VOL 07 | DEC 2015 www.efficientmanufacturing.in
EFFICIENT MANUFACTURING
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
Asset performance management
Driving maximum value from assets
EM - Interview Gaur Dattatreya
VP & Head of Business Unit Robert Bosch Engg & Business Solutions
(p. 28)
FOCUS Medical machining
P. 30
EVENT REPORT Solid Edge University 2015 P. 60
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E D I TO R I A L
Responding quickly & effectively “While the future may not look so promising with a very volatile global economy, it’s always worth taking advantage of every opportunity you have to try new things”
Here we are, the last month of the year. There were some ups and downs in the industrial growth in this year. But India still remains as a new growth leader in Asia-Pacific, having overtaken China. With the Prime Minister’s ‘Make in India’ initiative to place India on the world map as a manufacturing hub and give global recognition to the Indian economy, India’s manufacturing sector could touch US$ 1 trillion by 2025. There is potential for the sector to account for 25-30% of the country’s GDP and create up to 90 million domestic jobs by 2025. Instead of being a dumping ground for the companies across the world, India could attain a unique position of manufacturing excellence by this programme, for building worldclass products for our own consumption as well as for export. This calls for acquiring an ability to respond quickly and effectively to the changing demand conditions of the domestic as well as international markets. The zero defect mindset is the necessity to ensure the success of `Make in India’ programme, besides fostering technical excellence, with skill enhancement in our workers. Moreover, there is an acute need to improve India’s ailing infrastructure scenario and defunct logistics facilities. In short, it is a long road ahead! As we approach the end of the year, it is always a good time to regroup, reexamine and revisit your strategies and tactics—both from a business as well as an operational perspective. While the future may not look so promising with a very volatile global economy, it’s always worth taking advantage of every opportunity you have to try new things. Finally, with all the unrest and intolerance in the world, we hope you find the success! Best wishes!
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net
EDITORIAL ADVISORY BOARD Sonali Kulkarni President & CEO Fanuc India
N K Dhand CMD Micromatic Grinding Technologies
Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Vivek Sharma Managing Director Yamazaki Mazak India
S Ravishankar Managing Director DMG MORI India
Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan Dr P N Rao Professor of Manufacturing Technology Department of Technology University of Northern Iowa, USA
Satish Godbole Vice President, Motion Control Div Siemens Ltd Vineet Seth Managing Director India & Middle East Delcam Plc
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
EM | Dec 2015
7
CONTENTS
Market
10
Management
NEWS
INTERVIEW 28
16
“Physics for simulation�
“There is a shift in the quality trend�
Interview with Ravindra SD, Managing Director, Vollmer Technologies EVENT REPORT 58
Strengthening Indo-German relations
MEDICAL MACHINING
“Getting smarter for the best IoT infrastructure� Interview with Gaur Dattatreya, VP & Head of Business Unit, Robert Bosch Engineering & Business Solutions
Interview with Nicolas Huc, VP, Development & Product Manager, COMSOL 20
Focus
30
Challenges in the healthcare industry
The article briefs on the developments with which manufacturers can cater to any form of medical device or equipment manufacture without switching between different CAD/CAM providers
FACTORY TOUR REPORT 64
Building strong export market
A factory tour report on the recent visit of Taiwan machine tool industrial facilities
A post-event report on the recently held 4th VDMA Mechanical Engineering Summit at New Delhi 60
Designing without Boundaries‌
A post-event report on the recently held Solid Edge University 2015 by Siemens PLM Software in Cincinnati, Ohio, USA
22
COVER STORY Asset performance management
A read on how organisations with technology and know-how available today, can drive profitability from all industrial assets by creating a cooperative & collaborative environment enabled by real time technology
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CONTENTS
Technology
Cover image courtesy: Shutterstock
SUPPLY CHAIN MANAGEMENT 36
Lean guiding principles for the supply chain
CUTTING TOOLS 48
This article talks on Built-in Quality, one of the lean guiding principles to develop a lean culture in a supply chain operation
Taking hole deburring to new depths
A read on how the new Mechanical Edge Profiting process keeps exit burrs from negatively impacting tool rigidity, machining accuracy and tool life in deep, small-diameter through holes
GEAR MANUFACTURING 42
Ready for large tasks
The article discusses the large industrial measuring centres for gears adapting to the current market needs
MANUFACTURING IT 52
Achieving program excellence
A read on how aerospace & defense firms achieve program excellence with Siemens integrated verification management system
New Products 69 Drilling tools; Flexible clamp cables; Smart 3D sensors; Tribological filaments; 70 Centring points for drill bits; Shoulder milling tools; CAD/CAM sheet metal software; Compact mechatronic module; 71 Face milling cutter; Laser processing machine; Pneumatic drive machine; Precision hardened & ground flanges
Columns 07 08 72 72
EM | Dec 2015
Editorial Contents Highlights – Next issue Company index
9
MARKET | NEWS
BFW launches tech centre at Kolhapur
EDM summit organised by EDM Productivity Forum
BFW recently inaugurated a tech centre at Kolhapur to meet the growing needs of customers. It will showcase cutting edge new products for the customers’ next-gen requirements. The company will position dedicated service engineers and stocking of the spares closer to customers and, thereby, provide effective after-sales and service. In terms of application, engineers stationed at the tech centre will provide solutions to challenging problems faced by customers. For According to Raghavan, the centre trainings, company officials will will strengthen the company’s conduct customised & comprehensive presence in Kolhapur to meet the training programs for production customers’ next-gen requirements processes, engineering applications, maintenance, etc. Ganesh Technologies is the channel partner for Kolhapur. With market knowledge, sales expertise and customer relationships developed over two decades, this association will further strengthen the Kolhapur centre. According to Ravi Raghavan, CEO, BFW, “To meet the needs of customers in Kolhapur like sound castings, Mahabal metals, Mourya Industries, Caspro Metals, General Machine Tools, etc, we have decided to strengthen our presence here.”
EDM Productivity Forum (EPF) recently held its EDM summit across Mumbai, Pune, Nasik & Aurangabad. The 4-day event witnessed over 250 people from over 150 tool rooms visiting the forum. The event was jointly supported by Makino India and GF Machining Solutions and provided a platform for sharing best practices in The summit provided a platform to award best EDM machining. Industry practices in EDM machining experts like Stephen Harris from MWI, USA & N Konishi from TOKAI Carbon made technical presentations on the EDM process. Sadananda Koppalkar, Head - Business Development, Makino, used the platform to share inputs on how to improve the productivity on EDM machines. It also featured some of the best tool rooms in this region, where there were insights on the best practices & improvements in the EDM section. Also, there was the first ever benchmarking study done by Prime Industries amongst its clients across 4 cities. Over 35 clients participated in this study and winners were chosen in areas of best MRR, lowest wear and best surface finish achieved on EDM.
COMSOL releases Multiphysics® 5.2
Fair Friend Group acquires MAG Group
COMSOL has recently released COMSOL Multiphysics® 5.2 that provides simulation community the only fully integrated environment for creating simulation apps. It delivers new features, improved stability & robustness and faster execution. Major upgrades to the application builder available in COMSOL Multiphysics include the new editor tools for easy creation of user interface components, commands for dynamic updates of graphics, and more control over the deployment of simulation apps. Running simulation apps using COMSOL server in a corporate network or in the cloud is now up to five times faster. Many updates, new The software delivers new features, improved features and simulation application stability, robustness & faster execution examples are also available for the add-on electrical, mechanical, fluid, and chemical products. “We leveraged the Application Builder to more efficiently communicate complex design ideas across multiple simulation and process departments, which has allowed app users to easily explore the outcome of proposed designs,” said Borja Lazaro Toralles, Research Engineer on the Manufacturing Technology Centre (MTC) simulation team. Its features include ability to update graphics while running an app.
10
Fair Friend Group (FFG) has recently acquired MAG Group, a leading machine tool manufacturer for the automotive industry, which strengthens it position as one of the world’s leading machine tool suppliers. Speaking on the occasion, Dr Reiner Beutel, CEO, MAG, said, “MAG will benefit from the global footprint and financial strength of FFG, while our customers will benefit from the sharing of know-how and technology between our companies, increased production capabilities as well as local service wherever they are”. With MAG’s seven production facilities, FFG increases the number of machine tool factories to 51 across the globe, now covering Taiwan, Germany, Italy, Hungary, Japan, South Korea, China, Switzerland, India and USA, with a total of 32 brands. According to Jimmy Chu, Founder & Chairman, FFG, “I am happy to welcome MAG and its employees to our large family. I am confident that the integration of MAG into FFG will be beneficial for all of us, and for our customers and suppliers.”
EM | Dec 2015
Production Milling
5-axis Machining
High Speed Machining
DP Technology Corp. Catch us on
Multitasking mill-turn machining
MARKET | NEWS
Frost & Sullivan announces Sustainability 4.0 Awards
HaasTec to be held at Pune
Frost & Sullivan has recently announced the launch of its Sustainability 4.0 Awards 2016, which will take place on May 27, 2016 at Mumbai. The erstwhile Green Manufacturing Excellence Awards is a prestigious awards banquet that has become a premier platform acknowledging companies for their work in sustainability requirements across their value chains. The impact of transformational changes, unexpected disruptions in technologies and established operating systems has shifted the focus of industries toward sustainable practices. With an increasing number
of enterprises embracing approaches to sustainable development, the need to support these businesses and recognise their efforts has become paramount. Announcing the launch of the 7 th edition of the awards banquet, Nitin Kalothia, Director—Manufacturing & Process Consulting, Frost & Sullivan, said, “The parameters of perpetuity of a business has moved beyond revenue generation and management’s innovative thinking. To survive and thrive in today’s volatile ecosystem, corporates in India are imbibing sustainable development as part of their long-term strategy.” The sustainability program was instituted in 2009.
The HaasTec will soon take place in Pune, where innovative & affordable Haas CNC machine tools will be on view. Machines like UMC-750 fiveaxis universal machining centre and ST-35 big bore CNC lathe will be on display. All machine tools on display will be powered and performing demonstrations, cutting metal. Haas specialists from the HFO will be available to guide visitors through the demonstrations. The machines to be displayed at the event include UMC-750 five-axis vertical machining centre offering a capacity of 762 x 508 x 508 mm in the X, Y and Z-axis respectively; ST-35 big bore CNC lathe that can accommodate bars up to 102 mm in diameter and offers a capacity of 533 (dia) x 660 mm (length) with 806 mm of swing; ST-10Y turning centre with Y-axis; DT-1 drill tap machine with new 30 taper 15,000 rpm spindle, All machine tools on display will be powered and VF-2 VMC, VF-2SS, mini performing demonstrations mill and VF-7/50 VMC.
Grind Master bags the SME Business Excellence Award
Milacron India launches extrusion capabilities
Grind Master has recently received the SME Business Excellence Award in the mid-corporate segment under Engineering & Machinery sector organised by Karur Vysya Bank and Dun & Bradstreet (D&B) at New Delhi. The event, attended by eminent business leaders and senior government officials, also included the release of the publication “Leading SMEs of India 2015”. “It gives me great satisfaction that we are emerging on a national and Sameer Kelkar felicitated with international stage as a trustworthy the award & passionate machine builder,” said Sameer Kelkar, Executive Director, Grind Master, while receiving the award. Grind Master has been growing at a phenomenal rate in the past few years, closing FY14-15 with a turnover of more than `120 crores. As one of the large machine tool builders in India, it qualified in the “mid-corporate” category, thus, reflecting the transformation into a professionally managed business. Recently completing the 50th machine in China, the company has created a brand known for expertise & innovation in metal finishing internationally.
12
Milacron India inaugurated its Extrusion Open House at the Ahmedabad facility recently. It included the demonstration of an extrusion line in live production of cPVC pipes. At the event, Milacron received two orders for India-built pipe extrusion systems from local customers. The orders were for complete systems and included extruder, controller, die/ head, cooling/sizing tank, puller, cutting/saw and accumulation table. The first system will ship before the end of 2015 and the second system is scheduled to ship in Q1 2016. Speaking at the Milacron India inaugurated its Extrusion event, Brian Marston, VP & GM, Open House at Ahmedabad Global Extrusion Business, stated, “The conical twin screw counter rotating extruder producing cPVC pipe is one of our most popular extrusion technologies and we anticipate a strong demand for these machines in India and surrounding regions”. The three-day event catered to the needs of India’s growing construction industry. The extruder produced ¾ inch cPVC pipes and an injection moulding machine cPVC line Servo 150 was engaged in the production of cPVC fittings.
EM | Dec 2015
MARKET | NEWS
National Productivity Summit 2015 Indian Machine Tool Manufacturers’ Association firmly believes that it is Transforming India (NITI) Aayog, briefed on the current Indian economic necessary to recognise those scenario, the challenges and opportunities who have contributed to lying ahead. He then impressed upon the productivity improvement in importance of productivity and manufacturing Indian industries and to to the growth of the nation, in conjunction encourage more to emulate with the drive of the government on the ‘Make these pioneers. With this in India’ campaign, to equip the Indian objective, IMTMA hosts the manufacturing fraternity and scale them to National Productivity Summit greater heights in the global arena. every year. The summit this year Leading firms such as Ashok Leyland, was recently organised at Bajaj Auto, Bosch, Keihinfie, Lucas TVS, Gurgaon. Mahindra & Mahindra, Maruti Suzuki, Tata The event showcased the Motors, TVS Motor and Wabco India presented best productivity improvement The event showcased the best productivity improvement projects in their case studies on productivity practices, projects in metal working metal working industries all of which contested for IMTMA – ACE industries, which have excelled Micromatic Productivity Championship in achieving superior performance through sustained productivity Awards 2015 that gave away cash awards of ` 10 Lakhs. improvements. The two-day event witnessed around 300 participants from Wabco India, TVS Motors, Bajaj Auto, Keihinfie, Lucas TVS and SKF India 102 companies. L Krishnan, President, IMTMA, presented the welcome were adjudged the winners of the IMTMA - ACE Micromatic Productivity address, where he spoke on innovative approaches to address productivity Championship 2015 Awards. Further, a Vox Populi award was given to challenges, new ideas and concepts. Presentations were put up by teams TVS Motors. Also, plant visits to Hero Motocorp, Sona BLW Forging, from Maruti Suzuki, Honda Cars, Hitech Gears and Sartorius India Group. Hitech Gears and Honda Motorcycles & Scooters India were arranged a day During the event, Dr Saraswat, Hon’ble Member, National Institution of prior to the event.
Mikrosa wins i-NOVO Award During EMO 2015 in Milan, Mikrosa rceieved the i-NOVO Award from the online industrial fair DirectIndustry for its centreless external cylindrical grinding machine KRONOS S 250. The machine is designed for highvolume production in the high-precision segment and for the plunge and throughfeed grinding of workpieces in the diameter range of 1.5 to 35 mm, and is constructed with a plunge grind width of up to 245 mm. Its new design is geared systematically towards ergonomy and user-friendliness. The control panel, for example, has quick and simple height adjustment. So, the KRONOS S 250’s new design is operator can adapt it to his own needs geared systematically towards and avert potential postural defects. ergonomy and user-friendliness The machine’s sliding doors, which can be opened wide, are equipped with ergonomic door handles featuring an adjusted grip profile. To simplify the cleaning process, the machine’s surface structures were improved and the materials used were optimised. The centreless external cylindrical grinding machine is fitted with a multi-coloured signal light with an integrated flash function, thereby, providing optimum status visibility.
14
German machine tool industry performing valiantly In the third quarter of 2015, order bookings in the German machine tool industry fell by 1%, compared German Machine Tool Industry to the preceding year’s Order bookings and turnover remain at a high level equivalent period. Domestic orders rose by 9%, while demand from abroad was down by 7%. In the first nine months of 2015, order bookings stagnated compared to the previous year. Domestic orders fell by 3%, with demand Order bookings and turnover remain at from abroad up by 1%. a higher level According to Dr Wilfried Schäfer, Executive Director— VDW, Frankfurt, “In the year’s third quarter, our sector was boosted by orders from Germany itself and from the Eurozone. Western Europe proved to be the motor for demand in the German machine tool industry. The Americas, by contrast, were disappointing, with orders down across the board. Asia, as a whole, scored with modest growth. Good business with South Korea & Japan, however, was offset by a substantial minus in orders from China, the biggest market.” Order Intake [Index, nominal] 240
200
original values
12-months moving average
160
120
80
Order Intake, %-change to previous year 3Q 2015
40
Total
Domestic Foreign
0
-1
1-3Q 2015 0
+9
-3
-7
+1
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Note: Index basis shipments 2010=100, data until September 2015 Sources: VDW, VDMA
02.11.2015
Verein Deutscher Werkzeugmaschinenfabriken e.V. (VDW)
EM | Dec 2015
MARKET | INTERVIEW
“Physics for simulation” Nicolas Huc, VP of Development & Product Manager, COMSOL, briefs on combining many areas of physics for simulation purposes and features of the new version of COMSOL Multiphysics®, and shares his views on challenges in scientific modelling, in an interview with Shekhar Jitkar. Excerpts… Tell us more about the simulation software models that can be used to predict effects of heat transfer and thermal stress and to improve thermal performances of a given application? Heat transfer modeling in COMSOL Multiphysics® covers the 3 means of heat transfer: conduction, convection and radiation. Heat transfer by conduction handles non-linear material properties which can be, for example, temperature dependent. It also supports anisotropic material properties which is often needed for composite material modelling. It can be combined with the “Curvilinear Coordinates” interface to define the orientation of anisotropic material that have complex geometry configurations. Heat transfer by convection is supported for laminar and turbulent flow regimes, it can be combined with phase change to achieve high cooling performances. Heat transfer by radiation is implemented for surfaceto-surface radiation and radiation semitransparent media. All the heat transfer capabilities can be freely combined with all our structural mechanics capabilities for thermal stress modeling. The ability to combine many areas of physics for simulation purposes is the latest innovation of COMSOL. Can you elaborate more on it? COMSOL Multiphysics® has been designed to combine multiple physics from the beginning. This is not something that has been introduced recently, it is a pillar of the software. We are using a patented method for assembling the finite element discretisation of arbitrary equations. It offers an optimal framework for the numerical treatment of multiphysics problems. With this method, COMSOL Multiphysics® is able to treat all the physics (and the corresponding equations) in a coupled manner. For strongly coupled physics, this is the key to have high convergence rates and high accuracy. Models with strongly coupled physics correspond to configurations where two or more physics interact which each other and none of them is leading the other ones. For example, models with Joule heating where the electric properties are greatly influenced by the temperature. Natural convection is another example when the flow and the temperature are strongly coupled.
16
What is new in COMSOL Multiphysics® version 5.2? A lot of efforts has been put to implement hundreds of enhancements on existing capabilities. This makes COMSOL Multiphysics® 5.2 the most stable and finished product we ever released. Of course, there are new functionalities, but it is important to stress that great attention was paid to details and feedbacks to improve the software in all aspects (accuracy, performance, usability). The version 5.2 provides simulations experts the Application Builder, a mature simulation app design. It is a highly productive interface for app design that makes it possible for experts to embed their expertise in COMSOL Apps. COMSOL Server™ allows to deploy their simulation applications and have them used by users everywhere. Which are the industry segments that COMSOL is targeting globally and in India for the latest version of Multiphysics software? One strength of COMSOL is that COMSOL Multiphysics® is used for a wide range of applications in several different industries. It is used in automotive industry, for MEMS design, for defense and electronic industry as well as in food industry, medical applications, etc. How challenging it is to make the industry receptive to scientific modelling? My experience is that every industrial player has a number of challenges to address and that in some cases modelling and simulation provides a solution. In this case, scientific modeling is easily adopted. When scientific modeling doesn’t provide a satisfactory solution or when there is no identified challenge for it, then it’s almost impossible to convince someone to invest in something that does bring any identified benefit. I would say that the industry is already rather receptive to scientific modelling. The fact that simulation market is continuously growing tends to confirm that. I believe that the challenge is on our side. The more industrial challenges we address the more the industry will use scientific modelling and simulation. ☐
EM | Dec 2015
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MARKET | INTERVIEW
“There is a shift in the quality trend” Ravindra SD, Managing Director, Vollmer Technologies (a subsidiary of VOLLMER Werke Germany), believes that the trend today is shifting from the use of labour-intensive applications to automation. In his interview with Megha Roy, he discusses the latest innovations and trends in the industry. Excerpts…
Can you brief us on the latest developments happening at your end when it comes to handling sharp tools, saw blades, tooth shapes or tool geometries? For sharp tools, the machines are nearly stabilised to the saturation level, although there is still room for improving machine speed. The machines are stabilised in terms of technology. For rotary tools, Vollmer had launched a new concept for tool & cutter grinder at the GrindTec 2014, where Vgrind 160 was introduced. In the existing product portfolio for the circular saw blade grinding, we have also introduced new models to streamline the existing portfolio into modular machines, so that all machines look identical and have standardised parts & easy inter-changeability between machines. For saw blades, we have a range of machines. We make from the simplest of hydraulic machines to sophisticated 8-9 axis machines that can be automatically operated. We have also developed band saw blade grinding machines. In the area of tool geometries for saw blades, we always strive to improve on the hardware & software on our machines, so that the tools are processed in faster & simple manner. The new tooth shapes are derived by our customers based on the applications in question & we develop the machines to handle these tooth geometries. How does R&D work in your domain? We have an R&D team of 70 people working in Germany. They work towards product development—both on existing & new products depending on the market requirements. CNC tool and cutting grinders are the new introductions from the company. Besides, we are working towards a few new technology innovations. How do you look at the current scenario in the manufacturing industry in India? What are the major challenges in the industry? In general, the market is witnessing many ups and downs.
20
We saw a tough year in 2014. But towards the end of the year, our business picked up, and since then we have seen a good inflow of orders and the turnover has been good too. However, price is a major challenge in our industry. So, we have produced low cost machines with a reasonably good quality. Also, what customers are looking at and how many saw blades do they want to process in a day helps us to recommend machines according to the technology level. Can you elaborate on the demand & technological trends in your sector? How are the latest developments helping in creating new value for customers? In the rotary tool business, there are new technologies coming up like laser machining. Also, in medium to high-tech machines, there are some developments happening. Since price is a major influencing factor, specially in Asian markets, we keep end products in mind and develop our products
accordingly. We are serving customers in different sectors. Vollmer machines are known for quality and ease of operation. The customers have to only change the parameters based on the individual saw blades and start the machine. The machines are pre-loaded with the required software & the programs according to the customer needs, which helps them to work with our machines at ease. Can you brief us on your global as well as Indian market trends in the near future? India is facing a crunch of reasonably skilled manpower today. So, the mindset of customers is also changing. The market is moving from labour-intensive applications to automation and, thereby, trying to minimise labour-dependency & also ensuring consistent quality. Hence, there is a shift in the quality trend as well due to automation, and Vollmer has a wide product range to address this demand from the markets worldwide. ☐
EM | Dec 2015
I m ag e c o u r te s y : Shutterstock
C O V E R S TO R Y | M A N A G E M E N T
ASSET PERFORMANCE MANAGEMENT
Driving maximum value from assets
It is becoming more important than ever for all industrial operations to drive maximum value from all assets, due to increasing financial and competitive pressures. With the technology and know-how available today, organisations can drive profitability from all industrial assets by creating a cooperative and collaborative environment, underpinned by the appropriate measures of performance and enabled by real-time technology. 22
Dr Peter Martin VP, Business Value Consulting Schneider Electric peter.g.martin@schneider-electric.com
EM | Dec 2015
MANAGEMENT
With the rapid rise in industrialisation came a corresponding rise in the complexity of industrial operations. Prior to the industrial revolution, most people involved in the production of goods were generalists. They had skills and abilities that crossed multiple disciplines. But with the rise of highly complex industrial operations, leaders of these companies quickly learned that the best way to manage the complexity was to train specialists in key areas of the operation. No longer was the operator of a piece of equipment responsible for the maintenance of the equipment. Rather, separate maintenance and operations departments were established. The same was true for accounting, engineering, production planning and scheduling, and a number of other disciplines. Even within the field of engineering, multiple specialists areas were established, such as mechanical engineers, chemical engineers, electronic engineers and industrial engineers. Although creating these areas of specialty was initially critically important to getting these complex operations working effectively, it also led to today’s often disjointed industrial organisations. With time, each of these specialised disciplines developed their own vernacular and working practices, and subsequently became islands of specialty within the overall industrial operation. And it became more and more difficult for the specialists in one island to understand and communicate with those in other islands. Perhaps the largest impact of this “island of organisation� phenomenon has been right at the operational levels in a plant. In most industrial plants, the maintenance teams and the operations teams do not cooperate very well. In many plants, they actually seem to conflict with one another as they each try to carry out their responsibilities. Since these two teams work on the same asset base in the operation, this conflict may result in suboptimal operations and reduced profitability. Many industrial operations are feeling financial and competitive pressure as never before, and it is becoming more important than ever to drive maximum value from all assets.
EM | Dec 2015
C O V E R S TO R Y
Root of the conflict The conflict between maintenance and operations teams in industrial operations is not very surprising, once it becomes apparent how the performance of each team is measured. In industrial operations in which operations and maintenance performance are measured, the most common measure for maintenance is asset availability, while the most common measure for operations is asset utilisation. A cursory analysis of these two measures clearly shows that they tend to be inverse functions. That is, when the assets are running in a reasonable manner, increasing asset availability typically requires the reduction of asset utilisation and vice versa. This presents a real conundrum to industrial plants as illustrated in Figure 1. The problem this creates is that the maintenance department and operations department have to be in conflict with each other almost by definition. And the better each team is, the greater the level of conflict. It is difficult to identify an industrial factory or plant today in which the operations and maintenance teams really work cooperatively. This conundrum has become a major barrier to the performance improvement of many industrial operations.
Asset performance measures Before moving to approaches for resolving the conflict, it may be helpful to evaluate asset availability and asset utilisation with respect to their appropriateness for industrial assets. One issue with these two terms is that they are not very well defined. Also, asset availability typically is measured as the percentage of time an asset is available to the operation. This is an extremely limited view. An asset may be available, but in such poor repair that it can only output a small percentage of its designed capability. Although the asset may be available it is certainly not maintained to be in the condition that it should be.
23
C O V E R S TO R Y
MANAGEMENT
Maintained State vs Effective Utilisation
Optical Economic Asset Performance
Perhaps a better measure of performance is the current maintained state of the asset. That is: Maintained State = Actual Full Asset Output / Designed Maximum Asset Output And, perhaps the best measure of operations is a measure called effective utilisation defined as follows: Effective Utilisation = Asset Output / (Maintained State * Designed Maximum Output) Using these two measures would at least provide well defined metrics that relate to operations and maintenance while helping to reveal the true value of an effective plant maintenance program. The problem with these measures is they still do not solve the conflict since these new measures are still inverse functions (Figure 2). It is sometimes helpful to draw analogies from other performance driven operations to identify a solution. In car racing, which is an extremely well defined, performancebased sport, a similar relationship exists between the operations team (drivers) and maintenance team (pit crew). In discussing this with one of the most successful automobile racing organisations in the world, Hendrick Motorsports, the key to success was revealed. Rather than having the primary measures of maintained state or effective utilisation, the primary measure is winning the race. The other two are relegated to secondary measures. By defining a primary measure that both the pit crew and the drivers can effectively strive to meet they have managed to create an incredibly cooperative relationship across their race teams. And the results are phenomenal. Clearly, in industrial operations “winning the race” is not
the primary objective nor is it the primary measure of success. But industrial operations can learn from performance-based sports teams by trying to identify what the common objective is across industrial maintenance and operations teams. If such a common objective and resulting performance measure can be identified, the results in terms of both cooperation and performance improvement may be astounding. The difficulty is in defining the equivalent of the “win” in industrial operations. In other words, what is the overriding objective for both the operations and maintenance that should take precedence over the individual operating and maintenance KPIs? The effective answer to this question may be much simpler than it initially appears to be. The reason for the operations and maintenance teams in industrial organisations is directly tied to the overall objective for the organisation to begin with— to make money. Since real world constraints limit the ability to continually operate any asset at 100% maintained state and 100% effective utilisation, there must be some ideal position at which the performance of the asset is optimal from a financial perspective (Figure 3). If this point can be determined, it may be the equivalent of the “win” for that asset. The recent invention by Invensys of sensor-based, real-time accounting and operational measures provides the basis for effectively measuring the financial asset performance vector. By building a software model of the ideal operation of the asset, the current operational output of the asset at any point in time can be divided by the modeled ideal operational output, to provide an operational asset performance measure that can be trended in any historian.
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EM | Dec 2015
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C O V E R S TO R Y
MANAGEMENT
Asset Modeling Analysis
Asset Performance Management
This can in turn be compared with the financial asset performance trend to provide the critical information required for profit-based asset performance management. Decisions on how long to operate assets between preventive maintenance activities, whether to extend asset operation to meet critical production schedules and when to consider asset upgrade or replacement can be made from both an operational and financial perspective. The asset performance information can be provided to both operational and maintenance teams in simple contextualized dashboards or scorecards to provide guidance and feedback to those employees on how their activities favourably or adversely impact the operation. Since both teams are primarily measured to the same objective, the degree of cooperation and collaboration naturally increases. This new level of collaboration can produce impressive results in the form of increased profitability. Although this real-time perspective is a step forward on traditional asset-centric performance measures in industrial operations, it is limited because it only considers the instantaneous asset performance at any point in time, but does not take into consideration the lifecycle performance degradation as assets are utilised and either soil or wear down. This can be effectively accomplished by evaluating the asset performance from both an operational and financial perspective over time (Figure 4).
first step in the process of optimising the profitability from the assets. Figure 5 shows a simplified view of the traditional improvement progression from operations and maintenance teams. The right side of the model shows the operational progression from basic control, to advanced control, all the way to process optimisation. The success of these programs was typically measured by operational KPIs. Likewise, the left side of the model shows the traditional asset management progression from reactive, through preventive and all the way to predictive maintenance. The key step forward is when these two perspectives join together to provide a combined performance view and when the real-time financial and operational metrics provide the convergence mechanism. With the measures in place, industrial organisations can undertake a continuous profit improvement approach by identifying specific improvement projects and executing them. The key advantage provided by the asset performance system is that each improvement will be clearly measureable from both operational and financial perspective. This enables industrial operations to effectively understand what truly drives value and what doesn’t. With time, organisations learn to focus on those activities and actions that drive the most value. The result is unprecedented improvement in the profitability of the industrial operations.
Asset performance improvement
The technology and know-how is available today to help industrial operations better drive profitability from all industrial assets. Success in this area requires that companies break from traditional perspectives and create a cooperative and collaborative environment, underpinned by the appropriate measures of performance and enabled by realtime technology. �
Once the appropriate performance measures are installed, and the operations, maintenance, engineering, supervision and management teams are empowered with the information required to make better, collaborative and timelier decisions, the performance and profitability of the operation will start to significantly improve. But this should be viewed only as a
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Conclusion
EM | Dec 2015
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MANAGEMENT | INTERVIEW
“Getting smarter for the best IoT infrastructure” …says Gaur Dattatreya, Vice President and Head of Business Unit, Robert Bosch Engineering and Business Solutions, in this interaction with Maria Jerin, while highlighting the company’s endeavour on capitalising technology enablers for smart manufacturing. He also details about the manufacturing ecosystem that is prevailing in India as well as the roadmap for smart manufacturers. Excerpts… What was the outcome of the recent visits of the Indian Prime Minister Narendra Modi and the German Federal Chancellor Angela Merkel to Bosch facilities in Bangalore? Prime Minister Narendra Modi and German Federal Chancellor Angela Merkel took a tour of the facility at Bosch to get a very good view of how successfully and consistently German technology is supporting products in India. We showcased our state-of-the-art automotive products as well as our foray in the healthcare domain with the new India specific product for eye care. We also demonstrated our world class manufacturing capabilities and most importantly - our trainee development program. We emphasised the significant contribution that Indian engineers have made to Bosch’s success story in India, as well as to their current importance for the company’s worldwide activities in many strategic areas such as data mining and smart manufacturing. What is smart manufacturing? Is it the next wave of industrial revolution? How does it link with smart city concept?
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Smart manufacturing means increasing the use of IT in manufacturing areas. It helps the companies get more flexible, increase speed and improve quality. It goes beyond electronic control of machines and integrates digitally, the entire value stream of production – logistics, procurement, material flow, managing inventories and so on. For example, the RFID chip on the part that is being produced, will help identify itself to the machine, which will in turn, know which tools and process to be applied. This takes flexibility to a new level where potentially every part that is being produced on a line could be different. This is definitely relevant in today’s digital and connected era. Over the past few decades, manufacturing has evolved from being labour-intensive (traditional manufacturing) to a sophisticated set of information technology based processes (advanced smart manufacturing). Manufacturers are being propelled to a new age—the next and the fourth industrial revolution. This digital transformation in manufacturing will have huge impacts on both low-cost & high-cost countries and ultimately affect the local & global manufacturing value chain.
EM | Dec 2015
INTERVIEW | MANAGEMENT
“One has to develop a holistic plan for systematic investment in upgradation of material and human resources” Gaur Dattatreya
According to you, what are the technology enablers for smart manufacturing? How Robert Bosch capitalises on such technologies as a strategic asset for growth? Industry 4.0 combined with traditional manufacturing along with IT and the Internet of Things (IoT) are the key enablers for the transformation in the manufacturing sector. Global companies are introducing pilot projects in India on Industry 4.0. Initial results show up to 30% productivity increase, significant cost reduction and reduction of stock. At Bosch in India, we are investing in all of our 14 manufacturing plants to make them smart manufacturing locations in a time bound fashion. Additionally, we are offering services to Indian industry to help them in their transformation towards smart manufacturing. Adaptation to latest IoT technology and upgrading our existing machinery is a continuous process for us striving to achieve the best results in the world. We want to set an example of the best IoT infrastructure in the country and continue to churn out leading quality products. What do you think on the network of suppliers and vendors called as manufacturing ecosystem that is prevailing in India? Is the country ready to leverage smart manufacturing concept? All the technology pieces for smart manufacturing are available. Manufacturing ecosystem has to gear up and get into the digitally integrated environment. Each member of the ecosystem is required to develop their respective roadmap for transformation. The good news is that for integration you require additional joining pieces, you don’t have to throw away your existing lines. How Robert Bosch is keeping up pace on skill development to act as a knowledge provider for next generation manufacturing? Skill development is an important part of the new system. When automation increases, we will require less number of people (but highly trained ones) to operate lines than we require now. At the same time, additional roles will emerge
EM | Dec 2015
that will require different skills. Skill development and retraining is a necessary part of smart manufacturing. It will not mean reduced number of jobs; on the contrary there will be more demand for skilled people. At Bosch, we are devising and deploying programs to train our staff on the new requirements. This is also true for white collar jobs as well as leaders. Your company recently announced ` 650 crore of investment in Indian operations to implement connected production in all 14 manufacturing plants across the country. Is it a part of your strategy to align your plans with “Make in India” initiative by the Govt of India? As a part of the ‘Make in India’ business initiative, the Indian government aims to advance industrialisation and modernise production in the country. Connected manufacturing offers great opportunities to faster react to market requirements, reduce manufacturing downtimes, improve efficiency of supply chains and increase productivity factors, which all can contribute to increase the competitiveness of the Indian industry over the long-term. We are committed to the ‘Make in India’ campaign, hence, our focus is towards producing worldclass products using the best infrastructure, not only for consumption in India, but also for exports. The total investment that Bosch has made in our manufacturing plants spanning over more than 60 years will run in phenomenally large numbers which will surely humble the recent announcement of ` 650 crore. Can you comment on the roadmap for smart manufacturers? Roadmap is required for every manufacturer to transform and become smart manufacturer. Depending on the state of current automation and the desired position, one has to develop a holistic plan for systematic investment in upgradation of material and human resources. If improving flexibility, speed, quality or productivity is on your agenda, start your transformational journey now. ☐
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MEDICAL MACHINING | FOCUS
Challenges in the healthcare industry Healthcare companies are under pressure to provide this higher quality at lower cost and to increase their productivity to meet the growing demand. In order to meet these requirements, it is important to use advanced CAD/CAM software and CNC machines for machining of medical devices. As per a recent market report, India imports nearly 75% of all medical devices. The medical devices market in India, according to a leading analyst company, is over 3 billion US dollars annually, currently. This number will grow higher in the coming years. The reason for such massive imports is largely due to archaic standards, very little or no encouragement for indigenisation and improper application of said devices – to name a few. Adding to this, the comparative availability of trained professionals in the medical device domain – particularly in machining, to that of other engineering or medical fields adds to the challenges faced by the healthcare industry in our country. About 20% of these imported devices are made through direct high-end manufacturing / machining processes. This in itself is close to over 600 million US dollars a year.
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Vineet Seth MD – India & Middle East, Delcam Ltd, UK vseth@delcam.com
Driving factors Companies in the healthcare industry face the same demands from their patients that traditional engineering clients see from their customers for faster delivery of better and cheaper products. Patients want to receive higher quality products and services, and they want to complete their treatment in the shortest-possible time. At the same time, healthcare companies are under pressure to provide this higher quality at lower cost and to increase their productivity to meet the growing demand. These requirements can only be met through the application of more advanced and more automated technology. Multi-tasking machines are being used increasingly in the medical and dental industries, applications include the manufacture of all types of medical and dental
EM | Dec 2015
FOCUS | MEDICAL MACHINING
For specialist bone screws and smaller implants, it is very important to simulate machining beforehand
screw, prosthetics, and components for medical equipment. In order to drive these complex and multi-tasking machines, it is always important to use a CAM software that complements these machines in every way. The primary reason for using advanced CAD/CAM software and CNC machines, is to reduce the overall time and cost for creating the medical component. The benefits of medical machining may offer opportunities for reduced waiting times for the patient, avoiding unnecessary surgery, compress process times, reduce patient trauma, speed up patient recovery time and finally reduce medical costs – both for individuals and insurance companies.
Design & manufacture For example, Delcam’s healthcare solutions help design and manufacture custom-made maxillofacial implants for patients suffering with tumours or major bone loss. Typically, the reconstructive surgery carried out at the time involved a bone graft using a shaped portion of patient’s fibula. Aesthetic outcomes were often poor and the patient had to endure a lengthy period in a leg plaster cast while the fibula healed. Ideally, the surgeons would like to operate well beyond the margins of the tumour and insert the custom-made implant in the same procedure. Therefore, surgeons want implants to
EM | Dec 2015
be ready in time for the surgery and also that these implants are accurate in every aspect. The process used by customer begins when patient data in either a CT or MRI scan is received. This data is converted into STL format to produce prototype models of the skull and the implant. This enables the operation procedure to be practised in advance and ensures that there are no surprises in the operating theatre. The same technology is also used to produce drilling jigs and/or cutting jigs needed by the surgeon. The next decision concerns the manufacturing method for the implant. The more straightforward examples can be machined directly from medical-grade titanium using five-axis machining; but the more complex implants require a combination of additive manufacturing and machining. As far as bone screws and smaller dental implants are concerned, these are manufactured using a special type of machine called a Swiss-lathe. The Swiss-lathe is a multitasking machine that performs multiple operations simultaneously. Typically, the medical parts machined on Swiss-lathe are less than 25 mm in diameter. One can only imagine how critical and complicated it is to sequence the many moving parts and axes of a Swiss-type machine. Using a patented approach called divide-and-conquer, the programmer is able to view the part the same way the multiaxis lathe on which it is being machined sees it. The software
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MEDICAL MACHINING | FOCUS
With a computer-generated simulation of the machining process, the user can see in exacting detail what the part will look like after it’s been programmed, no matter how small it is
does so by breaking down a part into a series of machining tasks for different part faces programmed in ‘Face Windows.’ It lets the user see a multi-axis turn-mill for what it really is, which is to say, not just a mill and a lathe, but really a lathe with up to nine different types of milling capabilities, depending on the capabilities of the machine and the engineering requirements of the part at hand. Thus, this approach lets a user quickly program a part in the exact way his machine will cut the component. For specialist bone screws and smaller implants, it is very important to simulate machining beforehand. Often their critical features are not visible to the naked eye. However, the machines and tooling used to make these parts are huge by comparison. With a computer-generated simulation of the machining process, the user can see in exacting detail what the part will look like after it’s been programmed, no matter how small it is. In addition, with a full simulation of the machine tool itself, the user can see what, if any, machine collisions might occur during the manufacturing of a part.
Education & training Although these technologies are available and can be employed on a full scale, they do require skilled manufacturing engineers to be employed in order to achieve the desired results. For example, machining expertise in an aerospace company – where he worked earlier, helped a Delcam customer in optimising medical machining. Many of the
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materials used in medical machining are aerospace grades of aluminium and titanium that the engineer was familiar with from his earlier career and helped him reduce the machining time by half in a particularly important project. It may not always be possible to invest in skilled manufacturing workforce. There are tools like the Delcam Custom Software Core, which is a library of middleware software that allows one to interface their .NET applications to PowerMILL (CAM) and PowerSHAPE (CAD) software. This allows development professionals to streamline processes in a user-friendly and intuitive way, so that many complex tasks of medical device designs and CNC programming are greatly simplified. The custom solution, for example, can be used to automate the following t CAD process (iterative design) t Toolpath calculation t Post-processing t NC program transfer to the CNC t Computer aided inspection process t Report generation t Archiving and retrieval
3D printing An area of emerging interest is 3D printing, which essentially means that a component is built layer by layer, literally. A subset of additive manufacturing, 3D printing helps
EM | Dec 2015
FOCUS | MEDICAL MACHINING
save material wastage as the raw material is typically in powder form, fused by a variety of techniques – usually depending on the material and the 3D printing machine, to form the 3D part, which is input as a triangulated mesh CAD model. While 3D printing allows for complex shapes to be created that is otherwise not possible with subtractive machining, it is a much slower process and often quite expensive. Having said this, the cost of 3D printers are now coming down and there are also more material that are available for 3D printing. 3D printing is not limited to metal implants and generic medical devices alone. Even in the field of mass customisation, by combining the functionality of different software modules, Delcam has been able to generate and print a series of concept designs which demonstrate some of the possibilities for devices such as custom foot orthotics to be created by 3D printing. The process comprised of creating the orthotic designs where additional product features were added. These
included structural ribs for strength, high resolution 3D relief for aesthetics and textures/aeration holes for potential clinical benefits. Additive manufactured custom orthotic insoles process does not replace the faster and more economical subtractive milling method but it does open some new and interesting doors. For example, by 3D printing an orthotic, the practitioner is able to design the ideal custom insole unhindered by the restrictions of conventional manufacturing. For the immediate and present future, it is best to combine the strengths of additive and subtractive manufacturing – where possible, to derive the best value out of the process. With all of the above developments, manufacturers now have the opportunity to cater to any form of medical device or equipment manufacture without the need to change or switch between different CAD/CAM providers. This in itself will reduce half the complexities. �
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S U P P LY C H A I N M A N A G E M E N T | T E C H N O L O G Y
Lean guiding principles for the supply chain This article talks on Built-in Quality - one of the lean guiding principles, to develop a lean culture in a supply chain operation. With processes designed to make work flow correctly, and tools available to eliminate small problems before they grow large, employees can focus on delivering excellent products and services that increase overall customer satisfaction. In the supply chain arena, a lean culture offers tremendous rewards, but pursuing a lean strategy also requires a significant commitment. Luckily, becoming lean doesn’t mean you have to re-engineer your operation. You can work with a logistics partner to make continuous, incremental gains in quality and efficiency.
Built-in Quality: Get it right the first time High quality in the production and distribution of products improves your bottomline. If employees always know where to find the product they need, goods flow smoothly from one section of the facility to the next. Orders can be filled correctly, completely and on-time, satisfying customer demand. You save
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time because there’s no need to correct mistakes, and you save money because your product is never damaged and retailers don’t experience stock-outs. Your efficiency often allows you to take advantage of lower-cost transportation options. You can’t enjoy these advantages by inspecting for quality after the fact. The way to ensure quality is to perform work correctly the first time. That means building quality into every process.
Mistake-proofing to eliminate rework A company should engineer its supply chain processes with its workers in mind. Any worker should be able to perform processes perfectly to meet the requirements of customers and
EM | Dec 2015
S U P P LY C H A I N M A N A G E M E N T | T E C H N O L O G Y
Using tools like these, employee teams and their manager can stop fighting fires—rushing to correct problems after they occur—and concentrate on fire prevention
other stakeholders, such as regulatory agencies. Once the engineering team designs a process, they conduct a failure mode and effects analysis (FMEA)—a trial run in which someone tries on purpose to “break” the process. By locating weak points where mistakes might occur, the engineers are able to bring the process even closer to perfection. Next, the design team decides which metrics it will use to determine whether the process is meeting its requirements. Then it documents the standards for performing the work. The team describes the process in text and also creates simple howto instructions using photographs to illustrate each step for employees. When a lean business opens a new supply chain facility, it follows the procedures described above to create and document each process that workers in the facility will perform. It then monitors work in the facility for 90 days to make sure that all the processes are working as expected. Once those processes are validated, the facility is certified to be fully operational. Over time, as customers’ needs change and the facility starts to handle different products, the engineering team creates, documents and certifies new processes, always aiming to ensure that anyone can perform the work without error.
In-process controls Along with designing error-proof tasks, a company can implement safeguards that prevent mistakes while work is in process. Some of these in-process controls may be simple visual reminders. Technology also helps. For instance, an employee who is packing a box with ten items might use a scale to check the weight of that box. If each item weighs one pound, the employee cannot accidentally pack the box with eleven items. The ten-pound reading on the scale signals that the packing job is complete. This safeguard ensures that the employee sends only correctly-packed boxes to the next station. Bar code scanning systems help to maintain quality at many points along the supply chain. In a warehouse, pickers working along a row will scan location codes to ensure that they are in the right aisle. When they start picking, they scan the locations where product is stored to confirm that they have arrived at
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the right slots. The scanner display then tells the workers how many boxes to pick. As they carry out their instructions, they scan the labels on each box, and the system confirms that they have chosen the right products. These multiple checks help to ensure that pickers fill their orders correctly. Subsequent scans as boxes are loaded onto pallets or into a trailer further reinforce the quality chain.
Understanding root causes Even the most carefully-crafted processes, and the most reliable in-process controls, won’t eliminate errors completely. When a mistake slips past the safeguards, you need to dig down to get at the root of the problem. The goal is to further mistakeproof the process by ensuring that the error never has a chance to recur. Consider a series of orders that include a certain model of graphics cards for a desktop computer. Before these orders are loaded onto a truck, an audit finds that they all contain the wrong card. As soon as the auditor uncovers the mistake, it’s time to stop work and walk back through the process to discover what went wrong. It’s not enough to replace the wrong cards with the right ones for today’s shipment. The team needs to discover the cause of the error and correct it, so the process is performed perfectly in the future. A tool called the “Five Whys” helps employees step back through the process, discovering, for example, why the pickers picked the wrong card (because the bins were mislabeled) and why the bins were mislabeled (because the database contained an error), and so on. A tool called a fishbone diagram also helps employees analyse the causes of an error by: a) Drawing a central line labeled with the name of the defect (the fish’s spine) b) Drawing the “bones” that radiate from the spine to represent categories of problems that might cause the defect c) Brainstorming about possible causes within each category. Using tools like these, employee teams and their manager can stop fighting fires—rushing to correct problems after they occur—and concentrate on fire prevention.
EM | Dec 2015
S U P P LY C H A I N M A N A G E M E N T | T E C H N O L O G Y
Figure 1: Benefits of Built-In Quality
Lean Guiding Principles for the supply chain principle 2: Built-In Quality
Instant feedback
responsibility for quality control. A lean operation empowers employees to spot problems and fix them. But more than that, it empowers them to investigate why the problems occurred in the first place, in order to eliminate those ultimate causes and make sure the mistakes never happen again. To transform employees into quality experts, it’s essential to eliminate fear from the equation. Employees should feel free to voice concerns, and to stop the flow of work to correct an error. When someone spots a mistake, that should never become an occasion for blame. The goal is not to point fingers, but to set things right so the team can continue to do the best job possible for its customers. Then the team should celebrate the improvement.
In the quest for quality, there’s no room for delay. You can’t wait for a Friday meeting to tell a supply chain team that in filling an order for side view mirrors on Monday, it shipped rear view mirrors instead. Workers will be hard-pressed to recall who picked that order, which aisles they worked, what instructions they received and what exactly they did. Part of a team leader or supervisor’s responsibility is to help employees do their work according to established standards. When one of those leaders finds that a process is not working up to par, it presents an opportunity for coaching. The leader should take the employee aside immediately, explain what isn’t going right and provide instruction on how to do the work better. Leaders should also provide instant feedback when they observe employees performing their work remarkably well.
Get everyone involved In a lean culture, it is every employee’s job to perform work according to the documented standards and to take
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Conclusion A lean culture builds quality into every facet of its operation. With processes designed to make work flow correctly, and tools available to eliminate small problems before they grow large, employees can focus on delivering excellent products and services that increase overall customer satisfaction. ☐ Courtesy: Ryder Supply Chain Solutions
EM | Dec 2015
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G E A R M A N U FA C T U R I N G | T E C H N O L O G Y
Ready for large tasks Where large powers and high torque are required, large gears are the answer: in marine drives, cement & coal mills, wind turbines & hydroelectric power plant. The article talks on large industrial measuring centres for gears adapting to the current market needs. In manufacturing, precise measurements are the cornerstone for complying with very tight tolerances and ensuring the efficiency of the entire operation. Large measuring centres have to be fast and easy to operate in order to determine the current quality of the workpiece and decide on any necessary corrections in the process chain. The inner life of gear trains for wind turbines is especially quality-sensitive. These include cylindrical gears, cylindrical gear shafts, rings with internal gearings and planetary gears. Safe, reliable operation – even in heavy weather conditions – is absolutely essential, as the only way to safeguard a long and economic operating lifetime. The increasing size of parts is leading to ever greater challenges for production quality. Customers or classification
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Dipl-Ing GĂźnter Mikoleizig Product Management Gear Inspection Machinery Klingelnberg GmbH g.mikoleizig@klingelnberg.com
societies need complete documentation, and this can be assured only by regular measurement and testing. The high requirements for process reliability and the associated quality documentation call for robust metrology near to the production line. Manufacturers of large gears consequently need high-precision measuring devices which can be operated as easily as possible. The new ranges of model from Klingelnberg in the P series meet this need. The company now offers continuous measuring technology in the applications sector up to 3,800 mm. This satisfies maximum quality requirements and the standards of the classification societies. The new machine versions combine demanding geometry measuring tasks with high-precision gear measurement.
EM | Dec 2015
G E A R M A N U FA C T U R I N G | T E C H N O L O G Y
Mounting table with support and centering element
Shorter floor-to-floor measuring times Measuring centres for large gears are suitable for measuring workpieces with an outside diameter up to 3,800 mm and a weight up to 20,000 kg. The machines have a rotary table and three linear measuring axes for acquiring measuring data. The new rotary table provides high running accuracy (radial and axial runout < 0.5 Îźm) â&#x20AC;&#x201C; important prerequisites for accurate measurement of size, shape and position deviations during a single work cycle. A high-precision angle measuring system is integrated in the rotary table axis for rotational position acquisition. 3D stylus systems with digital data encoders are used for optimum measured data logging on the tooth flanks. The traversing paths of the linear axis allow inspection of up to 800 mm in the horizontal plane and vertical distances up to 2,000 mm. The rotary table and the linear measuring axes are powered directly by AC motors for greater guiding accuracy. The rotary table and the linear axis measuring attachment are supported on a load-bearing machine bed. Combined with a suitable foundation, this provides a geometrically reliable base for the measuring machine. The machine design enables inspection of various diameters and distances on the same workpiece in one set-up. The gear measuring centres are optionally available with a straight horizontal measuring axis, including a 3D stylus system or a downward angled measuring arm. The horizontal axis is useful in versatile applications for disc-shaped workpieces and shafts and for gear-cutting tools. The angled variant is particularly suited for testing gears in planetary systems used in the wind power sector. Here the task of measurement is to test internal gears with large gear widths and to perform high-precision dimension, dimensional (MFL) measurements in workpiece
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bores. The angled measuring arm can move the 3D stylus head inside the bore close to the measuring point, ensuring high measuring accuracy. Special features are used to facilitate loading prior to a measurement. Shaft-type workpieces can optionally be clamped with a column and tailstock for a fixing range up to 2,500 mm, so that they can be fixed between centres. Discshaped workpieces are placed on the rotary table of the measuring machine. Depending on the size of the workpieces, extra fixtures are available for this purpose. To make an accurate measurement, the position of the workpiece axis is determined in relation to the rotary table axis.
Control feature The control compensates deviations in a range up to 10 mm. This feature greatly simplifies loading of the measuring machine, as the operator no longer has the time consuming task of aligning the heavy workpieces with the rotary table axis. Centering elements together with an mm scale are quite sufficient. As an alternative, the measuring machines can be aligned mechanically via an air bearing integrated in the rotary table. This can be used to align even heavy workpieces exactly. Using the control software, the operator can quickly create a measuring program to define the measurement sequence. He enters the test parameters together with the standards or directives for analysis. The desired and actual form can then be compared reliably using the analysis software. This is important, as large gears with high profile and tooth trace loads need especially large modifications. Measuring times are shortened by programming fixed measurement sequences, and the centre performs the prescribed steps iteratively.
EM | Dec 2015
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G E A R M A N U FA C T U R I N G | T E C H N O L O G Y
Gear measuring centre P 150 W provides accurate and fast measurements of workpieces up to 1,500 mm diameter and a weight of up to 8,000 kilograms
Versatile adaptability In addition to the standard equipment, users can opt for additional features to customise a measuring centre. This enables them to respond specifically to a measuring situation. The resulting centering accuracy in the millimetre range is sufficient to start the measuring run immediately. Additional mounting tables with different diameters are available for large ring-shaped workpieces. These are designed to be changed with a short set-up time and effort. The fixtures used on the rotary table also fit the mounting tables. Centres are preferred for fixing shaft-type workpieces. Tailstocks in different types are available. Detachable columns with a tailstock are used for small workpieces or gear-cutting tools. Fixed columns with tailstock are available for testing extremely long and large shafts, enabling measurements on up to 2,500 mm fixing lengths. The column can be moved using a wireless remote control to adjust the arm for the necessary fixing length or to adapt it for the loading position. An optional automatic stylus changer speeds up the process if a number of different measurements are made in succession. The stylus is then changed automatically during the measuring sequence. Precision is maintained due to the high centering accuracy of the stylus holder plate. If the stylus still needs to be calibrated for certain measurements, this is done outside the centre of the machine. The operator sees the necessary instructions for a manual stylus change on the screen.
Measuring surface roughness The P series machines also have an optional feature for measuring surface roughness on the tooth flanks. The
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procedure is simple to adapt and functions on the skid plate principle. The parameters it provides a single run, together with other measurements, are the centre line average (Ra), the average peak-to-valley height (Rz) and the maximum peak-to-valley height (Rt). The special stylus system is changed either manually or automatically. Appropriate roughness sensing systems are available for the respective module sizes. Precise results can be obtained only if the workpiece temperature at the time of measurement is taken into account. A difference of a few degrees Celsius from the reference temperature (20 °C) will cause results to deviate by two-figure micrometer amounts when determining test parameters for profile tooth traces and for the base tangent length. To avoid such inaccuracies, the new P machines provide an optional workpiece temperature sensor. This has to be placed manually on the workpiece prior to the measuring run. The temperature measurement takes only a few seconds. All subsequent measurements are then related to the reference temperature. The angled measuring arm of the W version is fitted with a monitoring camera. The ultra-compact camera can be fixed flexibly on the measuring arm according to the intended measurement and the required viewing angle. Its primary task is to let the operator view the position of the stylus on the monitor of the control unit when measuring inside gear teeth, and make any necessary corrections. Feedback from the industry is the basis for developing new gear testing machines and measuring concepts. The main focus is on key market requirements for faster processes with simultaneously high quality standards. The modular design enables to customise measuring devices for individual demand in the industry. â&#x2DC;?
EM | Dec 2015
A D V E R T O R I A L | M A N U FAACDTVUERRTI NO RGI AI TL
If productivity matters, choose ESPRIT CAM software
This screw, about 1.5 cm in length, has a tapered core and a triple thread with variable pitch. It was produced for orthopedic surgery
Stainless steel Harpoon® suture anchors produced in ESPRIT
DP Technology has come up with one of the most revolutionary modules which is confined and specially customised for medical industry. This gives a chance to all the medical companies to make use of something which is specialised in their sector and kick-start its implementation from day one. The medical industry now faces challenges met by some of the other industries in past: the need for sophisticated, robust computer-aided-manufacturing (CAM) software for complex machining. ESPRIT CAM software, by DP Technology Corp, is the choice of many medical-industry manufacturers like Stryker, Johnson & Johnson, Smith & Nephew Orthopedics, Orchid Orthopedics, Chetan Meditech, Meril Life & many more that seek to make high-quality, complex parts and cut programming time. Performance enhancement is one of the major concerns in all these companies. Looking at the small sizes of variety of products it is very difficult for CAM software to provide accurate solution, automation options and reduce cycle time & programming time. With ESPRIT CAM software, the company provides training and support for its customers to improve their production line with a variety of automation options available inside the software. Any such complex operations like rechucking, broaching, thread whirling, pinch turning/milling, support axis synchronisation, etc are easily supported inside the software.
Customers’ quotes “The post processor’s accuracy and the training & support has been phenomenal” Chetan Meditech “ESPRIT is one of the few software in the world, which can support any kind of machine with any controller” Orchid Orthopedics
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As a worldwide leader in CAM innovation, it provides powerful solution to CNC programmers in all manufacturing disciplines. This high-performance CAM software is designed for ease of use and is compatible with all types of CNC machine tools. ESPRIT covers the spectrum of medical applications: 2-5 axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking mill-turn machining and B-axis machine tools. Saves time: ESPRIT maximises the capabilities of mill-turn machine tools. The software’s functionality includes mill-turn on C and Y axes and it combines turning, milling and drilling operations in one G-code program. Users can perform accurate 5-axis milling machining, whether simultaneous or indexed, and fully exploit the power and flexibility of machines equipped with a B-axis. Accurate simulation: ESPRIT features solid and dynamic simulation that eliminates the risk of collision. Simulation applies to the whole spectrum of cycles in mill-turn (2-5 axis) machining, as well as turning with multiple spindles and multiple turrets, up to 22 axes. The programmer verifies a listing combined with all milling and turning operations, plus associated cycle periods. Certified post processors: ESPRIT CAM software for sliding head machines generates quality G-code programs for Swiss turning that are highly optimised to minimise cycle times, reduce remnant waste, and preserve tool wear while maximising part quality. It does not provide post processor; it provides machine drives which provides accurate G-codes for any machine with any controller. ☐
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C U T T I N G TO O L S | T E C H N O L O G Y
Taking hole deburring to new depths A read on how the new MEP (mechanised edge profiling) process developed by Seco Tools keeps exit burrs from negatively impacting tool rigidity, machining accuracy and tool life in deep, small-diameter through-holes Burr formation creates challenges for part manufacturers across all industry segments, especially when drilling deep through-holes in critical components. In these applications, burrs of excess material form at both the entrance and exit of the workpiece, with the exit burr posing the most challenge. These burrs can lead to poor part quality and production inconsistencies, which are unacceptable in aerospace and other closely regulated industries. Manufacturers traditionally remove burrs with hand grinders, emery cloth or other manual processes. These methods, however, are slow and require the part to be moved and refixured for the deburring process. Even when performed by skilled personnel, it is impossible to achieve part-to-part consistency in manual deburring operations. Mechanised Edge Profiling (MEP), on the other hand, employs an engineered tool, guided by a machine toolâ&#x20AC;&#x2122;s CAM program,
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Teun van Asten Engineer, Marketing Servicesâ&#x20AC;&#x201D;Solid Milling Seco Tools
to remove burrs quickly and consistently. Hole edges can be finished to high-tolerance specifications on the same machine that drilled the hole initially. Seco Tools has developed a new MEP process that combines innovative tool design with 5-axis toolpaths to enable fast, repeatable deburring of holes deeper than 10 times diameter.
End user demands The aerospace industry specifies dimensions for certain part and hole edge conditions, including chamfer and radii. These features typically undergo approval and certification processes to meet tolerances measured in hundredths of a millimeter as well as ensure consistency from part to part. The deburring process has to achieve a precise balance
EM | Dec 2015
T E C H N O L O G Y | C U T T I N G TO O L S
As hole depth grows, the tool’s lengthto-diameter ratio also increases, making it less resistant to cutting forces and more prone to vibration
between machining away the burr without removing material from the part. Standard deburring and profiling tools used for MEP processing of part edges and other features include solidcarbide chamfering end mills as well as tools that employ indexing inserts with complex cutting geometries. Custom MEP tools have specific radii, chamfers, angles and combinations of those cutting edge features. The most sophisticated deburring tools have edge designs that produce a chamfer with a radiused edge preceded by lead-in and lead-out angles designed to prevent formation of secondary burrs. MEP tools commonly have square cutting edges, but ball nose and lollipop-style tools are available for profiling edges on contoured components that would otherwise restrict access of square-edged tools. Applied on a 5-axis machine, a ball nose tool can scan the line of a complex part profile and create a radius on a long contoured edge. Toolmakers also provide tools custom-engineered to profile edges and remove burrs at the entry or exit of larger through-holes. The custom tools feature complex cutting geometries. When cutting conditions are stable and cuts are smooth and uninterrupted, the tools permit use of more aggressive cutting parameters. Conversely, when features such as access holes interrupt the cutting path, parameters are more conservative to minimise tool wear and failure.
Deep, small-diameter holes The exit ends of deep, small through-holes are challenging to deburr because they require small-diameter tools. As
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hole depth grows, the tool’s length-to-diameter ratio also increases, making it less resistant to cutting forces and more prone to vibration, chipping or breakage. Moderation of the cutting parameters is necessary and deburring may not be fully effective.
Tool & process development Seco has developed an innovative tool concept and combined it with 5-axis toolpath strategies that facilitate effective deburring of the exit area of deep, small-diameter through-holes. The tool features a tapered shank with a large neck diameter where the tool enters the part. The design provides a 0.05-mm clearance between the neck and diameter of the hole. Below the entry of the hole the tool tapers to a smaller diameter and at its end are cutting edges. The CAM toolpaths employ 5-axis motion to tilt and rotate the workpiece so that the centreline of the tool circles around a point and describes a conical form at the hole exit, where the tool’s cutting edges remove the burr. At the same time, the neck of the tool at the hole entry effectively remains stationary and does not interfere with the sides of the hole. A Z-axis movement positions the tool in the hole and then the machine’s 5-axis capability combines X, Y, and Z motion to perform the deburring process.
Application & testing The tools and toolpaths deburring the exit of a 3.2-mm diameter, 36-mm deep through-hole, were initially tested. The length-to-diameter ratio was greater than 10:1. Initial
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C U T T I N G TO O L S | T E C H N O L O G Y
The tools and toolpaths deburring the exit of a 3.2-mm diameter, 36-mm deep through-hole, were initially tested
trial-and-error testing arrived at an optimal rotation rate of 1,200 rpm, a speed that enabled the tool to complete 128 holes without replacement. Deburring each hole required no more than three seconds, compared to manual deburring techniques that could require a full day or more to deburr an equivalent number of holes. Because the CAM program and machine control handled the toolâ&#x20AC;&#x2122;s movement, the deburring results matched exactly from the first hole to the very last.
Programming details To programme tool movement before the MEP process, the machine operator must enter the exact location and definition of the surfaces to be deburred. The tool length must be defined as well. Tools are ground to a tolerance within 0.0375 mm. The front end of the tool is ground in the same operation as the cutting edges, producing a relationship between the tip of the tool and the cutting edge within 0.0125 mm. The tool length is specified in the CAM program; the operator can confirm the tool length off the machine with a presetter or on the machine via a laser or touch probe.
MEP for multitasking? Some MEP tooling combines the machining of a part feature with a deburring operation. Select end mills, for example, locate the MEP machining feature at the top of its cutting zone to machine the hole diameter and then deburr the entry point in the same operation. Analyses of MEP applications have indicated that tools
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engineered to remove burrs at the entry of a through-hole provide longer tool life than those designed for eliminating burrs at the exit end. Tools for deep-hole exit burrs have a higher length-to-diameter ratio, making them more prone to instability and vibration that, in turn, accelerate wear. Therefore, a tool engineered to deburr both the entry and exit of a deep through-hole would exhibit longer life for the entry feature than for the exit feature, resulting in the need to discard the tool with much of its capability unused. Additionally, MEP tools that deburr the entry area of a hole can be reground, but the critical relationship between the cutting edge and tool tip in MEP tools for deep, small-diameter through-hole deburring precludes regrinding. The reason is that applying a reground tool would involve changing the offset in the machining program, something prohibited by the strict protocols of aerospace machining practices.
Conclusion Manufacturers continually respond to customer demands for increasingly tight part tolerances. The aerospace industry leads the trend, but requirements for precision and consistency are becoming stricter in the medical, energy and other industries as well. Deburring, an essential element of precision part production has long been carried out through manual methods. Unfortunately, these operations can be inconsistent from part to part and are expensive in terms of labour, setup and part handling expense. In fact, some end-users have banned manual deburring because it cannot be documented and certified. â&#x2DC;?
EM | Dec 2015
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
Achieving program excellence Integrating virtual and physical testing enables delivery of products on schedule and on budget. A read on how aerospace & defense firms achieve program excellence with Siemens integrated verification management system The complexity of aerospace and defense (A&D) products and the number of requirements that they must meet to gain customer or regulatory acceptance continue to grow. As a â&#x20AC;&#x153;system of systemsâ&#x20AC;? comprised of software, hardware and electronics, A&D products involve lengthy, multi-disciplinary development programs and interrelated verification activities to gain customer or regulatory agency approval. Whether itâ&#x20AC;&#x2122;s a commercial airliner, weapons platform or a spacecraft, failure is not an option. A&D companies compete in a global market place and execute programs with multiple global partners and suppliers. To be successful in this environment, A&D companies must demonstrate their ability to consistently execute programs across the extended organisation, delivering products that meet requirements on-schedule and on-budget. Integrating
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virtual and physical testing enables delivery of products on schedule and on budget. The benefits include: t Reduces program risks to schedule, budget & deliverables t Improves program performance with a single verification management system t Increases traceability of requirements from program through design, analysis, and test t Reduces verification costs with improved planning and execution t Enables proactive management of requirement compliance with real-time reporting t Accelerates program audits with accurate, up-to-date, documented deliverables and activities The Siemens PLM Software Verification Management solution enables companies to achieve this goal by connecting
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
requirements to all tasks, analyses, tests and data involved in the verification process, providing complete visibility and traceability across planning, design, analysis, test and final conformance reporting.
Providing full lifecycle traceability Programs must meet requirements that are set by their customers, contained in their contracts, and meet company product standards for design and safety, as well as industry requirements from regulatory authorities such as the Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA). Teamcenter software from Siemens PLM Software enables all program activities to be driven by these requirements, from initial program goals to the individual components that will make up the final product. With Teamcenter, full product lifecycle traceability makes it possible to ensure that all requirements have an approved verification method, that the method is executed, and that appropriate results are recorded to support achievement of the requirements.
Synchronising analysis from design through test As a full product lifecycle solution, Teamcenter can be used to communicate requirements to all disciplines in the product development process as well as changes to those requirements. This single collaborative source permits design, analysis, and test organisations to work in unison to ensure that analysis and simulation models are synchronised with design models for both production and test articles, and that physical test articles conform to requirements across disciplines. By synchronising these models, simulations representing the production design - as well as all the modifications made to the test article - remain valid for
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proving requirements are met. Teamcenter also provides integration of analysis-to-analysis (an often-overlooked failure point) by managing the process to take the outputs from one analysis and them as inputs to the next analysis, as well as all the other artifacts required to conduct the next analysis; other boundary conditions or inputs, models, etc. Only in this way are design analyses and tests truly integrated and connected.
Tracing the test to the physical test article Physical tests are a necessity for aerospace and defense products, and itâ&#x20AC;&#x2122;s imperative that tests prove that requirements are met. Proving a test valid requires that a sequence be followed from requirements to be verified to test plans that define the verification approach and that test articles and equipment are configured properly. Teamcenter establishes the path from requirements to test plans to test article to confirm that a test is required, properly planned, and accurately executed. If changes in requirements or the product design occur, Teamcenter can be used to immediately provide full visibility of their impact on plans, test articles, and tests including those already run that need to be re-executed. Teamcenter also maintains the complete history of all test articles and equipment, enabling full traceability to the past test article or analytical model configurations. In addition, Teamcenter provides complete instrumentation traceability: from measurement requirements defined by engineering in the test request; to the instrumentation plan; to the physical instrument installed on the test article and its calibration data through to the raw data and the reduced engineering unit data used for reporting compliance. Full traceability enables the ability to demonstrate that the test article matches the current engineering definition as well as the original production design at every stage.
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M A N U FA C T U R I N G I T | T E C H N O L O G Y
Physical tests are a necessity for aerospace and defense products, and it’s imperative that tests prove that requirements are met
Integrating verification management system
Conclusion
Moving from planning what to do to actually doing it requires task definitions, scheduling, and management. Teamcenter provides this functionality for all verification activities to link engineering, manufacturing, procurement, and test to support long lead planning, resource utilisation and execution of the verification activities. Verification requirements are linked to supporting documentation for virtual and physical test configurations, test plans, test procedures and test results to enable complete status reporting of the process. This holistic approach ensures efficient usage of resources and provides visibility into the process to ensure that deadlines are met. Requirements can be linked to activities on the verification management schedule as well as to a Work Breakdown Structure for correlation to financial reporting systems; integrating cost, schedule, and technical requirements in a single system. Additionally, the verification management solution includes a catalyst. This fast track implementation provides best practice models and preconfigured elements for activities such as defining data objects and roles that can be used in automated workflows. The open and configurable software allows you to control the appearance and behaviour of the Siemens PLM implementation, whether it is for a comprehensive PLM environment or a standalone verification environment. Deployment accelerators include recommended product selections, network design decisions, configuration procedures, deployment best practices and user training. The verification management catalyst enables you to accelerate the digital transformation of your enterprise. This allows you to improve productivity and achieve greater availability and reliability while reducing the total ownership cost.
The Verification Management solution in Teamcenter empowers A&D companies to successfully execute their programs on-schedule and on-budget by providing visibility and closed-loop requirement traceability into all activities of the verification process to confirm requirement compliance. With efficient planning, simulation, analysis and test execution in an integrated environment enabling confirmation of requirements achievement, Teamcenter supports program audits and reduces the time and cost of verification that ultimately improves program performance. A simple idea inspired this product. Thousands of decisions made it real. Making a great product takes more than inspiration. It takes thousands of decisions for a good idea to become real. Not just the big milestone decisions, but all the small decisions that lead up to them. The fact is anyone can make the decision that makes the difference in your product’s success. For leading companies throughout the world, Siemens PLM Software is an essential environment for immersive product decision-making. The solutions give everyone involved in making your products “high-definition PLM.” HD-PLM ensures that people get the information they need, when they need it—with absolute clarity—to make more informed decisions faster. No matter what industry you’re in—automotive or aerospace, electronics or energy, marine or medical, machinery and more—PLM software helps you make the smart decisions that go into making great products. ☐
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Courtesy: Siemens PLM Software
EM | Dec 2015
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EVENT | REPORT
Strengthening Indo-German relations With a participation of around 140 members, The 4th VDMA Mechanical Engineering Summit was recently held at New Delhi. The summit witnessed co-operation from German companies towards ‘Make in India’ campaign, and bestowed their support towards India’s future growth. A post-event report… With the recent visit of the German Chancellor Angela Merkel, both Germany and India have stepped up their bilateral cooperation and agreed upon 18 MOU’s. Today, the world is looking at India as the final destination for investments and growth and Hon’ble Prime Minister has set clear goals and reforms to help achieve them. The objective of these engagements are to support and augment the ‘Make in India’ programme through increasing the innovation and technology prowess of the Indian industry.
Highlights The summit started with a welcome note from Rajesh Nath, Managing Director, VDMA India, where he mentioned that the Prime Ministers clarion call to ‘Make in India’ holds enormous promise to transform the Indian economy. “Complemented by initiatives such as “Skill India”, Digital
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India, Schwach Bharat and Sagar Mala, a foundation is being laid for a multiplier impact on inclusive development. This has emphasised on the 4 Ds - demographic dividend, democracy, demand and the recently added 4th D - deregulation. This effort shows to be bearing fruit as India saw the highest foreign direct investment inflow for new projects among all nations in the first half of 2015, beating America and China.” He further adds that in January-June 2015, India attracted $31 billion (` 2.05 lakh crore) in capital expenditure (capex) from foreign companies, China, the largest economy in Asia, attracted $28 bn and the US got $27 bn in the period. Dr Corinna Fricke, Head Economic Section, Federal Republic of Germany in New Delhi reiterated the strengthening bonds between India and Germany and the increased bilateral trade between the 2 countries which crossed 17 Billion Euros in 2012. Dr. “There is immense potential for growth in the country but feels that it has been
EM | Dec 2015
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EVENT | REPORT
Rajesh Nath, MD,VDMA India; Arun Maira, Former Member, Planning Commission; Dr Rajan Katoch, Secretary, Department of Heavy Industry, GOI; Dr Corinna Fricke, Head Economic Section, Federal Republic of Germany in New Delhi; Ulrich Ackermann, MD, Foreign Trade Division within VDMA Frankfurt during the summit
at a growing slowly but steadily specially in the last few implementation of GST, Digital India and third party months,” she said. certification issues. This was followed by an address by Dr Rajan Katoch, The second leg of the technical session began with Secretary, Department of Heavy Industry, GOI. He “Prospects for Indo-German collaboration in high technology enlightened the audience on “Manufacturing in India – Road manufacturing” by Hermann Muehleck, Head—German to Progress”, where he explained the slew of measures taken Business Centre, India, Ernst & Young GmbH. The objective by his department as part of the ‘Make in India’ programme of the study was to identify high-technology sectors that are to increase country’s share of manufacturing in GDP to 25% most suitable for Indo-German collaboration. by 2020 from present 15%.” The session continued with “Application of Industry 4.0 in manufacturing” presented by Volker Schmid, Head—Asia Pacific, Festo Didactic SE. The concept was to inform & Showcasing Indian relations prepare for manufacturing of tomorrow, which is presently Ulrich Ackermann, Managing Director, Foreign Trade led by primarily Europe and other developed countries. Division within VDMA Frankfurt shared insights of the “Gaining importance in high-tech manufacturing, process German engineering industry, which attained a turnover in automation and end-to-end digitisation of business will 2014 of 212 bn Euro, out of which the export share stood at become a key driver for enhancing production and cost 77% with Asia contributing to 27% of this export share. “India efficiencies. The Indian IT sector holds strong know-how on is the 5th most important country for German Machinery software development and on digitisation of business exports, while the top three include USA followed by Italy and processes from which collaboration partners can benefit,” he Mexico. While India on the other hand, imported machinery explained. from China followed by Germany and Japan,” he said. The technical session ended with the insights on “Make in The keynote address on “Overview of the Indian Economy” India Mittelstand” by Satish Sharma, Deputy Secretary (EW), was presented by Arun Maira, Former Member, Planning Ministry of External Affairs. It is a first of its kind business Commission. This was followed by a presentation on “Goods support programme designed to offer services in coordination and Services Tax- Impact on Manufacturing Industry” by with the Indian Government and other entities. It starts with Sandeep Gupta, Partner, ASA & Associates LLP, spoke on the company selection and on-boarding; in the second stage “Goods and Services Tax- Impact on Manufacturing Industry”, market entry support will be facilitated. Also, a panel discussion where he presented various tax models implemented in was held on “Make in India—a slogan or reality” moderated by developed countries and reiterated that Dual GST is to replace Nath. The panelists highlighted the German dual system of different indirect taxes on goods and services by the central & education, which provides theoretical & practical knowledge state governments. to students. The students here are given an opportunity to not Next, Ajay Shankar, Chairman & Expert Committee, just learn, but also work in the industry, thereby, creating Regulatory Approval, organised a session on “Ease of doing technically skilled workforce from the onset.☐ business – approach from Indian government”, where he Courtesy: VDMA touched upon various issues like creating regulatory layovers,
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EM | Dec 2015
I m a g e c o u r t e s y : Siemens PLM Software
EVENT | REPORT
Designing without boundaries… Siemens PLM Software’s recently concluded Solid Edge University 2015 at Cincinnati, Ohio, USA, with the introduction of ST8 that delivers powerful modeling with unparalleled mobile flexibility & real-time access to vibrant global user community. The two-day event witnessed several general and breakout sessions, which helped users improve productivity, expand skills and experience the smart operation platform. A post-event report… There was a time when constraints of traditional 3D modeling were difficult to address to. However, things have changed now and with the latest version of Solid Edge—ST8, one can leave behind these complexities. ST8 has more flexibility built in its system, and, as such, is more effective. So much so, that people can come across their mother system and be able to be productive right away. It is also synchronous
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Megha Roy Features Writer megha.roy@publish-industry.net
& innovative, and helps to bring products faster in the market at a lesser cost.
Highlights Day 1 of the event started with a welcome note by John Miller, Senior Vice President & General Manager, Mainstream
EM | Dec 2015
REPORT | EVENT
Engineering, Siemens PLM Software. â&#x20AC;&#x153;Solid Edge provides companies of all sizes apt solutions for business needs. We are working towards widening the gap of people who insist on working only on the history-based system. With synchronous technology, there are a host of smart operations that can be performed in areas like sheet metal and stamping. It is powerful and saves times,â&#x20AC;? he explained. It was followed by a sessionâ&#x20AC;&#x201D;â&#x20AC;&#x153;Traversing New Terrain: Extending the boundaries of advanced roboticsâ&#x20AC;? by Philip Norman, Technical Lead, Ross Robotics, where he emphasised that Solid Edge is 3-dimensional.â&#x20AC;? Speaking on the platform, he opined, â&#x20AC;&#x153;It was easy to build & model components and analyse its behaviour & interactions with Solid Edge. However, my challenge was to get different identical parts to connect in the 3-dimensional space and analyse those interactions so that I could test my ideas rapidly. Today, I directly start working on the Solid Edge platform. Modeling things has become easy for me.â&#x20AC;? Norman has been using Soild Edge since 2003. The highlight of the day was the ST8 demo by Dan Staples, Vice President, Solid Edge Development & Craig Ruchti, Applications Engineer, Siemens PLM Software, where insights of ST8 was displayed. They pointed out that ST8 has enhanced pattern recognition for any collection of faces. â&#x20AC;&#x153;It can be run multiple times on the same part and extend reuse and editability of imported parts. It can also create pattern by table, by creating pattern using a table/spreadsheet, making pattern in irregular ways, not just rectangular or circular and linking patterns together for design automation. Besides, it can perform enhanced welding, enriched digital mockup and enhanced drawings,â&#x20AC;?showcased Ruchti. Day 2 witnessed 14 breakout sessions attended by people across industries. â&#x20AC;&#x153;Introducing Solid Edge into academic institutionsâ&#x20AC;? by Mike Brown, Academic Relations, Mainstream Engineering Software was one of them. Besides, presentations like â&#x20AC;&#x153;Design Automation Saves Time and Moneyâ&#x20AC;? was put up by Harry Irwin, Project Engineer, Schaferâ&#x20AC;&#x2122;s Electric Enclosures and â&#x20AC;&#x153;Design Without Boundaries in a multi-CAD World,â&#x20AC;? by Kevin Grayson, Technical Sales Consultant, Siemens PLM Software.
Accelerated modeling process In the latest release of Solid Edge, improvements to synchronous design intent management, complex sketching
EM | Dec 2015
Unfolding ST8: powerful, accessible and user-friendly Uniquely powerful t Intuitive design powered by synchronous technology: 4ZODISPOPVT NPEFMJOH JT FWFO NPSF JOUVJUJWF XJUI B TUSFBNMJOFE JOUFSGBDF UIBU EJTQMBZT POMZ SFMFWBOU JOUFOU t Flexible patterning: &YUFOEJOH UIF SFDPHOJUJPO PG IPMF QBUUFSOT XJUIJO JNQPSUFE HFPNFUSZ 4PMJE &EHF OPX SFDPHOJTFT SFHVMBS SFQFUJUJPO PG BOZ HFPNFUSZ BT B DJSDVMBS SFDUBOHVMBS PS FWFO VTFSEFGJOFE QBUUFSO t Design-in-context: %FTJHO PG DPNQMFY BTTFNCMJFT JT TJNQMJGJFE CZ UIF BCJMJUZ UP MPDBUF HFPNFUSZ GSPN VQQFSMFWFM DPNQPOFOUT XIJMF FEJUJOH JO QMBDF QBSUT PS TVCBTTFNCMJFT t Realistic drive system modeling: "DDVSBUF NPSF SFBMJTUJD TJNVMBUJPO PG DIBJO ESJWF BOE USBDL NPUJPO JT BDIJFWFE WJB B DVSWF t PMI-powered wire harness routing: 5FSNJOBM BOE DPOOFDUPS EFTJHOBUJPOT BOE QJO OBNFT BSF EFGJOFE BT QFSTJTUFOU QSPEVDU BOE NBOVGBDUVSJOH JOGPSNBUJPO 1.* MJOLJOH FMFDUSPOJD DPNQVUFS BJEFE EFTJHO &$"% JOUFMMJHFODF XJUI QIZTJDBM HFPNFUSZ XIJMF SPVUJOH BOE QSPWJEJOH B TJHOJGJDBOU XJSF SPVUJOH QSPEVDUJWJUZ HBJO t Speedy and intuitive routing: 8JSF SPVUJOH XPSLGMPX FOIBODFNFOUT QFSNJU QBUIT UP CF TQMJU BU B TQMJDF QPJOU BOE JOGPSNBUJPO DBO CF BUUSJCVUFE UP UIF XJSFT GMPXJOH GSPN UIBU QPJOU t Efficient revision comparison: &BTJMZ JEFOUJGZ EJGGFSFODFT CFUXFFO ESBXJOH SFWJTJPOT DSFBUFE JO 4PMJE &EHF DVUUJOH UIF UJNF CFUXFFO EFWFMPQNFOU BOE NBOVGBDUVSJOH t Automate common tasks: /FX DBQBCJMJUJFT TQFFE UIF DSFBUJPO PG &$3T &$0T BOE SFMFBTF UP NBOVGBDUVSJOH XPSLGMPXT
Accessibility unleashed t Solid Edge on Microsoft Surface Pro 3: 3VO GVMM 4PMJE &EHF EFTJHO TFTTJPOT PO UIJT MJHIUXFJHIU IJHIMZ QPSUBCMF QMBUGPSN 5IF 4PMJE &EHF VTFS JOUFSGBDF IBT CFFO PQUJNJ[FE UP VTF GJOHFS HFTUVSFT PO UIF UPVDI TDSFFO GPS WJFX NBOJQVMBUJPO BOE UIF 4VSGBDF 1FO GPS NPSF BDDVSBUF JOQVU GPS TLFUDIJOH BOE HFPNFUSZ TFMFDUJPO PQFSBUJPOT GPS BO JOUVJUJWF IJHIMZ QSPEVDUJWF VTFS FYQFSJFODF t Design collaboration on the go: 4VQQMFNFOUJOH FYJTUJOH PGGFSJOHT GPS J04 BOE "OESPJE UIF GSFF 4PMJE &EHF 7JFXFS BQQ PO 8JOEPXT FYUFOET TUBUF PG UIF BSU % EFTJHO DPMMBCPSBUJPO UP .JDSPTPGU T 4VSGBDF 1SP UBCMFUT t Easier access to best-in-class design technology: 6TF QSPGFTTJPOBM % $"% PO GMFYJCMF TIPSU UFSN DPNNJUNFOUT 4PMJE &EHF JT BWBJMBCMF WJB BGGPSEBCMF NPOUIMZ TVCTDSJQUJPOT BDSPTT UIF HMPCF
Amazing user experience t An unparalleled learning experience: 5IF 4PMJE &EHF -FBSOJOH 1PSUBM QSPWJEFT B DPNQSFIFOTJWF DPMMFDUJPO PG SFTPVSDFT EFUFSNJOFE UP RVJDLMZ BEWBODF ZPVS LOPXMFEHF t Work local, while reaching the world: 6TFST OPX IBWF UIF PQQPSUVOJUZ UP TIBSF XJUI PUIFS HMPCBM VTFST BT XFMM BT 4PMJE &EHF QFSTPOOFM WJB SFBM UJNF BDDFTT UP UIF EZOBNJD 4PMJE &EHF $PNNVOJUZ BOE 'BDFCPPL GPSVNT GSPN XJUIJO 4PMJE &EHF
and 3D feature recognition enable users to focus on designs, rather than design tools, resulting in an accelerated modeling process. Flexible modeling incorporating synchronous technology frees the user to intuitively produce realistic and accurate designs faster, thus, reducing time-to-market. Highlighting this, John Fox, Vice Presidentâ&#x20AC;&#x201D;Marketing for Mainstream Engineering Software, Siemens PLM Software, explained, â&#x20AC;&#x153;This combines parametric & direct modeling. So, it has more flexibility & precision and is more accessible to users.â&#x20AC;? Adding further, Say Tiam Go, Vice Presidentâ&#x20AC;&#x201D;Mid Market Portfolio, Siemens PLM Software, averred, â&#x20AC;&#x153;Larger organisations like Philips Medicals look for solution, where there is only one platform to design. They check how easy is it to migrate the data across. For them, ST8 provides a standard CAD platform. It is also beneficial for customers with multiple CADs.â&#x20AC;?
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EVENT | REPORT
The full version of Solid Edge ST8 can be installed on tablets running Microsoft’s Windows® 8.1 operating system, giving users more freedom to design anytime, anywhere. Speaking on the product development strategies, Staples shared, “We have a product planning & development team of around 15 people, which includes mechanical engineers, psychologists and graphic artists. They take care of the product development from the core. These strategies are based on themes like taking synchronous to new level, encouraging drafting, especially for sheet metals & creating a comfortable platform for people coming from other systems like SolidWorks.”
Simplifying 3D modeling Simplification of large and complex assembly capabilities in Solid Edge ST8, combined with its ability to accurately simulate and predict kinematic conditions, greatly accelerates the assembly design process and significantly reduces the need for physical prototypes. Also, it offers multi-CAD designs that design faster and intelligently without the constraints of traditional 3D modeling. As per Fox, “ST8 enhances speed. It helps design from concept to market. Today, it is important to have global supply chains, where one needs to work with more suppliers. One can import disparate types of CAD technologies with synchronous technology. It’s good in interpreting files & reading them, not as dumb solids, but as actual models that you can manipulate with.”
A way forward… Discussing the vision of Solid Edge for next decade, Staples highlighted that as the industry changes rapidly, we have to be flexible to change with it. “There are many developments happening in areas of cloud and Additive Manufacturing today. For defining our vision, we start from the core basis, i.e. being in sync with mechanical engineers and designers. Synchronous technology came to the picture only when we were done with CAD. However, drawings are still important. Also, sheet metal will get deeper with time. We will respond to Additive Manufacturing and cloud in a customer-oriented way. CAD is ultimately about the productivity at engineer’s desktop,” he concluded. While wrapping up the two-day event, a sneek peek on ST9 was presented, which displayed that the next version will have customisation & preference management and support for high resolution monitors in which Solid Edge UI will
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“We have design centres in Pune, which are responsible for our products. There is a vast growth in manufacturing & designing capabilities in India” John Miller, Senior Vice President, Mainstream Engineering Software, Siemens PLM Software “Our product development strategies are based on themes like how to take synchronous to new level, encouraging drafting, especially for sheet metals & creating a comfortable platform for people coming from other systems like SolidWorks” Dan Staples, Director, Solid Edge Product Development, Siemens PLM Software “One can import disparate types of CAD files with synchronous technology. It’s good in interpreting files and reading them, not as dumb solids, but as actual models that you can manipulate with” John Fox, Vice President—Marketing for Mainstream Engineering Software, Siemens PLM Software “The Indian market has a large workforce population. So, the professionals can learn the technologies much faster. Platforms like ST8 will not only enhance their learning process, but will make things smarter for the Indian market” Say Tiam Go, Vice President—Mid Market Portfolio, Siemens PLM Software “With Solid Edge, it is easy to build & model components and analyse its behaviour and interactions. Today, I directly start working on the Solid Edge platform. Modeling things has become easy,” Philip Norman, CEO, Ross Robotics
scale naturally with display resolution & have an easy access to Solid Edge UI. For part modeling, it will modify multiple bodies using a single feature and have solid sweep, which can sweep a solid along a path to generate cutouts or protrusions. In addition, for sheet metal modeling, a sheet metal clash in flat will be available to warn when plates clash in flat pattern. There will also be a Teamcenter tab on CommandRibbon to provide direct & easy access to commands and enhance learning experience of users.
EM | Dec 2015
REPORT | EVENT
Revamping robotic dynamics
Using Solid Edge from Siemens PLM Software has paved the way for many start-ups across the globe. The case study discusses how Ross Robotics has re-invented the way specialised service robots are designed, developed and used. Powered by new technology, robots are becoming cheaper, smarter and more autonomous. As a result, more robots are being deployed beyond the automotive factory floor, in diverse market segments like defense, agriculture and logistics. These so-called service robots, often used to tackle dull, dirty, or dangerous jobs, comprise one of the fastest growing segments of the robotics industry. The International Federation of Robotics reports that technology-driven start-ups are stepping up to meet the growing demand, representing 15% of the companies in this segment.
Configuring robots faster Philip Norman, CEO, Ross Robotics, has developed what he calls the world’s first and only modular robotic system – a platform that enables companies to configure application specific robots faster and more efficiently than traditional approaches. Ross Robotics’ platform includes numerous patented design elements. One is a coaxial physical/power/ data connector – just plug and twist to connect both power and data stream. Another involves bio-mimetic traction devices that enable robots to scramble through dense brambles, up and down stairs and even swim. Philip sees potential for their application in relief work, in the oil & gas industry or in security, among other sectors. One of Philip’s robots, heavily modified, is operating at the largest particle physics laboratory in the world for the European Organisation for Nuclear Research, known as CERN. “The
EM | Dec 2015
Large Hadron Collider, just outside Geneva has a very large amount of sophisticated equipment that needs to be monitored & maintained by robots, rather than people. Our robot system is largely non-metallic & non-magnetic as it is built using a hybrid plastic, non-magnetic metallisation process and can operate in extremely harsh conditions in the Collider,” explains Philip. Speaking further on his robots, he says, “One of our robots has performed remote monitoring in the CMS experiment – this is the experiment that captured the Higgs Boson equipped with cameras, LiDAR scanners and a number of other specialised sensors. The robot is now autonomous and can, therefore, operate without requiring a human controller.”
Towards advanced technology In the early days of his business, Philip designed with pen and paper, but, now, is a daily user of Siemens Solid Edge software. He understands the critical role that affordable engineering software has played in the success of his venture helping him design products as well as communicate complex ideas to customers. “We use Solid Edge as a rapid development tool to design the visuals and produce the real devices we deliver to customers,” he shares. He also recognises the unique advantages provided by Solid Edge’s synchronous technology, which he describes as “a curious combination of extreme accuracy and extreme fluidity.” ☐ Courtesy: Siemens PLM Software
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FA C TO R Y TO U R | R E P O R T
Building strong export market Taiwan has grown rapidly over the decades by focusing on exportled, higher-end electronics and tech industries. Mechanical industry, the country’s third largest industry segment accounts for more than 80% in the export market. EM was recently invited by TAITRA to have a visit on the Taiwan machine tool industrial facilities to witness the core competence of the industry. A factory tour report… What is impressive about Taiwan is despite being small (with a population of 23.4 million) and the extent of its diplomatic isolation, the country has managed to build a strong economy on the back of technology and innovation. It has one of the most evolved scientific and technological infrastructures in the world. Taiwan today is the global hub of the semiconductor and electronics industry. According to the Taiwan government’s plans and forecasts, the mechanical
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Maria Jerin Features Writer maria.jerin@publish-industry.net
industry has been identified as Taiwan’s 3rd largest industry after semiconductors and optoelectronics. The country is now the world’s fourth largest exporter of machine tools and it is expected to be ranked third in the coming years. Most of the machine tools rolled out in local factories are exported to one of the 138 markets overseas. To witness the success factors of this machine tool industry, Taiwan External Trade Development Council (TAITRA)
EM | Dec 2015
R E P O R T | FA C TO R Y TO U R
recently organised a week-long factory tour to explore the country’s world-class industry cluster, very well linked supply chain, the industry’s stable quality, fast lead time and reasonable price. The visit included eight companies, who are specialised in different product categories: SHIEH YIH Machinery (SEYI), producers of mechanical presses; Taiwan Asahi Diamond Industrial, manufacturing diamond tools; Kao Fong Machinery (KAFO), specialising in manufacturing various ranges of machining centres, gun drilling machine, moving column type; Goodway Machine Corp, specialising in manufacturing various ranges of turning centres; Manford Machinery, specialising in manufacturing wide range of machining centres, CNC lathes, tapping centre; Accutex Technologies, producing cutting edge techniques in CNC wire cut EDM; Quaser Machine Tools that include various ranges of machining centres, five-axes machining, ATC tool management system, FMC series; KAO MING Machinery, specialising in a wide range of machining centres and radial drills.
Exploring machininig dynamics The ability of Taiwan machine tools to compete with other countries without the support of a strong car industry or huge domestic demand depends entirely on Taiwan’s flexibility and adaptability. Taiwan’s machine tool industry supply chain, from R&D design to component manufacturing, assembly, testing and marketing, forms a complete system, thus, giving the industry an advantage. The shop floors are clean and well maintained with skilled technicians and contract labourers. Most of the critical machining components are machined by Japanese machines. “The mother machines are mainly from Japan that includes Mitsubishi, Mazak, etc,” said Jason Yu, Senior Sales, Operation Director, KAFO. The core components of the machine such as spindle, machine bed and bearings are assembled with high level of precision and accuracy. Pointing out this, Rock Liao, President, Quaser Machine Tools, said, “All core components are precisely assembled in a constant temperature controlled room, which possesses higher assembly quality and technology integration of machines than general competitors in the market.” During the whole assembly, every contacting
EM | Dec 2015
surface is precision hand scraped to increase the flatness and improve geometric accuracy. “The factory floor is incorporated with skilled engineers for scrapping to make accuracy in the component. The hand-scraping process is labour-intensive and must be performed by skilled craftsman who are trained in the technique,” noted Irene Mao, Sales Dept, Section Manager, KAO MING Machinery Industrial. Further highlighting the challenges on this, Raoul Su, Sales Manager, Manford Machinery, noted that too much effort is needed to draw skilled people into their industry as the manufacturing industry is losing its charm.
Enabling business competence Apart from the shopfloor factors, the companies have different product strategies that enable them to have business advantage. For example, SEYI’s product strategy includes servo technology, total solution application (Turnkey) and application of Industry 4.0. Goodway Machine has the business advantage of self-owned key component manufacturing. Talking on her company’s core technology; Rebecca Hsieh, Vice President, Sales Dept, Goodway Machine Corp, said, “Our product focus includes multi-tasking and turn-key solution for Japanese auto-parts industries. We have produced first live tooling turret in the country. We are also developing our own intelligent control system, G.LINC.” In similar way, Accutex Technologies develops its own controller for its wire cut EDM machines. Highlighting his company’s vision of to be 3rd largest wire cut EDM supplier in the world, Ray Liang, Vice President & CEO, Accutex Technologies, said, “Our quality strategy is in ICT technology, circuit test and PCBA inspection technology. We have also developed our own application, Accutex Remote Monitor, for Industry 4.0. We are spending 9.6% of our revenue in R&D, which is much higher than the average global standard.” He also averred that their competence is in research and not in sales. Adding his company’s role on R&D, Liao of Quaser said, “We have invested in advanced research & development tools such as new generation of CAD software and finite element analysis simulation software for machine design. Our cooperation with international research partners in the
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FA C TO R Y TO U R | R E P O R T
Kao Ming Machinery professional is explaining about the employee skills matrix
development of advanced motion control, high speed spindle competence factor is in Europe with around 30% market technology and thermal & vibration damping properties share. Manford Machinery has sold over 100 machines to the enables it to create innovative high speed & high performance USA government. machine designs.” The company’s strategy is in incorporating On a highly focused note, Quaser exports 60% of products automation and producing mill-turn combination machines. to the European market. Speaking on the quality factor, Liao It also offers cell automation system for skill engineer said, “Our competency with the German standard is because shortage. In general, the Taiwan machine tool industry is of our machine design and its assembly processes to extend producing matured five axis machining technology with high the life-time of spindle. We have our sales & service subsidiary level and more flexibility. Explaining further, Irene Mao in Switzerland to cater to Western Europe market. Our added, “Taiwan’s greatest novelties are improving the location competitors are mainly from Japan, Europe and North of change head for 5 face machines. It can increase X travel as America.” KAO MING Machinery Industrial’s main market is well as the change speed for head.” in USA, Germany and China with 30% market share each.
Market share – region
Market share – user industry
Interestingly, despite the political conflict, Taiwan companies are one of the largest investors in Mainland China. Many Taiwan companies have their subsidiaries in China to meet the huge local market. As for Mainland China and emerging countries in south-east Asia, central & South America, Taiwan’s exports mostly consist of machining centres & metal forming tools. Taiwan Ashai Diamond Industrial’s main market is Asian countries with 63% market share. SEYI has established XIE YI TECH MACHINERY (CHINA) subsidiary company in Dongguan, China. Speaking on the global performance of his company, Thomas Chou, Vice President, Sales & Service Division, SHIEH YIH Machinery Industry, said, “In USA, since past 2 years, the market is booming. Even some automobile factories from China & Japan have moved to USA & Mexico. We also have SEYI-America branch office in Tennessee, USA, to serve this market. In Europe, we have sold over 300 presses.” In the exports to more advanced nations in Western Europe and USA, lathes comprise a significantly high percentage, whereas metal forming tools are considerably lower. Meanwhile, machining centres have long established their position as the market mainstream. KAFO’s global market is mainly in the USA aerospace industry. Goodway Machine’s great
Machine tools are used by producers of many industries to make a virtually endless range of products. Recent technological innovations have given rise to many potential end-user markets, and with it, new opportunities and challenges for Taiwan’s machine tool industry. Speaking on the opportunities, Chou said, “We have firmly established the position in the global automotive supply chain with the sale of large tonnage presses in the range of 2400 ton. Leading automotive OEMs as well as many global tier 1 & tier 2 auto suppliers are now among the company’s key customers. Our products also find applications in metal hardware, home appliances, 3C components and transportation.” While highlighting the challenges, Dr Ming-Shong Lan, Chairman, Taiwan Asahi Diamond Industrial, mentioned that they want to have more market share in automotive industry because the electronic industry fluctuates often depending on demand which is not in the automobile industry. The company’s main market is in electronics industry with around 80% market share in making of TFT-LCD for Taiwan, Korea and Japan. The Taiwan machine tool industry is facing tough competition from its Italian and Korean counterparts, especially in the mid-end market segment. In an attempt to gain greater market share, some Taiwanese producers take on
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EM | Dec 2015
R E P O R T | FA C TO R Y TO U R
SEYI professionals with TAITRA representatives and journalists during the visit of Taiwan machine tool industrial facilities
niche market through intensive market study and diversified strategies. Speaking on this, Liang said, “Few years ago, our machines were used only for making parts in moulding industry. Now, parts are also made for aerospace & medical industry as well.” KAO MING Machinery Industrial’s major market distribution is in automobile and aerospace industry with nearly 50% shares each. The company is also supplying machines to defence market in China. Goodway Machine’s products find application in automotive, precision parts, 3C components and optronic.
India. But now, we are facing tough competition from India’s local turning centre makers where they have advantage in terms of price & service.” Some of the Taiwanese companies have partnered with Indian distributers to sell their machines. For example, Accutex partnered with Electronica group to sell their wire cut EDM machines and Manford Machinery has collaborated with S&T Engineers to sell their machining centres. “The performance in India, through the agent is about 20 machines every month,” added Raoul Su.
Market presence in India
The way forward…
Though Taiwan’s machine tools exports to India are growing, it is still finding many challenges to increase its market presence in India due to limitations from Indian government in terms of policies & guidelines, Indian rupee value depreciation, higher import duties of machine tools & accessory components and lack of infrastructure. Speaking on the current situation in India, Jack Chen, Senior Manager, Sales Department, SHIEH YIH Machinery Industry, was optimistic and he further briefed that their automotive tier 1 to tier 3 are looking for a boost in manufacturing. “We are expecting good business orders in the upcoming IMTEX 2016, where we will be exhibiting our innovation in large tonnage presses,” he said. Dr Lan opined that India is lacking when it comes to road and rail network. “It takes a plenty of time to transfer goods from one place to other,” he emphasised. Most of the Taiwan machines are sold to India by agents and dealers. Explaining this, Jason Yu noted, “We have our mould & car industry key customers in India like Motherson, Maruti-Suzuki, to name a few. We are selling an average of 30 machines in India every year. In recent months, we have received business orders from Honda plant, Mumbai, where we will be supplying our gear hobbing machines.” While explaining her company’s performance in India, Hsieh added, “Twenty years ago, we found our machines were selling in
According to a trade report by the Department of Commerce, Ministry of Commerce & Industry of India, Taiwan is among India’s top five machine tool suppliers in 2014. Trade between India and Taiwan is increasing rapidly with Taiwan’s machine tools exports to India growing by 11.6% in the first two quarters of 2015 (January to June). This comes in the wake of the overall Taiwan–India bilateral trade touching US$ 2.108 billion in the first five months of 2015. Taiwanese exports to India contributed USD 1.28 billion, while imports from India touched US$ 828 million. Taiwan’s machine tools export to India grew 10% in the first five months of this year. The country has exported US$10.12 billion of machinery, including US$1.64 billion of machine tools in the first six months of this year. The production value of Taiwan’s machine tool industry is expected to increase 1.3 -1.5% by 2017. India’s huge domestic market is a big attraction. Taiwan’s hardware & technology strengths and India’s software power and recent thrust on manufacturing can make them ideal partners. Taiwan companies are looking at manufacturing in India equally encouraging. It will help India build its manufacturing base in an area that is high-end and has enormous potential. India and Indian companies could learn a lot about building innovation and technological backbone from Taiwan. ☐
EM | Dec 2015
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T E C H | TA L K
Vibrations on CNC machines
Machining vibrations, also called chatter, correspond to the relative movement between the workpiece and the cutting tool. As the spindle and axes motors rotate on a CNC machine, there are numerous parts vibrating at the frequencies at which these motors are rotating. These vibrations result in waves on the machined surface and also affect machine bed and spindle housing. The spindle is vibrating in its bearings, the bed is oscillating up and down on the floor to which it is bolted, the turret is making angular movements about its axis of rotation and the various axes are making linear movements. Let us take an example of a small experiment, if one is trying to shake his right hand violently, as if shaking off water from it, one can observe the other parts of body shaking too –chest, shoulders, other arm and legs. They will all shake (vibrate) at the same frequency as the right hand. Because of the damping effect, the farther away a part is from the right hand, the less its amplitude, but its frequency will be the same. Damping is the effect of absorbing vibrations, and all the soft flesh and water (75% water) in the body is good for damping. The same phenomenon works in a CNC machine. The most violent shaking happens close to the sources of vibration (spindle, axes, tool changer, etc) and their amplitude reduces as one goes away. Finally, the tool vibrates against the part, and this causes poor dimensional accuracy, poor surface finish and poor tool life. On a well-designed machine, the quality of bearings and various mating parts reduces the amplitude of vibrations.
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G V Dasarathi Director – Applications Cadem Technologies das@cncetc.in
I m a g e c o u r t e s y : Cadem Technologies
Vibration problems during machining process generally result in noise, bad surface quality and sometimes tool breakage. The column talks on what causes these vibrations, and how they affect the part.
The vibrations result in waves on the machined surface and also affect machine bed and spindle housing
The design of the various structures and the material used in them dampen vibrations. All this leads to reduced amplitude of vibrations between the tool & the workpiece. In the market, we find same range of CNC machines but costing between X and 5X depending on the manufacturer. We wonder why there’s so much difference, and often say “Ah, those guys are just charging for their big brand name”. It’s not that. The price is higher because of better bearings, better material, better design, etc. This gives you closer tolerances, better surface finish, better tool & machine life. ☐
EM | Nov 2015
NEWS | TECHNOLOGY
Drilling tools
Flexible clamp cables
Dagger Master Tool Industries developed universal drills for reliable drilling in a variety of materials ranging from titanium to copper & steel. Universal series lines of the company offers machinists reliable drills that ideally cover standard applications at an excellent value for money – precise machining and good surface quality included. The product line provides appropriate universal tools for drilling of steel, cast iron, stainless and highly alloyed steel as well as non-ferrous Universal drills metals such as copper, brass, aluminium, tungsten copper and titanium. The company also offers suitable drills for the processing of plastics. It is specialised in micro tools. Even the smallest diameters belong to their standard product range. To reduce vibrations and, thus, achieve better machining results especially in small drilling operations, drills of Series 629, 630, 631 and 639 are equipped with a reinforced shaft. Polished flutes and chipping spaces also ensure a good chip flow. All these features result in a superb surface quality.
Extech Instruments offers two flexible clamp cables with Model CA3010 — 10" (25.4 cm) and Model CA3018 — 18" (45.7 cm) that allows meter’s capabilities to measure AC current up to 3000 A. The features of the flexible clamp cable include 7.5 mm cable diameter that fits into tight spaces and around large conductors. It measures AC current in three ranges. It has easy twist clamp cable closure to lock or open. It is compatible with most multimeters and clamp meters with standard sized banana plug inputs. It is certified with CAT III-1000 V, CAT IV-600 V category safety rating (for use only with multimeters that have equivalent CAT ratings). The flexible clamp cable has battery capacity indicator that provides battery condition. Its flexible clamp jaw easily wraps around bus bars and cable bundles where standard clamp adaptors and meters can’t. The complete pack includes 6.6 ft (2 m) lead with banana plugs, and two AAA batteries.
Dagger Master Tool Industries | Mumbai Email: mawate@daggermaster.com | Tel: +91-22-2494-3840
FLIR Systems India | New Delhi Email: manpreet.kaur@flir.com.hk | Tel: +91-11-4560-3555
Smart 3D sensors
Tribological filaments
ifm electronic introduces the new 3D O3M151 smart sensor that opens up new possibilities for vehicle automation and new assistance functions for automation tasks. The company’s 3D sensors are based on its patented photonic mixer device technology (PMD) for fast distance detection. The new 3D O3M151 smart sensor was specifically designed for outdoor use and difficult ambient light situations, thanks to the protection classes IP 67 and IP 69K. Big or small obstacles, uphill or downhill: it always keeps an eye on everything. Bright or changing light is no longer a problem for the 3D sensor. The O3M151 has O3M151 some integrated functions that can solve different applications. A highly developed algorithm from the automotive industry is used ensuring, for example, reliable automatic object recognition of up to 20 objects. This function can be used as collision warning, for example. For simple distance tasks typical functions such as minimum, maximum and average distance are available.
igus with a selection of four tribological filaments and the 3D print service, offers customers the possibility to print maintenance and lubrication-free special parts and small series. For the company, Additive Manufacturing is one more step to give the design engineer the greatest possible freedom in construction with lubricant- and maintenance-free plastics. The company has already introduced the world's first tribological filament for 3D printers last year, and has now expanded the series to a total of four materials. Since the Hannover Messe, it has also offered a 3D print service. Customers can turn to igus with their 3D data and have Tribological filaments & 3D print their parts printed quickly and without complications. Delivery times for printed parts depend primarily on the complexity of the components; still, here too the goal is delivery within 24 hours. With high-performance plastics and additive manufacturing, two modern technologies which combined promise maximum freedom in construction and high abrasion resistance meet.
ifm electronic India | Kolhapur Email: shreyansh_gunde@ifm-electronic.in | Tel: +91-231-2685920
igus India | Bengaluru Email: santhosh@igus.in | Tel: +91-80-45127810
EM | Dec 2015
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TECHNOLOGY | NEWS
Centring points for drill bits
Shoulder milling tools
KOMET GROUP has developed a choice of two new centring points for the KOMET KUB Centron® Powerline core bit drill which, with its multiple cutting edges, enables high feed rates and, as a result, short production times. The centring point is a crucial element of the KOMET KUB Centron® Powerline. It guides the tool precisely along the drilling axis, ensuring dimensional accuracy, straightness and outstanding KOMET KUB Centron® Powerline process reliability at drilling depths of up to 9xD. The core bit has two or, depending on the diameter, more than two quatron indexable inserts, which provide a high level of stability and optimal chip evacuation. The cutting distribution on each side allows short chips to be produced even when using materials that are extremely difficult to machine. The four cutting edges per indexable insert, various substrates and coatings and tailoured topographies for excellent chip control, soft cutting action, etc. allow for a long tool life.
Pramet has expanded its popular shoulder milling range with a new program of cutters, geometries and inserts. This includes a program of helical cutters for roughing applications. Offering a depth of cut up to 108 mm, the cutters are suitable for use with Pramet’s versatile ADMX 16 inserts and support medium machining of most engineering materials including cast iron, stainless steel and Helical milling cutter aluminium alloys. The large clearance between the cutting teeth, combined with internal coolant delivery, promotes efficient chip evacuation. The axial clamping of inserts on the end teeth increases milling stability. This creates less noise and vibration which, in turn, also reduces tool wear. For use with shoulder milling inserts ADMX11 and ADMX16, as well as the LNGX12 range, the new geometries’ positive rake angle provides low cutting resistance, reduced cutting forces and less power consumption. As part of the launch, two new positive geometries – MF and MM – have also been added for milling.
KOMET Precision Tools India | Bengaluru
Dormer Pramet | Gurgaon
Email: info.in@kometgroup.com | Tel: +91-80-6772-8000
Email: info.in@dormerpramet.com | Tel: +91-124-470-3825
CAD/CAM sheet metal software Radcam Technologies offers the latest version, Radan 2016 sheet metal software solution developed by Vero Software, UK. Radan 2016 provides an environment where the conversion of 3D assemblies to 2D CAD drawings can be done with customisable parameters that too with a single click of the mouse button. The 3D environment supports all global formats like STEP, IGES, SAT, Parasolid, etc. and also provides a unique feature of fly-through mode that allows the user to see inside an assembly. The documents that can be generated Radan 2016 in Radan have been revisited and they not only include the nest reports containing critical information such as part weight, part area, and cycle timing but also the bill of materials and now they can be customised easily. The latest version of Radan provides an update on the auto tooling feature with which the user can now tool specific areas of the part, thus, further increasing the tooling efficiency. Radcam Technologies | Bengaluru Email: info@radcamtechnologies.com | Tel: +91-080-4200-7936
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Compact mechatronic module SCHUNK has developed ERS rotary modules for rotary movements in the medium load range. The currently most compact mechatronic rotary module on the market is available in unit size 170 with a height of 66 mm, achieving a nominal moment of 5 Nm, and a maximum moment of up to 17 Nm. It is used for implementing flexible and compact system concepts. The core piece is a torque motor with a hollow shaft. It is light-weight and compact, ERS rotary modules and is absolutely wear-free, making it very reliable. It can endlessly turn up to 250 rpm to any intermediate position at a repeat accuracy of 0.01°. In contrast to rotary modules with a conventional servo motor, the ERS has no additional interfering contours and no elasticity. This long-lasting module from the company convinces with high acceleration, swiveling speed, and precision. On request, an integrated pneumatic holding brake ensures that individual positions can be reliably fixed. Schunk Intec India | Bengaluru Email: info@in.schunk.com | Tel: +91-080-40538999
EM | Dec 2015
NEWS | TECHNOLOGY
Face milling cutter
Laser processing machine
Seco Tools offers its general-purpose Quattromill face milling cutter in a new close-pitch version. Thanks to a special patented centre-locking insert screw design, the new face mill puts more teeth/inserts in the cut for higher feed rates, improved surface finishes and increased productivity. Instead of locking from the front, the company’s innovative insert screw locks/operates from the back of the insert pocket, eliminating the need for wedges or other extra parts and accommodating more inserts per cutter diameter. Additionally, the company significantly increased the density and strength of the Quattromill close-pitch Quattromill cutter bodies. Quattromill face mills are free cutting, feature positive cutting rake / negative radial rake geometries and accommodate a wide range of standard inserts for all workpiece materials. And due to their cutter geometries, the face mills excel in both stable and unstable machining conditions. With the company’s new close-pitch development, Quattromill boosts feed rates and overall milling performance.
EWAG introduces a new laser processing machine, the LASER LINE PRECISION for modern tool manufacturers to get started in laser technology. The latest short pulse fibre laser technology used in the green wavelength range (532 nm) offers highly efficient machining results for the commercially available diamond cutting materials such as CBN, PKD and CVC-D. Rotationally symmetrical tools of up to 200 mm diameter and up to 250 mm length as well as indexable inserts from 3 mm inscribed diameter and up to 50 mm circumscribed diameter can be Laser line precision machined without force with the LASER LINE PRECISION. The unique and patented ‘Laser Touch Machining’ machining process offers excellent surface quality, even on tools with complex or delicate geometries. Any cutting contours, clearances and 3D machining of chip breaker geometries can be performed in one clamping operation. The resulting flue gas and the vapourised material are suctioned away and carried to a corresponding suction/filter system.
Seco Tools India | Pune Email: Bharati.Sawant@secotools.com | Tel: +91-2137-667406
United Grinding India | Bengaluru Email: prabhakar@grinding.ch | Tel: +91-99-8013-8897
Pneumatic drive machine
Precision hardened & ground flanges
Suhner now presents a set of instruments in the form of the new pneumatic drive machine LRC 20 and the matching VSC extension system to reach the deepest corners. The new system can also grind, mill, and polish places that previously could be accessed only with great difficulty: in the distant corners of impellers or the insides of narrow pipes. The new drive LRC 20 machine LRC 20 gives you 20,000 rpm to work with in your hand. At the same time, it is extremely slender and manoeuvrable, and fulfils all safety, ergonomic, and energy efficiency requirements. And it is pleasantly quiet. Even under full load, the sound pressure level is only 69.5 dB. A centrifugal governor regulates the speed to such precision that it saves about 20% of the compressed air needed for conventional technologies. The exhaust air is directed backwards, protecting the work surface from lubricating oil and reducing noise levels even further. The system comes with matching extensions that can be attached to the machine for each application. Only 13 mm in diameter, the extension elements are very thin.
Wendt India has developed new precision hardened & ground flanges that are ideally suited for both conventional and super abrasive wheels. In the pursuit to excel the performance of super abrasive wheel it is important that the wheel is mounted, trued and Precision hardened & ground flanges balanced on the flange before mounting on the grinding machine. The company makes customised flanges to suit various makes/models of grinding machine may it be surface grinder, cylindrical grinder, centreless grinder, creep feed grinder and other similar machines. The flanges are manufactured from alloy steel case hardened and 58+2 HRC for its longevity and maintaining the precision. The flanges are made in diameter ranging from 100 mm to 500 mm. Larger diameter is also made depending on the customer requirement. In order to ensure accuracy of the grinding system from the locating taper of flanges and the flat surfaces, they are precision ground with surface finish of 0.4 μRa. The face and radial run out are maintained within 10μ, generally for precision flanges it will be within 5μ. The flanges are blackened for corrosion resistance and dynamically balanced prior to dispatch.
Suhner India | Bengaluru Email: automation.in@suhner.com | Tel: +91-080-2783-1108
EM | Dec 2015
Wendt India | Bengaluru Email: SajuAbraham@wendtindia.com | Tel: +91-94433-27680
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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights - Jan 2016 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net Features Writer Maria Jerin maria.jerin@publish-industry.net
» Composite machining Composite parts are finish machined by way of turning, milling, slitting, drilling, routing, etc. However, our knoweldge of machining conventional materials like aluminium, steel or cast iron cannot be directly applied since the basics of machining action and machineability of composites completely differ. Associated critical aspects must be carefully considered for successfully machining composites and the machine tool employed should be constructed accordingly. The upcoming issue highlights these trends.
» CAD/CAM CAD/CAM is used in firms that are involved in producing consumer electronics, electronic components, moulded plastics and a host of other products. The next issue highlights new developments in the CAD/CAM technology, which facilitates communication among those involved in design, manufacturing and other processes. » Rapid prototyping Rapid prototyping decreases development time by allowing corrections to a product to be made early in the process. By giving engineering, manufacturing, marketing, and purchasing a look at the product early in the design process, mistakes can be corrected and changes can be made, while they are still inexpensive. The next issue looks at advances in rapid prototyping, which will eventually lead to improved product development by enabling better communication in a concurrent engineering environment.
» Sheet metal working Modern sheet metal technology allows for pinpoint accuracy and low-cost production of virtually any material in virtually any shape. For all jobs, be it individual parts or large-size orders, today, state-of-the-art laser technology, high-performance IT control and intelligent logistics are very important. This allows mastering even the most complex geometries. In the January issue of EM, we take a look at the best practices, market trends and technologies in the sheet metal working industry.
Name . . . . . . . . . . . . . . . . . . . . . . .Page Hyundai WIA India . . . . . . Back Inside Cover, ifm electronic India . . . . . . . . . . . . . 55, 69 igus . . . . . . . . . . . . . . . . . . . . . . . . 4, 69 IMTMA . . . . . . . . . . . . . . . . . . . . . 14, 37 India School of Business (ISB) . . . . . . . . . 3 Jyoti CNC Automation . . . . . . . . . . . . . . . 5 Kao Fong Machinery (KAFO) . . . . . . . . . 64 KAO MING Machinery Industrial . . . . . . . . 64 Klingelnberg . . . . . . . . . . . . . . . . . . . . 42 Komet Group . . . . . . . . . . . . . . . . . . . . 70 Korloy India . . . . . . . . . . . . . . . . . . . . . 13 Manford Machinery . . . . . . . . . . . . . . . 64 Milacron India . . . . . . . . . . . . . . . . . . . 12 Mitsubishi Heavy Industries . . . . . . . . . . . 2 MMC Hardmetal . . . . . . . . . . . . . . . . . . 21 MotulTech India . . . . . . . . . . . . . . . . . . 33 PMT Machines . . . . . . . . . . . . . . . . . . 15, Quaker Chemical . . . . . . . . . . . . . . . . . 17 Quaser Machine Tools . . . . . . . . . . . . . . 64 Radcam Technologies . . . . . . . . . . . . . . 70
Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 dhiraj.bhalerao@publish-industry.net Prabhugouda Patil Bengaluru Contact: +91 9980432663 prabhu.patil@publish-industry.net Advertising Sales (Germany) Caroline Häfner (+49 - 89 - 500 383 - 53) Doreen Haugk (+49 - 89 - 500 383 - 27) sales@publish-industry.net Overseas Partner Ringier Trade Media Ltd China, Taiwan & South-East Asia Tel: +852 2369 - 8788 mchhay@ringier.com.hk Design & Layout Jogindar J Dumde (Graphics Designer) jogindar.dumde@publish-industry.net
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . .Page Accutex Technologies . . . . . . . . . . . . . . 64 Ace Micromatic Group . . . . . . . . . . . . . . . 1 Altair Engineering India . . . Front Inside Cover BFW . . . . . . . . . . . . . . . . . . . . . . . . . 10 Blaser Swisslube . . . . . . . . . . . . Cover, 27 Cadem Technologies . . . . . . . . . . . . . . . 68 Comsol Technologies . . . . . . . . . . . 10, 16 Dagger Master Tool Industries . . . . . . . . 69 Delcam . . . . . . . . . . . . . . . . . . . . . . . 30 Dormer Pramet . . . . . . . . . . . . . . . . . . 70 DP Technology . . . . . . . . . . . . . . . . 11, 47 EDM Productivity Forum (EPF) . . . . . . . . 10 EMAG . . . . . . . . . . . . . . . . . . . . . . . . 45 Fair Friend Group . . . . . . . . . . . . . . . . . 10 Femco Machine Tools Manufacturer . . . . . 51 Flir Systems India . . . . . . . . . . . . . . 57, 69 Forbes & Company . . . . . . . . . . . . . . . . 25 Frost & Sullivan . . . . . . . . . . . . . . . . . . 12 Goodway Machine Corp . . . . . . . . . . . . 64 Grind Master . . . . . . . . . . . . . . . . . . . . .12 Haas Automation India . . . . . . . . . . . . . 12
Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net
Name . . . . . . . . . . . . . . . . . . . . . . .Page Robert Bosch Engg & Business Solutions . 28 Rollomatic India . . . . . . . . . . . . . . . . . . 41 Ryder Supply Chain Solutions . . . . . . . . . 38 Schneider Electric . . . . . . . . . . . . . . . . 22 Schunk Intec India. . . . . . . . . . . . . . . . . 70 Seco Tools . . . . . . . . . . . . . . . 39, 48, 71 SHIEH YIH Machinery (SEYI) . . . . . . . . . . 64 Siemens PLM . . . . . . . . . . . . . . . . 52, 60 Suhner . . . . . . . . . . . . . . . . . . . . . . . . 71 TaeguTec India . . . . . . . . . . . . Back Cover, TAITRA . . . . . . . . . . . . . . . . . . . . . . . . 64 Taiwan Asahi Diamond Industrial . . . . . . . 64 Tyrolit India Superabrasive Tools . . . . . . . 43, United Grinding . . . . . . . . . . . . . . . 14, 71 Vargus India . . . . . . . . . . . . . . . . . . . . . 6 VDMA . . . . . . . . . . . . . . . . . . . . . 14, 56 Vollmer . . . . . . . . . . . . . . . . . . . . . . . . 20 Wendt India . . . . . . . . . . . . . . . . . . . . 71 Yamazaki Mazak India . . . . . . . . . . . 34, 35, YG1 Cutting Tools . . . . . . . . . . . . . . . 18,19
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EM | Dec 2015
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