EM Feb 2019

VOL 10 | FEB 2019 | ` 100 www.industr.com/en

EFFICIENT MANUFACTURING

PRODUCTION ECONOMICS

Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong

Maximising manufacturing operations

FOCUS Automotive Steel EM - Interview

EM - Interview

Sanjay Koul, Chairman & Managing Director, Timken India (p. 26)

Aravind Melligeri, CEO & Chairman, Aequs

(p. 28)

P. 34

SPECIAL FEATURE Composite Machining

P. 46

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E D I TO R I A L

Portending exciting advances The trade show dynamics are changing. The trade shows today are no longer reflecting the use of the old sales catalogues, they are becoming modern marketing machinery. For the organisers, the focus is now more on added value, which will entail bringing the right people together in the right place. For exhibitors, the emphasis is now more on personalisation, communicating specific information pertaining to visitors’ interests, through personalised digital offerings like apps, beacons, virtual reality, and social media. On the other hand, visitors who are well-informed about the developments visit the show with specific objectives, and are more interested in engaging in productive networking.

All of the trends portend exciting advances and changes in the trade show space, and this was very much visible in the recently concluded IMTEX and Tooltech.

IMTEX this year, on the occasion of its 50th anniversary, was much bigger than its earlier editions, with over 91000 visitors and over 1200 exhibitors. There were new topics and new halls added to this year’s show. The most noteworthy trend this year, which I am sure everyone must have observed, was an increased emphasis on customised solutions than standard products. Exhibitors were keen on understanding the market requirements to offer customised solutions pertaining to specific needs. There were more live demos this time to help visitors bring in relevance to their applications. Most of the visitors whom we interacted with visited the show with the objectives of “sourcing new solutions” and “staying up-to-date with market trends”. We captured the views of a few exhibitors in the Viewpoint section of this issue, who were quite optimistic on the manufacturing industry growth post-IMTEX. I am sure, you will find it an interesting read! Please do write to us with your feedback.

“The trade shows today are no longer reflecting the use of the old sales catalogues, they are becoming modern marketing machinery”

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

EDITORIAL ADVISORY BOARD Raghavendra Rao Senior Vice President Manufacturing & Process Consulting Frost & Sullivan

Dr N Ravichandran Former Executive Director Lucas-TVS Chief Mentor, UCAL Fuel Systems

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

N K Dhand CMD, Micromatic Grinding Technologies

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

Vineet Seth Managing Director Mastercam India

Dr Wilfried Aulbur Managing Partner Roland Berger Pvt Ltd

Sonali Kulkarni President & CEO Fanuc India

Dr Ravi M Damodaran Chief Technology Officer Greaves Cotton

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

EM | Feb 2019

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CONTENTS

Market

Management

10 NEWS

INTERVIEW 26

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“Initiating positive momentum for a bright future of cleantech in India”

Interview with Dr Sylvain Lemofouet, Co-Founder & CEO, Enairys Powertech START-UP 16

Focus

“IoT is quickly becoming mainstream”

AUTOMOTIVE STEEL

“Localisation and quality of the product is important”

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Sanjay Koul, Chairman & MD, Timken India 28

Steel & AHSS in automotive: Prominence and impact

The article discusses the importance of steel in the automotive sector and explores the use of AHSS in vehicle design

“OEMs prefer to work with SMEs” Aravind Melligeri, CEO & Chairman, Aequs

LEADERSHIP INSIGHTS 18

Vishal Mehra, Vice President & Director, iRam Technologies

“Embracing excellence!”

Tim Cook, CEO, Apple Inc

VIEWPOINT 30

IMTEX 2019: Exploring the visitor mindset

This section takes a peek into the visitor mindset and finds out how exhibitors’ exchanges have changed over the years

COVER STORY 20

Production Economics: Maximising manufacturing operations

Machine shops seek to produce a certain number of parts of a certain quality, in a certain amount of time, at a certain cost. Consistently achieving these goals involves controlling a myriad of factors including cutting parameters, tool cost and changeover times, machine tool utilisation, workpiece handling expense and material and labour costs. This cover story explores the importance and advantages of HVLM and HMLV considerations during production and manufacturing.

EM – the only industrial magazine in India that offers a three-dimensional perspective on technology, market and management aspects of manufacturing

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EM | Feb 2019

em.india@publish-industry.net | www.efficientmanufacturing.in | Ph.: +91 20 6640 5754

CONTENTS

Technology

CAD/CAM 38

Tackling greater challenges with CAM solutions

WELDING 42

The article explores how an entire machine shop can be run with one CAM software package

Exploring the role of Big Data in welding technology

This article offers an overview of the challenges and practical functions of Big Data in welding technology SPECIAL FEATURE

ENGINEERING MATERIALS 40

Scaling manufacturing obstacles with Additive Manufacturing

The article explores the advancements in Additive Manufacturing, which has liberated the production of components across industries from inefficiencies

46

Composites and its significance in the aerospace & defence sector The article explores two areas, which can be a source for bottlenecks when working with composites—springback and manufacturing planning

New Products 50 Cutting-edge analysis for perfect solutions 52 Intelligent single crank power press; Customised tandem lines; Milling grades for finishing applications; Compact 5-axis machining centres 54 Energy efficient air compressor; Turning inserts; Cutters for titanium processing; Stock dispensing system

Columns 05 06 08 56 56

EM | Feb 2019

Editorial Contents Guest Editorial Highlights – Next issue Company index

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Dr CSS Bharathy

CERTIFIED INDUSTRY 4.0 PROFESSIONAL, FOUNDER—FUSIONVR

Since the emergence of the Smart Factory concept in manufacturing, Digital Twins have become a vital part of Industry 4.0. In reality, the mainstream adoption of Industry 4.0 is not going to be immediate since the infrastructurereadiness level is yet to improve in most countries. However, existing case studies and reports make it evident that the next five to ten years are going to be the key for this radical digital transformation.

Digital Twins are virtual clones of their physical counterpart—connected and streaming data in real-time. They are not just the digital prototypes or CAD models.

This metaverse has the potential to represent most elements and dynamics of the physical world with remarkable productivity boost.

The entire lifecycle of an equipment, starting from design to creation, operation, troubleshooting and maintenance can be enhanced through Digital Twins.

Fusing the digital and physical worlds through immersive experiences, such as, Augmented Reality (AR), Virtual Reality (VR) or Mixed-Reality (MR) adds the real value to Digital Twins. This immersive technology adds additional perspectives 8

COMMENTS & COMMENTARY

GUEST | EDITORIAL

COMPANIES SHOULD REALISE THAT THEIR EXISTING DATA FROM THE PAST IS AN INVALUABLE ASSET to virtual objects, such as, depth, volume and scale in relation to the viewer, which helps the decision-makers to visualise huge volumes of data in a more natural, holistic and easily understandable 3D-space, for much faster and more informed decision-making.

The basic remote monitoring functionality of this virtual replica provides the ability for deep understanding of equipment and processes. Through implementing the concept of Digital Twins, enterprises can take the advantage of datadriven decision-making for enhanced production and profitability. Incorporating AI, computer vision, Extended Reality and Cognitive Computing abilities will make the ultimate Digital Twin, which can enhance performance, perform predictive

analysis, simulate tricky scenarios and even control processes.

Industries today are in a critical situation to make the strategic decision on moving towards these disruptive landscape and related investments. Conventional thinking on tangible investments, such as upgrading the machineries alone is never going to sustain businesses in the future.

Intangible asset creation, such as, Digital Assets and IPs are equally important to increase operational efficiency.

Companies should realise that their existing data from the past is an invaluable asset, which holds their best and worst production history in their DNA. Even though 80 per cent of this data is unstructured in most cases, these are the intangible assets, which have a clear advantage during digital transformation. Industries should make use of sensor price drops (60%), cost of bandwidth drop (40 times) and computing cost drop (60 times) in the last ten years, which are the major cost factors while preparing for the Industry 4.0 adoption. They should also start engaging Industry 4.0 consultants to ensure the right level of investments towards their digital transformation. ☐ EM | Feb 2019

M A R K E T | NNEEWWSS

Bharat Fritz Werner associates with Universal Robots Bharat Fritz Werner recently got associated with Universal Robots with the aim to penetrate the sector with new and affordable automation solutions. This partnership will leverage the productivity in the MSME segment by integration of collaborative robots in manufacturing processes. This aims to disrupt the traditional production setup of the MSME segment with top-notch automation solutions and dramatically impact productivity, quality and working conditions. It also aims to redefine the production processes by deploying robotic arms through a modular, flexible and user-friendly integration solution platform – Arjun. Commenting on the partnership, Ravi Raghavan, Managing Director, BFW, asserted, “This strategic partnership will bring collaborative robot technology on a modular flexible platform to MSME shop floors to enhance their manufacturing competitiveness significantly.”

CERATIZIT Group presents its cutting tool brands for India

CERATIZIT Group recently presented its new cutting tool competence unified brand structure for the Indian market at IMTEX 2019. Over the next few years, under the umbrella of the CERATIZIT Group, the four competence brands cutting solutions by CERATIZIT, KOMET, WNT and KLENK will continue the rapid growth shown in recent years. In the future, as a result of the cutting tool division being reorganised, customers will benefit from the bundled know-how of the four competence brands and access one of the most complete product portfolios in the industry. Present at the ceremony, Ashwani Sareen, Managing Director, CERATIZIT India, said, “We expect a 20 per cent sales growth for current business year as compared to the previous year.”

India’s factory activity expands at the fastest pace in 5 years IHS Markit recently compiled the Nikkei Manufacturing Purchasing Managers’ Index (INPMI=ECI) that rose to 54.7 in December from November’s 52.6, marking its fifth straight month above the 50 level that separates expansion from contraction. Another private sector survey showed that India’s factory activity expanded at the fastest pace in five years in December, buoyed by a rise in output and new orders, which allowed firms to raise prices.

Discussing her views, Aashna Dodhia, an Economist at IHS Markit, said, “Challenges remain as the economy adjusts to recent shocks, but the overall upturn was robust compared to the trend observed for the survey history.”

Mastercam distributes TDM solutions in India

Mastercam India has recently became a part of the TDM Systems partner network along with Sandvik Group. The CAD/CAM expert supports distribution of the TDM software in India. The demand and need for Tool Data Management, in mature Industry 4.0 applications is currently very large in one of the most important growth markets of the world - India. Commenting on the strategic partnership, Vineet Seth, Managing Director – South Asia & Middle East, for Mastercam APAC, said, "We are pleased to partner with another subsidiary of Sandvik - TDM Systems, and through our collective offering, provide customers with a well-rounded solution that involves the tooling system.”

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EM | Feb 2019

NEWS | MARKET

QVI India opens new office in Pune QVI India recently opened a new office in Pune, which was inaugurated by Fred Mason, Senior Vice President—Marketing, QVI USA, in the presence of Therese Corrigan-Bastuk, Product & Brand Marketing Director, QVI USA, along with Shreyansh B Hippargi, Managing Director, QVI India. The Pune office joins the existing headquarter office in Bengaluru. These two offices will act as bases of operations for sales and service of the company’s products in southern India. The company designs and builds a complete line of dimensional measuring systems that combine proprietary optical, laser, and contact sensors for precision measurement of manufactured components and assemblies.

ZF Pune plans to extend plant

ZF Pune recently conducted a groundbreaking ceremony to take the next extension step. The current facility, with its 16,770 sqm built-up space, is fully utilised with today’s commercial vehicle, car powertrain and aftermarket business. By the year-end, a new production complex with 4,000 sqm will be completed and offer additional space to accommodate further production and warehousing activities. Stating his views on expansion, Dr Holgen Klein, Member of Board of Management, ZF Friedrichshafen AG, stated, “This investment is a strong signal for the region and the commitment to grow business in it. India is an important growth market for ZF and therefore, we are expanding our presence here.”

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EM | Feb 2019

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MARKET | NEWS

IMTEX 2019 & Tooltech 2019 attracts 91,446 visitors Indian Machine Tool Manufacturers’ Association (IMTMA) recently organised the 50 th IMTEX & Tooltech 2019, at Bangalore International Exhibition Centre (BIEC), Bengaluru, on January 24-30, 2019. The event created a new record by attracting 91,446 visitors along with 1,222 exhibitors from 26 countries across the globe and had 7 country pavilions.

The exhibition featured several domestic and foreign visitors who sourced machines for their production units and showcased technologies which are vital for moving the Indian manufacturing and machine tool industry forward.

Marking 50 years, IMTMA introduced a series of new initiatives which were unravelled during the event.

Additive Manufacturing and Factory of the Future (Industry 4.0) are technologies heralding a new era in manufacturing, on which IMTMA had special pavilions and seminars. An Experience Zone was set up adjacent to Hall 4 in BIEC. The zone had an archaic collection of the IMTEX journey, including a display of vintage machines from a bygone era, pictures and a short film on the journey. IMTMA also released an IMTEX Coffee Table Book on January 25, 2019. The book captures the ethos of IMTEX and traces its growth over a timeframe of 50 years since 1969.

Besides, IMTMA constituted an Eco Design Award to encourage the adoption of eco-friendly practices in exhibition stalls. Six companies were conferred with awards in various categories.

Additionally, an International General Managers’ Meeting was held during the exhibition so as to exchange ideas, share knowledge and network. Another attraction for visitors was the presence of two humanoids to connect with technology in the campus during the show. Parallel events organised during IMTEX also had good turnouts. These events included, International Buyer-Seller Meet, i2 Academia Pavilion (a platform for academic institutions to showcase their research for the industry), Manufacturing Quiz Contest and Jagruti-IMTMA Youth Programme to familiarise engineering students with the machine tool industry. An International Seminar on Machining held a day prior to IMTEX on January 23, 2019 attracted about 350 delegates. Similarly, overall more than 150 trade delegations attended the exhibition. IMTEX 2019 & Tooltech 2019 has opened doors for the manufacturing industry to embrace new-age technologies and become competitive at the global level.

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EM | Feb 2019

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MARKET | INTERVIEW

“Initiating positive momentum for a bright future of cleantech in India” Dr Sylvain Lemofouet, Co-Founder & CEO, Enairys Powertech, in this interview with Suchi Adhikari, discusses the trends noticed in the cleantech industry, sustainable development, and the significance of the Swissnex Cleantech Week in India. Excerpts…

What are the latest trends and developments in clean energy storage solutions in India as well as globally? How is Enairys Powertech coping with these developments?

The global market for energy storage solutions is growing fast, mainly driven by electro-mobility and the deployment of renewable energies. Electrochemical batteries (Lead Acid, Lithium, Sodium-sulphur, etc) are currently taking the most advantage of this trend. After more than a decade of technology and product development, Enairys is now tapping into this market scene with its innovative HydroPneumatic Energy Storage (HyPES) system, a non-chemical and more sustainable alternative solution primarily intended to support decentralised power generation from intermittent renewable sources (photovoltaic, wind, etc).

With environmental concerns taking prominence globally, manufacturers are looking for increasingly sustainable and ecofriendly solutions. What are the solutions that Enairys Powertech offers, which can cater to this demand?

Enairys proposes an eco-friendly, integrated energy storage and management solution based on compressed air, which provides many benefits that are mainly based on electrochemical batteries. We offer environmental friendliness—due to the use of natural components, easy-to-recycle metals, all-in-one turnkey solution—with the possibility to combine various power sources (wind, photovoltaic, grid, etc), multi-energy solution—due to the capability to deliver or store electricity, air, heat and cold at the same time, thus optimising the overall energy efficiency.

We also offer long service life (+20 years)—related to hydropneumatic and power electronics, and cost competitiveness.

With the global focus on the Indian market, what is your company’s commitment to the Indian market?

India has an ambitious program for rural electrification and

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development of renewable energies, and energy storage is a key enabling technology which is necessary to achieve these goals.

Enairys’s commitment to the Indian market is to supply our clean, smart and affordable energy storage and management solutions to support and participate in the implementation of this program in a sustainable and economically viable way.

As a recent delegate of the Swissnex Cleantech Week India 2018, what challenges and opportunities do you foresee for the cleantech industry?

The main challenge I see for cleantech industry in India is the reduction of the cost of clean solutions to an acceptable level for massive adoption. I am afraid that without public support, this will take time particularly for the energy field, which is a capital-intensive industry; and we don’t have time to address the aforementioned issues. The main opportunity I see is the growing demand for environmentally friendly solutions, driven by local and global concerns. What I realised during my visit is that an effective political willingness is required to address these issues through the creation of favourable regulatory framework for clean technologies and realisation of several mega-projects of renewable energies. So, I think a positive momentum has been initiated to ensure a bright future for cleantech in India where the market potential is huge and Enairys is willing to be part of this future.

What are your company’s short-term and long-term plans for the Indian market?

Our short-term goal is to find a strong strategic Indian partner to produce and commercialise our innovative products in the Indian market. The idea is to firstly build pilot installations to test and validate the market, then develop this market, and later, set up a local production facility and distribution network to successfully serve the whole country. ☐

EM | Feb 2019

S TA R T- U P | I N T E R V I E W

“IoT is quickly becoming mainstream” Vishal Mehra, Vice President & Director, iRam Technologies, in this interview with Juili Eklahare, talks about how it is time for us to leverage IoT, AI and other technological tools to build new smart cities. Excerpts…

Tell us a little bit about iRam Technologies. What was the reason for starting this company?

There is a huge potential in the market regarding IoT-based products, which is why we came up with the idea of starting a company that can provide smart solutions for smart citizens now and in the future. iRam is a product development and technology company with the most advanced solutions based on IoT. The products and solutions from us are specially designed to make urban living more convenient, aligned with the government’s smart city initiative. The solutions are integrated with leading smart city command control platforms.

Where do you see the Internet of Things and its technologies creating the most impact in smart cities? How will the ‘Public Smart Parking’ for Bhubaneshwar, Kanpur & Nasik smart cities help smart cities to plan for new investments in parking spaces at required areas in the city?

A smart city is considered smart due to its inherent intelligence in dealing with its resources and environment by harnessing the potential of IoT and AI. As parking is a challenge that our cities are grappling with, we have developed IoT-enabled Smart Parking Solutions that are conducive to the Indian conditions.

Recently, we won smart parking projects for Bhubaneshwar, Kanpur & Nasik, wherein we will be installing our IoTbased smart parking technology, including parking gateways, parking management software, sensors, citizen application at 87 sites in Bhubaneshwar, 42 sites in Kanpur and 33 parking sites in Nasik, respectively. With this deployment, respective smart cities will be able to provide citizens convenience to find and reserve parking. iRam’s Smart Parking Solutions can be

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deployed in on-street, off-street and covered parking spaces.

What emerging technologies need to be deployed to help realise the smart city vision?

It is time for us to leverage IoT, AI and other technological tools to build new smart cities and transform the existing ones to unleash their true potential. Smart cities have started adopting various technologies like, IoT, etc, which make use of various components to create a connected network of devices across the city. The system of actuators and sensors play a key role and impact all levels of functioning in the city.

What are the significant shifts you see in IoT? Today, IoT is quickly becoming mainstream.

The reason for this is that IoT-enabled internet has created an extremely rich, heterogeneous array of business and consumer use cases. With the help of IoT, the internet has been transformed into real-time data that can be analysed to make business decisions and improve performance.

What is the road ahead for iRam Technologies?

As of now, we are working together with our partners and the government agencies for successful deployment of the current projects in hand. We are continuously developing new products and improving existing IoT products and solutions that can positively impact urban living. Besides, we are already working with another half a dozen upcoming smart cities and municipal corporations in India on various use cases and business models, which can be driven through our existing product line of smart parking, intelligent poles, smart street lighting and smart environment. ☐

EM | Feb 2019

LEADERSHIP INSIGHTS

Embracing excellence!

Tim Cook CEO APPLE INC

An enterprising leader and declared as one of the world’s most powerful people

by Forbes, Tim Cook is the Chief Executive Officer of Apple Inc. Being the face behind the world’s most easily recognisable company, he has been incredibly successful in adding to its global value. Under his diligent leadership, Apple has become the first public company in the US to be regarded as a $1 trillion company in terms of net worth.

Cook completed his industrial engineering degree from Auburn University followed by an MBA from Duke University.

In his early career, he worked for IBM for 12 years, and also served as the COO of Intelligent Electronics and Vice President for Corporate Materials at Compaq. His consistency, desire for excellence and several accolades made him stand out as one of the emerging leaders in the business world, and initiated him into his career as Senior Vice President at Apple in 1998.

In his new role, he was successful in revitalising Apple, making the company what it is today. He has not only dedicated his interests towards Apple, but is also well known for his philanthropy. Publicly declaring that he would donate his 18

BE THE BEST, NOT THE FIRST! entire stock of $120 million in charity, he famously stated, “You want to be the pebble in the pond that creates the ripple for change.” He is also dedicated to the development of his country, investing $350 billion to the US economy, and has promised to add 20,000 new jobs.

As the company’s CEO, the generous leader has made Apple the most profitable business in the world, and has pushed it to enter new territories. He has not only increased the user base of the iPhone, but has also partnered with IBM and Cisco, opening doors to specialised technology.

The introduction of the Apple Watch has also been a massive achievement and is regarded as the world’s most successful wearable. Plus, he has entered the music streaming industry and focussed on healthcare, Augmented Reality, privacy etc., making Apple a multi-dimensional technology giant, worth billions.

Often known for his democratic, thoughtful and charismatic leadership style, Cook insists on innovation, intuition, diversity and accountability as his core work ethic. His philosophy has always been, “Be the best, not the first”, and has focused his attention towards excellence. He states, “The sidelines are not where you want to live your life. The world needs you in the arena.”Under his leadership, Apple has created over 2 million jobs in America and abroad. His future plans for the company include setting up data centres and an Apple campus for better customer support. The visionary leader has also implemented 100% renewable energy in all of Apple’s facilities in the US. Cook’s dynamism and dedication towards ingenuity truly makes him one of the world’s most influential and powerful people and his legacy stands as an inspiration to young talents across the globe.

Suchi Adhikari SENIOR SUBEDITOR & CORRESPONDENT EM | Feb 2019

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C O V E R S TO R Y | T E C H N O L O G Y

Production Economics

Maximising manufacturing operations

Machine shops seek to produce a certain number of parts of a certain quality, in a certain amount of time, at a certain cost. Consistently achieving these goals involves controlling a myriad of factors including cutting parameters, tool cost and changeover times, machine tool utilisation, workpiece handling expense and material and labour costs. This cover story explores the importance and advantages of HVLM and HMLV considerations during production and manufacturing.

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Patrick de Vos, Corporate Technical Education Manager, Seco Tools

EM | Feb 2019

TECHNOLOGY

C O V E R S TO R Y

Manufacturing first evolved from craft-level, single-item output to mass production of standardised parts using machine tools

Production economics is the art and science of balancing process factors to achieve desired results. Over more than two centuries of machining history, the elements of production economics have multiplied in number. Manufacturing first evolved from craft-level, single-item output to mass production of standardised parts using machine tools. Improving manufacturing methods brought about a second generation of mass production, featuring production lines and output of increasingly greater numbers of identical parts—a high volume, low product mix (HVLM) scenario. Then, CNC machines and robots fostered a third generation of mass production efficiency.

Most recently, digital technology applied in programming, machine tool controls and workpiece handling systems is facilitating a fourth generation of manufacturing production, known as Industry 4.0, that enables cost-efficient, high-mix low-volume (HMLV) production.

To effectively accomplish the shift from HVLM to HMLV production, it is crucial that manufacturers recognise the changing and growing realities of production economics and take advantage of the information and technology available to analyse their operations and meet their goals. A key element of the transformation involves abandoning overly simplistic beliefs and practices and uncovering hidden costs that can undermine attempts to maximise productivity.

High volume, low mix, simple economics Standardised machining processes were developed in the 19th century to speed up production of identical products with interchangeable parts. Automotive manufacturing refined this HVLM approach to a maximum degree, establishing transfer lines and other methods to make hundreds of thousands or millions of the same part over and over for years.

EM | Feb 2019

The long-term nature of HVLM production allows manufacturers to fine-tune multiple process factors for maximum output, consistency and low cost. Ancillary technology, including tool and pallet changers and robots further minimise variability.

It is assumed that the operation runs perfectly and provides 100% yield with predictable costs—no unplanned idle times, no rejects, no rework and no secondary operations, such as, deburring.

One assumption is that tool cost is typically about three per cent of total production cost. The three per cent number is a convenient benchmark but is rarely valid. Workpiece material machining characteristics, for example, have great effects: a switch from steel to titanium in machining a part can increase tool usage by a factor of five. The three per cent proportion becomes 15 per cent, all else being equal.

Focusing solely on tool engagement time results in neglect of other factors, such as, idle times for tool changing. This approach is effectively hiding from reality. Manufacturers should understand that machining time, setup time, tool change time, loading and unloading, and other factors affect and interfere with each other.

A simplified example of unanticipated interaction of process factors involves a shop, machining a part that requires two minutes cutting time and a total of two minutes to load and unload the workpiece. Indexing the tool consumes a minute, and tool life is five workpieces, making tool indexing time 0.20 minutes per part. Because every part requires 4.2 minutes processing time, output is slightly more than 14 workpieces per hour. Each tool costs 15 euro, and tool life of five workpieces dictates that 2.8 tools (42 euro) are needed to produce 14 workpieces. Machine cost is 50 euro per hour. Altogether, production cost for 14 workpieces in one hour is 92 euro.

Then, attempting to speed output and productivity, the shop increases cutting speed by 10 per cent. That reduces

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C O V E R S TO R Y

TECHNOLOGY

cutting time by 10 per cent (to 1.8 minutes) but also cuts tool life roughly in half, meaning that one cutting edge will produce only two and half workpieces before indexing is required. Tool indexing time is still one minute and workpiece load/unload two minutes. Production time for one workpiece remains 4.2 minutes (1.8 minutes cutting, 2 minutes workpiece manipulation, and 0.4 minutes tool indexing) or 14 workpieces per hour. The machine and tool costs are the same, but now 5.6 tools (84 euro tool cost) are required to run for an hour. Despite the effort to speed output, production time for 14 workpieces is the same and cost rises from 92 euro to 134 euro.

In this case, increasing cutting speed does not make the operation more productive. Changing cutting time affects other factors in the machining system, in this example, tool life and tool indexing time. Accordingly, a shop must carefully consider the full consequences of process changes.

Another form of hidden cost involves execution of steps in the process. In many machine shops the time spent indexing inserts, for example, is a textbook case of hidden cost. The designated time to index an insert may be one minute. However, when measured in actuality on the shop floor, it can be two, three or ten minutes, a difference of 60 to 600 seconds.

High mix, low volume, complex considerations More recently, global competition is prompting manufacturers to create different versions of their products to match the needs of smaller subsets of users. Advanced computing technology permits rapid change of part designs and machining programs and also enables easy tracking of product variations and inventory. The result has been a shift to higher mix, lower volume (HMLV) production scenarios. Today, that approach has been developed sufficiently to enable efficient manufacture of single-digit or even single-item production runs.

The extended time horizon of HVLM production permits deliberate planning and fine-tuning of process factors. Planning is different in HMLV situations. Computerised engineering and inventory technologies support rapid changes in product type and output, but consequently the HMLV planning process must be complex and reactive. An order for ten parts may be followed by two, five, or even single-item lots of different parts. Workpiece materials may change from steel to aluminium to titanium, and

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part geometries from simple to complex. There is not enough time available to determine tool life through trials.

To manage tool life in HMLV situations, a workshop typically makes a conservative guess regarding a tool’s projected life and, to be safe, employs a new tool for each run, discarding it well before it reaches its full productive lifespan. Cutting time is only one factor in the overall picture. In HMLV production, the time required to manipulate different workpieces and fixtures, change tools and index inserts will often be longer than the actual cutting time. Tooling, machine tool, idle time, direct labour and workpiece material factors may contain hidden costs. The most recent approach to production economics takes into account tool and workpiece material costs, equipment and production cost, equipment cost during downtime and salary and maintenance costs.

Rapidly changing HMLV product requirements increase the difficulty of achieving high percentage yields. In the case of long-run HVLM production, trials and adjustments can produce yield percentages in the high nineties. On the other hand, HMLV yields may be binary. A successful single part run represents 100% yield, but when the part is unacceptable or a workpiece is ruined, the yield is zero. Demands for quality and cost and time efficiency remain the same, but first-time yield becomes an overriding requirement. In that case, avoiding tool breakage is perhaps the most important consideration. One advantage is that tool wear is a minimal concern in short run situations and a shop can apply, within reason, more aggressive and productive cutting parameters.

A related variable is determining when it is appropriate to index a tool. Waiting too long can result in a broken tool and at least an interruption in production, if not a damaged workpiece.

On the other hand, changing the tool too often increases expense in terms of tool cost itself as well as the time lost in stopping machining and indexing the tool. Determining when to change a tool requires examination of the change’s relation to the entire machining system, creating a tool change protocol, and then having the discipline to follow it.

Automated analysis From the early days of mass production, the number of factors affecting manufacturing productivity and costs has multiplied

EM | Feb 2019

C O V E R S TO R Y

TECHNOLOGY

Determining when to change a tool requires examination of the change’s relation to the entire machining system, creating a tool change protocol, and then having the discipline to follow it

many times over. As machining operations and equipment grew more complex, so did the relationships between the elements of manufacturing systems. None of the elements exists on its own; changing output volume requirements, for example, will affect tooling, equipment, maintenance, labour and other costs.

Determining the number of factors involved and their relationships to one another is itself a major challenge. The complexity requires a systematic approach to measuring, controlling and managing manufacturing processes.

Seco’s Productivity Cost Analysis (PCA) system examines the entire manufacturing process to determine ways to reduce costs and increase productivity. The basis of the system is Seco’s decades of worldwide manufacturing experience and knowledge.

Seco applies that knowledge in combination with sophisticated computer analysis and algorithms, including Monte Carlo simulation techniques that enable automation of cost modelling.

A qualified Seco representative performs the PCA, which evaluates all tools and technologies used in a process to generate a comprehensive report that includes both process information, such as, tooling and cutting data, and cost information, encompassing cost per part, output per hour and investment cost. PCA can evaluate processes ranging from a single machine tool operation to the complete path a workpiece takes on its journey through a manufacturing plant. The focus is on productivity improvements that have the largest impact on costs. The system takes bottlenecks or operational constraints into consideration and can recognise where more in-depth studies are necessary.

Working from a time and cost benchmark study of the subject operation or facility, in the initial stage the PCA software reviews

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tooling factors, including process parameters, cycle times and throughput requirements. Stage two involves the same process but makes adjustments in cutting conditions and tools being applied. Stage three can involve changing the process, combining operations and exploration of larger changes such as, machine tool upgrades. Manufacturers who utilise Seco’s PCA system can typically expect to benefit from total cost savings of up to 30 percent and productivity increases of up to 40 per cent, regardless of the industry sector they serve.

Maximising productivity The relationships of factors in a metal cutting system are not one-to-one. Changing cutting conditions, workpiece materials or product volume will impact tool life as well as many other aspects of the machining system. The challenge for production economics in a manufacturing facility is to be aware of those relationships and develop strategies to work with them in a pragmatic way.

Unfortunately, every shop worker cannot be a professor in mathematics and lacks the time to deeply explore the relationships.

As a result, suppliers offer process analysis and management services that give manufacturers a comprehensive picture of their specific operations and provide direction on ways to maximise the productivity and economic strengths of their efforts.

A frequent lament of shop owners is that they have plenty of work and paying customers, but still lose money. The solution to their problems is recognising the realities of the many factors at work in present-day production economics and uncovering and eliminating neglected and hidden costs so their manufacturing operations can attain maximum returns. ☐

EM | Feb 2019

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MANAGEMENT INTERVIEW

“Localisation and quality of the product is important” ….says Sanjay Koul, Chairman & Managing Director, Timken India, in this interview with Juili Eklahare. He reveals how the merger with ABC Bearings is more of capacity play and how the ease of manufacturing has to get better if India wants to become a global manufacturing hub. Excerpts…

Please tell us about Timken’s performance in the recent quarters and your target industry sectors.

For the last 3 to 4 years, Timken in India has been delivering a double digit CAGR growth. We have been growing strongly in the heavy commercial, agriculture and railway sectors. Apart from this, our penetration is growing due to the top quality in sectors like, metal, cement, infrastructure, etc.

We have been delivering profitable growth, despite the fact that the commodity pricing has gone up significantly in the last two years. However, the demand has been strong enough for companies in this space to do well.

Plus, with huge

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technological changes taking place in India, it is proving helpful for companies like us, who work at the cutting edge of the technology. As we cater to all applications covering from mobile sector (anything with wheels on it) to all kinds of stationary equipment, coupled with a powerful reach in India, we have been able to add lot of value to our end-customers. For example, we take pride in the fact that we are working very closely on projects where tunnels have to be bored for say METRO application or for prestigious trains like Train 18. Harsher the application, more the need for high performing bearings is where we fit in very comfortably.

Could you tell us about your expansion plans? After merging with ABC Bearings, are there any other plans for merging and further expansion?

We have doubled the capacity in our plant in Jamshedpur in the last two years, and it is already a centre of excellence for the Global Rail mobility. Timken In India is also investing at our Chennai facility which caters to large size industrial applications from around the globe. The Chennai facility is not part of Timken India limited but part of TERI. So, is the merger with ABC Bearings more of a value addition?

The merger with ABC Bearings is more of a capacity play and brings speed to the market. Here is a company with unutilised capacities that also caters to the heavy commercial and agricultural industry. This capacity can be upgraded to the quality levels which can qualify for the prestigious Timken brand and then be opened for the export play. So we are working on upgrading the facility on the technology front and at the same time, preserve the culture and ethos of the company.

EM | Feb 2019

INTERVIEW MANAGEMENT

Sanjay Koul holds a Bachelor's Degree in Mechanical Engineering from Birla Institute of Technology and Science, Pilani and a Master's degree in Business from Xavier Labour Relations Institute, Jamshedpur. He held various leadership positions, including National Sales Manager for Timken's rail business, Plant Manager in Jamshedpur and General Manager of Asia's supply chain based in Wuxi, China. He was also the Director of Manufacturing and Supply Chain for Timken's business in Asia operating from Shanghai, China.

What is the current manufacturing capacity at Timken?

Which end-users are driving the demand for roller bearings and gear drives?

In 2018, we saw that the commercial vehicle and the agriculture demand were very good and we had a very stable rail demand.

India has imported products worth more than US$ 5 billion in the engineering space alone in the last 10 years. One can imagine the number of jobs created if half of that was manufactured in India. To implement the ‘Make in India’ initiative in totality, localisation and quality of the product is important. A structured beginning of ‘Make in India’ has been made and is attracting How easy is it, in your opinion, to start and expand a investment already, encouraging people to produce more in the manufacturing plant in India? country. What’s more, India has the DNA to become the global India is a vast country that is governed by the central federal manufacturing base. So, we need Skill India, Infrastructure India, and state laws. The ease of doing manufacturing in the country Taxation India, etc. to expand ‘Make in India’ easily. Having said is getting better with every passing day. this, we cannot manufacture everything in The last four years have been phenomenal India, so we, as a manufacturing nation, in this regard but nowhere close to global will have to choose what is good for us as standards. We still have to battle a lot a value driver. At the end of the day, all of approvals which slowly are getting nations would look at the trade balances THE PAPERWORK FOR STARTING A changed to a single window clearance and hence, we also have to be a global PLANT IS EQUAL TO THE PAPERWORK system. With digitisation, things are citizens and help everyone achieve growth.

TO EXPAND THE PLANT becoming easy, but there is still a long way to go. Start a new factory or expand What are the manufacturing challenges an existing factory, the rigor is the same. in India and how can they be dealt with?

So all this has to become more simple in Today, India is opening its doors to the times to come. It also means that the investing companies major changes, providing lots of jobs and opportunities. So, have to be more responsible and very transparent. manufacturing is going to be the buzzword for many years to come in India. With that, resources are limited. This must be How has the ‘Make in India’ initiative played a part in the supported by the eco-system, which in turn, needs to be supported manufacturing plants in India? by the Government. And the Government has positively been The ‘Make in India’ initiative is a concept that every country would trying to overcome these challenges in the last 3-4 years. Even like to have. Every country would like to do its own manufacturing if the speed of overcoming the challenges is slow, the change for the simple reason that it provides not only better taxation base is happening. The company act and labour laws are changing. but also critical mass for jobs. At an intellectual level, India has Even environmental laws are becoming manufacturing-friendly, decided that it’s not good to import more goods. For example, without damaging the environment. ☐

‘‘

EM | Feb 2019

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MANAGEMENT INTERVIEW

“OEMs prefer to work with SMEs” ….says Aravind Melligeri, CEO & Chairman, Aequs, in this interaction with Juili Eklahare. He speaks about how efforts should be made to provide SMEs with access to information on business opportunities globally and how stepping into toy manufacturing has helped the group generate more employment.

Tell us about Aequs' role in the government’s 'Make in India' initiative.

Innovation, indigenous manufacturing and self-reliance are the key aspects to the success of ‘Make in India’. These should be encouraged, in addition to developing the capabilities of the industry to cater to exports. Domestic capabilities, in terms of designing and developing state-ofthe-art systems, should also be developed by leveraging cutting-edge technology.

At Aequs, our business model is not only to manufacture high volume machined parts and assemblies at competitive prices, but to also create the manufacturing ecosystem, which consists of several facilities supporting the entire manufacturing cycle from start to end, in order to maximise the in-country value add. We have built facilities at our Belagavi SEZ, which cater to aerospace forging, precision machining, special processing and assembly for aerospace industry.

With such an establishment, we are now able to achieve o v e r 90% incountry value

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add for some of the detailed parts, which was less than 30% just a few years ago.

Why do you think it makes sense for big players in the aerospace and defence manufacturing ecosystem to partner with SME suppliers? How can SMEs be a mainstay for India's aerospace and defence sector?

SMEs contribute 45% of the nation’s industrial output as well as 40% of total exports. They play a crucial role in mitigating the regional imbalances. Predominantly, SMEs are mostly located in tier II/III cities or semi-rural areas, facilitating development in the regions by creating infrastructure, jobs etc. This is very critical for a country like ours. If we look at the opportunities in our sector, commercial aerospace manufacturing itself is worth USD 100 bn per year, globally. Today, all organisations in India put together, export only USD 500 mn, which is less than 0.5%.

The global opportunity is growing at a CAGR of 5%-6%, taking the potential to USD 150-160 billion from USD 100 billion annually, over a decade’s time. Furthermore, India is among the top 10 spenders in defense procurement. The government has taken strong steps to strengthen public-private relationships by announcing that all government establishments need to work with private players – large, medium or small.

Globally, the aerospace and defence sector work closely with SMEs through a well-defined supply chain. These SMEs function as ancillary units to many large-scale industries in the country, fulfilling critical roles, such as, supplying raw materials and basic components. OEMs prefer to work with SMEs because of their innovative capabilities in niche manufacturing, lower overhead costs and their ability to absorb new technologies.

They generate healthy competition among entrepreneurs in the market, providing opportunities for skill and knowledge development. Efforts should be made to provide them with access to information on business opportunities globally. This

EM | Jan 2019

INTERVIEW MANAGEMENT

Aravind Melligeri holds a Bachelor’s degree in Mechanical Engineering from the National Institute of Technology, Karnataka and a Master’s degree in Mechanical Engineering from Pennsylvania State University. He has been conferred the ‘Young Achiever Award’ by the Indo-American Society. He serves on the board of QuEST Global, a company he co-founded in 1997, which is a globally recognised provider of outsourced engineering services.

You are planning a major foray into toy manufacturing. Of all the manufacturing products that you could have chosen, what drove you to take up toy manufacturing? Tell us your plans on how you are going to go about this?

With toys, we forayed into the ‘consumer’ vertical for the What do you think are some threats that the aerospace first time in 2016. As a proof of concept, it commenced manufacturing industry is facing right now? What is it that the with a 200,000 sq. ft. manufacturing unit in Aequs SEZ, Indian aerospace manufacturing industry currently lacks?

Belagavi. The Karnataka government has given us the India’s aerospace manufacturing approval to start a large new facility industry is still in its nascent stage and in Koppal for further scaling up this fragmented. Tier II and tier III suppliers vertical. We started with a vision to have started making components for the bring more economic value to the global commercial aerospace market region by generating employment – toy THE GOVERNMENT HAS TAKEN in India only recently. Today, OEMs manufacturing predominantly employs STRONG STEPS TO STRENGTHEN are increasingly making use of a global more labour, thus providing more job PUBLIC-PRIVATE RELATIONSHIPS supply chain. They are not only farming opportunities in the region. out a big chunk of machined and Since India has a labour arbitrage over sheet metal parts production, but also China, global players in the toy industry expecting vendors to supply large aircraft sub-assemblies and are looking at India for expansion. We saw an opportunity in even design expertise. creating in-country value by generating employment as well It is a capital-intensive industry that is characterised by as stimulating the country’s economy by increasing exports. a long project life cycle, spanning R&D, engineering design, Hence, we forayed into this segment. manufacturing and assembly. Due to intensive technology and safety demands, there are heavy investments on R&D What are the plans ahead for Aequs, 5 years down the line? and quality control. It is also critical to formulate a National Presently, Aequs generates about USD 100 million in sales, Aerospace Policy (NAP) that should give a direction to with over 2500 employees worldwide and aims at becoming where we want to be in the next 20 years. With the increasing a USD 300 million company by 2022. Machining is our core contribution from private companies, this policy becomes even competency and there lies a huge opportunity for scalability. more necessary, that could harness the knowledge residing in We are gearing up to bring in more capabilities in-house. We a fragmented setup. Such an institution could map indigenous acquired a company in France to enhance our capabilities in capabilities, address critical technology and training institutes manufacturing mission-critical parts like, landing gear and and needs, tax holidays, etc. Also, the policy changes should engine components. We have also built a robust supply chain create an investment vehicle which can help get access to and brought in desired capabilities to manufacture complex funds and technology easily. parts from India. ☐ will enable them to build relationships with international SMEs in global aerospace and defence programnes that will facilitate in enhancing their capabilities and impacting the entire supply chain positively.

‘‘

EM | Jan 2019

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V I E W P O I N T | TTEECCHHNNOOLLOOGGYY

IMTEX 2019: Exploring the

visitor mindset

IMTEX 2019 reached a new hallmark this year with its completion of 50 years. The exhibition has evolved tremendously over these years, especially with technological advancements taking place in the Indian manufacturing sector and the SME sector finding its place in it. While it was yet another year of umpteen exhibiting, meeting new customers and networking at IMTEX 2019 recently, exhibitors also gained a new perspective on the visitors that have been visiting the esteemed exhibition for years. The Viewpoint section takes a peek into the visitor mindset and finds out how the exhibitors’ exchanges have changed with time and what the visitors expect from IMTEX.

Suchi Adhikari Senior Sub-editor & Correspondent suchi.adhikari@publish-industry.net

Juili Eklahare Features Writer juili.eklahare@publish-industry.net

“Customers are matching their steps with global manufacturers”

A

Tarang Parikh, Managing Director, YG-1 Industries India

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t IMTEX 2019, we launched many products in the automotive segment. Additionally, we have brought in many products in the aerospace segment, as that is the future in India after automotive. Customers have diversified from traditional automotive shops to highly precise aerospace components. That’s the best part about IMTEX—it is very diverse. It is also one of the best platforms to brand and network for a company. The customer trend too, has changed.

People would come in the earlier days to just collect catalogues. But now, they are hungry to discover new technology and how it can benefit their businesses and are seeking to find ways in which they can reduce their costs, increase productivity and get their customers the best solutions. The trend has gone from traditional to technical—people are keener on discussing the latest technology available. Everyone, who visits IMTEX, is looking for the best solutions that they can get. Customers come prepared and do their homework before coming here— sometimes, they are even more prepared than the exhibitors themselves. They are matching their steps with global manufacturers and are thinking globally. This mindset will help strengthen the country and make us technologically strong.

EM | Feb 2019

TECHNOLOGY | VIEWPOINT

“It has been amazing to see the huge amount of confidence in the SME sector”

I

Ravi Raghavan, Managing Director, Bharat Fritz Werner

MTEX has grown immensely over the years. The quality has improved and we have more space to display solutions, which can show proof and build confidence in customers. We have put different technologies in different machines and the purpose of the displays is to show that this technology has been developed and is there. This year’s exhibition was a great platform to showcase what we have been working on and what we can deliver to the customer. Exhibitors are becoming more focused and identifying their customers, their requirements, and more specifically, showing them what they need. This is a great shift, because the efficiency of communication increases and the ultimate purpose is achieved by both the parties. Customers come with a team of their top management and not just a few buyers or engineers. Besides, many of them accompany not only to be part of this buying group, but also to see and explore latest technological solutions.

It has been amazing to see the huge amount of confidence even in the SME sector now.

Irrespective of the size or the experience of the customer, they want to make a serious bet and do not get intimidated by the size of the enterprise. They ask relevant questions, push through what they can expect to be of maximum value to them and want this value addition to be delivered to them. People have started thinking about the future as well—one group looks at what to buy now, while the other technical group discusses what has to be done next.

“A great opportunity to witness the latest technology developments”

With IMTEX completing 50 years this year, the exhibition is a great platform that offers

Chandrashekar Sharma, VP, Industrial Tooling & Machining Solutions Group, Kennametal India

global exposure. This year at the exhibition, we have displayed our latest products with tools and machines. Our displays also included solutions in transportation machining and their components, aerospace and energy component machining. The displays created a lot of buzz and enhanced the interest level of our customers and target market. While we expected good enquiries and business prospects, it was also a great opportunity for us to witness the latest technological developments over a period of time and find out what the others are offering as solutions and the expectations of the customers. Market segments from the automotive, aerospace, energy as well as the Defence Ordinance Board have contributed to a great mix of customers and made it a great show. We received enquiries from senior visitors and executives from the user segment and even machine-makers. With the growth story of India being so powerful in the coming years, most customers were looking to make their presence felt in the coming years. They have envisaged an interest in the new technology that has been displayed and how it can be used in their plant, so as to enhance the performance in their own industry.

“Facilities have improved in terms of infrastructure at IMTEX”

I

A K Sareen, Managing Director, CERATIZIT Group

EM | Feb 2019

MTEX is the biggest show in India for cutting tools and has improved a lot from the earlier days when it was held in Delhi or sometimes in Bengaluru. So, I think it’s a big plus that we are now fixed in one place. It is a humungous platform where not only Indian but international players in cutting tools, can come together. Also it’s wonderful how visitors from across the country and other parts of the world pay the exhibition a visit to interact and network. Interaction with visitors is still, more or less, the same. However, the facilities have certainly improved, in terms of infrastructure. Customers have a high level of interest here, who come to look at other options for their projects and people from the industry are using this platform to showcase new products, so that they can attract new customers. Our main objective at IMTEX was to showcase our four brands together on one platform. We are also showcasing lots of futuristic and innovative tools, and also present our capability as a group and bring in effective solutions for our customers.

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VIEWPOINT | TECHNOLOGY

“Any new concept, when launched in IMTEX, needs to be perfected”

P

Santosh Prabhu, Managing Partner, Tool Grinding Technologies

articipation in IMTEX is a part of our life, without which we have no identity. Technology is percolating down into the smallest corners of the industrial layers and is being transferred to the next segment of tool-makers in the automotive segment, which is an immense change in affordability. With our expertise of 14 years in this field, we have sold around 150 machines to companies in India and abroad. It’s a cyclic market where our previous machines speak about our market image and our service and refurbishment leaves an impression. It curates a trust factor between the company and customers. The global market, which is more cognisant, determines our success by acknowledging a simple prospectus—if one has 8 to 9 customers out of 10 still with them, one has a successful product. Over the past two years, we have ventured into four different markets—Germany, the US, Thailand and Indonesia. Taking into consideration the Indian market, we have to scale up our production by almost a third of the current rate. Thus, our first strategy is to increase capacity by building a new factory at Peenya, in Bangalore, which will also hold a demo centre and a showroom. The second strategy is to establish TGT in Germany and the US, by converting the direct sales into tech-centres.

“Helping the industry to achieve manufacturing excellence”

W

Santosh Kawade, Deputy General Manager – South, DesignTech Systems

e have been a loyal participant of the IMTEX exhibitions since many years. This year, we showcased some of the advanced CAE solutions, 3D Printing or Additive Manufacturing technologies. These solutions help the industry with their goals of product design and manufacturing excellence through solutions that augment productivity, generate greater ROI and enable them to achieve higher cost effectiveness. They also help them to remain competitive in the fast changing market space. We also showcased Product Design Analysis i.e. CAE solutions from Altair Engineering, and 3D Printing and Additive Manufacturing technologies from Stratasys. Besides this, our company has recently tied up with PTC as their value-added reseller so as to promote and sell IoT (Internet of Things), Virtual Reality (VR) and Augmented Reality (AR) solutions, ThingWorx and Vuforia in India. This is the entire range of solutions, which we have highlighted at IMTEX this year.

“Customers walk into IMTEX with an objective in mind”

I

Shankar Karnik, General Manager, Industrial Lubricants, ExxonMobil

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MTEX 2019 not only provides the prospect to meet with our customers but also gives us the opportunity to reach out to equipment builders that we work with and new ones as well. In terms of products, we showcase a complete range of metal-working fluids, which address the needs of the machine tool industry in general. When I say metal-working fluids, it goes beyond just the water-soluble cutting oils and operations that are done through the machine tools, but we also cater to the system requirements of the industry, such as, hydraulic oil and the range of greases and gear oils. Exhibitors are bringing in new technology and there is a trend towards reducing the size of equipment while it delivers the desired output. There is also a significant evolution in the components that are used. These are some of the aspects that we see externally that help the customers be more competitive in the global arena. Besides, we make sure that our customers select the right products, which are not only economically beneficial but also safe. We further cater to the environmental aspects right from the formulation stage, whether there is regulation or not. But our standards of delivery and products are the same across the world. Additionally, customers walk into IMTEX with a certain objective in mind. They are here to make decisions about the machines displayed here, based on their operational and customers’ needs. So, the interaction levels with customers are going up, where they are more aware and are at this forum to look for solutions. GST, also, has certainly helped make things much simpler while transacting with customers around the country.

EM | Feb 2019

TECHNOLOGY | VIEWPOINT

“IMTEX is more of showcasing technology for us”

I

Balwant Singh Bains, Head-Product Management & Marketing, Zavenir Daubert

MTEX is the platform where the interaction with the existing customers happens at a different level. We are also getting a chance to understand new areas, which we probably didn’t focus on earlier. It helps to connect with prospects in terms of bringing new products that we are planning. It also helps us to test whether a particular technology/product is sought after and brings in excitement, which has been relevant for us. We don’t do much of order-handling at IMTEX; it’s more of showcasing our technology. So, our interaction here is more of understanding what is new. As the theme for IMTEX has often been around Industry 4.0, we have introduced the concept of Chemical 4.0. This concept helps explain where chemical process management can be done through web-based services, which has garnered an interest from people. It is a gamut of things put together like, chemical process optimisation (value engineering of chemicals processes, right from the beginning to the end and the compatibility of the chemicals) and then process control of these chemicals while they are working in the tank, which is captured in a central system through IT systems. And then, tracking is done to ensure that the parametres are within the range.

We have also got a lot of enquires for distributorship. In terms of industry applications, we have DAUBERT 360 Program that has been helping our Indian customers get real-time truly global support & expert consultancy, that includes technical study, corrosion preventive packaging designing, validations in lab/field and support at receiving location in India or internationally. By focusing on customer’s customer, we have been able to reduce rejections, speed up response times, provide insights & assist in Production Part Approval Process (PPAP) processes at the international location.

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A U TO M OT I V E S T E E L F O C U S

Steel & AHSS in automotive: Prominence and impact The Indian automotive industry has come far over the past two decades and has risen to be one of the biggest growing markets in the world. For most automakers, steel remains a preferred material of choice. The article discusses the importance of steel in the automotive sector and explores the use of AHSS in vehicle design.

For a long time now, steel has been the preferred material for automakers worldwide. Using steel has let automobile manufacturers accomplish sought after standards of strength and safety for their vehicles at relatively low costs vis-a-vis other materials. According to the International Organization of Motor Vehicle Manufacturers, 97.3 million vehicles were produced in 2017, a 2.36% increase compared to 2016. And on average, 900 kg of steel is used per vehicle.

Steel is the backbone of the entire vehicle. In cars, these days, steel contributes to 65% of the weight and plays a huge role in the vehicles we see today. It protects the occupants of a car, reacts to road loads, provides comfort, and makes

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attachment points available to other components of the vehicle. Automobile manufacturers utilise steel for automotives because it is the toughest and most reasonable material accessible today for the application and can be engineered in a lot of diverse ways to fulfil the requirements of crash safety and the performance of the vehicle.

Steel distribution in vehicles The steel in a vehicle is distributed as follows: • 34% is used in the body structure, panels, doors and trunk closures for high-strength and energy absorption in case

EM | Feb 2019

F O C U S A U TO M OT I V E S T E E L

Advanced high-strength steels (AHSS) are now used for nearly every new vehicle design

of a crash • 23% is in the drive train, consisting of cast iron for the engine block and machinable carbon steel for the wear resistant gears • 12% is in the suspension, using rolled high-strength steel strip • The remainder is found in the wheels, tyres, fuel tank, steering and breaking systems

The role of AHSS Advanced high-strength steels (AHSS) are now used for nearly every new vehicle design. AHSS make up as much as 60% of today’s vehicle body structures making lighter, optimised vehicle designs that enhance safety and improve fuel efficiency.

With escalating concerns about human-induced greenhouse gases, global legislators have passed more stringent vehicle emission regulations through 2020, while considering further, aggressive targets for the next ten years.

Automakers are searching for new materials and engineering capabilities to meet requirements that often conflict. As an example, structural applications require materials characterised by high strength and stiffness, often achieved with greater thickness. But fuel economy and emissions are positively impacted when component thickness is reduced.

New vehicle designs with complex geometries are aesthetically pleasing, but difficult to form and join, compromised further by thickness reduction to achieve mass reduction targets. The global steel industry continues to

EM | Feb 2019

develop new grades of steel, defined by ever-increasing strength and formability capabilities, continually reinventing this diverse material to address these opposing demands.

These Advanced High-Strength Steels are characterised by unique microstructures and metallurgical properties that allow OEMs to meet the diverse functional requirements of today’s vehicles.

The AHSS family Besides, AHSS are complex, sophisticated materials, with carefully selected chemical compositions and multiphase microstructures, resulting from precisely controlled heating and cooling processes. Various strengthening mechanisms are employed to achieve a range of strength, ductility, toughness, and fatigue properties. The AHSS family includes Dual Phase (DP), Complex-Phase (CP), Ferritic-Bainitic (FB), Martensitic (MS or MART), Transformation-Induced Plasticity (TRIP), Hot-Formed (HF), and Twinning-Induced Plasticity (TWIP). These first and second generation AHSS grades are uniquely qualified to meet the functional performance demands of certain parts.

For example, DP and TRIP steels are excellent in the crash zones of the car for their high energy absorption. For structural elements of the passenger compartment, extremely highstrength steels, such as, Martensitic and boron-based Press Hardened Steels (PHS) result in improved safety performance.

Recently, there has been an increased funding and research for the development of the “3rd Generation” of AHSS. These are steels with special alloying and thermo-mechanical processing

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A U TO M OT I V E S T E E L F O C U S

Steel Strength Ductility Diagram

to achieve improved strength-ductility combinations compared to present grades, with potential for more efficient joining capabilities at lower costs. The broad range of properties is best illustrated by the famous Steel Strength Ductility Diagram, captured in the figure.

AHSS grades contain significant alloying and two or more phases. The multiple phases provide increased strength and ductility not attainable with single phase steels, such as, high strength, low alloy (HSLA) grades. HSLA materials achieve their strength through alloying and solid solution hardening, whereas AHSS are produced by using specific alloys and precise thermomechanical processing.

Reducing vehicle weight In the past, steels with tensile strength (UTS) levels in excess of 550 MPa were generally categorised as AHSS, and the name “ultra high-strength steels” was reserved for tensile strengths exceeding 780 MPa. However, today, there are multiple phase AHSS with tensile strengths as low as 440 MPa. So, using strength as the threshold for whether a steel qualifies as AHSS is no longer suitable. AHSS, with tensile strengths of at least 1000 MPa, is often called ‘GigaPascal steel’ (1000 MPa = 1GPa). Third Generation AHSS seeks to offer comparable or improved capabilities at a significantly lower cost.

New grades of Advanced High-Strength Steels enable car-makers to reduce vehicle weight by 25-39% compared to

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conventional steel. When applied to a typical five-passenger family car, the overall weight of the vehicle is reduced by 170 to 270 kg, which corresponds to a lifetime saving of 3 to 4.5 tonnes of greenhouse gases over the vehicle’s total life cycle.

This saving in emissions represents more than the total amount of CO 2 emitted during the production of all the steel in the vehicle.

WorldAutoSteel, worldsteel’s automotive group, completed a three-year programme in 2013 that delivers fully engineered, steel intensive designs for electric vehicles.

Known as the FutureSteelVehicle (FSV), the project features steel body structure designs that reduce the mass of the bodyin-weight to 188 kg and reduce total life cycle greenhouse gas (GHG) emissions by almost 70%. The FSV study commenced in 2007 and concentrates on solutions for cars that will be produced in 2015-2020. Today, we see the material portfolio developed through the FSV programme progressively being introduced into new products.

The global transportation industry is a significant contributor to greenhouse gas emissions and accounts for about 24% of all man-made CO2 emissions (International Energy Agency, CO2 Emissions from Fuel Combustion Highlights, 2018 Edition, p 13). Regulators are addressing this challenge by setting progressive limits on automotive emissions, fuel economy standards or a combination of both.

Many of the existing regulations began as metrics to reduce oil consumption and focused on extending the number of kilometres/litres (miles/gallon) a vehicle could travel. This

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F O C U S A U TO M OT I V E S T E E L

approach has been extended into the regulations, which now limit GHG emissions from vehicles.

Reducing emissions Extending the fuel economy metric to meet objectives to reduce emissions has unintended consequences. Lowdensity alternative materials are being used to reduce vehicle mass. These materials may achieve lighter overall vehicle weights, with corresponding reductions in fuel consumption and use phase emissions.

However, the production of these low-density materials is typically more energy and GHG intensive, and emissions during vehicle production are likely to increase significantly. These materials are often not able to be recycled and need to be sent to landfill. Numerous life cycle assessment (LCA) studies show how this can lead to higher emissions over the entire life cycle of the vehicle as well as increased production costs.

A key factor in understanding the real environmental impact of a material is its LCA. An LCA of a product looks at resources, energy and emissions from the raw material extraction phase to its end-of-life phase, including use, recycling and disposal.

the best out of the power of steels used for parts, while augmenting safety and bringing down weight. The importance of steel stands by the fact that

automakers continue to develop materials that will live up to forthcoming requirements. �

Courtesy: World Steel Association (worldsteel) Advt

Conclusion As consumers’ demands for lightness and robustness in vehicles have become more intricate, steel manufacturers look to modify their grades accordingly, with the priority being mass reduction, strength and safety on the road. Plus, the inclination towards a more fuelefficient car escalates the utilisation and relevance of AHSS. The automotive industry looks into unceasing research and development into AHSS, so as to get

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CAD/CAM | TECHNOLOGY

Tackling greater challenges with CAM solutions Computer-aided manufacturing (CAM) has allowed the manufacturing industry to increase the precision and speed of production. ESPRIT is one such CAM system, which can be used in the entire production process, from design to manufacturing. This article explores the benefits of investing in a CAM software solution, and how it has helped improve programming and manufacturing at Robin Technologies.

Founded in 1980 by Damien Robin, Robin Technologies is based in the county of Chantonnay in the Pays de Loire region, which is the third largest industrial region in France. The company focussed for several decades on manufacturing moulds. After the mould market became less profitable due to intense global competition, Robin Technologies began to apply its skill in Wire-EDM and 2 to 5-axis milling to subcontract machining of complex parts. The Pays de Loire region is home to major manufacturing companies such as, Airbus, Total and the Saint Nazaire shipyards. Robin Technologies became a contractor to these and other manufacturers, providing precision machining services.

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Hélène Horent Marketing Specialist EMEA DP Technology Europe Montpellier, France helene.horent@dptechnology.com

The company currently uses 15 numerically controlled machine tools, mainly from ONA and Mazak, to manufacture aeronautical maintenance tools, dyes for the agro-food industry, gearbox parts for the automotive industry, and various parts for the robotics and cosmetics industries. The managers at Robin Technologies continuously invest in the latest CNC machines, new manufacturing technologies and employee training.

Speaking on this, Tony Jourdain, Production Manager, explained, “My priority is to give our teams everything they need in order to be as productive as possible, including the latest production technologies and training in equipment and programming. The right CAM solution is a key part of achieving these goals.”

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TECHNOLOGY | CAD/CAM

CAM technologies have revolutionised the industry, endowing it with speed and precision

A smart CAM investment Robin Technologies selected ESPRIT because its complete functionality in milling, turning, multitasking, wire EDM, Swiss-style and B-axis machines enables the company to run its entire machine shop using only one CAM software package.

After purchasing ESPRIT, Robin Technologies successfully took the leap to 5-axis and 3D machining, a strategic choice that enables the company to meet the demands of the multiple industries that sustain the Pays de Loire region. “ESPRIT helped us improve our multitasking skills on our Mazak Integrex centres, making it possible to take on more complex projects and expand our manufacturing capabilities,” summarised Frédéric Allard, Turning-Milling Programmer for the company.

ESPRIT allowed Robin Technologies to minimise configurations, tools and maintenance. The time, not devoted to cutting on its Mazak Integrex machine tools, each of which includes two turning spindles for all-in-one machining and a lower turret, has also been reduced. Another strength of ESPRIT is its post-processors, which are tested and certified by the machine tool manufacturer and are open source so that they can easily be modified by the user. “ESPRIT gives us great flexibility,” says Sébastien Giraud, Head of EDM. “Currently, we have three EDM machines of different brands. The postprocessor provided by ESPRIT lets me move programs from one machine to another without difficulty.”

ESPRIT also allows one to maximise the capabilities of its ONA Wire-EDM machines. “It has allowed us to produce sophisticated parts on our ONA 4-axis Wire-EDM machines to high levels of precision,” Giraud said. Also elaborating on the advantages was Damien Roure, Head of ONA France, who claimed, “ESPRIT and the Usiprog distributor help our

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machines handle with increasingly complex wire cutting. The fast response of the ESPRIT teams is, along with the performance of the software itself, the strongest point of our partnership with ESPRIT.”

Meeting new challenges Soon after Robin Technologies implemented its new CAM solution, Airbus consulted with the company about producing a very complex gauge, which could only be machined using 5-axis milling. With the help of their sophisticated machine tools and ESPRIT CAM, the team was able to deliver the part on time, and met the quality and cost requirements of the customer.

Advanced training courses enable the company’s programmers to accept even more difficult challenges. For example, they were recently contracted to program a competitive mountain bike wheel hub, which required milling and turning many complex faces. It involved complicated operations like the Z-level roughing and composite spiral finishing. The ESPRIT support team helped Robin Technologies programmers to further develop their programming skills and programme the part in one day. “With the help of ESPRIT reseller, Usiprog, we can overcome all obstacles,” said Damien Berthelot, CAM Manager.

Speed and precision Thus, CAM technologies have revolutionised the industry, endowing it with speed and precision. By adapting its company strategy to changing market conditions and choosing reliable and experienced partners such as, ESPRIT CAM, Robin Technologies is positioned to succeed in the highly competitive contract machining marketplace. ☐

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E N G I N E E R I N G M AT E R I A L S | T E C H N O L O G Y

Scaling manufacturing obstacles with Additive Manufacturing The automotive sector at the global level has been transforming over the years, continuously reaching the zenith with evolutions in technology.

This evolution has been brought to fruition by the latest advancements in Additive Manufacturing. This article explores the advancements in Additive Manufacturing, which has liberated the production of components across industries from the bounds of inefficiency and has pushed the sector towards a more profitable and customer-oriented goal.

The automotive sector worldwide is growing rapidly and is also undergoing significant transformational changes. With the primary focus upon the funding activity in the electric vehicle ecosystem, shared mobility and safety, industries globally are looking forward to improving their efficiency and the sustainability quotient right from the manufacturing phase.

While the World Economic Forum, which assesses the manufacturing capabilities of more than 100 countries, ranks India 30th on the global manufacturing index, the government’s ‘Make in India’ initiative has played a crucial role in elevating the country’s manufacturing growth.

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Anand Prakasam, Country Manager EOS India

Even though we still have a long way to go before India can attain the position of a global leader in the manufacturing arena, companies in the automotive sector are looking at the prospectus of this tremendous scope in the sector and have been seen embracing it to leverage India as a hub for low-cost production and yet, high-quality products.

Surmounting manufacturing inconveniences The changing tides in the manufacturing sector are certainly witnessed among the segments such as, automotives. Today, the

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T E C H N O L O G Y E N G I N E E R I N G M AT E R I A L S

Additive Manufacturing is the solution for individualised serial production of high-end, weight-optimised components in automotive engineering

automotive industry is focused on energy-efficient engines, striving for reducing CO2 emissions and meeting the increasing demands for customer-specific components in serial production.

Quite often, other manufacturing practices come off as inefficient when faced with these challenges and another concern for the manufacturers is that, on most occasions, it is simply not possible to apply them to small batch sizes and still bring in great profits. The automobile components particularly customised in order to adapt accordingly to the customer-specific requirements reflect changing expectations of the new-age customers. Also, while considering the manufacturing segments where enhanced customisation is required, it has been observed that a distinct solution is the need of the hour. Another disadvantage of conventional manufacturing technique is that they limit design freedom. The end result obtained is that the components are always an outcome of a compromise between function and feasibility. Additive Manufacturing overcomes this negotiation between utility and viability of the product quite easily.

For this very reason, Additive Manufacturing is the singlemost competent solution to unravel the difficulties that the aforementioned cases pose. The chief benefit of Additive Manufacturing is that it allows cost-efficient manufacturing of individualised mass products. Additionally, AM technology allows maximum design freedom—a core element to enable the production of components with integrated functionality.

Pristine technology of facile production EOS Additive Manufacturing technology frees up development from these constraints as it only applies material where it is functionally necessary in the product. The incorporation of this technology facilitates the manufacturing of extremely light and yet highly rigid parts. The added benefit of manufacturing parts and components by such a method is that it can even comprise integrated functions. Simple parts such as hinges, brackets and pneumatic actuators, can be not

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only designed, but also produced and installed as integrated components—all with the AM technology. By reducing the mass of moving and/or accelerating components, manufacturers can also credit to their product an important direct enhancement of energy efficiency.

Additive Manufacturing is the solution for individualised serial production of high-end, weight-optimised components in automotive engineering. For any global manufacturer, Additive Manufacturing is quite the tool to achieve everything that a state-of-the-art manufacturing unit would require. This technology enables the production of components with integrated functionality. All this is achieved without the need for any tools, which thereby translates into the reduction of the development and production costs. What’s more is that the suppliers can easily respond to any customer requirements by offering individualised serial production of components as per the necessity of the customer.

Rapid prototyping based on Additive Manufacturing also means that automobile manufacturers can increase the efficiency of their research and development processes, which in turn enables them to get their products out in the market more quickly. The focus here is put on not just geometrical part accuracy. EOS is continuously expanding its range of new materials in order to ensure that parts are functionally reproducible, too, and can be almost effortlessly installed directly in serial production vehicles.

Next level of automotive evolution Hence, as the automotive sector continues to innovate and expand, manufacturers, too, are constantly looking for avenues to aid in its progression. In diverse avenues of manufacturing, such as from thermal management to battery optimisation, AM of today represents the fuel that has the potential to power the next level of automotive evolution and make the dream of an automated future a reality. ☐

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WELDING | TECHNOLOGY

Exploring the role of Big Data in welding technology A trend of digitisation, known as Industry 4.0, is resulting in a transformation of the industrial sector, in which Big Data plays a crucial role. It refers to data sets that are complex and large, and also refers to technologies used for communication and data processing. The following article is the second in its series, and offers an overview of the challenges and practical functions of Big Data in welding technology.

To take full advantage of Big Data in production, all the relevant information must be present in digital form and the stations involved must always be available—even beyond company and site boundaries. Security is an important aspect.

After all, we are dealing with sensitive corporate data, which must never be allowed to fall into the wrong hands. But a certain amount of risk is involved, both in local storage and cloud computing.

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Helmut Ennsbrunner Head of Preliminary Development —Business Unit Perfect Welding Fronius International sales@fronius.com

Data security It is important that welding technology manufacturers pay special attention to data protection when developing new hardware and software products. Various methods are suitable, one of which is using the latest cryptography to encrypt and authenticate the data. Ideally, data transmission should be based on the end-to-end principle, where the sender encrypts the

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TECHNOLOGY | WELDING

information in a trustworthy environment with a system that can only be decoded again by the receiver in an environment that is also protected. Certificates to verify that the data and the sender are genuine can also be used.

The potential risk of unauthorised access to sensitive data is still one of the reasons for the great scepticism towards big data in many companies. But this can be virtually excluded with the right precautions. Here however, it is not just the manufacturers who are required to implement correspondingly high security measures in their networks, users must do so as well. This starts by changing standard passwords into state-of-the-art secure passwords. What is more, the process data obtained is in many cases far less useful to competitors than companies usually assume. The benefits of Big Data usually far outweigh the risks.

Once companies have recognised this fact, acceptance of the new technology usually increases too.

Big Data versus smart data The potential of processing and using production data to create value within a company is great for optimisation, but is also a major expense. The quantity, variety, and speed at which the information is produced often pushes conventional IT infrastructures to the limit. New solutions and concepts are therefore required to master the never-ending torrent of data, and keep track of what is going on in the face of increasing complexity.

Big Data in its original meaning—collection of vast quantities of data, like the operations of major search engine providers—is less interesting for industrial manufacturing. This is why the term “smart data” has become established within this main concept, by way of differentiation. It describes useful, protected, and high-quality data that has been identified from comprehensive data inventories. The advantages of this preselection are that the amount of work involved is less and the required storage capacities are much lower. In a manner of speaking, Big Data is the raw material that has to be processed to realise its full potential. Which information is ultimately relevant to the user differs from application to application. In welding technology, for instance, important insights can come from recording external factors such as humidity and temperature.

Linking these to the device and process data and analysing them together could form the basis for further optimisation.

Practical implementation and range of functions Data collection and processing in the power source Most of the information that is relevant to the analysis, documentation, and optimisation of welding technology tasks is produced within the welding system. Modern power sources are

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fitted with high performance processors and high-speed bus systems to enable them to process and store it. Universally, digitised welding systems have been conquering the market since the 1990s. One of their advantages is that all the data is already available in digital form, and is therefore easier to use. Not only that, but power sources now provide numerous communication and networking options, such as Ethernet, WLAN, Bluetooth, or NFC (Near Field Communication). These make it possible to accurately depict and control even high-frequency arc processes such as CMT (Cold Metal Transfer) in real time. High-resolution data can also be continuously transferred to connected systems.

Modern welding systems collect information about current, voltage, or wire speed, welding speed, time, and job numbers.

These can be read on a PC or mobile device, for example.

Numerous opportunities are available to the user: viewing, editing, and deleting jobs (defined parameters for a specific welding task), or exporting them in different formats and applying them to other compatible power sources. The user is also able to compare the set and actual values for each task, and react quickly if there are deviations. In this way, ongoing production processes can be continuously improved and supporting documentation provided.

Another function is so-called limit monitoring, which refers to monitoring limit values. The user defines the upper and lower limits for certain parameters. The data is stored in the power source and visualised via a web browser, for instance. If the value in ongoing production exceeds or falls below one of these limit values, the welding system issues a warning or automatically stops the process, depending on the setting. This enables companies to implement intelligent and individual production monitoring, which can be relied on to protect the quality of their welding processes.

Data communication between the welding system and the user works in both directions. This means that it is also possible to adapt the range of functions of the power source to changing requirements by upgrading. Modern welding systems are usually suitable for several processes and process variants. This flexibility can be vastly improved by offering new characteristics and software updates. This increases investment security, particularly for companies confronted with frequently changing tasks. A universal security system also ensures data protection for each power source communication. For example, access to the different functions is individually controlled by creating different user profiles.

Data collection and processing across power sources Welding systems that make their data available to the user in a digital form, and which are fitted with the relevant communication functions, can also be integrated into a networked and automated production environment. This holds great

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WELDING | TECHNOLOGY

Although welding has been around for one hundred years, it has always kept up with technological advances

potential for further optimisation—by using a documentation and data analysis system, for instance. The software can collect and evaluate all the information, not only in relation to each machine, but also in relation to each component. This makes it possible, for instance, to have continuous documentation of set values at component level, so that when working with a certain component, each step is fully traceable—an enormous advantage for quality assurance.

Set values such as job data can also be observed and recorded by the system for the entire service life of a welding system. The user can also create and edit jobs centrally, and transfer them to various devices, thus saving valuable time. All the documented data can be evaluated easily and individually using filter functions. This gives users the best possible overview of their manufacturing, allowing them to target individual processes for improvement. The details of all the connected welding systems and their components are visible at a glance on the central dashboard of the analysis system. If a fault occurs anywhere, the operator is immediately informed and can react quickly. This helps manufacturing companies to achieve high-quality production, and is instrumental in significantly reducing costs. Using a data collection and analysis system across power sources is an attractive proposition, especially for industrial users who have to control and monitor a large number of automated welding systems.

Keeping up with technological advances Although welding has been around for one hundred years, it has always kept up with technological advances and has evolved continuously over the decades. Welding technology has not escaped the current trend towards increased digitisation and networking in the sector either—and as a part of this, Big Data is currently one of the most relevant topics for the industry and its customers. Collecting, storing, and analysing vast quantities of welding data, if done correctly, has huge advantages for manufacturing companies, whether optimising time and cost

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for their processes, meeting specifications with regard to documentation and traceability, or in quality management.

Big Data has also changed the focus of welding technology suppliers. For decades, electricity conversion was the key to success, but today, it is the digitisation of the welding process.

Communication, real-time data monitoring, data storage, cyber security, and intelligent man-machine interfaces are now the driving forces in development. The role of software tools in optimising parameters or managing wearing parts, for example, is becoming increasingly important. The symbiosis of hardware and software has guaranteed the perfect arc for more than 20 years.

This is why modern power sources are being given more and more networking and communication functions to go with their actual task. High performance processors and high-speed bus systems are a basic requirement. Welding data can then be transferred at extreme speeds and resolutions in real time, ready to be used, both in relation to each machine and to each component. Special documentation and analysis systems collect information from all the connected power sources and process them individually in accordance with the user’s requirements.

The result is a clear saving in time and cost, as well as higher quality and full transparency in production. For welding technology manufacturers, the future will not just be about creating the perfect arc, it must also be fully integrated into an overall process to ensure optimum component quality.

For many companies, the use of Big Data initially presents a challenge: existing IT infrastructures must be modified and upgraded, and data protection issues must be resolved. After all, sensitive company data must never be allowed to fall into unauthorised hands. However, the relevant safety precautions, and the creation and introduction of suitable hardware and software solutions for processing and using the data, are an expense that as a rule, more than pays for itself. If used properly, the advantages of big data far outweigh the costs and risks. ☐

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sales m mt@a cemi c ro ma ti c.co m

COMPOSITE MACHINING

S P E C I A L F E AT U R E

Composites and it’s significance in the aerospace & defence sector Composites have become increasingly important to the Aerospace and Defense (A&D) industry. To further examine the use of composites in the A&D industry, Tech-Clarity surveyed 181 A&D manufacturers. The article studies two areas that can be a source for bottlenecks when working with composites: springback and manufacturing planning.

Composites are turning into a highly pivotal element in the Aerospace and Defense (A&D) sector. In fact, Tech-Clarity’s Composite State of the Market study found that A&D companies overwhelmingly turn to composites to help with light weighting so that they can improve performance and realise better fuel economy. The study also found that while composites offer significant benefits, the expense of the material means companies should look at ways to get better insight. Inspecting how composites can be utilised in the A&D industry, TechClarity examined 181 A&D manufacturers. The study examines two parts – springback and manufacturing planning – that can be a cause for roadblocks when working with composites.

Springback can cause significant issues for A&D companies.

Springback is a manufacturing defect that can occur while the

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composite part is curing. Due to shrinkage, the material can deviate from the original molded shape. When this happens, the part is out of tolerance. Depending on how severe the distortion is, manufacturers have to spend extra time correcting the part to get it within tolerance so that they can assemble it. The good news is that companies, who have adopted best practices for composites, are much less likely to experience springback. Some of those best practices include using design guidelines and communicating ply level design information by providing direct access to the composite data in the engineering model.

Manufacturing planning is another important part of producing quality composite parts. It is especially crucial to produce parts exactly as designed. By following manufacturing planning best practices, one is more likely to produce composite

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S P E C I A L F E AT U R E

parts as designed. Best practices involve leveraging an accurate engineering model.

Understanding springback Manufacturers find that springback is usually severe enough that the distortion is outside of tolerance. When this happens, it takes extra time to properly adjust parts so that they fit together.

In other cases, the distortion is so bad that one cannot correct it, hence parts have to be scrapped. Given the expense of carbon fibre, this can significantly drive up cost. Companies, who take the right steps to minimise springback, will be much better positioned to have a competitive advantage. A whopping 70% of respondents indicate that they have problems with springback in curved panels. However, almost a third of respondents find that they even have problems with flat panels. Springback also comes from a variety of sources, but most commonly from resin shrinkage and fibre deviation.

Corrective actions for springback When springback occurs, the most common methods involve using a liquid shim or force fitting the part into the assembly. Both involve extra steps during the assembly process that take extra time. Figure 1 shows the most common practices for avoiding springback. The results show that A&D manufacturers are more likely to take the easiest and fastest approach of updating the tool rather than making design adjustments or ongoing process monitoring.

Identifying top performers Considering that springback is a source of excess time and cost, companies looking to save money should examine it more closely. Given how common it is, there is still work to do to reduce its occurrence. To identify some of these best practices, Tech-Clarity researchers isolated Composite top performers.

These companies were categorised according to how well they meet their targets for composite parts. The metrics used include the ability to meet: • Design due dates • Cost targets • Product development budget • Production cycle times The top 20 per cent, who do the best job of meeting these

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Composite Machining

targets, were considered Composite top performers and everyone else was labeled average. Based on the results, Composite top performers do a better job of managing their processes.

Avoiding springback Compared to average performers, Composite top performers are 32% less likely to experience springback. They are 41% more likely to use design guidelines compared to their peers.

Interestingly, beyond performance categories, companies who tend to specialise and stick with only one type of fibre, tooling, mould, and moulding material, are less likely to experience problems with springback.

On the other hand, those who take a variety of approaches and use different fibres, weave architectures, tooling, etc. can offer more options to support different applications. However, it becomes harder to develop the internal expertise and guidelines to avoid springback. Many manufacturers, who do not experience problems with springback, offer advice to avoid it. The advice falls in four buckets: • Experimentation: Making adjustments to the parts • Manufacturing adjustments: Adjusting production parameters & closely monitoring the cooling & curing process • Experience: Relying on expertise to make the right design decisions • Design and analysis: Using analysis and calculations to guide design decisions These suggestions have their benefits as well as some drawbacks. The first two options occur during production.

Manufacturing adjustments offer similar benefits. The second two options happen during design. For these options, experience is extremely helpful.

Many commented that they take care of springback during development and that calculations are key. One manufacturer said, “We take care of springback problems during design. We also use analysis to avoid any problems.” This approach may add a little time during design, but it takes less time to run simulations than it does to run those same experiments on the production floor. In addition, you avoid the costly waste.

Planning for manufacturing Once engineering work is complete, parts are ready for production. With composites, the link between the design model and produced part is especially critical. Even a slight

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COMPOSITE MACHINING

S P E C I A L F E AT U R E

Corrective measures to avoid springback

adjustment in fibre orientation can have a significant impact on strength. As such, produced parts must match the as-designed model as closely as possible or they may not meet the engineering criteria they were designed for. Manufacturing planning is a critical step to ensure parts are produced correctly. Most companies producing composite parts have a manufacturing planning system they use for composite parts.

Most companies use a variety of methods to communicate ply level design data to manufacturing. Overall, 2D drawings are the most common method. However, compared to average companies, Composite top performers are 84% more likely to provide direct access to the composite data in the engineering model. Using the engineering model directly saves time and leaves little room for misinterpretation or errors. However, the right technology must be in place to make it work. Furthering the use of engineering tools, the majority of A&D manufacturers use the design tool to create visual aids for composite parts, although many also use office applications.

By taking the information directly from the design tool, you can reuse more information rather than recreate it. This saves time and reduces the risk for errors.

Don’t overlook the time impact of changes Developing the manufacturing plan is a critical piece of producing quality parts. A significant amount of time goes into creating them, but an almost equal amount of time goes into making changes. Overall, it takes over a day to get the plan ready. To implement changes, for most companies, the process is currently very manual.

Given how manual the process is for 83% of respondents, there is an opportunity to reduce some of the time spent on manufacturing plans, especially changes. With better automation, rather than wasting time making manual updates, you can spend it on producing parts instead.

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Considering programming trends There is a fairly even distribution among approaches for creating programs to run automated fibre placement. Using the machine vendor’s software is the most common approach, but internally developed software and third party software are used with nearly equal frequency. A&D manufacturers tend to use automated layup machines from 2.2 different vendors. Changes are not easy here either as it takes 0.7 days to make a change to an automated layup programme.

Adopting best practices Many A&D companies have turned to composites to help them improve performance and realise better fuel economy.

However, the A&D industry is also under significant pressure to lower costs. Addressing manufacturing defects, such as, springback as well as better manufacturing planning can help A&D companies take advantage of the benefits of composites while improving design and production efficiency and lowering costs.

Springback can be a considerable source of excess cost and waste. Typically, springback causes parts to be out of tolerance so manufactures have to waste time correcting parts, or worse, scrapping them. By adopting best practices, such as, using design guidelines, A&D manufacturers can avoid springback.

Adopting best practices for manufacturing planning is another area where A&D manufacturers can improve quality.

It is crucial that composite parts are manufactured as designed to ensure performance. By adopting practices, such as, leveraging the engineering composite model for manufacturing planning and automating changes, A&D manufacturers will be better positioned to produce parts as designed, without quality issues. �

Courtesy: Tech-Clarity

EM | Feb 2019

TECHNOLOGY | NEWS

Cutting-edge analysis for perfect solutions ExxonMobil’s dedicated Field Engineering Services (FES) team brings its 40 years of expertise in oil analysis to give cutting-edge solutions to its customers across the world as precise analysis and informed recommendations are at the core of lubrication services. Backed by the strong support and technical knowledge of its formulators, scientists and engineers, the team specialises in early detection of potential damage in machine operations, ensuring minimum operational downtime and peak productivity for maximum profitability. As in-service oil analysis is essential for assessing the health of a machine’s operation, a sample of oil provides crucial information that can help increase productivity, reduce unscheduled downtime, improve equipment durability and lessen lubricant consumption.

Fast Mover Advantage The company offers a distinct advantage, conducting oil sampling up to 66 per cent faster than industry peers, which translates into sampling activity in just one-third of the usual time, hence, proving that time is of essence in an industrial setup. The conventional process of collecting and labelling the samples typically requires 24 labour hours per month, with a significant portion of that time dedicated to printing and filling out sample labels. In an effort to streamline the sampling and labelling process, the company has developed an alternative maintenance solution. The Mobil Serv Lubricant Analysis program eliminates the time-consuming sample labelling process by using pre-labelled sample bottles with QR codes and a unique number identifier. These QR codes and Mobil Serv Lubricant Analysis number identifiers allow the sample bottle to be quickly paired with a piece of equipment in the lubricant analysis system with no additional sample labelling, improving sample process efficiency, while reducing labour associated with oil analysis and cutting time.

When the sample is processed, the laboratory handles each bottle as a unique item. Each sample is coded, labelled and tracked through the entire process. By the time the test results are available, the equipment sample has directly benefitted from Mobil’s knowledge of lubricants, decades of OEM relationships and a strong heritage of hands-on application expertise. Sample comments are provided to help identify potential problems, list possible causes and recommend actions for follow-up. Also, the company’s technical services offer an extensive range of industrial services that are designed to help customers optimise their lubrication programs and machine availability.

Mobil Serv Lubricant Analysis (MSLA) The operators are advised to incorporate an oil and equipment condition monitoring program to maximise the productivity of machinery and reduce costs while making high quality synthetic lubricants. Mobil Serv SM Lubricant Analysis, armed with the in-depth understanding of Mobil products, brings a thorough knowledge of applications and equipment by working closely with original equipment manufacturers.

MSLA enables companies to conduct the entire process virtually on their mobile or tablet device through scan-and-go oil sampling bottles.

It provides informative reports on the condition of the customer’s equipment and lubricant.

Services • Engine Inspection: The engine inspection service encompasses expert inspections by well-trained engineers using borescopes and specialised tools, helping diesel engines run efficiently with potentially extended life.

The engineers use their expertise to inspect, report and document the condition of the internal components of diesel engines.

• Hydraulic Inspection: The hydraulic inspection competency details critical hydraulic equipment, revealing opportunities to improve performance. The engineers inspect, report and document the condition of critical plant hydraulic systems. They use inspection data to establish the optimum time to replace critical hydraulic components such as, pumps, valves, heat exchangers, filters and lubricants and then recommend maintenance practices to help improve system reliability.

• Lubricant Recommendation: The lubricant recommendation service provides expert guidance in selecting proper lubricants for the equipment, which can help minimise costly maintenance and repairs, while providing optimum protection to the assets. The experienced engineers assess current lubricants and recommend, when required, more effective product choices to help maximise equipment reliability for optimum productivity.

• Powertrain Analysis: The powertrain analysis service monitors transmission, differential and final drive oils for premature wear, contamination and oil condition. Powertrain analysis helps detect gear or transmission problems and lubricant contamination before they can result in costly downtime or repairs. The company brings its expertise to each of these services, offering customers cutting-edge solutions for their specific needs.

ExxonMobil Lubricants Pvt. Ltd. https://www.mobil.com/en/industrial

50

EM | Feb 2019

TECHNOLOGY | NEWS

Intelligent single crank power press

Customised hydraulic system

Chin Fong recently introduced an intelligent single crank power press, namely, OCP 110, which is equipped with multiple sensors and uploads massive monitored information through internet to Chin Fong Cloud.

This monitored information facilitates effective data analysis and visualisation. Also, it enables the users to get hold of production status and schedule. Plus, the technician could find out maintenance cycles from data feedback to prevent possible damage.

This results in accomplishment of the goal of high production rate and longer service life. This press could be coordinated with QDC (Quick Die Change OCP 110 System), AGV (Automatic Guided Vehicle) and industrial 6-axis robotic arm, which demonstrates press application with “intelligent” peripheral system and realises unmanned manufacturing and management.

DEES Hydraulic Industrial recently launched a hydraulic system, tandem lines, which is easy to maintain and powered by the motor and pump set. It has moving bolsters with Q.D.S. system (quick die change system) to make the heavy die change easier and faster. The fastpressing speed is between 30 and 150 mm/s and is controlled Tandem Line by the accumulator with the high approaching speed of 800 mm/s or larger and return of 600 mm/s or larger. The function of the cushion system present is to knock out the parts. All the speeds and the strokes including the slide and cushion systems are adjustable. The repetition is within ±0.05 mm. The DEES self-developed HD-FASTech technology completely solves deep-drawing’s low efficiency, greatly improving production efficiency. The tandem line can work 24/7. The company supplies the custom hydraulic presses with in-house design and manufacturing making it strong and robust for long operations.

Chin Fong Machine Industrial | New Taipei City Email: sale@chinfong.com.tw | Tel: +886-4-7524131

DEES Hydraulic Industrial | Taiwan Email: sales@spc.com.tw | Tel: +886-2-26018661

Milling grades for finishing applications

Compact 5-axis machining centres

Dormer Pramet recently launched the new milling grades, namely, T8010, T8030, M4303 and M4310, which provides durability and reliability in semi-finishing and finishing applications. Each is designed for high-speed milling for the die and mould segment, offering consistent wear and longer tool life. An ultra-thin PVD coating increases cutting edge toughness, while its substrate provides high Thread turning inserts with T8010 hardness and strength of cutting edge, preventing fracture by chipping. Meanwhile, the company has announced a high wear resistant grade for thread turning, T8010. The new T8010 is ideal for continuous high precision thread turning of steels, stainless steel, cast iron and super alloys.

It further extends the company’s Pramet assortment in this application area and supports the universal grade, T8030. It has enhanced plastic deformation resistance, which provides a stable cutting edge and allows for increased speeds. A gold finish on the insert provides a simple wear indicator, while a hard substrate and PVD coating has been optimised to deal with interior residual stress, helping to improve tool life.

Doosan Machine Tools recently featured the DVF Series of compact 5-axis machining centres. The series takes its place in the company’s line-up of vertical machining centres specifically designed for cutting diverse and complex shapes. The DVF 5000 comes standard with an 18,000 r/min integral 40 taper spindle. A FANUC 31iB5 CNC controller makes full 5-axis simultaneous control possible, DVF-5000 giving complete contouring capabilities. It also features a 500 mm diameter (630 mm option) built-in rotary table. Also, it offers a diverse range of tailored options and automation that make them ideal for unmanned machining.

They come automation-ready and supplied with an optional/retrofittable AWC, which provides additional productivity by offering up to 12 pallets to feed the machine for unattended machining. The company also demonstrated PUMA SMX super multi-tasking turning centres, which come with a lower turret for enhanced versatility and productivity. The turret is available on both the 10” chuck and 12” chuck models. Also, LEO 1600 (6-inch class lathe) and DEM 4000 (BT40 taper spindle and 400 mm long Y-axis) targeting entry-level customers’ simple cutting duties were presented by the company.

Dormer Pramet | New Delhi Email: gautam.ahuja@dormerpramet.com | Tel: 011-46015686

52

Doosan Machine Tools India | Bengaluru Email: sandesh.kumar@doosanmt.com | Tel: +91-9686670368

EM | Feb 2019

P R OBL E M S OLV E D

M A R P O S S P L UG A ND P L AY S OL U T ION S The innovative iWave2 wireless handle displays the measurement value in the operator’s hand.

Communication software developed by MARPOSS gives the opportunity to connect the iWave2 to any commercial computer. ALL MEASUREMENTS IN YOUR HANDS!

MARPOSS INDIA Pvt. Ltd.

147, Sector 7, IMT Manesar 122 050 - Tel. +91 124 4735700 | sales@in.marposs.com

TECHNOLOGY | NEWS

Energy efficient air-compressor

Turning inserts

ELGi Equipments recently launched a brand-new trolley-mounted compressor model–the PG75E-12.5. ELGi’s portable compressors, renowned for their reliability and ruggedness, are available in single and two-stage models. These compressors find a wide range of applications across the cable laying, blast hole drilling, exploratory drilling, construction, coal and marble mining, sandblasting, stone mining and crawler drilling. The portable screw air compressors feature energy saving eta-V Trolley-Mounted Compressor profile air-ends, resulting in significant savings in energy costs. Fitted with international warranty engines, every compressor ensures better fuel economy and lower emissions, all while providing uptime and durable performance at a low cost of ownership, coupled with longer service intervals and easy maintenance. In short, the key features include, energy efficient, highly reliable and worksite-friendly, centralised control panel for ease of use, easy manoeuvrability allowing quick turns and climbing slopes, large access doors for ease of maintenance, tow bars designed for safe highway running, with single and multi-axle tow bar options, and industrial grade steel and powder coated canopy for maximum corrosion protection and durability.

Seco Tools recently introduced the new -RR93 and -R3 geometries as part of its RCMx range of turning inserts. The -RR93 chip breaker boosts tool life, improves productivity, increases product reliability, enlarges chip-control working area and enhances surface finish. This new design replaces the -RR94 geometry.

The -R3 geometry excels in medium finishing applications in steels, difficult stainless steels and super alloys. It replaces the previous -R2 geometry.

RCMx range inserts Throughout the RCMx range of inserts, the RCMT20-R2 positive screw-clamped range additions significantly reduce machining vibration, yielding smoother finishes ideal for the surface areas of railway wheel finishing and medium roughing applications of difficult materials. Its optimally positioned grooves control chips even when depths of cut run as small as 1.5 mm, high feed rates range from 0.6 mm/rev to 1.2 mm/rev and cutting speeds reach 90 m/min to 160 m/min. The new -RR93 and -R3 geometries, as well as the Duratomic® grades, have been tested in the most common railway wheel materials, including R7, R8, R9, M1, Class B and Class C.

ELGi Equipments | Coimbatore Email: enquiry@elgi.com | Tel: +91-422-2589555

Seco Tools India | Pune Email: Bharati.Sawant@secotools.com | Tel: +91-2137667300

Cutters for titanium processing

Stock dispensing system

Hoffmann Group recently announced the launch of three new innovative cutting tools at IMTEX 2019. One of the debutant tools at the event included the GARANT master titan. The high-end GARANT master product family includes cutters for titanium processing as reliability is very important while machining pieces made of titanium. The Master Titan family tools are made from GARANT Master Titan premium substrate for maximum bending strength, polished chip flutes to reduce adhesion, defined edge hones for superior tool life, advanced coating that reduces heat input & leads to high wear resistance and overall, the tools offer a maximum process reliability. These tools offer impressive process reliability, productivity and up to 50% longer tool life. This portfolio offers different forms of tools: square/radius, torus & ball nose. They are highly useful for customers in aerospace and medical industries, which use different titanium grades extensively–Ti99.5, TiAl6Zr4Mo2Sn2, TiV10Fe2Al3 & TiAl6V4. The company’s global portfolio includes quality tools and workstations and storage solutions for industrial supplies. In its catalogue and e-shop, Hoffmann Group offers over 70,000 items from 500 leading manufacturers and its own brands, GARANT and HOLEX as well as another 500,000 articles listed in the database.

MAPAL has recently developed the new, cost-effective UNIBASE-S single automatic dispenser that can be connected to existing UNIBASE systems or be used as an individual solution. As the dimensions are compact, the UNIBASE-S stock dispensing system can be installed directly on the workbench. For example, the 96 or 192 compartments are ideal for storing indexable inserts, tools, chucks or personal protective equipment. This saves the employee a trip to the central warehouse and ensures productionrelated article procurement resulting in reduced UNIBASE-S logistics costs. Article removal is quick and uncomplicated in just a few steps. To do this, the employee logs on directly to the device via the integrated touchscreen.

Only registered employees can remove articles. If no employee is logged on, central locking is active. After the desired article has been selected via the pre-installed software, the search function of the software supports this, and an LED illumination identifies the compartment with the corresponding article.

The dispensing drum is rotated manually so that it is at the removal position and the article can be removed. The system automatically registers the withdrawal – in this way, the current status is always used.

Hoffmann Group | Pune Email: r.gour@hoffmann-group.com | Tel: +91-2067105806

54

MAPAL India | Bengaluru Email: rajeshkumar@mapal.com | Tel: +91-9741499824

EM | Feb 2019

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 - March 2019 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Senior Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net Features Writer Juili Eklahare juili.eklahare@publish-industry.net

» Die & Mould The die and mould industry in India has grown over the years and is a foremost contributor in the Indian economy. The industry plays a crucial role for a majority of the manufacturing industries, from electronics to healthcare. The next issue finds out the trends and growth drivers in the die and mould industry.

» High-speed Machining High-speed machining has been around for a few years now, but the laws of physics take on greater importance in the machining process. Aspects, such as, unbalance, thermal expansion, etc., can have an effect on process consistency. The following issue explores the challenges in high-speed machining in manufacturing. » Titanium Machining The key application of titanium has been in the aerospace industry and the enormous advance in aerospace and medical applications has headed towards much better ways of machining titanium.

The subsequent issue explores the scope & prospects and the vital elements in titanium machining.

» Production Software (ERP, MES) Precise, real-time visibility into the production and factory floor is a critical constituent of the current manufacturing setting. Manufacturing Execution System (MES) software raises visibility and transparency into all features of a manufacturing operation, while Enterprise Resource Planning (ERP) process helps a manufacturer manage and integrate the essential parts of its business. The next issue analyses the latest trends in MES & ERP.

Content Developer (Online & Print) Namrata Singhania namrata.singhania@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 Alok Kumar (Sr Manager – South) Bangalore Contact: +91 8861009443 alok.kumar@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 Tarun Kumar Pyne Design Head (Print & Web) Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: +91-7410006435/36

COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . .Page Aequs . . . . . . . . . . . . . . . . . . . . . . . . . .28 Apple Inc . . . . . . . . . . . . . . . . . . . . . . . .18 Bharat Fritz Werner . . . . . . . . . . . . . . 10, 31 Blaser Swisslube . . . . . . . . . . . . . . . . . . .15 Carl Bechem Lubricants India . . . . . . . . . . .9 CERATIZIT Group . . . . . . . . . . . . . . . 10, 31 Chin Fong Machine Industrial . . . . . . . . . . .52 Chiron India Machine Tools . . .Front Inside Cover CII . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 DEES Hydraulic Industrial . . . . . . . . . . . . .52 DesignTech Systems . . . . . . . . . . . . . . . .32 Doosan Machine Tools India . . . . . . . . . . .52 Dormer Pramet . . . . . . . . . . . . . . . . . . . .52 DP Technology Europe . . . . . . . . . . . . . . .38 ELGi Equipments . . . . . . . . . . . . . . . . . . .54 Enairys Powertech . . . . . . . . . . . . . . . . . .14 EOS India . . . . . . . . . . . . . . . . . . . . . . .40

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Name . . . . . . . . . . . . . . . . . . . . . . .Page ExxonMobil Lubricants . . . . . . . . . . . . 32, 50 FEMCO . . . . . . . . . . . . . . . . . . . . . . . . .49 Flir Systems . . . . . . . . . . . Back Inside Cover Fronius International . . . . . . . . . . . . . . . . .42 FusionVR . . . . . . . . . . . . . . . . . . . . . . . . .8 Hoffman Group . . . . . . . . . . . . . . . . . . . .54 Igus India . . . . . . . . . . . . . . . . . . . . . . .13 IHS Markit . . . . . . . . . . . . . . . . . . . . . . .10 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . .12 iRam Technologies . . . . . . . . . . . . . . . . . .16 Jainnher Machine Co . . . . . . . . . . . . . . . .37 Jyoti CNC Automation . . . . . . . . . . . . . . . .1 Kennametal India . . . . . . . . . . . . . . . 17, 31 MAPAL India . . . . . . . . . . . . . . . . . . . . .54 Marposs India . . . . . . . . . . . . . . . . . . . . .53 Mastercam . . . . . . . . . . . . . . . . . . . . . . .10 Micromatic Machine Tools . . . . . . . . . . . . .45

Name . . . . . . . . . . . . . . . . . . . . . . .Page MMC Hardmetal India . . . . . . . . . . . . . . .51 MotulTech India . . . . . . . . . . . . . . . . . . . .33 MurrElectronik . . . . . . . . . . . . . . . . . . . .25 QVI India . . . . . . . . . . . . . . . . . . . . . . . .11 Rittal India . . . . . . . . . . . . . . . . . . . . . . . .4 Seco Tools . . . . . . . . . . . . . . . . . . . . 20, 54 Tech-Clarity . . . . . . . . . . . . . . . . . . . . . .46 Tectly Oil & Chemicals (India) . . . . . . . . . . .23 Timken . . . . . . . . . . . . . . . . . . . . . . . . .26 Tool Grinding Technologies . . . . . . . . . . . .32 Walter Tools India . . . . . . . . . . . . Back Cover World Steel Association (worldsteel) . . . . . .34 YG-1 Industries (India) . . . . . . . . . . . 2, 3, 30 Zavenir Daubert . . . . . . . . . . . . . . . . 19, 33 ZF Pune . . . . . . . . . . . . . . . . . . . . . . . .11

Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Frank Wiegand (COO – Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `1000 em.india@publish-industry.net Tel: +91-7410006435/36 Printing Kala Jyothi Process Pvt Ltd, S.No 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of the magazine contents is only allowed with written permission from the publishing company.

The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.

Internet https://industr.com/en/ Digital edition http://issuu.com/publishi/docs

EM | Feb 2019

FOR A COMPLETE HEALTH CHECK-UP OF YOUR ELECTRICAL EQUIPMENT

FIND THE PROBLEM… BEFORE THE PROBLEM FINDS YOU. • Thermal Cameras • Clamp Meters • Multimeters • Non-Contact Voltage Detector • Moisture Meters • Flex Clamps

4

Circuit Identifiers Clamp Meters Continuity Testers Motor Rotation & 3-Phase Testers

Multimeters Power Analyzers Voltage & Current Testers Ground Resistance Testers

Images for illustrative purposes only.

Megohmmeters

Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs.

For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk

For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk

FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com

FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.flir.in

RNI No. MAH/ENG/2010/34603

Xtra·tec XT Performance and reliability extend your perspective. ®

Power and reliability in equal measure – a unique experience.

Xtra·tec® XT – the next generation of Walter’s highly successful range of milling tools boasts a remarkable new design feature: The pocket position design for the Tiger·tec® indexable inserts has been modified to deliver considerably more power at the same high level of process reliability.

A new perspective on productivity: Xtra·tec® XT – Xtended Technology from Walter.

walter-tools.com