EM Mar 2017

VOL 08 | MAR 2017 | ` 100 www.industr.com

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Defining winners & differentiators

FOCUS EM - Interview

EM - Interview

Steven Stokey, Executive Vice President, Allied Machine & Engg

Keshav Khurana, Executive Director, Wohlhaupter India

(p. 26)

Die & Mould P. 28, 32

SPECIAL FEATURE Welding Technology P. 52 (p. 26)

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E D I TO R I A L

Becoming smart!!!

“While Smart Manufacturing has become need of the day, we also need to consider whether our people are smart enough to embrace Smart Manufacturing”

The global manufacturing industry is changing dramatically. There has been a fundamental change in the way products are designed, manufactured and marketed, as a result of the changing consumer behaviour and their expectations.

Remanufacturing a product with additional or better features has become a necessary trend. Moreover, manufacturing plants are getting transformed from dirty, dangerous & dull to clean, safe & smart.

Since India has projected itself as the destination for manufacturing through `Make in India’ initiative, the industry here must catch up with this trend to succeed in the competitive global manufacturing industry. This eventually calls for Smart Manufacturing.

The question is whether India is ready for Smart Manufacturing adoption? Can Indian Jugaad be considered as Smart Manufacturing? The answers are both yes and no! While Smart Manufacturing has become need of the day, we also need to consider whether our people are smart enough to embrace Smart Manufacturing and whether it is cost-effective. What kind of skill upgradation is required and where do we get it from? How feasible it is to implement it across various levels in the current set-up and infrastructure, from shopfloor to top floor? I got an opportunity to deliberate on the topic in a panel discussion conducted recently during the Symposium on Smart Manufacturing, organised by IMTMA. The conclusion was first to focus on upgradation of technology infrastructure, supporting systems and skills so as to make them adaptable to Smart Manufacturing and then consider the implementation in phases, along with the required change in the mindset. Are you ready for this?

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

Satish Godbole Vice President, Motion Control Div Siemens Ltd

Vineet Seth Managing Director Mastercam India

N K Dhand CMD, Micromatic Grinding Technologies

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

Dr P N Rao Professor of Manufacturing Technology, Department of Technology, University of Northern Iowa, USA

Sonali Kulkarni President & CEO Fanuc India

Dr Wilfried Aulbur Managing Partner Roland Berger Pvt Ltd Dr Ravi M Damodaran President Technology & Strategy Varroc

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

EM | Mar 2017

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CONTENTS

Market

Management

10 NEWS

INTERVIEW 26

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“Making futuristic machines”

Interview with Chandrashekar Sharma, VP—Kennametal Cutting Tools and Machine Tool Business and Prabhakar J, Head—Machine Tool Business, WIDMA, Kennametal India 16

“Meeting high performance requirements”

“Bridge between education and industry”

“Better partnerships with customers”

Interview with Pallath Ravindran, Vice President, Tectyl Oil & Chemicals

28

Quantum shift in industry

A post- event report on the 18th edition of IMTEX organised by IMTMA at Bengaluru 66

Lights, Camera, Action!

A post-event report on the recently held Motion Meeting 2017 at Thun, Switzerland

EDUCATION & TRAINING 46

SPECIAL FEATURE 52

Probing simplifies set-up of mould tools

The article highlights how mould manufacturers can benefit from the advantages of the probing system, which far outweigh the costs associated with purchasing the probes

EVENT REPORT 56

Ensuring maximum productivity The article explains how the use of flexible and high-performance mould making machines have ensured an effective production of light alloy wheels

32

Interview with Arundhati, Co-founder & Managing Director, Plazma Technologies 20

DIE & MOULD

“Bringing value to customers’ business”

Steven Stokey, Executive Vice President, Allied Machine & Engineering Group and Keshav Khurana, Executive Director, Wohlhaupter India

Interview with Ramakant Reddy, Managing Director, LMT Tools India 18

Focus

Emerging trends in the Indian welding industry

The article talks on the changing dynamics of the Indian welding sector and opens new opportunities

Developing a collaborative framework for Make in India capabilities

The article briefs on the collaborative model of Next Generation Precision Grinder, which is an ecosystem to integrate the expertise of the Indian machine tool manufacturers, academic resources with the knowledge from across the globe

VIEWPOINT 60

Spirit of optimism and enthusiasm

The viewpoint discusses insights from industry exhibitors who participated at IMTEX 2017, sharing their experiences

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COVER STORY 22

Defining winners & differentiators

The cover story discusses the trends driving the global economy, analyses the challenges associated with the economic growth and the key shift in thought process that manufacturers need to adopt to take the winning leap towards achieving manufacturing excellence.

EM | Mar 2017

CONTENTS

Technology

Cover image courtesy: Shutterstock

New Products

HIGH SPEED MACHINING 36

Manufacturer gets aggressive with automated machining

MILLING MACHINES 40

The article highlights how a manufacturer of oil & gas industry equipment drives the spirit of continuous improvement with investment in multi-tasking machines by completely automating the machining process

Titanium milling and automation boost productivity The feature details how an aircraft component manufacturer overcomes the difficulties with investments in high-performance titanium milling and automated aluminium machining capabilities

69 Thermal imaging cameras; CNC turning centres; Universal NANOFINSIH machine; Solid carbide end mill; 70 Servo cables; Solid carbide drill; Cylindrical grinding machine; Vacuum and pressure switches 71 Quick-change pallet system; Tool insert holders; Boring tools

Columns 07 08 72 72

Editorial Contents Highlights – Next issue Company index

健椿 - 2017印度金屬廣告製作-三月號.pdf 1 2017/1/17 下午5:50

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EM | Mar 2017

9

MARKET | NEWS

Aequs to open new manufacturing facility in Goa

Entrepreneurship, Growth and Opportunities

Aequs recently announced that it plans to extend its ecosystem in the aerospace and defence sector. The company will open a high-end multi-capability aerospace and defence manufacturing facility in Tuem, Goa. This is the first venture of its kind in the private sector in India, which will manufacture high-end components & systems for aerospace and defence sectors. Speaking on the agreement, Aravind Melligeri, Chairman & CEO, Aequs, said, “The new facility in Goa is a sign of our commitment towards the Indian defence sector.

The facility will cater to aerospace and The sector relies heavily on defence sectors imported equipment and technology. With the new facility, we aim to support the ‘Make in India’ initiative for one of the most critical sectors in the country. Our strategy will also see technology transfers from aerospace giants around the globe, adding further to our manufacturing capabilities besides generating employment of close to 2000 people.” The facility will be a multi-capability precision engineering with CNC machines and new age technology to design and produce precision components.

CII and KPMG India recently published a report titled ‘Entrepreneurship, Growth and Opportunities,’ which examines the current trends and key themes that impact the Enterprise segment in the country. The report was released at the CII Entrepreneurship Conclave 2017 orgainsed by CII in Mumbai.

The aim of the report is to share insights with entrepreneurs to help build scalable business as well as leverage the significant growth opportunities the segment provides, over the next decade. The key The report was released at the CII themes emerging from Entrepreneurship Conclave 2017 the report include how can one manage scalable businesses by building excellence in operations; innovation, describing how relevant is your business going to be in near future and digitisation, discussing digital marketing for entrepreneurs and MSMEs. The report also explains the focus areas for scalability that includes continuous improvement and daily management, and for innovation it comprises of market & capability assessment and execution of the plan. Lastly, for digitisation, the report claims that measuring success and understanding the target base are the focus areas.

DesignTech Systems partners with Solidscape

IMTMA welcomes setting up of Tumakuru Machine Tool Park

DesignTech Systems recently announced a strategic partnership with Solidscape® for the distribution of high-precision 3D printers for manufacturing of wax patterns in India, Nepal, Bangladesh, Maldives, Sri Lanka and Bhutan.

DesignTech will develop the infrastructure to support the expansion and adoption of 3D printing custom manufacturing solutions. Speaking on this partnership, Fabio Esposito, President, Solidscape, said, “DesignTech Systems’ strong business reputation and broad footprint throughout India is ideal Vikas Khanvelkar and Fabio Esposito at to support Solidscape’s growth the launch in Mumbai plan. Having a world-class partner that can deliver top quality high precision 3D printing solutions for custom manufacturing, sales and service throughout India was our strategic goal. DesignTech Systems is the perfect partner to respond to customer demands on time, quality and cost value.”

Elaborating further on this joint venture, Vikas Khanvelkar, MD, DesignTech Systems stated, “Solidscape is a world leader in high-precision 3D printers for custom manufacturing. Their 3D printing accuracy and precision is unmatched globally. We are thrilled to forge an alliance with them.”

IMTMA welcomes the Government of Karnataka’s exchange of a memorandum of understanding (MoU) with the Government of India for setting up of Tumakuru Machine Tool Park in Vasantha Narasapura. The MoU was signed during the recent ‘Make in Karnataka’ conference held in Bengaluru. The Department of Heavy Industry has agreed to extend financial assistance to the Government of Karnataka for setting up a world-class A world-class industrial infrastructure to be set up industrial infrastructure at at the Tumakuru Machine Tool Park in Karnataka the Tumakuru Machine Tool Park. Welcoming the move, PG Jadeja, President, IMTMA and V Anbu, Director General, IMTMA, supported the establishment of an integrated industrial infrastructure facility, which will provide an ecosystem for production and make the machine tool sector more competitive. The park will also enable production of hi-tech machine tools, enhance exports and attract investments. Once functional, the park is expected to boost the domestic turnover of machine tools, while saving foreign exchange and reducing imports. Furthermore, the park will also create over 4000 jobs in manufacturing and administrative fields in India.

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EM | Mar 2017

NEWS | MARKET

New materials developed for use in aerospace components

Nasmyth Group establishes new company in India

Morgan Advanced Materials recently produced two new materials, which offer superior performance and higher casting yields when used in injection-moulded ceramic cores for the aerospace market. Building on the success of its existing range of specially-engineered ceramic core products, the new materials, P-57 and P-59, can generate exceptionally fine crosssections in aerofoil and turbine blade casting, while offering enhanced surface finish. Speaking on this new development, Robert Park, GM - Certech, Morgan Advanced Materials, explained, “As a business, our success is built New materials have been developed on working closely with customers which can generate fine cross-sections in throughout each stage of the aerofoil and turbine blade casting development and production process to deliver solutions, which respond to their unique commercial challenges. In this case, the development of our proprietary advanced ceramic materials P-57 and P-59 offer us superior performance in a number of areas, allowing us to facilitate the casting of design features that have previously been very difficult to achieve. With P-57 and P-59, our customers can now create smoother and more intricate shapes than ever before.”

Nasmyth Group recently celebrated the incorporation of its new company at the Aero India 2017 exhibition and air show in Bengaluru.

The inauguration of Nasmyth India further established the company’s presence in India and addressed a growing international need for design engineering expertise within the aerospace sector.

Speaking about this initiative, Peter Smith, CEO & Chairman, Nasmyth Group, explained, “It is hard for us to recruit engineers in the UK who are qualified to deliver the challenging level of engineering design and production skills that we require as a growing, leading-edge mid-cap supplier to global aerospace and associated industries. The new company that we have incorporated will provide a permanent and flexible core resource within Nasmyth Group to support our customers, now and in the future. It represents a big cultural and organisational commitment for Nasmyth Group and is driven by our need to access, train and develop a greater pool of qualified engineers, who are able to meet our business needs.”

Joint development of machinery project

ZF opens first technology centre in India

Starrag Group and Klingelnberg have recently announced that they are going to cooperate for the development of powerful products for complete machining and a joint purchasing policy. Speaking about this initiative, Jan Klingelnberg, CEO, Klingelnberg Group, said, “We are the perfect match in terms of technological know-how and also with regard to market segments. Starrag has intensive coverage of the aerospace area, among other things, and we have a strong presence in the automotive industry.” While Starrag has the entire technology spectrum for cutting, turning, drilling and grinding of metal workpieces in its portfolio, Klingelnberg is the gearing technology specialist. This includes the development and production of machinery for bevel gear and cylindrical gear machining. The cooperation is going to start with joint development of the machinery. Other cooperation projects are also in the pipeline. Elaborating further, Walter Börsch, CEO, Starrag Group said, “We have deliberately sought out the Klingelnberg Group as our partner because we have a very similar company philosophy and culture.”

ZF Friedrichshafen recently inaugurated its first technology centre in India in Hyderabad. The ceremony took place in the presence of K Chandrashekar Rao, Honorable Chief Minister of Telangana, Dr Stefan Sommer, CEO, ZF Friedrichshafen, Mamatha Chamarthi, Chief Digital Officer & Executive Lead - India Technology Center and other senior government and ZF officials. Speaking about this new development, Dr Stefan Sommer, said, “At ZF, we are experiencing substantial growth in many regions, and this Dignitaries at the inauguration of the new technology is especially true in centre opened by ZF India. In a dynamically changing and increasingly digital world, speed is of essence and we are proud to have been able to complete the set-up in a short period of time.

We look forward to establishing our presence in such an exciting part of the region and growing its reputation as an innovation hub.” Elaborating further on this initiative, Mamatha Chamarthi added, “The India Technology Center will be rapidly integrated into the engineering ecosystem of ZF and become a pillar of innovation for the company.”

EM | Mar 2017

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MARKET | NEWS

EMO Hannover 2017 to focus on production technology EMO, the world’s premier trade fair for metalworking sector, is scheduled to be It is expected that EMO Hannover 2017 will generate important impetus for held on September 18-23 in Hannover. The exhibition is being organised by implementing the much-discussed concept of Industry 4.0 or the Internet of VDW on behalf of the European Things (IoT). The trade visitors to the Association of the Machine Tool EMO are from the major industrial Industries (CECIMO) from Brussels, sectors like the automotive, machinery Belgium and in conjunction with the and plant manufacturers, aerospace, trade fair hosting company Deutsche precision mechanics and optics, Messe from Hannover, Germany. among others.

Addressing the market in India, Currently, the Indian economy is Christoph Miller, Director – Trade Fair, growing faster than the other newly VDW, said that this year’s expo is industrialising countries. The machine expected to create a record as tool consumption is predicted to grow compared to the previous edition held by 8.4% in 2017. The EMO Hannover in 2013. So far, the exhibitors covering 2017 exhibition will be a platform for 1,50,000 sqm of net exhibition area the Indian exhibitors to showcase has been confirmed. More than 400 their cost effective and technology exhibitors are from Asia alone. Further, rich solutions to the world 28 exhibitors have confirmed their The EMO Hannover 2017 exhibition was announced at a press conference metalworking sector. The VDW has participation from India and this count recently also included an India Day in the EMO is expected to increase. Miller further Hannover’s supporting programme. added, “The 2013 Hannover edition witnessed around 1,43,000 trade visitors On September 20, 2017, the Indian experts will be reporting on technical and from more than 110 countries. The proportion of abroad visitors stood at 42%. commercial trends in their homeland, and mapping out the resultant challenges It had attracted more than 2,130 exhibitors.” for production technology.

2nd symposium on Smart Manufacturing at BIEC, Bengaluru IMTMA recently organised the second edition of the symposium on Smart be boosted by the implementation of Industry 4.0. The government should Manufacturing at BIEC, Bengaluru, which focused on ‘Evolving the factory introduce policies around Industry 4.0 to leverage ‘Make in India’ campaign and of the future’. It was improve India’s industry attended by more than 250 competitiveness.” delegates from around 110 Interesting presentations companies. Smart factories, were also made by technocrats Internet of Things and who covered subjects, Industry 4.0 were some such as manufacturing plant of the key areas that were integration, integrated smart the topics of discussion automation, smart and costamongst participants at the effective automation, IIoT symposium. of robots, Big Data analytics The two-day event, Smart factories, IoT and Industry 4.0 were the key areas discussed during the symposium for smart manufacturing, which featured technical intelligent clamping and presentations, case studies, interactive sessions and panel discussions with gripping, smart logistics, and many more. The panel discussions debated and industry experts was the highlight. ‘Automation Buzz’, a concurrent exhibition brainstormed on the topics of application of Industry 4.0 & IIoT in Indian context displaying automation devices and systems, software and a host of automation and Smart Manufacturing – What is in it for me? solutions was also held concurrently.

Given the importance of the subject and wide coverage of topics, CEOs, top The symposium started with a keynote address by Rahul Gangal, Partner, management executives, senior executives, practicing engineers, industry Roland Berger Strategy Consultant, who gave an overview of smart consultants and R&D specialists from manufacturing industries, such as manufacturing in the Indian context, while highlighting the challenges, automotive, auto components, consumer durables, machine tools, tool rooms, roadblocks and opportunities that emerge from it. He said, “There is an aerospace, defence and railway units, general engineering and other discrete imminent need for a policy at national level in India for Industry 4.0. Exports will manufacturing industries also participated in the symposium.

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EM | Mar 2017

MARKET | INTERVIEW

“Making futuristic machines” Chandrashekar Sharma, Vice President— Kennametal Cutting Tools & Machine Tool Business and Prabhakar J, Head—Machine Tool Business, WIDMA, Kennametal India, in an interview with EM, brief on their company’s latest advancements that help customers adapt various configurations and meet the manufacturing needs of the industry. Excerpts…

Can you brief us on the new launches under WIDMA during IMTEX 2017?

Sharma: Under the WIDMA brand, we have four product ranges—Special Purpose Machines, Special Vertical turning machines, CNC Tool & cutter grinder machines and Fixtures & Tooling solutions. In fixturing solutions, we highlighted singleminute set-up change fixtures, CGcentered fixtures that facilitate quick rotations and fixtures that enable free chip flow during operations. In the tool grinding section, we displayed the PCD tool grinding machine with the latest features, including linear motors, load sensors and acoustic sensors.

The machine has built-in automation capabilities for dressing, probing, load/unload, honing, marking, etc.

Prabhakar: In the new launches, we have simplified machines by reducing the number of elements, thus, facilitating an easy and low maintenance, high reliability and superior performance.

What are your company’s strategies so as to meet customerspecific requirements?

Sharma: Today, customers are demanding a final output based on their input components. As such, we take the 3D data of these components and start programming through the CAM software. Then, with the help of our latest Novo tooling application software, we simulate the complete machining operations. This provides them with a complete machining strategy to achieve faster machining cycle time, reduce machining costs and improve productivity.

Prabhakar: In any metal cutting operation, the process is between the tooling, machine and fixtures.

We have expertise in all these areas, thus, helping customers to meet their specific requirements.

How is the acceptability of IoT-enabled machines with the Indian customers today?

Sharma: The whole concept of Industry 4.0 is currently sinking in the industry. Many companies during IMTEX have demonstrated IoT-enabled machines. I believe that remotely monitoring a machine’s performance during its operation will become an upcoming trend.

Prabhakar: In future, machines on shop floors should be interconnected and a lot of decision-making should happen remotely in terms of machining activities. We are working on this trend for making futuristic machines.

How do you decide to design the machines right the first time?

Sharma: We do the complete engineering empathising with our customer. We conceptualise the machine depending on the requirements and challenges faced by them. After discussing this with their application team to ensure that the customer’s inhouse knowledge is concurrent with our concept, the machine is passed to the design department. We then build up the entire design and do a complete FEM analysis (both static and dynamic) to understand its deliverability, and then finally go for manufacturing the machine.

Prabhakar: We also do a lot of process optimsiation on the machines and conduct operational excellence programmes such as DFME to improvise our product designs and process optimisation.

Which market sectors are targeted with WIDMA? Sharma: Our Special Purpose Machines are used for batch production and mass production of metal cutting operation, majorly in the automotive sector. The vertical turning machines finds application in pump & valve segment and the railwaywheel segment. The tool grinding machines are used by tool making customers for applications such as tool manufacturing and re-grinding. Lastly, fixtures are used by almost all industry verticals, such as the automotive, aerospace and railways.

Moving ahead, can you brief us on your expansion plans for the Indian market?

Sharma: Our company has been growing quite rapidly in India.

This year, a total budget of capex Rs 80 crores will be invested into the Indian facility. We have also expanded our shop floor facility by adding more machines and quality equipment to extend our production capacity. In addition, we are investing in developments of new software to automate the design process so as to bring new products to the market faster. ☐

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EM | Mar 2017

MARKET | INTERVIEW

“Meeting high performance requirements” …says Ramakant Reddy, Managing Director, LMT Tools India, while highlighting his company’s new launches at IMTEX 2017, in this interaction with Maria Jerin. He also discusses his company’s plan of expanding its manufacturing base so as to produce new range of cutting tool products locally. Excerpts…

Can you brief us on the business segment and market presence of your company in the Indian market?

In India, LMT Tools started its operation in 2003 as a sales subsidiary. Later, in 2013, we commenced our manufacturing facility in Pune which was built around 30,000 sq ft at MIDC Chakan. In this facility, we produce gear cutting tools, mainly hobs for the majority of the automotive companies in India. We also export gear cutting hobs to European countries from here.

Tell us about your participation at IMTEX 2017? What were the new products launched and how was the response?

At IMTEX 2017, we launched our carbide range of tooling solutions in Gear Cutting segment such as solid carbide hobs and indexable tools. In round tools segments, we have introduced new copy milling plate CopyMax2, which has improved cutting and material properties as well as a fully functional second cutting edge. With this, we are meeting the high performance requirements in the die and mould making industry. To provide with the best-in-class customised solutions, recently at AMB 2016, we adopted a new slogan ‘exactly yours’, which means supplying right tooling solution as per the requirements of our customers.

During IMTEX, we had discussions with many of our key customers, wherein we received good responses from quality visitors as well. Thus, we expect to make decent business in the coming months.

How has been the performance of the cutting tool industry so far? What are the key emerging applications that are driving towards growth?

Due to the recent demonetisation in India, a drop in the production & sales of the automotive industries was reported in the month of December 2016. As a result, the cutting tool industry had witnessed a considerable impact. However, the scenario

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started improving from the beginning of this year and as such, we have reported a growth in our January sales, as compared to the previous year.

The key emerging applications, which are driving towards growth, include gear cutting, auto components, etc.

How do you see the demand for your products in the Indian market currently?

We are quite competitive in the Indian market by supplying high quality and high productivity tools. The demand for our tooling solution is increasing, which has resulted in the spread in our customer base too. We believe that we are a market leader in the Gear Cutting segment. In other segments, such as Milling & Threading, Rolling Systems, Advance Tooling and Reaming, we are focusing on strengthening our market presence. A majority of our tooling business comes from the automotive industry. However, in recent years, we see a surge in the demand from the die & mould, medical equipment and aerospace manufacturing segments.

How do you strategise your business model so as to meet the challenging requirements from the customers?

We are constantly innovating and coming up with new grades, substrates and superior coating technology. This allows our tools to perform at higher cutting parameters, thereby, enabling our customers to benefit from productivity improvement and an increase in the tool life. We also provide a complete range of PCD tools for machining difficult-to-machine materials.

What are your company’s future plans for the Indian market?

In India, we are planning to expand our manufacturing base so as to produce product lines in the area of tapping, rolling, milling and threading locally. We are already in the process of producing solid carbide tools in our Pune facility. In the coming years, new products will be launched from this facility. ☐

EM | Mar 2017

MARKET | INTERVIEW

“Bridge between education and industry” …says Arundhati, Co-founder & Managing Director, Plazma Technologies. In an interaction with Suchi Adhikari, she discusses how her company plans to create grass-root level awareness of automation and robotics amongst students. Excerpts…

How has the plasma cutting technology evolved over the years so as to meet the challenging requirements in machining difficulttomachine materials?

At Plazma, we have innovated different forms of plasma cutting from 2D, 3D, to 6D and have met global standards. We believe in the 6D vision of working. An example of this would be our virtually indestructible, compact, water-cooled Plazma torch entirely made of stainless steel, with just two main consumables and best cutting economics. A Plazma cut edge is virtually slag-free, with minimal heating or distortion.

Tell us more about the technology behind your Plazma Torch Head.

Our focus is Plazma Technology made simple yet world-class. The US and other globally patented Plazma torch technology combined with a rugged non-electronic power source present the most reliable metal cutting tool. This metal cutting tool combined with robotic precision gives enormous benefits to fabricators. In robotics, we have recently received the Japanese patent for extension of robotic arm reach, which is useful in all robotic metal working application.

RoboPlazma Generation I technology for structural steel and metal cutting was developed on the shopfloors of our customers, by understanding customer requirements and solving them.

Plazma has successfully integrated robotics in heavy fabrication, hot steel processing and other industries. With RoboPlazma Generation II technology, we got into disruptive innovations for applications such as welding, measuring, grinding, marking, metal blasting, etc. The combination of Generation I and II technologies has been envisioned to transform Indian shopfloors into the ‘factory of the future’ comprising of digital engineering, artificial intelligence, collaborative human-robot automation and Industry 4.0. There are about 10 additional applications currently in development.

How is the potential and demand for robotic plasma cutting systems in India, especially in SMEs? To ensure international quality and consistency, SMEs have realised the need for bringing in a 2D automation solution and are still in the process of getting into the space of robotics. In fact,

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the perception of SMEs that robotic technology is meant only for huge quantity repetitive jobs is not true. Our RoboPlazma technology and its robotic intelligence enables our robots to do varied new jobs with equal accuracy, efficiency and intelligence.

Which are the industry sectors targeted for your products?

RoboPlazma Solution is applicable in multiple industries, such as heavy fabrication, metrology, automation, ship-building, offshore, petrochemicals, steel rolling mills, infrastructure and large metal working industries. In each industry, multiple applications related solutions are provided.

Our solutions are also used in majority of infrastructure project fabrication, such as airports, buildings, bridge builders, offshore platform builders, PEB, shipyards, energy equipment builders as well as stainless steel manufacturers to cut hot rolled plate.

How important is it for companies to have a culture of innovation?

Can you share your initiatives to boost the innovation culture?

Innovation enables a company to get that required edge over the competition and ensures that one stays ahead of the technology curve. For this initiative, we have started a RoboPlazma knowledge initiative. We have tied up with numerous local and global engineering colleges and universities by creating a platform for sharing our knowledge with engineering students and faculty.

At the RoboPlazma Technology Centre, we expose them to the world of robotics and automation, software and hardware. This is our way of making Roboplazma accessible to the education field, and become a bridge between education and industry.

Can you share your short-term and long-terms plans in India as well as outside India?

Our short-term and long-term goals are creating many ‘factories of the future’ in India, enabling the combination of man and machine to become the mainstay of the heavy metal industry, creating a grass root level awareness of robotics and artificial intelligence for students, becoming a company at the forefront of Industry 4.0 and innovating new efficient products. India needs to be known as an engineering giant, beyond IT and we hope to add to it. ☐

EM | Mar 2017

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MARKET | INTERVIEW

“Better partnerships with customers” Pallath Ravindran, Vice President, Tectyl Oil & Chemicals, in this interview with Suchi Adhikari, discusses the differentiating strategies that his company is implementing in order to create partnerships with customers and be a solution provider, rather than a product supplier. Excerpts…

What were the new products and technologies launched during IMTEX 2017?

This IMTEX, in line with our strategy of customised solutions, we have launched a new, sensitive product-line in India called Quenching Fluids, which is for the heat treatment market for the metals. These products are already available globally, but we are launching it for the first time in India. The reason we delayed was because we had to fine-tune our products as per the Indian market conditions.

What is the impact of the ‘Make in India’ initiative on the Indian manufacturing sector? How is your company strategising its plan for manufacturing activities in India?

It is a great initiative to boost the manufacturing sector in India. While a lot of activity is happening, the ground reality is still to take shape. Nevertheless, many companies are planning to come to India and set up a manufacturing base.

We, from Tectyl, have already taken this initiative forward. Last year, we set up a new plant in Chennai. All the products that we sell today are manufactured in India.

Brief us on the major trends in your industry sector in the upcoming years.

In the industry front, there is a graduation happening with a lot of machine technology and cutting tool technology coming into India. There is a huge change happening in the way machining is done in India. Another major change that will be noticed in the Indian metalworking industry is that there will be a stage when the fluid manufacturer will engage in a partnership with the customer.

How do you plan to align your company’s Vision 2020 strategy with these trends?

One of the major investments that we do in our company is in R&D. We have 25% of our staff in Korea, working in the

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R&D department. Our focus would be to work on customised solutions and gear up with the technology to make those solutions for our customers in the coming years.

What would be the differentiating factor in your product in comparison to the existing products?

We are gearing up for the future with the total fluids solution concept. This is the first step towards our partnership with customers. We bring in R&D along with sales to the customer, rather than only products. We look forward to better partnership in the future with the product profile that we are expanding. Right now, we are only into metal-cutting. Last year, we introduced metal-forming. This year, we are launching the quenching fluids and in the coming year, we will be launching rolling oils. This completes the entire portfolio of the metalworking applications.

We are one of the few companies who will be offering this entire package to customers. Customers will perceive us as a solution provider and not just a product supplier.

How has your company coped with the rapid pace of digitalisation and Industry 4.0 in the manufacturing sector?

We are new to the Indian market, in terms of the manufacturing facility and the organisation set-up. We are not fully into digitalisation yet, but the work is going on.

In a year or two, we will be completely geared for the entire digitalisation of the company.

How do you plan to expand your company’s market presence in India?

Our objective is to increase the market share in the next two years by providing product solutions and customised solutions to our customers. In terms of expansion, we plan to open a second plant in 2019 in India. We also plan to target the mining sector in the future. ☐

EM | Mar 2017

C O V E R S TO R Y

TECHNOLOGY

TOWARDS MANUFACTURING EXCELLENCE

I m ag es co u r tes y : S h u tter s to ck

Defining winners & differentiators

With the Indian government’s ambitious agenda to increase the contribution of the manufacturing sector to India’s GDP from its current 16% to 25% by 2025, this sector will witness to grow 5 times from its current base in the coming years. But this staggering growth is associated with challenges of today’s and tomorrow’s needs. As such, one who alters and re-defines the way manufacturing excellence has been thought of and put in motion in the organisation will be considered as winners. The feature discusses the trends driving the global economy, analyses the challenges associated with the economic growth and the key shift in thought process that manufacturers need to adopt to take the winning leap towards achieving manufacturing excellence.

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Pallab De Partner – Operations Consulting PwC Management Consulting pallab.de@in.pwc.com

Mandar A Mahajan Associate Director PwC Management Consulting mandar.mahajan@in.pwc.com

EM | Mar 2017

TECHNOLOGY

C O V E R S TO R Y

Some of the megatrends that are driving our economic, social, and political environment

The world is changing at a rapid pace and it can be hard to keep up. One way of making sense of the churn around us is to understand the major underlying forces, or megatrends, driving the economic, social, and political environment. All of these megatrends are already happening and their impact will continue to grow over the coming decade. These are the global events, which affect each and every country/region where the organisations want to operate.

Megatrends driving global economy The manufacturing companies, which form the backbone of the economy, communities and markets are adapting to these changes. Many global companies have responded to these megatrends and are capitalising on the disruptiveness these trends are causing. Some of these trends are as follows: Demographic shifts: The largest pool of young and employable workforce is not new to India. The UN predicts that by 2050, India will have over a billion people eligible to enter the job market. The impact is huge not only in terms of job creation, but also in having more people to save and pay taxes, which has the ultimate potential to transform economies and power investments.

Shift in global economic power: By 2050, the E7 economies (Brazil, Russia, India, China, Indonesia, Mexico and Turkey) are projected to be twice the size of the G7 economies (US, Japan, Germany, UK, France, Italy and Canada). It is a fact that through the FDIs and new entrants in the Indian economy, numerous industrial manufacturing companies will be citing an emerging market revenue growth as a key driving factor in earnings for both, now and in the future. India currently stands in the third place and is projected to overtake the US economy by 2040 in PPP terms.

Accelerating urbanisation: Smart city and urban development are important pillars of the government’s developmental efforts. The percentage of people living in urban centres is projected to grow from 50% today to approximately 72% by

EM | Mar 2017

2050. The organisation’s strategists have already started planning at city level than at consolidated levels.

Climate change & resource scarcity: We, as a nation, have already ratified the Paris Accord and will have impact on each of the industry in the way it consumes resources, power, energy and the impact it causes on the environment. The government’s ZED manufacturing initiative does focus on the Zero Effect.

Technological breakthrough: The impact of technology, convergence of industries created by digitisation, mobile technology, the cloud, and other breakthrough technologies have fundamentally changed the business landscape and are creating extraordinary value.

These are not just predictions, but they are a given. The impact is going to be seen exponentially over the period of the next decade. This has created immense opportunity for India and the business environment in which Indian companies operate in.

Challenges associated with economic growth India is already the third largest economy based on purchasing power parity. We will become the third largest by 2050 after China. With the current growth rate, the Indian economy will be worth USD 6 trillion as an economy in 20 years. The government has put forth an ambition of becoming USD 10 trillion in the same period with a staggering growth rate of 9% per year.

For the manufacturing sector, all of this has a far greater implication. Currently, the manufacturing sector contributes roughly 16% to the GDP of India. The government of India has the ambition of increasing this share to 25% by 2025. This means that while the economy will grow by 3 times in the coming 20 years, the manufacturing sector will grow by 5 times from its current base. This staggering growth will be associated with challenges, some of which are faced today and some of which will be faced in the coming future. Some of

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C O V E R S TO R Y

TECHNOLOGY

Currently, the manufacturing sector contributes roughly 16% to the GDP of India, but the government plans to increase this share to 25% by 2025

these challenges are: 1. Resource constraints including land, infrastructure, water, etc 2. Policy and regulator issues including government policies, compliances, safety, etc 3. Adaption of technology, including availability & understanding of technology itself 4. Lack of research & development and innovationrelated constraints 5. Lack of skilled manpower including the employability of the population Several government policies are seen to be addressing these issues through their campaigns & programmes, which have been launched recently. This is especially true with initiatives like the ‘Make in India’ or ‘Skill India’, where the ease of doing business ranking improvement and many other aids are provided by the government. The macro factors, which will aid this staggering growth, are getting addressed or will get addressed eventually.

Leaping towards manufacturing excellence The important point is, how does the organisation respond to this growth challenge? Looking inwards, what should the manufacturing organisation do? How can it be ready to take advantage of this massive shift? The winning leap lies in improving manufacturing competitiveness and bringing structural shifts in the way we address manufacturing excellence.

The winners will be the ones who are going to evolve the way they address the manufacturing excellence landscape. It will be the ones who alter and re-define the way manufacturing excellence has been thought of and put in motion in the organisation. The various concepts/tools/philosophies, such as

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WCM, Lean Manufacturing, TPM, etc do address problems, provide solutions and improve the organisation. These are the fundamentals required for the organisations but today, they have become table stakes, which is basically the minimum requirement.

Shift in thought-process is key We, at PwC, tried to reference our ‘Fit for Growth’ framework to replicate the thoughts for bringing the structural shift in the way organisations drive manufacturing excellence.

The tools & techniques will follow and will find the fitment in the following pointers. These are the fundamental thoughts in which the organisation has to rethink and focus in order to steer towards the journey on manufacturing excellence. The manufacturing excellence winners should focus on: 1. Identifying the differentiating capabilities: Identifying at least three to six differentiating capabilities, the things that your company does better than anyone else, enables you to compete in the most effective way. These are the capabilities, which the organisation already has and can be leveraged to create an edge over others in the business environment. Identifying these capabilities channels the organisational strategy & execution. These channeled manufacturing excellence initiatives gives purpose to the employees compared to the run-off-themill/generic agendas.

2. Align the cost structures with the identified differentiators: Deploy the investments in manufacturing excellence against the key identified capabilities. Commit to these differentiators. This commitment is the backbone of the success in manufacturing excellence drives. It is the indicator of

EM | Mar 2017

TECHNOLOGY

C O V E R S TO R Y

Manufacturing excellence drive takes a different shape through these three types of initiatives

the organisational strategy to be put into execution.

This commitment will also mean that the excellence drive will be working on the critical few areas, which the organisation strategy has identified as important for the future.

3. Re-organise for growth: Change the way the success of the manufacturing excellence is measured in light of the differentiating capabilities. The new metrics & organisational changes take shape in this step. The manufacturing excellence drive takes a different shape through the following three types of initiatives: a. Transformation initiatives b. Streamlining initiatives c. Continuous improvement The typical manufacturing excellence drives are seen to be woven around continuous improvement initiatives, but the growth requires the transformation initiatives, which are for the differentiating capabilities & streamlining initiatives in order to eliminate the bottlenecks. This step also requires re-thinking in terms of how the teams & various hierarchies will contribute towards achieving excellence.

4. Create an environment & evolve the culture: To embed & sustain this shift from table stakes manufacturing excellence drives to the strategy contributing to the manufacturing excellence drive, putting the culture to work is necessary. For sustenance, the differentiating capabilities will also help in identifying the key differentiating behaviours that are expected from individuals. These few yet critical behaviours will form as the models within which the workforce is expected to align. This alignment will ensure that the new manufacturing excellence drive sustains.

EM | Mar 2017

Putting organisational strategy to execution These fundamental thoughts can create unique manufacturing excellence initiatives for the organisations.

These initiatives will contribute towards putting organisational strategy to execution. The benefits that can be realised by applying these thoughts prior to launching the manufacturing excellence drive are immense. The drive created around these thoughts will ensure that right tools are used instead of running behind the jargons. This thinking will also help the organisations and the sponsors of the manufacturing excellence initiatives with a clear visualisation of what to expect from the efforts, what will be the areas that the drive need not address, the manners in which the efforts will help the organisation to execute the strategy, etc. The differentiators that the organisation identifies will play a vital role in each and every phase of the manufacturing excellence journey. Many organisations have started working towards this journey with these fundamental thoughts and will find themselves well equipped to address the changes coming through the megatrends.

Towards addressing competitiveness In conclusion, the megatrends and the growth potential of India needs the organisations to re-think on creating new ways of addressing the challenges. The Indian manufacturing sector needs to be ready for this growth and the changes that are visible.

The manufacturing excellence initiatives have to address the manufacturing competitiveness gap and lead the organisational change. This will not get addressed through having run-off-themill or table stakes oriented manufacturing excellence drives.

The re-thinking, therefore, needs to focus on how manufacturing excellence drives differentiators and evolve as winners. �

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MANAGEMENT | INTERVIEW

“Bringing value to customers’ business” …says Steven Stokey, Executive VP, Allied Machine & Engineering Corp, along with Keshav Khurana, Executive Director, Wohlhaupter India, while highlighting the benefits of both the companies coming together for the Indian market. He also discusses his company’s strategy so as to meet customer-specific requirements. Excerpts from the interview…

Can you brief us on the recent acquisition of Wohlhaupter

by Allied Machine & Engineering? How have both these companies benefitted from this partnership?

Our company is focused on drilling systems and Wohlhaupter is focused on boring systems. In the machining process, boring is the next operation after drilling. So, majority of our existing customers who are into drilling processes are also in need of boring tools to complete their machining activities. Hence, acquisition of Wohlhaupter is a strategic move for us as it provides complete solution to our customers.

According to this collaboration, we recently acquired majority of the shares of Wohlhaupter GmbH, Wohlhaupter USA and Wohlhaupter India. With this, we have a strong application engineering support in India with 18 engineers. We are bringing both organisations together and conducting training in exchanging ideas on both the company’s businesses to raise technical capabilities of our people.

competition dynamics within the Indian manufacturing industry change and what will be the benefits to the customers?

Globally, in the current scenario, all companies are constantly innovating to improve customer’s productivity and reduce their manufacturing cost per component. So as to succeed in the Indian market, we need to be flexible and responsive with customer discussion. We are listening to our customers’ challenges and providing them solutions for their problems.

Considering the demographics of India, a vast majority of the population in India is under 30 years old, which shows the huge workforce and the potential demand for a variety of goods and services. We entered into the Indian market at the right time in 2005 coinciding with the country’s growing economy.

Now, through this partnership, instead of an incremental growth, we can grow exponentially. We are driving to bring both our teams together to get much closer to our customers, respond to them faster and bring values to their business.

What are the factors that are driving innovations globally?

With the ‘Make in India’ in background, how will the

What is your company’s business model to cater to customer’s requirement to demand quality and productivity

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EM | Mar 2017

INTERVIEW | MANAGEMENT

“By supplying quality tools, it enables our Indian customers to compete on the global market by making flagship products that are of world-class standard. We have to bring value to our customers in order to increase their profits.”

Steven Stokey, Executive VP, Allied Machine & Engineering Corp

“Now, we are known to majority of the Indian machine tool companies together as AlliedWohlhaupter. Definitely, machine tool players need our help to take care of their tooling projects.”

Keshav Khurana, Executive Director, Wohlhaupter India

improvement on their shop floor?

Generally, people have different demands in terms of productivity, price and quality. Our business model is not to build products to be at the lowest price. We are known for our quality craftsmanship all over the world. By supplying quality tools, it enables our Indian customers to compete on the global market by making flagship products that are of world-class standard. We have to bring value to our customers in order to increase their profits. On the other hand, we are strengthening our relationship with machine tool builders so that our tools will be delivered along with their machines and opens up new opportunities for customers.

Khurana: Now, we are known to majority of the Indian machine tool companies together as Allied-Wohlhaupter. Definitely, machine tool players need our help to take care of their tooling projects. We got lot of inquiries from them and we have done lot of tooling valuable proposals for their customers. We have already established successful projects across India. They look at us as a solution provider for hole making. Wohlhaupter have relationships with certain companies and Allied have strong relationships with companies like Mazak. Now we are sharing our information, allowing both of us to be successful.

The tooling industry, today, faces challenges with the advent of new materials. Amidst these challenges lie many opportunities that are largely led by technological advancements. What is your take on this?

We have a long history of providing standard products that customers can use for machining difficult-to-machine materials. We have also developed special geometries that can form chips. Chip formation is the critical factor in machining these materials. Wohlhaupter and Allied together have wide range of solutions as far as chip formation is concerned.

EM | Mar 2017

Allied recently announced new GEN3SYS XT Pro line of high penetration drilling products, which features inserts and holders designed for three new geometries (P, K, N) and will be available for steels (ISO material class P), cast irons (material class K), and non-ferrous materials (material class N). Thus, we are aligning ourselves to make it easier for customers to understand.

What is your company’s approach towards digital platforms?

How are you leveraging such platforms to roll out tooling capability?

Khurana: Wohlhaupter has its own online digital platform called ‘Tool-Architect’ that has been designed to provide a fast and easy way to build a tool-based on customer specific requirements via search and filter functions. It is very easy to handle.

In a similar manner, Allied has established an online tool called Insta-Quote™. It is the most flexible and rapid method available and its user-friendly menu guides customers through a simple process to design, draw, obtain a quote and order customised tooling in minutes.

What are your plans for India, in terms of expansion, increasing market share, manufacturing activities, etc?

We have certain plans for the Indian market in the next 3 to 5 years. First year, together, we will be working to form an Allied–Wohlhaupter culture in India. As we continue to provide outstanding service to our customers throughout, then year 2 to 5 is about strategic planning for the Indian market.

It’s about adding more people providing outstanding service in a bigger way to other countries. Our vision in five years will be to have twice as many people as now. Then we want India to become a self-sufficient application group so that they can provide immediate responses to global customers, which is in place now. So, we want to continue to build that strength.

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DIE & MOULD

FOCUS

ENSURING MAXIMUM PRODUCTIVITY An in-house tool and mould making allows a higher degree of flexibility, along with having an absolute control over the quality of the moulds. This also adds to the accuracy and reliability of the machines, which in turn is an important consideration in maintaining daily business. The article discusses how with the use of DMG MORI’s flexible and high-performance mould making machines has helped the RONAL GROUP to ensure an effective production of light alloy wheels. A read on‌ 28

EM | Mar 2017

FOCUS | DIE & MOULD

moulds needed for the low-pressure casting of aluminium and delivers them to product facilities spread all over the world.

The sophisticated production is carried out with the expertise of its 74 specialists and a high-performance machine park that includes 16 machine tools from DMG MORI.

Manufacturing light alloy wheels

As a manufacturer of quality light alloy wheels, the RONAL GROUP supplies virtually all big car manufactures from its base in Swiss Härkingen. The wheels from the company that was founded in 1969 impress with their first-class design and high standards of quality. The company employs over 6,000 people worldwide at its total 19 locations. The Portuguese company ALRON Lda located in Murtede has also been part of the corporate group since 1990. It produces the tools and

EM | Mar 2017

“Light alloy wheels are far more than just an eye-catching feature on cars. They also contribute greatly to the safety of the vehicle”, says Andreas Dusold, Managing Director, ALRON. And that is exactly why the RONAL GROUP places such great demands on the quality of their products. “Our customers also expect this, of course,” he adds. The latter comprise more or less all big car manufacturers – from the Volkswagen Group to Mercedes-Benz and BMW and on to include the Toyota Group, to mention just a few. 97% of the light alloy wheels are destined for this OEM business. This also requires close cooperation with customers. According to Dusold, “We pursue a full-service philosophy in this respect. The scope of our service starts with the design and product development, including prototype construction and encompasses the entire serial production including all quality controls.”

The numerous process steps reflect just how complex it is to manufacture light alloy wheels— aluminium is first melted and then blanks formed in a low-pressure casting process.

These blanks undergo an X-ray control before being released for the next manufacturing steps. Heat treatment, mechanical processing, manual finishing and finally surface treatment round off the process steps. A key part of production is tool and mould making, which is carried out in-house, by the RONAL GROUP at its main plant in Switzerland and ARLON in Portugal. The location in Härkingen is responsible primarily for the development, while the Portuguese plant manufactures all the tools and moulds for the production facilities to be found all around the world.

State-of-the-art machine tool technology The importance of in-house tool and mould making is easy

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DIE & MOULD | FOCUS

A DMC 125 FD and a DMC 125 U duoBLOCK® from DMG MORI are among the latest investments in the machine park at ALRON

The plant in Portuguese Murtede supplies the production facilities with tools and moulds for low-pressure aluminium casting

for Dusold to expain. He says, “This allows us a high degree of flexibility and that means we keep absolute control over the quality of the moulds.” After all, the quality of the finished light alloy wheels depends on this. “The many years of experience of our employees is just as important for us as training young talent for the future,” he adds. The team can give full rein to its knowhow, thanks to the modern equipment in production. Where CNC technology is concerned, the machine park also boasts no less than 16 machining centres and lathes from DMG MORI. “The accuracy and reliability of the machines are an important mainstay in our daily business”, is how Fernando Silva, Production Manager at ALRON, explains the many years of continuous cooperation with the machine tool manufacturer.

The latest investments in production include a DMC 125 U duoBLOCK®, a DMC 125 FD and a CTX beta 1250 TC. For Silva, the diversity of the machine park is a decisive factor— “It means we can respond quickly and produce even complex components economically as well as in low tolerance ranges – often in a single setup.” In this way, they meet the high quality demanded of the moulds as well as the short delivery times.

As the person responsible for service and maintenance at ALRON, João Romão sets great store on the reliability of the machining centres and lathes. “It is necessary for us to keep downtimes to a minimum and to ensure a high level of process reliability.” Exactly why ALRON expects a competent, quickresponse service on the part of DMG MORI. “Here, too, the cooperation works really well”, Romão goes on to tell. The

DMG MORI Service Hotline alone is a great help, because of the uncomplicated manner with which it handles so many challenges. “Technical problems can often be solved simply over the phone.” The service staff identifies causes very exactly and gives detailed instructions for solving the problems. “We rarely need a service technician, but when we do this, it is arranged at very short notice.” In addition, Romão is satisfied with the fast response when spare parts are needed. “DMG MORI delivers from Germany within 20 hours,” he adds.

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Achieving competitive edge For ALRON, the high demands placed on DMG MORI as a machine supplier are a direct consequence of the RONAL GROUP’s business development. “By 2019, we intend to expand our current production of 18 million light alloy wheels significantly”, explains Dusold as the aim of the company. This would also mean a sustained expansion of the capacities of our tool and mould making operations. “In other words, we will work even more flexibly and reduce our throughput times in future”. And DMG MORI will continue to play a key role within the framework of this growth. This is because if we wish to keep a competitive edge on the market, we will also have to expand where production is concerned,” he concludes. ☐ Courtesy: DMG MORI

EM | Mar 2017

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DIE & MOULD | FOCUS

Probing simplifies set-up of mould tools Probing is an essential aspect of CNC machines. The article highlights how mould manufacturers can benefit from the advantages of the probing system, which far outweigh the costs associated with purchasing the probes.

BK Tooling, based in Bishop’s Stortford (UK), is vastly experienced in the manufacture of injection mould tools and the associated electrodes for die sinking. Over the years, it has seen these tools become complex as designers push the boundaries of what is feasible. Bob Tunks, MD, BK Tooling has been using Renishaw probing systems since he took delivery of his first CNC machining centre 20 years ago. That machine tool came equipped with a probe.

At the time, Tunks did not appreciate its value. He explains, “CNC machine tools have to have probing; to do without it would be a regressive step. Many toolmakers cite cost as a constraint, without recognising the cost of the time they are losing as a result of not probing parts on the machine tool.”

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Pay-as-you-probe approach BK Tooling’s most recent machine tool purchase – an XYZ 1060 HS high-speed vertical machining centre (VMC) – came equipped with the Renishaw Primo system, including a Primo Radio Part Setter and Primo Radio 3D Tool Setter. The Primo system addresses the primary concerns that prevent companies from making the transition to probing; namely perceived cost, fragility and complexity. The Primo system offers an industryfirst ‘pay-as-you-probe’ approach with minimal upfront investment costs. Two types of Primo Credit Token are available, offering either six months usage, or unlimited lifetime usage for experienced users such as Tunks.

EM | Mar 2017

DIE & MOULD | FOCUS

Without probing, it would take 20 minutes to reset a fairly simple mould tool

The system also comes with a self-study training kit and GoProbe; Renishaw’s new, easy-to-use probing software. It is protected against accidental damage with Primo Total Protect cover. “Buying a machine like this without probing is something that I would not even contemplate. You can set parts manually, but you do that without any confidence in where the datum is.

Probing is all about having the confidence of knowing where the part is on the table and not standing there hovering over the feedrate override,” explains Tunks.

Benefits of using probes BK Tooling sees the benefits of using Renishaw probes primarily when setting up moulds; particularly when they are returned for additional finishing work. Without probing, it would take 20 minutes to reset a fairly simple mould tool. For more complex moulds with multiple 3D reference points, it could be over an hour before he would be confident to begin cutting. With Renishaw probing systems, he can reduce the setting time to just three minutes, irrespective of the complexity of the workpiece.

“We can probe and datum the vast majority of our work within three minutes, but we are occasionally presented with special challenges,” he explains. “Recently, we needed to rework an existing mould tool using only a CAD model and the old tool, which didn’t have a single recognisable datum point on it.

Eventually by cross-checking, we evaluated 20 datum points. This took about an hour using the Primo Radio Part Setter. Without the probe, I estimate it would have taken at least half a day.”

The Radio 3D tool setter is also a major benefit to BK Tooling, which rarely uses reground tooling; instead relying on ‘virgin’ new tools for most of its work. The diameters of these new tools can be relied on as the manufacturers work to tight tolerances, but length setting is crucial. BK Tooling needs to be able to match the

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Z-heights of all the tools used on a workpiece in order to achieve the blending it needs on 3D profiles. Like the Part Setter, the Tool Setter works to a repeatability of 1 μm 2σ, which adds further to the consistency that BK Tooling is able to achieve.

“The time savings on second operation work is, for us, where probing really comes into its own and benefits our business. In combination with a CAD model, we are able to quickly pick up multiple datum points and start cutting the part much quicker than we could ever do manually, without probing. The time we are saving more than offsets the cost of the Renishaw probing system,” he explained.

Advantages of Primo system The Renishaw Primo system provides much more than initial workpiece probing. At BK Tooling, the Radio Part Setter is used to update offsets throughout the day to compensate for any thermal variations in the working environment. Movement within the machine tool is inevitable, especially in the Y-axis.

By probing the workpiece or other datums at regular intervals, this variation can be compensated for quickly and easily, with new datums being transferred to the machine’s CNC. Tunks explains, “We know that there will be some movement in the machine tool over the course of a day and with the speed of probing, we can check this more frequently, which equates to greater accuracy in the finished parts and makes us as consistent as we possibly can be.”

“We have had five machining centres, all of which have been equipped with Renishaw probing systems. I can’t see any reason now to buy a CNC machine tool without probing. The time savings that can be generated by probing either the workpiece or the tool far outweigh any cost associated with purchasing the probes,” concludes Tunks. ☐ Courtesy: Renishaw

EM | Mar 2017

HIGH SPEED MACHINING | TECHNOLGY

Manufacturer gets aggressive with automated machining The article highlights how the manufacturer of oil & gas industry equipment drives the spirit of continuous improvement with investment in multi-tasking machines by completely automating the machining process, along with adhering to strict part-processing standards and practices Only a few short years ago, automation was somewhat scarce within much of the manufacturing operations at GN Corporations Inc, in Airdrie, Alberta, USA. But the shop, driven by a strong forward-thinking attitude of continuous improvement, recently made a strategic automation leap to further increase productivity and ensure its global competitiveness well into the future.

GN provides the oil & gas industry equipment precision machined to customer specifications as well as produces its own line of standard products for the sector. According to John PleĹĄa,

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President and CEO, GN Corporations Inc, the fluctuations and intense competition within this industry can be a real challenge.

Automation as a major factor “Competing in North America is challenging, but when done on a global scale, shops start pitting themselves up against low-cost manufacturing countries, such as China, India and Mexico. And, when doing so, a shop had better be

EM | Mar 2017

TECHNOLOGY | HIGH SPEED MACHINING

GN provides the oil & gas industry equipment precision machined to customer specifications as well as produces its own line of standard products for the sector

20 to 30% more productive than the rest of the world,” warned Pleša. “This will allow a shop to compete when it comes to delivery times. However, they still have to beat out the competition on price. For us, automation has proven a major factor in achieving both of those critical objectives.”

At the heart of GN’s machining operations are about 60 Mazak machine tools. Of those, 14 are new and part of two completely automated machining cells GN refers to as its ‘Pioneer’ and ‘Frontier’ lines.

The two cells – each consisting of advanced multi-tasking machine technology and standalone robotics – have helped boost part consistency and increase production output significantly. As a result, GN successfully competes within and quickly adjusts to the challenging and ever-fluctuating North American and global oil & gas industry sectors.

Advanced machining technology Four Mazak INTEGREX e-500 multi-tasking machines set the foundation for the ‘Pioneer’ line that typically handles the production of long, shaft-type workpieces. These advanced machines feature turning and milling spindles for single set up operations as well as fully programmable tailstocks in support of secure and accurate operations.

The 10 Mazak INTEGREX i-200ST multi-tasking machines within the ‘Frontier’ line feature two turning spindles, a milling spindle and lower turret that afford GN efficient DONE IN ONE® part processing production.

The machines also sport Mazak’s new SmoothX CNC that provides the shop the shortest possible machining cycle

EM | Mar 2017

times, especially in fine increment programs for simultaneous 5-axis operations. The control incorporates a wide variety of advanced programming functions for ease of use and highspeed, high-accuracy machining performance.

Other Mazak machines at GN include QUICK TURN NEXUS 450-II MY multi-tasking machines with live milling spindles and Y-axis machining capabilities; INTEGREX i-400ST multi-tasking machines, each with two turning spindles and lower turrets; and a Mazak CYBERTECH TURN 5500 with a 15” spindle bore and maximum part diameter machining capacity of 32”.“Much like us, Mazak continuously evolves. They’ve advanced from simple 2-axis lathes and 3-axis milling machines into multi-tasking machines, automation and digital connectivity,” said Pleša. “One of the key features that sold us on the Mazaks is that the machine technology easily integrates with automation.” All the parts GN machines play a critical role while in use, so much so any part failure can lead to catastrophic outcomes in the field. This is why the shop operates under a ‘zero defects’ initiative because there can be no bad parts. According to Pleša, automation provides the processing consistency necessary to maintain such an initiative. Most components are made from 4140 and 4340 heat-treated steels as well as from some exotics such as Inconel, magnesium and others unique to the industry. Tolerances can range from +/-0.015” to as tight as +/-0.0005” depending on part complexity.

Increasing production capability According to Chamith Rathnayake, Lean Manufacturing

37

HIGH SPEED MACHINING | TECHNOLGY

The shop focuses heavily on lean manufacturing and adhering to strict part-processing standards and practices

Manager at GN Corporations Inc., the shop focuses heavily on lean manufacturing and adhering to strict part-processing standards and practices.

“For us, it is not about the number of parts going out the door, per se,” said Rathnayake. “Instead our goal is to meet the specifications set for each and every one of the parts we produce. We calculate and determine all aspects of a job – from cost per part to tolerances and machining processes.

And fulfilling all those set requirements ultimately results in parts produced and delivered in the shortest amount of time possible.”

For every one of its components, GN marks and tracks them from start to finish. Any defects can then be quickly traced back to who manufactured the part, measured it, crated it and even shipped it – all down to the day and time to ensure the error never again happens.

Both the Pioneer and Frontier cells improve upon part setup and cycle times, while also providing additional lightsout production capacity at GN. But what is most critical for the shop is that the cells basically eliminate any necessary human intervention within the process, which greatly diminishes the chance for errors and deviation from one part to the next.

GN gave the Pioneer cell this name mainly because it is a completely new approach to manufacturing oil & gas industry equipment for which it is used. The cell was also the company’s first/pioneering venture into a major automation project.

The four Mazaks in the Pioneer cell double GN’s production capability by providing the output of eight of the shop’s other non-automated machines running 24/7. This cell also reduces

38

labour requirements by 75%. The Pioneer operates three shifts, five days a week and typically for eight hours or more at a time without any human intervention.

Automated machining processes All the necessary machining, gauging/quality control (QC) and deburring of parts happen within the Pioneer cell.

Because the four Mazaks are multi-tasking machines, they allow GN to complete the parts in one set up and two operations. Additionally, if needed, the shop can quickly and easily switch the whole cell over to run a different family of parts.

Adam Jarantowski, Head of Manufacturing at GN Corporations Inc and the lead in the Pioneer line project, said that it was a challenge to automate the particular part processing operations of the cell – mainly because the parts and the machining they require are very complex.

“To automate the processes and machine parts in as few operations as possible definitely required multi-tasking machines,” explained Jarantowski. “Without the Mazaks, producing the parts would require a lot more than just four machines as well as several additional operations.”

Pioneer uses two Fanuc robots. One, with a 600-kg capacity, rides on a rail to load and unload the Mazak machines, while the other, a smaller one, works at the partgauging station. An in-line coordinate measuring machine (CMM) measures parts and feeds the resulting data into the machine tools for on-the-fly offset adjustments, and completed parts from the cell are 100% inspected.

EM | Mar 2017

TECHNOLOGY | HIGH SPEED MACHINING

According to Roubaud, continuous improvement is the catalyst to the company’s push for increased automation

Currently, Pioneer processes 4140 heat-treated steel parts that require two operations and two machines; so two parts are completed simultaneously. The cell runs a specific family of parts, and each of the Mazak machines is capable of running any of those variations.

Because GN opted for 160-tool magazines on its INTEGREX e-500s, the shop can load each machine with at least three sets of the same tooling, as well as accommodate boring bars up to 24” long for part diameters as big as 35.5”.

Redundant tooling allows the cell to run continuous and lights out. Operators are also able to replace worn tools at the back of the machine without interrupting cell operations.

GN uses a presetter and radio frequency identification (RFID) chips/tags for all the Pioneer cell’s tooling. Once a tool is set, its particular information is stored in the tag that the Mazak machines read and use to automatically make the necessary offset adjustments. So, cell production never misses a beat, according to Jarantowski.

Driving continuous improvement Alex David, Manufacturing Associate at GN Corporations Inc, heads the company’s Frontier cell and said that the key to its success is the ability to complete parts in single setups on the Mazaks. The cell runs 24/7 and, for the most part, unmanned with one operator that keeps it supplied with raw material.

Like the Pioneer cell, GN’s fully automated Frontier line also relies on Mazak multi-tasking machine technology. The Frontier name represents its use of special first-of-its-kind

EM | Mar 2017

multiple-part-loading robot automation. Each of the INTEGREX i-200STs has its own robot that loads and unloads parts and moves them to a CMM for in-process gauging.

The cell’s CMM provides the Mazaks with in-process offset information and checks parts once they are completed.

If parts are out of tolerance, they move to Quality Control for evaluation to determine the cause.

Juan Roubaud, Plant Manager at GN Corporations Inc, credits Pleša with further strengthening GN’s drive in continuous improvement, especially in regards to advanced manufacturing technology. Roubaud, who has been with GN over 13 years, said that the parts have, over the years, become much more complex. Processing them on standalone turning centres and milling machines has become inefficient and makes for extremely long turnaround times, which, in the spirit of continuous improvement, is why GN first incorporated multi-tasking machine technology. And now, according to Roubaud, continuous improvement is the catalyst to the company’s push for increased automation.

Both Pleša and Roubaud agree that automation, such as that of the Pioneer and Frontier lines, is the next generation of manufacturing, and for GN, Mazak is and will continue to be a strategic supplier.

“Our relationship with Mazak goes back over 20 years,” said Pleša. “They are an integral factor in the success of GN not only as a partner in machine tool technology, but also in automation, and many machine tool suppliers these days tend to fall short in that capacity.” ☐ Courtesy: Mazak Corporation

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MILLING MACHINES | TECHNOLGY

Titanium milling and automation boost productivity In recent years, manufacturers are facing challenges of meeting customer demands for lower part costs and higher production capacity in the aerospace industry. The article details how an aircraft component manufacturer overcomes these difficulties with investments in highperformance titanium milling and automated aluminium machining capabilities.

In the aerospace manufacturing industry, whether applications demand aluminium or titanium milling, it takes the right equipment to achieve the productivity and cycle times that make a company globally competitive. One company that can attest to this is JWD Machine Inc of Fife, Washington, United States.

For the past three decades, JWD has

40

honed its skills in the production of complex parts and assemblies composed of composites and hard metals, such as titanium, high-nickel alloys and highheat-treat steels. It’s capabilities have turned heads at some of the world’s largest aerospace, defence and transportation manufacturers—including Boeing, Goodrich Landing Gear and GE Aviation.

The company has been recognised as a

Boeing Supplier of the Year award winner, and it is known by others outside of the aerospace manufacturing industry for its development of the widely used TechniGrip™ fixturing system. With its long and growing list of accomplishments, JWD understands that it has a reputation to uphold in the face of relentless competition, which is why the company embraces and leads with high-

EM | Mar 2017

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MILLING MACHINES | TECHNOLGY

The integral drive, high-torque spindle of a81M provides the power and rigidity necessary for large-diameter boring and face-milling operations in titanium and other hard-metal applications

performance machining technology.

“The competitive nature of the aerospace manufacturing market has a trickle-down effect on the supply chain that places ever-increasing pressure on tier suppliers like us,” said Jason Mohon, Manufacturing Director, JWD. “With each order, parts are growing in complexity and materials are becoming increasingly more difficult to cut. Today, we are required to hold tight tolerances during titanium milling operations. This kind of intense competitive environment requires manufacturers to remain on the cutting edge of technology in order to keep part costs low.”

Titanium milling determination When machining titanium and other hard metals, reasonable tool life coupled with high metal-removal rates is critical to offering a competitive and profitable cost per part. Manufacturers attempting to remove large volumes of titanium using standard machining centres oftentimes lose that competitive edge due to limited cutter life, which results in exorbitant tooling costs. As such, JWD recognised the need for a machining platform that offered an extra-rigid construction, highpower spindle design and efficient cooling system that would enable the company to

42

achieve the necessary metal-removal rates and tool life to efficiently perform longreach and large-diameter boring operations in hard metals.

“A lot of aerospace manufacturing facilities don’t want to mess around with hard metals, such as titanium, highheat-treat alloy steels and stainless steel.

It is difficult and expensive work—a high-risk, high-reward scenario. One mistake or broken tool can cause the loss of profit margin in just one run. When machining hard metals, a purpose-built, hard-metal machining centre is a must,” explained Mohon.

After months of market research and testing, JWD invested in two Makino a81M horizontal machining centres (HMCs). It found that the integral drive, high-torque spindle on the a81M machines provided the power and rigidity necessary for large-diameter boring and face-milling operations in JWD’s hard-metal applications.

“Due to the rigidity and thermal stability of the a81M machines, we are just as precise in the evening as in the morning,” said Mohon. “In an average hard-metal application, we’re expected to hold repeatability as tight as 0.0005 inch, and in some boring processes the requirements can be as tight as 0.00025 inch. The a81M machines provide the

perfect cutting conditions to meet and even exceed these demands, all while taking out higher volumes of material to eliminate 80% of our previous boring operations.”

According to Mohon, the enhanced power and rigidity of the a81M machines are best complemented by its highpressure (1,000 psi), high-volume (20 gal/ min) through-spindle coolant technology.

With this coolant system, JWD is capable of meeting throughput demands without the rapid tool degradation witnessed by many standard machine platforms.

“Heat and limited tool life have not been an issue for us, and if there’s anyone else who can attest to this, it’s our tooling vendor,” said Mohon. “On the a81M machines, we are able to apply feeds and speeds that would burn up tools and rattle most standard machine platforms.

For instance, in a recent titanium milling application, we applied a 4-inch shouldercutting face mill with 18-mm inserts at 80% radial engagement and 0.375 inches depth of cut. This level of performance has enabled us to increase our productivity by an average of about 25%, while simultaneously extending tool life anywhere from 17 to 23% for a total reduction in tool expenditures of approximately 15%.”

Tool management has been another

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Despite the PS95’s 40-taper design, JWD has performed many operations on the machines that previously required a 50-taper machine

benefit of the a81M. At JWD, the company manages up to 60 tools on one machine and 137 on the other. When purchasing the a81M, these features, along with the machine’s highperformance Professional 5 (Pro 5) control, were attractive selling points.

“There are many tool management and user functions built into the a81M platform that help our productivity,” said Mohon. “The ease of the control and the tool life monitoring feature were added benefits that have made our lives easier by allowing more unattended operation, improved repeatability and fewer scrapped parts.”

Expanding reach through accurate machining One capability that JWD recently identified as a gap in its operations was a true full 5-axis machining platform for more modern applications featuring complex, 3-D contours. This led the company to invest in a Makino D500 5-axis vertical machining centre. Unlike the 5-axis rotary tables that JWD has added to its other machines, the D500 features a dual-motor direct-drive table design that provides enhanced speed and torque for precise part positioning and reductions in out-of-cut time.

“With full five-face part access, the

44

D500 allows us to machine more complex features with fewer setups,” said Mohon. “In addition, the machine’s precise positioning and tool-tip control have enabled us to achieve circular interpolation results within plus or minus 0.0003 inches.”

The D500 Pro 5 control software was already a familiar feature to JWD employees, who appreciated its improvements to 5-axis machining performance and operability. Likewise, the machine’s Tool Center Point control has led to accurate control and alignment of the tool tip for improved accuracy and surface quality.

“Typically in a 4- or 5-axis machine, you need to program from the centre line of rotation to do true multi-axis machining,” said Mohon. “With the D500, you pick just one local coordinate and the machine automatically tracks that point from the centre line of rotation, substantially reducing set up time and set up complexity.”

Tooling up for aluminium While JWD had successfully expanded its hard milling and 5-axis machining capabilities, the company recognised that in order to rapidly grow its overall revenue by 25 to 50%, it needed to broaden its market base. To accomplish

this, JWD made aggressive investments in automated aluminium machining capabilities. It’s solution was a flexible manufacturing system that included the Makino Machining Complex (MMC2) and two Makino a61nx HMCs. “Competition is already well established in the aluminium aerospace manufacturing market, so we knew we had to hit the ground running with technologies that could have us out producing many competitors early on,” said Mohon. “The Makino automated cell enables us to run lights out, which ultimately allows us to offer a lower cost per part than several of our competitors, while maintaining a healthy profit margin.

The flexibility and scheduling capabilities of the MMC2 is far superior to the other technologies we investigated—the machining performance and customer support sealed the deal.”

The folks at JWD liked the cell’s ease of use compared to competitive systems.

The company used Makino’s Engineering Services and training as a resource to get the cell up and running in their shop.

“Makino’s assistance with the equipment set up and application engineering saved us a lot of time in getting the cell optimised and allowed us to quickly get the most out of the machines,” said Mohon.

EM | Mar 2017

TECHNOLOGY | MILLING MACHINES

The a61nx machines provide a 500mm work zone and a 14,000-rpm, HSK 63A with 240 Nm of torque for heavy cutting. Their robust casting design and roller-type linear guides ensure that the entire work envelope can be effectively used.

“We transferred a job from our other automated systems to the a61nx and realised a 67% decrease in cycle time,” said Mohon. “Additionally, we’ve been able to improve efficiency and throughput in other areas of the shop floor by reallocating employees who would have been stuck stationed at each machine. They are now able to take on more challenging growth opportunities.”

The cell manages a dynamic production schedule and builds a database of parts that is ready whenever repeat production orders come through, reducing setup time, downtime and programming. Its unattended capabilities have enabled the company to run lights out for increased overall throughput.

As the company grows, it plans to add another machine to the cell to increase capacity and keep competition at bay.

large aluminium and structural parts to market. To do that, we plan to continue to explore our internal capabilities and constantly improve our processes.

“What matters most to JWD is creating the highest quality product in a timely manner. We want to be efficient so

that we can pass that savings along to our customer. Makino makes it easier to employ all the technical aspects that we require to do that, and we intend to continue using their technology to achieve what we need.” ☐ Courtesy: Makino Advt

Technology improves efficiency JWD’s new equipment has increased the company’s capability, productivity and efficiency. The machines have had a positive effect on the business’ competitiveness and bottom line, and they have attracted skilled employees who are eager to work with such advanced technology.

“So much has changed since we first began operating in 1978,” said Mohon.

“What JWD is doing today is utilising the latest technology in order to stay ahead of the times, expand our complex hard metal and aluminium capabilities, and remain globally competitive. In the next five years, we want to expand our industry reach even further—bringing a variety of

EM | Mar 2017

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E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y

Developing a collaborative framework for Make in India capabilities To address the limited capability among Indian machine tool manufacturers to produce high precision machines, a model on Next Generation Precision Grinder (NGPG) has been developed. This project also illustrates the development of a collaboration frame work to integrate the expertise available with the Indian machine tool manufacturers, academic resources, etc with the knowledge available from across the globe.

Next Generation Precision Grinder (NGPG) is an indigenously designed and manufactured grinding machine tool to achieve higher precision and tolerances. More specifically, it is an external cylindrical grinding machine with sub-micron precision capabilities of form & geometric accuracies on the ground component. Currently, requirements of high precision components used in several sectors like automobile, defence, aerospace, etc are met through ‘high cost imported machine tools’, where technology is not available for purchase by Indian machine tool manufacturers.

As per recent reports, more than 40% of the machine tools purchased in India each year is imported and it is rapidly increasing due to the technological advancement taking place

46

elsewhere. Also, it is observed that the requirement of high precision machines in the Indian manufacturing sector has been rising rapidly over the last decade.

Development of NGPG After sustained discussions between Micromatic Grinding Technologies (MGT), Indian Machine Tool Manufacturers Association (IMTMA), Indian Institute of Technology Madras (IIT–M) and Science-based Technology Innovation and Management Solutions (STIMS Institute), it was decided that the development of cylindrical grinding machine would be taken up as a case study for developing higher precision

EM | Mar 2017

T E C H N O L O G Y | E D U C AT I O N & T R A I N I N G

GOI

Review Committee

IIT - M

IMTMA

Faculty

NGPG Students

STIMS Institute

MGT

End Users

Industry Professionals IMTTF

CMTI

Abrasives & Other suppliers

Eco-system leading to NGPG

Eco – system leading to NGPG machine tools, as it is widely used in the automotive sector. A formal proposal for the ‘Development of Next Generation High Precision Cylindrical Grinding Machine Tool’ was submitted to the Office of Principal Scientific Adviser (OPSA) to the Government of India and the same was sanctioned in November 2011.

IMTMA: IMTMA facilitated the interaction of members from academia (IIT Madras) with its members (grinding machine tool manufacturers) and helped to identify a suitable industrial partner for the project.

STIMS Institute: STIMS Institute provided active support, training and mentoring on System Thinking and Transformational Skills through all phases of this project. Also educated the project team on “System Approach” as applicable to precision grinding processes.

IIT-Madras & MGT: Teams from IIT-M and MGT formed the working base for the successful execution of project. Team of students (PhDs, M.Techs and B.Techs) from IIT-Madras worked on various aspects of the project, such as systematic experimental studies to characterise the performance of existing machine tools; developing various models that identified technical pathways for the development of NGPG machine, etc.

Government of India: It has steered the project by providing a team of experts to review the progress periodically.

The team comprised of eminent experts from the machine tool industry as well as academic institutions.

According to PJ Mohanram, Senior Scientific Advisor, IMTMA, following are the learnings of the project: 1. Cooperative R&D is entirely possible between industry and academic/R&D institutions in India as long as

EM | Mar 2017

everyone is focussed on the same common goal (i.e.) advancement of academic knowledge that supports commercially viable end results.

2. Such an approach is most appropriate for medium to long term R&D projects (3-5 years), not those requiring immediate development.

3. At higher reaches of technology, the scientific inputs can only be brought by academia, since industry mostly does not have the needed resources.

4. There are tools and resources available from facilities like AMTTF that could be deployed by students and industry professionals. Developing such eco-system enhances efficiency and reduces the total cost and investments needed in such projects.

5. A structured project with system thinking leading to clearly laid down quantified objectives stands a good chance of success.

6. There must be a driver each from industry and academia, who make it their personal mission to complete the project successfully.

7. It is essential for the industry and academic institution to continuously interact and jointly work on the project at every stage. Such collaboration also benefits from engagement of organisations, such as IMTMA and international experts in knowledge integration.

8. A free exchange of information and data is essential, without being worried about Intellectual Property (IP) confidentiality at every stage. This can be secured through a mutual Non-Disclosure Agreement (NDA) at the start.

9. If properly reviewed and managed periodically (as by the

47

E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y

Features

O.D. Grinder (Initial)

NGPG (New)

6.5 5

2.5 3

>1.0 3 / 300

0.5 1/ 300

SIZE Process Scatter - 6σ (Microns) Tolerance Grade (IT)

FORM Circularity (Microns) Cylindricity (Microns / mm)

SURFACE QUALITY Surface Finish (Microns)

System approach framework for development of NGPG

PRMC), it is possible to complete such projects within the time and budget allotted.

System approach for knowledge integration The main focus of this project was to integrate the knowledge available with the Indian machine tool manufacturers, academic resources like IIT–M and any other resources available inside of India and combine it with the knowledge available from across the globe. To characterise the performance of the machine tool, it was necessary to develop a diagnostic tool for the grinding process. This characterisation tool developed at IIT–M is now in commercial use.

Machine tool is a complex interacting system, with various factors affecting its precision capability. But any machine tool and its use can be conceived as an ‘input-transformationoutput’ system to simplify and standardise the characterisation and developmental process. The figure shows a schematic representation of the characterisation and development of cylindrical grinding machine and its use as an input/ transformation/output system. This system approach framework has been used throughout this project.

To characterise the performance of the machine tool, it was necessary to develop a diagnostic tool for the grinding process. This characterisation tool developed at IIT–M is now in commercial use. With the performance benchmark

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0.40

0.25

NGPG performance results and comparison

established, detailed testing of the machine and its subassemblies were carried out. Resources in India, such as AMTTF have been of great value in the machine tool characterisation methods techniques and the necessary instrumentation for that.

From these tests, the performance characteristics of the machine and the various factors affecting the precision were identified. These observations were then used to analyse and model the interactions and determine the modifications required to the inputs to meet the targeted specifications of high precision grinder. However, the interactions in a system as complex as machine tool can only be understood by a combination of both experimental and analytical techniques.

Role of machine tool precision The following factors affect the precision of the cylindrical grinding machine tool and in turn the quality of ground component: Geometric and kinematic accuracy: A combination of errors on a cylindrical grinding machine usually affects the size and form of ground component. In the NGPG machine, these errors were minimised and kept within certain optimum levels. Volumetric accuracy model and sensitivity analysis were used to identify critical errors and their limits.

Structural rigidity: Static and dynamic compliance of

EM | Mar 2017

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E D U C AT I O N & T R A I N I N G | T E C H N O L O G Y

“To solve problems, the knowledge and resources are available in India.

Each resource looks at the problem through a peep hole – their vantage point only. The challenge is to harness all this knowledge through a simple framework where relevant science, engineering and management issues can be integrated.”

Dr Subramanian, President, STIMS Institute Inc, USA

“Active hands on collaboration between IIT–M students and our engineers were a key element for the success of this project.”

NK Dhand, Chairman, Micromatic Grinding Technologies Ltd

“Each aspect of machine tool development is well known to the academic researchers, pulling them all together as a system for a well-defined goal and commercial outcome is not a traditional practice. But such goal-oriented system integration is essential for commercially-relevant research outcomes in a highlypractice oriented area, such as manufacturing technology.”

Prof Ramesh Babu, IIT – Madras

Addressing transformational skills Developing the NGPG from a concept to commercially viable machine (end-to-end innovation) was formulated and executed based on the system approach framework. In fact, the NGPG machine in itself shows that a ‘transformational’ output and the required ‘skill’ set are already available if anyone is willing to leverage them.

Going forward…

“We needed an industry-university collaborative framework, such as ones in countries like Germany.

NGPG has been an excellent example of developing such collaboration using resources available entirely within India.”

PJ Mohanram, Senior Scientific Advisor, IMTMA

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different assemblies in the machine tool affect the form and finish of the ground component. During the development of NGPG machine, the compliance of critical subassemblies were identified and improved. The improvements include the design of structural interfaces as well as the design of certain critical features of the subassemblies, such as carriage and table system, wheel head, workhead and tailstock assemblies.

Thermal stability: These include quasi static deformation/ drift of machine tool structure, linear axes, spindle, etc. These usually manifest to affect the size and form of ground component and also affect both, short term and long term process capability and tolerance control. In the NGPG machine, such thermal deformation/drift were controlled by improvements to the design of linear axes and wheel spindle.

Mechatronic and controller system: The performance of the mechatronic systems in the machine tool affects its mechanical performance and can affect the size, form and finish of the ground component. Various aspects of the mechatronic system were fine tuned to improve the stable performance of the machine tool.

Consistency of grinding process: The performance of the grinding process was optimised with the development of diagnostic tool and associated analysis techniques. This allowed the design of grinding and dressing cycles that can meet output requirements on a consistent basis.

The success of NGPG project, i.e. converting an industryacademia collaborative research and development effort into a commercially viable product, enabled the team to pursue with the government to set up a centre for Advanced Manufacturing Technology. With the help of the Department of Heavy Industry (DHI), Government of India, a centre called Advanced Manufacturing Technology Development Centre (AMTDC) is set up at IITM Research Park, as an independent registered society to take up collaborative efforts with the industry. Currently, 11 projects, related to machine tools, robotics and drives and controls, from six different companies have been taken forward. ☐

EM | Mar 2017

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W E L D I N G & A S S E M B LY | S P E C I A L F E AT U R E

Emerging trends in the Indian welding sector Developments in materials and welding processes are characterised by a certain level of continuity and long-term development. Nevertheless, they have to keep pace with the increasing speed of change in the dynamic industrial environments they serve. Most industries are exploring new or alternative materials for improved or new products.

The ‘Make in India’ campaign is driving change, innovation and investment in new processes throughout Indian manufacturing, not least in the field of welding and joining technologies. A good example of this can be seen in the increasing desire by designers, to incorporate a greater number of dissimilar materials in the mix of a manufactured product.

This trend is particularly noticeable in the automotive and aerospace industries, where light-weighting, efficiency and enhanced functionality are demanded by end users and legislators alike. Such factors have generated a good deal of research and development in how to weld two different metals,

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Chris Wiseman Industry Sector Manager Equipment, Consumables & Materials TWI

and the more extreme case of metal to composite or polymer joining. There are proven solutions in both cases; such as solid state friction welding and the use of surface texturing and structural adhesives.

Opportunities for Indian manufacturers These technologies have been developed over many years, often in western economies, at a time when India was less well placed to invest. Conversely, India can now maximise its own investment strategies by leapfrogging intermediate welding

EM | Mar 2017

S P E C I A L F E AT U R E | W E L D I N G & A S S E M B LY

technologies and acquiring, or developing for itself, state-ofthe-art processes, especially for greenfield manufacturing sites. Examples of such opportunity can be seen in laser welding and friction stir welding, which are relative newcomers to India, but both processes have been through many years of intensive development. Refinements, such as fibre laser power sources, delivering high power densities for thicker section welding and stationery shoulder friction stir welding tools, enabling high integrity solid state joining of titanium alloys are readily available for Indian manufacturers.

However; it should be remembered that arc welding remains the predominant source of processes for joining metals, and is likely to do so for sometime to come. In a global welding equipment market of around $18 billion, more than $13 billion is still spent on arc welding machines. In India, as in many other countries, more than 80% of all welding is arc welding ranging from traditional ‘stick’ electrode methods to more sophisticated automated systems, such as orbital TIG welding for critical parts including aerospace and pressure vessels. At TWI (The Welding Institute), the most frequent users by far, of our arc welding information web pages, are Indian engineers and welders. Global research and development in arc welding is still highly active, with incremental process improvements still being achieved.

Examples include; “Low Stress – Low Distortion” techniques for thin sheet metal and “Activated TIG” which enables better weld penetration. More recently, there has been much work carried out in using combination methods, such as Hybrid Arc Welding, which offers both penetration and fill advantages and less stringent fit up requirements. This process is attracting great interest in India, especially in the automotive and aerospace sectors.

A survey carried out by DVS has suggested the following likely trends in established and new or disruptive welding process use in industry in the next 10 years— Arc welding (constant), Lasers (considerable increase), Spot welding (considerable decrease), Friction welding (constant), Adhesives and mechanical fasteners (considerable increase), Robotics (considerable increase). These trends support statements from companies such as Audi, in the automotive sector. They predict a much greater use of aluminium and composites in the next 10 years, and almost no steel. The automotive sector is the largest user of welding in India.

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Greater opportunities are arising for skilled people in India, especially in advanced manufacturing, and partly driven by significant investment by overseas companies

Training modules for skilled employees Whilst most of the world is struggling with a shortage of welders and welding engineers, India is busy creating a resource that is envied, and often used, by other countries.

One comparative illustration is the USA where, according to the American Welding Society, the average welder is 54 years of age, and there are about 200,000 less of them than required.

Qualified Indian welders are in demand globally and this is presenting an interesting dichotomy for the ‘Make in India’ campaign. It is generating much thought on how best to create an indigenous skilled Indian labour force that delivers in India.

Consider this; TWI has offered training for welding engineers in India since 1986, with a globally recognised accreditation known as CSWIP. This qualification is attractive to many industries, including the oil & gas sector, which pays top rates for such engineers. Currently, TWI trains around 2000 to 3000 Indian students each year to this standard and, until recently, most of these highly qualified people have taken their skills abroad, especially to the Middle East oil fields. However, there now appears to be a slowing of this ‘welder emigration’, which may be partly due to the recent low oil price – but other factors are affecting the trend.

Greater opportunities are arising for skilled people in India, especially in advanced manufacturing, and partly driven by significant investment by overseas companies. UK-based

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Rolls Royce, GKN and BAE Systems have all established considerable engineering facilities in India and have done so, not for cost advantage, but primarily for the pools of talent they can access amongst India’s young engineers. India is now the world’s largest producer of small cars with many of the international players there. The same can be said for construction, energy and component manufacturers up to tier-1 suppliers. This FDI, coupled with the strength of Indian OEMs is having a powerful impact on the current, and likely, trends emerging in the Indian welding sector.

There is increased demand for ensuring best practice in traditional welding procedures. This creates good business for training providers, and fresh impetus for Indian home grown welding research. The 6th International Institute of Welding Research and Collaboration Colloquium, held in Hyderabad last year, produced a plethora of Indian papers and presentations. There are important developments in arc, electron beam, laser beam and solid state welding processes, being carried out in Indian institutions that are of a pedigree second to none.

All of this technology push, and the pull of end users of welding is making a major up-skilling drive inevitable. India has about 40 million SMEs, many of them with welding capabilities. For ‘Make in India’ to succeed, high value manufacturing indigenous supply chains are essential. For example, aerospace sector expansion in India will be ultimately stifled, if it cannot access components and materials from within. ☐

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EVENT | REPORT

Quantum shift in industry Spread across an area of 66,000 sq mts, the 18th edition of IMTEX was all about showcasing the latest industry solutions and future technologies in the area of metal cutting machine tools. With over 1,000 exhibitors, the seven-day exhibition became the largest IMTEX ever to deliver new manufacturing systems for improvement in productivity and quality standards. A post-event report…

Orgainsed by the Indian Machine Tool Manufacturers’ Association (IMTMA), IMTEX 2017 & Tooltech 2017 recently concluded at the Bangalore International Exhibition Centre (BIEC) in Bengaluru. Spread across six halls over an area of 66,000 sq mts, the exhibition registered a footfall of 75,440 visitors, where over a thousand machines in operational mode were showcased.

The event was inaugurated by Shri Siddaramaiah, Hon’ble Chief Minister of Karnataka; Girish Shankar, Secretary (HI), Department of Heavy Industry, Ministry of Heavy Industries & Public Enterprises, Government of India; DV Prasad, IAS, Additional Chief Secretary, Commerce & Industries Department, Government of Karnataka; Dr Naushad Forbes, President, Confederation of Indian Industry (CII), along with PG Jadeja, CMD, Jyoti CNC Automation & President, IMTMA; P Ramadas, Managing Director, Ace Manufacturing Systems & VicePresident, IMTMA and V Anbu, Director General, IMTMA.

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Speaking on IMTEX 2017, Jadeja opined that the exhibition has yet again provided a platform for the launch of new machines with latest technologies related to the machine tool industry.

“Technologies, such as Internet of Things, Industry 4.0, 3D printing, etc attracted large number of visitors, mostly technology professionals including 158 trade delegations from public and private sectors, such as automobiles, auto components, defence, aerospace, railways, power and energy, pharmaceuticals, etc.”

Along with the exhibition, BIEC also celebrated its 10th anniversary this year.

Highlights The seven-day exhibition witnessed international participation from 23 countries including, China, Czech Republic, Germany, Italy, Spain, Taiwan and United States of America. Also, orders worth ₹1,670 crore and enquiries to the

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value of ₹18,989 crore were generated during the exhibition.

Compared to IMTEX 2015 & Tooltech 2015, the booked orders have shown an increase of 16%, whereas the generated enquiries increased by 21%.

Speaking on the new hall added to the exhibition ground, V Anbu, Director General, IMTMA, said, “With the addition of a newly constructed state-of-the-art hall measuring 17,500 sq mts, IMTMA was able to provide more space for exhibitors to showcase machines which in turn translated into more orders and enquiries than ever before.”

A major highlight of the show was the ‘International Buyer Seller Meet’ organised by IMTMA and EEPC (Engineering Export Promotion Council), which saw participation of 57 international buyers from 19 countries. The show also hosted student-centric programmes, such as i2 Academia Pavilion

with a participation of forty academic institutes; Jagruti (a programme to orient engineering students with emerging technologies) with a participation of 31 engineering students and Connect (an awareness programme for young engineers visiting IMTEX), which included sessions addressed by CEOs of machine tool manufacturing companies with a participation of 31 engineering colleges.

The event also witnessed Milind Kelkar, Executive Director, GrindMaster and Mohini Kelkar, Managing Director, GrindMaster, being felicitated with the IMTMAPremier Outstanding Entrepreneur Award in memory of Vinod Doshi for their remarkable contribution to the manufacturing industry.

The next edition of IMTEX will be held in January 2019.

Courtesy: IMTMA Advt

METAL WORKING FLUIDS

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EVENT | REPORT

“The nature of IMTEX has improved in breadth and scope. This edition has created more opportunities for buyers and sellers.

Today, there is a shift in the industry with the realisation that machines need to be self-contained.

Also, customisation is required in manufacturing and companies need to be adaptive. Since the customers’ requirements are ever-changing, the manufacturers need to be efficient to change quickly and be flexible.”

“With Jagruti, Connect and i2 pavilion programmes, technologies, such as IoT, Industry 4.0 and 3D printing attracted large number of visitors— mostly technology professionals, including 158 trade delegations from public and private sectors, such as automobiles, auto components, defence, aerospace, railways, power and energy, pharmaceuticals, etc.”

Jamshyd N Godrej, Chairman - Exhibitions, IMTMA and CMD, Godrej & Boyce Mfg Co Ltd

Parakramsinh Jadeja, President, IMTMA & CMD, Jyoti CNC Automation

“With the addition of a newly constructed state-of-the-art hall measuring 17,500 sq mts, IMTMA was able to provide more space for exhibitors to showcase machines which in turn translated into more orders and enquiries than ever before.

Technologies, such as IoT and Industry 4.0 were the key highlights of IMTEX 2017.”

“India is clearly poised for a next level of growth. In terms of manufacturing, capacity utilisation is catching up in most consumer industries and investments in capital seem to go high as well. As such, IMTEX provides the industry a platform to connect to next level for people. Post the exhibition, we collate the leads and based upon the number of leads generated, we ensure all customers are attended accordingly.”

V Anbu, Director General, IMTMA

Chandrashekhar Sharma, Vice President Kennametal Cutting Tools & Machine Tool Business

“At IMTEX, we discussed about our Additive Minds, a consulting & knowledge transfer programme with quality visitors and received good response from them. We will evaluate these responses and then decide on the investment required for this programme. We had experienced quality visitors and we are looking forward to take it up with them.”

“This year, we haven’t launched any product, but targeted solutions that can cater to the future requirements of the industry. Manufacturing is majorly based on the automotive sector. IMTMA has taken the initiative to invite delegation from defence and aerospace sectors, besides the automotive industry. We have the capability to cater to such sectors with specialised solutions. Post IMTEX, we will study their requirements.”

Anand Prakasam, Country Manager, EOS India

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Mohini Kelkar, Managing Director, GrindMaster

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“India is a very big economy; it’s growing very fast and is also among the fastest growing economies of the world. Exhibitions like IMTEX help manufacturers meet customers. Being an industrial exhibition, we get exposed to industrial customers. Post the exhibition, we coordinate on making the best use of whosoever we have had meetings with.”

“Siemens showcased cutting-edge digitalisation solutions that help in virtual part production using digital twin concept and cloud-based data services – Mindsphere. In future, modernisation of Indian industries will create growth opportunities for the machine tool industry. We are witnessing a transition towards Indian OEMs. With an increase in the total contribution from the Indian OEMs, there is greater need to enhance competencies.”

HD Bang, Managing Director – Sales, YG Cutting Tools

Vijay Pratap Singh, Head—Motion Control BU, Digital Factory Division, Siemens

“At IMTEX, we have focused on our industrial cooling solutions. As such, there has been two kinds of customers—exhibitors who have incorporated our cooling solutions in their machines, and end-users buying those machines who are indirectly our customers. We are a solution player, once customers see value in our products; the business is done for us.”

“IMTEX is better organised this year compared to its previous editions. The exhibition is gradually getting in-line with the international standards. In terms of visitors, there are many people interested in discussing the technical issues and looking for solutions to their problems. This year, we have emphasised on Industry 4.0. We were able to demonstrate our new technologies and solutions in this industry trend and have received good enquires.”

Ajay Bhargava, Managing Director, Rittal India

Surender Sood, Managing Director, Marposs India

Compiled by Team EM

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EM | Mar 2017

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VIEWPOINT | MARKET

Spirit of optimism & enthusiasm Despite the current uncertain market conditions, the recently concluded IMTEX 2017 exhibition witnessed a spirit of optimism and enthusiasm amongst the manufacturers, exhibitors and customers. Most exhibitors unanimously agreed that IMTEX has only grown bigger and better and showcased a wide range of innovative technological solutions that met global standards. In this feature, we bring to you exclusive insights from participating industry exhibitors at IMTEX 2017 and their impressions of this international platform. Excerpts…

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

“Helping manufacturers achieve higher efficiency & productivity” What were the products from your company showcased during IMTEX 2017? Were there any new technologies launched as well?

For this edition of IMTEX, we have showcased products, which support majority of the industries, namely, automotive, food & beverage or the ancillary industries. We have recently extended this product line and are showcasing it to the Indian industry as it can help them to achieve higher efficiency and productivity.

Rashmikant Joshi, Managing Director, Festo India

How has the IMTEX metal-cutting exhibition evolved over the years? How is the exhibition helping Indian machine tool/cutting tool manufacturers to advance their technology standards so as to compete globally?

Over the years, IMTEX has become one of the major engineering exhibitions, be it this edition of cutting tools of metals or the forming industry. Here, we find OEMs across the world, showcasing their technology, which is helping the industry as well as companies to showcase their product evolution over the years. IMTEX is now a primary exhibition in India. We, as a nation, are becoming very competent in the global market because of the product technologies and the quality of labour.

So, the new technology that is coming to India is helping the OEMs to see the latest technology that is in the market and they are trying to imbibe this technology in their product design.

Given that the global manufacturing companies are moving towards the next industrial era – Industry 4.0, how were these trends and technologies observed at IMTEX 2017?

The big giants of Industry 4.0 stakeholders have already started showcasing Industry 4.0 in a big way. However, in India, it will take some time, given the kind of machines that we have and our current technology, but manufacturers do recognise this as the future. The products, which support Industry 4.0, have to be launched and this is one of the important objectives of Festo India as well.

What are the main factors that are driving manufacturing excellence globally? How well does IMTEX 2017 represent these latest manufacturing innovations?

Manufacturing excellence is driven by the need of the world population, in terms of better products. Every year, the product goes to the next level. This indirectly is driving the manufacturing benchmark, with regards to the cost or the precision or the productivity. It is all interlinked and currently, what we see is the availability of quality manpower, which is the foundation for Industry 4.0. IMTEX has done a good job of bringing the stakeholders from across the world, which is helping them to showcase their technologies and this is the starting point for absorbing the latest technologies.

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MARKET | VIEWPOINT

“Manufacturers have to adopt smart manufacturing” What were the products from your company showcased during IMTEX 2017? Were there any new technologies launched as well?

IMTEX is a platform for us to showcase our new technology from the last two years. We try to make sure that we demonstrate new technology at every edition of IMTEX. The last two years, we have focused more on the machines. While we also having an entire product catalogue, we are also demonstrating machines, which are for grinding, honing, etc. Additionally, we have launched seven machines this year. Apart from machines, we have also offered coolants, which was demonstrated at our stall at IMTEX 2017. Grinding and honing can only happen if there is a quality coolant system involved in the process. We also offer conventional abrasives.

How has the IMTEX metal-cutting exhibition evolved over the years? How is the exhibition helping Indian machine tool/cutting tool manufacturers to advance their technology standards so as to compete globally?

Over the years, IMTEX has gained good traction, both nationally and internationally. The number of participants, both from machine manufacturers and visitors, has been good, with a majority from the southern and the western part of India. We have had inquiries not only from companies, but also from students. When the visitors come at IMTEX, they come with their specific requirements, which change with time. This makes the manufacturers inquisitive of their needs. Hence, the demand is understood and manufacturers try to see how international and global standards can be met. This is how it helps advance the technology.

Rajesh Khanna, Chief Executive Officer, Wendt India

Given that the global manufacturing companies are moving towards the next industrial era – Industry 4.0, how were these trends and technologies observed at IMTEX 2017?

To be globally competitive, manufacturers have to adopt Industry 4.0 and smart manufacturing.

More machines have to be looked into and they have to be ‘smart’ in nature by way of gauging the tool and a lot of automation and sensors have to be incorporated. Further, in order to be a part of the ‘Make in India’ initiative, we have to be making it at a lesser manufacturing cost and smart manufacturing does help with this objective.

What are the main factors that are driving manufacturing excellence globally?

In order to be competitive, manufacturers need to focus on excellence in every field. Excellence should be maintained not only in the manufacturing process, but in the entire process. This includes right from the time the product enters the premise of the company till the time the product is delivered and serviced. Excellence ensures efficiency, increase in productivity and saving of costs.

Quality, deliverability, reliability and consistency are the main factors of manufacturing excellence.

The platform of IMTEX helps us, as a nation, to showcase that we are not only excellent in our IT and services sector, but are also taking a lead in the manufacturing sector.

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“Industry 4.0 is the future for all manufacturers”

Martin Kaiser, Head – Sales Export, Vollmer

What were the products from your company showcased during IMTEX 2017? Were there any new technologies launched as well?

This year, at IMTEX, we had two grinding machines available in our booth. One machine was the re-sharpening machine, which is a benchmark in the Vollmer product range. We have exhibited this machine many times in India and we have sold a lot of these machines. So, this is a very wellknown machine in the market. The second machine we showcased is a brand new machine and a new segment for Vollmer. It is a 5-axis tool grinding machine, which Vollmer introduced for the very first time three years ago in Germany. This machine was showcased for the first time at IMTEX. With this new machine, which is a unique concept in the market, we hope that we generate new interest in the market and amongst our customers.

How has the IMTEX metal-cutting exhibition evolved over the years? How is the exhibition helping Indian machine tool/cutting tool manufacturers to advance their technology standards so as to compete globally?

Vollmer has been participating in IMTEX since 2007. The exhibition has developed a lot over the years in terms of exhibitors, visitors and the technology. We also recognise the fact that India, in general, follows high technical rules and standards, which is the norm in Europe or in other parts of the world. IMTEX is a very good platform for Indian as well as global machine tool and cutting tool manufacturers for actively promoting their high-tech machines and technological solutions.

Given that the global manufacturing companies are moving towards the next industrial era – Industry 4.0, how were these trends and technologies observed at IMTEX 2017?

Most of the machine tool manufacturers and exhibitors who showcased at IMTEX are part of the Industry 4.0 phenomenon and it is the future for all manufacturers. The trend is definitely towards Industry 4.0 and each company, which is producing machines, will follow this in the future.

This was well represented at IMTEX 2017.

Taking into consideration the current uncertain economic situation in India, what are the possible ways in which exhibitions like IMTEX can drive growth in the manufacturing sector?

Economy has a lot to do with politics and it is difficult for us, as manufacturers, to influence the economy. So, each company has to find its own unique way of navigating through this uncertain economic situation in order to fulfill its requirements. We, as companies, cannot change politics, but we can adapt in a certain way and we can try to push the customers in order to move ahead and overcome this situation in a certain and specific way.

How well does IMTEX 2017 represent the latest manufacturing innovations?

IMTEX 2017 has represented the latest technological innovations, solutions and products that cater to global standards very well.

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MARKET | VIEWPOINT

“Indian manufacturers to adopt IoT in a big way” How has IMTEX metal-cutting exhibition evolved over the years? How is the exhibition helping Indian machine tool/cutting tool manufacturers to advance their technology standards so as to compete globally?

IMTEX is one of the most important branding events for the metal cutting machine tool industry in India. A large number of potential users and customers of machine tools have visited the show. It is an event for machine tool companies to launch their new products and technology developments suitable for the market. The customers visit and discuss the application of the latest technology for manufacturing their components and improve quality and productivity. It is a great place for learning for all.

Given that global manufacturing companies are moving towards the next industrial era Industry 4.0, how were these trends and technologies observed at IMTEX 2017?

IoT or Industry 4.0, which has taken the western manufacturing world by storm, was certainly being seen at the show. Foreign companies and the leading Indian companies are showing IoTready features on some of the connected machines to enable users and machine tool suppliers to monitor performance such as productivity, diagnosis of potential failure, etc. We expect the Indian manufacturers to adopt IoT in a big way soon and IMTEX showcasing examples of this will help the initiative. At IMTEX 2017, we were showcasing machines with IoT features. Ace Designers is the first machine tool company in India to offer IoT-enabled machines as a standard feature.

Shrinivas Shirgurkar, Managing Director, Ace Designers

Taking into consideration the current uncertain economic situation in India, what are the possible ways in which exhibitions like IMTEX can drive growth in the manufacturing sector?

The manufacturing industry has to continuously address the challenges of improving quality and productivity, regardless of the economic situation. It is particularly important during uncertain conditions. IMTEX is a great place to meet and exchange ideas with the machine tool industry towards this objective and to find practical solutions to their problems.

IMTEX provides a good platform for networking with customers and vendors. What would be your company’s strategy post IMTEX 2017 to get the maximum out of the exhibition?

We launched a good number of machines with automation, IoT and higher-end machines at the show this year. We had a large number of potential customers and users who visited us. We also launched a few promotion offers for our customers and we expect a large number of leads to pursue sales post the show. IMTEX is the most important branding event for our company.

How do you plan to align your company’s Vision 2020 strategy with the latest manufacturing trends along with government’s initiatives such as ‘Make in India’, ‘Digital India’, etc?

We not only make in India but we also design and develop all our products ourselves in India. This is how we contribute to the latest government’s initiatives.

What are the main factors that are driving manufacturing excellence globally? How well does IMTEX 2017 represent these latest manufacturing innovations?

Quality, productivity and competitiveness are the main factors that lead to excellence. At IMTEX 2017, there has been a practical demonstration of various innovative solutions towards this objective.

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VIEWPOINT | MARKET

“Focus on getting the best quality in an economical way” What were the products from your company showcased during IMTEX 2017? Were there any new technologies launched as well?

We had displayed two different machines at IMTEX this year. We are into the manufacturing of super-finishing or micro-finishing machines. This is used to serve high-profile or high-finish applications and very high accurate applications. We showcased one machine for a shaft application and one machine for a wiring application. This goes to the automobile industry or the bearing industry.

Sameer S Kartha, Managing Director, Thielenhaus Microfinish India

How has the IMTEX metal-cutting exhibition evolved over the years? How is the exhibition helping Indian machine tool/cutting tool manufacturers to advance their technology standards so as to compete globally?

This year, at IMTEX, we found that the platform presented us with a greater potential for customers for our company. It is not just IMTEX, but also government policies such as the ‘Make in India’ initiative that are helping Indian manufacturers to advance their technology. We are a German company and we look forward to start a factory in India, most likely at Bengaluru.

IMTEX is a good platform for the Indian manufacturers to compare their products with the global market and have exposure to global technology.

What are the main factors that are driving manufacturing excellence globally?

To achieve manufacturing excellence, it is important to focus on how we can get the best quality in an economical way. Many Indian customers fail to recognise that good quality comes at a cost. In order to be cost-effective, many customers often compromise on quality by investing in sub-standard machines. This can actually incur loss as it is a waste of time and money.

Instead, investing in a good, high-quality machine can not only ensure quality production, but is also an investment for the future.

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EVENT | REPORT

Lights, Camera, Action!

In the global league of manufacturing, to remain competitive in the manufacturing industry necessitates an organisation to shine high with its stars and starlets. The Annual Motion Meeting 2017, recently concluded at Thun, Switzerland, on these lines, witnessing grinding professionals STUDER, SCHAUDT and MIKROSA presenting their latest launches.

A post event report...

United Grinding hosts an annual conference with its sales partners and international press to highlight the latest developments, machine sales trends, investment in production and roadmap for the upcoming years. This year, with the theme of “Lights, Camera, Action,” the Motion Meeting 2017 was organised to showcase its latest advancements at the United Grinding headquarters at Thun, Switzerland. Does STUDER, SCHAUDT and MIKROSA have a place on the Walk of Fame?

Yes, this year’s edition witnessed the re-launch of S11 cylindrical grinding machine with extended functionality and the company’s vision for the next industrial revolution – Industry 4.0.

Addressing at the annual press conference, Fred Gaegauf, CEO, Fritz Studer AG and Schaudt Mikrosa GmbH, said, “We make our customers more successful, by responding to their requirements. To do this, you first have to understand the

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

customer's individuality. Easier said than done, in a time when the complexity of processes is steadily increasing and customer requirements are also growing significantly.” And yet the three companies achieve this, also thanks to their flexibility in production and constant pursuit of innovation. “We are well on track, even if we have not met all our targets”, confirmed Gaegauf.

To this end, the cylindrical grinders have invested heavily in their production technology and hugely reduced processing times, which ultimately also benefits the customer.

Incoming orders 2016 started very positively for STUDER after a successful Grindtec trade fair, but this trend could not be maintained throughout the year and Fritz Studer AG finished the year below

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“We make our customers more successful, by responding to their requirements. To do this, you first have to understand the customer's individuality” Fred Gaegauf, CEO, Fritz Studer AG and Schaudt Mikrosa GmbH

“Irrespective of the political uncertainities in many countries that caused us problems, we are right on track now” Jens Bleher, Managing Director, Fritz Studer AG & CSO, Cylindrical Grinding Technology Group

“We strive to achieve perfect processes, so that we can provide excellent products and services. We want to impress our customers with our effectiveness” Gerd König, COO, Cylindrical Grinding Technology Group

target. What are the reasons for this? “The VW diesel scandal, the weak economy in China and the continuing effects of the euro exchange rate as well as political uncertainties in many countries caused us problems”, explained Jens Bleher, Managing Director, Fritz Studer AG and CSO of the Cylindrical Grinding Technology Group. STUDER's most important sales markets are Western Europe, followed by Germany, China and North America.

SCHAUDT MIKROSA was unable to continue the success of 2015. After a strong spring, incoming orders remained clearly below the set targets. Orders in Germany, with a percentage of 25%, primarily come from automotive manufacturers and their suppliers. Another big market is China, with a percentage of 26%.

Efficient value creation in the operation segment STUDER, SCHAUDT and MIKROSA focus on strengthening core competencies along the entire value chain and have invested around 40 million CHF in their plants during the last few years.

New buildings have been added and new machine tools have been installed and networked based on optimised logistical criteria.

The cylindrical grinders have integrated central manufacturing processes into their own value creation chain in order to guarantee high process stability.

At the same time, they have founded their own PuLs® Six Sigma Academy with the internal PuLs® philosophy, based on the Lean Six Sigma method. This enables the employees to shape their own working culture and to constantly examine and improve processes and systems. “We strive to achieve perfect

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processes, so that we can provide excellent products and services. We want to impress our customers with our effectiveness”, said Gerd König, COO, Cylindrical Grinding Technology Group.

The future starts now In order to maintain the innovation leadership of STUDER, SCHAUDT and MIKROSA in the future, the focus will be on the following projects: • Industry 4.0: Here, the cylindrical grinders are focusing on the acquisition of machine and process data. The goal is predictive maintenance. The aim is to avoid unexpected downtimes for customers and to make production more plannable and efficient.

• Smart sensors: Here STUDER, SCHAUDT and MIKROSA develop active, autonomous sensors to fully measure and also actively support the grinding process.

• Universal series: Following the successful market launch of the completely revised internal grinding machine series, STUDER is continuing to work on issues that make the customer more successful, as is the norm for a trendsetter.

• Cooling lubricant: In cooperation with IRPD AG, which operates in 3D printing, STUDER is developing coolant nozzles for laminar flow conditions. These allow the lubricant to be accurately directed into the grinding slot, so that the optimal cooling effect is achieved at the desired location.

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STUDER has integrated the OPC UA standard into its ‘StuderWIN’ machine software

The S11 with extended functionality will increases customer benefit significantly

The S11 with extended functionality

closely with our customers”, he explained. STUDER is specifically working on the following: Simple and secure networking: The basis of Industry 4.0 is the networking of machine, logistics, product and our customers' business systems (ERP, SAP). Everyone must speak the same language here. This is achieved through the simple and secure software interface used worldwide, OPC UA (Open Platform Communication Unified Architecture). STUDER has integrated the OPC UA standard into its ‘StuderWIN’ machine software. The machine can assume two roles here: OPC UA Client and Server. This enables STUDER machines to be integrated simply and securely into the environment of the digital factory.

Elimination of unplanned machine downtimes: The United Grinding Group adopts the ‘Predictive Maintenance’ approach here. In order to make this possible in future, the data of the individual assemblies and components are recorded and analysed. Different measured variables are needed here, to form a clear picture of the individual assemblies and components.

This requires continuous learning and is an ongoing process.

“Once there is a clear vision, suitable strategies and measures can be precisely planned and the right tools developed”, convinced Josi. Another project that is being tackled is the “One Push Remote Solution”. This means that if an assembly or component fails, despite Predictive Maintenance, the problem can be rectified at the press of a button and the customer can be offered optimal support.

Who is at the centre here? With the use of new technologies and digitalisation, we must never lose sight of the customer benefit. Concluding on the role of people in the digital factory, Josi said, “Doubtless the requirements will change and different competencies will become important. However, people will remain an essential part of the system in future. Because the fourth industrial revolution should ultimately serve people and not vice versa.” ☐

The extended functions will particularly please users of the new S11 - the smallest production cylindrical grinding machine in the STUDER portfolio: Now they can profit from the diverse advantages of the STUDER standard grinding cycles and the grinding software for offline programming StuderGRIND. Using the software, StuderWINfocus together with Fanuc control provides the basis for a flexible scope of use, which increases customer benefit significantly.

"The customer naturally still has the opportunity to design his program as flexibly as possible using micro functions. With the STUDER standard grinding cycles, however, he has even more convenience and support with the S11," highlighted Christian Josi, Project Manager, Fritz Studer AG. The uniform control platform guarantees program consistency on all machines running Windows operating systems. This is regardless of whether the program is programmed directly on the Control or is generated externally with StuderGRIND. STUDER confirms the functions that can be offered immediately are the Fanuc 0i-TF Control, the chuck-work head, which goes along with C-axis option, HSG-Spindle, the new balancing system with contact detection and die StuderGRIND software with extension packages. These functions will take some time to get ready for the production and the new enclosure will be released in Q3 of 2017.

The next industrial revolution – Industry 4.0 Industry 4.0 is a vision. But what lies behind it? STUDER gets to the bottom of this issue and showcased just what this vision entails. “A smart factory isn't simply created overnight.

It is necessary to focus on certain areas”, noted Josi. “For STUDER, the basic principle applies, that all further developments should lead to a customer benefit. We work

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EM | Mar 2017

NEWS | TECHNOLOGY

Thermal imaging cameras

CNC turning centres

FLIR Systems has announced three new Exx-Series advanced thermal imaging cameras for electrical, mechanical, and building applications: the FLIR E75, E85, and E95. The redesigned, Wi-Fi-enabled Exx-Series features intelligent interchangeable lenses, laser-assisted autofocus modes and area measurement functionality, improvements to FLIR’s patented MSX® imaging technology, and a larger, more vibrant 4-inch touchscreen. These distinctive features, combined with increased sensitivity and increased native resolution, will help professionals identify hot spots or building deficiencies before potential problems become expensive repairs. In redesigning the Exx-Series, the company developed a new range of compact intelligent, interchangeable lenses that the camera automatically recognises and calibrates, Exx-Series E95 eliminating the need for manual calibration. The ExxSeries now also features laser distance measurement that assures precise autofocus to improve temperature measurement accuracy, and specifically for the FLIR E85 and E95 models, provides the data for on-screen area measurement in square feet or metres. In addition, these models offer increased thermal detector resolutions with up to 464×348.

Geedee Weiler offers two innovative cost effective Flex Turn and Lean Turn CNC turning machines. The Flex Turn CNC machine can be fitted with linear tooling arrangement or eight station turret coupled with independent live tool, thus, providing a combination of turning/ milling operations to reduce the manufacturing cost per component. This machine is suitable for manufacturing medium size parts in the field of automobile, agriculture, surgical equipment, home appliances, aerospace Flex Turn and jewellery. The Lean Turn CNC machine is compact in size and highly suitable for small/medium parts where volume is high. It combines high speed machining with high precision and productivity, which offers cost effective machining solutions. Depending upon the number of operations involved and the size of the component, up to 7-tools can be used for parts having a diameter of less than 20 mm.

The company also developed its latest model Flex Turn Neo that features modified top cover and automatic top door so that automation can be added depending on the requirements.

FLIR Systems | New Delhi Email: flirindia@flir.com.hk | Tel: +91-11-4560-3555

Gedee Weiler Pvt Ltd | Coimbatore Email: sales@gdweiler.com | Tel: +91-422-2413513

Universal NANOFINISH machine

Solid carbide end mill

Grind Master has launched disruptive SMX500 Universal NANOFINISH machine for the finishing of next generation automotive powertrain components. An automotive powertrain facility usually has the following 3 types of NANOFINISH machines, microfinishing for crankshafts, microfinishing for camshafts and superfinishing for gearbox shafts. The SMX500 combines the functions of these 3 machines with its versatile NX Series NANOFINISH Units into one machine – making it a very flexible setup. There are 6 breakthrough technologies introduced SMX500 in the SMX500 (patent pending for 3 inventions). The machine requires no setup change and seamlessly identifies and processes the loaded part type. It integrates part inspection (finish and geometry) inside the machine itself and is equipped with the user-friendly Industry 4.0 compliant NANOSMART control system. The company is a global technology leader in the NANOFINISH range of products for automotive powertrain components, including microfinishing, superfinishing of crankshafts, camshafts and transmission shafts.

Hoffmann Group has introduced new solid carbide end mill called as GARANT MasterSteel SlotMachine that offers 5 cutting edges and a new type of knuckle form profile, thereby, achieving high feed rates. The end mill is particularly suitable for milling deep slots from solid and also for machining delicate components. Based on its unusual geometry, it produces chips that are short, fine and tightly rolled. These are easily cleared by the flat chip-breaker recesses.

The GARANT MasterSteel SlotMachine permits plunge angles up to ten degrees.

The cutting edge design includes honing to minimise the risk of breakaway.

The ultra-fine grain substrate greatly GARANT MasterSteel SlotMachine increases the resistance to breakage, while the enhanced coating also optimises the wear characteristics and reduces the rate of heat input. The unequal spacing ensures a smooth cutting action. The new solid carbide end mill extends the GARANT MasterSteel product range, which currently includes the existing classic four-edge end mills and also the GARANT MasterSteel PickPocket universal end mill plus two solid carbide drills.

Grind Master Machines | Aurangabad Email: sales@grindmaster.co.in | Tel: +91-240-2374104

EM | Mar 2017

Hoffmann Quality Tools India Pvt Ltd | Pune Email: india@hoffmann-group.com | Tel: +91-20-6707-2399

69

TECHNOLOGY | NEWS

Servo cables

Solid carbide drill

igus has developed a new CF29 servo cable series that offers safe movement in energy chains with a bending factor of 6.8xd, even in a temperature range of -35°C. This product range extension provides completely new possibilities for energy supply to drives, for users with very tough requirements such as ambient temperatures or small installation space. The CF29 chainflex servo cable series features a core structure optimised for motion combined with a gusset-filling extruded TPE inner CF29 servo cable series jacket as well as a highly flexible TPE outer jacket. In order to offer its customers an even better selection, the company is now expanding its high-end range with this new servo cable and an additional series for data and bus cables. All cables were successfully tested in a climatic test chamber with real-world mechanical loads and temperatures, within the 2,750-square-metre-large test laboratory. This allows the cable manufacturer to guarantee a service life of 36 months for all cables. And this applies even for cables with the highest dynamics and the most complicated movements.

Mitsubishi Materials has extended the drill diameter of new generation solid carbide drill series such as MVS (internal coolant), MVE (external coolant) and WSTAR in the range of 12.1-20 mm. The new generation solid carbide drill series adopts new coating grade, ‘DP1020’ specialised for a drill reduced friction resistance and improved wear resistance, thereby ensuring high versatility and longer tool life. It maintains smooth chip evacuation by adopting a wavy cutting edge design. It also achieves longer tool life by improving the cutting edge rigidity. With the unique ‘ZERO-µ surface’, the cutting edge retains its sharpness and smoothness. It achieves both increased machining stability and longer tool life by controlling a crack of a coating and wear. It’s original coolant hole shape ‘TRI cooling technology’ increases the flow of coolant and rapidly eliminates the heat Solid carbide drill series generated by cutting. The solid carbide drill series with drill diameter in the range of 3-20 mm is available in the market now and drill diameter of 12.1-20 mm has been added recently.

igus (India) | Bengaluru

MMC Hardmetal India | Pune

Email: Harish@igus.in | Tel: +91-80-49127809

Email: mayur.kulkarni@mmci.co.in | Tel: +91-20-6520-8430

Cylindrical grinding machine

Vacuum and pressure switches

Palmary Machinery offers a new model OCA-3235 of CNC angular wheelhead cylindrical grinding machine that can simultaneously grind both diameter and face of automotive components such as crankshaft, transmission shaft, drive shaft, etc. The cylindrical grinding machine is equipped with unique hydrostatic bearings on wheelhead spindle. The wheel spindle runs by using a special hydro-static bearing and is especially ideal for OCA-3235 precision grinding work. It features high speed, no friction between metals, no heat generation, deformation-free and extra high accuracy with continual use. The machine’s X- and Z-axis simultaneous movement may dress the wheel in specific shape for multiple-step grinding purpose. It features an angular type wheel seat that includes independent hydraulic and lubrication system, with hydro-static slide ways and high precision ball screws to ensure ultra-high positioning accuracy. The company is a specialist in design and manufacturing of various grinders and exports to over 40 countries around the world. The quality of Palmary production has achieved international levels and has been certified by ISO 9001 and CE standard.

Schmalz has developed a new series of vacuum and pressure switches that open up completely new communication possibilities and make processes much more transparent. The VSi version is easy to integrate into systems and makes vital process data visible.

The switch communicates with all conventional field-bus systems via IO link and also allows you to read out information using a smartphone. The new electronic VSi switch VSi vacuum and pressure measures and monitors low and excess pressure in automation and handling systems. The digital VSi switch can be integrated into existing systems with minimum effort via the IO link.

The recorded status data reaches control level rapidly via the IO link interface. For the system operator, this means more transparency, diagnostics and parameterisation and shorter response times in the event of faults or errors. The switch is available in three versions: without a display, with an integrated display or with an external operating display. Depending on the application, a pressure, vacuum or combined version can be chosen.

Palmary Machinery | Taiwan Email: palmary@grinding.com.tw | Tel: +886-4-24929799

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Schmalz India | Pune Email: schmalz@schmalz.co.in | Tel: +91-20-4072-5500

EM | Mar 2017

NEWS | TECHNOLOGY

Quick-change pallet system

Tool insert holders

Schunk offers miniature quick-change module VERO-S NSE mikro that transfers the effect of fast component change with the SCHUNK VERO-S quick change pallet system to a new dimension. It is now possible to change miniature components in confined spaces reliably and precisely at a repeat accuracy of < 0.005 mm within seconds. The compact miniature module is an VERO-S NSE mikro important piece of the puzzle for more efficiency in the production of small workpieces and components. It is suitable for fast workpiece, component and pallet change in light machining as well as in assembly cells and measuring machines. At a height of only 12 mm and an outer diameter of 49 mm, VERO-S NSE mikro is the most compact quick-change pallet system in the world. The corresponding clamping pins have an outer diameter of just 10 mm. The clamping pin is positioned via short tapers and fixed with three slide assemblies. Locking is achieved mechanically by means of a spring assembly. The system is self-locking and designed for form-fit clamping.

Seco Tools has adapted its line of reliable, accurate thread chaser holders to support Steadyline® vibration damping bars and Capto tooling. With special carbide-pin locating systems, patented pocket seat surface patterns and highpressure coolant delivery, these holders guarantee consistent insert positioning, superior rigidity and effective chip evacuation. Adapted for tooling with Capto C6, Capto C8 or Steadyline GL50 connections, these new holders accommodate a wide selection of multitooth chasers or single-tooth inserts that Thread chaser holders efficiently perform external and internal threading operations, providing increased options and added flexibility for push or pull configurations. Previously available in a square shank design, the company’s thread chaser holders produce API and common licensed thread profiles across the full range of OCTG materials. The combination of a chipbreaker geometry and direct coolant delivered through the insert and chipbeaker creates optimal chip formation with increased tool life. Maximum pressures reach 70 bar on the new Steadyline and Capto versions of the thread chaser holders and 200 bar on square shank holders.

SCHUNK Intec India | Bengaluru Email: info@in.schunk.com | Tel: +91-80-40538999

Seco Tools India | Pune Email: seco.india@secotools.com | Tel: +91-2137-667300

Boring tools Zen Wu Zheng Sun Tool has introduced two types of boring tools series 289 and 207. The 289 series is used for cutting soft materials such as copper, aluminium and plastic. The company recommends the customers to use 289 series with 10% Co and micro grain 0.6µ materials with TiN coating. With special blade design, the tools have outstanding cutting performance. The 207 series is used for cutting hard materials that include HRC 60o Boring tools heat-treated steel. The company recommends the customers to use 207 series with 12% Co and micro grain 0.4µ materials with ALTiN coating. The optimised blade with special angle design and coating in coordination make the tools wear-resistant and high red hardness. To meet customers’ needs, the company is continuously developing the boring tools for titanium alloy and for stainless steel. The boring tools find its application in the area of internal broaching for small parts, barrels, lenses of mobile phones, pipework, appliances, medical equipment, aeronautic tubes, etc. The company was established with the brand name JSK. Zen Wu Zheng Sun Tool | Taiwan Email: first@jsk-tools.com.tw | Tel: +886-7-3525743

EM | Mar 2017

Statement about ownership & other particulars about EM, as required to be published in the first issue every year after the last day of February FORM IV (See Rule 8) 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Monthly 3. Printer’s Name: Shekhar Jitkar Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 4. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. Names & addresses of individuals who own EM and partners or shareholders holding more than 1% of the total capital in publish-industry India Pvt Ltd: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 10-03-2017: a) publish-industry Verlag GmbH, NymphenburgerStrasse 86, 80636 Munich, Germany b) Kilian Mueller, NymphenburgerStrasse 86, 80636 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief.

Dated: March 17, 2017 Sd/SHEKHAR JITKAR Signature of the Publisher

71

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 - April 2017 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Senior Features Writer Megha Roy megha.roy@publish-industry.net

» Casting & Forging Despite radical reforms in manufacturing processes, casting as a production technique is still adopted heavily to build complex products. Basic technologies in casting & forging have not undergone much change, but the emphasis has changed. The world has become more environmentally conscious and technologies have to conform to more and more stringent environment norms.

The next edition will highlight some of the trends in the casting & forging sector.

» Industrial robotics There are new factory robotic trends emerging every day, like the addition of vision and sensors to make robots easier and safer to work with in a humanpopulated environment. The upcoming issue will discuss these advanced technologies incorporated in robotics. » Geometric Dimensioning & Tolerancing The proper use of Geometric Dimensioning and Tolerancing (GD&T) within a welldefined product development effort can identify a bad design before it results in a lot of needlessly expensive parts. The next issue highlights the importance of GD&T in manufacturing.

» Green machining practices The demand for sustainability is growing stronger every day, and manufacturers are looking for ways to comply to reduce their impact on the environment and increase profitability. The concept of green manufacturing aims at design and implementation of processes that will eliminate waste and reduce environmental impact in work practices and plant operations. The special feature in the forthcoming issue will talk on these practices in detail.

Features Writer Maria Jerin maria.jerin@publish-industry.net Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net Advertising Sales & Marketing Sagar Tamhane (General Manager – North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net Dhiraj Bhalerao (General Manager – West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugoud Patil (Senior Manager – Bengaluru) Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Tarun Kumar Pyne Senior Graphic Designer (Print & Web) Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752

COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . .Page Ace Designers . . . . . . . . . . . . . . . . . . . .63 Ace Micromatic Group . . . . . . . . . . . . . . . .1 Aequs . . . . . . . . . . . . . . . . . . . . . . . . . .10 Allied Machine & Engineering . . . . . . . . . .26 Blaser Swisslube . . . . . . . . . . . . . . . . . . .31 CECIMO . . . . . . . . . . . . . . . . . . . . . . . .12 CG Tech . . . . . . . . . . . . . . . . . . . . . . . .33 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Comsol Multiphysics . . . . . . . . . . . . . . . .19 DesignTech systems . . . . . . . . . . . . . . . .10 Deutsche Messe . . . . . . . . . . . . . . . . . . .41 DMG Mori . . . . . . . . . . . . . . . . . . . . . . .28 Festo India . . . . . . . . . . . . . . . . . . . . . . .60 FLIR Systems . . . . . . . . . . . . . . . . . . 49, 69 Ganro Industrial . . . . . . . . . . . . . . . . . . . .53 Geedee Weiler . . . . . . . . . . . . . . . . . . . .69 Grind Master Machines . . . . . . . . . . . . . . .69 Hoffmann Quality Tools India . . . . . . . . . . .69 ifm electronic India . . . . . . . . . . . . . . . . .51 igus . . . . . . . . . . . . . . . . . . . . . . . . . 2, 70

Name . . . . . . . . . . . . . . . . . . . . . . .Page IIT – M . . . . . . . . . . . . . . . . . . . . . . . . .46 IMTMA . . . . . . . . . . . . . . . . 10, 12, 46, 56 Jainnher Machine Co . . . . . . . . . . . . . . . .45 Jyoti CNC Automation . . . . . . . . . . . . . . . .3 Kennametal . . . . . . . . . . . . . . . . . . . . . .14 Kenturn Nano Tech Co . . . . . . . . . . . . . . . .9 LMT Tools India . . . . . . . . . . . . . . . . . . .16 Makino . . . . . . . . . . . . . . . . . . . . . . . . .40 Mazak Corporation . . . . . . . . . . . . . . . . .36 Micromatic Grinding Technologies . . . . . . .46 MMC Hardmetal . . . . . . . . . . . . . . . . 15, 70 Morgan Advanced Materials . . . . . . . . . . .11 MotulTech India . . . . . . . . . . . . . . . . . . . .57 Nasmyth Group . . . . . . . . . . . . . . . . . . . .11 Palmary Machinery . . . . . . . . . . . . . . 70, 35 Plazma Technologies . . . . . . . . . . . . . . . .18 PwC Management Consulting . . . . . . . . . .22 Renishaw . . . . . . . . . . . . . . . . . . . . . . . .32 Rollomatic India . . . . . . . . . . . . . . . . . . .43 Royal Precision Tools Corporation . . . . . . . .13

Name . . . . . . . . . . . . . . . . . . . . . . .Page Schmalz India . . . . . . . . . . . . . . . . . . . . .70 Schunk Intec India . . . . .Front Inside Cover, 71 Seco Tools India . . . . . . . . . . . . . . . . . . .71 Siemens India . . . . . . . . . . . . Front Gate Fold Starrag Group . . . . . . . . . . . . . . . . . . 11, 21 STIMS Institute . . . . . . . . . . . . . . . . . . . .46 TaeguTec India . . . . . . . . . . . . . . Back Cover Tectyl Oil & Chemicals . . . . . . . . . . . . . . .20 Thielenhaus Microfinish India . . . . . . . . . . .64 TWI . . . . . . . . . . . . . . . . . . . . . . . . . . .52 UCAM India . . . . . . . . . . . . . . . . . . . . . .17 United Grinding Group . .Back Inside Cover, 66 Vargus India . . . . . . . . . . . . . . . . . . . . . . .6 Vollmer . . . . . . . . . . . . . . . . . . . . . . . . .62 Wendt India . . . . . . . . . . . . . . . . . . . . . .61 YG -1 Cutting Tools . . . . . . . . . . . . . . . .4, 5 Zen Wu Zheng Sun Tool . . . . . . . . . . . . . .71 ZF India . . . . . . . . . . . . . . . . . . . . . . . . .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+91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted.

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

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EM | Mar 2017

UNITED GRINDING:

MÄGERLE

BLOHM

JUNG

STUDER

Solutions for precision machining UNITED GRINDING Group The UNITED GRINDING Group is the leading manufacturer of precision machines for grinding, eroding, lasering, combination machining and measuring. We offer our customers comprehen­ sive services worldwide. www.grinding.ch

United Grinding GmbH – India Branch Office · # 487, D1 & D2A, 4th Phase, KIADB Main Road, Peenya Industrial Area, Bangalore – 560058 Tel: +91 80 3025 7600 · Fax: +91 80 3025 7603 · Email: info.in@grinding.ch · URL: www.grinding.ch

SCHAUDT

MIKROSA

WALTER

EWAG

high feed & high positive sbmt 09/13 inserts

Xevt, eXcellence in Aluminum mAchining

TaeguTec India Pvt. Ltd. Plot Nos.119 & 120, Bommasandra Industrial Area, Phase 4, Bengaluru 560 099, India +91-80-2783-9111 +91-80-2783-9123 sales@taegutec-india.com www.taegutec.com