a great lubricant, but is poor at heat dissipation. When water and mineral oil are mixed with other ingredients, one gets an optimal coolant. This mixture is designed to inhibit rust, tolerate water hardness, resist thermal breakdown.
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G V Dasarathi Director – Applications Cadem Technologies das@cncetc.in
I m a g e c o u r t e s y : Cadem Technologies
This article talks about the importance of using coolants in machining operations and the different types of coolants available in the market
80% of the heat generated is carried away by chips and coolants take away the rest
Additives in coolants Among the additives are rust-preventers and bacteriainhibitors. When the water evaporates, the additive forms a thin protective film on the workpiece and prevents rusting (which is oxidation). ‘No coolant’ is better than ‘Intermittent coolant’. Intermittent coolant alternately heats and cools the tool and workpiece and can lead to thermal cracks, and is hence worse than no coolant at all. ☐
EM | Aug 2016
NEWS | TECHNOLOGY
Industrial Ethernet, I/O system
Drilling tools
Beckhoff has introduced EtherCAT P with a wide range of IP 67 I/O options. The extensive IP 67-rated I/O range available for EtherCAT P minimises wiring requirements and facilitates the highly flexible, decentralised data acquisition of all I/O signals in a machine or system. With EtherCAT P, Beckhoff combines ultra-fast EtherCAT communication and power supply (2 x 24 V DC/3A) in a standard 4-wire Ethernet cable. It enables direct power supply for both EtherCAT P slaves and the connected sensors and actuators in EtherCAT P I/O products such a way that separate power lines can be eliminated, considerably simplifying system cabling. EtherCAT P, which is now fully supported by the EtherCAT Technology Group (ETG), reduces material costs for machinery, time and cost of installation as well as the frequency of errors in the installation process. In the machine itself, it also minimises the installation space required for drag chains, cable trays and control cabinets. The entire automation process benefits from the reduced size of sensors or actuators are made possible.
Dormer offers PFX range of drill tools that improves versatility and productivity to meet most deep-hole drilling needs. Providing a costeffective option for a wide range of applications, all PFX drills are manufactured from high speed cobalt steel and suitable for use in a variety of materials for drilling depths from 3xD to 25xD. This includes 3xD stub (A920, A921), 6xD jobber (A900, PFX deep hole drill range A901), 10xD long series (A940, A941) and 15xD to 25xD extra length (A976, A977, A978). All feature a straight shank and parabolic flute design for increased chip space and improved evacuation. This design allows greater hole-depths to be achieved in some cases without the need for pecking. A thick web increases the structural strength of the drill for greater rigidity and minimises the risk of tool breakage. In addition, a special point geometry provides additional benefits including excellent centering, eliminating the requirement for a pilot hole and reducing the cycle time of the application. Also, it reduces thrust force and power requirements, ensuring accuracy is maintained.
Beckhoff Automation | Pune
Dormer Pramet | Gurgaon Email: info.in@dormerpramet.com | Tel: +91-124-470-3825
Email: info@beckhoff.co.in | Tel: +91-20-4000-4800
Milling cutter
Deep-hole drilling machine
Gühring has developed a new Ratio end mill, the RF 100 Diver milling cutter that covers five operations with one tool. Called the all-rounder amongst end mills, the tool can perform five operations involving drilling, ramping, slotting, roughing and finishing, thereby, reducing the tool consumption. The Diver end mill works at very high cutting speeds on all materials which results in faster machining at a lesser tooling cost. For RF 100 Diver customers with constantly changing tool requirements and a high demand for machining flexibility, the company’s new development is an optimal solution. The RF 100 Diver establishes new standards for plunging that is able to plunge up to a ramping angle of 45°. Thanks to this unique technical characteristic with the RF 100 Diver, a seamless transition from slotting to drilling can be achieved – and in most materials. Due to the steep plunging angle, an enormous amount of material can be removed. At the same time, excellent chip evacuation can be achieved, which results in high process reliability.
HONG JI offers new deep-hole drilling machine, CNC ST-3000. With drilling capacity from ø5 mm to ø40 mm and the maximum drilling length of 3000 mm, this bed type machine is suitable for drilling water line of big plastic moulds, oil channel of spindle sleeve for heavy-duty turning machine and parts of hydraulic press machine. All axes are hardened slide ways made by cast iron with surface hardness HRC60 to offer a stable CNC ST-3000 performance for drilling big holes with the range of 3000 mm length. The machine spindle is equipped with high-precision bearings imported from German companies to offer stable spindle rotation upto 6000 RPM. The dimension of worktable is 3000x1000 mm and can be loaded upto 20 tons components owing to 200 mm width of hardened slide way of X-axes. It also has 2 metres width of main column and two sub-columns to support Y-axes movement. Hence, processing is as stable as drilling holes in high position of component. The machine structure can uphold upto 40 tons.
Gühring India | Bengaluru Email: sklnprasanna@guhring.in | Tel: +91-80-40322500
EM | Aug 2016
HONG JI Precision Machinery Ltd | Taiwan Email: jasonlin@hong-ji.com.tw | Tel: +886-4-23350356
77
TECHNOLOGY | NEWS
Plastic strain wave gearing for robots
Replaceable head drill
igus expands the robolink modular kit with new plastic strain wave gearing for low-cost robotics. The robolink D modular kit from igus offers users the ability to assemble cost-effective custom robotic systems. Now the company has further expanded its range to offer more scope for design. This gives the ability to combine motors and joints in several sizes with the standard controls to make a complete 6-axis low-cost robot made of plastic and Plastic strain wave gearing for a aluminium. The strain wave gearing robolink joint has the advantage that it has minimal backlash and thus ensures a precise adjustment with incredible smoothness. It is very compact and has a high transmission ratio. The gearbox consists of an outer ring gear and a flexible wear-resistant inner ring gear made of iglidur high-performance plastic. The company also offers a decoupled option of motor and joint. The two components are connected to each other by an aluminium profile – the result is a better weight distribution on the axis, whereby more load can be lifted.
MAPAL has further developed the triple cutting edged Tritan-Drill to bring the first standard triple cutting edged replaceable head drill to the market. Replaceable head systems in the machining industry are the first choice when it comes to meeting the demands of rising raw material prices, resource efficiency and streamlining of stocks. On the TTD-Tritan-Drill, TTD-Tritan-Drill tool head and tool holder are joined by Hirth serrations. This connection is particularly stable so that all the benefits and the performance level of the solid carbide equivalent are fully retained with the replaceable head variant. It can be used reliably and stably even in difficult drilling situations, such as with inclined bore entrance or in cross bores. The tool is perfectly centred via its pronounced drill tip and ensures very good connection at lower costs, because with the new replaceable head system, the use of costly carbide is limited to the tool head. This guarantees lower costs even with large diameters and ensures optimum torque transmission.
igus (India) | Bengaluru
MAPAL India | Bengaluru
Email: santhosh@igus.in | Tel: +91-80-45127810
Email: info@in.mapal.com | Tel: +91-80-41782500
Optical incremental encoder
Modular assembly systems
Renishaw offers VIONiCplus™, a new optical incremental encoder system that has been launched as part of the VIONiC™ digital all-in-one encoder series. The VIONiC design combines all necessary interpolation and signal processing inside the readhead and eliminates the requirement for additional external interfaces. To this end, the company developed a new Versatile Interpolation ASIC (VIA) chip to perform all of the functions originally executed by the interface. VIONiCplus Other features, working in conjunction with the Advanced Diagnostic Tool (ADT), bring the end-user wide-ranging monitoring and diagnostic feedback. The VIONiCplus incremental encoder is the culmination of research into the latest fine compensation architectures and advances in modern optimisation algorithms leading to unparalleled heights of performance. By leveraging advances in digital interpolation and signal processing techniques, the company has built an encoder with Sub-Divisional Error (SDE) below ±10 nm – unprecedented from a 20 µm-pitch scale. VIONiCplus is the first conventional optical encoder to deliver the performance advantages of ultra-fine pitch (<4 µm) systems with numerous additional benefits.
Schunk has introduced new quick-adjustment module and clamping unit for high-performance assembly with more than 10,000 possible combinations. At the core of the design is a unique support column system consisting of numerous standardised pillar profiles, adapter plates, centering and connecting elements and offering maximum flexibility of the system design. To further expand the application possibilities, the company now presents two new components – the SCHUNK VEH adjusting unit and the SCHUNK APDA mounting plate. The SCHUNK VEH adjusting unit enables especially easy and precise fine adjustment of handling systems. The flat and compact quickadjustment module can be directly positioned under the bases of pick & place units or other handling VEH (below) + modules. The SCHUNK APDA mounting plate APDA (above) expands the already very diverse combination options of the modular system. It allows mounting of components directly above existing pillars in order to produce especially compact solutions. The mounting plate offers diverse mounting options on all five surfaces and is ideal for pillar diameters of 55 mm and 35 mm.
Renishaw | Pune Email: samina.khalid@renishaw.com | Tel: +91-20-4900-1589
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SCHUNK Intec India | Bengaluru Email: info@in.schunk.com | Tel: +91-80-40538999
EM | Aug 2016
NEWS | TECHNOLOGY
Solid-carbide end mills
High precision machines
Seco Tools offers Jabro ®-Solid2 JS554 range of solid-carbide end mills with smaller neck diameter options to increase application range, thereby, gaining further utility and versatility. These latest tools provide greater clearance when machining complex components, such as those found in aerospace, medical and general machining applications. Smaller neck dimensions make it easier to access parts clamped in complicated fixturing arrangements, as well as enable users to take full advantage of 4-axis and 5-axis machining capabilities. The neck sizes are optimised to retain tool rigidity while providing full compatibility with standard toolholder connective systems. The tools maintain their ability to productively machine materials in the ISO P, M, S and other material groups. JS554 Jabro®-Solid2 JS554 end mills provide high stability and low deflection. They also bring an excellent price-performance ratio to a range of applications, and these latest additions further expand the line’s advanced capabilities. The range of JS554 end mills covers tool diameters from 3 mm to 20 mm and typical cutting lengths 2xD + 2 mm.
Thielenhaus Microfinish has developed a flexible and compact machining solution – Sphero – based on platform proven in medical technology. This high-precision tool machine is equipped with a tool spindle unit that can swivel up to 90 degrees, allowing the optimal machining position to be chosen for every process. The clamped workpiece rotates at up to 4,500 revolutions per minute. This, in combination with the Microfinish tools’ corresponding form, enables the absolutely reliable machining of the entire outer surfaces of spheres and the inner surfaces of cups. The Sphero associated tool unit is arranged vertically and is easily accessible for quick retooling. Due to the integrated tool changer with capacity for up to ten tools, even complex machining processes can be carried out in only one clamping process. If necessary, a polishing process can be integrated following the Microfinish machining process. Workpieces with diameters of up to 75 mm can be machined on the Sphero. However, very small tools can also be used, and even thin-walled components can be machined.
Seco Tools India | Pune Email: seco.india@secotools.com | Tel: +91-2137-667300
Thielenhaus Microfinish India | Chennai Email: info@thielenhaus.in | Tel: +91-44-2433-7800
Indexable holemaking platform
Absolute encoder
WIDIA has introduced new Top Cut 4 indexable drilling platform targeting end users that machine a broad assortment of products and need one drill for a variety of drilling applications and workpiece materials. Expanded capabilities and improved performance combine for outstanding results in the new Top Cut 4™ indexable holemaking platform. Top Cut 4’s breadth of application capabilities include through- and cross-holes, inclined entry and exit opportunity, 45º corner, half-cylindrical, concave, and chain drilling. And four true cutting edges combined with Top Cut 4 WIDIA-grade technology results in notably higher speeds and feeds, higher metal-removal rates, and extended tool life, all of which means lower cost per edge. Top Cut 4 periphery and center inserts each feature proprietary cutting profiles for excellent centering capability and workpiece penetration. The inner and outer (center and periphery) inserts are clearly differentiated for no mixups, and are available in grades for high-speed applications, high toughness demands, and high metal-removal rates in general. Specific geometries are available with reinforced cutting edges and a steep chipbreaker.
Hengstler offers new ACURO ® AX65 encoder with dimensions of 70 mm depth and 59 mm diameter – typically half the size of conventional explosion-proof encoders. This will prove extremely valuable to system designers seeking space-saving solutions. Furthermore, the fact that the device can be replaced separately from the cable, the presence of fewer hood screws, and the potential for ring network configuration (less wiring), makes the AX65 an attractive proposition for customers looking to lower their total cost of ownership (TCO). Among numerous attributes, international explosion-proof certification (both ATEX and IECEx for mining, gas, dust) makes the AX65 ideal for global markets that include oil and gas platforms, mines ACURO® AX65 encoder and chemical plants to list a few. Moreover, the design team at Hengstler has also ensured that AX65 is equally adept in environments subject to constant salt water exposure (thanks to the use of a marinegrade stainless steel housing), while shock resistance of 2000 m/s² and axial/radial shaft load capability of 300 N are some of its other features.
Kennametal India | Bengaluru Email: bangalore.information@kennametal.com | Tel: +91-80-480-57369
EM | Aug 2016
Hengstler | Germany Email: info@hengstler.com | Tel: +49-0-7424-890
79
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 - Sep 2016 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Senior Features Writer Megha Roy megha.roy@publish-industry.net
» Hydraulics & Pneumatics The fundamental drivers of change in the fluid power segment include safety, standards & compliance, manufacturing efficiency, and operational efficiency. The next issue will give insights on these emerging trends, technologies and innovations in hydraulic and pneumatic systems in industrial applications, with application stories as examples.
» Test & Measurement Many companies are considering the need to reduce test costs, while improving productivity by incorporating latest test & measurement technologies. The subsequent issue will highlight compact articles from domain specific industrial experts. » Workholding & Fixturing In recent years, there has been a significant change in the design of workholding & fixturing, which are crucial to the support environment of these highperformance machines. The next edition will discuss these trends.
» Additive Manufacturing Additive Manufacturing refers to a process that builds 3D objects by adding layer-upon-layer of material. The term AM encompasses many technologies including subsets like 3D printing, Rapid Prototyping (RP), and Direct Digital Manufacturing (DDM). The upcoming edition will feature how AM is reinventing the way we work in recent years.
Features Writer Maria Jerin maria.jerin@publish-industry.net Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugoud Patil (Senior Manager – 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 Jogindar J Dumde (Graphics Designer) jogindar.dumde@publish-industry.net
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . .Page Ace Manufacturing Systems . . . . . . . . . . .26 Ace Micromatic Group . . . . . . . . . . . . . . .41 AMT . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Beckhoff Automation . . . . . . . . . . . . . . 1, 77 Bharat Fritz Werner . . . . . . . . . . . . . . . . .33 Blaser Swisslube . . . . . . . . . . . . . . . . . . .47 Cadem Technologies . . . . . . . . . . . . . . . .76 CMTBA . . . . . . . . . . . . . . . . . . . . . . . . .10 DesignTech Systems . . . . . . . . . . . . . 10, 58 Dongguan Glorystar Laser Technology Co . .23 Dormer Pramet . . . . . . . . . . . . . . . . . . . .77 Durr Ecoclean. . . . . . . . . . . . . . . . . . . . .71 Emerson . . . . . . . . . . . . . . . . . . . . . . . .44 EuroBlech . . . . . . . . . . . . . . . . . . . . 11, 29 ExxonMobil Lubricants . . . . . . . . . . . . . . .10 Fatty Tuna India. . . . . . . . . . . . . . . . . . . .13 FEMCO . . . . . . . . . . . . . . . . . . . . . . . . .72 Forbes & Company . . . . . . . . . . . . . . . . .17 Gedee Weiler . . . . . . . . . . Front Inside Cover Geometric . . . . . . . . . . . . . . . . . . . . . . .11 Goodway Machine Tool Group . . . . . . . . . .72 GSA Technology . . . . . . . . . . . . . . . . . . .72 Gühring India . . . . . . . . . . . . . . . . . . 14, 77 Hartford Motors . . . . . . . . . . . . . . . . . . .72 Hengstler . . . . . . . . . . . . . . . . . . . . . . . .79
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Name . . . . . . . . . . . . . . . . . . . . . . .Page HIWIN Technologies . . . . . . . . . . . . . . . . .72 HONG JI Precision Machinery . . . . . . . 35, 77 Hyundai WIA India . . . . . . . Back Inside Cover ifm electronic India . . . . . . . . . . . . . . . . .51 IFS world . . . . . . . . . . . . . . . . . . . . . . . .18 igus (India) . . . . . . . . . . . . . . . . . . . . . 2, 78 IMTMA . . . . . . . . . . . . . . . . . . . . . . 55, 62 J J Strossmayer University of Osijek . . . . . .30 Janatics India . . . . . . . . . . . . . . . . . . . . .43 Jyoti CNC Automation . . . . . . . . . . . . . . . .3 Kennametal India . . . . . . . . . . . . . . . . . .79 Keyarrow . . . . . . . . . . . . . . . . . . . . . . . .72 Kirloskar Ebara Pumps . . . . . . . . . . . . . . .12 Kirloskar Pneumatics . . . . . . . . . . . . . . . .62 LANXESS . . . . . . . . . . . . . . . . . . . . . . .12 Litz Hitech . . . . . . . . . . . . . . . . . . . . . . .72 MAPAL India . . . . . . . . . . . . . . . . . . . . .78 Messe Munchen . . . . . . . . . . . . . . . . . . .39 Micromatic Machine Tools. . . . . . . . . . . . .62 Mitsubishi Elevators India . . . . . . . . . . . . .12 MMC Hard Metal. . . . . . . . . . . . . . . . . . .15 MotulTech India . . . . . . . . . . . . . . . . . . .37 Murrelektronik India . . . . . . . . . . . . . . . . .69 Pilz India . . . . . . . . . . . . . . . . . . . . . 40, 57 POSA Machinery . . . . . . . . . . . . . . . . . . .72
Name . . . . . . . . . . . . . . . . . . . . . . .Page PTC . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Renishaw. . . . . . . . . . . . . . . . . . 54, 61, 78 Rolls Royce . . . . . . . . . . . . . . . . . . . . . .24 SCHUNK Intec India. . . . . . . . . . . . . . 48, 78 Seco Tools . . . . . . . . . . . . . . . . . . . . . . .79 Siemens . . . . . . . . . . . . . . . . . . . . . . . .36 SMC Pneumatics. . . . . . . . . . . . . . . . . . .45 Stratasys AP. . . . . . . . . . . . . . . . . . . . . .26 Stratmann Consulting . . . . . . . . . . . . . . . .26 Suhner India. . . . . . . . . . . . . . . . . . . . . .16 TaeguTec India . . . . . . . . . . . . . . Back Cover Thielenhaus Microfinish . . . . . . . . . . . . . .79 TMBA . . . . . . . . . . . . . . . . . . . . . . . 53, 72 Tongtai Machine & Tool . . . . . . . . . . . . . .72 Triune Exhibitors . . . . . . . . . . . . . . . . . . .11 U Tech Associates . . . . . . . . . . . . . . . . . .49 UCAM India . . . . . . . . . . . . . . . . . . . . . .21 UCIMU . . . . . . . . . . . . . . . . . . . . . . . . .12 University of Ljubljana . . . . . . . . . . . . . . .30 Vargus India. . . . . . . . . . . . . . . . . . . . . . .6 VDW . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Wendt India . . . . . . . . . . . . . . . . . . . . . .65 YG1 Cutting Tools . . . . . . . . . . . . . . . . . 4,5 You Ji Machine Industrial . . . . . . . . . . . . .72
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EM | Aug 2016