VOL 08 | OCT 2017 | ` 100 www.industr.com/en
EFFICIENT MANUFACTURING
Lean in automotive manufacturing Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
ROADMAP FOR IMPLEMENTATION
EM - Interview Vijay Kalra, Chief of Manufacturing Operations, Mahindra & Mahindra [AS] (p. 34)
FOCUS Cutting Tools P. 40 SPECIAL FEATURE Industrial Maintenance P. 58
Š 2017 SCHUNK GmbH & Co. KG
VERO-E compact – The set-up time optimizer VERO-E compact is the modular quick-change pallet system for very fast and extremely precise resetting of workpieces, clamping devices or other equipment on modern 3, 4 or 5-axis machining centers. It reduces set-up times by up to 90% and thus ensures optimum use of the machine capacity.
High tech from a family-owned company
90%
Set-up time reduction quick-change pallet system
Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for safe, precise gripping and holding. schunk.com/Lehmann
Clamping pallet with chuck
Clamping pallet with magnetic clamping technology
Clamping pallet with clamping force blocks
| TC11-02E |
Machine control for Industrie 4.0 with TwinCAT
www.beckhoff.co.in/Industrie40 Beckhoff provides the ideal foundational technologies for Industrie 4.0 and Internet of Things (IoT) applications via standard PC-based control. With the TwinCAT engineering and control software, machine control systems can be extended to support big data applications, cloud communication, predictive maintenance, as well as comprehensive analytical functions to increase production efficiency. As a system-integrated solution, TwinCAT IoT supports standardised protocols for cloud communication and enables the easy integration of cloud services right from the machine engineering stage. In addition to fault analysis and predictive maintenance, TwinCAT Analytics offers numerous opportunities to optimise machines and systems in terms of energy consumption and process sequences.
POWERING YEAR 10 Beckhoff Automation Pvt. Ltd. Pune – 411 006, India Phone: + 91 20 40 00 48 00 info@beckhoff.co.in
zero Largest Test Lab. Widest Choice. 36 Month Guarantee.
... zero Downtime ... From #1 in moving cables.
34 M strokes tested*
138 M strokes tested*
27 M strokes tested*
26 M strokes tested*
41 M strokes tested*
20 M strokes tested*
22 M strokes tested*
76 M strokes tested*
66 M strokes tested*
65 M strokes tested*
53 M strokes tested*
97 M strokes tested*
138 M strokes tested*
50 M strokes tested*
22 M strokes tested*
HYBRID
TORSION
FOC
CAT7
Zero Downtime solutions for your toughest moving cables: 1244 cables from stock make chainflex the largest motion cable range - for torsion, motor, servo, hybrid, control, data, BUS, ethernet and FOC cables. chainflex cables are developed and tested in the industry´s largest test lab. With 600 parallel tests on 2750 m2, 1.4 million electric measurements and 2 billion cycles per year, you find cables that solve your toughest "zero downtime" challenge. And with up to 7 motion quality classes, you find just the right cable for your application - for less money. Calculate life online and order today with a 36 month guarantee.
MEASURING
BUS
®
®
plastics for longer life
®
* All test reports and more here: www.igus.in/chainflextests
igus (India) Pvt. Ltd. 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post Bangalore - 560048 Phone +91-80-45127800 Fax +91-80-45127802 info@igus.in ®
TS NEW PRODUCMO
LEADERS of INNOVATION TE LAUNCHED A 2017 HANNOVER
Advanced Threading Solutions
I n n o v a t i v e G r o o v i n g & Tu r n i n g S o l u t i o n s
TM Solid TMDR
Drilling, Thread Milling & Chamfering
TM Solid HCN
for Long Threads Up to 3xDo (Thread Diameter)
microscope
New Miniature Toolholders & Internal Tools with Coolant
GrooVical
New Close to Shoulder Positive Rake Grooving Insert
VG-Cut
A NEW GENius on Hand APP
VARGUS INDIA
24/7
Unit Nos. 16 & 20, 1st Floor Mega Centre
High Pressure Coolant Tools
Pune - Nasik Highway, Chakan, Pune - 410501
Tel: +91 9011553000 info@vargusindia.com
VARGUS Ltd.
mrktg@vargus.com www.vargus.com
E D I TO R I A L
Talking about buzzwords! B
uzzwords always become the topics of discussion in any conference. A few years back, “innovation” was the buzzword, then came ‘green manufacturing’, later it was ‘lean manufacturing’, followed by ‘sustainable manufacturing’. After that ‘next-gen manufacturing’ and ‘factory of the future’ became the most discussed topics in the conferences. Then ‘Make in India’ was there for some time. Now ‘smart manufacturing’ is the most popular buzzword. Go to any industrial conference happening these days, and you’ll get to hear government officials, bureaucrats, industry professionals and academicians talking only about ‘smart manufacturing’ where Industry 4.0 and IIoT are the highlight areas. The recent Automotive Industry 4.0 Summit by CII was no exception. Packed with a huge list of speakers, the event covered the topic in a much detailed way. What it lacked probably was in touching upon the ground realities when it comes to deployment of advanced technologies in the brownfield plants. Going back to lean manufacturing, we have a Cover Story in this issue which talks on efficient implementation of lean in manufacturing while making the value-added steps in the process flow. It’s quite a sensible and worthwhile read for those who want to enhance their company’s competitive edge. The Viewpoint section introduced in this issue features industry experts deliberating on the opportunities in the high-end machines tool segment in India. Increasing exports over imports by bridging the technology gap is a need of the day for the Indian manufacturing industry. This is possible by tapping the opportunities existing in the high-end machine segment, by leveraging on our strengths in cost competitiveness, favourable investment conditions, and better engineering & designing capabilities. Enjoy reading this issue and do write to us with your feedback!
“What today’s events lack probably is in touching upon the ground realities when it comes to deployment of advanced technologies in the brownfield plants”
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
A&D India | Aug-Sep 2017
7
CONTENTS
Market
Management
12 NEWS
INTERVIEW 34
22
“Global lubricant market will witness growth”
Interview with Shankar Karnik, General Manager—Industrial, ExxonMobil Lubricants 24
Focus
CUTTING TOOLS
“Being lean, flexible & agile are the new rules of the game”
Interview with Vijay Kalra, Chief of Manufacturing Operations, Mahindra & Mahindra Ltd [AS]
“We are committed to cause of sustainability”
40
Take a reverse path to machining success
The feature discusses the roadmap that the manufacturers need to follow so that they can produce a certain number workpiece of a desired quality within the appropriate period of time and cost
Interview with Kamal Nandi, Business Head–EVP, Godrej Appliances VIEWPOINT 36
Machine tools in India: Opportunities in high-end products
The viewpoint section analyses how Indian manufacturers can work out the gap of India having a high consumption rate of high-end machines
COVER STORY 26
Lean in automotive manufacturing
There are standard principles that must be applied to any lean implementation—such as increase customer value and reduce waste— but the specific limitations, strengths, resources, and production needs of each organisation will dictate how those principles are realised. The feature implements that lean requires creativity and a deep knowledge of a company’s operations and culture as much as it requires keen and thorough analysis.
EM – the only industrial magazine in India that offers a three-dimensional perspective on technology, market and management aspects of manufacturing
GET EFFICIENT NOW!
SUBSCRIBE TO
8
EM | Oct 2017
em.india@publish-industry.net | www.efficientmanufacturing.in | Ph.: +91 20 6640 5754
CONTENTS
Technology
Cover image courtesy: FUJITSU Glovia Inc
ADVERTORIAL 18
The Orion Story: High performance Indian HMC for the global market
ADDITIVE MANUFACTURING 54
Focusing on integrated design
The feature highlights the application benefits of integrated design from the stages of initial styling to prototyping to design & manufacturing
A success story on the usage of the Orion platform by auto-component makers and HMC users in India COOLANTS & LUBRICANTS 44
A step towards a greener planet
The article highlights the bio-concept in the cutting fluids that becomes an essential global requirement for manufacturing organisations MACHINING CENTRES 48
Selecting the right machining centre
The article briefs on the essential criteria & considerations that manufacturers must keep in mind to select the right machining centre
EM | Oct 2017
SPECIAL FEATURE 58
Efficient cleaning solution in transmission re-manufacturing
An application story on the usage of Durr Ecoclean’s fully automatic cleaning solutions by ATP Industries Group to improve working conditions and sustainability
New Products 60 Drilling tools; Clamp meter; Cable tiewraps; Round insert cutter for difficult-to-cut materials 61 CNC cylindrical grinding; Clamping system; Complex machining unit; Flange seal 62 Grinding tools 63 Smart screwdriver; Ring rollers
Columns 07 Editorial 08 Contents 10 Guest Editorial 64 Highlights – Next issue 64 Company Index
9
Dr Nageswara Rao Posinasetti
PROFESSOR, DEPARTMENT OF TECHNOLOGY UNIVERSITY OF NORTHERN IOWA
Additive Manufacturing, which is also called as 3D printing started in 1984 as a prototype development process that has come a long way today as a mainstream manufacturing process. It has now become a process of choice to make complex, small, and expensive components that are designed specifically for AM. The affordability of AM has increased a lot during the last 10 years to bring the process from the design departments to the mainstream manufacturing. Initially, AM was adopted to do develop tooling for processes such as investment casting. After its successful use in tooling with the developments in the metal AM machines, it is now possible to use AM to directly produce the final tooling. For example, Michelin prints close to a million metal tire moulds per year, which will be used in its plans for moulding the tires. Most of the AM processes utilised laser to melt the build material either polymer or metal powder. These have the limitations on the strength due to the sintering process involved. Newer processes are under development for example, XJet is jetting tiny particles of metal into a liquid that provides a much 10
COMMENTS & COMMENTARY
E D I TO R I A L | G U E S T
MAINSTREAM ADDITIVE MANUFACTURING finer metal grain structure. Similarly, Inkbit inject-head printing system uses conductive inks with high resolution, and good material properties, paving the way for high performance functional polymer parts. One of the early adopters of AM are for the use in medical and dental industries. For example, orthodontist can get a 3D scan of your teeth and then custom design the braces specifically for you to provide Invisalign braces. MRI scan is used to get patient-specific cranial implants that have fewer side effects while lowering surgical costs. University of California researchers have developed ‘MucoJet’, a 3D printed vaccine administration device that has the ability to shoot a pressurised stream of vaccination into the cheek tissue, removing the need for injections. Other major adopters are aerospace where complex geometries with lower
mass are required. GE Aviation has been making fuel nozzles for its nextgeneration turbofan engines that have been approved to fly by FAA. Similarly, other aerospace manufacturers have adopted AM to build parts for aircraft that would reduce the weight while also decreasing the cost of flying by improving fuel economy. It is expected that in GE by 2020, 25% of its products will be impacted. Automakers have utilised AM as prototyping as well as for tooling applications from the very beginning. However, now they are also using to produce the direct parts that will go into the cars. To this extent, German car makers appear to be investing heavily in AM. Time, therefore, has come for all manufacturers to look at the use of AM across the value chain where it can be gainfully employed to reduce the bottlenecks while improving the economy. Also, the academic institutions should incorporate AM in their curriculum in the long run and in the short run offer tailored courses for industry that would help propagate the use of AM. ☐ EM | Oct 2017
FOR A COMPLETE HEALTH CHECK-UP OF YOUR ELECTRICAL EQUIPMENT
FIND THE PROBLEM… BEFORE THE PROBLEM FINDS YOU. • Thermal Cameras • Clamp Meters • Multimeters • Non-Contact Voltage Detector • Moisture Meters • Flex Clamps
4
Circuit Identifiers Clamp Meters Continuity Testers Motor Rotation & 3-Phase Testers
Multimeters Power Analyzers Voltage & Current Testers Ground Resistance Testers
Images for illustrative purposes only.
Megohmmeters
Just like the human body, electrical equipment require a complete examination to identify any glitches. Whether the process is of installation, maintenance or repair, Extech’s testers and meters are always up for the task. To ensure smooth operation of your electrical equipment, Extech offers a wide range of test instruments that help you identify a problem before it occurs. For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk
For more details call us on: +91-11-4560 3555 or write to us at flirindia@flir.com.hk
FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.extech.com
FLIR Systems India Pvt. Ltd. 1111, D Mall, Netaji Subhash Place, Pitampura, New Delhi – 110034 Fax: +91-11-4721 2006 | Webiste: www.flir.in
MARKET | NEWS
Renishaw & Infosys to deliver Additive Manufacturing solutions Renishaw and Infosys recently announced a strategic partnership to offer an end-to-end roduct development service using metal Additive Manufacturing technology. The two companies are combining their engineering expertise and global resources to help customers accelerate their deployment of AM for volume production of end-use metal components. Elaborating on this, Sudip Singh, Global Head— Engineering Service, Infosys, said, “Infosys has developed a rich knowledge base of AM design best practices, coupled with powerful design tools to analyse and optimise product designs, so that we can take full advantage of the flexibility that AM offers.”
Gleason expands its presence in India Mahindra & Ford to explore strategic cooperation in India Mahindra Group and Ford Motor Company recently agreed to explore a strategic alliance designed to leverage the benefits of Ford’s global reach and expertise and Mahindra’s scale in India and successful operating model. The agreement between the two companies will allow each to leverage their mutual strengths during a period of unprecedented transformation in the global automotive industry. Speaking on this alliance, Jim Farley, Executive VP & President – Global Markets, Ford, said, “This alliance can help us deliver the best vehicles and services to customers while profitably growing in the world’s fifth largest vehicle market.”
Gleason recently innaugurated its new 65,000 sq ft facility in Aerospace Park in Bengaluru. Several product demonstrations were showcased which included the introduction of a new gear finishing cell by the Gleason India Team. Speaking on this, John J Perrotti, President & CEO, Gleason, said, “The investment in this new facility makes an important statement about our belief in the Indian market and its growth potential, but most importantly, it is recognition of our confidence in our Gleason Team in India to serve our customers at the highest level.”
ExxonMobil & Primetals Technologies sign global lubrication agreement ExxonMobil and Primetals Technologies have signed a global lubricants agreement to provide lubricants and enhanced technical services exclusively to Primetals Technologies customers. The offer includes three new product families engineered specifically for the unique performance requirements of Primetals Technologies high speed long rolling and flat rolling systems. Speaking on this, Gabriel Royo, VP & Head—Metallurgical Services, Primetals Technologies, said, “As a leading lubricants supplier for the metals industry, ExxonMobil is the ideal partner to help us deliver a complete solution providing world-class products and technical support for our advanced equipment designs.”
12
EM | Oct 2017
MARKET | NEWS
Morgan Advanced Materials is capitalising on growth in the ceramics market
Morgan Advanced Materials recently purchased an ANCA FX5 Linear machine, dedicated to the high volume production grinding of ceramic parts. The company designs and manufactures advanced ceramic components from a portfolio of cutting edge materials in ceramics. Elaborating on this, Steve Thompson, GM, Morgan Advanced Materials, said, “We reviewed and tested several different machines to evaluate which was best suited for grinding the most advanced and hardest ceramic materials. At the end of our extensive testing, we found that the FX Linear was the only machine that achieved consistent and accurate results that could meet our stringent requirements.”
MG Motor inaugurates first facility in India
UK-based car maker, MG Motor (Morris Garages) recently announced the inauguration of its first manufacturing facility at Halol in Gujarat. The company said that it will be making an initial investment of Rs 2,000 crore with an initial capacity of 80,000 units per year in the first phase. Speaking on this, Rajeev Chaba, MD, MG Motor, said, “We aim to contribute to the ecosystem in Gujarat including all stakeholders by generating employment opportunities for local talent, leveraging the capable supplier base and contributing to the overall benefit of the society.” The company will roll out its first product from the plant in 2019.
Siemens and HP partner to advance 3D printing Siemens and HP recently announced that they are accelerating 3D printing for industrial production through the creation of a new HP-certified Additive Manufacturing (AM) software module from Siemens. Elaborating on this, Michelle Bockman, Global Head—3D Printing Commercial Expansion & Development, HP, said, “HP and Siemens are bringing together the best in design and manufacturing workflow software for the best in 3D printing. We look forward to collaborating with Siemens to continually raise the industry bar on what’s possible for customers with the voxel-level design capabilities of our Multi Jet Fusion 3D printing solutions.”
KKR to buy Hitachi Koki Hitachi Koki recently announced that it will be acquired by KKR within six months and may inject fresh funds into the company. Elaborating on this, Dattatraya Joshi, Executive Director & Secretary, Hitachi Koki India, said, “KKR acquired Hitachi Koki in March 2017. Hitachi decided to sell its subsidiary to focus on its core area of manufacturing. At the end of the day, they want to increase the scale of the company and the group as a whole and also the profitability. There will be coordination to increase the scale of the investee company.”
14
EM | Oct 2017
MARKET | NEWS
TCAP research centre to boost automotive industry
Total, an international oil and gas company, recently announced that it facilitates technical assistance and R&D in the areas of lubricants, special fluids, fuels additives and fuels at their research centre TCAP (Technical Centre Asia Pacific) in Mumbai. The Research Centre provides value added technical support in the areas of product development, analysis, product training and field-testing. Speaking on this, Dilip Vaswani, Chairman & MD, Total—South Asia, said, “TCAP will facilitate development of products that can meet the unique needs of customers to save costs, reduce downtime and improve performance.”
ZF seeks to join forces with start-up ecosystem ZF recently announced that it will be giving budding start-ups an opportunity for long-term associations and/or direct investments. Expanding partnerships with start-ups allows the company for greater innovations in engineering and accelerated speed to market. Speaking on this, Mamatha Chamarthi, Chief Digital Officer, ZF, said, “Collaboration with start-ups will accelerate the digitalisation of our products, processes and culture. Expanding our partnerships with newly emerging start-ups alongside our traditional partners will help us to deliver added value to our customers through enhanced products and services.”
DMG MORI presents awards to top supplier partners At the EMO Hannover, DMG MORI presented the ‘Partner Award 2017’ to five of its supplier partners. Masahiko Mori, President, DMG MORI and Christian Thönes, Chairman— Executive Board, DMG MORI honoured Schaeffler Technologies as the overall winner at the DMG MORI partner summit. The other companies that had impressed by their outstanding performance in the close and constructive cooperation with DMG MORI were August Steinmeyer, Fanuc Corporation and Siemens as well as MT Srl. The projects in which the award winners were involved stand out through exceptional innovative power in the areas of process optimisation and product development.
QuEST Global join hands with Siemens QuEST Global and Siemens have reached an agreement to build and deliver a suite of digital manufacturing solutions for customers across verticals. Speaking on this, Ajay A Prabhu, COO, QuEST Global, said, “This partnership underlines QuEST's continued commitment to our customers as they foray in their connected enterprise journey.” Also elaborating on this was Suman Bose, MD & CEO, Siemens PLM Software India, who added, "Siemens is happy to partner with QuEST Global to offer the complete suite of digital manufacturing solutions built on the Siemens Digital Twin portfolio.”
16
EM | Oct 2017
TECHNOLOGY | ADVERTORIAL
ORION
The Orion Story: High performance Indian HMC for the global market To meet the demand for ‘world-class’ HMCs for the Indian and global market, BFW has developed the Orion-series of next-gen HMCs. The project was initiated 5 years back as a platform development by the Indian & German engineering team. Today, Orion platform is a preferred choice over imported machines for many reputed auto-component makers and other HMC users in India. Going ahead, we see Orion as a global brand making its footprint in geographies outside India. The Orion story is a successful case study in structured product development process. Market outlook Indian manufacturing is looking ahead for sustainable enhanced growth. Thanks to long term policies, decisions like GST by Govt and focus on attracting investments in diverse industry segments. The below mentioned segments are expected to grow at healthy growth rate. • Auto sector, a major user of machine tools, will grow by 3.5 to 4 times from the current size of US$ 74 billion to reach
18
about US$ 300 billion by 2026. The Indian auto industry has already become the third largest one since 2016. • General engineering and consumer durables are likely to grow at 15% during the next two years • New emerging sectors like defence & aerospace, consumer durables, and green investments in auto sectors are likely to enhance demand for machining centres in the coming years India is the 13th largest manufacturer of machine tools in the world as per the Gartner’s World Machine Tool Consumption
EM | Oct 2017
ADVERTORIAL | TECHNOLOGY
Orion - H12000 Orion - H10000 Orion - H8800
ORION
Orion - H8000
Modular Design Concept
Orion - H6600 Orion - H6000
Orion - H5500
Series 3
Orion - H5000
Series 2 Series 1 Survey Report 2016. Domestic manufacturers have about 30% share of HMC’s consumption in India. The primary drivers for imported machines are higher productivity, precision and reliability. Japan, Germany, Italy and Korea dominate the import machine segment. To cater to this demand and to favourably improve Indianbuilt HMCs on an equal footing with imports, BFW has introduced the Orion series of next-gen HMCs for catering to the growing requirements of the user industries.
The ‘Orion’ philosophy Orion is a prominent constellation of eight bright stars located on the celestial equator and visible throughout the world. Orion series is a constellation of eight next-gen horizontal machining centers setting new benchmarks in specifications and performance for our global clients. It is a result of IndoGerman engineering excellence for clients seeking cutting edge performance. The engineering philosophy behind Orion next-gen HMCs is based on four strong principles of: ✓ Precision ✓ Productivity ✓ Reliability ✓ Operator ergonomics The design philosophy behind Orion is ‘modularity in design’ or a design approach that subdivides a system into smaller parts called modules, which can be independently created and then used in different systems. Orion platform has three series, covering a range of pallet sizes starting from 500 x 500 pallet up to 1250 x 1000 pallet sizes. Orion
horizontal machining centres are designed and manufactured to deliver excellent machine precision with the use of high-precision components and of thermo-stable materials, which include: ✓ Robust structural parts made of cast iron for high rigidity and damping ✓ High precision roller type LM guide-ways and DIN standard high precision ball-screws ✓ Spindle cooling, ball-screw core cooling and motor flange cooling with PID control ✓ Heidenhain linear scale (optional) for higher precision
Design objectives The primary design objective of Orion product series was to develop next-gen horizontal machining centers with the following features: • Precision & productivity • Reliability • Aesthetics & ergonomics • Compact footprint with space-saving measures • Completely modular construction with interchangeable spare parts
Design principles of Orion series Orion Precision: Proven precision of Orion is a result of the winning combination of the below mentioned characteristics: i. FEM analysed structural parts: Due to the FEM analysis, the following features in the developed machine could be improved:
Enabling Progress Vertical Centers | Horizontal Machining Centers | Vertical Turning | Horizontal Turning | Special Machines | Customised Solutions E M | Machining Oct 2017 19
TECHNOLOGY | ADVERTORIAL
FEM Analysis
✓ Radial stiffness improved by 55% with reference to machine column without increasing weight for enhanced cutting performance ✓ Resonance frequency of column improved by 15% with reference to existing column for enhanced servo dynamics ii. Thermally stable machine column: Use of refrigeration – type chiller help to control column temperature with reference to inputs fed by evenly spaced & placed temperature sensors along the column iii. Ball-screw core cooling: Ball-screw core cooling through deployment of an effective mechanism has often ensured high positional accuracies iv. Axes motor flange cooling: Effective axes motor flange cooling has helped to minimise transfer of motor temperature to the machine structure, hence ensuring thermal stability of column and guaranteeing stable machine performance v. Spindle cooling: Effective cooling of spindle bearings and motor coil, hence ensuring superior & precision spindle performance vi. Rigid bed: Use of a rigid, cast bed of single-piece construction has contributed to minimising the effects of temperature variation Orion Productivity: Proven shopfloor productivity through operations of Orion HMCs is a result of the greatly improved features that have been incorporated in the machines: i. Servo-driven tool magazine: Use of servo-driven tool magazine ensures optimal clamping and unclamping sequencing complete with error sensing mechanism to
20
Thermal Stability
correct magazine movement during operation. Tool magazine comes with 40/60/80 tool capacity options. Due to servo-drives, tool loading and unloading is made possible even while machining. ii. Servo-driven ATC: Servo-driven high speed ATC ensures fast, smooth and reliable tool change with the capacity to handle tool weights up to 12 kg iii. Efficient chip disposal system: Efficient chip disposal is made possible through locating the chip conveyor within the bed along with the addition of: ✓ Direct chip disposal from stocker side ✓ Rear side chip disposal ✓ Dual chip conveyor with hinge and scraper conveyors to handle steel, cast iron and aluminium chips ✓ Ample shower wash facility to avoid chip accumulation 16/40/70 bar coolant through pressure with drum and cyclone filtration system ✓ Oil skimmer to remove oil content & improve coolant life iv. Rotary-type servo-driven APC: Rotary type servo-driven automatic pallet changer for quick and smooth work piece change irrespective of load. APC arm up/down movement is guided on LM guides. v. Servo-driven index table: Servo driven index table with 1° x 360 divisions positioning with Hirth coupling of ±1 arc seconds accuracy vi. DDRT table: Use of state-of-the-art direct drive rotary table for highest positioning accuracy, reliability & speed Orion Reliability: Proven machine reliability of Orion HMC operations is a result of the use of a combination of sub-systems that ensure safe & stable operation of the machine at all times:
ADVERTORIAL | TECHNOLOGY
Machine geometrical accuracies ISO Value (mm)
ORION STD (mm)
Straightness
0.020
0.005
Squareness
0.020
0.010
Spindle run out @300 mm
0.015
0.006
As per ISO 230-1
ISO 230-4: 2005(E) Circular deviation
Circular deviation (CCW) Value 3.4µm
Circular deviation (CCW) Radius
100.0000 mm
Sample rate
22.222 Hz
Feedrate
599.0 mm/min
Run direction
CCW
Plane under test
XY
Bi-directional positioning accuracy and repeatability as per ISO 230-2 As per ISO 230-2
ISO Value (mm)
ORION STD (mm)
Bi directional positioning cccuracy A
0.032
0.008
Bi directional repeatability R
0.018
0.005
Test position Star angle
180°
End angle
180°
Overshoot angle
180°
Run 1
20.0µm/div
i. High quality lubrication system: High quality lubrication unit and cartridges ensures minimal losses due to friction during movement and hence stable machine operation ii. 60-tools magazine: Use of a large magazine capable of operating 60 tools gives additional flexibility to schedule continuous machining cycles involving numerous tools and operations iii. Sensors box: Sensor box with moulded cables, plugsocket connectors and LED indicators ensure easy, error-free operation of temperature sensors with seamless feedback mechanism Orion Aesthetics & Ergonomics: Spectacular machine aesthetics & looks and improved ergonomics to build in ease of operation is a result of the combination of these features: i. Wide operator Access: Wider operator door with large windows for easy access & visibility. Provision of swivel type operator panel for easy operation. ii. Easily accessible maintenance panel: Easily accessible maintenance panel has ensured ease of maintenance for service personnel iii. Wide APC door: Wide APC door for easy access to work – piece with a convenient loading height of 1100 mm iv. Well-illuminated work area: Use of LED lamps for APC loading, tool loading, and machining area ensures better illumination for operator to monitor machine during and between cycles v. HMI screens at tool loading station: Provision of HMI (Human Machine Interface) ensures that the operator
chooses the right tool & maintains the right tool sequencing during and between machining cycles vi. Foot switch at tool station: Provision of foot switch helps operator control tool clamping & unclamping during and between machining cycles
Performance against known ISO standards The Orion series of machines are known to achieve high levels of static & dynamic accuracies that have often exceeded or bettered the values specified by known ISO standards. Due to these reasons, it is well-placed to meet all known and implied user industry requirements with respect to productivity, precision and reliability.
Redefining next-gen performance Market acceptance: Orion platform has established itself during the last five years. The product is gaining on-market acceptance with each passing day. BFW has significantly enhanced the manufacturing capacity to meet the increasing demand of HMCs. Orion is already a preferred choice of many Indian clients and is rapidly increasing its footprint in India. BFW will take forward the Orion next-gen HMCs and establish it as a global brand. It is in process of launching its 5-axis range of HMCs being branded as Orion FX, salient features of which are universal head, high pressure through-coolant, zero-point clamping and uninterrupted chip flow. ☐ Courtesy: BFW
Catering Intrinsic Engineering Needs & Industry Solutions BFW machines are playing role in diverse Industry sectors with a wide range of applications
EM | Oct 2017
21
MARKET | INTERVIEW
“Global lubricant market will witness growth” …says Shankar Karnik, General Manager—Industrial, ExxonMobil Lubricants, in this interview with Megha Roy. He discusses how the growth of the automotive industry boosts the lubricant market, while stating the growth analysis of the concerned segment. Excerpts… Given that the industrial lubricant market demand has been increasing rapidly in the recent years, how do you look upon the market drivers towards achieving this goal? We are committed to helping companies be safer, productive and aware of environmental care practices. We help our customers remain sustainably competitive, produce efficiently and make their mark on the global arena, leveraging our technology leading Mobil SHCTM, MobilGreaseTM range of premium products supported by application expertise that commit & deliver advancing productivity benefits. In addition, by taking a proactive, predictive approach to maintenance through our Mobil ServSM Lubricant Analysis (MSLA) programme, we help our customers to prevent costly production delays and equipment failures, while helping to protect workers as well as the environment. With our lubricant business growing steadily, more customers are requesting superior oil analysis to improve machine efficiency and reduce downtime. How well is India positioned in the global lubricant market? Can you highlight the major challenges faced in your industry? India is the third largest in Asia and fifth largest lubricant market globally in consumption volume behind the US, China, Russia and Japan. However, the lubricants market is also dependent on the manufacturing and industrial business for existence & sustenance. This is also dependent on global macro trends. For example, according to a report by the Society of Indian Automobile Manufacturers (SIAM), in the month of July, automobile sales have gone up by 10% in India. This appetite will drive demand for lubricants for automobiles. The global industrial lubricant market is expected to witness a high growth rate in the upcoming years due to the growth in the automotive industry. What is your take on that? The global lubricants market is going to witness growth with increasing demand in the market driven by end use customers. We are looking at transportation as a large and
22
key area of growth, which would be driven by passenger as well as commercial vehicles. Growing disposable incomes will continue to boost new passenger vehicle sales, while growth in manufacturing will drive the demand for logistics and in turn further fuel the need for more commercial vehicles. Protecting the environment is an important goal in the industrial lubricant industry. How does your company help minimise environmental impact? Proper lubrication plays an important role in reducing the environmental footprint of industrial operations. Our company’s commitment to a lighter environmental footprint includes delivering lubrication solutions with advanced products & innovative services that help our customers achieve their operational and sustainability goals. Also, our advanced lubricants can help improve component life and provide for longer service intervals to reduce lubricant disposal and related maintenance waste. Friction-reducing lubricants offer energyefficiency benefits by reducing energy demand, which helps lower energy costs and reduce greenhouse gas emissions. Moving ahead, can you share your future plans in terms of developing cutting-edge technologies and increasing market share in the business portfolio and the expansion plans for the Indian market? At Mobil Industrial Lubricants, we work in partnership with customers to address concerns, and drive developments to help customers and their customers to make their operations more efficient and profitable. The Mobil Industrial Lubricants’ product portfolio in India is well positioned to support the economic and industrial growth taking place in the country. We will continue to work closely with leading equipment manufacturers/builders to ensure that our products deliver the optimum performance for their intended applications and that we deliver the highest level possible of application expertise. ☐
EM | Oct 2017
MARKET | INTERVIEW
“We are committed to cause of sustainability” …says Kamal Nandi, Business Head–EVP, Godrej Appliances, in this interaction with Maria Jerin, while discussing the market readiness to accept new technologies in the areas of sustainable products. Excerpts… What is your view on the current market situation in India? How well is the market ready to accept new technologies in the areas of sustainable products? In the home appliances industry, consumers actively seek new technologies that are beneficial to them either in performance or convenience and are ready to pay a premium for such features. However, the adoption of new technologies in the area of sustainable products has still not been able to get the desired results when it comes to sales. Sustainability is yet to become a major consideration driver in the minds of consumers when it comes to the buying decision of home appliances. It is a ‘good to have’ feature for which consumers are not ready to pay a premium. Given its criticality for the environment, we however remain committed to the cause of sustainability. Your company has recently launched GreenCo initiatives for SMEs. What are the benefits of such an initiative for the industry? The Govt of India’s initiative ‘Zero defect, zero effect’ is in line with the philosophy of sustainable manufacturing. The objective is to find ways to encourage more industries to go green by suggesting greening efforts that are economically viable. We at Godrej Appliances are trying to spread this awareness and are not restricting this thought only to our supply chain but wish to take it across other industry sectors too. Our factories were the first in India to be GreenCo platinum rated and we have been continuously sharing our learnings and experiences and inspiring other industries to join in. Today, more than 100 companies are GreenCo rated. We were the first to take it to our suppliers and today even other SMEs are taking inspiration from our suppliers and joining the journey. SMEs form a large part of the manufacturing sector. This co-operation will thus help our nation too. What are your company’s recent launches that address the issues impacting environmental and sustainable ecosystem? Godrej Appliances recently launched one of India’s greenest
24
inverter AC, which also delivers a very high energy efficiency of 5.8 ISEER making it amongst the most efficient ACs in the country. With this ISEER rating, Godrej NXW Inverter AC doesn’t merely meet the 5-star requirements of the current BEE energy rating norms but it is also future-ready and complies with the proposed BEE energy table of 2019. It comes with a unique Green Inverter Technology. This clever combination of Inverter Technology and the Green Balance Technology helps in achieving the highest energy efficiency in the most eco-friendly way using the world’s greenest refrigerant R290, which has zero Ozone Depletion Potential and minimum Global Warming Potential. How do you strategise your business model so as to improve your market presence across various market segments in India? While we are continuously improving our offerings in the existing spaces of refrigerators, air conditioners, washing machines and microwave ovens through a mix of new products and technologies, as well as processes & manufacturing improvements, we are also expanding our presence across other strategic spaces that complement our business – be it the niche sector of medical refrigerators or the expanding market of chest freezers. However, our core principle of being differentiated & consumer-centric remains to be our underlying philosophy in every segment we choose to operate in. This ensures that we are able to extract a premium by offering value to the customer. Moving ahead, what are your company’s future plans for the Indian market? We are upbeat about the forthcoming festive season and expect a growth of 30% during this period backed by launches across the four core categories that we are present in. We will continue our focus on building green and premium energy-efficient products including our recently launched adjacency categories like medical refrigerators and chest freezers. The slur of innovations will continue in the next year with multiple launches in the pipeline. ☐
EM | Oct 2017
Good for the environment and good for you Skin friendly and 100% bactericide free Blasocut coolants are our area of expertise for over 40 years. Within this period of time we have continuously improved our Bio-Concept - for the benefit of our clients and the environment:
– Free of formaldehyde and boric acid – Years of stability without the addtion of additives or bactericides – Compliant with the latest EU regulations
Find out more about the Liquid Tool under blaser.com
Blaser Swisslube India Pvt. Ltd.
Gurgaon, Pin – 122002
Tel 0124 4994000
india@blaser.com
www.blaser.com
C O V E R S TO R Y
TECHNOLOGY
LEAN IN AUTOMOTIVE MANUFACTURING Roadmap for implementation
It is important to remember that Lean is not a ‘one size fits all’ philosophy. There are standard principles that must be applied to any Lean implementation—such as increase customer value and reduce waste—but the specific limitations, strengths, resources, and production needs of each organisation will dictate how those principles are realised. As such, implementing Lean requires creativity and a deep knowledge of a company’s operations and culture as much as it requires keen and thorough analysis. Read on… 26
Jim Errington EVP Sales + Service Fujitsu Glovia, Inc Marketing@glovia.com
EM | Oct 2017
TECHNOLOGY
C O V E R S TO R Y
The workcell is a space on the factory floor where all of the work necessary to complete the assembly of one part is done
For many years, ‘Lean’ has been a hot topic among automotive manufacturers. It is well known in the industry as the method Toyota has used successfully to streamline operations, reduce cost, and optimise the quality of its products. Lean has a clearly defined set of principles to guide you in applying it to your manufacturing process. The principles to apply Lean in the manufacturing processes are as follows: Determining the customer-defined value: When all aspects of the manufacturing process meet the customer’s needs at a specific price and time, the customer-defined value is met. When the customer doesn’t respond to a product by ordering more, the OEM often makes the mistake of adding more bells and whistles to the product or adjusting the price. If that doesn’t work, the OEM employs another marketing strategy even when it is clear that the customer has already decided against the product. In this case, the producer is focused on fixing the internal process and not on rethinking the product value from the perspective of the customer. Lean thinking clears the board, ignoring existing assets & technologies, and rebuilds the process into one that ensures product flow and no waste. Identifying & analysing the value stream: The value stream includes all the steps & processes necessary to put the raw materials together to create the finished product and deliver it to the customer. Implementing Lean involves analysing the value stream, which identifies three types of actions throughout the stream: actions that create value; actions that do not create value but are unavoidable because of the restrictions of current technologies, production methods, and assets; and actions that create no value and are avoidable. These actions are individually assessed, and those that do not directly create
EM | Oct 2017
customer value are either redesigned so that they do create value or are removed from the process. Making the process flow: When the customer value has been precisely determined, and the value stream has been analysed & optimised, all of the actions in the process must be made to flow efficiently. Doing this requires a change of perspective from one that groups tasks by type to one that focuses on how the product should meet customers’ needs. The tendency is to think that grouping similar tasks will keep everyone busy and will automatically guarantee that the process flow will be efficient, but this isn’t true. On the contrary, this often makes the process rigid and not adaptable to changing requirements. The product flow is disrupted, and time is lost while the product waits for the next operation, or workers change over to another activity. The workcell, a key lean concept, results in optimal workflow. The workcell is a space on the factory floor where all of the work necessary to complete the assembly of one part is done. Workers don’t have to cross long distances to access all of the machines they need to produce a part; the machines are always near them and arranged in such a way as to minimise movement. Production lines are usually organised into groups of workcells. Establishing customer ‘pull’ through the process: The way to incorporate agility into the process so that customers always get what they want is to make it possible for the customers to continuously communicate their needs to each part of the manufacturing process. In effect, the customer is ‘pulling’ the product through the process. Lean manufacturing methods make use of the Kanban system to do this—a system in which signals (usually in the form of cards) containing updated information about customer needs accompany the product
27
C O V E R S TO R Y
TECHNOLOGY
Lean manufacturing methods makes use of the Kanban system
through each step of the manufacturing process. This informs workers of the customer value, reminds them that they are working to achieve customer value, and guarantees that customers know that they are getting what they need. Constantly perfecting the process: When companies accurately identify customer value, analyse the entire value stream to make it more efficient, and make the value-added steps in the process flow efficiently by letting customers pull value from it, something remarkable happens. The people in every part of the process begin to realise that better results can be achieved with less effort and cost, and that this can continue indefinitely. As the process becomes more efficient, previously hidden waste in the process is exposed. This becomes the impetus for further review and refinement of the product flow. When product teams are in close communication with customers, they can always find ways to specify customer value more accurately and enhance flow and pull in the process. Employees who discover ways to improve the process receive immediate positive feedback, and they realise that they too have a stake in delivering real value to the customer. This encourages them to be even more involved. In some companies, it is the lower-level managers who are the first to buy into the Lean philosophy. They propose ways to incorporate Lean into the enterprise by devising proof-ofconcept efforts to show upper management the potential benefits of adopting Lean on a larger scale. This can be a challenge, but as the business begins to show increased customer satisfaction and corporate profits, the message becomes clear: Lean thinking, when implemented correctly, can enhance the company’s competitive edge. However, to implement Lean
28
correctly, you must understand it correctly or you may do more harm to your manufacturing process than good. Without some convincing evidence that it will succeed, businesses will not be motivated to invest the time and effort needed to become more efficient. The following section discusses a Lean implementation using Fujitsu Glovia’s ERP that helped automotive parts manufacturer, Keihin America to fundamentally rethink the production processes, thereby, achieving Lean manufacturing.
Keihin’s Lean solution While working on the specifics of its Lean implementation with the Lean specialists and Glovia, the planning group at Keihin hit upon an important realisation—Keihin employees could be continually motivated to come up with solutions to make the manufacturing processes leaner and more efficient. The virtue of this idea was that it acknowledged that each worker had the most intimate knowledge of his or her task, not the manager. Ideas would percolate from the ground up, not be imposed from the top down. The workers could then evaluate the solutions and present them to management for approval. The planning group realised that putting this process into place would achieve the goal of employee involvement and the Lean objective of constantly perfecting the solution. Cross-functional workgroups would be the foundation of this process. At regular intervals, a group dedicated to the task of managing this process would form cross-functional groups of associates from factory workers to upper management. Then week-long brainstorming sessions would be scheduled with the
EM | Oct 2017
Your Partner in the Tooling Industry
TYROLIT in India | +91 80 23121811 | sales-metalprecision@tyrolit.co.in
A Company of the SWAROVSKI Group www.tyrolit.com
C O V E R S TO R Y
TECHNOLOGY
When Lean is implemented with careful planning based on an understanding of what it can be expected to achieve, the benefits are real
goal of producing and evaluating five or six ideas for improving efficiency. The sessions would follow this agenda: 1. Create the solution: Any member of the group proposes a complete, practical solution to a valid business problem that he or she had encountered, or seen others encounter, as part of the group’s work. 2. Depict the solution: The group creates organisational charts, proposed process flows, and other materials to represent the solution. The idea of this step is to add as much ‘real world’ detail as possible and to show what will happen to real people if the solution were implemented. Everyone is encouraged to contribute ideas and opinions as the concept develops. 3. Create metrics of the solution: The group gathers all of the relevant data it needs to generate metrics that predict, as accurately as possible, the likely outcome of implementing the solution. Examples of these metrics are projected cycle times, lists of what is value-added in the process and what isn’t, labour costs, and costs of investment. The idea is to prove the proposed solutions through standard methods of business analysis. The business prediction modules, the ability to model data, and the business data aggregation and presentation capabilities of the Glovia ERP software are important resources in this step. A mentor who is well-versed in Glovia technology sits at a computer running Glovia modules during this step. If, for example, the group needs current scheduling data or a quantitative view of the operations of any assembly station, the mentor can provide that immediately. 4. Decide which are the best ideas and refine them: The group decides which five or six ideas are the best and comes up with ideas to improve them. New metrics are generated if necessary.
30
Benefits After this process was established, it took Keihin between three to five years to see most of the benefits. The expected gains in employee involvement and continual improvement of the manufacturing process were apparent relatively quickly, but over time, Keihin also began to see benefits that it didn’t foresee at the planning stage: • Manager and worker buy-in: Because the workgroup made management and scheduling decisions as part of the brainstorming process, the planning group recognised early on that there was a danger that the more traditional, changeaverse managers in the company would not react well to the change to lean. However, they discovered that those managers found it helpful that they were presented with solid metrics along with detailed proposals and not just PowerPoint presentations filled with general ideas. They knew that the teams had looked at the costs involved and projected outcomes and savings. This made it easier to decide whether a proposal should be given the green light for further study, and this won over even the more reluctant managers. Another advantage for the managers is that the process made it much easier to gain buy-in from the workers because everyone knew that the proposals didn’t just come from the top down. Employees at all levels of the organisation were more confident in the proposals from the beginning. • Worker education: For many workers, the brainstorming sessions were their first exposure to the kinds of aggregate business data managers work with every day. Even if their daily job is that of a line worker at a specific station, for example, when they see the data, they start to gain a better
EM | Oct 2017
C O V E R S TO R Y
TECHNOLOGY
perspective of how their performance and tasks fit in with the manufacturing process as a whole. After several iterations of brainstorming sessions, workers bring a more comprehensive understanding of the process to the sessions, and the ideas they generate are better informed and more intelligent. • Revolutionary ideas: In a production line, a fixture is a tool that holds the part to be assembled in place so that line workers can manipulate it. Fixtures are custom-fit to the part, so when the parts are changed in a production line the fixtures must also be changed. During one brainstorming session, an ambitious proposal was made to remove all fixtures from all production lines. The workgroup found a way to make it work and management approved it. Now Keihin no longer incurs the costs of creating and disposing of fixtures. Production line changes are faster and more efficient because Keihin no longer needs to track the fixture with the part. This improves scheduling and inventory management. Many new ideas for improving efficiency have been proposed during the brainstorming sessions that may not have been considered by upper management. When Keihin America had to choose between building its business by becoming more efficient or expanding its manufacturing capacity and incurring the overhead costs associated with that, the company chose the wiser course and invested in Lean. Glovia technology continues to play a crucial role in Keihin’s drive for greater efficiency and less waste in its production. As a result, profits and new business opportunities have increased dramatically.
32
Conclusion Lean promises a lot—including increases in production capacity and product quality; reduced production time, inventories, and cost; and consistent and timely deliveries. It is very popular in the industry right now, but how much of the sales pitch is hype and how much is grounded in reality? The reality is that Lean is a tool, and like any tool there is a correct, and an incorrect, way to use it. When Lean is implemented with careful planning based on an understanding of what it can be expected to achieve, the benefits are real. When Lean is implemented based on a misunderstanding of its basic principles, a lot of labour, time, and money can be wasted by a ‘solution’ that can actually make the problem worse. A company that is in short-term, crisis-mode thinking may mistakenly turn to Lean as a quick fix for its problems. It isn’t a quick fix. It is a substantial investment for long-term profit that requires continuous reevaluation and refinement. Lean is a hot topic in the manufacturing industry right now, but fundamentally it is only the latest development of an idea that is as old as industrial production itself—the idea of making production as efficient as possible. You should look past the hype and make your approach to lean informed and intelligent. Then you will realise the real benefits of Lean, and your company may become the next lean success story. Courtesy: Fujitsu Glovia Inc For more info, visit www.glovia.com
EM | Oct 2017
MANAGEMENT | INTERVIEW
“Being lean, flexible & agile are the new rules of the game” According to Vijay Kalra, Chief of Manufacturing Operations, Mahindra and Mahindra Limited [AS], the trends that will shape the auto industry in the future include diverse mobility, autonomous driving, electrification, 3D printing and connectivity. In this interaction with Megha Roy, he briefs on his company’s approach towards Industry 4.0 practices. Excerpts…
How do you see the Indian automotive industry in terms of know-how for manufacturing processes that helps in increasing its foothold to become a prominent destination for the global manufacturing industry? What are the concern areas in this context to be addressed? In the last decade, the Indian auto industry has emerged as a very strong player, thanks to the high level of customer expectation & fierce competitive environment from the global players. We are moving ahead and need to keep up the pace by adapting to new and emerging technology trends. To become ‘world-class automotive manufacturing hub’, there must be concentrated effort from both the Government and the automotive industry to create an enabling ecosystem. These include an enabling regulatory environment,
34
developing the requisite talent and skills, fasttracking of infrastructure development, incubating R&D and innovation culture and enhancing supply chain competitiveness. Manufacturing enterprises, big & small, today have increasing focus on optimising performance, productivity and asset management as well as an effective technology management. How is your company’s approach towards this? At Mahindra, going beyond the operational efficiency, which is more of hygiene, we also focus strongly on operational effectiveness. We want to utilise our resources in doing right things, rather than doing too many things which does not give us the competitive edge. Being lean, flexible & agile have become the new rules of the game. We are focusing on developing capable and engaged teams who can meet the global standards at an optimum cost and deliver right value to the customers. Mahindra & Mahindra not only has a vast presence in the Indian market, but also has a remarkable demand in the overseas market. Going forward, how do you strategise your business model so as to become one of the top auto manufacturers globally? We are focused on developed markets, such as, South Africa, to build the Mahindra brand in an extremely competitive environment. We continue to dominate the South Asian markets (Bangladesh, Bhutan, Nepal, and Sri Lanka) with our complete range of auto and farm products and are developing markets in East Africa (Kenya, Tanzania, Uganda), North Africa (Algeria, Egypt, Tunisia, Morocco),
EM | Oct 2017
INTERVIEW | MANAGEMENT
A veteran in the auto sector, Kalra has over three decades of experience with leading organisations and an in-depth understanding of TPS and other global manufacturing practices
West Africa (Ghana, Nigeria), and South East Asia (Indonesia, Philippines) to build the Mahindra Brand across the world.
all physical assets and their integration into digital ecosystems with value chain partners. We have partnered with experts in digital manufacturing / design innovation and trying to look Increased environmental concerns are also driving the auto at our entire value chain for leveraging digitisation for our industry to continual weight reduction of vehicles and lower competitive advantage. CO2 emission. What steps are being initiated by your company Our approach is both top-down & bottom-up and we are to address such challenges? doing pilot digital projects at our plants, The CO2 discussion in the automotive supplier interface & customer interface industry is continuing at an intense so that we understand it better & then go pace, we are the first Indian company to ahead in big way if it really makes business WE ARE FOCUSING ON announce its internal carbon price - US$ sense. We have identified these 5 levers: DEVELOPING CAPABLE AND 10 per tonne of carbon emitted, also Internet of Things, Augmented Reality, ENGAGED TEAMS WHO CAN MEET first in India to sign “EP100” project Artificial Intelligence, Big Data Analytics THE GLOBAL STANDARDS AT AN (The Climate Group). We use Life Cycle & Additive Manufacturing for improving Assessment (LCA) as a tool to assess quality, cost, productivity, speed to market OPTIMUM COST AND DELIVER the environmental impact associated RIGHT VALUE TO THE CUSTOMERS & asset utilisation. However, technology is with all the stages of a product’s life an enabler and not an objective. from raw material extraction through We understand people capability is materials processing, manufacture, distribution, use, repair the key here & hence giving special emphasis on the training and maintenance, and disposal or recycling. and development of current skills / future skills in our talent As an organisation that places keen emphasis on management process. We need to work on re-skilling and sustainability and eco-friendly practices across every process upskilling. To conclude, as an industry we need to move from and product, we introduced a hybrid technology on the the catch-up mode to a more defining targets mode. Here Scorpio. By reducing fuel consumption, Intelli-Hybrid helps ‘Make in India’ has to move beyond just manufacturing in Scorpio owners contribute towards a cleaner and greener India, to more designing and engineering in India. tomorrow. India’s first fuel efficient smart truck ‘Blazo’, ‘Jeeto CNG’ & ‘eSupro’ are testaments of our endeavour in the Moving ahead, how do you foresee the importance of same direction. We continued our electric ambitions with the inculcating sustainability initiatives within organisations in launch of the innovative e-Verito, India’s first zero-emission the manufacturing vertical? all-electric sedan, e2oPlus, the all electric city smart car. At Mahindra, we view sustainability as a vital business strategy. For us, sustainability is to enable enduring business Given that Industry 4.0 defines the future of manufacturing, by rejuvenating the environment and enabling stakeholders to how is your company aligning towards such advanced concepts Rise. Our company has a mission to adopt & enable benchmark to achieve a cutting-edge in the manufacturing industry? sustainable practices to be a top 10 global automotive brand and Industry 4.0 concentrates on the end-to-end digitisation of to deliver FarmTech prosperity. ☐
‘‘
EM | Oct 2017
35
VIEWPOINT | MARKET
As per recent industry data, high-end machine tools are majorly imported in India. This leads to widening the gap between the production and consumption ratio of the machines in India. Given that India has a high consumption rate for these high-end machines, the viewpoint section analyses how Indian manufacturers are working this out as an opportunity. Excerpts...
NK Dhand, CMD, Micromatic Grinding Solutions
36
I M AGE C OURT ES Y: EMAG
Machine tools in India: Opportunities in high-end products
High-end machine tools, as the name signifies, are either large size machine tools or highprecision in nature. The local demand of such high-end machine tools, in numbers, is always much smaller (10% or less) than the total demand. To be viable, therefore, manufacturers of such high-end machine tools have to get adequate numbers from the international market through exports. Since the 90's, when the Indian manufacturing industry took off, Indian machine tool manufacturers naturally had to first concentrate on the large volume domestic demand because high-end manufacturing requires very high investments too. Besides, export of any machine tool requires deep pockets to support & sustain the export sales & services. Internationally too, all the players of the high-end machine tools are established in their domain businesses anywhere from 50-100 years & duplicating such manufacturing & expert application capabilities in short time is almost impossible. China has taken a smart approach by buying reputed European companies of high-end machine tool & learnt their game by huge financial commitment by the Chinese Government In fact, IMTMA had also recommended this to the Indian governmnet in the technology roadmap for the Indian machine tool industry in 2010. In the absence of the same, an alternate but much slower process that the Indian machine tool industry has started adopting is their own development of such high-end machine tools, partly supported by the DHI's grants for MT technology development through the centre of excellence set up at IIT-Madras. Very high financial & technological requirements for manufacturing such high-end MT's will allow the domestic manufacturers to make progress & reduce the consumption gap in the country very slowly.
EM | Oct 2017
er to
Regist
VISIT
Driving manufacturing processes of the future 13 – 15 December 2017 Bombay Exhibition Centre, Mumbai, India www.smartindustrysolutions-india.com
Make your factory future ready Be a part of the pioneer edition of Smart Industry Solution India focusing on the growing need of “Industry 4.0” and “Smart Manufacturing”
Solutions for –
automotive
oil & gas
chemicals
f&b processing
pharma
packaging
machine tools
warehousing
electrical & electronics
plastic & rubber
For more information, please contact: Sonam Kanal / Nikita Pires Tel: +91 22 61445900 sonam.kanal@india.messefrankfurt.com nikita.pires@india.messefrankfurt.com
Scan to Register
VIEWPOINT | MARKET
The Indian machine tool industry is working towards developing new technologies and bridging the technology gap which were existing earlier. For the previous financial year 2016-17, domestic manufacturers catered to about 47% of the machine tool demand in India, which is likely to go beyond 50% in the current year. The Indian manufacturers are developing technologies in high-end machines in collaboration with prestigious institutions, such as IIT-Madras, to develop the latest technologies, which will give fruitful results in the upcoming years.
V Anbu, Director General, IMTMA It’s a huge but challenging opportunity to enter the high-end machine tool business. It is waiting to be picked. The challenge is the customer perception that Indian machine tool companies are not matured enough in offering solutions and risk customer investments. Indian companies would need to strategise and work to set this right. It means much investment in resources either in technology, right solutions or marketing, etc. But on the other side, regular machine tool business itself seems to keep us busy. So, possibly the Indian companies could think of an independent subsidiary under a new brand, with the intention to approach ways and means to solve, appeal and offer high-end machines to garner these markets.
Sudhir Mehta, CMD, Pinnacle Industries Past Chairman, CII(WR)
Managing Director, UCAM
We cannot attain manufacturing excellence unless we have a robust machine tools segment. With the Government’s thrust on ‘Make in India’, we are in the global spotlight and our future capabilities and success as a leading manufacturing hub relies very much on the growth of our machine tools industry. India is considered as the preferred destination for outsourcing by numerous global manufacturing companies, due to cost competitiveness, favourable investment conditions, ease of doing business, better engineering and designing capabilities. However, according to the 2016 World Machine Tool Survey by the Gardner Business Media, India ranks 13th in the production of machine tools globally, but it is the 10th largest consumer. This offers us a significant growth opportunity to increase production share in an expanding consumer market scenario. Due to this demand supply gap, we rely majorly on imports. Also, majority of high-end machine tools manufacturers in India cater to the automotive industry due to which other segments route out their demands through imports. We need to enhance our manufacturing capabilities to deliver highaccuracy, niche machine tools for a wide range of industries. Technology upgradation, vigorous R&D efforts, increased investments and presence of large-size players in the industry are some of the key areas we need to act upon.
Any country aspiring to be a manufacturing powerhouse must have strong and capable equipment makers for various processes and applications. Bridging the gap between production and consumption is a great opportunity for the Indian machine tool makers. Developing technologies by various means – R&D, acquisition & collaboration is key to produce high-end machines. Building this capability will also enable Indian companies to succeed in the international market and grow the exports. This is especially required for building quality solutions for upcoming manufacturing sectors in aerospace and defence.
38
Indradev Babu,
Sameer Kelkar, CEO and R&D Head, Grind Master Machines
EM | Oct 2017
MARKET | VIEWPOINT
Maulik Patel, Executive Director, Sahajanand Laser Technology
The gap between the consumption of Indian machines and the international machine is huge, and it has been there since the beginning. It started way back when the technological gap between both international machines and nationally developed machines was unfathomably large. Over the period of time, it has created a deep impact over the Indian mindset. Now at the other hand, we have been attaining industrial evolution since a couple of decades. Though we have come a long way in terms of advancement, however, we are yet to cover a long distance in terms of changing the mindset. The scenario has progressed and in many industries, the high-end machinery has progressed to either assembling or manufacturing nationally. The Indian manufacturing sector has been ascending on a rapid growth since the end of 19th century and this progress has gained pace. In order to take the advantage of national high consumption rate, we crucially need collective efforts from the entire Indian industry along with the Government. Lately, we have been observing this taking place gradually.
India is considered a preferred destination by global manufacturing companies for setting up production facilities and for outsourcing, due to cost competitiveness, favourable investment conditions, better engineering & designing capabilities and above all good communication skills. The widening of gap between the production and consumption ratio of the machines in India is primarily due to the low technology solutions being manufactured in the country. In order to narrow the gap, the Indian machine tool industry needs to benchmark their equipment against technologically advanced machines, which are currently being imported. There is also a high possibility that an Indian solution, both cost-effective and efficient, will emerge from this exercise. In addition to the above, investment in R&D will enable India to be at par with the global players.
KV Suresh, Country Head, ZF India Advt
METAL WORKING FLUIDS
THE INDUSTRIAL LUBRICANTS DIVISION OF THE GROUP motul.com Motul 119 boulevard FĂŠlix Faure 93300 AUBERVILLIERS - France Tel: +33.1.48.11.70.30 Fax: +33.1.48.11.70.38
Atlantic Lubricants & Specialities Pvt. Ltd. 301, Ketan Apts., 233, R.B. Mehta Marg Ghatkopar East, Mumbai 400 077 Tel: + 91 22 2501 1960/2501 1961 Fax: + 91 22 2501 1928 EM | Oct 2017
SPECIALTY LUBRICANTS MAINTENANCE LUBRICANTS HIGH PRESSURE DIE CASTING QUENCHING FLUIDS 39
C U T T I N G TO O L S | F O C U S
Take a reverse path to machining success Despite varying methods, manufacturers share a common goal of producing a certain number workpieces of a desired quality, in a specified amount of time and at an appropriate cost. The article discusses the roadmap for the manufacturers, wherein, one needs to first analyse the overall targets of the manufacturing operation and plan proactively to steer processes so as to provide desired results. C
To achieve profitable machining of quality parts, many manufacturers follow a micro-scale path, beginning with tool selection and application and solving problems in a reactive way. However, current research suggests the reverse of that approach with a focus on three major components or aspects of the overall machining process. Manufacturers should begin with an examination of the entire machining process, focusing on the elimination of rejected parts and unforeseen downtime that represent critical roadblocks to a manufacturer’s goals. After a stable and reliable process has been established, an analysis of production economics is undertaken to balance production rate and manufacturing costs. Finally, careful selection of cutting conditions and tools will fully optimise the machining process.
40
Quality first
M
Y
The achievement of consistent product quality is the most important element of the goals shared by all manufacturers. If the machined parts do not achieve the level of quality specified by the customer, it doesn’t matter how many, how fast or how cost effectively the parts are machined. Quality standards include tolerances, surface finish and partto-part consistency. Manufacturers always claim that part quality is an accepted, intrinsic part of their operations. Much of the time, however, that claim is optimistic or self-deceptive. In reality, throughout the manufacturing industry a significant percentage of workpieces is defective and must be reworked or scrapped. Producing defective parts extracts a high cost, not only in
EM | Oct 2017
CM
MY
CY
CMY
K
F O C U S | C U T T I N G TO O L S
material, labour and machine time, but also in disruption of production plans. Some shops create an illusion of reliability or predictability by including the occurrence of rejects in their production scheduling. In an instance when a customer requires ten parts, planners might prepare for machining of twelve parts in anticipation that two will be lost/scrapped. Such efforts waste resources and time, producing either unacceptable parts or unneeded inventory. For example, focusing only on maximum output by exclusively pursuing lower cycle times can damage the reliability of a metalworking operation. When an operation constantly runs at the limits of performance, exceeding those limits results in rejected workpieces and lost time and money. Part output must be balanced with machining parameters that provide a secure machining process. On the other hand, the cause for rejected parts may be a separate issue from the productive elements of machining. In one case at a manufacturer of aerospace components for instance, burrs remaining after machining made a certain family of parts unacceptable to the customer. Because deburring operations required manual work that added 20% to the cost of 健椿 - 2017印度金屬廣告製作-三月號-修改-更新logo.jpg.pdf 1 2017/7/11 下午4:39
EM | Oct 2017
the parts, production output became a secondary issue behind the need to find a way to eliminate the formation of burrs.
Minimising unplanned downtime Maximum utilisation of manufacturing resources requires the minimisation of downtime, which, most simply, is the period when the machine tool is not making chips. Some downtime is necessary and planned. This includes the time spent programming and maintaining the machine tool, installing fixturing, loading and unloading workpieces and changing tooling. Manufacturers account for planned downtime in their production schedules. However, production of unacceptable parts results in unplanned downtime. When a rejected workpiece must be remachined, the time consumed originally machining it represents unplanned downtime and is wasted. Traditionally, shops take a reactive approach to reducing unplanned downtime. When a problem halts production, the search for a solution begins. Rather than waiting to react to a negative situation, a better approach is proactive planning that recognises key targets for the operation and steers the process Advt
41
C U T T I N G TO O L S | F O C U S
The image illustrates the consequences of bad quality
toward them from the beginning. Most shops spend 20 percent in preparation efforts followed by 80 percent implementation and testing. The ideal would be to invest 80 percent in preparation and the rest in implementation and adjustments if necessary. In preparing for a machining operation, a shop should analyse its targets and develop reliable processes to achieve them. The primary target is not always increased production rates. Although some manufacturing situations, such as automotive part production, remain true examples of highvolume mass production, manufacturing in general is moving more towards high-mix, low-volume scenarios. In mass production, losing 50 or 100 parts when developing a machining process that will turn out hundreds of thousands of parts over a long period of time represents a tiny percentage of the overall volume and can easily be absorbed. However, in a high-mix, low-volume situation, the process must be as fully developed as possible before partmaking even begins. High-mix, low-volume scenarios can involve small batches, single-digit lot sizes or even custom one-part runs. In these cases, rejection of a few parts represents the difference between a profit and a loss.
Proactive process analysis Proactive analysis of a machining operation, while ultimately of great value, can itself be time consuming. The reliability of a metal cutting process is affected by a multitude of individual factors including workpiece configuration and materials, equipment process capabilities and data, tools/tooling systems, human factors, peripheral equipment and maintenance issues. The end use of a manufactured product, and thereby the workpiece material from which it is made, determines many of the important factors affecting process reliability. For example, the machining of critical aerospace components made of nickelbase alloys must be analysed with the workpiece materials’ poor heat conductivity and tendency to work harden in mind. Use of sharp cutting tools and conservative machining parameters will
42
provide a balance of productivity and productive consistency. Conversely, aluminium workpieces are considered to be free machining, but cutting tools must be sharp as well as wearresistant to withstand the material’s abrasiveness. Chip-control tool geometries as well as chip-management peripheral equipment such as high-pressure coolant and machine tool chip conveyors also play major roles in assuring the reliability of aluminium machining operations. CNC and automation systems can help provide a high level of predictability in machining operations, but their effective operation depends on human input. Under-informed or careless programming will result in highly automated production of defective parts. Human input is also a factor on the shop floor, where workpiece loading and fixturing and ongoing maintenance of production equipment must be executed properly to prevent unplanned downtime.
Conclusion The goal of producing a certain number workpieces of a desired quality, in a specified amount of time, at an appropriate cost is shared among all manufacturers. Achieving required part quality is paramount, because an unacceptable part is worthless no matter how quickly or cheaply it has been produced. Many manufacturers address part quality problems from a micro-scale or individual point of view. However, it is better to first analyse the overall targets of the manufacturing operation and plan proactively to steer processes to provide those results. After developing reliable production processes of parts of sufficient quality, manufacturers should consider production economics of their specific situation in order to assure the profitability that enables a business to survive. And finally, selection of cutting conditions and cutting tools enables full optimisation of the process to maximise results. � Courtesy: Seco Tools
EM | Oct 2017
Value Beyond Experience
Reduction Gear GREASE TECTYL EUREKA 114 NO.0 TECTYL EUREKA 114RE NO.00 • Special synthetic GREASE with newly developed lithium soap & synthetic Base Oil • Sophisticated lubrication points of reduction gears • Extended lubrication life with excellent performance
Tectyl Oil & Chemicals India Pvt. Ltd. H.Q.: #508-509, ILD Trade Center, Sohna Road, Sector 47, Gurgaon, Haryana, India Tel : +91 12 4436 2931
www.tectylasia.com Factory: No. 140/3,4A,4B,4C,4D, Kiloy Village, Sriperumbudur Taluk, Kancheepuram, Tamilnadu, India
COOLANTS & LUBRICANTS | TECHNOLOGY
A step towards a greener planet With an increasing demand for greener products globally, manufacturers are gearing up to cater to these market needs. The article highlights the unique Blasocut bio-concept in the cutting fluids which is free of bactericides. We have been observing the developments in the Indian manufacturing sector, which has been undergoing significant changes in accepting and demanding newer technologies much faster than a decade ago. Competitiveness in manufacturing is an ongoing discussion in almost all the companies and various forums. It is good to see the build-up of serious efforts on this topic and emergence of a holistic view on productivity in manufacturing, which drives the competitiveness. The easy and common approach is to push the manufacturing units to cut down on direct costs incurred in buying or spending on the machinery, equipment and other peripherals used and required to manufacture various components, which are necessary to produce original equipment.
44
Punit Gupta Managing Director Blaser Swisslube India p.gupta@blaser.com
Environmental-friendly coolants Moreover, it is becoming a global requirement for all manufacturing organisations to contribute towards a greener planet. These initiatives are either due to global regulations or self-consciousness towards the environment. Blaser Swisslube has designed Blasocut, featuring a bio-concept, which works in harmony with nature. It is a cutting fluid which is free of bactericides. It’s actually finely dispersed oil-in-water emulsions, thanks to modern technology. It allows the colonisation by specific, waterborne bacteria (termed ‘primary bacteria’) that push back all other bacteria by consuming the available nutrition, which limits their own growth as well. The benefit is long-term emulsion stability and one of the safest
EM | Oct 2017
COOLANTS & LUBRICANTS | TECHNOLOGY
Skin friendly 40 years of experience
No additives necessary
Free of boric acid and formaldehyde
Environmentally friendly
Water-miscible metalworking fluids based on Bio-concept have been Blaser Swisslube‘s strength for over 40 years
Blasocut – 100% bactericide free formulations to use across the world for customers. Water-miscible metalworking fluids based on the well established term Water-miscible Blasocut emulsions stay biologically Bio-concept have been Blaser Swisslube‘s strength for over 40 years. inherently stable, without the need for bactericides – a concept Blaser Swisslube introduced 40 years ago. Bio-concept products are designed through their constituents to become naturally populated by a significant number of these harmless, environmental bacteria, as they contain no bactericides.
The way it works It is thought that primary bacteria immediately consume foreign organic substances that are present in or introduced into the coolant, effectively preventing the establishment of other bacterial species. The benefit is that they restrict the growth of all other micro-organisms under normal operating conditions.
Benefits for end users The emulsions based on this bio-concept gives the benefit of optimal process reliability, long life cycles and makes it as one of the mildest & safest formulations in the world for users. Additionally, there are no storage and dosing complications. Uncontrolled growth of bacteria in conventionally formulated metalworking fluid emulsions may cause problems. Such bacteria may decompose emulsion ingredients, reduce the pH value and cause bad odours. This is the main reason why bactericides are commonly added to metalworking fluids.
Bio-Concept with rainwater, demineralised or softened water Bio-Concept works everywhere. Water of good microbiological quality has a positive impact on emulsion stability. Water with a high microbiological contamination may lead to an imbalance in the emulsion. However, this occurs rarely. This Bio-Concept is robust. It is important to note that the primary bacteria are not delivered with the metalworking fluid concentrate.
46
After the life of coolant is over, it is disposed-off as per the prescribed norms by pollution control board. Disposing off coolants is one of the areas, which raise eyebrows especially in this day and age when health and environment become challenging topics. This is where Blasocut comes in to support long emulsion life & users get the benefit.
A new dimension in machining Metal working fluids (coolants) are often neglected when people discuss the aspect of productivity in machining and overall profitability. In fact, this is a new dimension in machining. It is possible to exploit this new dimension and execute and implement it successfully. It needs a very transparent approach on total manufacturing costs to deliver a documented and measurable added value. In this context, the new dimension of productivity with Blaser Swisslube’s global Liquid Tool positively approaches customers in the machining industry.
Leveraging effect It is fascinating to see the large positive impact, which can be brought by little investment in this area of metalworking fluids. Blaser Swisslube has been able to demonstrate this dimension very well. In many closely held studies, customers have been able to achieve productivity improvements in the range of 8-15 per cent through Liquid Tool. In terms of tool cost, the effect can be approximately 20-40 per cent reduction. Time is the biggest currency and we need to take a holistic view on overall values, which can be generated from the Liquid Tool to get the best out of machines and tools. Liquid Tool is built on expertise & experience in metal working processes of the company including its people, technology driven formulations and customised services. It is possible to gain much larger benefits by having a strong trust on this approach. Secure process reliability and one of the safest formulations to use for human health and environment in the world are values to our customers to extract further higher output from their machines and tools. ☐
EM | Oct 2017
MACHINING CENTRES | TECHNOLOGY
Selecting the right machining centre Choosing the appropriate machine centre can be a challenging task for manufacturers today. The article highlights the essential criteria and considerations that manufacturers must keep in mind in order to select the right machining centre. Considering the varied requirements of end users, the selection of an appropriate machining centre demands certain clarity. Starting from a simple 3-axis and a spindle configuration to multi-axis & multi-spindle configuration, the selection range is really wide. Different user segments necessitate certain features and configurations. Due to continuous demand for enhancing the productivity and performance of the machine, there have been developments in the sub-systems used on the machine tools. For those who are looking out for consistent output and quick set-up changeover, the entry level of VMCs or HMCs with 3 linear axis and a spindle makes the job shop versatile for undertaking of diverse machining jobs.
48
HS Ramprakash VP – Engineering Ace Manufacturing Systems
Criteria for selecting the right machine Some of the factors that would need some consideration in order to select the machine and its configuration include size of the work piece, nature of operations, number of set-ups required to complete the operations, special features required to support intended process, requirement to camouflage loading and unloading time of the components when the machining cycle is in progress, methodology of work piece holding and clamping, cost of manufacturing, precision level of the component (demand on the process), lifetime cost of ownership, technical abilities of the shopfloor manager, analysing if the customer is a job shop or end user and if the requirement is a replacement
EM | Oct 2017
MACHINING CENTRES | TECHNOLOGY
High speed drill tap machining centres
machine on an existing line of machines. The four salient features which ought to get the main focus while deciding an appropriate model or version of a machining centre would be the axes strokes, spindle speeds, floor space requirement to install the machine and spindle power and torque. Based on the size of work piece and the work holding fixture, table size will get decided and this, along with the work envelop to be covered, will decide the axis strokes. Type of operations and speed of operations will directly influence the spindle taper size and the spindle power required.
Yielding a faster return on investment According to HS Ramprakash, Vice President – Engineering, Ace Manufacturing Systems, the usual concern that they get when they suggest a horizontal machining centre to a customer is that it is too expensive. Machine tool users look at machine cost but merely miss out on return on investment. By design and construction, VMC is much lower in cost compared to the HMC. Normally, VMC is less than 50% of the cost of HMC for its equivalent features. But the return on investment is much faster in the case of HMC. Typically, a HMC comes with an index table or a rotary table. Replacing three machines with one not only reduces the investment cost, but also the floor space, elimination of redundant tools and the fixtures. The productivity that one can achieve with an HMC can yield a faster return on investment. Some of the advantages of HMC over VMC are reduced manpower and operator intervention, more effective spindle utilisation, shorter cycle time, reduced inventory (work in process) and easy chip evacuation. Although HMC might not be the choice of machine for all the components, there are factors like quality, application, return on investment, cost, etc. which can make one consider an HMC.
50
Irrespective of the geographical location, where the machine would be installed, smaller foot print machines are popular with users. A machine designed for smaller foot print needs to be highly reliable, as any break down (even planned preventive maintenance) will be difficult to attend in a line, due to reduced accessibility.
Salient features of the machine Spindle speed and power/torque: This is a very important feature, which has to be understood and selected depending upon application. Generally, if the machine is meant for machining an aluminium component, the spindle speed should be minimum 80-8000 rpm. It is advisable to opt for direct drive for precise application. For precision machining on cast iron/ steel, direct drive with higher power spindle motor is recommended. The spindle run out will be very good since there is no side load on the spindle due to belt drive. The power up series motors are used when wider constant power range is needed. However, these are expensive compared to normal motors of the same power. Generally, these motors are selected for application where bigger dia-cutters like, 100/125/160 mm are used extensively for machining cast iron/ steel components. Spindle bearing and spindle speeds: Spindle rigidity is inversely proportional to the maximum speed of the spindle for a given size of spindle bearing. Higher the spindle speed, lower is the spindle rigidity. Lower the maximum spindle speed, higher is the spindle rigidity. Higher preloaded spindle bearing of ø70 with a spindle speed range of 45-4500 rpm is very good to machine steel & cast iron components. Ø 80 mm spindles with medium preload are still better to machine steel & cast iron components. The tool life on higher preloaded bigger dia-spindles is better. Often, an option of
EM | Oct 2017
MACHINING CENTRES | TECHNOLOGY
Twin spindle machining centre
spindle cooling can be offered to ensure retention of running accuracies on prolonged/continuous use. Axes rapid traverse & chip to chip time (CTC): The chip-tochip time (CTC), slide acceleration, rapid traverse & spindle acceleration decides the idle time during the component machining cycle. When the acceleration/deceleration time of the slides and spindle are lower along with higher rapid traverse of the slides, the idle time and hence, the chip-to-chip time is lower. In the long run, high speed machines will earn better return on the investment done. Size of the machine: Generally, the VMC’s sizes are referred and identified by the Y-axis stroke and X-axis stroke and HMC’s sizes are identified by the pallet size, which decides the size of the component that can be machined. The size of the table of VMC will decide the size of the component that can be mounted and the axes strokes will decide the area that can be machined. Daylight area: In VMCs, it is the gap between the spindle face and the top of the table. Lower the daylight, shorter is the height of the component that can be machined. Whenever index tables or rotary tables are used with cradle type fixture, we need to have higher daylight area to ensure that the component with the fixture will not interfere with the cradle base. The component height and width will decide the additional daylight area required on the machine. Coolant through spindle (CTS): This feature has become more prominent these days due to its ability to reduce the running cost of the machine by reducing the cycle time and increasing the tool life. The main application is for drilling of holes of L/D ratio up to 30 and insert type-drills of L/D ratio up to 10. They are also used for other machining application like reaming, boring, etc where accuracies and depth of cut play a critical role. As a thumb rule, we need to supply 0.75 to 1.25 times ‘D’ (size of the hole) lpm oil coming out of the tool for effective chip evacuation. We need high pressure and low flow for smaller dia components. For bigger dia, we need low pressure & high flow.
52
It is very important to ask the tool supplier to provide the size of the oil holes for critical applications and long L/D ratios. Another important aspect for CTS is to supply coolant with 20 micron filtration for better tool life and high machining tolerances. Automatic pallet changer (APC): Essentially ‘APC’ is a productivity enhancer offered on majority of the VMC’s as an optional feature and in some of the HMC’s, APC is a built-in standard feature. APC option is selected basically to reduce the idle time. While the auto cycle is in progress on the spindle side, operator can load/unload at the station side in the back ground. While selecting this option of ‘APC’, one should keep in mind the operator’s fatigue if the automatic cycles are of shorter duration (<60 seconds). Number of tools in the magazine: Number of setups and number of tools required by the application decides the tool storage capacity. On the VMC machine models with single spindles magazine with capacity of 6/12/16/20/24/30 and 40 are offered. On VMC with two spindle variants, magazine to support each of the spindles has a storage capacity of 20 tools. On the HMC machine models, the tool storage capacity ranges from 12 to over 100. Chip conveyors: A conveyor is determined by the material being machined and the nature of chip produced by the process. Normally for aluminium, cast iron, nylon, nonferrous material like brass, bronze, copper, etc, scraper type chip conveyor with rotary drum filtration is recommended. On the other hand, steel material machining application, which will result in longer chip generation, needs slat cum scrapper type chip conveyor. In certain applications, magnetic chip conveyor can be effectively adopted. A coil/screw conveyor can also assist in evacuating the chips to rear end. These are some of the important considerations that will help manufacturers to choose the right machining centre with the essential add-on features for the application intended. ☐
EM | Oct 2017
4TEX Drill â&#x201E;˘
4TEX Drill Advantages Improved tool holder rigidity and increased reliability provided by the stronger core
Superior chip evacuation
provided by the 2 twisted coolant holes
Improved hole size
from the stronger core and increased coolant volume
Longer tool life
Periphery Edges
provided by the 4-sided insert design
Center Edges
Increased penetration rates
due to single effective cutting on light duty machines
Simplified tooling selection
with ISO-specific insert geometry/coating combinations
Boring Drilling
Reaming
Burnishing
Wohlhaupter India Pvt. Ltd. An Allied Machine & Engineering Company B-23, B Block Community Centre Janakpuri, New Delhi - 110058 Website: www.wohlhaupterindia.in
Threading Specials
info.india@alliedmachine.com info.in@wohlhaupter.com | +91 11 41827044
A D D I T I V E M A N U FA C T U R I N G | T E C H N O L O G Y
Focusing on integrated design 3D printing is often used to speed up the pace of product design and is becoming a key part of manufacturing as well as prototyping. But to get the most benefit from new technologies like 3D printing, especially for consumer durables, it is key to have an integrated design and manufacturing system that enables collaboration and preserves accuracy throughout the entire delivery process. A read onâ&#x20AC;Ś Collaborating an integrated design and manufacturing system allows one to create the product that he wanted to design faster without expensive and damaging recalls. That product may have to be smarter than it would have been in the past. Use of IoT is coming to more household products with sensors that can track changes in the environment like temperature and pressure, monitor usage and deliver information that can help manufacturers investigate problems, and maybe even anticipate failures. But these smart, connected products are also more
54
Russell Brook Marketing Director EMEA Mainstream Engineering Siemens PLM Software
demanding in terms of design and manufacturing. You need to deliver more complex electromechanical designs that incorporate those sensors and electronics into previously analogue products, without increasing costs.
Application benefits of integrated design Taking advantage of these trends (and coping with these new pressures) is easier if you have an integrated design system
EM | Oct 2017
Creating Tool Performance
A member of the UNITED GRINDING Group
HELITRONIC DIAMOND EVOLUTION Efficient rotary eroding and grinding machine, Two-in-one
The HELITRONIC DIAMOND EVOLUTION is a high efficient solution within our EDM portfolio for rotary eroding of PCD/CBN tools and grinding of HSS/carbine tools in one single clamping cycle on a minimal footprint. Tool diameters from 1 to 165 mm, tool lengths up to 185 (255) mm, each item can weigh up to 30 kg. www.walter-machines.com
United Grinding GmbH – India Branch Office & Technology Center # 487, D1 & D2A, 4th Phase, KIADB Main Road, Peenya Industrial Area, Bangalore – 560058 Tel. +91 80 3025 7600 · Fax +91 80 3025 7603 · madabhavi@grinding.ch · www.grinding.ch
Creating Tool Performance
A D D I T I V E M A N U FA C T U R I N G | T E C H N O L O G Y
ST9 Boombox section
that can cover you from initial styling to prototyping to design to manufacturing: Groupe SEB: The company better known for their Krups, Moulinex and Tefal brands went from introducing 140 new products in a year to 200 â&#x20AC;&#x201C; a 43% improvement by using Solid Edge software for computer-aided design as an integral part of its overall product lifecycle management system; this software also made its manufacturing processes more reliable at the same time. With everyone at the company being able to access the PLM tools on different devices, they could share knowledge and keep up with standards and policies. This means they could move from having individual teams working on developing new products to building processes that go across multiple disciplines. Zumex: The company found similar benefits when it wanted to develop its orange juicing systems faster; the company was able to cut development time in half with Solid Edge. Getting better collaboration between different departments meant it could use the same improvements in its domestic and professional models. And it was able to show off new products long before they were ready to go on sale using high definition visualisations and virtual prototypes. This helped them educate their sales team and retailers and establish a strong market. The first step in getting to market faster is improving productivity with a system that includes tools optimised to speed up every individual stage of your process while still preserving accuracy. These tools should be integrated to take you all the way through the process. When youâ&#x20AC;&#x2122;re working in 3D CAD, for example, Solid Edge synchronous technology makes creating and editing 3D models faster and easier. By combining the speed and simplicity of direct modelling with the flexibility and control of parametric design, synchronous
56
technology allows you to rapidly create new concept designs, easily respond to change requests, and make simultaneous updates to multiple parts within an assembly. With this design flexibility, you can eliminate cumbersome pre-planning and avoid feature failures, rebuild issues and time-consuming rework. The power of synchronous technology also allows you to treat other 3D CAD models just like native files, supporting seamless collaboration with suppliers and partners.
Creating protoptypes As designs become more complex electromechanically, you need a system that lets you prototype the electrical design as well as the mechanical with a complete set of modelling tools. The tool set must extend past part and assembly design and include speciality applications for frame design, capturing welding operations, stylised design, wiring, schematics and cut lists with a precise bill of materials for the product and more. Additionally, those applications need to be designed for the task at hand. We call this process specific applications, which provide the user with only the tools and operations needed to complete a certain task. Automatically flowing that information through the design process means that you use the original design information to produce your manuals and support documents, at a lower cost, and with increased information. You can also track components, even if the spec changes (because the components list will be updated automatically), giving you better inventory control. Thatâ&#x20AC;&#x2122;s useful for support and maintenance after you ship, and it gives you a clear view of what products are affected by any faults or recalls.
EM | Oct 2017
T E C H N O L O G Y | A D D I T I V E M A N U FA C T U R I N G
3D printing is increasingly coming in-house rather than being sent out to a specialised bureau or building physical prototypes. Look for a design system that lets you send files to 3D printers for design verification and prototyping without requiring your engineers to become experts in managing 3D printers. That way, you’re not just increasing the efficiency of your workforce on the tasks they’re already performing during design but you’re actually creating an environment that improves the design of the final product. For example, engineers can test how well parts fit together and if they look the way they should, early in the design phase when it’s relatively inexpensive to make changes. One example of how you might differentiate your product could be industrial design. Some of the most successful household goods manufacturers are shifting to higher-end, premium products that appeal to customers who are looking to trade up (and those products often have higher margins as well as higher price tags). Premium products need premium industrial design, and if you’re paying for a top flight industrial designer, you need a system that lets you get the most value from the designs they provide. That means getting their original 2D sketches into your design system and converting them to 3D accurately while being confident that you can manufacture the design they envision.
When you do that, you get an additional asset; virtual prototypes that you can use to evaluate and market your future product long before it’s finished. A photorealistic 3D model of your product that you can animate and show in action, even on mobile devices like tablets and smartphones, is a great tool that you can use to get customer feedback and gear up sales promotions before you spend money on manufacturing.
Conclusion Industrial designers may not take manufacturability into account, so when you build your design to get the look they have created, you need to think about everything. This includes continuity of curves between different materials, lines that are left by injection moulding, and the need for kinematic and finite element analysis to make sure your materials and design deliver the performance you want. This requires a system that lets you go from sketch and design concept, to 3D model, to design for manufacturing, to managing designs once a product ships. And this needs to happen in one end-to-end workflow that takes advantage of what you’ve learned in other teams and on other products. The result is, you get to market faster, you save money and you get the design right the first time. ☐ Advt
EM | Oct 2017
57
I N D U S T R I A L M A I N T E N A N C E | S P E C I A L F E AT U R E
Efficient cleaning solution in transmission re-manufacturing An application story on how by changing over from an aqueous cleaning process with numerous manual interventions to Durr Ecocolean’s fully automatic cleaning helped auto parts maker to improve cost efficiency and sustainability Based in Cannock Wood in the English county of Staffordshire, ATP Industries Group has evolved into Europe’s largest independent remanufacturer of automatic and manual transmissions, transfer boxes and other mechanical and mechatronic drivetrain components for cars and off-highway vehicles. “Our customers include vehicle manufacturers such as Ford, Fiat-Chrysler, Volvo, Aston Martin, Land Rover and JCB, to whom we supply products and services into 35 countries worldwide out of our headquarters plant & subsidiary sites in the U.S. and China,” says Mark Bowen, Sales Director, ATP Group. In line with the quality standard, all components of a reconditioned unit must be like new and in some instances better than new, both technically and visually. To achieve this objective, the incoming transmissions and components are initially cleaned and disassembled by hand. Next, the individual parts made of aluminium, steel, cast iron, plastics and other materials were precleaned with brushes and a solvent at dedicated cleaning stations in order to remove oils, greases, carbon deposits and road dirt.
58
Doris Schulz Schulz Presse Text Germany doris.schulz@pressetextschulz.de
Any foreign matter still adhering to the parts was removed in simple, semi-automatic washers using an aqueous medium, and then the parts were dried manually with compressed air. On the other hand, the cleaning method gave rise to an unwholesome work environment with elevated air humidity, airborne oil particles, and high noise levels. Operators in these areas had to wear ear protectors. “About three years ago, we, therefore, consulted various cleaning equipment manufacturers to learn about alternatives. Dürr Ecoclean UK presented us a solution at the time but it exceeded our budget. For a while, therefore, we simply continued to work as before”, recalls Adrian Aston, Technical Director, ATP.
Convincing test results and machine concept Last year, prompted by brisk growth in demand and the company’s own rising quality requirements, ATP’s management approached Dürr Ecoclean again and carried out a series of initial
EM | Oct 2016
S P E C I A L F E AT U R E | I N D U S T R I A L M A I N T E N A N C E
cleaning trials at the UK test centre. This was rounded out by further testing with genuine parts at the Filderstadt test facility in Germany. “The results were so impressive that we ordered two EcoCCore type cleaning systems right away”, Aston adds. The innovative solvent-based cleaning system that can work with hydrocarbons and modified alcohols is run with a nonhalogenated hydrocarbon at ATP. Following disassembly, the transmission parts are arranged in a defined position in cleaning baskets measuring up to 670 x 480 x 400 mm (LxWxH), adapted to the size of the work chamber. These baskets are conveyed to the machines in the cleaning section where an operator selects the appropriate cleaning program. At present, ATP uses 9 different programmes with process parameters set to match the respective transmission type, material, and degree of contamination. The cleaning cycle takes between 6 and 14 minutes to complete. “We clean 65 baskets per shift in each system, with just one lady operator in attendance. Before, we needed between 8 and 10 operators to clean these parts”, reports Aston. To achieve the required cleaning result in such a short time, the EcoCCore is equipped with are innovative process technology such as, e.g., advance steam degreasing. With this technology, the oil-containing solvent is not passed into the flood tank, contrary to common practice, but is directed straight into the distillation unit. This design minimises oil deposits in
the flood tank while counteracting the accumulation of oil in the solvent. Moreover, the machines feature ultrasonic devices in addition to the standard injection flood wash system. “We check our cleaning quality by gravimetric tests once per week. With the EcoCCore, we have been achieving approx. 30% better results on a consistent basis”, recounts Aston.
Optimisation in every respect The improved cleaning results not only helped ATP to further optimise product quality, which has already generated additional business. The company also reports substantial gains in productivity and cost-efficiency. Likewise, the new cleaning process is top notch in terms of sustainability. The water consumption of the old cleaning systems amounted to around 100,000 litres per year, a volume that is now saved. This is in addition to the savings on cleaning chemicals. “Payback on the new machines will occur much sooner than we had calculated. In addition, we benefit from a much more pleasant and cleaner work environment. Our clients and ourselves have gotten so used to this situation that we are already in discussions with Dürr about the purchase of a fourth system – for cleaning the complete transmissions prior to disassembly so that here, too, visible cleanliness will be achieved”, concludes Aston. ☐ Advt
Reliability is the foundation of a successful business relationship SUHNER India Pvt. Ltd. Bangalore +91 (0)80-27 831108 automation.in@suhner.com
TECHNOLOGY | NEWS
Drilling tools
Clamp meter
Seco Tools offers Feedmax –P drilling tools with the latest development in geometry and coating technology. The Feedmax –P’s new geometry and dark-coloured TiAlN coating enhance chip management and deliver high application security, allowing shops to generate more holes faster and with less required drills. In addition to strong straight cutting edges, the drill’s coolant holes are in close proximity to the cutting edges for more efficient cooling, and its Feedmax –P narrow land margins minimise the heat exposed to the drill, while an enhanced flute design protects drill point corners and maximises the control and evacuation of chips. With its new coating, the Feedmax –P lets shops run machine tools to their full drilling potentials. Together with the drill’s strong point geometry, cutting speeds of 190 m/min are possible in SMG P5 without sacrificing tool life. The company offers the Feedmax –P in diameters ranging from 2 mm to 20 mm (metric)/.078” to .787” (inch) and in length-to-diameter ratios of 3xD, 5xD and 7xD.
FLIR offers CM83 and CM85 that are industrial-grade power clamp meters engineered with advanced power analysis and variable frequency drive (VFD) filtering functions to meet the needs of electrical troubleshooters. These meters offer additional features including Bluetooth® technology to connect compatible mobile devices for remote viewing and sharing, and METERLiNK® technology, to wirelessly embed electrical readings into radiometric infrared images on compatible FLIR thermal cameras. They feature VFD mode that provides superior accuracy for working on VFD-controlled equipment; have advanced power efficiency and harmonics measurements for FLIR CM83 system level performance analysis; has true RMS voltage and current plus non-contact voltage detector; has a powerful LED lamps that is assisted with clamping and are bright enough to serve as a primary work light. In addition, they have a 2 metre drop tested with lifetime warranty. The company designs, develops, manufactures, markets, and distributes technologies that enhance perception and awareness. It brings innovative sensing solutions into daily life through the thermal imaging systems, visible-light imaging systems, locator systems, etc.
Seco Tools | Pune Email: seco.india@secotools.com | Tel: +91-2137-667300
FLIR Systems India | New Delhi Email: manpreet.kaur@flir.com.hk | Tel: +91-11-4560-3555
Cable tiewraps
Round insert cutter for difficult-to-cut materials
igus has developed a unique strain relief system (cable tiewraps) with a honeycomb structure for its energy supply systems. Cable tiewraps play a predominant role in strain relief today. Every individual cable is fixed to an e-chain, which is often a job consuming a lot of time and space. Cable tiewraps are used quickly and can often only be used once. The company revolutionises the Honeycomb-shaped strain relief system strain relief in the e-chain with the bionically inspired honeycomb system. This saves the designer's engineering and assembly time. Cables and hoses can simply and gently be pressed into the honeycomb. It is then closed, whereby the outer walls of the honeycomb cavities are pushed gently but extremely tightly around the cables. In this way, the structure simply adapts to the cable diameters. The honeycomb can be mounted in seconds; in comparison to the often used cable tiewraps or other strain relief solutions, the user saves about 80 percent assembly time. The new system saves space and protects the cables in the e-chain.
MMC Hardmetal offers ARP, which is a new round insert cutter series for difficult-to-cut materials. The ARP series has the highest level of run-out accuracy among our indexable insert, screw-on type tools. This helps to increase tool life by spreading the cutting load evenly across all inserts. This accuracy is especially important when machining titanium and heat resistant alloys and stainless steels. The cutter is suitable for roughing of turbine blades used in the aerospace and power generation industries. Its features include highly accurate seating that realises minimal change of run-out accuracy when indexing ARP series the inserts compared to conventional tools. It also has a wide seating face and 2 side location faces that prevent inserts from moving during cutting; special rake face on each quadrant of the insert provides a smooth chip flow for low cutting resistance; chip breakers for various applications; M breaker for general use, R breaker is a strong cutting edge type and the L breaker is a sharp cutting edge type.
igus (India) Pvt Ltd | Bengaluru Email: Harish@igus.in | Tel: +91-80-4912-7809
MMC Hardmetal India | Pune Email: mayur.kulkarni@mmc.co.in | Tel: +91-20-6520-8430
60
EM | Oct 2017
NEWS | TECHNOLOGY
CNC cylindrical grinder
Clamping system
Palmary Machinery offers CNC cylindrical grinder multi-spindle wheelheads type that will meet different kinds of workpiece grinding process requirement. This machine equips the swivel wheelhead (B-axis) which was driven automatically and has the minimum setting angle 0.0003 degrees, it allows the prompt position and superior grinding accuracy results. The wheelhead swivel position accuracy could be less than 1” (one second) for the customer’s high CNC cylindrical grinder multiaccuracy requirements. With the Fanuc spindle wheelheads type CNC conversational mode controller and maximum 4 numbers of grinding wheels installed, it’s easy to operate the required programming. For different application, such as the inner diameter, outer diameter and end face area grinding, the company provides more work efficiency at one time clamping in this CNC cylindrical grinder multi-spindle wheelheads type. With the company’s slogan ‘precision, perfect and excellent’, the company strives hard for pursuing a higher technological level. The quality of Palmary production has achieved superior international levels and has been certified by ISO 9001 and CE standard.
Schunk offers TANDEM TBA-D supporting jaw system that transforms the SCHUNK TANDEM plus clamping force blocks into multi-purpose powerhouses. For the first time it is possible to cover the whole clamping areas with clamping inserts from the company’s standard chuck jaw program for stationary workpiece clamping. Instead of several different special chuck jaws, with the TANDEM TBA-D supporting jaw system, the user just needs a few standard inserts, which can be quickly configured and are usually available from stock. This reduces TANDEM TBA-D supporting both the investment volume and jaw system implementation time to a minimum. Standard interfaces allow different variations for raw and finished parts as an option including gripper jaws, stepped jaws, prism jaws, soft jaws, jaws with pull-down, jaws with T-nut, and many more. The supporting jaws are assembled with four screws at the base jaw of the clamping force block, maximising rigidity. The SCHUNK TANDEM TBA-D is available in three sizes for clamping ranges from 8 to 70 mm, 18 to 120 mm, or 30 to 200 mm. SCHUNK Intec India | Bengaluru
Palmary Machinery | Taiwan Email: palmary@grinding.com.tw | Tel: +886-4-2492-9799
Email: info@in.schunk.com | Tel: +91-80-40538999
Complex machining unit
Flange seal
SUHNER’s production expert division, SOMEX, provides customers with highly customised solutions and develops machining units for very complex processes. One such client had commissioned SUHNER Automation to manufacture a unit that would perform abrasive cutting of metallic workpieces using a diamond disc. Adhering to the customer’s specifications, SOMEX’s project team opted for a MAX100, in order to ensure that the job was performed to a high Complex machining unit with MAX100 standard. The machine’s operating environment required the following changes to be made to the MAX100, which was equipped with a 30 kW drive motor: Reinforced sealing to protection against splashes of cutting fluid and creation of overpressure in the body and in the housing to prevent micro particles from penetrating. The machining unit installed at the client site has a laser measuring device, which automatically adjusts the speed of the MAX100. Thanks to the quality of the planning, the execution and the customer’s feedback, the customer decided to have a second – identical – unit installed.
Trelleborg Sealing Solutions offers Zurcon® DRV5 Flange Seal, which acts as an insurance policy for Equipment's SAE J518 and ISO 6162:1 flanges. The Zurcon® DRV5 flange seal showcases an advanced seal design that provides safe and leak-free flange connections in hydraulics, press manufacturing, and materials handling applications. Additionally, the Zurcon® DRV5 flange seal is designed to work with standardised SAEJ518 and ISO 6162:1 flanges. The Zurcon® DRV5 flange seal is constructed Zurcon® DRV5 from Zurcon® Z20 which features superb resistance properties. The advanced seal design, combined with proven Zurcon® Z20 materials, allow the Zurcon®DRV5 flange seal to prevent extrusion and nibbling, eliminate micro-pumping leakage, and increase duty cycles. The benefits of the Zurcon® DRV5 flange seal deliver excellent value and performance for SAEJ518 and ISO 6162:1 equipment flanges. The seal’s operating temperature is of the range -35 ºC to +110 ºC / -31 ºF to +230 ºF for standard Z20 version; -50 ºC to +110 ºC / -58 ºF to +230 ºF for Z22 version.
MMC Hardmetal India | Pune Email: mayur.kulkarni@mmc.co.in | Tel: +91-20-6520-8430
Trelleborg Sealing Solutions | Bengaluru Email: Anjali.tiwari@trelleborg.com | Tel: +91-80-3372-9001
EM | Oct 2017
61
TECHNOLOGY | NEWS
Grinding tools Tyrolit offers the STARTEC PG-1 product line that provides highperformance grinding tools for peel grinding tungsten carbide. The specification used involves a highstrength metal bond combined with an extremely stable diamond type, enabling long tool life and reduced noise levels during grinding. As there are few market entry barriers with regard to solid tungsten carbide tools, many competitors are active on the international market, most of them offering lower prices. At the same time, there is a rise in the performance levels demanded by operators, such as higher stock removal rates, longer lifetimes and greater precision. In order to meet these growing demands, tools of the highest precision with complex cutting geometries and the best possible surface finishes are a must. With the STARTEC PG-1 product line, the company is able to offer its customers the same familiar high grinding power and tool lifetimes for STARTEC PG-1 peel grinding. The grinding tools of the STARTEC PG-1 product line feature a high stock removal rate and reduced edge wear, as well as achieving a very good surface finish on the ground workpiece. Due to the continuous rise in the performance levels demanded by customers, Tyrolit's products are constantly under development. The new STARTEC PG-2 range for rough grinding in the peel grinding process was introduced for the first time at the EMO 2017 trade fair in Hanover.
New generation for rough grinding and smoothing Just like the earlier model STARTEC PG-1, the new STARTEC PG-2 rough grinding wheels are also based on a high-strength metal bond and new, extremely wear-resistant diamond types. Combined with an innovative core,
STARTEC PG-2 offers an even higher stock removal rate. In line with this, the finish grinding wheels have also been optimised for our customers; they are available in a choice of new metallic or vitrified bonds. This makes it possible to select the perfect combination of rough and finish grinding wheels for any machining task with specially adapted diamond grain sizes. The high edge stability of the STARTEC PG-2 product line ensures the same familiar low wheel wear and the consequent improvement of productivity. The innovative design of the new grinding wheels means that there is absolutely no unwanted grinding noise and is significantly quieter than other grinding tools on the market.
Success factors: Process expertise and experience Tyrolit application engineers are on hand around the world to help customers choose suitable grinding tool and the associated process parameters. Peel grinding is a very complex process, particularly when it comes to defining the right grinding and dressing parameters. the company has therefore invested in developing process expertise in the area of peel grinding. After all, the required precision, i.e. dimensional accuracy and surface finish, can only be achieved in the shortest possible process time with the optimum settings. With the grinding wheel from the STARTEC range, operators benefit from a high-efficiency grinding tool for every grinding task â&#x20AC;&#x201C; from peel grinding right through to polishing. This means that the process expertise and application technology developed by Tyrolit can benefit all customers. The company's philosophy is to offer these customers innovative, highquality system solutions and to optimise processes so that grinding times are reduced and tool quality is increased. This is a sustained approach that guarantees our customers a long-term competitive advantage. Tyrolit India Super Abrasive Tools Pvt Ltd | Bengaluru Email: subrahmanya.kumar@Tyrolit.com | Tel: +91-9686501324
62
EM | Oct 2017
NEWS | TECHNOLOGY
Smart screwdriver Bosch Power Tools India has announced the launch of a smart screwdriver ‘Bosch GO’. The screwdriver will be initially available on Flipkart and Amazon India to cater to evolving needs of the Indian millennial consumers. ‘Bosch GO’ is the smart screwdriver where a simple push gets the work done and its intelligent E-clutch system knows when to stop on reaching the target torque. The strong spindle lock closes the gap between manual and automatic Bosch GO operation helping users to stop impending work on demand. The lithium-ion battery powered screwdriver is compact and easy to carry around anytime, anywhere. The tool is designed to be as close to the shape and size of a manual screwdriver in order to help the Indian user leapfrog from manual effort to effortless working with minimal discomfort. Developed with an extended UX approach and with a user-friendly design, it adds an aesthetic value to repair tasks. From tightening to loosening screws, this smart screwdriver comes with adjustable 5/2.5 Nm torque and the speed goes upto 360 rpm. Bosch Power Tools India | Bengaluru Email: bpt@in.bosch.com | Tel: +91-22-24952071
Ring rollers Schuler offers a new series of ring rollers developed in close cooperation with the forging industry. In the process, the developers have come up with a number of special features that directly benefit customers. The position of the upper bearing of the mandrel, for example, can be adjusted in height. Therefore, the length of the roller mandrels can be Ring roller adapted exactly to the ring geometry, which leads to considerably reduced bending and die loads. Through an additional roller mandrel drive, all forming dies can also rotate during idle times, thus cooling evenly on all sides. The innovative machine concept with a comparably low construction height also improves accessibility for a quick change of the roller mandrel. In combination with the main roller in a cartridge design, a die change is possible in just a few minutes. Due to the short equipping times and high technical availability, the company therefore also offers an economical solution for the production of small lot sizes. Schuler India | Mumbai Email: info@schulerindia.com | Tel: +91-22-6680-0300
EM | Oct 2017
63
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 - Nov 2017 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Assistant Editor Megha Roy megha.roy@publish-industry.net Senior Content Developer – Digital Maria Jerin maria.jerin@publish-industry.net
» Automotive Manufacturing While vehicles are now produced at a much faster rate as compared to a decade ago, automakers must continue to balance increased productivity and efficiency with quality and innovation to tackle with the sluggish demand trends in this sector. Automotive manufacturers and suppliers also need to take crucial steps in controlling costs through inventory management and stringent production processes. Analysing the latest technologies, material and production strategies for this sector, the next issue will feature modern technologies used in advancing manufacturing for the automotive industry.
» Industrial Bearings The useful life of any bearing depends to a great extent on the care and maintenance it receives. This is especially true in industrial applications, where operating conditions tend to be harsh, loads are very heavy and contamination from dirt and scale are common. The upcoming issue features the maintenance, handling, inspection practices and much more of bearings.
» Machine Tool Market Dynamics The global economic activities and global consumer spending would decide the growth of the industrial production and in turn, the use of machine tools in manufacturing. The industry therefore has developed a strong correlation with the global economic growth and economic activities. The subsequent edition will focus on the global perspective of the machine tool industry and market dynamics.
» Simulation Modelling Simulation modeling is the process of creating a digital prototype of a physical model to predict its performance in the real world. It aids designers and engineers to understand under what conditions and in which ways a part could fail and what loads it can withstand. The next edition will focus on the importance of simulation modelling which is rapidly becoming an integral part of digital enterprises.
64
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 ABB . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Ace Manufacturing Systems . . . . . . . . . . .48 Ace Micromatic Group . . . . . . . . . . . . . . .46 Autodesk . . . . . . . . . . . . . . . . . . . . . . . .15 Beckhoff Automation . . . . . . . . . . . . . . . . .1 Bharat Fritz Werner . . . . . . . . . 18,19,20,21 Blaser Swisslube . . . . . . . . . . . . . . . . 25, 44 Bosch Power Tools . . . . . . . . . . . . . . . . .63 Carborundum Universal . . . . . . . . . . . . . .17 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 DMG Mori . . . . . . . . . . . . . . . . . . . . . . .16 Durr . . . . . . . . . . . . . . . . . . . . . . . . . . .58 EMAG . . . . . . . . . . . . . . . . . . . . . . . . . .33 Emuge – Franken India . . . . . . . . . . . . . .63 ExonMobil . . . . . . . . . . . . . . . . . 12, 22, 31 FEMCO . . . . . . . . . . . . . . . . . . . . . . . . .49 Flir Systems . . . . . . . . . . . . . . . . . . . 11, 60 Fujitsu Glovia Inc . . . . . . . . . . . . . . . . . . .26 Gleason . . . . . . . . . . . . . . . . . . . . . . . . .12 Godrej . . . . . . . . . . . . . . . . . . . . . . . . . .24
Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net
Name . . . . . . . . . . . . . . . . . . . . . . .Page Grind Master Machines . . . . . . . . . . . . . . .38 Hitachi Koki . . . . . . . . . . . . . . . . . . . . . .14 Igus . . . . . . . . . . . . . . . . . . . . . . . . . 2, 60 IMTMA . . . . . . . . . . . . . . . . . . . . . . 38, 51 Jyoti CNC Automation . . . . . . . . . . . . . . . .3 Kenturn Nano Tec . Co . . . . . . . . . . . . . . .41 Mahindra & Mahindra . . . . . . . . . . . . . . .34 Mahindra Group . . . . . . . . . . . . . . . . . . .12 Marposs India . . . . . . . . . . Back Inside Cover Messe Frankfurt . . . . . . . . . . . . . . . . . . .37 MG Motor . . . . . . . . . . . . . . . . . . . . . . .14 Micromatic Grinding Solutions . . . . . . . . . .36 Mitsubishi Electric India . . . . . . . . . . . . . .23 MMC Hardmetal . . . . . . . . . . . . . . . . 13, 60 Morgan Advanced Materials . . . . . . . . . . .12 MotulTech India . . . . . . . . . . . . . . . . . . . .39 Palmary Machinery . . . . . . . . . . . . . . . . .61 QuEST Global . . . . . . . . . . . . . . . . . . . . .16 Rajamane Industries . . . . . . . . . . . . . . . .57
Name . . . . . . . . . . . . . . . . . . . . . . .Page Renishaw . . . . . . . . . . . . . . . . . . . . . . . .14 Sahajanand Laser Technology . . . . . . . . . .39 Schuler . . . . . . . . . . . . . . . . . . . . . . . . .63 Schunk Intec India . . . . .Front Inside Cover, 61 Seco Tools . . . . . . . . . . . . . . . . . . . . 40, 60 Siemens . . . . . . . . . . . . . . . . . . . . . 14, 54 Suhner India . . . . . . . . . . . . . . . . . . . 59, 61 TaeguTec India . . . . . . . . . . . . . . Back Cover Tectyl Oil & Chemicals . . . . . . . . . . . . . . .43 Total . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Trelleborg Sealing Solutions . . . . . . . . . . .61 Tyrolit India . . . . . . . . . . . . . . . . . . . . 29, 62 UCAM . . . . . . . . . . . . . . . . . . . . . . . . . .38 United Grinding . . . . . . . . . . . . . . . . . . . .55 Vargus India . . . . . . . . . . . . . . . . . . . . . . .6 Wohlhaupter India . . . . . . . . . . . . . . . . . .53 YG1 Cutting Tools . . . . . . . . . . . . . . . . . 4,5 Zavenir Daubert . . . . . . . . . . . . . . . . . . .47 ZF . . . . . . . . . . . . . . . . . . . . . . . . . 16, 39
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
EM | Oct 2017
MARPOSS 4.0 T H E S M A R T FA C T O RY T O G E T H E R
WIRELESS HANDLE The innovative Marposs iWave2 wireless handle with its integrated colour display and ergonomic design is the perfect partner for any dimensional inspection requirement in today’s flexible workshop. Marposs Communication Soſtware gives the user the opportunity to connect i-Wave2 to any computer for data collection. Marposs is the partner you need to make Industry 4.0 a working reality. MARPOSS INDIA Pvt. Ltd. · 147, Sector 7 - IMT MANESAR - 122 050 · Tel.: +91 124 4735700, Email: sales@in.marposs.com
RNI No. MAH/ENG/2010/34603