EFFICIENT MANUFACTURING
VOL 03 | 2015 www.efficientmanufacturing.in
E F F I C I E N T M A N U FA C T U R I N G
KOMPENDIUM 2015 KOMPENDIUM 2015
The Manufacturing Yearbook Series that outlines global machine tool industry trends, advanced manufacturing processes & technologies, and contemporary management strategies
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E D I TO R I A L
Sharpening the technological edge
“Sharpening the technological edge should be the key priority for manufacturers to ensure that skills are continuously adapted to the growing demands of technical progress and globalisation”
Promising… a term that best describes the state of the Indian manufacturing industry, as we step into 2015. The overall recent market developments and the mood in the industry indicates that India should witness a strong growth cycle in the coming years. The success of Mars Orbiter Mission (MOM) has proved the country’s technological capabilities for building up the technology hub of the future and could open the doors to lucrative space deals with the US and Europe. This will also give a big boost to Indian private industries which will fetch them more orders from the defence sector. Secondly, the “Make in India” initiative by the Prime Minister, Narendra Modi, has already started building the long-awaited feel-good factor in the Indian industry. In the long run, this ambitious campaign will help in creating cost effective manufacturing, generating more jobs, increasing purchasing power, and making a larger market available to manufacturers. Nevertheless, there will be challenges in short-term as well as long-term. Though the most often quoted are the timely execution of policies, a steady supply of talent, and infrastructure improvement, there are some which go beyond. If India is to maintain an 8-9% per annum GDP growth rate over the next decade, the manufacturing sector must grow at 12-14%. The industry would have to take a more long-term perspective and not merely tout the cost and efficiency factors. Of course, today’s industry leaders display all the confidence of the new India. They have thrived in the reform era. They have focused on cost-cutting and improved productivity during the downturn period. There are a few who have set internationalclass benchmarks. Most importantly, there is a spirit of “can do” and the long suppressed native entrepreneurship of the industrialist is in full flow. But, where do we go from here? How can the growth trend be carried beyond the cyclical boom? Industry, today, needs innovation and quantum leaps in technology in order to generate sustainable growth. Sharpening this technological edge should be the key priority for manufacturers to ensure that skills are continuously adapted to the growing demands of technical progress and globalisation. And most importantly, an effective industry-institute partnership to nurture innovation and achieve knowledgebased leads. At this juncture, I am happy to present you the 3rd edition of EM Kompendium, packed with all the information required to keep you up-to-date on the market developments and technology trends in the global machine tool industry. On the pages of this manufacturing yearbook, you will find industry leaders sharing their success stories and discussing on manufacturing strategies for sustaining the growth. I am sure the features in this issue will make interesting reading, to make it a truly collector’s copy!
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
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CONTENTS
Market 04
NEWS
Management 86
08
THE INDIAN WAY OF AEROSPACE MANUFACTURING
A read into the the twin concepts of Engage India and Enable India, relevant to the Indian aerospace manufacturing 12
“PRECISION TOOLS TO ACHIEVE EXACTING STANDARDS”
88
“MORE AUTOMATION & CAD/CAM TECHNOLOGIES ARE BEING USED”
90
Interview with Ramon Cenarruzabeitia, MD, Fresmark Arnold Precision Engineering 15
16
92
Interview with Antxon López Usoz, Chairman, AFM 94
LOCAL CLIENTS”
Interview with Jean-Camille Uring, President, CECIMO
Management MANAGEMENT TRENDS
GLOBAL MACHINE TOOL INDUSTRY
80
“INDIA DEVELOPING AS A MANUFACTURING
18
24
Interview with L Krishnan, President, IMTMA “MAINTAINING COMPETITIVENESS ON THE BASIS OF CUSTOMISATION”
Interview with Yoji Ishimaru, President, JMTBA
49
GLOBAL CEOS
50
“MODINOMICS WILL ATTRACT INVESTMENTS &
Interview with Ho-Keun Song, Chairman, YG-1 Co Ltd
INDEPENDENCE & MANUFACTURING
Interview with Carl Huang, President, TMBA “LOOKING FORWARD TO CO-OPERATION BETWEEN INDIAN & CHINESE ENTERPRISES”
Interview with Chen Huiren, President & CEO, CMTBA
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Interview with Pawel Duzniak, President, Europe & India, Walter Tools AG 62
“CONTINUING GLOBAL RECOVERY REMAINS A BIG OPPORTUNITY FOR MANUFACTURERS”
Interview with Clive Martell, Chief Executive, Delcam Plc 64
“ACTIVELY CONSIDERING MANUFACTURING FACILITY IN INDIA”
Interview with Teruhiko Masuda, President—Advanced Materials & Tools Company, Mitsubishi Materials 66
“INCREASING CUSTOMERS’ COMPETITIVENESS”
Interview with Stephan Nell, CEO, United Grinding 68
“THE NEED IS TO GET MORE OUT OF MACHINES BY REDUCING HUMAN INTERVENTION”
Interview with Ben Taylor, Global CEO, Renishaw Plc 70
“R&D AND ROBUST PROCESSES CAN TURN INNOVATIONS INTO MARKET SUCCESS”
Interview with Prof Dr Frank Brinken, Vice Chairman, Starrag Group Holding 72
“INTELLIGENT AUTOMATION IS THE TREND”
Interview with Eric Y T Chuo, Chairman & CEO, Hiwin Corporation 74
“MULTI-TASKING MACHINING SOLUTIONS WILL ALSO GAIN MORE ACCEPTANCE IN THE INDUSTRY”
“DRIVEN BY THE NEED OF PROVIDING
Interview with Chuang Kuo Huey, Chairman, Femco
INNOVATIVE SOLUTIONS”
Interview with Dr Akimitsu Nagae, Vice President, Yamazaki Mazak Corporation
“INDUSTRY HAS A CONTINUOUSLY EVOLVING APPETITE FOR IMPROVEMENT”
BOOST INDIAN MANUFACTURING”
“HEADING TOWARDS TECHNOLOGICAL INTELLIGENCE”
MANUFACTURING TOMORROW
A read on the analysis of the past trends and the challenges to understand the future of manufacturing
HUB”
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IMPLEMENTING MANUFACTURING INNOVATION
A read on the paradigm shift in the manufacturing industry with the adoption of smart manufacturing techniques and management strategies
“FOCUS EFFORTS ON CREATING ADDED VALUE”
Interview with Alexander Blum, President, Blum-Novotest GmbH
“FORMING A UNIQUE ECOSYSTEM WITH OUR
“TOOLS ARE ENSURING FASTER CUTTING
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ACHIEVING GREATER PROXIMITY TO CUSTOMERS”
“OUR AIM IS TO BE AN INNOVATION LEADER”
Interview with Marc Blaser, CEO, Blaser Swisslube
“MANUFACTURERS MUST WORK TOWARDS
Interview with S Subbarayan, Deputy GM, Makino India
Interview with Keshav Khurana, Director-Sales, Wohlhaupter India
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“MARKET TO CONSOLIDATE IN 2015-16”
PARAMETERS”
81
Interview with Lars Bergstrom, Group President & CEO, Seco Tools
“INDIA AMONG THE TOP TEN DESTINATION
Luigi Galdabini, President, UCIMUSISTEMI PER PRODURRE
“WE WILL BE SEEING MORE INTELLIGENT TOOLS”
COUNTRIES OF ITALIAN EXPORT”
“INDIA IS TODAY WILLING TO INVEST, IMPROVE & BE COMPETITIVE”
“POWERING BUSINESS THROUGH CORE
Interview with Dr Wilfried Schäfer, Executive Director, VDW
Interview with B C Rao, MD, Kennametal India 14
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COMPETENCES”
Interview with Rajesh Khanna, Chief Executive, Wendt India 13
“KEEPING INNOVATION ON THE FOREFRONT”
Interview with Douglas K Woods President, The Association For Manufacturing Technology - AMT
MARKET TRENDS
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“WE SEE A NEW WAVE OF INNOVATION & PRODUCT COMPLEXITY EMERGING”
Interview with Alain Iun, Vice President, Marketing – Asia Pacific, Siemens PLM Software
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Contents.i
CONTENTS
Technology 29
GAME CHANGERS
30
“PIONEER IN CUSTOMER-FOCUSED APPROACH”
“TRANSFORMING THE INDIAN MACHINE TOOL INDUSTRY”
Interview with M Lokeswara Rao, MD, Lokesh Machines Limited & Past President, IMTMA 36
“BRINGING GLOBAL BRANDS TO INDIA”
AEROSPACE MANUFACTURING 106
“INITIATOR OF FIBRE LASER CUTTING TECHNOLOGY”
Interview with Dr Arvind Patel, MD, Sahajanand Laser Technology Ltd 42
MANUFACTURING IT 108
MANUFACTURING”
44
DIE & MOULD 110
“BE FOCUSSED & PASSIONATE IN YOUR
Interview with Indradev Babu, Managing Director, UCAM “GAINING MARKETS THROUGH DESIGN-LED INNOVATION”
Interview with Milind Kelkar, Executive Director, Grind Master Machines
Solving complex mould design challenges
A feature on how the integration of design & manufacture helps to transfer machining information related to standard components and features,
BUSINESS”
46
How to select the best CAD/CAM tool?
The article analyses the features & parameters that users must consider while choosing the best CAD/CAM tool
“THE VISION OF LARGE-SCALE
Interview with Srinivas G Shirgurkar, MD, Ace Designers Limited
The technological trendsetter
The article highlights the need to deploy high performance automation solutions for higher flexibility & traceability in aircraft manufacturing
Interview with Nickunj Shah, Chairman & Managing Director, Nickunj Eximp Entp 40
Assessing high-speed machining conditions
The article discusses differences in aluminium machining performance obtained at high & low cutting speeds to enhance machining performance
PLATFORMS”
38
Six spheres of high precision machining
The article briefs on the integrated approach to help the manufacturing industry achieve maximum profitability EDUCATION & TRAINING 121
Arriving at the best-fit CNC machine
The article summarises the key parameters to be considered while purchasing a CNC machine
COOLANTS & LUBRICANTS 104
“TAKING ‘MADE IN INDIA’ TO GLOBAL
Interview with A V Sathe, Chairman, Pragati Automation
Machining of composite machine parts
The feature deals with the accurate consideration of critical aspects to successfully machine composite materials
“AN INDIGENOUS HIGH ACCURACY MACHINE MANUFACTURER”
118
COMPOSITE MACHINING 102
Interview with Shailesh Sheth, Independent Corporate Advisor, Director & Strategy Adviser to BFW & ATE Groups and Past President, IMTMA 34
The ultimate cutting tool
The article highlights the need for innovation and development in laser cutting machines
Interview with Narendra K Dhand, Chairman – Micromatic Grinding Technologies 32
MACHINING
LASER CUTTING 98
CUTTING TOOLS 114
Making headway through cast iron machining
Thee article highlights the various choices in selecting the appropriate cutting tool
Products:
124 Indexable inserts with positive geometry; Software with advanced CMM-type capabilities; Turning machine for vertical 4-axis shaft machining; 3D printing material & tape; 125 Clamping force blocks; Brush motors & accessories; Fibre laser cutting machine; Contact cooled rotary screw air compressor 126 1-D code and 2-D code readers; Adjustable pocket disc mill cutters; Complete metrology software; Industrial PC 127 Grinding tools with diamond and CBN; Insert for shoulder milling applications; CNC rotary surface grinder; CNC gantry routers
Columns 01 02 128 128
Editorial Contents Highlights – Next issue Company index Advt
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India to catch up with China’s growth rate
Indian businesses optimistic about economy in 2015
Buoyed by the economic reform measures taken by the Indian government, the World Bank has said that India would catch up with China’s growth in 2016-17. The World Bank in its report also forecast a growth rate of 7% each in the fiscal year 2016 and 2017 as against China’s 7% and 6.9%, respectively. The World Bank estimated a growth rate of 5.6% in 2014 and has The World Bank has forecast a growth forecast a growth rate of 6.4% rate of 6.4% for India in 2015 in 2015, while that of China as 7.4% (estimated) in 2014 and 7.1% (forecast) in 2015. According to the report, growth in South Asia rose to an estimated 5.5% in 2014 from a 10-year low of 4.9% in 2013. “The upturn was driven by India, the region’s largest economy, which emerged from two years of modest growth,” said Kaushik Basu, Senior VP (Development Economics) and Chief Economist, World Bank.
As per the to reports by Grant Thornton, Indian businesses have emerged as the most optimistic about the economy in 2015, with 98% people suggesting they are positive about the policies of the new government, way above the global average of 35%. According to the report, 94% of Indian businesses are expecting an increase in revenues and 89% expect rise in profits in the next 12 months, thanks to the new government’s significant steps to unleash economic reforms, ease regulatory shackles and improve India’s image globally. Around 41% of businesses 94% of Indian businesses are expecting in India believe that exports would an increase in revenues grow in the next 12 months, much better than the global average of 18%, and 53% plan to ramp up investments in new buildings in 2015. Moreover, employment prospects look bright too for 2015 as 73% expect to hire workers — the global average is just 28%.
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Boeing may set up manufacturing base in India
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DIPP on an overdrive to boost manufacturing
US aircraft maker Boeing is in talks with the government to set up an Giving a big boost to “Make In India”, the Licensing Committee chaired by aircraft manufacturing base in India. Once set up, it would be a part of the Secretary, Department of Industrial Policy & Promotion has recently cleared ‘Make in India’ programme, under which the government wants companies 19 proposals for industrial license. These included applications for defence to not only manufacture for India but production from major players like M/s export too. “Boeing continues to work Reliance Aerospace Technologies with suppliers in India in not only Limited, M/s Bharat Forge Limited, M/s manufacturing, and has also invested Mahindra Telephonic Integrated Systems significantly in equipment, training, Limited, M/s Punj Lloyd Industries tooling and quality systems with Limited, M/s Mahindra Aero Structure partner companies. They are now Pvt Limited, M/s Tata Advanced Materials integrated into Boeing’s global supply Limited. Many of these proposals were chain. Partnerships will be important pending with the Government for several According to sources, Boeing is The Licensing Committee chaired by to how we go forward, and selectively years. It has been possible to approve evaluating equity partnership Secretary, Department of Industrial we may look at equity partnerships,” these cases as a consequence of the opportunities in India Policy & Promotion has cleared 19 said a Boeing spokesperson. According simplification of FDI policy vide Press proposals for industrial license to sources, Boeing is evaluating equity Note 7, which has raised the FDI cap in partnership opportunities in India. “We defence from 26% to 49% and permitted had set up a factory with TAL (a Tata enterprise) in Nagpur, where composite portfolio investments upto 24% of the total equity of the investee / joint floor beams for the Boeing 787-9 are produced,” said a senior Boeing venture company under automatic route and doing away with requirement official. of 51% equity ownership by a single Indian investor/company. > www.efficientmanufacturing.in
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IKMPL to double parts sourcing biz
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Showcasing India’s manufacturing might
India Kawasaki Motors, is expected to double its business of sourcing HANNOVER MESSE 2015 will provide a boost to India’s manufacturing parts from India for its overseas competence, while adding a new plants during the year. The leaf to Indo-German bilateral subsidiary of the Japanese relations. India will be the official company, which assembles four Partner Country for this year’s superbike models at a facility in HANNOVER MESSE edition to be the premises of the Bajaj Auto held from April 13-17, 2015. Corporate office at Akurdi, also “India is an emerging economic plans to assemble more models in giant which is going to open up India will be the official Partner the country. “Our parts business is enormous sales potential for our Country for HANNOVER MESSE, 2015 The company, which assembles four growing rapidly and has exceeded German and international superbike models plans to assemble expectations. Currently, valued at exhibitors at HANNOVER MESSE,” more models in India Rs `30-40 crore, parts like the commented Dr Jochen Köckler, member of the Deutsche Messe Managing forklift and shock absorbers are Board. Together with German Chancellor Angela Merkel, Prime Minister exported to Kawasaki plants in Japan & Indonesia. The company expects Narendra Modi has confirmed to officially open HANNOVER MESSE 2015 on this value to double this year, and will also add some more items to the list,” April 12, 2015. Marc Siemering, Senior VP, Deutsche Messe AG, said, “India said Nashikawa Singeto, Deputy MD, IKMPL. Elaborating on their plans for will be showcasing itself to the world as a modern, upwardly mobile assembly, Singeto added that there are plans to add two or three more economic power, while it simultaneously takes advantage of the models to the Kawasaki portfolio in the country, which currently includes opportunities offered by the trade fair to invest in modern technology to two imported Completely Built Units. strengthen its domestic economy.” > www.efficientmanufacturing.in
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Testing machine tool technologies
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Siemens has recently launched operations at its new Technology & like automotive, automotive supply, aerospace, power and medical. The Application Center (TAC) at Bengaluru, which organises knowledge sharing centre also houses Siemens Financial Services, an international provider of programmes and provides application support business-to-business financial solutions. and training to customers and educational “The modernisation of Indian industries is institutes. Spread across 6,500 sq ft, it will allow creating growth opportunities for the machine Indian machine tool manufacturers and users to tool industry. Bringing a differentiated product to get hands-on experience of the latest CNC the market in a cost-effective manner is technologies and solutions from the company imperative for the success of our customers in and its partners. today’s competitive market. Siemens TAC, like The centre will organise knowledge sharing other six Siemens TACs across the world, will programmes, provide application support and function as a knowledge hub for cutting edge training to customers and educational institutes technology, as our customers and partners among many other initiatives. In addition to embrace newer machine processes and demonstrations of Siemens SINUMERIK CNC equipments,” said Joachim Zoll, Global Head controllers and CAD/CAM solutions, it will also Machine Tools Business Segment, Siemens. The centre will organise knowledge sharing According to the Indian Machine Tool use SinuTrain, a simulation tool, for training users programmes & provide application support Manufacturer’s Association (IMTMA), the current to gain higher productivity using technologyspecific functions and features from the company. market size of the machine tool industry stands It will also showcase how Siemens solutions and services for machine tools, at $ 2,050 million (around ` 12,300 crore) of which the domestic production drives and automation work together to optimise operational costs, makes for only around 33% of the total consumption. > www.efficientmanufacturing.in maximise ROI, enable higher productivity and precision in key industries
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Driving to Industrie 4.0 According to Frost & Sullivan, constantly evolving customer needs are Viswanathan, Director— Industrial Automation & Process Control Practice, transforming the manufacturing processes Frost & Sullivan. “There will be new and globally. This is driving a new industrial unconventional companies with radically revolution commonly referred to an new business models making a foray into Industrie 4.0 (I4.0)—a platform that the industrial space. Traditional industry enables the unification of information boundaries are rapidly blurring owing to amongst participants in the entire value the nature of applications that may sprout chain, from product inception to design, up during the course of Industrie 4.0,” he manufacturing, services and even added. refurbishment. The end result will be a Industrial vendors are currently trying to grand system in which all processes are imbibe the idea of Industrie 4.0 within their completely integrated and will exchange product framework, and aspire to information in real time. reposition their existing solutions in line The company has been analysing Industrie Industrie 4.0 (I4.0) enables the unification of information amongst with this new industrial paradigm. The 4.0 and strongly believes that there is an participants in the value chain company is currently is planning to fill the urgent need to understand the end-user missing end-user link in the Industrie 4.0 perception to benefit from the changing business landscape. “Industrie 4.0 story through dedicated end-user based focus groups. With this initiative, is fully set to answer the challenges lying ahead. An enormous transformation Frost & Sullivan aims to understand end-user perspectives on Industrie 4.0 in the industrial landscape can be foreseen. Companies that fail to pre- and emerge with actionable intelligence for all suppliers in the industrial empt this transformation will be left behind. Their products or solutions value-chain. > www.efficientmanufacturing.in may become obsolete and eventually disappear”, explained Muthukumar
World’s largest scooter plant in Gujarat
Innovation Excellence Awards for KBL
Honda Motors is setting up the world’s largest scooter plant in Gujarat to roll out ` 12 lakh units annually and achieve leadership position in the Indian 2-wheeler market. The ever-rising demand for scooters that has far outstripped supply has prompted the company to set up its first dedicated scooter plant in Ahmedabad. “Even as we have more than doubled our scooter capacity in India, The ever-rising demand for scooters that we have not been able to has far outstripped supply match up the demand,” said YS Guleria, VP—Marketing & Sales, Honda Motors. “While scooter production has trebled in the past decade, we still have a backlog of 60,000 scooters that should multiply in the festive months ahead,” he added. The company would also spend ` 1,100 crore on the new plant in Ahmedabad and expand its range with a few more offerings.
Kirloskar Brothers Limited (KBL) was recently awarded ASSOCHAM’s 3rd Innovation Excellence Awards 2014. The company’s all-women Coimbatore plant won the ‘gold award’ for its advancement in science and technology. Dr RV Raj Kuumar, Divisional Head - Coimbatore plant, KBL, received it from Lt Gen Anil Chait, Ministry of Defence, at the national ASSOCHAM India summit in Delhi. The award is a recognition to the efforts made by KBL’s all women Coimbatore plant that was established in 2011. “In less than three years of its establishment, GreenCo rated KBL’s Coimbatore plant has conferred many significant national awards,” said Raj Kuumar. Since its Dr RV Raj Kuumar, Divisional HeadCoimbatore plant, KBL, receives establishment, the workers at the plant the award took 60 seconds to assemble a pump. The female associates have significantly reduced this time to 17.25 seconds in April 2014 that has tripled the plant production to 34,000 pumps per line per month. The plant has set another benchmark and bagged a prestigious award by the Limca Book of Records for its project ‘Mahila Mission 20.’
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Bigger boost for enterprises after Mars Orbiter Mission After the success of Mars Orbiter Mission, ISRO is expected to offer more to build or launch commercial satellites. “The mission has helped build a orders for components and equipment to public and private enterprises. formidable image for India, and such businesses from other countries are Speaking on this, Kannan P S, Director— naturally expected to grow in large volume,” Marketing, Vajra Rubber said that the said M V Kotwal, President—Heavy company has been asked to prepare Engineering, Larsen & Tourbo. The company larger orders now. On similar lines, S M has made parts worth $5.7 million for ISRO Vaidya, Business Head—Aerospace in recent years. Division, Godrej said, “What ISRO has However, it is not just the private sector demonstrated is the reliability of our companies that are benefiting from the system, and we should be able to success story of ISRO, public-sector leverage it now for launching remoteenterprise Hindustan Aeronautics, too, has sensing and commercial satellites for got a big boost. The company delivered a others.” He further added, “These are bare satellite structure and a deck panel to only stray examples till now; this should the organisation. “Our differentiator is the become routine and we should see more cost effectiveness and reliability, as in the such satellites being launched every first attempt itself we have been successful, month. That is where we see the big Enterprises, which contributed to the Mars Orbiter Mission are while other countries had to make several boost to Indian private industries expecting large orders from the global market attempts. It talks about the quality of the and ISRO.” work that we are doing and the components Similarly, Antrix Corporation, the commercial wing of ISRO, has also got a that are going inside,” said R K Tyagi, Chairman, Hindustan Aeronautics. > www.efficientmanufacturing.in boost with this success. It now expects large orders from the global market
Renishaw opens additive manufacturing tech centre in Pune Renishaw has recently set up its first Indian additive manufacturing (metal 3D printing) technical centre in Pune, which was revealed by Nick Clegg, the UK Deputy Prime Minister. The additive manufacturing (AM) technical centre at Pune also maintains the company’s long term commitment to the Indian market. It will sit alongside Renishaw’s existing key strategic AM technical centre locations in the UK, USA, Canada, Germany & China, with additional centres are also planned for other key markets. “The thrust of the additive manufacturing technical centres is to create a Nick Clegg, the UK Deputy Prime Minister platform on which to work in close announced the setting up of the additive partnership with our customers to manufacturing technical centre help them realise the benefits of AM in their products and manufacturing processes. Our new Indian AM technical centre will be equipped with the latest products and will be staffed by our knowledgeable local team who are well versed in service, applications and process engineering,” said Rhydian Pountney, Director — Sales & Marketing, Renishaw India. > www.efficientmanufacturing.in
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Additive manufacturing technologies at EMO MILANO 2015 EMO MILANO 2015, to be held on October 5-10, 2015, at Fiera Milano will devote an exclusive area to additive manufacturing technologies in the exhibition. Exhibitors will display their products, ranging from machine tools, robots, and automation systems to mechatronics and auxiliary technologies, representing an industry worth €64 billion, on more than 345,000 m2 at the exhibition premises. The 2015 exhibition will mark the debut of additive technologies, a fast developing sector yet to be fully explored. The, exhibitors will display machines along with other products designed for the mechanical engineering industry. A whole series of meetings, workshops and conferences will also take place during the exhibition. “A special area of the exhibition has been devoted to additive manufacturing, thus, completing the 2015 world exhibition’s index of products with one of the fastest growing technologies, whose groundbreaking impact will be felt in a very near future,” said Pier Luigi Streparava, General Commissioner, EMO MILANO 2015. > www.efficientmanufacturing.in
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IMAGE C OURTESY: Airbus
MARKET | TRENDS
The “Indian way” of aerospace manufacturing The article deals with the twin concepts of Engage India and Enable India that are relevant to the Indian way of aerospace manufacturing as these help to explore the potential synergy between the two concepts and ensures allocation of attention and resources to achieve an optimal balance between them.
Aravind Melligeri Chairman & CEO Aequs
The Indian way is for the public and private sectors to collaborate to achieve simultaneously the dual goals of meeting India’s air defence needs and nurturing the development of an indigenous aerospace manufacturing industry. Achieving the former would strengthen our national security, achieving the latter would invigorate economic growth.
framework for the Indian Way of aerospace manufacturing. To generate a healthy discussion of the components that must be added to this framework, the concepts of Engage India and Enable India should be introduced. Engage India refers to all of the requirements, policies, mandates, rules, incentives, protocols and principles that impact how aerospace sector players engage with each other and with India’s government to serve India’s air defence needs. The term concerns foreign players and Make, Engage, Enable indigenous players, both public and private. So for example, the Hon’ble Prime Minister, Narendra Modi’s “Make in India” recent decision to use the “Make India” and “Buy and Make initiative provides a practical regulatory and communication India” procurement categories of DPP-2013 for approximately
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half of India’s defence weapon & equipment needs and the increase of the FDI ceiling to 49% are examples of Engage India. So are the provisions in DPP-2013 to level the playing field for private sector players vis-à-vis the Defence Public Sector Undertakings (DPSUs). So is changing the process for awarding Maintenance transfer of technology (ToT) from nomination, which had favoured the DPSU’s over private players, to bidding based on merit. Of course the defence offset policy is an example of how players engage with India’s air defence procurement strategy. Complementing Engage India is the concept of Enable India, which refers to all of the policies, resources and activities dedicated by private and public players in India to develop, enhance and expand the indigenous capabilities, capacities and competencies in the aerospace sector. Examples of Enable India include the India’s Ministry of Defence (MoD) provision of loans and equity support, as part of the India Opportunities Fund, for micro, small and medium-scale enterprises (MSMEs) to develop defence equipment. Provision for favourable tax and tariff treatment of Special Economic Zones (SEZs) is another example. The twin concepts of Engage India and Enable India are relevant to our discussion about the Indian way of aerospace manufacturing; because they help us explore the potential synergy between the two concepts and help us allocate attention and resources to achieve an optimal balance between them. Using the twin concepts to assess the strength of the “Make in
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India” initiative, it becomes apparent what Hon’ble Prime Minister, Modi’s administration has made laudable advances in Engage India, more attention and resources should be dedicated to advancing Enable India. This is because setting the rules of engagement amongst foreign and domestic players to grow India’s indigenous aerospace manufacturing is necessary, but not sufficient. We also need to create the necessary supportive mechanisms to nurture the birth and the subsequent maturation of India’s indigenous aerospace manufacturers.
FDI example One example of how an imbalance between Engage India and Enable India can frustrate “Make in India” for aerospace manufacturing is India’s FDI policy which requires or favours Indian executives and managers in joint ventures with foreign players. This Engage India stipulation is frustrated by a dearth of such talent in India’s aerospace sector. Another example is the capping of FDI at 49% for most cases. While some industry experts in India favour limiting FDI to ensure Indian control of the enterprises, other experts, particularly western OEMs such as Lockheed Martin and Boeing favour raising the FDI ceiling above 49% to enable them to wield greater control over their investment of talent, finances, and intellectual property. Central to this tension is the risk/reward profile of individual investment
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opportunities. Engage India uses the incentive of access to the huge Indian defence market, third largest in the world, to enforce technology-sharing and risk-sharing by foreign aerospace players – an onerous situation which many of them resolve by limiting their investment of talent, finances and intellectual property. Indeed, the net FDI under the previous 26% ceiling yielded a dismal $5 million and no significant manufacturing technology transfer. The two examples above clearly illustrate that Engage India alone is not sufficient: “Make in India” needs both the concepts to achieve India’s aerospace indigenisation objectives. When Enable India develops the design, manufacturing and program management capabilities, capacities and competencies to fully exploit foreign investment and technology transfer, then the foreign players will consider the FDI and offset stipulations of Engage India less of an imposition and more of a framework for facilitating collaboration. Once foreign OEMs such as Airbus and Boeing discover the enhanced aerospace capabilities produced by Enable India, they will come to rely on India as a vital manufacturing partner to enable them to move up the value chain (e.g. cleaner propulsion, smart materials) in aerospace.
The Indian way To advance the Indian way of aerospace manufacturing, the Indian government should adopt following Engage India measures: Rationalising the FDI ceiling limit and stipulations to encourage greater participation by foreign OEMs strengthening offset requirements to promote greater technology transfer level the playing field for private sector players vis-àvis the Defence Public Sector Undertakings (DPSUs) strengthen legal framework for enforcing contracts streamline the bureaucratic process for launching businesses and securing construction permits and infrastructure. To complement the above, the Indian Government needs to invest in the following Enable India measures: Making greater investments in R&D and technology transfer, making greater investment in infrastructure (especially power generation and transportation), increasing access to affordable capital (i.e. interest rate reduction), providing funding and tax incentives and human capital development, enacting legislation enabling more flexible deployment of labor, providing loans and equity support small and medium-scale enterprises (MSMEs) to develop defence equipment, providing favorable tax and tariff treatment of Special Economic Zones (SEZs). A few of these measures are
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discussed at greater length below. Promising Enable India actions such as Karnataka’s Aerospace Policy 2013 – 2023, India’s first such policy, should be expanded in scope, scale and substance and should serve as a model for a national level policy for the aerospace industry. Such policies nurture the emergence and growth of ecosystems of aerospace manufacturing excellence, bringing much needed economic growth to local communities and advancing the “Make in India” initiative. In regards to R&D, India’s government needs to invest more in R&D for promising technologies which could be incorporated into commercial aircraft programs in 10 or more years into the future. To a greater extent than the vast majority of other industries, aerospace R&D is closely tied to government spending on national defence R&D. From a peak Defence Research & Development Organisation (DRDO) spend of 6.4% of total Indian Defence budget in 2008, the DRDO has fallen consistently to only 5.1% in 2014. In comparison, the US spends about 11% of its defence budget on R&D, Russia about 7%, and China about 6%, which makes India’s defence budget for R&D only about a third of China’s in absolute terms. With the recent news of modest retail inflation and moribund manufacturing sector growth, the Reserve Bank of India (RBI) should ease monetary policy and cut interest rates to reduce the cost of capital for Indian businesses. Because manufacturing is one of the most capital intensive industries, the success of the “Make in India” campaign is jeopardised by high interest rates. India’s current bank rate of eight per cent (the interest rate the central bank charges commercial banks) is one of the highest in industrialised economies and thus hinders the ability of Indian manufacturers to compete globally. Prime Minister Modi’s administration should reinstate the SEZ incentives - if not for all then for at least the manufacturing sector - which had been rolled back by the preceding administration for political, not economic reasons. These incentives are powerful levers for encouraging foreign investment and promoting the export industry, particularly manufacturing, and thus directly support “Make in India.” These SEZ incentives can work synergistically with defence procurement offsets and higher FDI ceilings to encourage JV partnerships in SEZs between indigenous aerospace manufacturers and global OEMs. In summary, when Engage India works in concert with Enable India, significant indigenisation can result quickly. This seamless blending should characterise the Indian way of aerospace manufacturing. ☐ > www.efficientmanufacturing.in
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MARKET | INTERVIEW
“Precision tools to achieve exacting standards” Rajesh Khanna, Chief Executive, Wendt India, in an interview with Megha Roy, briefs on the increasing use of tough-to-grind materials which mandates the manufacturers to adopt latest technologies, stringent quality standards and manufacturing methods to stay competitive in their respective areas. How is the business scenario for your company in India and globally in the current market situation? We manufacture super-abrasive grinding wheels and tools in diamond & cubic boron nitride (CBN). The business performance of our company is largely a reflection of the performance of automotive, engineering, cutting tools, ceramics, refractory, glass, steel, construction & infrastructure and few others. Can you elaborate on the current stake holding of your company? What are the technological benefits of overseas support for your Indian customers? Our company has 40% stakeholding by Carborundum Universal, a Murugappa Group company and another 40% stake holding by Wendt GMBH, while the remaining 20% being held by public. We have our 100% owned subsidiary units too, at Thailand and Sharjah, UAE. With our plant at Hosur, we bring the state-of-art international technology in the Indian grinding & honing industry.
of honing/grinding machines. We are launching the twin spindle honing machine and the modified version of the eco range of tungsten carbide ring grinding machine used for mini steel plants with an inbuilt gauging system. What is your company’s approach on R&D and innovation? Besides having our in-house R&D facility recognised by the Department of Scientific and Industrial Research (DSIR), Government of India, we also have access to the centralised R&D facility of CUMI. In 2009, we formally launched i@Wendt (Innovation at Wendt) for future growth. Can you comment on the trends in metalworking – technology & customer needs? Lighter, harder and often difficult-to-machine materials are expected, which necessitates high speed grinding, creep feed grinding, laser and water jet machining as alternative technologies. Customers have started demanding more exacting standards in terms of stringent dimensional accuracies, finish, geometrical tolerances and overall quality. We are also noticing the trend towards additive manufacturing and 3D printing.
How do you look at the opportunities and challenges within the industry in 2015? How will IMTEX help your company in tapping these opportunities in 2015? How do you look at the demand trends globally One needs to be a local player. The industryin the manufacturing sector, in general? structure and the presence of many small The demand in the manufacturing sector is unorganised players and proprietor run on the rise whether in India and elsewhere, companies, resorting to stop gap practices for their short-term especially in the last few years. Increased activities and gains is one of the challenges in the industry. In India, industry investments in large manufacturing facilities and exclusive offers growth opportunity with several MNCs coming in, with manufacturing zones are also seen. The “Make in India” sizeable investments in manufacturing & key growth sectors. initiative is expected to have a positive impact on the domestic This influx has been gaining momentum year-on-year. It, in industry. turn, calls for using precision tools for achieving exacting standards with high productivity - be it cutting tools or super What are your diversification and expansion plans for India and abrasive grinding wheels, in rough machining or fine finishing globally? operations. Moreover, the increasing use of tough-to-grind We continuously work on expanding our footprint in the materials, like super alloys, ceramics & composites has been overseas market. We already have two of our 100% owned necessitating the manufacturers to adopt latest technologies, subsidiaries in Thailand and UAE. We have added honing stringent quality standards and manufacturing methods to machines to our machine tool portfolio in a technical remain competitive. collaboration with Delapena, UK. ☐ > www.efficientmanufacturing.in During IMTEX 2015, we plan to showcase the new models
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INTERVIEW | MARKET
“More automation & CAD/CAM technologies are being used” B C Rao, MD, Kennametal India, in an interview with Megha Roy, gives an overview of the changing trends in the cutting tool industry, while highlighting the rapid absorption of technological advancements and expanding insert capacity to address the growing demand. How do you look at the current scenario in the cutting tool Can you elaborate on the R&D activities and innovation roadmap industry in India, in terms of challenges, customer requirements, of your company in the coming 5 years? technology trends, etc? Our R&D is engaged in constant innovations. We introduce The Indian cutting tool industry is growing moderately with “Innovations” – an array of new products every year, which help mixed growth in different manufacturing sectors. The long customers to improve productivity yet reduce machining costs. term perspective is very optimistic with various government More than 40% of our turnover comes from products that we initiatives, including the “Make in India” campaign. Customers have developed in the past five years. We have a clear roadmap of look for high performance tools at competitive prices to technological advancements to address the changing customer reduce manufacturing costs. So, we develop tools with higher needs in the aerospace, automotive, general engineering and productivity and longer tool life, while reducing the “cost per energy & process. We re-invest considerable amount of our edge”. With the increasing use of advanced machines & work earnings in R&D and with more than 4500 active patents, materials becoming difficult to machine, our engineers constantly work on solutions technological advancements in material in material science, surface protection and sciences, coatings, surface treatments and processes to develop innovative solutions. cutting geometries are imperative. We develop products & services to address these Are there any plans for further manufacturing demanding needs. expansion in the Indian market? We have been growing in the Indian market. Can you highlight on the major changes Our company has invested significantly in the witnessed in the cutting tools sector? With Bengaluru manufacturing facility. We have the changing demand scenario, how do you also expanded our insert capacity recently to plan to align your market strategy for business address the growing demand. We also drive growth? more products to be manufactured in the One of the major changes that the industry Indian market and our company is committed is facing today is the rapid absorption of to investments for the same. technology and the gaps in some sectors on the availability of skilled workforce to adapt to this changing How do you foresee the performance and order book of the environment. More automation & CAD/CAM technologies Indian cutting tools market in 2015-2016? How is Kennametal are being used in manufacturing today than in the past, which positioned in this regard? demands reliable and multi-tasking cutting tools. There is a The Indian cutting tool market is witnessing a moderate growth drastic reduction in the concept to design manufacturing of and is expected to grow at a faster pace in 2015-2016. We are parts, putting time pressure on the manufacturing portion of working to improve the supply chain, so that our customers value chain. Selection of tools, checking machine interferences, experience faster deliveries of standard products. Also, we selecting optimum parameters and interfacing tools with the have a focused “component specific” team to deliver the most CNC pregame are done more rapidly than before. They are competitive & best tooling solutions for selected components, becoming more digital. Our company has made significant and help our customers with horizontal deployment of proven progress making process planning simple & affordable to global solutions, which prevents re-inventing. Our service customers through NOVO, which helps them to precisely initiative with tools boos and reconditioning centres have process planning for a given component in less time as brought our products & services closer to customer locations. compared to conventional approach. This is a tool that can This will further expand as the market develops and we are guide customers from Art -> Part -> Profit. fully geared up to serve. ☐ > www.efficientmanufacturing.in
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MARKET | INTERVIEW
“India is today willing to invest, improve & be competitive” Ramon Cenarruzabeitia, Managing Director, Fresmak Arnold Precision Engineering, in an interview with Megha Roy, speaks on manual & automated vices for an efficient clamping process and highlights the changing technologies in machining and clamping. Can you brief us on the emerging market & technology trends in vices, clamping technologies, spindles and jaws? The market has shown us that larger vices have gained ground to smaller ones. However, with the new 5-axis machines, we are discovering a new field in which there is a lot to do. Self-centering vices were popular in the past for round parts clamping, but sales were marginal. With new machines, these vices have been in the spotlight and many European companies are investing money in both 5-axis machines and vices. Machining usual methods have changed drastically with these machines. Machining & clamping processes have also changed. Now, the whole part is machined in one single clamping, just by holding the piece with only 3 mm clamping surface. Clamping technologies has a broad world. Even in machining centres, clamping depends on many factors, like size of the machine, shape of the part, number of parts per load, total amount of parts to be machined and how many clamps one needs per day/week/month/year.
What are the major challenges & opportunities in your industry segment, in terms of new technology adoption, varying customer demands, customisation, etc? With time, our company has moved from high pressure vices to other fields, like customised workholding. There is one step in between, consisting of designing in jaws to adapt each jaw for different work pieces with irregular geometries. Here, we are working more because with a little investment (jaws are not expensive), we can use the vice for different parts. People work with this clamping by fixing the vice to the table and then changing only the jaws for every different part. We are also working in customising set-ups. Focused to automotive & aerospace industry, here, each part needs a single and personalised solution. We are also working towards revolution in clamping.
Do you have any expansion plans in the Indian market in the coming years? We consider India as one of the markets with more projection at this time. Solid democracy, good education, skilled people, What would be the criteria for selecting a vice or a spindle for a good future-based investment program for the country’s particular application? development and interest of enterprises makes the Indian An operator does clamping with manual vices. Some vices, e.g, market attractive. high pressure vices have a pressure regulator, which means that the pressure we apply in every single clamp is always the What are your expectations for the performance of the Indian same. Apparently, this is nothing special, but if we consider machine tool industry in 2015-2016? How will it impact the that every time we use a manual vice without this regulator, performance of your business sector? the pressure is always different; we can easily conclude that There has been a change in the performance of Indian machine the bending of the fix jaw will also change according to the tool market rather than in the industry. Currently, India has pressure. It simply means that whenever we clamp a part, the nothing to see with what it used to be 10 years ago. The change accuracy on the positioning of the piece is very low as we are has been enormous. When I look at the past, I see a country not able to control the pressure. not very sensitive to improve in machining, but what I see However, there is another way to improve our productivity today is a totally different country willing to invest, improve, through automated vices that runs by using pneumatic air or be competitive and become one of the top countries. ☐ hydraulic oil. The key is how long your set-up time is and there > www.efficientmanufacturing.in these vices have to be considered as the best solution.
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INTERVIEW | MARKET
“Market to consolidate in 2015-16” S Subbarayan, Deputy General Manager, Makino India, in this interview with Megha Roy, discusses the comprehensive machining solutions to meet customer requirements and the introduction of innovative machines with multi-axis machining capability for several applications. Which strategies do you adopt to expand your market share in India? Apart from Bengaluru and Pune, do you have plans for future manufacturing expansion in India? Makino came to India with the strategy of providing comprehensive machining solutions, rather than just selling equipments. That is why within the first two years of direct operations, the company set up its technology centre in Bengaluru (1998) to develop and provide turnkey solutions to our customers locally. Over the years, our company has set up many such centres throughout the country and is focused on providing local solutions in the areas of machining process, work-holding fixtures, specialised cutting tools & process automation. These centres are equipped with the latest machines & equipments to perform actual integration and testing of these processes. Our customers have benefited from this comprehensive approach and their patronage has helped us grow to this level in the Indian market. What are the current demand trends in the metal cutting industry? What are the market drivers sector-wise for your technologies? Our traditional focus is on the automobile industry – both high volume parts machining and die & mould industry. During the last few years, we have also improved our focus on electrical, aerospace and medical industry. We are witnessing a positive trend in almost all the segments. There is a growing market in need of new machine tools and cutting tools and newer, more cost effective concepts and processes. In many cases, the younger, smaller manufacturing companies, can be quicker to implement newer technology and gain from the benefits of today’s leading manufacturing concepts and communication tools. Some of the demand trends are increased production demand, shorter production lead-
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times, increased machine tool utilisation and continuously improved product quality. What are the latest innovations in your domain? How is your company catering to the challenges in small-part 5-axis machining & related automation? The focus on innovation has been efficiency in the machining process, utilising the best of cutting tool & machine tool technology. Versatile spindles and high speed controllers have made today’s machine tool very efficient, leading to lowest cost of machining. Multi-axis machining in a single setup also eliminates setup times and errors. Our company has introduced many innovative machines with multi-axis machining capability for several applications such as automotive high volume part production, die mould core & cavity applications and aerospace/medical applications. We have also introduced the latest CNC horizontal machining centres—N2 and N2-5XA, for manufacturing medical and small aluminium parts. The new N2 platform is a high-productivity solution contained in a small package that consumes less than 26 sq feet of floor space, including a coolant tank and standard chip management. Its 5-axis N2-5XA configuration pushes this productivity even further with five-sided part accessibility and opportunities to consolidate operations. What is your expectation for the performance of the Indian machine tools market in 2015-2016? After two successive years of stagnant performance, we see a positive trend in the year 2014-15. We see a consolidation of the market and a very positive growth in the year 2015-16. ☐ > www.efficientmanufacturing.in
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“Tools are ensuring faster cutting parameters” Keshav Khurana, Director - Sales, Wohlhaupter India, in an interview with Megha Roy, briefs on the current trends witnessed in the tooling industry that leverages boring operations. PrimeBore precision boring tool is the latest innovation from your company. Can you elaborate on this? Primebore is a fine boring tool covering the range of diameter 6 mm to 128 mm. It comes in a kit which has all the accessories to cover this range. The Primebore head can be adjusted in 2 microns diametrical adjustment. The body is thru coolant and has serrations on top for strong clamping, even the insert holders have serrations on them. The tool body is balanced at 12000 RPM. The kit is in the form of a box and comes at an attractive price, thus, ensuring to bring our company’s quality to customers at a lower price. What strategies have been adopted by your company to produce innovative, modular tool systems for machining centres and offering customised solutions for boring operations? We are proud to say that we are the first company in the world to develop modular connections for boring tools. This modular system was developed by us in 1973 and it ensures the flexibility of use for the customers. They can easily use the tools for varying applications and different machines. Right from the modular MVS connection to the aluminium body tools, autobalance arrangements, combiline cutting, etc, we are the pioneers in taking the boring field ahead. The boring range offered by us of diameter 0.4 mm to 3255 mm is the biggest in the industry. How do you meet the increasingly demanding machining requirements of many industries? The boring range offered by us is 0.4 mm to 3255 mm in diameter. This helps in catering to all kinds of industry, right from the small size medical or electronics industry as well as heavy engineering industries, who are into machining of big
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crank cases for ement plant machineries and turbines, etc. Can you brief on the initiatives taken by your company towards achieving innovative tooling solutions for customers? We have made the world’s first boring & facing head in 1937, world’s first modular connection in 1973, the first aluminium body tool for weight reduction, and the small size boring tool starting from 0.4 mm. These are all examples of what we have been doing. Today, we can proudly claim that we are world leader in digital boring tools. What are the latest trends witnessed in your sector? The tools have been robust, thus, ensuring faster cutting parameters. There are also products, which can do multi operations, like modular boring tool for internal boring, outside turning, grooving, chamfering, etc. We offer very less spares and more of combinations to use our modular tooling connections so as to reduce a huge inventory at customers place. Can you brief us on your global market expectations in 2014-15 term? We expect a positive approach of the market. Mechanical engineering firms are forecasting a production growth of 2% in 2015 at the global level. But still it is not good enough for dynamic development. We need overdue following the performance in 2013 & 2014. Various factors are effective at global level like France, Russia and Italy—three of the top export markets that have regularly been a source of negative headlines. So, we may see a slowdown at global level. However, we still hope a positive response from the European (mainly Germany & American) markets. ☐ > www.efficientmanufacturing.in
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MANAGEMENT | TRENDS
Implementing manufacturing innovation Technology upgradation goes hand-in-hand with the performance of the Indian manufacturing industry. As such, major industry verticals are looking forward to the paradigm shift in the manufacturing industry with the adoption of smart manufacturing techniques and management strategies. Excerpts from EM’s interactions with a few industrial leaders… Today, the manufacturing sector is an important instrument in the process of fostering India’s economic growth. In every five-year plan, India has continued establishing this sector and innovating technological breakthrough. As a result, manufacturing clusters have developed along major infrastructure corridors. Currently, Indian manufacturing is labour-intensive and primarily specialises in low-end industrial products. Considering the challenges and emergence of new manufacturing technologies, the Indian manufacturing companies are working towards driving growth in the Indian industry by unlocking the transformational value with technology. Sharing their analysis of technology trends and reviewing customisation benefits for a better Indian manufacturing landscape are Carlos Cardoso, Chairman, President & Chief Executive Officer, Kennametal Inc;
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L Krishnan, Managing Director, TaeguTec India; Brajesh Kumar, General Manager – Engineering, Walter Tools India; Arun Shivaram, Director, Global Technical Centre India (GICI), SKF; Lars Bergström, President & CEO, Seco Tools; Vidyadhar Limaye, Director–India, Faurecia Interior Systems India; Vineet Seth, Managing Director — India & Middle East, Delcam Plc; P N Krishnaswamy, Technical Director, Bohler – Uddeholm India and Dr N Ravichandran, Executive Director, Lucas-TVS Ltd.
Reconditioning tools: Smart manufacturing In the current competitive manufacturing world, customers are looking for ways to increase productivity to manufacture in the most cost effective way. As such, they want to make aircraft,
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TRENDS | MANAGEMENT
“We bring the knowledge along with the technology innovation to address our customers’ challenges and improve their productivity & performance,”
Carlos Cardoso, Chairman, President & Chief Executive Officer, Kennametal Inc
vehicles, mobile equipment, etc, as fuel efficient as possible. Speaking on this, Cardoso believes that it is necessary to bring knowledge along with technology innovation to address the customers’ challenges and improve their productivity & performance. “We provide custom solutions and leveraging technologies such as 3D printing; offering solutions for highspeed machining; working with the latest in composite materials and development of advanced materials, super hard tooling solutions and engineered surface and coating technologies,” he said. During the machining process, as the cutting edge wears, only a small amount of the cutting tools’ material is lost. As such, to improve tooling economy, carbide tools needs to be reground and recoated. Highlighting on the trends in this process, Krishnan explained that resharpening is a critical operation to extend & restore full potential of a tool. “Till sometime in the past, users were using in-house or local resources for resharpening. Current parameters and productivity expectations of customers make it very critical to avoid any compromise in the performance. The industry has now started investing in facilities comparable to new tool production for resharpening for both in-house and outsourced activities. In the rest of the world, the trend is moving towards specialised service centres and original manufacturer-controlled resharpening. This will gain momentum as tools get more specialised in terms of geometry & coating.” Reconditioning tools is also smart for business and the environment. Speaking on similar lines, Kumar said, “Companies save money, reduce inventory and avoid material waste through reconditioning. Geometry, purpose, substrate, and coating, all play a part in driving the decision to recondition a tool. Other factors include the value of the part, tool life, complexity of the process, location, and the technical level of the operation. The simpler the tool, the better candidate it is, for reconditioning. Carbide drills are the most commonly
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“The challenge is customers want the latest trends and technologies at a lesser cost. Our aim is to provide the best technology, which will increase the delivered value to our customers,” Arun Shivaram, Director, Global Technical Centre India (GICI), SKF
In India, many suppliers are becoming capable at the zero level and eventually after a month they increase their capability,”
Vidyadhar Limaye, Director–India, Faurecia Interior Systems India
resharpened tools. When the drill gets dull, one can re-dress the front end, or if it is chipped and has heavier damage, it can be repaired by cutting off the worn front tip of the drill and then regrinding it.”
Providing technology upgradation In a highly competitive & market driven environment, consumers are open for technology adoption. Hence, industry leaders need to experiment with advanced technologies for superior functionality. Speaking on this, Shivaram opined, “The challenge is they want the latest trends & technologies at a lesser cost. We provide the best technology, which increases the delivered value to our customers.” Looking at new products in the market is an important consideration too. Highlighting this, Bergström added, “One of our customers said that they want Seco to tell them what tools
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MANAGEMENT | TRENDS
“Installing the latest CNC machines helps to reduce machining time, facilitates better accuracies and faster delivery. A 5-axis machine is also useful.” P N Krishnaswamy, Technical Director, Bohler – Uddeholm India
they need to work on for new materials, even before they know it themselves. This requires us to work not only with them, but “We keep a very close eye on where also with the material vendors. We keep a very close eye on the market is heading in terms of where the market is heading in terms of new materials. In the new materials” aerospace industry in particular, even if they are talking about Lars Bergström, President & CEO, Seco Tools new materials today, it will take quite a lot of time before they have certified that and put it into practice.” Moreover, proper capability and strategies can also provide solutions to improve the output of the tool room industry. “With the help of robots and According to Limaye, a pole of competence provides huge advanced material handling support to the suppliers. “In India, many suppliers are becoming systems, lights out machining is capable at the zero level and eventually after a month they being practiced in the die and increase their capability, thus reducing the cycle time of making mould sector effectively,” tools,” he added. Just like any other industry, an efficient Vineet Seth, Managing Director — India & Middle East, Delcam Plc software support is essential for the tool room industry too. Asserting on the importance of robots & advanced material handling systems, Seth opined, “These days, with the help of robots and advanced material handling systems, lights out important requirement of the tool room is being right at the machining is being practiced in the die and mould sector very first time. Better planning and ERP can also lead to a better effectively. The reason for this is the availability of robust machine utilisation,” said Krishnaswamy. software solutions that control important aspects of the automation through reliable systems.” How to achieve manufacturing excellence? In addition, there are a host of new technologies evolving To go hand-in-hand with the global manufacturing industry, over the years. Besides conventional technologies like die sinking & wire EDMs, new generation manufacturing Indian manufacturers are in a continuous struggle to become extensively uses hard machining and complex profiling on more productive and efficient. Some vital considerations in this multi-axis machining centres to completely finish the die & regard are balance between customers, employees and partners. mould with little need for manual finishing and correction. One cannot accelerate one at the cost of another. So, to achieve Supporting these machining methods are new developments in manufacturing excellence, organisations need to concentrate design analysis, inspection techniques and complex on three areas — technology, methodology and peoplelology. programming systems. “Installing the latest CNC machines “Now, that the whole world is open to Indian manufacturers, we helps to reduce machining time, facilitates better accuracies have to constantly look for technologies in the global space and and faster delivery. A 5-axis machine is also useful. The most adapt to our requirements. ln case of methodology, it’s time
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MANAGEMENT | TRENDS
“ln case of methodology, it’s time companies bring in TQM as part of their route to business excellence” Dr N Ravichandran, Executive Director, Lucas-TVS Ltd
companies bring in TQM as part of their route to business excellence. It is a management approach that aims to succeed in faster and stable growth of an organisation by involving all its members in economically producing quality,” said Dr Ravichandran. Since it’s a continuous struggle for the industry to become more productive, the trend in the industry is to look at cost, relying on external partners & suppliers to help them with productivity. It is also towards more automation, hi-speed machining and flexible production. According to Bergström, This is required in higher level of tooling to ensure right productivity. “Though some customers are working on low cost machines & tooling, the trend is deviating as components are becoming complex & new material choices have come in. One of the challenges in the industry is how to find the talent and the people who are willing to work and find the same type of enthusiasm we have felt over the years to work in this environment,” he added.
For a better tomorrow To make the Indian tool room globally competitive, it is necessary to focus on bringing better efficiencies, addressing lack of technology, low investments and better liasioning & partnerships with the OEMs. It is also important to seek their support in reinforcing commitments to grow the domestic production. Keeping in mind that production requires an ability to react to frequent product changes, shorter production runs, lower inventory levels and higher productivity; Krishnaswamy suggested that integrated performance through MAGMA, FLOW 3D, CRM, 3D design, machine simulation software and cash flow follow up through software should be implemented. “While a strong buyer-seller partnership can bring the required
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“Resharpening is a critical operation to extend and restore full potential of a tool. It is also smart for business and environment,” L Krishnan, Managing Director, TaeguTec India
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output; focusing on quality improvement rather than comparing the price difference between Indian & China is ideal for a competitive efficiency,” he said. So, the Indian manufacturers are leaving no stone unturned to become successful global machine tool builders. Industry leaders are looking for adopting management mantras to maintain sustainability. Adding his thoughts on this, Bergström commented that customers can be very demanding sometimes. “One needs to step back and consider what is making sense for the employees, partners and thereby take very conscious decisions. The balance in the ecosystem of customers, employees and partners is also important. This has been one of my mantras to bring in the sense of fairness. Second, there is a time to deliberate. But at the time of implementation, you need to brutally execute,” he concluded. ☐ > www.efficientmanufacturing.in
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Manufacturing tomorrow
Evolving continuously into new technologies, the manufacturing world has equipped itself with sophisticated yet customised solutions. Understanding what lies in the future of manufacturing needs due analysis of the past trends and the challenges put forth in this century
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Satish Lele Vice President – Asia Pacific Automation & Electronics Frost & Sullivan satish.lele@frost.com
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Coverstory
TRENDS
Manufacturing is the cornerstone of the global economy. The transformation of economies from ‘developing’ to ‘developed’ was invariably through the path of industrialisation. Even as the nature and contribution of manufacturing changes as economies mature, its importance remains undiminished. In developed economies, while its contribution to GDP and direct employment reduces, manufacturing is the driving force for growth in productivity, innovation and investment in R&D. With the world population set to touch the 9 billion mark by 2050, manufacturing needs to continuously evolve to meet the additional demand for manufactured goods. As the manufacturing environment continues to change, a few questions always come to our minds. What will the factory of the future look like? Will it be radically different from what we see today or just extensions of current form? How will they be organised and managed? What will be the role of technologies and people? The vision of future manufacturing is not merely an intellectual exercise but an important business imperative for organisations.
Manufacturing in the 20th century The word ‘manufacturing’ traces its origin from the Latin words ‘manus’ (hand) and ‘facere’ (to make). For the longest time it remained so until the industrial revolution and the development of first machine tools to convert metal. Thereafter, the pace of innovation and technology advanced very rapidly and was necessitated by the ever growing demand. The 20th century was defined by consumerism and ‘use and throw’ attitudes. Businesses, households and individuals required increasing products to meet their needs for transportation, entertainment, education, business and personal pursuits. Attitudes to quality and performance changed, with users’ expecting high levels of reliability, functionality and service. The manufacturing sector over all these years responded to these changes through the following: Importance of manufacturing function: Manufacturing capability was considered an important asset for competitiveness. The ability to manufacture high quality and high technology products fetched a premium and brands were recognised through their manufacturing ability. Germany, Japan and USA made significant investments in their shop floors and goods manufactured in these countries became synonymous with the ‘best of the best’. Manufacturing strategy found its rightful
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MANAGEMENT
place in the business strategy development of organisations. Economies of scale: Plant size and production volumes became an important consideration of manufacturing strategy. The underlying belief was that ‘higher the volume, lower the cost of production’. Companies competed with each other to build mega factories, at the same time creating global supply chains to keep them running efficiently. The 20th century was a constant chase for achieving perceived economies of scale. Productivity and quality: Production managers believed that their primary responsibility was improving productivity and quality. Robotics, automation and IT were used generously and operations became ‘unmanned’. Product design, materials and processes became focus areas in this improvement goal. As a result of the pressures on productivity and quality a number of manufacturing best practices like TPM and Six Sigma came into existence that claimed universal applicability in delivering improved performance. Innovation: Manufacturing became the important vehicle for driving innovation and R&D. Investments in research made by manufacturing organisations surpassed others that helped transform products and processes through technology, chemistry and connectivity.
Manufacturing challenges in the 21st century The advances in manufacturing came with their own set of challenges. The core foundations of high volume production with JIT inventory management were shaken during the Fukushima disaster in Japan and the flooding in Thailand. They exposed an important weakness of concentrated manufacturing wherein suppliers and OEMs matched production volumes to meet assembly line demand. The impact was that it took six months to a year to restore normal production levels. As supply chains get extended to different parts of the world, its risks increased proportionately. Another fallout of the era of large production runs coupled with tight controls on cost and inventory was the staggering number of recalls in the last few years. Automotive, food, pharmaceutical, electronics and the aviation industry have all suffered due to this. Cars have been recalled for defects in seatbelts, airbags, steering, braking systems and even potential fire hazards. From 2010, the automotive industry has recalled more than 35 million vehicles for quality defects. This amounts to a staggering 20% of vehicles produced, or one in every five
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MANAGEMENT
TRENDS
Intelligent design
Intelligent process planning
Intelligent quality management
Intelligent manufacturing
Intelligent control
Intelligent scheduling
Intelligent diagnostic and maintenance
Intelligent manufacturing system
vehicles produced annually. Global automation players as well as local car producers have been impacted by the recalls. Beyond the dent in brand image, it calls for a massive logistics exercise in identifying, scheduling and replacing defective components. The important debate towards the end of the 20th century was on sustainability of manufacturing. Driven by environmental and social pressures the world began to introspect and consider options beyond the status quo. According to the data published by the International Energy Agency, the industry sector consumed 79% of global coal, 35% of natural gas, 41% of electricity and 9% of oil in 2010. Considering the manufacturing growth over the next few decades, especially in developing economies, the amount of energy that will be required demands a fundamental shift in our manufacturing processes. Added to this is the environmental impact of manufacturing which is creating water stress in many regions along with issues related to managing solid, liquid and gaseous waste.
The way forward: Sustainable manufacturing Future manufacturing will rest on three important pillars – Green, Intelligent and Flexible. These three themes, essentially capture the frontiers in which manufacturing will evolve in the quest to make it sustainable. Numerous terminologies to describe future manufacturing have emerged – clean, conscious, benign or responsible – but they essentially mean the same thing. Manufacturing has to evolve in a way that it can support our planet in the future.
Green manufacturing The foundation of Green manufacturing is laid on the important principles of minimisation of energy and material inputs into the manufacturing ecosystem; minimisation of
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waste material and emission outputs from the manufacturing ecosystem; and maximising the reuse of material and energy in the manufacturing ecosystem. While this appears simple in concept, it presents enormous efforts in implementation. Melynk and Smith define green manufacturing as “a system that integrates product and process design issues with issues of manufacturing planning and control in such a manner as to identify, quantify, assess, and manage the flow of environmental waste with the goal of reducing and ultimately minimising environmental impact while also trying to maximise resource efficiency.” Green manufacturing embodies the concept of ‘cradle to cradle’. Manufacturing organisations need to understand that this is no longer a fashion statement but makes business sense as well. Frost & Sullivan has been analysing choices companies make in promoting a ‘Green’ image. The top response is that it provides them competitive advantage in the marketplace and in that process provides greater opportunities for growth. The largest challenge is still in the initial higher investment that needs to be made in technology and processes which makes the ROI difficult to justify.
Intelligent manufacturing An intelligent manufacturing system is highly automated and responsive with embedded systems that create an ability to integrate information at every level to make the right decisions real time. New technologies are advancing equipment intelligence capability to transform production and supply chain processes. These will transform firms from just being product oriented to business oriented by horizontally integrating processes using huge quantities of data that will be increasingly accumulated. A recent report, ‘Factories of the Future’ published by the Manufacturing Leadership Council at Frost & Sullivan notes that “intelligence and decision technologies for manufacturing
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TRENDS
Mass production
Mass customisation
Mass individualisation
Centralised manufacturing
Decentralised manufacturing
Subtractive manufacturing
Additive manufacturing
Flexible manufacturing system
Invest Green
Produce Green
Operate Green
systems are being developed to analyse data and to generate intelligent algorithms that enable automated manufacturing 5 and logistics systems to control work flow, material flow, and information flow of the global supply chain networks. By seamless integration of intelligence and decision technologies, manufacturing systems will completely changing the way we manage our factories, logistics, outsourcing, and supply chain networks.” Definition of an ‘intelligent manufacturing system’ is still emerging, with scholars, researchers and practitioners according high priority to its development. Kerak et. al. (2012) hold the view that an intelligent manufacturing system can evolve only when all the components become intelligent. To make this possible all devices and equipment will be interconnected through extensive use of sensors that provides real time intelligent information about performance, safety, quality and equipment health.
Flexible manufacturing The third pillar of sustainable manufacturing is flexibility. This is the capability of the manufacturing function to deal with uncertainties and cope with supplier and customer fluctuations. Given its importance for a firm, flexibility will no longer be limited to the shop floor but will become part of corporate strategy and will have far reaching impact on future manufacturing. In their book, ‘New Age of Innovation: Driving Co-created Value through Global Networks’, Pralhad and Krishnan outline their central concept, N=1 and R=G. They argue that the sources of competitive advantage for firms is changing where each customer is seen having a unique requirement (N=1) and access to suppliers and customers is global (R=G). Traditional measures of flexibility in manufacturing included machine, routing, production volume, mix, and product interchangeability to manage external uncertainties. In the future the metrics will be based on a firm’s ability to
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offer a customised product for each consumer. Manufacturing will have to adopt new technologies to meet these requirements and the flexibility paradigm will be stretched to its extreme. An important enabler of flexibility will be additive manufacturing, which is more commonly known as 3D printing. The world’s first 3D printable gun ‘Liberator’ grabbed media attention recently for all the wrong reasons. It prompted fears of the potential threat of arms proliferation as anyone could download and manufacture on a 3D printing machine. However, in the context of evolution in flexibility and distributed manufacturing, it is an important step into the future.
Future of manufacturing The pace of change in the manufacturing environment will be determined by the importance it is given by corporate management. A big influence in this is the fluctuating economic environment and the short term focus that firms get sucked into. This is reflected in a survey conducted by the Manufacturing Leadership Council at Frost & Sullivan, where companies were asked how their executive management was looking at the way plants and factories will be run five to 10 years in the future. The good part is that almost 40% of the companies surveyed have a formal process in designing their manufacturing strategy over the decade. Even as manufacturers embrace digital manufacturing, collaborative management structures, and more real-time production models, certain time-honoured disciplines will remain in force. Reducing costs, improving productivity, finding new markets, increasing customer satisfaction, and product innovation remain at the top of manufacturers’ priority lists as they look into the next 10 years. These are the disciplines that will shape and test the new ideas, models and practices of future factories. Those that master a combination of both the new and the proven will most likely be winners. ☐ > www.efficientmanufacturing.in
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Section co
INTERVIEW INDUSTRY
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THE MAKING OF GAME CHANGERS “You have to learn the rules of the game. And then you have to play better than anyone else,� said the great mathematician Albert Einstein. So has been the case of major Indian machine tool industry players. This dialogue with eminent industry leaders and experts of the Indian machine tool industry brings forth the challenges, successes, learning and inspirations that drive them to be the game changers of the industry, not just for India but for the global machine tool industry as well.
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GAME CHANGERS | DIALOGUE
“Pioneer in customer-focused approach” Narendra K Dhand, Chairman – Micromatic Grinding Technologies, MD – Micromatic Machine Tools and Director – Toyoda Micromatic Machinery India, briefs on his journey as a novice machine tool manufacturer to the leader at the largest machine tool group of India Please elaborate on how your journey in the machine tool industry began. After completing my studies in the US, I joined my family business of auto parts manufacturing. During my initial days at the facility, I ran a heat treatment plant, and met V S Goindi for the first time. He initiated the idea of starting a company in partnership. Goindi is a machine tool expert with CMTI background. Thus, Micromatic Machines (2M) was formed in 1973. In the beginning, we did many job work for the engineering industry. Grinding machines were built later as the accuracy level of these machines available in the market was not high. Incidentally, Goindi knew Sathe from Pragati Automation since his CMTI days. So we approached Sathe to design the grinding machine. Sathe, in my opinion, is the numero uno machine tools designer in the country. As a
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business strategy, we realised that, “products that are difficult to make are easy to sell & vice versa”. Thus, our first grinding machine was built in 1977, which is still in operation. Sathe also wanted a very high precision machine not only in terms of design but also quality. Goindi, my partner was an expert in achieving those accuracies in a cost-effective manner. This is how we managed to bring our first grinding machine to the market. This machine won the best design award and the best product award during IMTEX in 1979. Our closest competitor was HMT, which at that time had achieved accuracies of only 5 microns roundness; whereas, we had designed & built the machine to achieve an accuracy of 2 micron roundness. We had to prove this accuracy during IMTEX as we were a new entity in the market. Thus, we got the first movers’ advantage.
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DIALOGUE | GAME CHANGERS
“Once a trusting relationship has been built, success comes naturally. A trusting culture has to be constantly nurtured in the organisation” N K Dhand
Which challenges did you face as a newcomer in the in all aspects but also that neither half lacked any important inputs. The products were divided; the people working for industry? Normally, every machine tool requires sales, maintenance, those products were also divided. It was ensured that if a senior after-sales service and at that time, big companies had their person is going to in one part, the next person from the team own service or network divisions. Small companies like us goes to the other, so that none suffered. The products also were dependent on pan-India distributors for nationwide sales had an equally divided possible revenue source. The entire & service support. Our option was to approach big companies, document was prepared within 30 days. That was a challenging so that they could do the sales and after-sale service for us. time to rebuild the organisation independently. Machine tool But it was also a major concern as our grinding machine was manufacturing is not an easy game and I am thankful to all my a homegrown (not time-tested) design that might need quick colleagues & partners who helped me in this journey. service support & customer hand-holding for longer duration, Which memorable experiences helped you in achieving the which large distributors are not accustomed to provide. This challenge was the game changer for us as along with Sathe, current position? we set up our own marketing and sale-service company, which The 1990 split of the company was a memorable experience. was later joined by our group companies. We also brought in Another big challenge we faced was the stretch of 4-5 years the customer-focused approach right from the beginning. This from 1998. Those were very bad years for business as economic slowdown had hit the country. We had to take a very tough call has been the hallmark of Ace Micromatic Group’s USP. in the year 2002 to right size human resources by 25%. Looking What has been your learning as one of the pioneers in at that experience now, I can say that despite downsizing, we functioned without work getting disrupted or any serious grinding technology? I am very open to learning from any possible source (last year mental backlash, which is a major achievement in the history at the age of 71 now, I took 2 MOOC on-line courses). By of this organisation. applying those learnings, I have been able to achieve success. I am a mechanical engineer but not a machine tool design What is next on your career graph? engineer. Unlike Sathe, Machado, Shirgurkar & Ramdas, who About three years back, we had a vision exercise. As per this are hardcore design experts, I am the only one who is not a vision, as MGT completes 50 years of operations in 2023, we machine tool design engineer. I had lot to learn and manage aim to be among the top 10 grinding machine tool companies all the aspects of the machine tool business. Another major in the world. We are very strongly working to achieve this learning is the fact that every relationship has to be trusted. vision, through R&D, new product development and building Once a trusting relationship has been built, success comes international marketing platforms, which will take its time to naturally. A trusting culture has to be constantly nurtured in set up. the organisation. What is your advice to entrepreneurs to achieve success in In your professional journey, which have been the major the highly competitive machine tool world? For any entrepreneur, sincerity, integrity, hard-work, openness achievements? The main turning point came in the year 1990, when we to learning new things and the passion for whatever he/ vertically split the company in a strategically planned manner. she believes in is very important. Also, building a trusting The way the split was managed is quite interesting. One of the relationship is the key to success. You should not relate to partners was assigned the task of division into two equal halves, people if only he is useful, that doesn’t work. You must really and the condition was that the other partner would choose consider and treat all equally. If one adheres to love and which half he wanted to have. Since the person dividing the compassion – basic values of human behavior, trust comes assets was not going to be the chooser, he had the unenviable automatically. ☐ > www.efficientmanufacturing.in task of ensuring that not only both the halves were really equal
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GAME CHANGERS | DIALOGUE
“Transforming the Indian machine tool industry” Shailesh Sheth, Independent Corporate Advisor, Director & Strategy Adviser to BFW & ATE Groups, and Past President, IMTMA, shares the unabated efforts put in to transform the Indian machine tool industry and the challenges he faced redefining PMT’s core competence from being a turning machine expert to being a precision round part specialist. What has been your role as the game changer in the Indian going beyond the machine tool Industry, I cultivated focus on machine tool industry? the whole manufacturing sector of India. I organised several Very early in life, I discovered that I was uncomfortable with manufacturing summits for CII, long before ‘Made in India’ small talk; mine was a restless soul, constantly looking out for became fashion and ‘Make in India’ the new buzzword. Under larger fields to play in, bigger canvasses to paint on, and rising the aegis of UNIDO, I worked with over 200 SSIs in pan India. above petty pleasures. I became leader of the Students Union, Connecting the dots of these individual constituents of my volunteered for army training in a forward outpost close to work, a pattern emerges. You may call that pattern ‘A Game no man’s land in Tithwal sector of Kashmir, won Best Student Changer’. prize for all I did other than excel in studies and opting for my first job in Kolkata when Naxal Bari movement was at its How has been your professional journey so far…can you peak. These, ‘beyond run of the mill’ experiences shaped my mention major achievements? character and as I look back, the seeds of being a game changer I passed MBA from IIM-Ahmedabad in 1969. IIM really gave were planted in those early, young and adventurous days. shape, focus and depth to my passion for out-of-the-box When I was elected as President of IMTMA in 1994, I thinking. It made me a strategist. Passing out, I opted to go instantly seized the opportunity to influence the machine tool for the most difficult assignment to date that I have handled industry as a whole rather than my own company alone. Then, – going to Kolkata to work in a company that was slowly but
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DIALOGUE | GAME CHANGERS
“Even if you don’t succeed, that you have made your best efforts itself will give you high brand equity” Shailesh Sheth
surely sinking! Working under a British turnaround specialist excellence, etc were not in vogue then. But coming to terms MD, we did manage to bring the company back to profits and with the sharp verdict on the napkin, my mind became clear. I in those five years learnt many key lessons that only violent, am an avid believer of Swami Vivekananda, and for decades I internal and external turbulations can teach. In 1973, I returned have carried a small card in my wallet that quotes him “You are home, so to say, and joined Perfect Machine Tools Company the creator of your own destiny”. I accepted the challenge and since then till today, the effort to transform Indian machine (PMT). This is where my machine tool journey began. My wife’s family owned PMT, so my entry into it was no tool industry continues unabated. This relentless ‘push’ earned doubt a favoured one. But my passage through the company me the title of “Guru” of the machine tool industry and the was anything but smooth. I had many unfavourable tags, “IMTMA H R Gupta Life Time Achievement” award. This was son-in-law, MBA but not an engineer, too young, a potential the signal that the challenge was met head-on and I thank the competitor to existing power structures, and so on. Yet, I rose person who wrote the anonymous words for providing me to the MD’s position, fighting all the way and I firmly believe, with the purpose. on my merits alone. In the 20 odd years that I spent in PMT, I can count What have been your biggest learnings? several crucial achievements. The most important was to First, that acceptance and respect are not automatic. You have change the very DNA of PMT from being a trading outfit to to earn them. Second, do not think the world is all bad and a manufacturing enterprise, from a company to an institution, tailor your acts accordingly. Think the world is good and treat redefining company’s core competence from being a turning it so. This could result in some short-term suffering but will machine expert to being a precision round part specialist and yield long-term goodwill no money can buy. Third, be sensitive to criticism, not be defensive. Find out forging global partnerships with companies in Switzerland and the root cause and try to overcome it. Even if you don’t succeed, Germany. In the next phase of my journey, the most satisfying that you have made your best efforts itself will give you high accomplishments were to set up, for a Swiss company, a brand equity. Fourth, my grandfather taught me not to bark back at a manufacturing plant in India in under 14 months without bribing anyone, later acquiring a company in Germany, and barking dog. Find out what ails him and try to help him. Finally, my father-in-law taught me that you should not be now being referred to as “Guru” of the industry. It is truly a ‘receiver’. You must always be the ‘giver’. If you give all the humbling. time, resources will always come to you. These five have been Which was the most challenging phase of your life and how my guiding mantras, both in my personal and my professional life. did you overcome it? I was attending National Council meeting of CII when a neatly folded paper napkin reached me. Curious, I opened and read a Next on your success graph... message scribbled on it. It said “Indian machine tool industry Two words, ‘thought leadership’. I want to write, teach, share deserves to die”. I sank in my chair. I tried to locate the person whatever knowledge and experience I have accumulated. Work who wrote it to discuss the matter but did not succeed as he with the young and strengthen their hands, their resolve and wished to remain anonymous. I could have ignored it. But their motivation to lead India into the future. ☐ “NO”; some sleepless nights later, I interpreted it as a “Voice > www.efficientmanufacturing.in of the Customer”. This was back in 1995. TQM, business
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GAME CHANGERS | DIALOGUE
“An indigenous high accuracy machine manufacturer” M Lokeswara Rao, Managing Director, Lokesh Machines Limited, and the Past President of IMTMA, details on his challenging journey from a small scale unit to a leading provider of turnkey machine tool and automation solutions. What has been your role as the game changer in the Indian machine tool / cutting tool industry? We had brought in a personalised approach to our customers and rather than focusing on mere numbers, we relied on providing value and reliability. This has endeared us to our esteemed and discerning customers who constitute almost 75% of our repeat business. Please share your professional journey with us and your major achievements…What made you to venture in this field and how you started? More than four decades ago, I had started my career at HMT
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Hyderabad. After a brief stint that lasted less than seven years, I obtained a methodical understanding and insight of the manufacturing industry. With the experience, I decided to chart my own course and started a small scale unit supplying components to HMT and other Hyderabad-based engineering companies. With an intense desire to manufacture a full-fledged product, I choose machine tools with which I was familiar. Thus, Lokesh Machines Limited was incorporated in 1984. Our team is credited with several modest achievements such as securing turnkey machining lines from MNCs like John Deere, Volvo Eicher, etc. In the initial years, we have helped leading auto
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DIALOGUE | GAME CHANGERS
“Being the only Indian manufacturer to secure turnkey orders from multinational companies against stiff global competition could count as a great achievement” M Lokeswara Rao
original equipment manufacturers substitute critical special purpose machines with indigenous high accuracy machines like CAM & CRANK Borers, etc. Which memorable experiences have helped you in achieving your current position? There have been several mentors who had been my peers at HMT as well as outside who had encouraged me when I decided to give up my job and start on my own. A short program on entrepreneurial development by a state government agency had shortlisted me amongst many applicants which shaped my initial entrepreneur days. Undoubtedly, our customers were very tolerant and encouraging in developing us and helping us reach the position where we are today. Which was the most challenging phase of your life? How did you manage to overcome it? The initial years after setting up Lokesh Machines, had been very challenging. We were the first company in the private medium sector to have invested heavily on the best-of-thebest mother machines those days. The accumulated losses virtually eroded our entire net worth and the going was indeed difficult. As they say, when the going gets tough, the tough get going. Then we persevered and the then customers saw us for what we were and started supporting us with orders of machines which very few people in the country could manufacture those days. Can you share those moments in which you thought you had achieved a great feat? The first special purpose machine to M&M built by our team was indeed a great feat. Being the only Indian manufacturer to
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secure turnkey orders from multi-national companies against stiff global competition could count as a great achievement too. Exporting CNC machines to Japan which is considered the Mecca of machine tools and which is the world’s largest exporter of machine tools is indeed a proud achievement. Exporting special purpose machines to China a few years back had been a notable accomplishment by our team. What according to you has been your biggest earning/ learning? Would you like to mention any names in your professional life from whom you got inspirations? Learning never ceases and every day brings in new lessons/ learning. S M Patil, the then Managing Director, HMT, had been my prime motivator to run machine tool factory successfully. Mullapudi Harischandra Prasad, the then Chairman and Managing Director of M/s Andhra Sugars Limited Group of Companies, had been my motivator to become an entrepreneur. What’s next on your success graph? Niche machine tools are under development which could see launches in 2015. Being a provider of turnkey solutions, I would like to see our company provide higher levels of automation and unmanned machining solutions and see ourselves as a leading exporter of machine tools in the next few years. Your advice/tips to new entrepreneurs on success mantra in manufacturing? Entrepreneurs have to be rooted to the core competencies, persevere hard and never cease to learn. ☐ > www.efficientmanufacturing.in
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GAME CHANGERS | DIALOGUE
“Taking ‘Made in India’ to global platforms” A V Sathe, Chairman, Pragati Automation and Ace Designers, an entrepreneur at heart, talks about his role in the making of Ace Micromatic Group and his zest for new technology to make the ‘Made in India’ label a global brand. Please brief us on your role as the game changer of the Indian machine tool industry. I started ‘Pragati’ in the year 1977 in partnership with FIE Group of Ichalkaranji. In the next few years, I started ACE, Micromatic Sales and AMS, in partnership with my friends from CMTI and HMT. I am personally responsible for ‘Pragati’, which produces machine tool accessories like tool turrets for CNC lathes and automatic tool changers for machining centres. We are the only manufacturers of these products in India, exporting 50% of our production, all over the world & notably to Germany. We are now confidently entering low cost markets of China and Taiwan, because we find that our production costs are lower and our technology levels are on par, or better. This is a game changing moment as we are demonstrating that India is the lowest cost producer of machinery and if we sincerely try,
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we can get a much larger share of international machine tool production. How has been your professional journey so far? I completed M-Tech in machine tools from IIT-Bombay. I was working as Chief of Designs at CMTI when I resigned to start Pragati. During my initial years with CMTI, I was sent to Czechoslovakia for two years’ training. This was a beautiful opportunity, because I could work in the design offices of three different companies, producing lathes, gear cutting machines and grinding machines. While working with CMTI, I realised that the industry is not making use of CMTI facilities. I was also pained to realise that Indian machine tools had no respect in international markets, and that Asian countries like China and Taiwan are racing ahead of India. I therefore decided to resign and try to make a modern product, sell it all over the
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DIALOGUE | GAME CHANGERS
“Sensible pricing, based on production cost, will give handsome rewards in the long run” A V Sathe
world and get some respect to the ‘Made in India’ label. Today, I have the satisfaction that I am very near to that goal. Pragati products are exported all over the world, and Pragati is now an internationally recognised brand name.
development for cost reduction of his components. This aspect helped me to always look for cost control during design and manufacturing, and helped Pragati to remain comfortably competitive even in the Chinese market.
Which have been the most memorable experiences in your What is next on your success graph? journey? We are now investing heavily to double our production capacity. We were regularly supplying a small quantity of our turrets India will produce almost ` 2000 crore worth of CNC machine to a Polish Company. This company was taken over by a tools in the present year. However, all the components that go very large German company. The German company saw our into CNC systems, ball bearings, encoders, linear guide-ways, turrets working in the Polish factory and they liked what they etc are not made here. As a result, almost 50% of the cost of saw. This started a long association with Germany. Later, this inputs to a CNC lathe goes into imported components. We are German company also tried our ATCs and started using them. trying to correct his situation by working on low cost CNC Today, this company is our largest customer, accounting for system, consisting of CNC control, servo drives, spindle drives almost 25% of our total sales last year. and motors. If we succeed in developing this CNC package, A Brazilian manufacturer of grinding machines visited we plan to produce low cost CNC lathes in high volumes. I our stall during a EMO-Hannover show. He was also a jolly am also setting up a publishing house in Pune, to publish politician, talked about South-South Co-operation and vocational training books in Indian languages. In the first year, suddenly placed order for 10 of our turrets right at the show. books will be in Marathi language. Other languages will follow He never used these turrets. But within a year, his company in the coming years. I firmly believe that proper professional was taken over by another Brazilian machine tool company. training in mother tongue is the key to increased productivity The new owner saw the turrets lying in stores and used them of our workforce. out of curiosity, and we started getting turret orders from this unknown party. We supplied almost 3000 turrets to Brazil in What is your advice to entrepreneurs entering the the next 5 years. manufacturing market? Normally, new entrepreneurs have good technical background, Which were the moments where you felt that a great feat has but limited capital. In the initial years, you are required to do been achieved? routine jobs to sustain the company. But set aside some time Around three years back, Pragati put up a plant in China, near for the development of a technology intensive product. Such Shanghai at a cost of ` 25 crore. China is a much bigger market a product, when developed, will not have much competition compared to India. Our technology levels are at the same (or and will give you good margins. Concentrate on products with sometimes better) level compared to China and we at Pragati volume potential. There are many numbers of small products, are capable of producing products at lower cost than in China. waiting to be developed in the machine tool field. We have therefore taken this decision of investment in China. Product pricing should be based on ‘high volumes, low We are hopeful of a breakthrough next year. If this happens, it margins’. Do not try to get best possible price, because this will be a great feat for us. limits market volume. Sensible pricing, based on production cost, will give handsome rewards in the long run. When we What has been the biggest learning through this journey? developed our tool turret, import duties were high and the Who has been your inspiration from the start? normal practice was to fix your prices 10% lower than landed Control of production cost and ultimately the final cost is price. We went against the practice and fixed our prices at the key to growth. Once this is done, the world becomes your 30% below the dollar price in Europe, because we ultimately market. Pragati was started in partnership with FIE Group intended to export to Europe at these prices. Today, we are of Ichalkaranji. Panditrao Kulkarni of FIE has a down-to- reaping the benefits of this policy. ☐ > www.efficientmanufacturing.in earth engineering mind. He is constantly engaged in process
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“Bringing global brands to India” Nickunj Shah, Chairman & Managing Director, Nickunj Eximp Entp stresses on the strategic establishment of marketing networks for global giants in the Indian market and their innovative contribution to critical projects by ISRO. What has been your role as the game changer in the Indian machine tool / cutting tool industry? In the nascent stage of the cutting tools market in India, we have played a catalytic role in bringing together some of the world-leading brands and the relevant customers in the private sector. Further, aggressive promotion and association with the critical projects in the aerospace, engineering and power sectors have facilitated further awareness of the latest technologies available. Lastly, introduction of products from giants like ATI STellram, ZCC etc and also ensuring its availability through the pan India, NICKUNJ marketing network has established our role of a game changer. Please share your professional journey with us and your major achievements…What made you to venture in this
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field and how you started? NICKUNJ started as a single product company over three decades ago. Genesis was the strong belief that “innovation knows no bounds” and a passion to make India technologically self-reliant – to bring the latest technologies of the advanced nations to Indian shores. In its journey spanning 35 years and dotted with milestone achievements, we have been able to enlist the association of formidable partners - renowned overseas manufacturers, pioneers in most cases, giants in terms of technological expertise and global reach. With a product portfolio swelling to 4000 items, we cater to the requirements of most of the segments of the Indian industry. Lastly, successful foray into manufacturing with two units operational at Baddi in Himachal Pradesh and Umbergaon in Gujarat was the crowning glory. As an extension of business of the MCS SBU
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“Remaining within the purview of policies, one must develop the tenacity to stay rooted to core business and expand wherever technological and customer synergies exist” Nickunj Shah
and deeply sensing a void in awareness and easy availability made NICKUNJ take a plunge into the cutting tools segment. And the progress so far has vindicated our stand. Which memorable experiences have helped you in achieving your current position? In the course of our journey, the memorable experiences have come from the global suppliers, the titans of the Indian industry – understanding their passion of doing business, their dedication and most importantly, the unique ownership feeling that they possessed about their businesses. Greater joy has come from the realisation that we have been able to successfully draw on the company’s core competency of sourcing difficult to procure products and helped avoid many critical/strategic projects attain posterity on the drawing board itself. That the name NICKUNJ has become synonymous with innovative products/solutions with satisfaction guaranteed, in itself, is a memorable experience to cherish.
Can you share those moments in which you thought you had achieved a great feat? Being in the business of supplying products and offering services, there cannot be greater joy than experiencing a partnership in the progress of our loyal customers – their projects coming to fruition. Also, it was a great feat when “Chandrayaan” was launched successfully and “Mars Orbiter Mission” was successful as we have been one of the vendors to ISRO for these projects. Being congratulated by ISRO for being a part of these great feats can definitely be listed as one of the greatest achievements! What according to you has been your biggest earning/ learning? Would you like to mention any names in your professional life from whom you got inspirations? My biggest earning is the goodwill & respect from my customer who believes in my brand and has confidence in NICKUNJ. Learning is an ongoing experience and every challenge has been a learning experience. Facing, understanding, accepting and overcoming challenges is the biggest learning. In the course of our journey, there have been numerous persons who have contributed to my learning - my customers, business partners and principals. And it is difficult to name all of them.
Which was the most challenging phase of your life? How did you manage to overcome it? Past few years have seen hyper-competition and slow growth with companies constantly striving to hold on to their current positioning in the market place. NICKUNJ too was not an exception to this challenge. In the changed business context, What’s next on your success graph? traditional ways to retain the market share and ensure growth It is a continuous journey. We wish to remain as the most became less relevant. It was innovative strategy coupled with preferred partner for all our customers and ensure substantial leaning on conservative business acumen that has helped us growth for all the stakeholders. We will be on a constant lookovercome the challenge. We have also faced sudden challenges out for technological advances and new product launches, when our principals – overseas suppliers whose products upgrade our product portfolio to ensure that our customers’ were introduced, assiduously marketed and popularised in journey from vision to realisation becomes as smooth and the Indian market, suddenly decided to go on their own once hassle-free as possible. the product attained a leadership position. Quick thinking and resolute initiatives ensured that equivalent products were Your advice to new entrepreneurs on success mantras in sourced and introduced in no time. As a strategy, NICKUNJ manufacturing? has now started popularising its own brands in most product Remaining within the purview of policies, which significantly segments, which will, in the wake of a similar challenge, pave impact the economic and industrial activity, one must develop the way for instant replacement by an equivalent supplier or the tenacity to stay rooted to core business and expand wherever backward integration by manufacture of the product locally technological and customer synergies exist. ☐ > www.efficientmanufacturing.in without losing the market share.
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“Initiator of fibre laser cutting technology” Dr Arvind Patel, MD, Sahajanand Laser Technology Ltd, winner of innumerable awards for pioneering laser cutting technology and bringing the Indian laser industry to the global platform, briefs on the challenges and continuous efforts put in to begin a dream run from an innovation to a global market leaders’ position. What has been your role as the game changer in the Indian machine tool / cutting tool industry? Manufacturing the world’s first fibre laser cutting machine is the key achievement I’ve made in my career that stood as a game changer. The impact of fibre laser cutting system was felt not only on the domestic market but also reached the global fabrication industry. It was the time when the world turned its attention towards India; much amazed of the fact that India has got capabilities to challenge the rest of the world with its technical and engineering expertise. My approach towards process simplification and innovation would be the other one that I consider as ‘A game changing factor’. Since inception of SLTL, our focus was to offer simplified solutions to the existing manufacturing complexities. We have developed
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Game Changers Management Interview_Aravind Shajanand.indd 40
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various turnkey automation solutions and work stations that had rapidly got the market’s attention for its undoubted productivity and unquestionable reliability. Laser marking machine is one machine that stands as a proven example for companies to evolve their production process to achieve quality and productivity. Please share your professional journey with us and your major achievements…What made you to venture in this field and how did you start? After completing my graduation from the Gujarat State University, I found myself a challenging job in the sales department of a yarn spinning machine manufacturing company. Few years later, with considerable knowledge and
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DIALOGUE | GAME CHANGERS
“Product & brand reliability and value proposition are the two strong pillars which helped us to stay up straight and overcome recession” Dr Arvind Patel
experience, I had a chance to shift to my dream job of working with ISRO. Here is where I was introduced to lasers. Scientist there used lasers to process hard materials like ceramics. It has to be machined to a precision of microns. I was pretty amazed seeing the big laser system put into use for such applications. During my previous job, I happened to visit Surat, famous for jewellery and garments. There, I saw many small and medium scale workshops in the business of cutting, blotting and polishing diamonds. They were doing it in the conventional method. This stuck my mind. Why can’t we use lasers to cut diamonds which carries the similar property of toughness? I shared my idea with my colleagues. No one was ready to guide me further about it. I was not a person who could giveup things easily. This idea was wagging in my mind for a long time. One fine day, along with my friend, I visited one of a small scale diamond processing workshop and told the proprietor that I could use technology to cut diamonds precisely by which he could reduce the entire processing time to one third. Since time is money in diamond processing business, the proprietor readily nodded his head for me. With funds accumulated from his business circle, we imported the required components for the laser machine which I was planning to build. With extensive study and learning, we were successful in building a laser machine capable to process diamonds. Within a month’s time, we were able to process thrice as much of diamonds processed manually. The investors were happy with that as they could get instant ROI. Our journey continued over the years with the serial introduction of laser integrated solutions to the world.
few months to keep moving in the market. We overcame the hardships through our commitment and trust that we built with our prospects and clients. Product & brand reliability and value proposition are the two strong pillars which helped us to stay up straight and overcome recession. What according to you has been your biggest earning? In the course of my career, this is one of the notable events that made me proud in gaining another feather to India’s crown for technological advancements. In 2008, the 4th International symposium on High Power Fibre Laser and its applications was held at St Petersburg, Russia. During this event, I was the only person invited to present an application research paper and deliver a lecture on “High Power Fibre Laser & its Application”. India’s capability in laser technology was recognised by the world. It was indeed a proud and prestigious moment for the Indian laser industry as SLTL was the only company invited from all over the world. For me, this is one of the greatest earnings in my life. What’s next on your success graph? Global expansion and product development are at the top of our agenda. We already have our international operations at Germany, UK, USA and China. Now we are concentrating in expanding our market to Middle East. Product & application development are continuous processes at SLTL. Each year, a new product hits the market from our side. We are focusing on developing laser metal processing systems catering to aerospace and automobile sectors requiring critical engineering and treatment.
Which was the most challenging phase of your life? How did Your advice to new age entrepreneurs to achieve success in you manage to overcome it? I see challenges and bottlenecks in life as important as the pulse the manufacturing sector? in our body; without which, it’s impossible to live and achieve. Don’t wait for opportunities to knock your door; you will have Right from the day when I was discussing my idea to implement to keep your door open before it stops at your door step to lasers to cut diamonds, I was discouraged and criticised by few knock. With increasing global population, the market size for friends and colleagues. But, once I was successful in bringing each and every commodity is growing; so is its supply. So, try my idea alive, people started believing me; they started to to work from now to enjoy the “First mover’s advantage”. Focus see my hidden potential. All I did was to find a valid reason on solving an issue or address a requirement through your albeit technical and personal from their criticism and started product. Don’t spend time on developing a ‘Me too product’. improving it. On the business side, it was the market stagnation The world already has got many options. What it needs is a that shook India in early 2000s. It was such a tough time when better solution. ☐ > www.efficientmanufacturing.in we couldn’t manage our operating expenses. We struggled for
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“The vision of large-scale manufacturing� Srinivas G Shirgurkar, MD, Ace Designers Limited, the largest manufacturer of CNC lathes in India, discusses the challenges and successes he witnessed since the start of his entrepreneurial career as a machine tool designer & manufacturer in 1979, in this interaction with Sumedha Mahorey. Can you elaborate on the major achievements in your professional career? After passing engineering from Bangalore University, I joined Central Manufacturing Technology Institute in 1970. Working as a design engineer, I got the opportunity to work on a variety of machine tools. After working for 10 years, three of us, Ashok Sathe, Benedict Machado and me, all of us from CMTI, set up Ace Designers in December 1979 offering Machine Tool Design services. We designed almost two dozen machines for various customers in the initial years, but realised that none of these machines hit the market as a product which could
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be produced in quantities. To tackle this, we decided to build machines of our own. We got our first order in 1983 from Kar Mobiles Ltd, an engine valve manufacturer, part of Rane Group of Companies. They asked us to make engine valve copy turning machine, valve straightening machine and friction welding machine. After building these machines, we realised the challenges of making SPMs. We realised the need to build standardised products, for larger quantities. Thus, the decision was taken to initiate manufacturing of turning machines. We started with minimal investment; we were after all working in government institutions. We brought out the first CNC lathe
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“We have chosen to grow very rapidly and by the year 2022-23, we should be in the top 10” Srinivas G Shirgurkar
and exhibited it in IMTEX-Mumbai. We also bagged an award for it. From then on, we have focused on only turning machines in machine tools. Which challenges did you face in the initial days? Our challenge was manufacturing in large quantities. We gradually started building the ecosystem for producing large numbers by investing in the right machines. We invested internally, facilities to make all critical parts used on our machines. Also, we set up our own facility for sheet metal parts, as we were not finding vendors to do that and hence, invested in laser cutting machines, CNC bending machines, among others. We set up a couple of ancillary units to make our components, one for machining larger parts and the other, to machine medium sized parts. We maintained that our ancillary units should not be dependent on the main company; only 50% should be manufactured for us and the rest for others. As we grew, we decided to make machining centres, for which Ace Manufacturing Systems was set up. We roped in P Ramdas and S Prabhakar to start this company. We partnered with Micromatic Grinding Technology and set up Micromatic Machine Tools to market our products in India and abroad. We have over 500 sales and service with 30 offices all round the country and abroad. We work as a group under the brand of Ace Micromatic. We as a group produce almost a third of all machine tools produced in India by value and are the largest in the business in India.
machines a year. This learning gave us tremendous opportunity to deploy our vision to be a large scale manufacturer. What is next on your success graph? We as a Group are the 58th largest machine tool company in the world. Our aim is to be ranked in the top 10. We have chosen to grow very rapidly and by the year 2022-23, we aim to be in the top 10. For this, we need to grow at 35% every year. We are making large investments in capacity; and are vertically integrating to have control on our costs and quality. We have also set up our own foundry to cater to our Group’s requirements. Can you elaborate on the leadership style which has brought you this success? We started with the three of us and today, as a Group, we are approximately 2500 people. We are design and technology people with no management expertise. Whenever we come across a challenge, we learnt the fundamentals of those fields, be it marketing, finance, HR, through books or took help of specialists from the field. Since the last six years, we are following the CII Business Excellence Model, which has helped us to scale our business and run efficiently.
What are your suggestions to entrepreneurs entering the machine tool industry? As per our experience, entrepreneurs come across multiple challenges. Any entrepreneur starts with expertise in one domain, but to run a business you need knowledge on a host Any memorable moments from your professional journey? We realised that the demand for any product was very price of domains. This is certainly a big challenge. Every time we sensitive. Thus, we decided to bring down the price of our came across a problem, we went through the best books on machines to jumpstart demand. This was a very memorable that subject and learnt from it. For example, when we wanted experience. In early 1990s, when our economy was liberalised, to have a marketing strategy, we studied Michael Porter’s book the auto industry was growing. There was increasing demand on strategy and learnt the principles of strategy. We could for auto components and these companies started sourcing immediately apply those principles in our context. One of the parts from job shops. We had a good market for our products objectives of the strategy is to make a choice whether to be a then, but price became a problem for these job shops. We cost leader or a differentiator. The book said that you have to were selling one of our popular machines Jobber at about take up one objective and stick to it and not divert from it. We `15.5 lakh per machine then, we dropped the price to `13.5 decided to be the cost leaders and produce in large quantities lakh (discounted by 15%). The result: the orders moved from and we have stuck to that strategy diligently. ☐ 50 machines per year to 150 machines in the first year, 300 www.efficientmanufacturing.in machines in the second year and now it’s more than 1500
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“Be focussed & passionate in your business” Indradev Babu, Managing Director, UCAM, the pioneers in manufacturing CNC rotary tables in India, briefs on his challenging journey of introducing the product in India and sustaining it to become a market leader in the technology. What has been your role as the game changer in the Indian machine tool / cutting tool industry? UCAM has been able to strongly contribute to Indian manufacturing, particularly in the metal cutting fraternity. UCAM launched CNC rotary table way back in the mid 90’s, when the demand for 4th axis solution was still very nascent. As customers started to realise the benefit of 4th & 5th axis in machine tool applications, the need for such products also increased. We realised this need and offered a slew of products along with supporting accessories, so that customers are provided with an array of solutions to enhance their productivity. Please share your professional journey with us and your major achievements…What made you to venture in this field and how you started?
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I began my career as a Mechanical Engineer at Bharath Electronics Limited, Bangalore. There I worked for about 8 years and then quit to start an ancillary unit to produce precision machined components. I was quite disillusioned with the nature of work, so later the business was diversified into the machine tool industry. My quick study revealed that no one was manufacturing CNC rotary tables in India. I felt that this product, though intricate, can be worked on. The initial journey was extremely difficult, as I was new to the machine tool Industry and building the UCAM brand was even more challenging. It took years of hard work and struggle to build the business to this level. Today, we are strongly present in the international market. Which memorable experiences have helped you in achieving your current position?
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DIALOGUE | GAME CHANGERS
“Backward integration is a very good strategy for better overall performance” Indradev Babu
Key customers have always been the inspiration – they provide To our great amazement, the products were well-appreciated novel opportunities that are challenging and demanding. Next and all the displays were sold for cash at the show. I really was the learning gained from our failures (product failure thought that it was a feat that too quite unexpected. at customer site) and finding a suitable solution utilising all available resources to solve the customer’s need. We always What according to you has been your biggest earning/ came out stronger and more mature while at the same time, learning? Would you like to mention any names in your earning the confidence of the customer. professional life from whom you got inspirations? My biggest learning has been about how customer perceives Which was the most challenging phase of your life? How did you and the way to build a brand that customer can depend on. you manage to overcome it? Also, I learnt that backward integration is a very good strategy The most challenging phase of my life was when I was for better overall performance. The one person who stands out transitioning from the job-work business to a product-based in inspiring me is my good friend Allesandro Luzzi from Italy; one. The company finance was already negative and this I found him to be a great mentor to me, always inspiring with stress led me to the hospital, battling for life. The financials new ideas and thoughts. went down to an extent that getting discharge from hospital was a challenge. While I was convalescing in the hospital, I What’s next on your success graph? strategised a way to rebuild the business and leverage finances We have a clear strategy to be one among the top 5 players in to pay the accrued debt. I also found suitable supporting hands our line of business internationally. While we have the product to manage the business. I implemented this plan step-by-step range, technology and competitive pricing, acceptability of an and gradually came out of the crisis. Indian brand is the biggest challenge. We intend to overcome with a strategy that we are right now deploying step by step. Can you share those moments in which you thought you had However, we still need 3-4 years to reach that position. We achieved a great feat? have also diversified into allied products like torque motors After the first journey of offering our products, there were many through its independent divisions. feedback and complaints. I decided to take a fresh look at our products. A bench mark of leading international products was Your advice to new age entrepreneurs to achieve the starting point and with a will to develop products of equal manufacturing success? or better performance, we came out with the range which we Be innovative, whether it is in product design, business model launched at the first international show we participated in, i.e. or HR practices. Differentiate your products and services. EMO Milan 2003. There is no option but to be highly focused and passionate in The most salient feature of the product was that it not only your business and work hard. ☐ had the aesthetics but also performed better. It was highly > www.efficientmanufacturing.in competitive and attractive compared to international products.
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“Gaining markets through design-led innovation” Milind Kelkar, Executive Director, Grind Master Machines, elaborates on the journey of his company from a small SSI unit in metal finishing to a global technology leader in metal finishing and deburring. What has been your role as the game changer in the Indian I did my Production Engineering from VJTI, Mumbai. machine tool / cutting tool industry? After passing out in 1980, I did a job with Tata Motors in Pune Design & innovation has been a passion for me. It was always for 3 years in their Machine setting and Maintenance Division. exciting to develop different types of machines and work on Then, together with my wife Mohini (who is also Production various finishing and deburring processes. We always took up Engineer from VJTI), started a small unit in a garage in my these challenges and so we now have a very large product basket. home town Aurangabad in 1984. We first built cookware buffing Similarly, since we attempted to export our machines to various machines for Nirlep. Subsequently, we went on developing countries, we could balance the order flow. It also gave us a various kinds of machines. In the year 2000, microfinishing good exposure to observe and absorb the various technologies technology caught our attention and we started developing used worldwide for metal finishing and deburring. microfinishing machines. In order to offer complete solution to the customers, we cooperated with some German and Japanese Can you share your professional journey with us and your companies who make the deburring and polishing tools and major achievements…What made you to venture in this abrasive tapes. In 2003, we signed a Licensee Agreement with field and how you started? US Company who are the pioneers in Microfinishing GBQ
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UNITED GRINDING:
MĂ„GERLE
BLOHM
JUNG
STUDER
SCHAUDT
MIKROSA
WALTER
EWAG
IMTEX 2015 Hall 3A Booth B 105
Solutions for precision machining UNITED GRINDING Group The UNITED GRINDING Group is the leading manufacturer of precision machines for grinding, eroding, lasering, combination machining and measuring. We offer our customers comprehensive services worldwide. www.grinding.ch
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“We always looked for a demanding customer and this gave us ample opportunities to learn and develop so as to achieve our current position” Milind Kelkar
technology for camshafts & crankshafts. We developed India models to fulfill the demands of our Indian customers. We also started exporting these machines to our partners in US and UK. In the field of deburring, we got an opportunity to develop precision deburring machines for our Swiss partners who sold these machines in Europe. We have been participating in trade fairs in Germany, Turkey & Thailand since 2005. This has given us a good exposure and platform to export. In 2010, we started exporting to China through local agent and in 2014, we set up sales & service office in China. In 2012, we introduced robotic solutions for deburring & fettling of castings & forgings as well as machine tending applications. Started in 1984 in a garage, Grind Master is now recognised as a global player in metal finishing and deburring. With over 4000 machines across 6 continents, serving a wide range of industries, we bring a world of experience in machine technology and process knowledge. A Grind Master solution is characterised by design-led innovation supported by a robust organisation and strong service. A result of absolute engineering with passion. Which memorable experiences have helped you in achieving your current position? We had great learning experience whenever we took up any new machine design or whenever we started working with any new multi-national customer. We always looked for “A demanding customer” and this gave us ample opportunities to learn and develop so as to achieve our current position.
them world-class machines from India. I think the passion for taking such challenges and hard work can only help to overcome them. Can you share those moments in which you thought you had achieved a great feat? It was an exciting moment when we bagged our first order from General Motors. Particularly, since we got this order against German competition and on the basis of our technology and not the cost. The customer wanted faster set up change time to which I agreed and we indeed developed a quick change system to ensure this. This order was a very big challenge for us and involved several late nights. But with this order, we could enter in China Auto OEM Market in a big way. This also made us develop elaborate Project Management System. What according to you has been your biggest earning/ learning? Would you like to mention any names in your professional life from whom you got inspirations? It has been a continuous learning process and it will continue to be so. I am still equally excited to see some new technology or an innovation as I used to when I was 25-years-old. I have met several people and companies across the world and have learnt from almost each one of them. What’s next on your success graph? Last year, we set up a sales & service office in China. Now we want to expand in similar way across the globe. We would also look at new technologies and cooperation possibilities.
Which was the most challenging phase of your life? How did Your advice to new entrepreneurs on success mantra in manufacturing? you manage to overcome it? I think throughout our journey from 1984 till now, we have Passion and commitment are the two basic values which are faced many challenges. First, there were machine design absolutely must for any successful machine tool manufacturing. and development challenges. Then, it was developing the Consistent upgradation and development of technology and organisation to build consistently good quality machines. constant innovation are also important mantras. ☐ > www.efficientmanufacturing.in Then there was a challenge to reach out to the world and offer
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GLOBAL CEOS INTERVIEW “Management is efficiency in climbing the ladder of success; leadership determines whether the ladder is leaning against the right wall,” says Stephen Covey, one of the world’s foremost leadership authorities, organisational experts, and thought leaders. With the changing manufacturing landscape where technology is transforming the shop floor and the way the top management functions, efficient, effective and foresighted leadership is the only mantra to success. This interview series with Global CEOs brings forth their leadership traits, thought processes while handling global markets and their vision for the Indian market. - TEAM EM
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GLOBAL CEOS | INTERVIEW
“Modinomics will attract investments & boost Indian manufacturing” Ho-Keun Song, Chairman, YG-1 Co Ltd, a leading South Korean manufacturer of cutting tools, in this interaction with Sumedha Mahorey, stresses on the strong growth likely in the aerospace and medical industries, their expansion plans for India while strategising on products of high quality at competitive prices by change and innovation, to win the market. Excerpts… How is the business scenario for your company in India and globally in the current market situation? In 2015, the global economy will grow higher than 2014 but the growth will be weak and marginal. USA will lead the global economy, as it grows higher than 2014 through expansion of investment and industrial production. Euro Zone will not show a clear growing trend and Japan economy will show the improvement in consumer confidence level but slow growth in export market and investment will limit it. Emerging countries will recover their growth slowly. The Chinese Government focuses more on economic structure, balanced growth and slowdown in investment. Thus, the economy will continue to grow but its growth rate will be slowed down. Brazil expects to show its economic growth by expansion of industrial output due to reduction of uncertainty and new economy after election. ASEAN countries will boost their economy due to political stability and government-driven-economic reform.
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It is expected that Modinomics, which is led by India’s new Prime Minister Narendra Modi, will boost Indian economy by reforming Indian economic structure into a market-friendly one. I expect Modinomics to attract investments and boost Indian manufacturing sectors, leading in long-term growth. How do you look at the opportunities and challenges within the industry? The growth of the global economy is slow & weak, so we do not expect to witness increase in the demand for cutting tools. On the other hand, competition is likely to intensify between manufacturers from advanced and emerging countries. The technology gap will become smaller in the cutting tools industry. However, industrial sectors such as aerospace and medical industries are expected to grow strongly. It will challenge YG-1 to penetrate in new industries & markets, and provide opportunities to develop new tools and compete with high-end market.
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INTERVIEW | GLOBAL CEOs
“We are developing new tools and new coating across the market, developing our own production technology to keep and improve the consistency of quality” Ho-Keun Song
What is your approach towards R&D and innovation strategies? R&D is one of the top priorities and is driving our growth & development. While we are investing to grow and train our engineers and recruit overseas talents, we are developing new tools and new coating across the market, developing our own production technology to keep and improve the consistency of quality. How are the business networks spread across the regions & their contribution in your company’s growth? YG-1 has 7 factories in Korea and 13 factories in overseas. YG-1 has its own 31 overseas manufacturing and/or sales companies in 21 overseas countries, including 2 Indian manufacturing facilities. Our global subsidiaries provide the customers with the logistic and technical services. Currently, our main export market is EU and North America. We’re expanding our market share in the emerging market of China, India, Brazil and South East Asian markets. Which are the potential end-user industry segments for your company? Our current end-users are in the general engineering and mould & die industry. We’re developing and focusing on the tools market for mass production customers in the automotive and aerospace industries. We are also targeting medical and power generation industries. Can you comment on the trends in metalworking – technology & customer needs? In the end-user industry, high-speed machining and automation are growing. Industries are enforcing the trend of weight lightening with composite material, diversification of material and the hardness of the material. We also expect to grow nano and micro size machining in the industry. Due to the environmental issues, dry cutting is also getting popular. Along with such trend in end-user industry, demand for longer tool life, high-precision, micro-cutting tools will grow and YG-1 is providing such high-performance cutting tools in the market. How do you look at the demand trends globally in the
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manufacturing sector, in general? After the world economy went down with global financial crisis, manufacturing industries are treated as the engines of economy, providing employment. In advanced countries, manufacturing is reshoring while labour cost is increasing in developing countries and demand of labour is reduced due to automation in manufacturing. The reshoring and diversification of manufacturing base will be increased with digitalisation of manufacturing representing 3D printer. On the other hand, as the slow growth of global economy becomes normal, we do not expect the manufacturing sector to grow highly, although competition will be severe. Companies should provide customers with products of high quality at competitive prices by change and innovation, to win the market. What is your diversification & expansion plans for India and globally? India is the 7th largest automotive manufacturer and the 9th largest civil aviation market. As these industries expect to grow in double digits, the machine tool industry will grow in proportion. In order to expand our market share in the growing Indian domestic market, we’re investing in new manufacturing facilities in India and the mega project will start in 2015. With the raising young working population in India, YG-1 is planning to expand its manufacturing base in India for not only domestic market but also export market. How do you look at making manufacturing an appealing industry to attract the right talent? With general and standardised commodity of products, decreased gap of technology, increase of price competition, servicitisation and digitalisation of manufacturing, the service activity of manufacturing sector becomes important. Its employee portion in R&D, marketing, logistics, etc thereby increases. This creates and adds value in the manufactured products. Also, the talent in such areas becomes important in manufacturing. To attract the right talent in the manufacturing sector, the industry should invest in digitalisation, IT infrastructure, be open to recruitment of the employees globally and invest in training them. ☐ > www.efficientmanufacturing.in
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GLOBAL CEOS | INTERVIEW
“Driven by the need of providing innovative solutions” Dr Akimitsu Nagae, Vice President, Yamazaki Mazak Corporation and President, Japan Society for Precision Engineering, speaks on Mazak’s innovation strategies, productivity improvement tools and the diversification and expansion strategies globally and in India. Excerpts from his interview with Shekhar Jitkar…
How has been the performance of Mazak in India and globally, in the current market situation? Mazak is doing quite well globally. In India too, our company has shown good performance because of its large portfolio of products suitable for a variety of industries. The main growth drivers for Mazak in India in 2014 were power, oil & gas, auto and general engineering. How do you look at the opportunities and challenges within the industry?
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Over the years, Mazak has been developing products keeping in mind new opportunities and target industries. In addition to that, Mazak puts strong emphasis on innovation and “DONEIN-ONE” concept. This concept incorporates all machining processes from raw material input through final machining – in just one machine. It provides the ability to reduce production lead time, improve machining accuracy, reduce floor space and initial cost, lower operating expenses, reduce operator requirements and to improve the work environment. As a result, the concept not only streamlines production, but also
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INTERVIEW | GLOBAL CEOs
“The new development of products is driven by the need of providing innovative solutions to customers, so that they can produce components at high accuracy consistently, with higher productivity” Dr Akimitsu Nagae
There has been an aggressive trend in collaborative partnerships and acquisitions all over the world. Is Mazak looking at such kind of opportunities in future? This collaborative partnerships has been going on in machine How are Mazak’s R&D and innovation strategies vis-à-vis tool sector over the years. Mazak is a unique company, which has been successful globally in not only selling their products changes in the market requirements? Mazak keeps its eyes and ears close to the customer requirement but manufacturing as well. It has 10 manufacturing plants globally. The new development of products is driven by the globally - 5 in Japan, 1 in USA, 1 in UK, 1 in Singapore and 2 need of providing innovative solutions to customers, so that in China. The USA manufacturing plant was built in 1974 and they can produce components at high accuracy consistently, UK in 1987. with higher productivity. What are your diversification & expansion plans for India Productivity improving machine tools has been the strength and globally? Any plans to start manufacturing in India? Mazak has been expanding globally in opening new technology of Mazak. Can you brief us on this? Productivity improvement comes from two aspects - the first centres and expanding its manufacturing activities. In 2013, is to have high speed machines and the second one is to have Mazak’s new plant in China was inaugurated and in 2014, the multi–tasking concept in these high speed machines. Our expansion of Singapore plant took place. In last 3 years, we company has been known in the market to be very successful opened 6 technology centres around the world. Today, we have in both the above aspects. We manufacture not only advanced 79 technology and technical centres in 20 countries worldwide. machine tools, such as multi-tasking centres, CNC turning The technology centres are the local bases to introduce centres, machining centres and laser processing machines, technology solutions to customers by demonstrating the newest but also automation systems with the concept of “DONE- machines, displaying the latest applications, offering advice on IN-ONE” to support global manufacturing by providing parts machining, providing training and many other services. exceptional productivity and versatility. We will continue to The Indian market is very important for Mazak and we are develop productivity improving machine tools for progress in closely monitoring the developments in this market. We will take suitable decision about manufacturing at the right time. ☐ manufacturing as well as society. improves overall management. The multi-tasking machines are good example of that and has been very successful in the global market.
> www.efficientmanufacturing.in
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GLOBAL CEOS | INTERVIEW
“We will be seeing more intelligent tools” Lars Bergstrom, Group President & CEO, Seco Tools, endorses standardisation, customisation and recycling approach in manufacturing through his company. He believes that increasing digitalisation will be the trend that will rapidly change industry conditions and impact production. In this interview with Shekhar Jitkar, he elaborates on the technology trends in the metalworking industry and his company’s strategies towards growth. How is the business scenario for your company in India and us for our knowledge and the practical attitude we have globally in the current market situation? working together to improve profitability. With the launch of India will continue to be one of our priority markets. We aim MyPages, we will further strengthen the co-operation with our to grow faster than the market development during next year, customers. both in India and globally. Regardless of the development of the market, I am convinced that Seco Tools will continue to How do you look at the opportunities and challenges within grow with the strong program of products we launch next the industry? year. We have great opportunities working closely with our customers and strengthen their competiveness. One area that How are you progressing towards building your company’s is growing in importance is what we call DCR (Documented brand for the future? Cost Reductions), which shows the savings we can help our By living our values and focusing on bringing value to our customers achieve. customers, we will strengthen Seco Tools brand. We have a strong position in the market and our customers appreciate What is your approach towards focus on R&D and
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INTERVIEW | GLOBAL CEOs
“The greatest threat to the new technology is that standardisation is largely lacking in the information and communication technology used in the manufacturing industry” Lars Bergstrom
innovation strategies? We have a strong tradition in R&D. As an example, we will launch almost 3700 new products and services during next year. We will continue to drive innovations within the company. India, which is one of our R&D hubs, will play an increasingly important role.
customer’s reality is currently of considerable relevance to the manufacturing industry. This is an area in which we, at Seco, have traditionally excelled. The challenge now lies in how we can utilise the trends we are identifying and how to adapt them to customer requirements. Customers primarily want simplicity in the form of easier tool maintenance, work methods, production and recycling. What they don’t want is to How are the business networks spread across the regions & have a complicated work flow. Our task is to make their lives simpler and in this regard, we are facilitated by digitalising their contribution in your company’s growth? We have a strong local anchoring around the world, supported solutions. I am convinced that we will be seeing more intelligent tools by globally adapted processes and solutions. I believe this will in the future. We are already developing tools today that are help us in supporting our customers in an efficient way. capable of adapting themselves in different ways. Now, it is a Which are the potential end-user industry segments for your matter of embedding sensor systems and communication into the tools as well. The greatest threat to the new technology company? The aerospace and automotive industries are important for us is that standardisation is largely lacking in the information and communication technology used in the manufacturing as well as all our customers within general engineering. industry. Everyone has a proprietary system and as long as Can you comment on the trends in metalworking – there are no standards, we will operate as isolated islands. To succeed, we must be involved in and influence the standards. technology & customer needs? There are several overall trends that are impacting the manufacturing industry and its customers. I believe that we How do you look at the demand trends globally in the will continue to see a drive for improved productivity, where manufacturing sector, in general? we are strong and have a good potential to help existing and It will vary a lot over the world; USA and Asia will probably be the big drivers during next year. Looking at different new customers. Recycling, and for us the recycling of cemented carbide indicators, shows the uncertainty that we are facing, still we inserts, is a current trend. It creates many advantages for Seco remain positive and will focus on growing our business during Tools and its customers. The initiative we drive aims to improve next year. One trend that is clear is the digital revolution that the company’s environmental footprint and secure our supply we see in the world. of raw material in a process that requires minimal effort for our customers. As a finite resource, new production of tungsten What are your diversification & expansion plans for India will eventually come to an end. In addition, recycling has a and globally? significantly lower climate impact than new production. And We will continue to build on our strength, that we are perceived as the trend is that we and our customers become greener, this as a knowledgeable partner that understands the challenges our customer faces, this together with our strong offering will will have an impact on how we work. Other examples are the increased networking in society, drive our growth going forward. In India, we will continue to accessibility and local adaptations of what industries are expand our research and development operation as well as offering their customers. However, increasing digitalisation continue to invest in production. The development over the may be the trend that most rapidly changes industry last years have focused a lot on building both capacity but also conditions. It is impacting our own production and perhaps as important to build knowledge among all our employees. ☐ more importantly, our customers’ production. www.efficientmanufacturing.in Customising a product offering in accordance with a
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GLOBAL CEOS | INTERVIEW
“Our aim is to be an innovation leader” ...says Marc Blaser, CEO, Blaser Swisslube, who represents the third generation of the family‐owned business, founded in 1936. In this discussion with Srimoyee Lahiri, he elaborates on the growing trends in metalworking and the approach towards R&D aligned with innovation strategies. How is the business for your company in India and globally in the current market situation? What are your plans for India and globally? The manufacturing industry in India has witnessed a strong growth in the last decade. The overall size of the manufacturing industry has expanded significantly. We are expecting the industry, along with the metalworking fluid potential, to keep on increasing in the upcoming years, even though, there will always be some temporary hiccups in the economy as we have experienced in the past two years in India. For more than ten years, we have been able to establish ourselves as a leading
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technology company in India, which is oriented to provide highest measurable value to our customers. Our goal is to build and maintain sustainable business partnerships with our customers on a long-term basis in the metalworking industry within India and globally. How are you progressing towards building your company’s brand for the future? Brief us on your current business model. We are progressing well. Blaser Swisslube’s goal is to optimise its customers’ manufacturing processes with the liquid tool. In
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INTERVIEW | GLOBAL CEOs
“Manufacturing technologies are evolving to support the needs of the industry to ensure optimised quality of components with least possible manufacturing time, which will reduce the overall cost per component and assure optimal process reliability” Marc Blaser
close cooperation with the customers and based on a holistic bacteria – the so-called primary bacteria; these bacteria take view of the manufacturing process, our company presents the up the biosphere of the metalworking fluid and keep “foreign possibilities to fully exploit the potential of machines and tools bacteria” out. The primary bacteria pose no harm to people by using the right metalworking fluid which becomes a liquid or the metalworking fluid in any way. It ensures a long-term tool. Our aim is that the industry sees the metalworking fluid stability and a consistent performance of the metalworking as a relevant component in a machining process and not just fluid. This unique formulation is a small effort being made as a necessary evil. Machine, cutting tool, machining strategy, by us along with our customers to contribute towards a safer material and metalworking fluid influence a machining planet. operation significantly. Productivity, economic efficiency and machining quality depend in large part on the choice and What is your approach towards R&D and innovation quality of the metalworking fluid and on the expertise of the strategies? We invest a considerable amount of our revenue into R&D machining specialists. projects. We have the largest laboratory of the industry in How do you look at the opportunities and challenges within Switzerland headquarters, which includes the special fields the industry? What are the emerging demand trends globally R&D, customer service, analytics and microbiology. Our aim is to be an innovation leader. We constantly look into our in the manufacturing sector, in general? With the growing demands of high quality manufacturing, product portfolio and upgrade it to bring in new technology together with tight timelines of project deliveries, the formulations, which bring our customers real, tangible manufacturing industry is constantly facing the challenges benefits. In our in-house technology centre, we have created of working on higher productivity with improved quality. the optimum conditions for simulating and testing the latest Manufacturing technologies are evolving to support the needs machining technologies with our new developed metalworking of the industry to ensure optimised quality of components fluids. with least possible manufacturing time, which will reduce the overall cost per component and assure optimal process How are the business networks spread across the regions & reliability. A thorough analysis of the machining situation their contribution in your company’s growth? brings an opportunity and is the basis for a competent advice Our headquarters are based in Hasle-Rüegsau, Switzerland. on machine, tool, parameter and metalworking fluid selection. Currently, we are active globally in about 60 markets with Only if all elements work hand in hand, an optimisation of a our own subsidiaries and representative offices. Every local subsidiary, representative office is close to its customers. Each machining process is achievable. branch office is essential for our overall company growth. Can you elaborate on the trends in metalworking – Which are the end-user industry segments for your technology & customer needs? Regulatory hurdles more and more restrict the use of biocides company? in metalworking fluids, especially in Europe but increasingly Our clients can be found in every segment – everywhere where also in the BRICS countries. Blaser has introduced a biological metal is machined and chips are dragged out. This includes concept over 40 years ago in its strive to protect both, the general machining job shops, watch-making, medical, aircraft machine operators and the environment. With our Bio-Concept and automotive industry and its suppliers as well as various ,a deliberate effort has been made not to use bactericides and other component manufacturers, among others. ☐ > www.efficientmanufacturing.in to promote the presence of specific, harmless, waterborne
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GLOBAL CEOS | INTERVIEW
“Focus efforts on creating added value” Alexander Blum, President, Blum-Novotest GmbH, a process integrating manufacturer of measuring and testing solutions in this interview with Sumedha Mahorey, elaborates on the continuing trend of distribution of highly automated production systems in the coming years and the company’s focus on global sales & service roll-out globally and in India to get closer to its end users. Excerpts… How is the business scenario for your company in India and and people in all countries since the development to produce globally in the current market situation? closer to local markets and more customised to local end-users Currently, about 450 highly motivated employees are working will proceed, both in the area of investment and consumer for Blum-Novotest GmbH and the number is growing rapidly. goods. These production systems require the full support of The same applies for our subsidiary in India, which was manufacturers to enable them to provide their full potential to founded in 2011. At our subsidiary in Bengaluru, we employ end-customers. 16 people. We also have 3 sales and service offices in Chennai, Pune and Gurgaon. What is your approach towards focus on R&D and innovation strategies? How do you look at the opportunities and challenges within We respond to the needs of our customers and focus our the industry? effort systematically on creating added value and benefits We are consistently following up the changes in the for them. As with the previously developed digital/analogue manufacturing world. Growing accuracy requirements touch probe TC76-DIGILOG, which was especially developed and, above all, the development of automated production for measuring and testing workpieces, we are now presenting processes to secure stable and high quality levels are becoming many verification possibilities from one source in these new increasingly more important in this respect. The distribution developments: The measurement of workpieces and bores, the of highly automated production systems will continue during determination and compensation of workpiece temperatures, the coming years worldwide. It holds chances for companies as well as the verification of the workpiece surface roughness.
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INTERVIEW | GLOBAL CEOs
“We are offering attractive positions in an interestingly multi-cultural environment – glamorous by not only requiring technical skills but also language and social skills to succeed in the modern world” Alexander Blum
How are the business networks spread across the regions & in highly productive applications of high-value, technically sophisticated workpieces or in the production of hightheir contribution in your company’s growth? When we at Blum-Novotest decided to approach the world priced components. The user trend of the second direction market from the Central European niche in 1997, we hoped of development departs with high speed from simple, hard for today’s success but it was certainly not guaranteed. After to automate standard machines to what I would like to call some changes in the 30th year of its existence, the company “consumable machines”. These machines are produced in large had just started forming a fresh structure with the present quantities unrelated to orders in modern flow concepts and three divisions in measuring and test technology. At the are favourable, easily equipped with options by dealers and beginning of our internationalisation, the focus was on our end-customers and, above all, easily automated eg by robot measuring components for machine tools. Today, however, our solutions. They are increasingly used in automated turnsubsidiaries support all of our three divisions worldwide. In key production solutions for SMEs and also in interlinked, 2012, this network was able to prove its technical capability automated production processes of consumer goods or the also in the most complex projects under demanding conditions, series production of smaller components in the automobile for example with projects for Blum-Novotest test benches from industry or in medical engineering. Today, we encounter both Japan and China through to India, the UK, USA and Brazil. automated cells and interlinked series production solutions on all continents, irrespectively of the local cost situation. In this Which are the potential end-user industry segments for your connection, the use of sensors in machine tools is constantly company? gaining importance. In particular, the uses of applicationWith our innovative measuring and testing technology, we connected sensors/ instrumentation like workpiece and tool are a successful partner of the international machine tool, measuring systems. The capabilities of this instrumentation automotive and aerospace industry as well as energy and often precede the capabilities of machine controls today. medical technology. Overall, where numerical controlled Analogously scanning touch probes, roughness tests, eddy machine tools are used there is a potential need for our current instrumentation or measuring heads independent products. of machines are only some of the keywords concerning the technical possibilities to generate closed process chains in Can you comment on the trends in metalworking – modern production systems/machines. technology & customer needs? On one hand, there is the increasing use of complex, often What is your diversification & expansion plans for India and multiprocess-capable production machines with integrated globally? automation. These units, which range in the high investment We are going to continue our global sales and service roll-out bracket, are still complex in operation and do not support globally and India to get closer to our end users and support closed process chains sufficiently. In the future, however, they not only in service & maintenance but in application support will increasingly present themselves on the world market with to help generate the ROI for the end user who has decided for simpler user surfaces, support of self-controlling processes our product. ☐ and embedded in the organisational production flow of the > www.efficientmanufacturing.in operator via CAD/CAM and ERP. They are typically employed
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GLOBAL CEOS | INTERVIEW
“Industry has a continuously evolving appetite for improvement” Pawel Duzniak, President, Europe & India, Walter Tools AG, affirms the reforming policies of the Indian government for the manufacturing sector and elaborates on the opportunities and challenges within the industry, during an interview with Srimoyee Lahiri. How is the business scenario for your company in India and globally in the current market situation? Globally, we are growing faster than the market development. The same is true for Walter India which has registered impressive growth against all odds in comparison to the local market. The company in India has growth plans through market share gain and distribution base expansion during the next five years. We rely on a solid growth strategy, which enables us to provide our customers a competitive advantage through innovative technologies, premium product quality and expert engineering services. How are you progressing towards building your company’s brand for the future? Our competence brands Walter, Titex & Prototyp bring together an extensive engineering experience and are known for having the best tools in the fields of milling, turning, hole-making and threading. The company is globally acknowledged as the supplier for complete machining solutions. Our positioning in
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India is in line with our global market approach. We have been working very closely with our customers in optimising their manufacturing processes using our comprehensive product portfolio and wide experience from all competence brands. How do you look at the opportunities and challenges within the industry? These are challenging but interesting times, which calls for manufacturers to device processes and technology that not only address the markets requirement of price with profitability but also technological innovations that provide a competitive edge to meet the end user’s demand. It is thus, an imperative obligation to be there for our manufacturing clients and provide them this needed competitive advantage through innovative cutting tool technologies, product quality and Expert Engineering Services. What is your approach towards focus on R&D and innovation strategies?
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INTERVIEW | GLOBAL CEOs
“We will continue to undertake initiatives that will help Indian industries to achieve the highest standards of manufacturing efficiencies” Pawel Duzniak
The perpetually growing competition in the manufacturing Walter Engineering Kompetenz each day. The unprecedented pace of technological change gives sector, both from local and global players, has led to increased end-user expectation towards cost and technological opportunities to businesses for creating growth through rapid competitiveness. Today, manufacturing companies need to act conversion with newer technologies. Identifying customer’s as cutting tool experts offering optimised machining solutions needs – often before they realise it themselves and creating the right solution, drives business growth. For leaders of for increasing productivity as quality. In this context, the company has set benchmarks with innovative technology (like Walter) it is most important to highly innovative products and services. Walter Xpress, for leverage the voice of the market and respond to their dynamic example, is an incredibly fast ordering and delivery service requirements. for high quality special tools from Walter, Walter Titex and Walter Prototyp. With this automated software, quotations What are your diversification & expansion plans for India for enquiries are calculated and provided with 3D models of and globally? special tools within 24 hours. Further, quick manufacturing Walter is not shying from investing in India as its faith in the and delivery are clear advantages of the special tools service, India growth story remains intact. Of course, we are quite aware of the present predicament alongside the confidence Walter Xpress. of a revival. While the market is flat with eminent signs of Which are the potential end-user industry segments for your revival and we do feel that things would be getting better in India sooner than expected. My optimism comes from the new company? While the automotive segment contributes to a major share government in India and its reforming policies, which has given of our business, Walter has established its dominance in other a good boost to the economy. The Prime Minister of India has resilient segments like railways, aerospace, power equipment called upon the world with the “Make in India” slogan, thus striving to make manufacturing sector in India move upwards. and so on. Our state-of-the-art technology centre at Pune exhibits The purchasing power of the rural segment would also go up. competencies through live demonstration of the latest from This will have a positive impact on the FMCG sector as well the machining world. Prototype development, prove-out of as the auto sector. Things will certainly change for the better. new products and process optimisation solutions along with In the long term, India’s good educational standards, a young technology exchange and specialised training for customers population and the growing middle class as the driving forces for and engineers are few of the major offerings that customers the economy. Despite the current challenges, you cannot deny these opportunities. Of course, some key policies including the can experience through our technology centre. huge import duties need refinement. The customs and other Can you comment on the trends in metalworking – related policies are not very business friendly. This is making accessibility to advanced technology expensive and that is a big technology & customer needs? Today, end-users are demanding the latest in technology at disadvantage for Indian manufacturers. Also, infrastructure the most economical cost. The industry has a continuously development needs to be given the highest priorities. We can evolving appetite for improvement which calls for challenging foresee India becoming a major manufacturing economy in the applications, surfaces & materials to be machined. On top of times to come. Walter wants to partner Indian manufacturers that greater precision is required to be achieved at an ever in this growth; we will continue to undertake initiatives that increasing productivity rate with rock solid process security. will help Indian industries to achieve the highest standards of We concentrate with a holistic approach on the entire range manufacturing efficiencies. ☐ of our client’s applications and on what they can achieve using > www.efficientmanufacturing.in our specialised process optimisation solutions, thus, delivering
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GLOBAL CEOS | INTERVIEW
“Continuing global recovery remains a big opportunity for manufacturers” Clive Martell, Chief Executive, Delcam Plc, discusses how customer needs are evolving for faster and easier programming with more sophisticated machine tools in today’s times while elaborating on the emerging trends in metalworking technology. How is the business scenario for your company in India and globally in the current market situation? Delcam is doing well in India, with steadily increasing sales of our manufacturing software. Even so, we feel that India is still a market with significant potential for further growth. Globally, we are also seeing a steady increase in sales in most areas, with particularly good increases in China, Korea and in UK.
R&D, to build the company’s international reputation. Most importantly, we continue to strengthen our training and support areas to ensure that our customers are able to gain maximum benefit from their investment in our CAD/CAM software. Despite all the marketing that we do, positive comments from our existing customers remain the best way to build our brand recognition.
How are you progressing towards building your company’s brand for the future? We continue to invest heavily in marketing, as well as in
How do you look at the opportunities and challenges within the industry? The continuing global recovery remains a big opportunity for
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INTERVIEW | GLOBAL CEOs
“We continue to strengthen our training and support areas to ensure that our customers are able to gain maximum benefit from their investment in our CAD/CAM software” Clive Martell
manufacturers, particularly for suppliers to the automotive All users of machine tools are potential users of Delcam’s and aerospace industries. The challenges remain the same software. Automotive and other types of engineering are the – finding ways to increase productivity and improve quality, most important areas but we also have sales into many other while keeping costs under control. industries, such as jewellery, engraving, footwear manufacture and healthcare. Brief us on your current business model. Delcam is a wholly-owned, independently-operated subsidiary Can you comment on the trends in metalworking – of the US company Autodesk. We are headquartered in technology & customer needs? Birmingham, the UK, with subsidiaries and joint ventures in Customer needs are for faster, easier programming and faster, main industrial countries, including India. more sophisticated machine tools. More sophisticated machine tools, such as turn-mill equipment and five-axis machining What is your approach towards focus on R&D and innovation centres, are more productive but can be more difficult to strategies? program without the appropriate software. For many years, Delcam has invested around 25% of its turnover in R&D to ensure that our software remains a leader How do you look at the demand trends globally in the in the various fields in which we operate. This strong focus manufacturing sector, in general? on R&D is continuing following our recent acquisition by Global demand continues to grow, driven in particular by the Autodesk. We continue to employ by far the largest R&D team automotive and aerospace industries. Recent exhibitions, such in the CAM business. as the IMTS Chicago, are reporting increased attendances and high levels of sales of equipment. How are the business networks spread across the regions & their contribution in your company’s growth? What are your diversification & expansion plans for India As mentioned above, Delcam has subsidiaries or joint ventures and globally? in the main industrialised countries. Our sales are divided Delcam is already well represented in India with offices in between Europe, Asia and the Americas, with something more the main manufacturing centres. Our future expansion will than one third in Europe and something less than one third in focus more on strengthening our existing centres rather than the USA. Sales in all three regions are growing, with Europe setting up more new offices. The automotive industry is growing slightly faster than Asia and USA. likely to remain our most important sector, both in India and globally, but we see many opportunities to expand, especially Which are the potential end-user industry segments for your in aerospace and in healthcare. ☐ > www.efficientmanufacturing.in company?
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GLOBAL CEOS | INTERVIEW
“Actively considering manufacturing facility in India” Teruhiko Masuda, President— Advanced Materials & Tools Company, Mitsubishi Materials, a leading cutting tool manufacturer in Japan, in an interview with Megha Roy, discusses the company’s investment plans in R&D to launch new grades, geometries and coating technologies for establishing the cutting tools brand globally. How is the business scenario for your company in India and globally in the current market situation? In India, we have registered a sizable growth year-on-year. Even though the growth of the cutting tool industry has slowed down a little in the past few years globally, our company had a pleasant journey accomplishing a double digit growth last year. We intend to continue it for the next couple of years. On a long-term basis, we see good growth opportunities for the cutting tools business worldwide. Especially, India & China will contribute a lot to MMC’s global growth. How are you progressing towards building your company’s brand for the future? We respond to customer’s challenges with professional craftsman and do our best to actively contribute to their
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success. We strive to become the only tool manufacturer globally offering “your personal craftsman studio”, where our customers can find state-of-the-art technologies & products. They can also find solutions anytime, anywhere in the world and share our excitement on the latest technology trends & product innovation. As such, it is the studio where we think, share, create and develop together with our customers exciting solutions to meet their specific needs. How do you look at the opportunities and challenges within the industry? Our company’s core strength is in developing varieties of cutting tool materials and coatings. So, opportunities are plenty. Challenging materials, complex geometries, increasingly specialised quality and performance requirements are the main
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INTERVIEW | GLOBAL CEOs
“In today’s world, rapidly changing market demands require special efforts to implement new technologies at a competitive price, stipulated time frame & user-friendly ways” Teruhiko Masuda
factors putting enormous pressure on development of cutting tools. As a result, product life cycle has reduced significantly, increasing development, manufacturing & service costs. Apart from this, skilled manpower to establish the technology is a major concern. What is your approach towards focus on R&D and innovation strategies? In today’s world, rapidly changing market demands require special efforts to implement new technologies at a competitive price, stipulated time frame & user friendly ways. This is one of the biggest tasks for the industry. We are also spending a major portion of our revenue on research & development and have already come up with a series of new products, making our company one of the leading cutting tools brand globally. Which are the potential end-user industry segments for your company? So far, the automotive sector has contributed prominently in our business compared to other sectors. This is likely the case for most of the cutting tools suppliers globally. However, looking at the growth in impending sectors like aerospace, energy and medical engineering, we have recently launched many new products like the new turning & milling grades, solid carbide drills MVE & MVS, exchangable head endmills iMX, new PCD milling cutter F-Max, a wide range of small tools, etc. We will be aggressively focusing on these sectors in the coming years.
machining of alloy steel, cast iron & aluminium alloys. But due to strict environmental policies, higher demand and the need to increase the resilience of the product, work materials are changing and as such, high temperature alloys, high strength materials or composite materials are in demand now. To cope with these changes, MMC Japan is investing handsome amount of revenue on research & development to launch new grades, geometries or coating technologies. For example, we recently launched smart miracles end mill series with irregular helix & improved gash geometry for effective chip evacuation. This product is also powered by innovative coating technology called TOUGH-Σ to enhance smoothness & sharpness of the cutting edge for a longer tool life. How do you look at the demand trends globally in the manufacturing sector, in general? Demand in the manufacturing sector globally will go up steadily. However, specific markets like India, China, USA are bound to contribute significantly in the coming years.
What is your diversification & expansion plans for India and globally? There has been a request from many of our customers to have a manufacturing facility in India and we are actively considering it. We would like to offer competitive solutions to our esteemed customers in price, overall quality and lead time as well. We are looking forward to joining the “Make In India” campaign too. This may take a couple of years. We are also going to invest Can you comment on the trends in metalworking – smartly in various manufacturing facilities in Europe, the USA technology & customer needs? & South East Asia. ☐ > www.efficientmanufacturing.in Conventionally, metal cutting industry was governed by
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GLOBAL CEOS | INTERVIEW
“Increasing customers’ competitiveness” Stephan Nell, CEO, United Grinding, strongly believes in being close to the customers so as to increase customers’ competitiveness and in turn make his company’s brand stronger. He shares his views on the opportunities and challenges as well as technology trends and market demand in the grinding sector globally, in this interview with Shekhar Jitkar. Excerpts… How is the business scenario for your company in India and thanks to our locations around the world. The customer is the globally in the current market situation? focus of all activities. Customer benefit should be the driving We’re expecting a growing grinding market worldwide in 2015, force that motivates us to perform excellent work and make including India. The geographical distribution of the machine our brand stronger. orders shows an improvement in the situation in Germany. The Latin countries of Europe are showing signs of recovery. How do you look at the opportunities and challenges within Eastern Europe is growing constantly, and Northern Europe is the industry? also starting to become more active again. Investments should We find opportunities and challenges in being close to the now have bottomed out in Asia (and particularly China). North customers and investing constantly in R&D. This brings us into America is likely to remain at a very strong level. the best position for further growth. Along with our own R&D department, we also cooperate with universities to research How are you progressing towards building your company’s into new processes and technologies. This gives us access to brand for the future? new ideas that we may not come up in-house. Our motivation is to increase our customers’ competitiveness. Our brands’ products and services enable our customers Brief us on your current business model. to operate their production more cost-effectively and to The United Grinding Group is the world’s leading supplier constantly develop it further. As the world’s No. 1 in hard of machines for hard fine machining. With its eight strong fine machining, we can offer our customers a local presence, corporate brands - STUDER, SCHAUDT, MIKROSA,
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INTERVIEW | GLOBAL CEOs
“Increase in construction spends in both developed and developing markets, rebounding of automotive production, and rapid industrialisation are all contributing towards augmenting demand for grinding machines” Stephan Nell
as well as finishing flat, conical and cylindrical surfaces; sharpening and forming substrates; removing or snagging rough projections taken from stampings and castings as well as polishing, buffing and cleaning surfaces. Technology advances in grinding machines are fast transforming the grinding process, making it more automated and productive. With sophisticated CNCs, latest software and growing number How are the business networks spread across the regions & of axes being made available on advanced grinding devices, a single machine can now perform multiple grinding functions. their contribution in your company’s growth? United Grinding and our brands have worldwide subsidiaries, One of the most significant developments in CNC grinding is including India; competence centres in North America, China; the new control technology that enables closed-loop grinding sales & service organisations in Mexico, Russia, Italy, France, and facilitates easy running of machines. High-speed and Spain, Brazil, Japan, Singapore, etc. We have over 140 agents or accurate grinding machines are growing in demand, given distributors in more than 40 countries worldwide. With over the stringent end-user quality standards for finished products. 2,300 employees, the companies of the United Grinding Group Efficiency is an important topic in this area. Therefore, we have set up our company philosophy - PuLs®. are always close to their customers. United Grinding India is the sales and service subsidiary for all eight company brands. The customer care team of United How do you look at the demand trends globally in the Grinding India offers application expertise and provides manufacturing sector, in general? complete solutions including tooling, programming and According to companiesandmarkets.com, global market acceptance for all critical and specific requirements. It offers for grinding machines is forecast to reach US$6.3 billion by a range of reliable services which include machine installation, 2020, driven by robust industrial and manufacturing activity training, application support, preventive maintenance, parts in developing countries and steady replacement demand and repair service. We have our own showroom to demonstrate in developed economies. Rapid economic development, industrialisation, expansion in manufacturing bases, and our products to our customer. massive investments in machinery were largely responsible Which are the potential end-user industry segments for your for the market’s strong evolution over the years. Future growth will be led by strong GDP gains in developing countries and company? We deliver solutions in nine main industries: automotive capital investments in the manufacturing sector. Increase in & suppliers, energy, medical, aerospace, tooling, machine construction spends in both developed as well as developing manufacturers, transportation and heavy industries, die & markets, rebounding of automotive production, and rapid industrialisation are all contributing towards augmenting mould, and precision engineering. demand for grinding machines. In the medical devices’ Can you comment on the trends in grinding – technology & manufacturing sector, growing demand for prosthetics is driving the need to upgrade outdated production technologies customer needs? Grinding machines represent indispensable machine tools with new and advanced CNC tool grinders. ☐ used in finishing processes in almost all industrial and > www.efficientmanufacturing.in manufacturing facilities. Grinders are used for roughing
WALTER, EWAG, MÄGERLE, BLOHM, JUNG - the group has the most extensive application knowledge, product portfolio and range of services in the market. We have the broadest application know-how, machines and services portfolio in the grinding machine industry and all our activities are focused on customers’ success.
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GLOBAL CEOS | INTERVIEW
“The need is to get more out of machines by reducing human intervention” Ben Taylor, Global CEO, Renishaw Plc, in this interview with Srimoyee Lahiri, discusses how companies are looking at technologies and equipment that can produce parts faster and more accurately to enable multiple operations to be completed in a single setting, reducing the need to move parts between machines and enabling new capabilities. Excerpts…
How is the business scenario for your company in India and globally in the current market situation? Renishaw Metrology Systems India has several operations. In Pune, we have a software development group and also electronics and mechanical assembly for a range of products supplied all over the world. We have seen a much improved market within India over the past six months. The last two years have been challenging due to the economic slowdown in key sectors such as automotive and power generation and of course, the political changes in the country. However, we continued our expansion and growth as a company. This can be attributed to the fact that when companies reduce expenses on capital manufacturing equipment, such as the purchase of new CNC machine tools, they strive to maximise output from their existing assets. How are you progressing towards building your company’s brand for the future?
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We believe that the success of the company has been built on three key strategic pillars – a high level of investment in innovative products and processes, a focus on high quality, efficient manufacturing and the ability to support our customers across the globe with strong local technical support. We continued to invest heavily in all of these aspects. Last financial year we spent 15% of sales on R&D and engineering, We continued to invest heavily in our manufacturing facilities (including CNC machine tools and electronics assembly systems), and we invested in expanding/relocating facilities in several markets including Germany, China, Poland, and Hong Kong. How do you look at the opportunities and challenges within the industry? Companies in India continue to pursue more production throughput and greater capabilities from their machining processes. These demands force machinists to identify and eliminate wasted cycle time and causes of poor performance.
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INTERVIEW | GLOBAL CEOs
“We see India as an important market and we will continue to invest and expand to match market demand and expectations” Ben Taylor
As such, automation is at the forefront of developments in machining technology. The need to get more out of machines by reducing human intervention and the causes of scrap is driving developments in machining technology. Brief us on your current business model. In addition to the ongoing investments in new product development, manufacturing and strong global support, one key aspect of our business model is the ongoing transition from being primarily a supplier of products to capital goods manufacturers, to also becoming much more focused on delivering a full solution directly to end-users. Our experience in our core product lines, highlighting that our customers need assistance in solving their problems, is being carried across into our newer product lines, including gauging products, metrology fixturing systems and metal additive manufacturing (3D printing) systems. This requires that our sales and support teams are given the training to be ever more knowledgeable, not just about what our products do, but also how they can be applied to benefit our customers’ processes and practices. By truly understanding our customers’ needs we are able to offer cost-effective, efficient and easy-to-use solutions. Which are the potential end-user industry segments for your company? Renishaw works with many manufacturing sectors including aerospace, automotive, defence, power generation, medical and general engineering, to name a few. Within these sectors, we are working with the prime OEMs and down the supply chains to the tier suppliers and anyone manufacturing components can benefit from our proven solution offerings. Can you comment on the trends in metalworking – technology & customer needs? Companies are looking at technologies and equipment that can produce parts faster and more accurately and in particular multi-tasking machines which enable multiple operations to be completed in a single setting, reducing the need to move parts between machines and enabling new capabilities. Multi-task machines present more complex challenges in programming, setting and operating.
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How do you look at the demand trends globally in the manufacturing sector, in general? By having such a strong global presence in so many industry sectors and with a diverse range of customers - from the largest aerospace manufacturers to small job shops – we are able to gain excellent feedback on market trends. Also, regular reports from our subsidiaries, throughout the year we hold many sales and technical conferences which enables trends to be discussed and acted upon. What are your diversification & expansion plans for India and globally? In India we have over 300 staff divided between software development, manufacturing, and sales and support. We see India as an important market and we will continue to invest and expand to match market demand and expectations. New product launches and technologies will also necessitate the need to increase resource when and as required. This same philosophy is applied to all markets globally. In October, the British Deputy Prime Minister, Nick Clegg, announced our plans to set up our first Indian Additive Manufacturing Technology and Technical Centre based in Pune. We will initially have three AM machines processing different material powders. This move in itself will open up exciting opportunities for the Indian market and show that we are serious about this technology. I believe the additive market is relatively new and the opportunities vast. There has been a real ‘buzz’ about the additive technology over the last two years and whilst it is an exciting technology the application of it is critical and should be applied correctly. Additive is not a replacement for subtractive manufacturing and radical new approaches to design should be applied to ensure that the component design is optimised to meet the true capability of what additive technologies can provide. The applications and machines behind additive will develop and just as CNC did many years ago will evolve quickly as the technology becomes main stream and accepted widely across a broad spectrum of manufacturing sectors. ☐
> www.efficientmanufacturing.in
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GLOBAL CEOS | INTERVIEW
“R&D and robust processes can turn innovations into market success” Prof Dr Frank Brinken, Vice Chairman, Starrag Group Holding AG and Chairman, Economic Committee, CECIMO, discusses his company’s strategic plans for India and global markets, and briefs on the market trends and challenges in the metalworking sector, in this interview with Shekhar Jitkar. Excerpts… How is the business scenario for your company in India and globally in the current market situation? In the first three quarters of 2014, new orders received by Starrag Group declined only in European region and that decline can be traced to the large orders that had been received in 2013, resulting in a higher than normal order intake as well as to lower investment activity in Russia. On the other hand, incoming orders from Asia and North America continued to rise during this period. I see the recession 2013/2014 as a short-term bump in a long-term growth story. Political direction changes are never a good ground for capital investment stories. The economic outlook for India is mid-term positive. How are you progressing towards building your company’s brand for the future?
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Starrag Group products are marketed under the following strategic brands: Berthiez, Bumotec, Dörries, Droop+Rein, Heckert, Scharmann, SIP, Starrag, TTL, and WMW. Starrag made an audacious step in 2013 becoming the 1st European quality machine tool company to start manufacturing in India for the Indian market. Of course, the past recession has also impacted our business plan. We continue to roll out new models which experience a warm welcome by premium customers in India. How do you look at the opportunities and challenges within the industry? On a global scale, Europe will continue to be the place to lead and launch innovations in the machine tool industry. The European consumption, however, does not grow significantly. Companies’ investments are capacity sustaining and/or
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INTERVIEW | GLOBAL CEOs
“Only profitable companies can be reliable long-term partners for customers who generally are using the investments for 10+ years” Prof Dr Frank Brinken
productivity and quality/cost enhancing. You can only win with top technology and quality in this market. Dynamic market development can only come from Asia. In the Americas, the data indicates a further shift of manufacturing to the Mexico and the Southern States. What is your approach towards focus on R&D and innovation strategies? R&D and robust processes to turn innovations into market success is oxygen for profitable companies. Only profitable companies can be reliable long-term partners for customers who generally are using the investments for 10+ years. I believe having the right product will ensure the company’s continued business success even in the market where the general economic environment has weakened.
renewable and conventional power generation, industrial application, the transport sector, medical instruments and implants and finally being Swiss, of course, the watch and jewellery industry. In addition to its portfolio of machine tools, Starrag Group provides integrated technology and maintenance services that significantly enhance customer productivity. Can you comment on the trends in metalworking – technology & customer needs? A clear trend is to machine more complex parts in one step in order to meet the Six Sigma quality demands of the end users. The same cry for more consistent quality of machined parts leads to increasing factory automation offerings, which also enhances the trend to smaller lot sizes and elimination of setup times. The old US business school formula of low labour cost and depreciated or cheap machine tools does no longer work in a global economy.
How are the business networks spread across the regions & their contribution in your company’s growth? Starrag as well as Tornos already have the necessary size to How do you look at the demand trends globally in the serve industrialised markets globally. Both companies have manufacturing sector, in general? started manufacturing in Asia and both are present with Currently, we see a big hype by not really knowledgable financial guys trying to lure innocent investors into leading customer service organisations. In the view of future market challenges, Starrag Group ‘3D printing’. If you look at the valuations of some of these is bringing its organisational structure into even closer start-up companies who have yet failed to show any profit you alignment with its target customer groups and their specific can clearly see a bubble emerging. People forget that “Rapid Prototyping” is a successful needs and demands. Instead of the former Business Units 1–4, the new structure will consist of the following operating units: 20-year-old technology for R&D work and small parts with lots aerospace & energy, transportation & industrial components, of variations. I am convinced that this technology will evolve and precision engineering. Each business area will have full over time with improved powder metallurgy and find suitable responsibility for its designated market segments and its niche applications 10 years down the road. The other trends are investments which take the factor product brands. The existing regional sales networks are also being structured to promote clear lines of responsibility of labour cost out of the equation and where the vendor can in congruence with the new operating structure. The clearly show a fact-based total life cycle cost advantage. fourth operating unit, customer service, will continue to be responsible for all after-sales activities throughout the Group, What are your diversification & expansion plans for India ranging from spare parts to maintenance and repair, and for and globally? We are already here in India with our manufacturing set-up the development and deployment of new service products. started in 2013! And we are launching a full series of machining Which are the potential end-user industry segments for your centres shortly. ☐ company? > www.efficientmanufacturing.in Starrag concentrates on the market segements — aerospace,
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GLOBAL CEOS | INTERVIEW
“Intelligent automation is the trend” …says Eric Y T Chuo, Chairman & CEO, Hiwin Corporation, in an interview with Megha Roy. Also the Chairman of Taiwan Machine Tool Builder’s Association, Chuo speaks on the varied range of robots offered by the company, while illustrating on the industrial manufacturing capability, mechanical engineering know-how and world-class manufacturing cost control system, enabling total solution to the customers. Excerpts... How is the business scenario for your company in India and globally in the current market situation? In 2014, our company’s business in India has grown to 40% since 2013. As for global market, it has grown more than 30%. Our global business keeps growing with new products such as 6-axis (articulated) robot, SCARA robot, delta robot, wafer robot and medical robot equipment. How are you progressing towards building your company’s brand for the future? Currently, we are in the second position in linear motion &
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system control products. We keep developing new products to service our customers. Our vision is to bag the first position in the world within a couple of years. How do you look at the opportunities and challenges within the industry? Industries are looking for companies that can provide products to meet their need for better, cheaper and faster products. Our company continues to develop new products with innovative technology and offer customers good quality product, reasonable price, value-added service and total solution.
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INTERVIEW | GLOBAL CEOs
“Our global business keeps growing with new products such as 6-axis articulated robot, SCARA robot, delta robot, wafer robot and medical robot equipment” Eric Y T Chuo
Brief us on your current business model. With a strong management team and powerful global resource in integration capability, we continue to engage in the production of high-tech precision & high-value-added products. From single components, subsystem components, system components to the complete special purpose machine development, Hiwin exploits advantages of the industrial manufacturing capability, mechanical engineering know how, and world class manufacturing cost control system to establish a new standard of total solution. What is your approach towards focus on R&D and innovation strategies? We have seven R&D centres and over 500 engineers to provide product development and design in ESI (early supply involvement) services worldwide. We also work with academia, customers and suppliers together to develop new products & services. Customer’s need drives us to continue working on R&D and innovation. We have more than 2,500 patents globally. How are the business networks spread across the regions & their contribution in your company’s growth? We have over 100 distributors worldwide and 13 subsidiaries. We have entered the Indian market for 28 years now with three distributors in India. This network contributes our business growth. As for India market, we have an annual growth of 40% in 2014.
manufacturing energy and manpower, such as machine centres with twin turrets & twin spindles and 5-axis machines. We also develop ballscrew with preload/lubrication diagnosis. Preload diagnosis can monitor and measure the ballscrew’s preload change when the machine operates. Lubrication diagnosis can remind operators to check if the ballscrew is lubricated normally. Such technologies can reduce production cost by 45%. We have also developed DD (Direct Drive) rotary table using the Hiwin CRB (Cross Roller Bearing) and DD (Direct Drive) motor on the rotating axis. This will play a key role in the new 5-axis machining centre. How do you look at the demand trends globally in the manufacturing sector, in general? The manufacturing sector is the basis of all industries. Our products have been supplied to all the industries. The demand of manufacturing sector will keep growing as long as the new technologies keep evolving. We hope to develop new products to meet such requirements. Our medical robots include robotic gait training system, endoscope holder and hygiene system. Robotic gait training system has passed the European medical equipment certification last year. With the high demand, we believe our medical robots will be applied worldwide. Through vertical integration, we create strong cost saving advantage and flexibilities. We also provide excellent quality for medical equipment with competitive cost that helps patients to obtain the needed treatment with reasonable cost.
Which are the potential end-user industry segments for your What are your diversification & expansion plans for India and globally? company? We have widespread & diversified industrial customers, such We will set up Hiwin India by 2017 to offer better engineering as precision machinery, industrial machinery, automation, service and support to our customers in India. Currently, we biochemistry, home automation, human care, medical, FPD have 13 subsidiaries, including Germany, USA, Japan, Swiss, (Flat Pannel Display), semiconductor, transportation, energy Czech, France, Italy, Singapore, Korea, Israel, Russia, UK and China. saving and environmental, solar and medical equipment. As far as diversification is concerned, our company’s range Can you comment on the trends in metalworking – of product lines such as ballscrew, guideway, special bearings, industrial robots, etc can be applied to many different technology & customer needs? Intelligent automation is the trend for industries. With industries. ☐ > www.efficientmanufacturing.in both functions and automation design together, we save
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GLOBAL CEOS | INTERVIEW
“Multi-tasking machining solutions will also gain more acceptance in the industry” Chuang Kuo Huey, Chairman, Femco, in this interview with Megha Roy, highlights the business prospects of the Indian industry, the evolution of his company from selling standalone machines to customers, to a solution provider by offering turnkey solutions. How is the business scenario for your company in India and globally in the current market situation? Despite a gradual slowdown in India and Taiwan trade & economic relations, the region still remains India’s largest trading partner. So, our company has been regularly evaluating the unfolding economic scenario in India and its expected impact on the business prospects of the Indian industry in the region. Last few years, Femco Group has been undertaking the exercise to gauge the business sentiments of the Indian industry doing business with or investing in the Asian countries. How are you progressing towards building your company’s brand for the future? Our company was represented in the Indian market through agents. However, realising the market potential, we took the first step towards this market by entering & establishing our own presence in 2011. The second step was followed by establishing our own technology centre in Pune, which is a highly industrialised place to showcase products and demonstrate its capabilities. In 2011, we had started with three people in India and now we have around 20 people in different disciplines such as sales & marketing, service and application. Today, we have progressed
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from selling standalone machines to customers to solution provider by offering turnkey solutions. How do you look at the opportunities and challenges within the industry? India offers a huge potential. It is the 11th largest country in machine tool consumption. This phenomenon is linked to the spurt in manufacturing. India has already become a manufacturing hub for various industry segments such as automobile, power, oil & gas, valves, etc, which means there are huge opportunities. Some major challenges in the industry include price sensitive market, long decision making cycles, currency fluctuations and local manufacturers. Brief us on your current business model. With Indian headquarter at Pune, we are expanding in various important industrial locations by setting up our own representative offices. We also have a Delhi representative office in place and immediately after IMTEX 2015, we will induct new regional offices at Chennai and other places. What is your approach towards focus on R&D and innovation strategies?
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INTERVIEW | GLOBAL CEOs
“India has already become a manufacturing hub for various industry segments such as automobile, power, oil & gas, valves, etc, which means there are huge opportunities” Chuang Kuo Huey
After having an Indian market for four years now, we have realised the market requirements of our products. For example, the FT-2 machine that we have integrated in the auto tool changing mechanism for facing head. Our design team is busy in bringing smaller machines with facing head and auto pallet changer, which will meet market demands. How are the business networks spread across the regions & their contribution in your company’s growth? We have headquarters in Pune and various sales associates/ dealers across different regions. This has already spread our business presence. In India, we are spreading in different regions. We are coming up with a representative office in Delhi. Similar steps will be followed in the near future in other regions too. Which are the potential end-user industry segments for your company? Alloy wheel manufacturers, oil & gas, power and heavy engineering are the major industry segments for our products. Can you comment on the trends in metalworking – technology & customer needs? Metal working industry is banking on high equipment reliability, cost effectiveness and affordable automation besides increased accuracies of machine tools. Multi-tasking machining solutions will also gain more and more acceptance in the industry. How do you look at the demand trends globally in the manufacturing sector, in general? As far as India is concerned, heavy engineering segment is growing at 20 – 25 % annually. This increase in demands will create larger business opportunities. What are your diversification & expansion plans for India and globally? In order to expand our presence across the highly industrialised locations / regions, we are inducting our own representative offices. In addition, we are also introducing more appropriate machine models and configurations to meet the larger expectations & demands of the industry. ☐ > www.efficientmanufacturing.in
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GLOBAL CEOS | INTERVIEW
“We see a new wave of innovation & product complexity emerging” Alain Iun, Vice President, Marketing – Asia Pacific, Siemens PLM Software briefs on how emerging markets, with high quality and more cost-competitive alternatives are affecting regional competition across the manufacturing landscape, during an interview with Srimoyee Lahiri.
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How is the business scenario for your company in India and environments and lifecycle support. Our aim is to further globally in the current market situation? strengthen our position as a technology leader in these areas We are very bullish on the long-term growth prospects in India, and ultimately help our customers create the next generation and have therefore made significant investments here, both in of smart products. terms of infrastructure as well as people. The manufacturing industry in India faced a slowdown in the last few years, How do you look at the opportunities and challenges within but we believe a revival is just around the corner. Initiatives the industry? like the “Make in India” campaign launched by the Hon’ble Opportunities in our region are abundant and we believe that Prime Minister will go a long way in securing the country’s Asia is going through a manufacturing renaissance of sorts. manufacturing competitiveness, and enhancing her global According to recent reports by Nasdaq, the IMF expects the image as a source of high-quality and precision-engineered economy in China to grow by 7.1% and in India by 6.4%, in products. 2015. In countries such as Vietnam, Indonesia, Thailand, Malaysia and the Philippines, the industrial machinery industry How are you progressing towards building your company’s is projected to capture a larger share of global trade over the brand for the future? next 10 years as their expansion outpaces that of developed We continue to focus on the global trends that propel nations. Through the advances of technology, we see a new and challenge the industry and our customers - digital wave of innovation and product complexity emerging. As we transformation is a key business driver and a new addition look at our customer’s digital enterprises, we see three critical to this focus. Siemens is investing in software solutions to components: innovation, realisation and utilisation – realisation realise innovation and power our customer’s digital enterprise being critical to success in next generation manufacturing - moving from the conceptual to the real, connecting virtual and realising innovation in a complex environment. The development and production planning with real production challenges that we face are overcoming and seizing these
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GLOBAL CEOS | INTERVIEW
“With emerging markets such as Vietnam and Thailand offering high-quality and more costcompetitive alternatives, regional competition across the manufacturing landscape is heating up” Alain Iun
opportunities by looking at the innovation process and linking ideation and utilisation. The opportunity here, is to reduce cycle time and increase yield, this is the only feasible way to deal with constantly increasing complexity in products and manufacturing enterprises. What is your approach towards focus on R&D and innovation strategies? It starts with innovation and our investment in R&D through corporate technology and the emphasis placed on expanding our portfolio. By continuing to invest in these, Siemens has become the only company to provide integrated hardware and software solutions across the entire spectrum of industry automation. It starts with corporate technology directing the global shared R&D budget, managing and executing research projects yielding patents and standardisation, developing best practices and sharing knowledge amongst global divisions and regional companies. We also work closely with research partners including customers, universities, research institutes and other companies. Through this investment and organisation we are working on several innovations today that will impact PLM and the way companies design and build products. In order to be closer to our clients and to have access to top talent, we have setup several product development centres around the world. Which are the potential end-user industry segments for your company? I would say almost any industry where innovation is the key business driver and necessity for competiveness, with customer’s looking for real industry solutions integrating product and production lifecycles. Traditionally, PLM has been successful in automotive, industrial machinery & heavy equipment, hightech electronics and aerospace & defense. However, over the last three years, there has been an increasing need for PLM solutions in the marine, medical and shipbuilding industry. What are the emerging trends in metalworking/technology & customer needs? The metalworking industry has a lot of opportunities ahead in this region. With domestic growth soaring and companies
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from the US and Europe continuing to see the value in having an outpost in Asia, despite all the talk about re-shoring, these are trends that will impact growth in a positive way. However, the industry also faces challenges that may hinder this growth – such as boosting capacity to service customers quickly, streamlining processes to improve overall production efficiency and minimise cost and time overruns. Additionally, with emerging markets such as Vietnam and Thailand offering high-quality and more cost-competitive alternatives, regional competition across the manufacturing landscape is heating up. Regarding technology, that’s where the solutions to the abovementioned challenges lie. For success in this manufacturing environment customers need to embrace digitalisation. How do you look at the demand trends globally in the manufacturing sector in general? Manufacturing, globally, is set to enter into a new phase. When combined with rising wages in Asia, higher shipping costs and the rise in consumer demands, companies are shifting their manufacturing strategies from outsourcing overseas to developing products closer to where they will be sold. The reason is fairly obvious, the faster the inventory can be moved to the consumer, the sooner the costs to warehouse - ship and dock goods can be freed up. This is a trend that reflects the nature and significance of the demand in the manufacturing sector. What is your diversification & expansion plans for India and globally? In our conversations with customers in India, we frequently come across one recurring theme: shortage of skilled workers. Many of them have expansion plans that are on hold because of their inability to hire and retain skilled resources. We decided to do our bit to improve this situation by talking to academic institutions, including those focused on vocational skill development in remote areas of the country. We also started engaging with state governments to jointly develop centres of excellence to impart training to students of engineering as well as encourage research projects. ☐ www.efficientmanufacturing.in
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Section co
INTERVIEW INDUSTRY
> INDIA
> JAPAN
| 79 |
> TAIWAN
GLOBAL MACHINE TOOL INDUSTRY
> CHINA
> US
> GERMANY
> ITALY
> SPAIN
> EUROPE
This interview series with the global machine tool industry association leaders features an overview of the performance of the machine tool industry world over and highlights how integration between manufacturing technology companies & the industry is of prime importance. These industry stalwarts are being profiled based on the discussion of their business strategies and the global market is analysed taking into consideration three aspects of production, consumption and forecast. - TEAM EM
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“India developing as a manufacturing hub” L Krishnan, President, Indian Machine Tool Manufacturers’ Association (IMTMA), shares his insights on the latest initiatives taken to improve India’s trade ties in terms for manufacturing related products during an interview with Srimoyee Lahiri How do you look at the Indian machine tool industry in terms of its strength, capabilities, export potential, technological advances & innovations? The Indian machine tool industry has developed good design and development capabilities and is able to develop machines in mid-level applications as well as special purpose machines. India’s domestic market absorbs almost its entire production, so exports have tended to be low. Indian companies have started to make their presence in Europe and select countries in South East Asia recently. Indian machines are price competitive in their range making them suitable for exports. What are the initiatives taken to improve India’s trade ties in terms of manufacturing related products? Government of India has taken key initiatives for improving the business environment, fast tracking manufacturing and liberalisation of FDI policy. The ‘Make in India’ campaign aims to remove the bottlenecks and in turn develop India as a manufacturing hub. It has also fast paced the development of industrial corridors and industrial clusters through initiatives such as creation of a National Industrial Corridor Development Authority for industrial corridor development and setting up of National Investment and Manufacturing Zone. Can you highlight on the performance of the machine tool industry in the year 2013-14? The year 2013-14 was a challenging one. There was an overall decline in consumption, production and imports. The production was down by 10%, consumption by 30% and imports by 39%. However, if we look at 2014, the industry has grown in the second half.
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Currently, integration between machine tool companies is a key benefit to the industry. What is your take on this? Development and diffusion of machine tool technology through closer integration between machine tool companies will result in faster and increased productivity. Integrated machine tool parks are good examples of this. A cluster of machine tool builders, makers of accessories, components, foundry, etc will have a common facility centre for all companies setting up shop in the park. The park will have common facilities like an effluent treatment plant, testing lab and R&D centre for new technologies. This will essentially help small and medium scale enterprises expand their manufacturing capacities. IMTMA is in the process of setting up a machine tool industry park in the southern region and also plans to replicate this in west and north. Given that the industry-university collaboration is quintessential for the development of the machine tool industry, can you brief on the participation of the Indian universities in this regard? IMTMA has initiated the Academia-Industry Pavilion in IMTEX for exchange of knowledge and ideas. Institutions present their technologies in specific areas to the industry. R&D and educational institutions can identify industry needs. Staff and students of institutions can see the best practices in metalworking first hand and enhance their skills. To reduce the technology gap, IMTMA Technology Centre organises training programmes for students, keeping in mind productivity and upkeep of machines and machine tool design. Students get industry-ready after undergoing the training. This can be replicated in other institutions. ☐ > www.efficientmanufacturing.in
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I N T E R V I E W | G L O B A L M A C H I N E TO O L I N D U S T R Y
“Maintaining competitiveness on the basis of customisation” Yoji Ishimaru, President, Japan Machine Tool Builders’ Association (JMTBA), talks about the importance of integration between machine tool companies and the utilisation of research & development ability and excellent intellectual assets of universities for machine tools industry, in this interview with Srimoyee Lahiri What are the initiatives taken to improve trade ties with India in terms for manufacturing related products? Hon’ble Prime Minister Narendra Modi’s “Make-in-India” campaign, with the aim of making India a manufacturing base of the world is the latest buzz in the industry. To fulfill this goal, machine tool is the core equipment as foundation of production facility. By providing high quality Japanese machine tools of high productivity with perfect service, we would like to contribute to the development of the manufacturing industry in India. Which are the various exhibitions – domestic and international, in which your organisation is representing Japan industry? JMTBA provides information of new manufacturing technologies to manufacturers in fast-growing Asian market by hosting JIMTOF in Tokyo. Also, we have been participating in major international machine tool exhibitions like IMTS, EMO, CIMT for a long time. In addition to these, we have been actively attending Asian exhibitions including METALEX in Thailand, CCMT in China, and so on. The importance of IMTEX in India for us is rapidly growing in line with the advancement of industrialisation of India. Currently, integration between machine tool companies is a key benefit to the industry. What is your take on this? In the early 2000s, mergers and acquisitions, capital tie-ups and business alliances had been actively carried out in Japan. Recently, these activities are rather settled down. Most of
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Japanese machine tool companies are small and medium-sized enterprises (SMEs). Despite their relatively small average size, they are renowned for their ability to maintain competitiveness on the bases of customisation and responsiveness to customer needs. They are specialised in niche markets into which most of the leading larger manufacturers find difficult to enter. We expect this trend will continue. Also, substantial number of machine tool manufacturers are required to exist to pursue wide range of customer needs in various industries, such as information-communication-technology, medical, aircraft, energy, etc. Given that the industry-university collaboration is quintessential for the development of the machine tool industry, can you brief on the participation of the universities in this regard? Utilisation of research and development ability and excellent intellectual assets of universities is essential for machine tools industry. Today, advanced technology, such as ICT (Information Communication Technology), is indispensable to develop innovative machine tools. In this sense, fusing university-based research competency with industry-specific knowledge is getting more and more important. In fact, close collaboration among industry, academia and government is needed to facilitate advanced research and development in machine tool industry which is a kind of infrastructure of the society. ☐ > www.efficientmanufacturing.in
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Heading towards technological independence & manufacturing intelligence” Carl Huang, President, Taiwan Machine Tool & Accessory Builder’s Association, in an interaction with Megha Roy, discusses the forte of Taiwan machine tool industry in terms of its competitive strength through innovation in accordance with market demand & the goal to create flexible production technology in the coming years How do you look at the Taiwan machine tool industry in terms of its strength, capabilities, export potential, technological advances & innovations? From the first CNC machine tools in 1970s to the state-ofthe-art of high-speed cutting, multi-axial, and multi-task application; the fast-changing product development of Taiwan machine tool industry significantly reduces processing time, enhances efficiency and increases profit for clients. Around 90% of the machine tool builders are small to medium enterprises, and more than 85% of them major in metal cutting machine tools. Currently, the 4th exporting country in the world, it not only achieves competitive strength through innovation in accordance with market demand, but also creates flexible production technology. As such, Taiwan plays the key role in the global machine tool industry to raise the attraction of
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investment. For technological advances and innovations, Taiwan is heading towards technological independence & manufacturing intelligence. Taiwan machine tools industry has made great progress in the development of controllers and other key components, such as AB shafts and C shafts for direct drive motors and has, thus, freed itself from depending on foreign suppliers. How are you planning to promote the ‘Made in Taiwan’ brand globally? Through TMTS, TMBA plays an important role in promoting the Taiwan machine tools industry. Also, enhancing the interaction between Taiwan’s leading companies and the government helps to obtain remarkable progress in
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I N T E R V I E W | G L O B A L M A C H I N E TO O L I N D U S T R Y
“Taiwan machine tools industry has made great progress in the development of controllers and other key components, such as AB shafts and C shafts” Carl Huang
international cooperation. Taiwan-made products are often $ 0.191 billion in the first half year, down by 3% YoY and 5.8% seen as state-of-the art technologies & products. Taiwan MoM, followed by Thailand with exports of $ 0.094 billion, manufacturers have years of technical experience since they decreased by 22.3% YoY and up 15.6% MoM. have grown up amid technology development for over half a century. We believe Taiwanese machine tool products are Which are the various exhibitions – domestic and compatible for its reasonable prices. By attending various big international, in which your organisation is representing metalworking and related trade shows in Taiwan and overseas Taiwan industry? allows buyers to see, touch and try the products. Also, it allows We had organised The TMTS 2014 – Taiwan International us to show our strength and capability. Attending trade shows Machine Tool Show recently, which showcased an innovative is a great way to promote “Made in Taiwan” brand. “Exhibition integrated with manufacturing supply chain” exhibition. It provided a significant platform for the global Can you highlight on the performance of the machine tool machine tool manufacturers & consumers. industry in the first half year of 2014? Exports of Taiwan machine tool in the first half year of 2014 How are you planning to promote Taiwanese machine tools were USD 1.81 billion, up 4.9% YoY. Exports in June 2014 in India? were USD 0.352 billion, an increase of 8.1% MoM and a rise of We plan to participate in the overseas exhibitions, such 13.2% YoY. As the economic forecast shows positive in Europe as IMTEX, as a group of Taiwanese exhibitor and form our and USA, wearable gadgets become popular and commercial pavilion at the show. opportunity of Internet of Things (IoT) is highly expected, which would contribute to Taiwan’s expanding export Currently, integration between machine tool companies is a performance. key benefit to the industry. What is your take on this? According to custom statistics published by Directorate In the machine tool industry, there is already tool alliance General of Customs and Department of Statistics and analysed called M-Team, which consists of five machine tool companies, by TMBA, Taiwan’s top 10 exporting areas of machine tools namely Victor Taichung, Yeong Chin,Tong-Tai, Quaser, Litz, are China (including Hong Kong), USA, Thailand, Turkey, and 20 accessory companies. This integration was established Germany, Korea, Netherlands, Russia, Indonesia, Malaysia. six years ago in Septemer 2006, with Taichung Victor & YCM. China (including Hong Kong) is the largest export market The alliance formed a network and with co-operation, became with export value of $ 0.602 billion in the first half of 2014, a successful. We believe there will be more co-operation between rise of 6.3% YoY. Exports in June 2014 with a share of 33.2% companies and factories in the coming years. ☐ > www.efficientmanufacturing.in has increased by 3.5% MoM. Exports to the USA contributed
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Looking forward to co-operation between Indian & Chinese enterprises” Chen Huiren, President & CEO, China Machine Tool & Tool Builders’ Association, in this interaction with Megha Roy, highlights on the strong manufacturing ability of the Chinese machine tool industry, while discussing the highs and lows of the global industry. How do you look at the Chinese machine tool industry ability and enough reserve of advanced technical worker. Also, in terms of its strength, capabilities, export potential, our structural adjustment requires the foundation of technical technological advances & innovations? progress. So, there are more companies willing to establish China is the biggest country in producing machine tools R&D centre in the country to provide continuous drive to the worldwide, not only in quantity but also in category ranging development of the industry. from household general-purpose machine tool to 5-axis CNC machine tool needed by aerospace field; from ordinary How are you planning to promote the ‘Made in China’ brand punch to press production line for auto’s covering parts; from globally? grinder with nanometre grade to planer type milling machine The best channel to promote our brand is through over 10-meter in width; from non-traditional machining to international professional exhibitions. The exhibitions help additive material manufacturing and 3D printer; from robot to make demonstrations and expand the publicity effect via to automotive various links and the like. technical forum, magazine and website. CMTBA owns two China is the biggest importer and consumer market of exhibitions, namely, CIMT and CCMT. We invite machine tool machine tools in the world with large inventory and excellent buyers across the world to visit these events. They display the machining equipment. Therefore, it has a strong manufacturing strength of enterprises of the Chinese machine tool industry. It
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I N T E R V I E W | G L O B A L G L O B A L M A C H I N E TO O L I N D U S T R Y
“The overall environment of the economic slow-down and transformation of development pattern has generated a comprehensive & persistent impact on the industry” Chen Huiren
organises the Chinese enterprises to attend overseas exhibition. We are also organising a delegation to attend the forthcoming exhibition of EMO in Milano, Italy. Can you highlight on the performance of the China’s machine tool industry in the year 2013-14? The Chinese machine tool industry has been in the slow-down trend in 2014 since the second half of 2011. Currently, it is still in the downward trend since the influence of growth continues to slow in the country’s economy. The overall environment of the economic slow-down and transformation of development pattern has generated a comprehensive & persistent impact on the industry. The change of development environment also provides the optimum opportunity for the industry’s adjustment & transformation, while bringing pressure and challenge. The reserve mechanism it has formed provided strong external power for the transformation of the industry. Which are the various exhibitions – domestic and international, in which your organisation is representing the Chinese industry? China’s huge potential market and production capacity lay a solid foundation for CCMT and CIMT to push various global trade opportunities. Currently, we are using the two exhibitions in the changing times to hold docking activities and communications for various levels and different contents to provide a stage suitable for enterprises, both at home and abroad to demonstrate their adaptation to the changing market. How are you planning to promote the Chinese machine tools in India? Any specific initiatives?
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India is the third largest export market of the Chinese metal-working machine tool. Members from CMTBA have participated in exhibitions such as IMTEX for several years. It has been observed that the Chinese enterprises have strong desire to exploit the Indian market. Seen from the present, the most efficient path to tap the Indian market is to attend the exhibition there. We hope having an opportunity to get in touch with the representatives from the industries of autoparts and military to discuss deep cooperation, if possible. Currently, integration between machine tool companies is a key benefit to the industry. What is your take on this? Integration of enterprises exerts co-operation benefits but not every co-operated project is successful. I’ve observed some enterprises that club mutual understanding & trust as the foundation of the integration and management & technical fields as complementary. I’m looking forward to cooperation between Chinese and Indian enterprises with an open attitude. How has been the performance of industrial trade activities with India this year? There has been both competition and a certain degree of complement in the machine tool industries between China and India. The percentage of export to the Indian market has increased from 1.4% to 1.9% in the metalworking machine category. As far as the import is concerned, the percentage has increased from 1.5% to 2.3%. However, the proportion in each market of both the countries is still not high enough. I believe that both countries can exert more potentiality on each other markets. ☐ > www.efficientmanufacturing.in
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Keeping innovation on the forefront” Douglas K Woods, President, The Association for Manufacturing Technology-AMT, gives an overview of the performance of the US machine tool industry and highlights the key initiatives taken to improve trade ties with India, during an interaction with Srimoyee Lahiri. How do you look at the US machine tool industry in terms of its strength, capabilities, export potential, technological advances and innovations? Overall, the US manufacturing technology market continues to be very strong. In the fifth year of recovery from 2008-09 recession, the industry continues to grow and build strength. Strong market conditions in the automotive, aerospace, energy, and medical industries are leading to manufacturers continuously looking for ways to improve productivity, and they are making investments in the newest technologies to help them meet their goals. Additionally, the average age of capital equipment installed at US manufacturing facilities is 22 years, meaning there is an aggressive push to invest in newer technologies in order to meet demand. Many other factors are playing into the market’s strengths. Interest rates and energy
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costs continue to remain low and labour costs are stable. As a result of those factors, in addition to a desire to shorten supply chains and produce goods closer to end users, foreign direct investment in the United States continues to grow. US foreign direct investment stood at $230 billion in 2013 according to the Bureau of Economic Analysis, with $94 billion tied to manufacturing. AMT is directly involved in these areas in a major way. We recently announced a partnership with VDW, the German Machine Tool Builders’ Association, to launch the International Additive Manufacturing Award (IAMA), recognising excellence in additive manufacturing innovations from around the world. We are currently accepting entries, and the first award will be given in March 2015. AMT is also the organisation behind MTConnect, a free and open-source communications standard for manufacturing equipment and
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“The developing National Network of Manufacturing Innovation is a system of hubs, located throughout the US, dedicated to a specific advanced manufacturing technology” Douglas K Woods
IMTS contributed $647 million in manufacturing technology orders in September 2014, the highest since March 1998. Automotive sales are expected to hit around 17 million units in 2015. With an aging Baby Boomer population, medical has also been an important and growing industry, and shale oil and natural gas exploration are strong drivers for the energy What are the initiatives taken to improve trade ties with industry. Going forward, we expect more strong performance in 2015. Industry experts predict anywhere between 5%-20% India in terms of manufacturing-related products? In 2006, AMT’s board recognised the growing importance of growth for manufacturing technology orders in the coming year. manufacturing across various sectors of the Indian economy, Oxford Economics forecasts that US industrial production will and approved the development of the Chennai Technology continue to grow annually between 3-4%. It is also predicted Centre (CTC). The centre acts as a ‘bridge to the US that construction and off-road equipment industries will see manufacturing technology,’ where AMT members can establish growth as state and local governments move to repair and a presence in India to begin developing relationships with replace roads, bridges, and other aging infrastructure. Indian manufacturers. Since many of our member companies work with OEMs across the globe, they are familiar with their Currently, integration between manufacturing technology manufacturing process requirements and standards. The companies is a key benefit to the industry. What is your take CTC displays the latest in manufacturing technologies from on this? the United States, and also creates opportunities for Indian Company-to-company collaboration has been the key to driving companies to interact with our member companies to find ideal efficiency and productivity for all manufacturers, especially solutions for any of their advanced manufacturing applications. in robotics and automation. Likewise, major manufacturing Additionally, we also conduct a yearly trade mission to India. technology OEMs are partnering with providers of vision These trade missions create avenues for senior management systems, software, robotics, controls, tooling, etc to create from our member companies to visit and interact with top turnkey systems to the benefit of the customer. These allow management of selected manufacturing companies from across customers to benefit from all the different supplier partners various sectors of the Indian economy, which opens doors for throughout the whole range of the industry – something that future trade opportunities. Finally, AMT participates in various would be difficult for any one company to support and deploy. manufacturing trade shows in India. The AMT/USA pavilion On a larger scale, you also see this type of collaboration taking at these shows, including the IMTEX, allows our members to place on a higher level between business, government, and academia. The developing National Network of Manufacturing showcase their products to many potential buyers in India. Innovation is a system of hubs, located throughout the US, Can you highlight the performance of the manufacturing dedicated to a specific advanced manufacturing technology – additive manufacturing, digital manufacturing and design, technology industry in 2013-14? This was an exceptionally strong year for the industry in many lightweight materials, next-generation power technologies, facets. The ISM PMI hit a three-year high this past October, and photonics. These hubs are focused on leveraging the best signaling a strong end of the year. Durable goods orders have knowledge and resources from all partners to quickly bring been over $240 billion since May 2014. In September, we had technologies to market, keeping innovation on the forefront to one of the strongest editions of IMTS - The International the benefit of all US manufacturing. ☐ > www.efficientmanufacturing.in Manufacturing Technology Show on record. The success of devices. We actively promote the use and development of the standard not just for our members but throughout the manufacturing community. The use of such a standard is an important element of the emerging “smart factory” – a fully integrated and connected operation for seamless productivity.
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Powering business through core competences” Dr Wilfried Schäfer, Executive Director, German Machine Tool Builders’ Association, VDW, discusses the continuous intensive efforts taken by the German machine tool industry to offer new products and innovations and briefs on the performance of the industry in the current year, in this interview with Srimoyee Lahiri. How do you see the German machine tool industry in terms With an export ratio of more than 70%, the global market is of its strength, capabilities, export potential, technological the No.1 field of action for the German machine tool industry. advances and innovations? More than 36% of German exports in 2013 went to Asia, around German machine tools are high-tech, and in demand all over 48% to Europe, and about 16% to USA. The most important the world. The German machine tool industry is the export market is China, which takes about a quarter of Germany’s world champion, with a total of almost €8 billion last year, exports, followed by USA. The dynamic Indian machine tool and the second-largest producer of machine tools worldwide. market currently ranks 16th. The leading technological position, and intensive efforts to continually offer new products and solutions, for example, What are the initiatives taken to improve trade ties with helped to ensure that the sector got through the 2009 crisis India in terms of manufacturing-related products? comparatively well, and recovered its original strength Since the late 1990s, India’s economy has been growing by an relatively quickly. In addition, the German machine tool annual average of more than 7%. Machine tool consumption, industry is broadly diversified. This applies to both the markets too, has increased continuously over recent years. Currently, and to the technologies involved. Germany supplies machine however, the trend has stalled. The signing of the bilateral trade agreement between the European Union and India, tools to around 170 different countries.
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“With an export ratio of more than 70%, the global market is the No.1 field of action for the German machine tool industry” Dr Wilfried Schäfer
which has been under negotiation since 2007, could doubtless intensify trade relations still further. The biggest obstacle up to now from an Indian viewpoint was Brussels’ demand that environmental and social standards be specified in it as well. So far, there is no sign of this changing. Can you highlight the performance of the machine tool industry in the year 2013-14? For the German machine tool industry, the years 2013 and 2014 are principally characterised by a process of consolidation. Following an unprecedented decline in production output during the years 2009/2010, and an equally unprecedented subsequent catch-up, the international demand for machine tools calmed down in 2011. Nonetheless, German manufacturers managed to keep their production output stable in 2012 and 2013 at above €14 billion. In the ongoing year, we are expecting production output to maintain this level. At around €14.6 billion, it will then be the highest level we have ever achieved.
them itself, next to the IMTEX in India and also fairs in China, Russia, Brazil, Thailand and Turkey. Currently, integration between machine tool companies is a key benefit to the industry. What is your take on this? Company mergers do not necessarily have to be an advantage for the customers concerned. Potentially, they restrict competition. This can show up disadvantageously both in the development of new products and solutions and in the pricing involved. Anyway, size in itself is not a value in the machine tool industry. Only 7% of our firms in Germany employ more than 1,000 people. More than half of them, by contrast, have between 100 and 500 staff on their payroll. So far, we have done very well with this structure. The firms are operating worldwide, and at the leading edge of technological advances. They are flexible, and can respond to new challenges faster than some large corporations. A smaller company, however, has to be more rigorous in setting priorities, because its capacities do not suffice for ubiquitous participation. Concentration and focusing on core competences, however, are not the worst thing in the world.
Which are the various exhibitions – domestic and international, in which your organisation is representing Given that the industry-university collaboration is the German industry? The VDW organises two trade fairs of its own. The EMO quintessential for the development of the machine tool Hannover—the world’s premier trade fair for the metalworking industry, can you brief us on the participation of the Indian sector which is scheduled in September 2017. On the universities in this regard? other hand, we also organise METAV in Düsseldorf – the Close cooperation between universities and the companies international trade fair for metalworking technologies which concerned is one of the important criteria for success in the is scheduled for February 2016. It primarily addresses the German machine tool industry. At the moment, however, I am German and European markets. For this purpose, we have just not aware of any collaborative project with Indian universities. unveiled a new concept with the slogan “Power your business”. A few years ago, there was a shared project in the other Both these events showcase the entire spectrum of products direction. India’s Ministry of Industry collaborated with a for industrial manufacturing operations: machines, tools, Fraunhofer Institute from Chemnitz in the east of Germany, automation, measuring instruments, software, but also new on “green, clean and energy-efficient production technology”. trends like additive manufacturing. The EMO is positioned German manufacturers have already built up an impressive as a global innovation forum, at which all front-ranking fund of expertise here, which can be beneficially utilised in international vendors want to showcase innovative products India as well. ☐ for their customers. In addition, the VDW applies for shared > www.efficientmanufacturing.in stands at trade fairs in important export markets, or organises
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“India among the top ten destination countries of Italian export� Luigi Galdabini, President, UCIMUSISTEMI PER PRODURRE, in this interview with Srimoyee Lahiri, affirms the continuous collaboration with India aimed at improving mutual market advantages and establishing common goals with long-term orientation. How do you look at the Italian machine tool industry in terms of its strength, capabilities, export potential, technological advances & innovations? Relying on a time-honoured tradition, ranking third in the world for export and fourth for production, the Italian machine tool industry is recognised worldwide for its very high technological content and its strong customisation of the proposed solutions, capable of meeting specific requirements of users. Italian machine tools stand out from competition for their high flexibility and for being manufactured side-by-side with the customer. This work implies a large expenditure of energy, but it allows to build tailor-made machines for specific requirements. These characteristics are particularly appreciated also by the Indian market which, in response to a need for
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strengthening and making its own manufacturing system more and more competitive, has always paid great attention to Italian technology. What are the initiatives taken to improve trade ties with India in terms of manufacturing related products? The relationships are certainly very positive. India is among the top ten destination countries of Italian export in the sector; in particular, in 2013, the Indian market purchased machine tools from Italy for a value of â‚Ź124.6 million. This market is particularly interesting for the Italian companies in the sector and it is already recognised as one of the big manufacturing industries in the world. Nevertheless, it still has a large, unexpressed potential, which can and must be developed also in cooperation with Italy.
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“Italian machine tools stand out from competition for their high flexibility and for being manufactured side-by-side with the customer” Luigi Galdabini
With India, there is a continuous collaboration aimed at at the end of 2013. On the other hand, the figures of Oxford improving the mutual market advantages and at establishing Economics are confirming a growth in Italian consumption common goals with long-term orientation. As Italian machine from now to 2017. tool manufacturers’ Association, we supported important initiatives on the Indian territory such as “Italian Technology Which are the various exhibitions – domestic and Centre”, one of the concrete initiatives carried out by the international, in which your organisation is representing Ministry of Economic Development and Federmacchine, the Italian industry? within the larger project “Machines Italia in India”, conceived UCIMU-SISTEMI PER PRODURRE, with about 200 member to support the Italian companies in the penetration of the companies covering 70% of the Italian production in the field, Indian market. The new centre for the promotion of “Made in is the official representative of the category and intends to Italy” in the sector, based in Pune, is promoting the ITC mark safeguard the interests of the sector by promoting the growth and the brand of eleven Italian enterprises manufacturing and visibility of the sector enterprises in the traditional and capital goods which cooperate to develop new contacts with emerging markets. Other than the promotion of the sector and the provision the world of Indian institutions, culture and industry: this is essential for supporting the internationalisation of Italian of a wide range of services for its member companies, the Association's commitment translates into the organisation of enterprises in the area. A remarkable experience is that of PIATTAFORMA INDIA specialised, focused trade shows, such as: BI-MU/SFORTEC, (PLATFORM INDIA), which intends to be a real hub capable of Italian biennial exhibition dedicated to machine tools, robots, providing assistance and advice to the companies interested in automation and auxiliary technologies; LAMIERA, addressed working in the area. The purpose of the initiative is to support to the forming machinery sector and MECHA-TRONIKA, the the enterprises in their internationalisation activity. For this last one created, dedicated to the intelligent solutions for the reason “Piattaforma India” avails itself of the collaboration of management of industrial processes. an Indian officer who works as a facilitator directly on site. Currently, integration between machine tool companies is a Can you highlight on the performance of the machine tool key benefit to the industry. What is your take on this? For the Italian companies wishing to work on the global industry in the year 2013-14? As evidenced by the preliminary figures processed by Centro market, the main hindrances are a small company’s size, high Studi & Cultura di Impresa (Studies Dept) of UCIMU-SISTEMI shipping costs and expenses for analysis and mapping of PER PRODURRE, in 2014, production attained €4,685 million, markets. Through the web network it is possible to overcome marking a 4.4% increase compared to the previous year. Exports these difficulties thanks to the possibility of sharing the costs have once again confirmed to be the driver of the sector trend, and having a workstation on the territory. Moreover, it allows registering a 4.7% upturn at €3,615 million, capturing 75.7% to benefit from the advice of local experts who can explain of the total production made by Italian manufacturers. After the social, legal and economic dynamics of a country having all, over the last 5 years, the ratio of export on production has several entrance and introduction difficulties. In any case, any gained 13%, considerably supporting the Italian machine tool kind of collaboration cannot disregard a proper understanding sector. In particular, in the third quarter of 2014, the index of with local institutions, as in the case of the above mentioned Italian orders showed a 19.1% increase over the same period of Italian Technology Centre. ☐ > www.efficientmanufacturing.in the previous year, thus, continuing the positive trend started
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Manufacturers must work towards achieving greater proximity to customers” Antxon López Usoz, Chairman, AFM Advanced Manufacturing Technologies (AFM) elaborates on the latest activities taken by the association to help build larger business units in the Spanish machine tool industry, during an interview with Srimoyee Lahiri How do you look at Spain’s machine tool industry in terms of its strength, capabilities, export potential, technological advances & innovations? The Spanish sector is the third in the European Union in terms of production and export, and ninth in the world. The already strong internationalisation tendency of our companies has been consolidated over the last few years even more, as they export more than 80% of their production. In terms of technological innovation, this is intrinsically related to the development of our sector, which is being constantly driven to advance, in order to make the most cutting-edge sectors of the economy more competitive. The sector becomes an integrator of the latest technologies developed in different areas in order to respond to their customers’ demands in terms of greater productivity, greater energy efficiency, less waste, etc. In this
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sense, the effort made by our companies is noteworthy and if compared with other sectors, it is quite high. We estimate that our companies earmark an average percentage of around 5% of their turnover to research, development and innovation. With high specialisation in large machines and in piece-process applications, our manufacturers must continue to work towards achieving greater proximity to customers, more technology, more qualified people and more internationalisation, as we have been doing until now. What are the initiatives taken to improve trade ties with India in terms for manufacturing related products? India is an important destination for Spanish export. Although, it dropped to the ninth position of our export ranking in 2013, in the previous four years, India was among the five
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“We have a long and fruitful relationship with the most important universities of our surrounding area, more specifically with the departments related to engineering and advanced mechanical manufacturing” Antxon López Usoz
major markets for our products. That is why AFM has been participating, since the first edition, in the IMTEX fair, which will celebrate its 17th edition in 2015. Many companies from our association have had an important presence in the Indian market for the past twenty years. Participation in the major fair of the Indian market is completed each year with a couple of trade missions that are specialised in customer sectors of special importance in India.
Germany, BLECH EXPO. We will end the year with FABTECH in Chicago, USA. In 2015 we will also carry out trade missions in Russia, Mexico, USA, China, and also in India, among other countries. Currently, integration between machine tool companies is a key benefit to the industry. What is your take on this? One of the challenges of our strategic plan is to increase the size of our companies. We need to have larger business units, not as an end but as a means to be able to compete better and for that reason, we, at the association, are activating all types of actions, aimed at grouping companies together and helping them find synergies, common interests, collaboration projects, etc. All of this will help generate structural type alliances among companies. This is essential to be able to address the challenges we have to face.
Can you highlight on the performance of the machine tool industry in the year 2013-14? We believe that in 2014, our turnover was slightly less but similar to that of 2013. For the moment, with the data of the first months of the year in hand, we can say that the number of incoming orders is somewhat less than last year, so we see certain uncertainty in the short term. However, the Spanish market has experienced an improvement (although the drop was so strong that it will take time to make up lost ground) Given that the industry-university collaboration is and we hope that this tendency will continue. On the contrary, quintessential for the development of the machine tool the international situation is very diverse: Asia is at a standstill industry, can you brief on the participation of the Spanish at the present time, after years of spectacular growths. Europe universities in this regard? is slowly waking up (France, Italy, United Kingdom, etc, We, at AFM, have a long and fruitful relationship with the although a better response from Germany is expected). The most important universities of our surrounding area, more NAFTA area (USA, Mexico and Canada) is the market with specifically with the departments related to engineering and the best perspectives. Promising markets such as Russia or advanced mechanical manufacturing. We collaborate with Brazil produce large doses of uncertainty due to their political them so that the training they give responds to the companies’ situation. We hope to be able to compensate in the more active needs. We jointly organise a Congress on Machine Tool and Advanced Manufacturing Technologies, and we also participate markets what others have lost. in numerous employment forums in order to attract the most Which are the various exhibitions – domestic and brilliant technical students to our companies. We also have a international, in which your organisation is representing training centre, called IMH, which arose on the initiative of the association and its member companies, through which Spain industry? We will start the year, precisely, in India, with the Indian we attempt to channel the training for the sector. It is also a metal cutting machine tool exhibition - IMTEX 2015, which pioneer in the dual training system in Spain. In the field of will be held in Bengaluru from January 22 to 28, 2015. Twelve R&D, apart from the universities, technology centres also play Spanish firms will participate in this exhibition as a group. an essential role. We have three of these technology centres We will continue with TECMA in Mexico, Industrie Lyon that engage in manufacturing technologies and other specific in France, Hannover Messe in Germany, the CIMT Fair in ones that have to do with materials, etc. ☐ Beijing, China, Metallobrabotka in Moscow, ExpoMetálica > www.efficientmanufacturing.in in Bogota (Colombia), EMO in Italy, and another time in
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Forming a unique ecosystem with our local clients” Jean-Camille Uring, President, The European Association of the Machine Tool Industries (CECIMO), in this interaction with Srimoyee Lahiri, underlines the importance of industryuniversity partnership as a building block of innovation in the machine tool sector. How do you look at the European machine tool industry interaction with clients. In short, the European machine tool in terms of its strength, capabilities, export potential, industry profits from its vast experience in developing and technological advances & innovations? applying advanced manufacturing technologies, and its dense The European machine tool industry is highly competitive network of suppliers and users. on the global markets. We export about 80% of all produced machine tools and over a half of exports is shipped outside What are the initiatives taken to improve trade ties with Europe. Our machine tool builders are known all over the India in terms for manufacturing related products? world for their highly innovative, state-of-the-art machines. India is an important trade partner for CECIMO and an The new technological solutions offered by the sector are born emerging global economic power. The value of CECIMOfrom the integration of different technologies into complex India trade grew from €110.8 million in 2003 to €506.8 million products. This definitely requires the involvement of experts in 2013. European machine tool producers are also looking from different fields. In addition, the European machine for investment opportunities in India and there are already tool sector forms a unique ecosystem with its local clients. a couple of production units established. European machine Our companies succeed because of their deep understanding tool builders follow with interest international trade policies of the clients’ market challenges and requirements, and this of their countries. The EU and India launched the Free knowledge comes from a long market experience and close Trade Agreement negotiations in 2007. The agreement will
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G L O B A L M A C H I N E TO O L I N D U S T R Y | I N T E R V I E W
“Industrialisation of emerging economies, especially in Asia, has considerably widened the global reach of the European machine tool industry” Jean-Camille Uring
improve access to each other’s market, create the structure key benefit to the industry. What is your take on this? for investment and the rules that frame trade. We believe that The European machine tool sector is dominated by SMEs, and finalisation and adoption of the agreement will bring the EU- the combination of flexibility and professional expertise has India trade relations to a new level and intensify cooperation allowed companies to build a loyal customer base. However, the industrialisation of emerging economies, especially in Asia, between manufacturers. has considerably widened the global reach of the European Can you highlight on the performance of the machine tool machine tool industry. With the demand for their products increasing, machine tool builders have had to scale up their industry in the year 2013-14? The European machine tool production records modest production, sometimes by merging with other machine tool growth and increases from 22.7 in 2013 to €22.9 billion companies. They do not only have to face rising demand, but in 2014. Despite several unfavourable events in the world, also a growing need for a global service network providing their including the Chinese economy becoming more consumption- customers with quality service. Therefore, uniting resources based, extreme weather conditions in the United States and and know-how is often a wise strategic choice for companies. the deepening crisis in Crimea, the machine tool market remains stable. The last couple of years, CECIMO’s machine Given that the industry-university collaboration is tool production was driven by exports. Now, we start to see a quintessential for the development of the machine tool modest revival of local consumption. In 2014, the estimated industry, can you brief on the participation of the European machine tool consumption will grow 6% to reach €13.4 billion. universities in this regard? CECIMO’s trade still remains at high levels despite a small Indeed, industry-university partnership is one of the building decline in exports this year. CECIMO’s exports will record blocks of innovation in the machine tool sector. There are €17.9 billion in 2014. The growing demand for machine tools various models of collaboration at the regional, national and has also increased imports: in 2014, European machine tool European levels which aim at putting universities and companies imports rose 5% to €8.4 billion. Comparing the imports with together and helping the sector bridge the gap between “ideas” the exports, the European machine tool industry creates highly and “products”. At European level, there are good examples of industry-university cooperation within the Horizon 2020 positive trade balance of €9.5 billion in 2014. Programme, and we see that universities across Europe lead Which is the main exhibition in which your organisation is research consortia composed of companies along the value chain, from suppliers to end-users. Key research areas relevant representing the European industry? CECIMO promotes the world leading machine tool exhibition to the machine tool industry include ICT-enabled modelling, EMO. This fair takes place every two years in Hannover and simulation and forecasting technologies, manufacturing of Milan alternatively. The next edition, EMO Milano 2015, will custom-made parts for personalised products and flexible take place from October 5 to 10, 2015, at the exhibition centre production systems. As initiators of research in such areas, Fieramilano under the slogan “Let’s build the future”. EMO universities play a pivotal role in guiding the consortium in the is a point of reference for the metalworking sector, allowing right direction and making sure that research projects finalise participants to showcase their latest products and make with exploitable results and demonstrations. We also see that, business contacts with visitors over the world. The exhibition in addition to universities, more and more research institutes happens this year at the last stage of EXPO Milano which will and research centres of companies are getting involved in research innovation projects and playing leading roles. ☐ certainly add to the unique EMO atmosphere. Currently, integration between machine tool companies is a
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> www.efficientmanufacturing.in
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INTERVIEW INDUSTRY
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TECHNOLOGY & MARKET Developments & trends Introducing the recent technology advancements in the manufacturing world, these series of articles showcases the latest advancements and trends in machine tools, cutting tools, coolants & lubricants, laser cutting, composite machining, aerospace manufacturing, die & mould, education and training and manufacturing IT.
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IMAGE C OURTESY: Sahajanand Laser Technology
LASER CUTTING | TECHNOLOGY
THE ULTIMATE CUTTING TOOL Major developments in today’s versions of advanced lasers offer faster cutting speeds to reduce cost, ability to cut complicated shapes in wider varieties of materials, user friendliness, non-dependency on skilled operators and intelligent features to take care of cutting failures. Laser technology had undergone many innovative developments in the past 5-6 years. These innovations have forced manufacturers to come up with new updates and integration. Increasing awareness and experience of users of this technology has played a significant role in defining the actual requirements of industry applications and to develop new generation laser cutting machines. According to Vijay Agwan, Regional Director – West, Indian Institute of Welding and an independent consultant, “Laser beam is the most intense and flexible heating tool; packing the energy density up to 108 kW per mm2 and focusing it in the extremely small area of 40 µm of diameter. This virtually makes it the ultimate cutting tool.” Highlighting on the progress of laser technology over the years, Sachin Gambhire, Manager – Sales, Laser Products
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Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
Section, Yamazaki Mazak India Pvt Ltd, says, “Comparing technologies in the late 90’s and early 2000’s, faster processes like turret punch presses have taken over conventional processes like gas cutting, oxy acetylene cutting, plasma cutting, etc. Faster productivity with bulk volumes attracted sheet metal processing industry to adopt turret punch presses to deliver goods faster and in huge volumes. However, it lacked many aspects in terms of processing complex shapes for one time requirements, short life span of components, smaller batch quantities, which led to unavoidable tooling cost and inventory, etc. These factors played a vital role for sheet metal industry to move towards laser and to come up with ideal processes for lower to medium thickness ranges, especially due to flexibility and smaller batch with complex geometry type production requirements.”
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TECHNOLOGY | LASER CUTTING
“Integrating fibre laser cutting systems with linear drive is a leap in manufacturing fibre laser cutting systems” Dr Arvind Patel, Director, Sahajanand Laser Technology Ltd
Fibre laser cutting India was the first to offer fibre laser cutting system to the world in the year 2006. Since then, sheet metal fabrication industry around the globe saw tremendous growth opportunity and has significantly changed the way in which sheet metal profiling is done. Initially, the fibre laser technology was prominent for welding applications. Dr Arvind Patel, Director, Sahajanand Laser Technology Ltd, elaborates, “Fibre laser technology’s capability to perform complex profiling operations in a much accurate manner lead to its widespread utilisation in cutting operations. Its economical performance of system stood best. Its quality of cut, repeatability and accuracy achieved through fibre laser system, made its penetration into other applications as well. Other than sheet metal, tube and angle cutting applications also felt the need of fibre lasers. Also, the cutting methodology involved in pipe and bevel cutting does not require fibre lasers. But, the operating swiftness and efficiency demanded fibre lasers.” Fibre laser cutting is now gaining importance in processing automobile chassis & body. The flexibility of fibre laser systems acts as an important factor to reach the complex geometries, meeting international quality and at high speed. Discussing emerging technologies in fibre laser cutting, Dr Patel avers, “Fibre lasers with varied power options are now emerging as a replacement for turret punch. Fibre lasers are now finding its place in the turret punching industry due to its capabilities in faster profile cutting, and quicker return on investment. Catering to defence & aerospace industries, fibre lasers are now capable of cutting reflective metals, metals with special coatings, and even thickness more up to an inch. Apart from fibre laser technology, the cutting systems are now designed to suit various industry requirements & accommodate large sheets, with rigid gantry, hybrid machines having tube cutting and bevel cutting options. Integrating fibre laser cutting systems with linear drive is a leap in manufacturing fibre laser cutting systems. Linear drive optimises the efficiency of the cutting process by improving accuracy, repeatability, and speed.” Fibre laser source manufacturers have also developed high power laser sources to cater industry demand to process metals with lesser costs and faster productivity. Gambhire notes, “Processing of reflective materials, which was a major limitation for CO2 lasers, has been taken care by new generation high power fibre laser cutters. With no optics and reduced complexity of beam delivery by fibre optics cable, this technology made it
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“Advances in lasers’ power, improved cutting speeds & edge quality and lower operating costs plays a vital role in the development of newer applications” Sachin Gambhire, Manager – Sales, Laser Products Section, Yamazaki Mazak India Pvt Ltd
“Laser beam is the most intense & flexible heating tool; packing the energy density up to 108 kW per mm2 and focusing it in an area of 40 µm of diameter. This makes it an ultimate cutting tool”
Vijay Agwan, Regional Director – West, Indian Institute of Welding and an Independent Consultant
easy to cut reflective materials with faster feed rates and reduced cost per piece. While fibre lasers are faster in lower than 6 mm thick sheets, CO2 lasers are more effective in cutting higher thickness sheets. Hence, CO2 and fibre laser technologies does not cross or compete each other but, in turn, users can now select wisely among two technologies as per application.” Thus, laser industry developments have equipped users with alternates in making the process faster, dependable and cost-effective.
Impact of new material development Newer applications include more widespread use of lasers to cut the automotive industry’s latest hot-stamped, lightweight, ultra-high-strength steels (UHSS) that are being used to make smaller, more fuel-efficient automobiles much stronger and safer than earlier models. Gambhire points out, “Lasers can efficiently cut the hot-stamped steels and hydro formed parts that make up some of automotives strongest sheet metal components, such as car and truck A and B-pillars, as well as dashboard structures. Cutting UHSS materials does not necessarily require higher-power lasers. Typically, the thickness of those materials rarely exceed 2-2.5 mm, so the materials themselves do not require a higher-power laser, and the complexity of the 3-D component limits the cutting speed. It cannot just go with full speed, like with flat-sheet cutting.” Elaborating further, he says, “Apart from these automotive
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LASER CUTTING | TECHNOLOGY
applications, there is huge awareness about the importance of good material quality as vital input to laser cutting process. The quality of inputs such as material surface qualities, gas quality, environment in which lasers are maintained plays an equally important role in quality of laser cut parts. These stringent quality requirements for laser cutting have led the steel manufacturers to develop a special grade as ‘laser steel’ which can be cut efficiently with laser beam and are meant for wider use in higher thickness carbon steel cutting applications. On new material developments and laser technology application, Dr Patel says, “In case of automobile industry segment, the processing time is much critical. It’s only the fibre laser that could perform best in a shorter time span and at a very low operating cost. Five-axis and robotic cutting systems have been successfully developed and incorporated for processing various automobile parts and structures.” Since the sheet metal fabrication industry is rapidly growing across the globe, there is a huge demand for fibre laser cutting systems. A 3 kW fibre laser system could cut up to a thickness of 20 mm steel. Dr Patel elaborates, “A majority of requirement in sheet metal processing industry falls under this thickness. If required more, there are options that the existing laser systems could be upgraded to cut more thickness. Fibre lasers have an edge on its best operating cost in comparison to other laser cutting technologies. Of course, it is the operating cost that determines the profitability of the operation. Fibre lasers are the best in this.”
Latest improvements in power & beam quality Advances in lasers' power, improved cutting speeds and edge quality, and lower operating costs have opened more avenues for the use of laser technology. Gambhire avers, “Gain in power, speed, and laser beam quality during the past decade have helped manufacturers use the systems in more areas. Also, better beam quality reduces the need for secondary operations. Fibre laser has smaller beam diameter at cutting point. So, a
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The technology involved in any laser cutting system is the best combination of laser source, transmission, the controller, the drive and the rigidity of the machine supporting the movement of axis at high speed
combination of smaller beam wavelength with diameter, helps to cut lower thickness parts in much complex and intricate shapes such that slits of 0.1 mm can be cut out of 0.8 mm thickness material.” Dr Patel adds, “Fibre lasers are 50% efficient as compared to CO2 laser systems. Also, the power consumption of a 3 kW CO2 laser system is higher than that of a 3 kW fibre laser system. The beam quality of a fibre laser system matters in the absorption level of metals. Latest fibre lasers operating in the market are also capable of profiling reflective materials viz, Al, BR, CU, TI, etc.” Commenting on latest addition to technology, Gambhire states, “To cut higher thickness, manufacturers have been forced to develop high power CO2 lasers beyond 4 kW laser power. These high power lasers are capable of overlapping into the plasma cutting range up to 30 mm / 32 mm thickness in mild steel and up to 20 mm stainless steel and higher thickness aluminium up to 15 mm – 16 mm.”
New applications Today, laser technology is easily used to cut 2D or 3D sheetmetal parts and to make high-quality, high accuracy parts for 3D application as automobile body panels, structural fabrication parts such as pipe cutting, channel cutting, etc. Explaining the various laser cutting applications, Agwan, affirms, “Laser manufacturing activities currently include cutting, welding, heat treating, cladding, vapour deposition, engraving, scribing, trimming, annealing, and shock hardening. Laser manufacturing processes compete both technically and economically with conventional and non-conventional manufacturing processes such as mechanical and thermal machining, arc welding, electrochemical, and electric discharge machining (EDM), abrasive water jet cutting, plasma cutting, and flame cutting. While water jet cutting, a recent development, is a process used to cut materials using a jet of pressurised water as high as 60,000 pounds per square inch (psi). Often, the water is mixed with an abrasive like garnet that enables more materials
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TECHNOLOGY | LASER CUTTING
TYPICAL PROCESS APPLICATIONS AND USES CO 2 LASER
WATER JET CUTTING
Typical process uses
Cutting, drilling, engraving, ablation, structuring, welding
Cutting, ablation, structuring
3D material cutting
Difficult due to rigid beam guidance and the regulation of distance
Partially possible since residual energy behind the workpiece is destroyed
Materials able to be cut by the process
All metals (excluding highly reflective metals), all plastics, glass, and wood can be cut
All materials can be cut by this process
Material combinations
Materials with different melting points can barely be cut
Sandwich structures with cavities
This is not possible with a CO 2 laser
Cutting materials with limited or impaired access
Rarely possible due to small distance and the large laser cutting head
Properties of the cut material which influence processing
Absorption characteristics of material at 10.6 µm
Material thickness at which cutting or processing is economical
~0.12" to 0.4" depending on material
Common applications for this process
Cutting of flat sheet steel of medium thickness for sheet metal processing
to be cut cleanly to close tolerances, squarely and with a good edge finish. Water jets are capable of cutting many industrial materials including stainless steel, Inconel, titanium, aluminium, tool steel, ceramics, granite, and armor plate. This process generates significant noise.” Adding further, Gambhire explains, “Major key factors which forced manufacturers to come up with the present versions of advanced lasers are requirements of faster cutting speeds, reduced cost per piece, cutting complicated shapes, user friendliness, requirement to cut wider varieties of materials, non-dependency on skilled operators, intelligent features to take care of cutting failures, etc. One can witness very interesting trends in development of laser cutting machines for two extreme ends of the laser applications. First, the eagerness of end users to cut higher thickness has forced manufacturers to develop high power CO2 lasers beyond 4 kW laser power ie 5 kW, 6 kW, etc. These high power lasers have taken over a share of business from plasma cutting (in the range up to 30 mm/32 mm thickness in mild steel and up to 20 mm stainless steel processing). Second, the requirement in terms to process lower thicknesses with faster productive rates and less cost per piece and to process lower thickness reflective material has resulted in development of fibre lasers. These two extreme end laser applications have resulted into two extreme choices to use high power CO2 lasers for higher thickness high accuracy cutting requirement and to use fibre laser for lower thickness, high productivity, reflective material processing with low cost per piece.”
Need for newer applications With new material development and demand for lightweight products, laser applications have grown multifold in the last
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Possible, but there is a danger of delamination Limited ability Limited due to the small distance between the nozzle and the material Material hardness is a key factor ~0.4" to 2.0" Cutting of stone, ceramics, and metals of greater thickness
SOURC E: Vijay Agwan
SUBJECT
five years. Gambhire highlights, “Advances in lasers’ power, improved cutting speeds and edge quality, and lower operating costs play a vital role in the development of newer applications. These include more widespread use of lasers to cut the automotive industry’s latest hot-stamped, lightweight, ultrahigh-strength steels (UHSS) that are being used to make smaller, more fuel-efficient automobiles much stronger and safer than earlier models. Lasers can efficiently cut the hot-stamped steels and hydro formed parts that make up some of automotives strongest sheet metal components, such as car and truck A and B pillars, as well as dashboard structures. Cutting UHSS materials does not necessarily require higher-power lasers; typically, the thickness of those materials rarely exceed 2-2.5 mm, so the materials themselves do not require a higher-power laser, and the complexity of the 3-D component limits the cutting speed. It cannot just go with full speed, like with flatsheet cutting.” Fibre applications are also found in the automobile industry to trim car and truck bodies. Dr Patel affirms, “Fibre lasers are widely used for chain welding of automobile doors and edge welding of roof tops as well. Even in case of two wheelers, welding of fuel tanks demand fibre lasers. Drilling on heavy automobile wheels is again a new concept where fibre lasers are used. All these processes get the best processing time, with utmost quality and elimination of post processing. Fibre lasers have been recently used for laser hardening applications as well. Hardening of crank shaft is the best example.” With laser technology being widely used in the manufacturing sector for multiple applications and precision, the coming decade is likely to see many new innovations and applications to suit the requirements of various sectors globally. ☐ > www.efficientmanufacturing.in
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COMPOSITE MACHINING | TECHNOLOGY
MACHINING OF COMPOSITE MATERIAL PARTS Composite parts are finish machined by way of turning, milling, slitting, drilling, routing, etc. However, the knowledge 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 accordingly be constructed. Composite materials are used increasingly in products to take advantage of their unique properties of high specific stiffness, strength and low coefficient of thermal expansion.
What are composites? Composites are a combination of two or more materials and are not homogenous. One of the materials is in the form of strong fibres which play a role of “reinforcement” and are distributed in a weaker base called “matrix” which serves to distribute the fibres and to transmit the load to the fibres. Some typical fibres are glass, carbon, boron, aramid or kevlar, silicon carbide, etc. The fibre skeleton, appearing as a bundle of parallel
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T Subramanian VP - Special Projects Bharat Fritz Werner Ltd subramanian@bfw.co.in
fibres or woven rings, has geometrical orientation depending on force directions and is enveloped in a matrix of thermoset or thermoplastic material. These are Polymer Matrix Composites (PMC), also called Fibre Reinforced Polymers (FRP). Metal Matrix Composites (MMC) are increasingly found in the automotive industry wherein the matrix is a metal such as aluminium with the reinforcement fibres such as silicon carbide. Ceramic Matrix Composites (CMC) are used in very high temperature environments.
Machining composites Composite parts are always near net shape when the
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TECHNOLOGY | COMPOSITE MACHINING
Hole exit
Delamination Spalling
Uncut fibers Uncut resin
Typical defects in drilling a hole in a part made of composite material
Delamination and breakout affects in most casesthe internal structure of the basic component and cannot be repaired
comparatively quite small machining is required and the value of the part at this stage is usually quite high. Scrapping during machining a part, made of composite material (CM), when in the final stages of its production is usually prohibitively high and disastrous. Repairing is generally not feasible. The critical issue being – though the amount of machining is quite as small compared to machining an equivalent metallic part, the cost, difficulty, value and impact of that machining can be considerably higher. Due to the essential characteristics of nonhomogeneity, the theory of ‘machining’ actually ‘cutting’ action at the tool tip is completely different from that of metallic materials. It also depends on the properties of the specific fibre and matrix materials, fibre orientation and type of weave, etc. Hence, machining of CM is in every case an experiment. It is actually ‘controlled & managed breaking’ rather than machined. The tools & the actual machining conditions are to be tailored to each specific CM. When we consider machining of glass fibre vs carbon fibre, glass is more abrasive than carbon, which causes tools to wear faster. Carbon is more brittle than glass, and makes a finer dust that can pose larger cleanliness issues.
machining are fibre type, resin type, fibre orientation at point of contact, part thickness, matrix hardness & heat sensitivity, and construction whether it is a solid laminate or of a sandwich construction. Tool life is generally predictable as long as there is no change in the part’s resin, fibre or fibre-winding angle.
Tool types & tool cost management
Some of the tool materials opted for machining composites are carbide, coated carbide, diamond coated CVD (Chemical Vapour Deposition), PCD coating, Diamond Like Coating (DLC), Diamond Film Coating (DFC), Zirconium Nitride Coating (ZNC), Crystalline Diamond Coating (CDC). Generally, higher the hardness of the coating, costlier is the tool. However, it is important to estimate the total costs instead of being misled by just the initial cost of purchase. If a PCD tool costs three times, for example, than that of a CVD tool, but it works four times the length – then costlier PCD is economical in the end. On the other hand, a low-fibre volume fraction will permit less aggressive and less expensive tool material. Selection of coating material is critical and must be carefully done. When machining composite structure worth hundreds of Challenges faced in machining composites thousands of rupees, spending more per tool might be justified Some of the main difficulties faced during machining in the end. Longevity and re-servicing of the tool are to be composites are the melting of matrix due to too much heat, taken into account while estimating the total costs. fracturing of fibres instead of shearing smoothly, splintering/ delaminating of layers. The typical remedial solutions are Conclusion retaining the cutting edges to be extra sharp and not allowing Machining of composite materials is a tricky affair and is them to become dull. Minor dullness of tool means rubbing, which produces excessive heat, in turn, causing change of shape completely different from our knowledge of machining parts of due to melt downs. Rubbing should be avoided at any cost. The steel, cast iron or aluminium material. The tool’s cutting action clearance for the cutting edge should be sufficiently high to also differs since composites are basically non-homogenous give a clean-cut. The material reacts differently to machining materials. The part being quite expensive at the machining depending on the type of fibre reinforcement, winding angles stage, it is important to carefully finalise the tool and cutting and resin formulas. Often dedicated tool sets are used for each conditions based on actual trials. The machine tool must be component. It is important to know a tool’s predicted effective equipped with appropriate facilities like dust management and tool conditions monitoring, etc. ☐ life and change it before dulling occurs. > www.efficientmanufacturing.in Variables influencing the composite responding to
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COOLANTS & LUBRICANTS | TECHNOLOGY
ASSESSING HIGH-SPEED MACHINING CONDITIONS The article discusses differences in aluminium machining performance obtained at high & low cutting speeds, the influence of the metalworking fluid and its composition in enhancing machining performance High-speed machining (HSM) offers the potential for increased productivity and improved part quality in the production of aluminium engine & transmission components for the automotive industry. The use of high speeds and feed rates in a machining operation can yield increased rates of productivity and can also result in improved machined surface finish and reduced machining forces. Such effects are thought to result from reduced heat generation during cutting, reduced contact time between the tool & workpiece surfaces and also from the limiting shear stress properties of the metal, which are often exceeded under high speed machining conditions.
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High v/s conventional speed machining To better understand the influence of metalworking fluids in aluminium high-speed machining, machining tests were performed at both lower conventional speeds and at high-speed conditions. While considering the history of the origins of HSM, it was determined that the heat generated between the chip and the cutting tool would increase with increasing cutting speed, up to a critical speed dependent upon the metal being cut. With further increase a critical speed would be reached, at which point the chip removal temperature would decrease with
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TECHNOLOGY | COOLANTS & LUBRICANTS
BUE formation is an extremely dynamic process with formation and loss of adhered metal from the cutting edge
further increasing speeds. Given this analysis, and the presumption that machining performance (forces, BUE formation, tool wear, etc) are all largely influenced by the heat generated at the tool chip interface, it would be expected that overall machining performance would decrease with increasing cutting speeds prior to the peak cutting speeds and then begin to improve as speeds exceed the peak value. To investigate this premise, machining tests were performed using cast 380 aluminium at cutting speed values below, equal to, and above the peak cutting speed value which was plotted for non-ferrous metals. Using a 0.25 diameter carbide step drill, machining of Al 380 was performed using spindle speeds of 2,900 RPM, 10,000 RPM, and 18,000 RPMs, with these cutting speeds corresponding to one below, one at and one beyond the critical speeds as they relate to chip removal temperatures.
Machining performance To assess the machining performance at these three different cutting speeds, the axial machining forces, tool flank face wear, machined surface finish, and hole dimensions were measured. The axial machining forces, while providing a measure of the energy required for the operation, also provide a useful indirect measure of the mechanical and thermal demands on the tooling and the potential tool life to be expected in a given operation. The machining forces climb considerably when speeds are increased from 2,900 RPM up to 10,000 RPMs. However, as the speeds increase further to the HSM conditions (18,000 RPMs), the cutting forces level off and actually start to decrease. Thus
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it can be concluded that the mechanical and thermal demands on the tooling are reduced at HSM conditions and improved tool wear will likely be obtained. To support such conclusions, the tool flank face wear was measured following chemical removal of the built up edge from the tool cutting surface. The flank face wear length on the tools used at the three cutting speeds, wear is significantly reduced as the cutting speeds increase from 2,900 RPM to 10,000 RPM with a further wear reduction obtained at the high speed conditions of 18,000 RPMs. While tool wear is an important issue in aluminium machining, the amount or degree of built up edge formed on the cutting tool can be an equally or often more critical parameter to be considered. Built up edge when formed often leads to a degradation of the machined surface finish, as well as loss of accuracy of size or dimensions of the holes produced. To assess the impact of HSM conditions on this parameter, the degree of BUE formed on the cutting tools, and subsequently the hole finish and form, were measured for each of the three cutting speeds utilised. While BUE formation is an extremely dynamic process with formation and loss of adhered metal from the cutting edge constantly occurring, examination of the tooling following the machining operation still offers a useful assessment of the tendency for this to happen. It is clear that the use of the high cutting speeds of 18,000 RPMs yield a significantly lower level of BUE formed on the cutting tool edge. � Courtesy: Quaker Chemicals > www.EfficientManufacturing.in
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AMEARNOASGPA E MCEENMT A| NI N U TFA E RCVTIUE R WI N G | T E C H N O L O G Y
The technological trendsetter The aerospace industry is the technological pacemaker when it comes to state-of-the-art production techniques. Very few sectors take what is feasible and then implement real products in such a consequential and creative way. Satish Godbole VP - Motion Control Div Siemens Ltd
Today, the Indian aerospace industry, including the civil aviation sector, is witnessing an unprecedented growth. However, this industry too faces the challenge in increasing productivity, efficiency, optimising manufacturing costs & weight of carriers. Composite materials are gaining popularity for their role in weight reduction. This is because composites are versatile and are used for both structural applications and components, right from hot air balloon gondolas and gliders, to passenger airliners, fighter planes and the space shuttle. Applications range from complete airplanes to wing assemblies, helicopter rotor blades, propellers, seats and instrument enclosures. Aircrafts today are aiming to make 50% of their airframe from composites. Higher degree of flexibility and traceability has become the need of the hour for an aircraft manufacturer to achieve a competitive edge. However, this can be achieved only by deploying high performance automation solutions. Siemens, as a partner to the aircraft builders and machine builders, has developed dedicated control solutions that guarantee the highest degree of quality and productivity.
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The entire spectrum of aircraft component manufacturing primarily involves 5-axis machining of structural parts and engine components; laser drilling; machining of gear; laser beam and water jet cutting; tape layering/fibre placement; and virtual machining & productivity enhancement. Five-axis component manufacturing: In an aircraft industry, production of highly stressed work pieces involves machining of a high proportion of material. With 5-axis machining of structural components, up to 90% of the raw material can be removed during machining. This calls for extremely high metal removal rates, which can only be achieved with highly efficient machines. The emphasis is more on maximum dimensional accuracy and surface quality, rather than machining capability. The most efficient way to achieve this is with 5-axis milling, the most advanced metal cutting discipline. In addition to high performance hardware, the control systems used in 5-axis machining centres must incorporate
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T E C H N O L O G Y | A E R O S PA C E M A N U FA C T U R I N G
Laser drilling requires optimum adaptation of the control system
specific programming, motion control and compensation functions for complex machining tasks. It is also important to match and optimise motion control to the requirements of a particular machining task.
hardness and conductivity of the material to be machined. Water jet machining has also been adopted by many aircraft builders & suppliers. The strength of high pressure is particularly apparent in cutting composite materials and temperature-sensitive lightweight metals.
Laser drilling: Drilling is another fast-growing application of laser technology which is increasingly popular in aerospace Tape layering / fibre placement: In modern aircraft construction, industry. Laser drilling involves applying sufficient energy to a large quantity of aluminium components are being replaced one point on the workpiece so as to achieve controlled by complex parts made of fibre-reinforced materials – primarily evaporation of material. Thanks to its great precision and fast carbon fibre reinforced plastics (CFRP). Most structures are on machining time, it is rapidly overtaking other technologies such fuselage, an aircraft’s main body section, and wings. This reduces as conventional drilling and spark erosion, as the method of weight and greatly simplifies assembly and logistics. While, until choice for machining very hard materials from which, for recently manufacturing was mostly performed manually, the example, turbine blades are made. Laser contour drilling, an trend is now to automate the processes. Two of the particularly intelligent combination of laser drilling and laser carving, can important trends are automatic tape layering for flat and slightly provide a highly efficient way of making tapered ventilation curved components such as wing cladding and fibre placement holes in turbine blades for even better turbine performance. for more curved components such as fuselage segments. Like other innovative laser-based machining methods, laser drilling requires optimum adaptation of the control system for Virtual machining & productivity enhancement: Anyone who this challenging technology. wishes to achieve productivity enhancement, must analyse and optimise the entire CAD/CAM/CNC process chain. CAD/CAM Machining of gears: A gear that runs quietly has to be system, NC program and CNC itself must be optimised without produced on a machine which runs quietly because the gear adversely affecting the ongoing production or risking machine surfaces are memories of vibrations that are present during damage. Usually, final stage of NC programming in work manufacturing of the gear. A machine which rises to the planning is the graphic simulation of machining process and challenge of precision and high-quality gear production has to verification of workpiece with aid of special applications. With be mechanically and electronically stiff over a wide range of manufacturers having global productions facilities, the key lies unsteady frequencies due to tooth count of the cutter and in various components reaching the assembly facility at the right rotational velocity. time. To achieve this, strong Manufacturing Execution Systems (MES) should be in place that collates data from shop floor to Laser beam & water jet cutting: Increasingly, materials top floor. This ensures a smooth aircraft assembly. being employed in aircraft construction are extremely difficult All these processes can be carried out with 100 per cent to cut. These can be machined with conventional chip removal precision and accuracy based on the choice of technology that is or EDM at high cost, which can be used in limited circumstances deployed at every level. Hence, it is essential for an aircraft only. One alternative to conventional manufacturing processes manufacturer to opt for innovative technologies that would give is to use a laser. This technology can be utilised with geometric him a competitive edge. � > www.efficientmanufacturing.in flexibility, highest possible precision and is independent of
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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
HOW TO SELECT THE BEST CAD/CAM TOOL? The goal of CAD/CAM developers has always been to be in sync with the changing market expectations. In this context, many developers have come up with many innovative concepts in digital prototypes to optimise designs, streamline documentation, better data management, compel realistic visualisations, among other features. This article analyses these features and parameters that users must consider while choosing the best CAD/CAM tool for their operation.
Sumedha Mahorey Deputy Editor sumedha.mahorey@publish-industry.net
SAMEER KONDEJKAR, HEAD - GEOMETRY TECHNOLOGY SOLUTIONS, GEOMETRIC LIMITED Two key criteria are getting added to the existing traditional criteria while selecting the best CAD/CAM software. These are – firstly, intelligent software with inbuilt knowledge: it’s no longer just about the tool. Users are looking for knowledge and industry best practices in-built in the software to help their work, and secondly, ease of use: with skilled workforce crunch in developed countries, and need for fast scale-up of workforce in developing countries, ease of use for software that removes the need for extensive training has become a must. As new generation tools bring easy access to downstream process knowledge, it will help shorten overall design to manufacture cycle and enable design engineers to think of better design options as per target industry than worrying about design syntax or semantics.
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Manufactu
T E C H N O L O G Y | M A N U FA C T U R I N G I T
SUBASH NAMBIAR, VP & COUNTRY MANAGER – INDIA, PTC The first parameter is to find out if the CAD software is meeting the changing environment and keeping pace with the growing market demands. Manufacturing industry has faced many challenges. Some of the major challenges are to keep pace with growing customer and market demands; every manufacturing company is looking forward to evolve new products, resulting in increased product complexity. The second point is to see how the software is helping the manufacturing companies in connecting various data sources and helping to get consistent designs. Disconnected tools, disparate data sources and inconsistent processes can inadvertently lead to inefficient engineering methods and inconsistent designs. This lack of visibility into product data diminishes any potential for reuse and may introduce additional errors because of inaccurate data and time-consuming tasks. Inefficient, inconsistent product development processes and incomplete product definitions can drive up costs and lead to product delays. The high number of disparate tools further raises the total cost of ownership and results in fractured processes. Labour and production costs skyrocket and productivity suffers when errors and poor quality have to be addressed. The result: lower operating margins and lost opportunities. With a consolidated, integrated product development infrastructure, the total cost of ownership is minimised and processes are standardised. Increased visibility into product data minimises late-stage changes and enables reuse of designs and other engineering IP. A complete digital product definition enables more effective digital prototyping, testing and other downstream activities.
VINEET SETH, MD - INDIA & MIDDLE EAST, DELCAM PLC CAD is a huge domain and encompasses an equally wide area of application. From simple 2D drafting to complex machine and civil assemblies, CAD forms the base of all designs – or it has been so for the past decade or so. In the manufacturing perspective, CAD software needs to allow for the quick and efficient design of parts and assemblies. It should also have the capabilities to allow the designer to model the most complex of parts with minimal efforts and in a reasonable amount of time. Needless to say, the CAD tool should also allow the designer to communicate the design intent and the manufacturability of the product to the shop floor. There should also be a flawless interaction between CAD and CAM, thereby enabling designers and programmers to make quick and necessary changes without necessarily having to depend on each other at all times. One of the most important features in CAD should also be the ability to read in a multitude file formats including native file formats of other CAD software. In terms of handling different entities, Tribrid modellers (surface, solid and polygon mesh modelers) are known to be far more accurate and flexible for the product & tool designer. Lastly, there should be a very good rendering tool to communicate the aesthetics of the product to the end user. On the CAM front, the ideal CAM software is one that is easy to use, is fast, accurate and allows the programmer to address the most complex of parts with ease. Typically, turning, turn-milling, multi-axis milling and wire EDM are the modules that should be a part of the CAM software. This will provide its users a uniform interface, and allow programmers across departments to access a common tool, parameters and knowledge bank. The CAM software should also have powerful editing tools to help advanced as well as novice users suit the tool path as per special requirements. One of the key aspects of CAM software is its Post Processor. This tool converts the cutter location data which is internal to the CAM software, to a language that is understandable to machine tools (G&M codes – as well as canned cycles). A robust post processor ensures that the programmers intent is quantified on the machine tool and results in saving time and money for the organisation. A good simulation tool also helps the programmer to visualise, virtually, how the machine kinematics will respond to the given program.
RAJIV BAJAJ, HEAD - MANUFACTURING , AUTODESK INDIA & SAARC Some of the key criteria for selection of a good CAD/CAM tools is reliability and stability. Other important features include features such as — A capable and efficient 3D design: The 3D model must accurately represent every part in the company’s products and the relationships among them. To maximise efficiency, designers should be able to design in 3D with as few steps as possible without compromising product quality. Compatibility with customers and suppliers: One has to choose a CAD system that’s popular in that industry and supplier community. This choice will eliminate the need to translate files from one system to another. Translation takes time and sometimes introduces errors. Innovative R&D: Computing technology is constantly changing and that too at a rate when in a few years the CAD system becomes obsolete.
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DIE & MOULD | TECHNOLOGY
SOLVING COMPLEX MOULD DESIGN CHALLENGES It is very true of modern CAD systems, that they are the first stage of manufacturing, where future manufacturing problems are considered, evaluated and remedied, thus saving precious time and money. Not only this, but with the integration of design and manufacture in the same window, it is now possible to flawlessly transfer machining information related to standard components and features, making the entire system very efficient. Plastics have replaced nearly all of our everyday products from their earlier form and function. I remember when I was growing up, toothpaste used to be packaged in aluminium/tin tubes, with the cap being aluminium too! Talcum powder, soap cases, television cabinets, etc, the list can go on. All of these were in a completely different shape and material than what we see today. Much of this has changed due to the universal adaptability of plastics, and the ease in which we are able to provide intricate form to these polymers. It is therefore now, a given fact, that we can create any shape/size of an object in
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Vineet Seth Managing Director India & Middle East Delcam Plc vseth@delcam.com
plastic, as long as it is practically manufactureable. However, there are many challenges that need to be overcome in order to make an improbable mould design possible, and the existence & continual development in CAD software helps to address these complex challenges.
Modern CAD systems When plastics were first gaining popularity, parts were simple. Most products were designed on a drawing board, so it
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Tribrid modelling, breaks all design barriers and allows the designer to blend relief, surfaces and solids into a single entity, be it a core or cavity
was natural that the tooling was designed that way as well. These were the days when most of the drafting work was manual, and prone to errors. As CAD has evolved into 3-D, the complexity of plastic moulded parts has increased. Modern plastic products seek to be increasingly creative in terms of form, while being more functional and durable. For the mould designer, these new forms have forced a requirement for CAD systems to be able to accurately reproduce complex shapes, not just for the visible parts of the product, but especially for the functional parts of the mould, such as parting surfaces. Modern CAD systems are able to better handle complexities, and provide the designer with many intuitive tools and step-bystep wizards to accomplish their work. Let us consider the basic process of analysing a component for determining its parting surface. Often, with components that have varying and complex form, the parting line is not very easily created. With the help of certain analysis tools like smoothness, undercut, minimum radius, curvature-shading, thickness analysis amongst others, the designer is able to ensure that the component, as well as the mould cavity/core is free of micro defects.
Meeting challenges Ask any mould designer the key pain area, and they will unanimously voice that it is the selection and creation of the parting line. Undercut shading allows the designer to fix the principal vertical axis, and then based on this axis, automatically create a curve across the component, which will be the obvious parting line. In many cases, this parting line is ideal. However, for components that are aesthetic in nature, or have slide cores in alternate axes, it becomes very important for the designer to manually trace a parting curve – based on given data, experience and mould complexity. In such cases, wizard based routines in tools such as Delcam PowerSHAPE allows the designer to
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choose split points, at critical nodes, from where the surface can be split along a specified vector direction. The upshot of this is better moulds and parts, faster. Specialised mould design software allows the tool designer to quickly and accurately divide a complex component into cavity and core halves, complete with all of the necessary split and run-off surfaces. Fast and intuitive tools allow the mould designer to isolate and extract complex sliding core mechanisms directly from the initial 3-D design, and then animate them to check for fit, function and clearances. Minimum radius and thickness shading allows the designer to plan better for reinforcing critical regions in the core/cavity. Once the main mould parts such as cavities, cores, slides and mould locks, have been defined, the completed mould stack is only a few clicks away. Standard and user-defined components including complex mechanisms, such as hot runners, staged ejectors, lifters, etc can be added to the basic stack at any time, each with associated holes and pockets for fitting. One of the areas where designers face problems during the design process, is the ability to reach & manipulate the core control of each surface that they would like to work on. When we speak about automotive plastic components, certain parts such as the head/tail lamp mould core/cavities can get extremely complex. One of the facts of moulding, is that the original component only acts as a base reference – as there are various draft angles & shrinkage values that are added to individual regions in a core/cavity. The designer therefore needs tools that will help him give this flexibility to pick and modify, or to select a group of components and make the necessary modifications. “Direct modelling” tools in CAD software now allow designers to choose the area of interest and perform selection specific modifications – interactively. For more complex interactions at the wireframe level, there are tools available to perform discrete operations on surface point, curve and tangent normal, thus
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Minimum radius and thickness shading allows the designer to plan better for reinforcing critical regions in the core
giving the experienced designer advanced control over form and factor.
Breaking design barriers
This is especially true of large moulds with many standard components, numbers of which go into hundreds. This feature makes the model “lighter” and provides the designer with a smoother handling experience. Additionally, automated parentchild relations between components of a mould tool enable a realistic animation of the mould operation.
Particularly in advanced CAD software like PowerSHAPE, the designer is also able to work with solids, surfaces and triangle models in the same window. This unique concept known as Automating the processes Tribrid modelling, breaks all design barriers and allows the Most mould making companies still require paper drawings. designer (especially of consumer products & packaging products) to blend relief, surfaces and solids into a single entity, Automated drafting creates general assembly and a detailed be it a core or cavity. When we look at plastic bottle moulds, toy sheet of any components or plates with a single click. Automated moulds etc, photographs depicting scenery, complex logos, etc bills-of-material give instant access to online ordering systems can be converted quickly into 3D reliefs and placed in the core/ for purchasing the standard plates and components, guaranteeing cavity as needed. What would have otherwise taken days of hard that the entire build is ready on time, every time. The end result is a complete, fully detailed and accurate 3-D model of the labour is now possible to be created in a matter of minutes. Powerful yet easy-to-use, process-driven Wizards guide the mould tool, and it is here that the real benefits of the process mould designer through the remaining operations — positioning become apparent. Although the initial design can in some ejectors and other components, and creating cooling channels. instances take longer than using traditional methods, In the event of a design change, all of the Wizards, right back to manufacturing from this point forward is mostly automatic and the very beginning of the process, can be re-played with the new requires very little human intervention, as far as process part geometry, eliminating the need for repeating the process parameters are concerned. The 3-D model of a single plate, for example, is not simply a traditional CAD solid; it is a library of from scratch. When it comes to mould base and standard components, manufacturing data, allowing machining of all the holes and like ejector pins, guide pillars, bushes, finger cams and the likes, pockets to become a one-click operation when used in the modern CAD software offers flexibility to the designer by conjunction with a CAM system. Each hole or pocket is not just allowing them to choose between industry standard components a geometric entity, but instead holds complete details of its and user-defined components. While the industry standard function and how it is to be machined. User-defined rules are components are stored in a library in the CAD software, the automatically applied as each plate or component is machined, user-defined components are actually based on constrained creating all necessary toolpaths quickly and accurately. For relations, which make it very easy and faster for the designer to complex cavities, cores and split surfaces, full 3-D CAM allows perfect reproduction in tool steel using up to five-axis create these, without having to start from the beginning. Further, many small features, for example, treating multiple simultaneous control for fine surface finish. ☐ common components as instances of the actual model help in > www.efficientmanufacturing.in reducing the overall size of the mould assembly to a large extent.
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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
MAKING HEADWAY THROUGH CAST IRON MACHINING The article highlights the various choices in selecting the appropriate cutting tool from the cast iron material, turning and milling points of view. Manufacturers face several variables and challenges when determining the right tooling to maintain competitiveness in cast iron machining operations. Not only are there several different types of cast irons, the material itself can vary from one casting to the next. So to choose the appropriate cutting tool insert geometries and grades, manufacturers must understand all the factors involved and take into consideration their entire production chains if they are to successfully achieve the best combination of quality, cost and productivity.
The advancements Today’s cast irons are a lot more advanced and better understood than they were 20 years ago. In some cases, this makes them an excellent alternative to steel in a time when there is a constant pressure to lower prices and improve productivity. Generally speaking, cast irons are getting lighter,
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Mikael Lindholm Product Manager – ISO Turning Seco Tools
Michael Karlkvist Product Manager – Face Milling & Mass Application Seco Tools
stronger, more affordable and now have higher wear resistance. These materials also yield free machining, work well in producing complex shapes as well as have high machinability. Keep in mind, however, the level of strength, cost and machinability varies between cast iron types, which include grey, vermicular, silicon alloyed ferritic ductile, nodular ductile and austempered ductile. For each type, there are several grades with widely differing mechanical properties. These variations mainly result from the differences in the microstructure of the metal matrix that surrounds the graphite. In addition to having to choose between the different types of cast irons, manufacturers must also take into consideration that cast iron metallurgy is quite complex. The casting process in its very nature will generate microstructures with properties that vary between a part’s surface and its internal body. Therefore, one could say that two different microstructures co-exist within the same casting. Also, cast iron quality varies
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Technolog
T E C H N O L O G Y | C U T T I N G TO O L S
The smaller size of insert gives the possibility to provide diameters starting from 0.75” (20 mm), with a maximum diameter of 2.50” (63 mm)
from one foundry to the next, meaning even if the type of cast iron is the “same,” variations in the casting process could generate significant differences, in terms of machinability levels, from one workpiece to the next. Take grey cast iron for example. Its machinability is affected by variations in the surface and by other near-surface conditions, such as mould residues or free ferrite, the latter which is iron in its purest form, that disturb the manufacturing process in different ways. The former creates harder and randomly located zones, while the latter results in softer areas of the workpiece. These variations cause predictability deviations that influence machinability. Therefore, manufacturers must have carefully planned logistics, from casting to storage to machining, to ensure they have consistent workpiece batches that are large enough for their applications.
Turning
Consider grades for turning, which is a high area of focus in this type of machining process. In the past, cutting tool companies would have several insert grades from which to choose. Today, the goal is to reduce the number of grades needed by creating top performance solutions that can still handle a wider range of cast iron materials and specifications, which, in turn, make the selection process easier. Some cutting tool companies are using advanced coating processes to create two- and three-grade strategies for their customers. Seco Tools, for example, has a two-grade turning strategy made possible via its exclusive Duratomic® coating technology grades where aluminium and oxygen are manipulated at the atomic level to create inserts with a combination of exceptional toughness and abrasion resistance Maintaining material for cast irons. In terms of actual cast iron turning operations, It is important to have the properties of the workpiece under everything is dependent upon a manufacturer’s specific the best possible control at any given time. After all, any application. Manufacturers must determine the number of variations can negatively impact total productivity, either operations necessary to accomplish their goals, no more and directly or indirectly. When workpiece properties are unclear, no less. If the workpiece properties are unknown, a manufacturers can look to tooling systems and cutting strategies manufacturer may opt to include an extra finishing cut, to make up for any material quality shortfalls. However, the which impacts product lead times. However, by applying the trick is to know what tools and strategies are the right fit for a right tooling for the conditions and requirements of the particular application. Cutting tool companies are continuously component, a manufacturer can reduce the number of developing new turning and milling products that help operations. overcome the variables and challenges manufacturers face A more specific turning operation scenario might involve when working with cast iron materials. But this can be a feat in a manufacturer machining components within a just-in-time itself because every material, manufacturer and application supply chain as indicated earlier. In such a situation, batches around the world is unique. A cutting tool company may have of as-cast workpieces are sometimes out of specification in product solutions with wide application windows for cast iron, terms of near-surface conditions, yet must still be machined but much depends on individual customer needs and the despite an increased cost per part caused by reduced tool life chosen machining strategy or method. and productivity. At which point, the manufacturer must While some manufacturers are willing to spend the money carefully decide between different types and grades of inserts, on a wide variety of insert types and grades to optimise every which might include cemented carbide and polycrystalline application for maximum productivity, others choose a limited cubic boron nitride (PCBN) tooling. However, if the foundry selection of inserts and grades with an “all-around character” supplying the grey cast iron, for example, provides a consistent to make their processes easier to manage but then experience quality level, manufacturers can reach unbeatable productivity lower productivity. levels using PCBN tooling.
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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
Double Octomill has a thick robust direct-pressed insert that ensures high strength and low risk of edge breakage
Milling When it comes to milling cast irons, there is a lot more complexity involved as compared with turning the material. While the type of insert grade a manufacturer uses is important, it is even more critical to look at the total cutting solution. A manufacturer must also consider – in addition to insert geometries and grades – cutter body types and the number of cutting edges as related to the component being machined. Doing so plays a key role in achieving a low cost per part. Today’s cutting tool companies are trying to fulfill customer needs and simplify cast iron machining by providing solutions that are easier to apply and that perform better for as many types of materials and applications as possible. For example, heat and coolant are not ideal for cast iron machining, especially in milling. Therefore, cutting tool companies are working on top-performing grades for milling in both dry and wet conditions. These companies are also looking to help manufacturers reduce machining times through cutting solutions that can effectively rough and finish in one pass.
Cutter In terms of selecting the best type of cutter for cast iron milling, there is no real one-size-fits-all answer. But generally speaking, the type of milling cutter that seems to be making a lot of headway these days would be a negative cutter with inserts that have positive rake angles and in a grade that handles both wet and dry conditions. By having a positive cutting rake angle in a negative cutter, manufacturers benefit in multiple ways – freer cutting action as well as reduced power consumption and heat generation, all of which leads to longer tool life and an increase in usable cutting edges. For example, consider face milling an engine block where there are a lot of cavities. When the milling cutter machines over each cavity corner, the goal is to avoid chipping those cavity edges. If the manufacturer is using a worn cutter in conjunction with high cutting forces, there is an increased risk of chipping out sections of the
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workpiece material — a negative cutter with a positive rake angle can help avoid such a scenario. Keep in mind, however, while one type of cutter may be able to successfully cut all the different types of cast irons, that does not mean it can effectively machine every type of workpiece shape. For that reason, cutting tool companies offer different shapes of cutters, from square shoulder mills to face mills and everything in between. Manufacturers must think about the surface they need to cut, asking themselves — is it square in form or very long? Are the wall thicknesses thin or thick, weak or stable? And, how secure is workpiece clamping?
Machine tool Furthermore, manufacturers also need to consider the type of machine tool they are using in their operations. When machining cast iron materials, there is a higher dynamic load, so the machine tool must be highly robust and provide high power & high stability. All of which puts strain on the machine. However, in these instances, a negative cutter with the positive rake angle can help lower the power requirements of the machine tool and reduce forces on machine spindles as well. But in the end, with so many variables to consider, if a manufacturer wants increased productivity and predictability in their cast iron machining efforts, the best action is for them to work closely with their cutting tool supplier. As a valuable resource, today’s manufacturers must combine their extensive knowledge of their own manufacturing technology with that of a tooling suppliers’ in-depth knowledge of machining. Because of such collaborations, manufacturers keep abreast of the latest advancements in manufacturing, as well as gain an understanding of how machining innovations play into manufacturing process optimisation. The end result is that a shop continues to increase its competitive advantages and differentiate itself as a technology leader in the increasingly challenging global market. ☐ > www.EfficientManufacturing.in
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MACHINING | TECHNOLOGY
SIX SPHERES OF HIGH PRECISION MACHINING An integrated approach implemented based on the consideration of six spheres – machine tool, cutting tool, work material, cutting fluid, machining accessories and machining parameters – will help the manufacturing industry eliminate dead time, minimise scarp rate, provide consistency and high quality precision parts at low cost, with maximum profitability.
Anil Srivastava Chief Technology Officer TechSolve, Inc, USA Srivastava@techsolve.org
Global market is becoming very competitive day-by-day. Company’s reputation depends upon product quality and to make substantial profit they need to make quality products faster and at a lower cost. Precision machining is a process where a part can be machined to a very tight tolerance. In general, it is a moving target that is hard to define. Several decades earlier, precision machining may have required a tolerance of 0.1 inch while today it could be .0005 inch. The tolerance requirement for turbine blades made of titanium alloys may be in the range of 0.0005”-0.001” while the large airframe structures made of composite materials may require only 0.005” tolerance limits. Precision machining, in general, requires a scientific approach to make part with specific requirements and many of the quality issues are these days controlled by ISO 9000 or similar certifications. To achieve consistent precision part quality, six spheres of machining play significant role. These are machine tool, cutting tool, work material, cutting fluid, machining accessories and machining parameters used to machine the part.
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All the six spheres are the integral part of a machining system and influence the machining process. In recent years, advancements in all the six spheres have been made. Applying scientific approach and machining intelligently can sustain product quality and maximise profitability. Here are further details about each sphere and how they impact precision machining. Machine tool: It is the first most significant factor to be considered for machining a part with high precision and consistent quality. Machine’s static and dynamic stiffness and damping properties play a significant role in precision machining. Most manufacturers under-utilise their current machine tool since they do not use scientific approach. Once the machine tool dynamics is known it is easy to find sweet spot at which a machine should run providing maximum metal removal rate (MRR), minimising cycle time and at the same time avoiding possible detrimental effects on the machined part quality such as chatter marks. An example in Figure 1 shows that knowing the machine
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TECHNOLOGY | MACHINING
Figure 1: Machining precision parts with enhanced productivity using scientific approach
Figure 2: Schematic diagram showing super-finishing using magnetic abrasive process
tool characteristic (chatter stability diagram), metal removal comparison with coated and uncoated cutting tools that are rate (MRR) could be increased four (4x) times by running the commercially available in the market. machine at a lower speed of 17,300 RPM in place of using Work material: The precision that needs to be maintained maximum speed limit of 20,000 RPM. The axial depth of cut during machining also depends upon the work material to be could be increased five times (5x) reducing the machining time machined. Material’s mechanical and thermal properties, to 4 min 42sec from 21 min 40 sec without sacrificing the quality microstructure, inclusions, heat treatment all play major role of the precision machined part. With the advancement in in selecting the machine tool, cutting tool and also the optimal machine tool, multi-tasking (5-axis) machineswith rigid work machining parameters to maintain required precision. For platform, quick-change tool holders, high-torque spindle system, example, aluminum alloys can be machined at much higher advanced CNC controls, and high-pressure coolant or speeds and feeds while aerospace materials such as titanium cryogenicthrough-coolant system, are commercially available in and nickel-based alloys which have low thermal conductivity the market. Selecting a proper machine tool is important to and high chemical affinity with tool material at higher achieve needed precision of machined part. temperatures are machined at much lower cutting speeds and Cutting tool: Proper selection of the cutting tool is another also need machine tool with high rigidity, high horsepower important factor in machining precision parts cost-effectively. and torque capabilities. The heat generated during cutting is The selection of a cutting tool depends upon the type of material proportional to cutting speed and does not dissipate quickly in to be machined. Longer tool-life is one of the major criteria for machining of such exotic materials. Machining of composite selecting a cutting tool. Cutting tool manufacturers are materials requires cutting tools with high abrasion resistance. consistently striving for better cutting tool quality. Tools with Cutting tool geometry also plays a significant role in machining variety of material grades, shapes, geometries (micro-edge), of composites. coatings (single, multiple, and/or nano-layer) are commercially Cutting fluid: One of the outstanding opportunities for available and competing in the market. In general, toughness, decreasing costs and increasing productivity in precision wear and thermal resistance of the cutting tool are important machining rests in the proper selection of cutting fluid.The requirement. The most recent advancement in cutting tool diversity of work materials and products to be made, create a application is to use cutting tool with super-finished cutting difficult situation in fluid selection within a production facility. edge. This super-finishing of cutting edge is precisely done using However, one should keep in mind that cutting fluids help in Magnetic Abrasive Process (Figure 2). flushing away the chips, cooling the workpiece and machine A typical example of super-finishing of the cutting edge tool, thus, maintaining the dimensional stability. Proper using MAP is given in Figure 4. The machining tests conducted selection of cutting fluid also decreases friction between the during turning of titanium (Ti-6Al-4V) alloy showed better tool and chip, giving a better finished surface.Many waterperformance of super-finished carbide cutting inserts in based, emulsions/micro-emulsions, synthetic, semi-synthetic
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MACHINING | TECHNOLOGY
Figure 3: Performance based optimisation of Ti-6Al-4V milling
Figure 4: Measurement of unfinished and super-finished cutting edge of the insert
cutting fluids with different kind of additives are commercially available in the market that can help in machining precision part. The recycling, filtration, disposal, safety and environmental control factors are also important consideration during the selection and use of a cutting fluid. With the evolution of cutting fluid technology, new methods for cutting fluid applications such as High Pressure Cooling (HPC), Minimum Quantity Lubrication (MQL), Spray/Mist Cooling, and Cryogenic Cooling are being gradually adopted in production environment.A new development in this direction is the application of Atomised Cutting Fluid (ACF) system. In ACF application, atomised droplets are first generated from a given cutting fluid and then mixed with pressurised and controlled air/CO2 flow to direct the droplets at the cutting zone. An application of ACF system in machining of titanium (Ti-6Al-4V) alloy shows ~30 to 40% increase in tool-life and better surface quality can be achieved if the atomised fluid delivery is optimally impinged within the cutting zone. Machining accessories: These provide assistance in the machining of parts and in assessing or monitoring the part as it is being machined. A new fixture design might hold workpiece and allow multiple machining operations in one set-up. An effective part process and work holding design can help make the part making process faster, more accurate and, ultimately, more profitable. There is continuous development in CAD/ CAM software systems. They have become an integrated part of precision machining system and help in controlling the process, making precision parts with increased spindle utilisations. Acoustic Emission (AE), vibration, touch probe, vision and/or laser based sensor integration on the machine tool to directly or indirectly monitor the cutting process is also increasing as they play a major role in precision machining by process monitoring, control and on-line metrology.
Machining parameters: The final major sphere of the precision machining system is the ‘machining parameters’. Selection of optimum machining parameters such as speed, feed and depth of cut is very important consideration in machining precision part. A scientific approach based on design of experiments (DOE) is very helpful in selecting the optimum process parameters for precision machining. An example of performance based optimisation is shown in Figure 3. The Machining Data Hand Book recommends a speed of 2000 RPM to machine the titanium (Ti-6Al-4V) alloy part with a selected 4-flute solid carbide endmill. Based on design of experiments, a different combination of process parameters is selected. The speed is reduced to 1600 RPM while the axial depth of cut is increased from 1 mm to 3.8 mm. This increased the metal removal rate three times (3X) and a better quality of machined surface. Thus, three times (3X) increase in productivity and subsequent cost savings are achieved by using optimum machining parameters. Further, using optimum machining parameters and optimal tool-path trajectory with maximum utilisation of spindle power provided 63.5% time savings in machining a part.
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Summary An integrated approach implemented based on the consideration of all the above six spheres will add competitive advantage and certainly help machine shops and manufacturing industry eliminating a lot of dead time, minimising scarp rate, providing consistency and high quality precision parts at low cost with maximum profitability. �
> www.efficientmanufacturing.in
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Education
T E C H N O L O G Y | E D U C AT I O N & T R A I N I N G
Arriving at the best-fit CNC machine Seleting the right machine tool for an application is an important task to perform before making an investment decision. This article summarises the key parameters to be considered while purchasing a CNC machine. As on date there are many manufacturers offering machines of similar specifications. But if consideration of each and every parameter by comparing technical specifications is done, one may get many insights and opportunity to enter in depth. Most of the people make the mistake by selecting machines based on limited parameters like maximum size of parts for machining, weight carrying capacity, cost benefits, etc. There are many more considerations, including selecting a CNC machine that performs current applications, yet is versatile enough to take
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Mukesh Mahajan General Manager — Operations Ferromatik Milacron India mukesh_s_mahajan@milacron.com
on new challenges in the future. When it comes to multitasking equipment, one size by no means fits all. Although, very sophisticated machines can process extremely complex parts in a single setup. But, a somewhat simpler machine can provide more cost-effective solution for your needs. It all depends on the complexity of the parts. Looking at brands & specifications, it is very difficult to say what is better as per specifications. Comparing technical specifications is important, but that needs to be related with
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While reviewing the product, one must talk to people who are already using it and visit the nearest shop where a similar machine is in use, to gain a firsthand understanding of the machine in operation
tangible benefits it offers in terms of specifications, otherwise comparison is just of mathematical significance.
Selecting the machine There are hundreds of CNC machines in the market today. These come in different types of shapes and sizes. Some are designed for specific applications, while others for general purpose. There are several things to be considered and reviewed before purchasing a CNC machine. These include the level of precision required; speed & feeds required to operate the machine; comfort & knowledge of similar types of tools; the application required to use the CNC machine; the type of cut required and how much a buyer wants to spend upfront. After the purchase, there are several steps required to operate CNC machine successfully. These include setting the machine, ensuring that the platform is stable & the CNC machine is secure. The right material in the right size and thickness are important attributes to consider while selecting the material. Also, fixturing selection should be such that it saves time and is cost-effective. Thorough testing involves spending an extended period of testing before moving to production. There are different variables that go into successful use of the CNC equipment like the type of cut; type of material to cut; machine type; spindle type; depth of cut and feed rate.
Key considerations Some of the key points while selecting machine include:
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Working envelope: While considering CNC machine requirements, one needs to consider the maximum job size, if there will be multiple jobs to be manufactured and plan ahead the type of work that will be taken up on the machine. The thumb rule is the larger the cutting area or bed size the more expensive is the machine. The larger envelop will help to accommodate bigger fixtures and work pieces. What materials will be cut: This question catches people clueless as present investment is based on the work they do today and not what they will be doing next in future. Cutting accuracy: Every component of the machine must be designed and built with excellent structural stability and from carefully selected materials. Ease of operation: The less time an operator spends for setting up, completing changeovers and monitoring machining operations, the less is the cost-per-part. That’s why it is important that a machine is capable of performing certain operations with minimal operator involvement. Axes details & dimensions: All axis travel should be decided based on the overall part outer dimensions plus diameter of cutter in case of machining centres. The outer diameter of all the preloaded ball screws and manufacturer needs to compare amongst all the available offers for all axes. Tool chain magazine ATC: One needs to select total number of pockets in the ATC based on the number of operation to be carried on the machine considering all the varieties of parts. While doing this, one needs to take care for the size and weight of tools, because oversize tools will call to keep adjacent pocket to be empty.
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Education
T E C H N O L O G Y | E D U C AT I O N & T R A I N I N G
Positional accuracy & repeatability: This may vary based on the feedback device which includes the high resolution encoder or scales. Based on the parts accuracy needs, one can decide to go for precise scales. Control system: Must be capable of handling complex applications, be compatible with leading CAM/CAD software and yet easy to program and operate. Expert training and troubleshooting help should be readily available. Display screen should have proper size having easy readability to operator. The parts program storage capacity is also very important parameter to check. Spindle speed & power: The most important thing is to see the spindle taper and rated power of motor in continuous rating /30 min rating for energy cost. The maximum spindle speed RPM needs to verify based on the type of parts to be machined and raw material to be machined. Table type: Maximum weight of the parts to be loaded on the table and fixture weight should be around 80% of total weight carrying capacity of the table provided by manufacturer to maintain its geometry for long time. If the part calls for machining on all four sides then rotary motion of the table should be selected. If parts are of the irregular shape then for clamping ‘T’ slot table is a proper choice. Centralised automatic lubrication & headstock cooling system: One needs to verify whether auto lubrication suffices to all traverses or some places need to have manual lubrication points. Coolant system: Based on type of machining and accuracy required, one needs to select cooling channels through spindle
EM KOMPENDIUM | 2015
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Education & Training-CNC.indd 123
Form 8.indd 123
and also Niagara coolant flow on the parts to maintain work piece temperature to ambient. Reliability & technical support: This means performing consistently over time and operating with only routine maintenance. A machine tool that doesn’t deliver repeatable results, that often breaks down or needs excessive servicing is a drain on productivity. This possibly is the most important thing, but often overlooked factor to consider when deciding what machine to purchase. Ease of maintenance: One should look for easy access to critical components and clearly defined maintenance procedures and consider preventive maintenance plans. Optional accessories: There are many accessories based on the application that can be thought like oil skimmer, air blast, auto tool length, washing gun, coolant temperature controller, magnetic separator, chip conveyor, AC for panel, coolers for ball screws, etc. Data: One needs to ask all the manuals related to operation, programming, circuit diagrams in duplication which are in day to day use. In addition, it is good to have machine set-up & parameter data and laser calibration report in soft form. Floor space is also very important to know to place it in the plant layout including area needed for maintenance and fixtures storage, because floor space may vary from manufacturer to manufacturer despite having similar specifications. ☐
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TECHNOLOGY | NEWS
Indexable inserts with positive geometry
Software with advanced CMM-type capabilities
Walter AG IBT FYQBOEFE JUT 5JHFStUFD 4JMWFS® SBOHF XJUI UISFF FGGJDJFOU Renishaw IBT JOUSPEVDFE B SBOHF PG QSPDFTT DPOUSPM TPMVUJPOT UIBU IFMQ QPTJUJWF TUFFM DVUUJOH HFPNFUSJFT BO PGUFO VOEFSFTUJNBUFE JOTFSU UZQF UBDLMF UIF JODSFBTJOH ESJWF UP MFBO XIJDI TIPXT JUT GVMM QPUFOUJBM XJUI MPX DVUUJOH QSFTTVSFT BOE PO TNBMM NBOVGBDUVSJOH GSPN OFX EJBNFUFST 5IF UISFF OFX *40 1 HFPNFUSJFT XJUI B QPTJUJWF CBTJD TIBQF BSF UFDIOPMPHJFT GPS QSF QSPDFTT DBMMFE '1 .1 BOE 31 BOE IBWF CFFO BEEFE UP UIF UPPM SBOHF PG UIF NBDIJOF DBMJCSBUJPO UP PO MJOF BOE 5àCJOHFO CBTFE TQFDJBMJTU 5IF JOEFYBCMF PGG MJOF QPTU QSPDFTT NFBTVSFNFOU JOTFSUT GPS TUFFM NBDIJOJOH BSF BWBJMBCMF 5IF OFX 0.7 1SP TPGUXBSF JODMVEFT JO UIF QSPWFO 811 4 811 4 BOE BEWBODFE $.. UZQF DBQBCJMJUJFT 811 4 5JHFStUFD 4JMWFS® DVUUJOH HSBEFT XJUI BO FYUFOEFE SBOHF PG HFPNFUSJD '1 ' GJOJTIJOH JT PQUJNJTFE GPS EJNFOTJPOJOH BOE UPMFSBODJOH GJOJTIJOH TUFFM BOE BDIJFWFT UIF CFTU (% 5 GVODUJPOBMJUZ QMVT UIF BCJMJUZ TVSGBDF GJOJTI RVBMJUZ BOE DIJQ DPOUSPM GPS UP XPSL XJUI NVMUJQMF BMJHONFOUT JO B The new OMV Pro software includes more advanced CMM-type capabilities with an FYBDU QSFDJTJPO NBDIJOJOH .1 TJOHMF QSPHSBN BO BEWBOUBHF JO extended range of geometric dimensioning Walter FP4 for finishing, MP4 for . NFEJVN GPS NJE SBOHF TUFFM XPSLJOH XJUI NVMUJ BYJT NBDIJOF and tolerancing (GD&T) functionality medium machining and RP4 for NBDIJOJOH JT UIF VOJWFSTBM EFTJHO PG UPPMT 5IF TPGUXBSF JODMVEFT roughing with positive indexable inserts the three new inserts and is TJNVMBUJPO DBQBCJMJUZ BO JOUVJUJWF QBSUJDVMBSMZ XFMM TVJUFE UP NBDIJOJOH HSBQIJDBM JOUFSGBDF BOE DSZTUBM DMFBS SFQPSUJOH GPSNBU UIBU NBLF JU MPOH DIJQQJOH NBUFSJBMT TVDI BT 4U TUSVDUVSBM TUFFM PS PUIFS MPX DBSCPO BDDFTTJCMF UP TIPQ GMPPS TUBGG 0.7 1SP T (% 5 NFBTVSFNFOU XJ[BSE IFMQT TUFFMT 5IF HFPNFUSZ JT BWBJMBCMF XJUI UXP DMFBSBODF BOHMFT ¡ BOE ¡ VTFST DSFBUF TUBOEBSEJTFE SFQPSU FMFNFOUT CBTFE PO JOUFSOBUJPOBMMZ BT XFMM BT JO B QSFDJTJPO TJOUFSFE BOE B QSFDJTJPO HSPVOE EFTJHO 5IF SFDPHOJTFE TZNCPMT BMMPXJOH PQFSBUPST UP DPNQBSF QBSU NFBTVSFNFOU DMFBSBODF BOHMF PG ¡ FOBCMFT NBDIJOJOH PG TNBMMFS EJBNFUFST SFTVMUT PO UIF NBDIJOF XJUI UIPTF PO UIF NBOVGBDUVSJOH ESBXJOH > www.efficientmanufacturing.in
Turning machine for vertical 4-axis shaft machining
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3D printing material & tape
EMAG Group PGGFST 75 UVSOJOH NBDIJOFT XJUI UIF TUSFOHUIT PG GPVS BYJT igus IBT SFDFOUMZ QSFTFOUFE JUT GJSTU % QSJOUFS GJMBNFOU EFTJHOFE VTJOH TIPSU USBWFMT BOE QPXFSGVM NBJO TQJOEMF UIF TBNF GFBUVSFT PG JUT JHMJEVS 5IF GVMM JNQBDU DBO CF CFTU GFMU XIFSF UIF TFMG MVCSJDBUJOH CFBSJOHT 5IF DPNQPOFOU CBUDIFT BSF MBSHF 0G EFDJTJWF GJMBNFOU TQFDJBMMZ EFWFMPQFE GPS JNQPSUBODF JO UIF VTF PG UIFTF UVSOJOH NPWJOH BQQMJDBUJPOT JT UJNFT NBDIJOFT JT UIF iUXP TJEFEw NBDIJOJOH NPSF BCSBTJPO SFTJTUBOU UIBO QSPDFTT XIJDI NBTTJWFMZ SFEVDFT UIF DPOWFOUJPOBM % QSJOUFE NBUFSJBMT NBDIJOJOH UJNF PO UIF 75 UVSOJOH 5IF GJMBNFOU JT PGGFSFE JO B TUBOEBSE NBDIJOF 'MFYJCJMJUZ JT HVBSBOUFFE XJUI UIF NN UIJDLOFTT "MTP UIF OFX VTF PG UXP UPPM UVSSFUT XJUI FMFWFO NN UIJDL USJCP UBQF NBEF GSPN TUBUJPOT FBDI BMM PG XIJDI DBO CF JHMJEVS " IBT CFFO JOUSPEVDFE CZ FRVJQQFE XJUI UVSOJOH UPPMT BOE ESJWFO UIF DPNQBOZ 5IF UBQF DBO CF This 3D printer filament is up to 50 UPPMT "VUPNBUJPO JT GVMMZ JOUFHSBUFE PO CPOEFE JO NBOZ XBZT QSPWJEJOH Automation is fully UIFTF UVSOJOH NBDIJOFT GSFFEPN PG EFTJHO JO UIF DPOTUSVDUJPO times more abrasion-resistant than conventional materials integrated on the VT 2-4 0O UIF 75 UVSOJOH NBDIJOFT JU JT UIF PG USJCPMPHJDBMMZ TUSFTTFE TMJEJOH turning machines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www.efficientmanufacturing.in
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> www.efficientmanufacturing.in
EM KOMPENDIUM | 2015
1/16/2015 3:30:48 PM
1/16/2015 9:15:25 PM
Tech New
NEWS | TECHNOLOGY
Clamping force blocks
more
h an
ning
ality
Brush motors & accessories
Schunk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he jaw quick-change system BWM UPQ GSPN CFIJOE PS GSPN FJUIFS TJEF minimises the set-up time of the UIF EJSU SFTJTUBOU BOE NBJOUFOBODF TANDEM KSP plus clamping force GSFF TFU VQ UJNF UVSCP DBO CF BMTP blocks to less than 30 seconds VTFE JO DPOGJOFE TQBDFT XJUIPVU BOZ SFTUSJDUJPOT " TNPPUI SVOOJOH ESJWF FOTVSFT BO FYUSFNFMZ TJNQMF PQFSBUJPO 5IF DIBOHJOH KBXT DBO CF FRVJQQFE XJUI TUBOEBSEJTFE DMBNQJOH JOTFSUT GSPN TUBOEBSE DIVDL KBX QSPHSBN BOE XPSLQJFDF TQFDJGJD DIBOHJOH KBXT DBO CF VTFE
Crouzet Motors IBT JOUSPEVDFE %$NJOE CSVTI NPUPST UIBU BSF RVJFU FWFO VOEFS GVMM MPBE BOE PGGFS FYDFQUJPOBM FGGJDJFODJFT MPOH TFSWJDF MJGF BOE B XJEF SBOHF PG HFBSCPYFT BOE BDDFTTPSJFT 8JUI WJSUVBMMZ OPJTFMFTT PQFSBUJPO UIFTF NPUPST BSF QBSUJDVMBSMZ XFMM TVJUFE UP BQQMJDBUJPOT JO NFEJDBM CJPQIBSNBDFVUJDBM MBCPSBUPSZ JOEVTUSJBM NBDIJOFSZ BOE IJHI QFSGPSNBODF PGGJDF FRVJQNFOU BOE TZTUFNT 5IFTF DBO CF VTFE JO B WBSJFUZ PG PUIFS IJHI The brush motors have a QFSGPSNBODF BQQMJDBUJPOT TVDI BT QVNQT noise level of only 35 dB, BOE WBMWFT SBJMXBZ BOE SBJMDBST BT XFMM BT about the sound of a NJMJUBSZ BOE BFSPOBVUJDT 5IF CSVTI NPUPST whispered conversation and IBWF B OPJTF MFWFM PG POMZ E# BOE E# 20 dB less than the current MFTT UIBO UIF DVSSFOU NPUPS TUBOEBSE SBOHF motor standard range 5IF OFX QSPEVDU SBOHF JODMVEFT BOE XBUU NPUPST XJUI B NN EJBNFUFS BOE BOE XBUU NPUPST XJUI B NN EJBNFUFS 5IF CSVTI NPUPST TVQQPSU BOE WPMU QPXFS TVQQMJFT BOE BSF BWBJMBCMF XJUI TFWFSBM BDDFTTPSJFT BOE BEBQUBUJPOT JODMVEJOH SFBS CSBLF PQUJDBM PS )BMM FGGFDU FODPEFST PS DIBOOFMT DPOOFDUPST BOE XJSFT
> www.efficientmanufacturing.in
> www.efficientmanufacturing.in
Fibre laser cutting machine
Contact cooled rotary screw air compressor
Sahajanand Laser Technology IBT MBVODIFE #SBINBTUSB *OGJOJUZ XJUI B 8 GJCSF MBTFS *U JT B NBDIJOF QFSGFDUMZ UVOFE GPS B TUBSU VQ GBCSJDBUPS *U JT UBSHFUFE to those who opt to shift to a OPO DPOUBDU UZQF QSPGJMF DVUUJOH NBDIJOF 5IF 8 GJCSF MBTFS DVUUJOH NBDIJOF IBT OP QBMMFU *U IBT B DVUUJOH CFE XJUI B DPOWFSUJCMF FODMPTVSF 5IJT TBWFT BSPVOE JO MFOHUI UP UIBU PG B QBMMFU JOoPVU EFTJHO The control panel has also lost close to 5IF DPOUSPMMFS BOE UIF DPPMJOH 60% in size and is embedded to the rear TZTUFN PG UIF MBTFS DVUUJOH end of the machine NBDIJOF IBE VOEFSHPOF TFSJPVT TPQIJTUJDBUFE XPSL UIBU BEEFE UP UIF DPNQBDUOFTT *OGJOJUZ EPFTO U IBWF B TFQBSBUF CMPDL PG DPOUSPM TZTUFN MJLF JUT QFFST 5IF DPOUSPM QBOFM IBT BMTP MPTU DMPTF UP JO TJ[F BOE JT FNCFEEFE UP UIF SFBS FOE PG UIF NBDIJOF 5IF NPTU BEWBODFE TUBUF PG UIF BSU OFTUJOH TPGUXBSF EFWFMPQFE CZ UIF DPNQBOZ IBT CFFO JODPSQPSBUFE JOUP *OGJOJUZ *OGJOJUZ XJUI B 8 GJCSF MBTFS DPVME QFSGPSN PO NN TUFFM
Ingersoll Rand IBT MBVODIFE &WPMVUJPO™ — B CSBOE PG DPOUBDU DPPMFE SPUBSZ TDSFX BJS DPNQSFTTPS 5IF OFX &WPMVUJPO™ CSBOE IBT CFFO EFTJHOFE TQFDJGJDBMMZ UP NFFU JOEVTUSZ SFRVJSFNFOUT XIJMF EFMJWFSJOH FOFSHZ FGGJDJFOU QFSGPSNBODF *U PGGFST B XJEF OFUXPSL PG DFSUJGJFE BOE XFMM USBJOFE UFDIOJDJBOT BOE FOHJOFFST DBQBCMF PG TVQQPSUJOH DVTUPNFST XJUI DPTU FGGFDUJWF TFSWJDF TPMVUJPOT UIBU XJMM IFMQ LFFQ UIFJS DPNQSFTTFE BJS TZTUFN BU QFBL QFSGPSNBODF 5IJT SBOHF PG DPNQSFTTPST JT EFTJHOFE XJUI UIF MBUFTU UFDIOPMPHZ QSPWJEJOH QSPNJOFOU CFOFGJUT JODMVEJOH NPSF $'. L8 UIBU This range of compressors QSPWJEFT NPSF BJS GMPX $'. XJUI MFTT is designed with the latest QPXFS DPOTVNQUJPO L8 MPX technology providing NBJOUFOBODF DPTU UIBU JODSFBTFT UIF MJGF prominent benefits including PG UIF DPNQSFTTPS BOE MPOH MJGF VMUSB more CFM/kW that provides DPPMBOU UIBU JODSFBTFT QSPEVDUJWJUZ BOE more air flow (CFM) with less FGGJDJFODZ PG BJS FOE *U JT B POF TUPQ power consumption (kW) TPMVUJPO XJUI SFGSJHFSBOU BJS ESZFS BJS GJMUFS BOE SFDFJWFS UIBU QSPWJEFT NPJTUVSF GSFF BJS UP FOIBODF UIF MJGF PG FOE FRVJQNFOU
> www.efficientmanufacturing.in
EM KOMPENDIUM | 2015
3:30:48 PM
Tech News new layout_EM Jan 15.indd 125
Form 8.indd 125
> www.efficientmanufacturing.in
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1/16/2015 9:15:25 PM
TECHNOLOGY | NEWS
1-D code and 2-D code readers
Adjustable pocket disc mill cutters
5IF OFX 01$ 8 BOE 01$ 1 TFSJFT % DPEF BOE % DPEF SFBEFST GSPN Pepperl+Fuchs DPWFS B CSPBE SBOHF PG BQQMJDBUJPOT 5IF 01$ 8 NPEFMT PGGFS BO FYDFMMFOU DPTU CFOFGJU SBUJP BOE BSF TVJUBCMF GPS B IPTU PG TUBOEBSE BQQMJDBUJPOT BU TUBOEBSE TQFFET 5IF 01$ 1 NPEFM JT QFSGFDU GPS NPSF EJGGJDVMU UBTLT *U DBO IBOEMF IJHI TQFFE BQQMJDBUJPOT XJUI NPWFNFOUT VQ UP N T PS SFBEJOHT T BOE JT FRVJQQFE XJUI VOJRVF QPMBSJTBUJPO GJMUFS UFDIOPMPHZ 3FMJBCMF DPEF SFBEJOH JT HVBSBOUFFE PO IJHIMZ SFGMFDUJWF TVSGBDFT TVDI BT NFUBMT QMBTUJDT 1$#T VOEFS GJMNT BOE PO DVSWFE The OPC120P model TVSGBDFT 0UIFS IJHIMJHIUT PGGFSFE CZ UIJT EFWJDF can handle high-speed JODMVEF B SPUBSZ FODPEFS JOQVU GPS QBUI applications with movements TZODISPOJTBUJPO BOE UIF BCJMJUZ UP SFBE CBSDPEFT up to 10 m/s or 100 readings/s VQ UP NN JO MFOHUI UISPVHI NVMUJQMF JNBHF and is equipped with unique DBQUVSF 5IF IJHI EFQUI PG GPDVT FOBCMFT polarisation filter technology SFBEJOHT PWFS B MPOH EJTUBODF XJUIPVU NBLJOH QBSBNFUFS DIBOHFT .PSFPWFS UIF DPEF SFBEFST BSF BWBJMBCMF JO B SBOHF PG JOUFSGBDFT UIBU JODMVEF 130'*/&5 34 BOE &UIFSOFU 5IF 01$ TFSJFT SFBE UIF %BUB.BUSJY $PEF $PEF $PEF &"/ BOE 1IBSNBDPEF DPEF TZNCPMPHJFT
Seco Tools IBT FYQBOEFE JUT MJOF PG EJTD NJMMJOH DVUUFST UP CF FWFO NPSF DPNQSFIFOTJWF BOE GMFYJCMF 1SFWJPVTMZ BWBJMBCMF JO B GJYFE QPDLFU EFTJHO UIFTF DVUUFST OPX DPNF JO BEKVTUBCMF DVUUJOH XJEUIT UIBU SBOHF GSPN UP NN BOE EJBNFUFST GSPN UP NN 8FMM TVJUFE GPS NJMMJOH B XJEF WBSJFUZ PG BQQMJDBUJPOT UIF BEKVTUBCMF QPDLFU EJTD NJMM DVUUFS GFBUVSFT B VOJRVF JOTFSU HFPNFUSZ BOE DVUUFS EFTJHO UIBU SFEVDFT The 335.25 adjustable pocket disc DVUUJOH GPSDFT BOE PQUJNJTFT DIJQ mill cutter features a unique insert GMPX GPS BO PWFSBMM RVJFUFS NPSF geometry and cutter design that QSPEVDUJWF BOE NPSF SFMJBCMF reduces cutting forces and optimises NBDIJOJOH PQFSBUJPO *O BEEJUJPO UP chip flow for an overall quieter QSPWJEJOH TUSPOH QFSGPSNBODF JO TMPUUJOH PQFSBUJPOT UIF BMTP PGGFST IJHIMZ QSPEVDUJWF CBDL GBDJOH DJSDVMBS BOE IFMJDBM JOUFSQPMBUJPO BOE QMVOHJOH 5IF DVUUFS FNQMPZT SFQMBDFBCMF DBTTFUUFT NBLJOH JU RVJDL BOE FBTZ GPS VTFST UP QSFDJTFMZ BEKVTU UIF XJEUI PG DVU 5IFTF DBTTFUUFT GFBUVSF B TQFDJBM DPBUJOH GPS FYUFOEFE EVSBCJMJUZ
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Complete metrology software
Industrial PC
FARO Technologies JOUSPEVDFE $". .FBTVSF ‰ JUT OFXFTU TPGUXBSF GPS UIF 'BSP"SN¥ -BTFS 4DBO"SN BOE -BTFS 5SBDLFS *U PGGFST B DPNQMFUF DPOUBDU BOE OPO DPOUBDU NFUSPMPHZ TPMVUJPO 5IF OFX DBQBCJMJUJFT BOE FOIBODFE GVODUJPOBMJUZ QSPWJEF DVTUPNFST UIF WBMVF PG IBWJOH B TJOHMF QBSUOFS XJUI BO JOUFHSBUFE TPGUXBSF BOE IBSEXBSF TPMVUJPO UIBU JT TVQQPSUFE CZ B XPSMEXJEF TFSWJDF OFUXPSL *U DBO CF VTFE XJUI BMM PG '"30 T NBKPS NFUSPMPHZ IBSEXBSF TVDI BT UIF 4DBO"SN GPS $"% UP QBSU BOBMZTJT BOE JT QFSGFDUMZ TVJUFE New features such as point GPS UBTLT TVDI BT UIF JOTQFDUJPO PG GSFF BOE cloud registration, cross DPNQMFY GPSNT BOE FWFO TPGU PS GMFYJCMF section analysis, deviation NBUFSJBMT UIBU BSF EJGGJDVMU UP JOTQFDU XJUI B markers and the enhanced UBDUJMF TZTUFN /FX GFBUVSFT TVDI BT QPJOU live colour scan, support DMPVE SFHJTUSBUJPO DSPTT TFDUJPO BOBMZTJT and boost user experience EFWJBUJPO NBSLFST BOE UIF FOIBODFE MJWF DPMPVS TDBO TVQQPSU BOE CPPTU VTFS FYQFSJFODF JO EBUB DPMMFDUJPO BOE QPJOU DMPVE BOBMZTJT 5IFTF OFX DBQBCJMJUJFT TJNQMJGZ BOE BDDFMFSBUF UIF NFBTVSFNFOU QSPDFTT CZ HVJEJOH PQFSBUPST JO UIFJS QSPCJOH BOE TDBOOJOH BDUJWJUJFT
5IF OFX "VUPNBUJPO 1$ GSPN B&R VOJUFT UIF 1$ XPSME XJUI IBSE SFBM UJNF BQQMJDBUJPOT %FTQJUF JUT VMUSB DPNQBDU IPVTJOH UIF "VUPNBUJPO 1$ JT B GVMM GMFEHFE 1$ TZTUFN UIBU SFQSFTFOUT B NJMFTUPOF JO UIF QFSGPSNBODF DBQBCJMJUJFT PG FNCFEEFE TZTUFNT XJUI BO FGGFDUJWF QSJDF QFSGPSNBODF SBUJP "WBJMBCMF XJUI TJOHMF EVBM PS RVBE DPSF QSPDFTTPST UIF DPNQVUJOH QPXFS PG UIF TZTUFN JT GVMMZ TDBMBCMF "U UIF VQQFS SBOHF PG Automation PC 2100 QFSGPSNBODF JU FWFO FYDFFET UIF QFSGPSNBODF PG NBOZ $PSF J TFSJFT QSPDFTTPST 3FHBSEMFTT PG UIF WBSJBOU UIF BCTFODF PG GBOT PS PUIFS SPUBUJOH DPNQPOFOUT NFBOT UIBU OP NBJOUFOBODF JT SFRVJSFE 0UIFS TUBOEBSE GFBUVSFT JODMVEF UXP HJHBCJU &UIFSOFU JOUFSGBDFT BT XFMM BT POF 64# BOE POF 64# JOUFSGBDF 'JFMECVT DPOOFDUJPOT TVDI BT 108&3-*/, PS $"/ DBO CF JOEJWJEVBMMZ DPOGJHVSFE BOE DPNQBDU .-$ CBTFE $'BTU DBSET XJUI (# PS NPSF BSF BWBJMBCMF UP NFFU FWFSZ NFNPSZ OFFE 5IF HSBQIJDT FOHJOF VTFE CZ *OUFM "UPN QSPDFTTPS JT EFSJWFE GSPN $PSF J UFDIOPMPHZ BOE QSPWJEFT QPXFSGVM QSPDFTTJOH BMM UIF XBZ VQ UP 'VMM )%
> www.efficientmanufacturing.in
> www.efficientmanufacturing.in
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Form 8.indd 126
EM KOMPENDIUM | 2015
1/16/2015 3:30:53 PM
1/16/2015 9:15:26 PM
Tech New
NEWS | TECHNOLOGY
Grinding tools with diamond and CBN
Insert for shoulder milling applications
TYROLIT 45"35&$ 91 1 QSPEVDU MJOF JODMVEFT IJHI QFSGPSNBODF HSJOEJOH UPPMT XJUI EJBNPOE BOE $#/ 5IF BSFB PG BQQMJDBUJPO JT TPMJE DBSCJEF BOE )44 DVUUJOH UPPM QSPEVDUJPO 45"35&$ 91 1 QSPEVDUT EFMJWFS BO JNQSPWFE QSPGJMF SFUFOUJPO BOE B IJHI USBWFSTF TQFFE BU UIF TBNF UJNF $VTUPNFST CFOFGJU JT B MPX QPXFS DPOTVNQUJPO BU NBYJNVN DVUUJOH EFQUI 5IJT IJHI QFSGPSNBODF JT TVQQPSUFE CZ B QFSGFDU DPNCJOBUJPO PG OFX CPOE TZTUFNT BOE PQUJNJTFE BCSBTJWFT 5IF New diamond crystals are used for creep feed OFX NFUBMMJD CPOE TZTUFN grinding in solid carbide TIPXT BO PQUJNVN BEIFTJPO UP UIF HSBJO 5IJT MFBET UP JNQSPWFE MJGF UJNF BU IJHIFS USBWFSTF TQFFE 5IF TBNF MFWFM PG QSPEVDUJWJUZ JT HJWFO XJUI $#/ BT BCSBTJWF HSJU 5IF IJHI DVUUJOH BCJMJUZ PG UIF OFX 45"35&$ 91 1 HSJOEJOH XIFFMT SFEVDFT UIF HSJOEJOH GPSDFT 5IF IFBU EFWFMPQNFOU JT SFEVDFE BU UIF TBNF UJNF 5IF IJHI QSPGJMF SFUFOUJPO BU GVMM DVUUJOH EFQUI JT SFNBSLBCMF
TaeguTec has introduced 8/(9 B EPVCMF TJEFE JOTFSU NPTU TVJUFE GPS TIPVMEFS NJMMJOH BQQMJDBUJPOT BU MPXFS UP NPEFSBUF DVUUJOH QBSBNFUFST *U DPOTVNFT MFTT QPXFS UIBO BOZ PUIFS DPOWFOUJPOBM DVUUJOH FEHF QPTJUJWF TIPVMEFS NJMMJOH JOTFSUT 8JUI DVUUJOH FEHFT JU JT OPU POMZ FDPOPNJDBM CVU BMTP JUT DVUUFST GBDF NJMMT BSF BWBJMBCMF JO EJBNFUFST UP NN 8JUI B BQQSPBDI JU JT TVJUBCMF GPS GBDF NJMMJOH With a 90 deg WNGX 08 approach, TRVBSF TIPVMEFS )FMJDBM DVUUJOH it is suitable for face milling & FEHF JT GPS TNPPUI DVUUJOH BOE square shoulder MFTT SJHJE TFUVQT BOE NN UIJDLOFTT HJWFT TUSPOH DVUUJOH FEHF TVJUBCMF GPS IJHIFS GFFE SBUFT *U JT TVJUBCMF GPS VQ UP NN %P$ BOE DPOTVNFT MFTT QPXFS UIBO DPOWFOUJPOBM DVUUJOH FEHF TIPVMEFS NJMMJOH JOTFSUT *U JT BQQMJDBCMF GPS DBTU JSPO TUFFM BOE TUBJOMFTT TUFFM DPNQPOFOUT XJUI TVJUBCMF HSBEFT
> www.efficientmanufacturing.in
> www.efficientmanufacturing.in
CNC rotary surface grinder
CNC gantry routers
Wendt T $/$ 3PUBSZ 4VSGBDF (SJOEFS 834 TFSJFT JT B BYJT HSJOEJOH NBDIJOF ESJWFO CZ 4JFNFOT %& %& % 4- DPOUSPMT 834 TFSJFT PG NBDIJOFT 834 ) 7 BOE 834 ) 7 BSF BWBJMBCMF JO CPUI IPSJ[POUBM BOE WFSUJDBM TQJOEMF BSSBOHFNFOU 5IF NBDIJOFT BSF NBOVGBDUVSFE XJUI BOE XJUIPVU FMFDUSPNBHOFUJD DIVDL BOE VTFE GPS UIF HSJOEJOH PG QSFDJTJPO QBSUT GPS UIF WRS Vertical Spindle BVUPNPCJMF BOE FOHJOFFSJOH JOEVTUSZ 5IF TQFDJBM GFBUVSF PG UIF NBDIJOF JT UIF NBTTJWF NVMUJ QJFDF HSBZ DBTU JSPO DPMVNO IPVTJOH BMM UIF BTTFNCMZ VOJUT XJUI UIF FYDFQUJPO PG UIF IZESBVMJD BOE DPPMBOU MVCSJDBOU TZTUFN BOE UIF TXJUDI DBCJOFU 5IF TPMJE DPOTUSVDUJPO PG BMM BTTFNCMZ VOJUT QSPWJEFT SJHJEJUZ GPS UIF FOUJSF TUSVDUVSF EVSJOH HSJOEJOH .BKPS GFBUVSFT JODMVEF SPUBSZ UBCMF EJBNFUFS GSPN NN UP NN VTFS GSJFOEMZ PQFSBUJOH DZDMFT GPS SPVHI TFNJ GJOJTI GJOJTI HSJOEJOH TQBSL PVU BOE ESFTTJOH XJUI B TQFDJBM &43 GFBUVSF JODPSQPSBUFE UP BEESFTT QPXFS TVQQMZ GBJMVSF BOE TVEEFO TUPQQBHF PG UIF NBDIJOF o WFSUJDBM DBSSJBHF SFUSBDU CZ NJDSPOT 5IF NBDIJOF JT JEFBM GPS QSFDJTJPO HSJOEJOH PG BVUP DPNQPOFOUT MJLF DPOOFDUJOH SPET SPDLFS BSNT FOHJOFFSJOH DPNQPOFOUT MJLF EJF NPVMET DPNQSFTTPST WBMWF QMBUFT QVNQT FUD
Haas Automation’s OFX SBOHF PG (3 $/$ HBOUSZ SPVUFST BSF OPX GJUUFE XJUI DIJQ HVBSET CZ JODSFBTJOH UIF TBGFUZ BOE DMFBOMJOFTT PG UIF NBDIJOFT 5IF EFTJHO UFBN IBT DSFBUFE BO JOOPWBUJWF FODMPTVSF CBTFE PO GVMM QFSJNFUFS MJHIU DVSUBJOT GPS UIFTF WFSZ TVDDFTTGVM HBOUSZ TUZMF NBDIJOFT %FTJHOFE UP LFFQ PQFSBUPST BOE NPWJOH DPNQPOFOUT BQBSU UIF DPODFQU GPS UIF USBWFMMJOH HVBSE JT TJNQMF ‰ DIJQT BOE DPPMBOU JOTJEF QFPQMF PVUTJEF 'SPN B TBGFUZ BOE Featuring a powerful 40-taper milling DMFBOMJOFTT QFSTQFDUJWF UIJT DMFBSMZ PGGFST HSFBU BEWBOUBHFT UP DVTUPNFST head, GR routers are available in two model configurations: the GR-510 'FBUVSJOH B QPXFSGVM UBQFS NJMMJOH and the GR-712 IFBE (3 SPVUFST BSF BWBJMBCMF JO UXP NPEFM DPOGJHVSBUJPOT UIF (3 BOE UIF (3 8IJMF UIF GPSNFS PGGFST USBWFM JO UIF 9 : BOE ; BYJT PG Y Y NN SFTQFDUJWFMZ UIF MBUUFS PGGFST DVTUPNFST MPOHFS 9 BOE : USBWFMT PG Y NN BOE UIF TBNF NN ; BYJT &BDI (3 HBOUSZ SPVUFS IBT B SQN L8 WFDUPS ESJWF TQJOEMF UIBU QSPWJEFT UIF QPXFS UP DVU B XJEF SBOHF PG EJGGFSFOU NFUBMT BOE UIF TQFFE UP DVU WBSJPVT QMBTUJDT BOE BEEJUJPOBM MJHIU NBUFSJBMT -POH FYUSVTJPOT BOE MBSHF TIFFUT PG NBUFSJBM DBO CF QSPDFTTFE XJUI FBTF
> www.efficientmanufacturing.in
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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
EM Highlights - February 2015 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Deputy Editor Sumedha Mahorey sumedha.mahorey@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net
» Die & Mould Die and mould makers in India can today compete globally and have over the years recorded transformational and high all round market growth. The main issue in Indian tool rooms is shortage of capacities which is met through imports by OEMS. The large scale growth in manufacturing capacity will be needed to meet the demands of large number of OEMs desiring to make India their global manufacturing hubs. The next issue takes a look at the trends that would lead to rapid manufacturing growth of toolings. .
» Manufacturing IT Manufacturing IT plays an important role in the manufacturing technology development. Get to know about the new technologies in Manufacturing IT in the next issue of EM. » Grinding Machines Ultra-precision grinding technology for electronic & optical parts has been improved mainly because of advancement in grinding technology using free abrasive grains. The next issue highlights the recent developments in grinding machines.
» Engineering Materials Material technology has advanced by leaps with development of many new materials with extraordinary properties suited for industrial use. Read about the latest in thermoplastic and thermoset polymers, metals, ceramics, semiconductors, fibres, and other engineering materials in our forthcoming issue.
Features Writer Megha Roy megha.roy@publish-industry.net Advertising Sales Sagar Tamhane (Regional Head - North & East) Contact: +91 9820692293 sagar.tamhane@publish-industry.net 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
COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Aequs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Geometric limited . . . . . . . . . . . . . . . . . . . 108
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Sahajanand Laser Technology . . . . 40, 98, 125
Ace Designers . . . . . . . . . . . . . . . . . . . . . . 42 AMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Haas Automation . . . . . . . . . . . . . . . . . . . 127 Hiwin Corporation . . . . . . . . . . . . . . . . . . . . 72
Sandeep Engineers (Witte) . . . . . . . . . . . . . 27 Seco Tools. . . . . . . . . . . . . . 18, 54, 114, 126
AFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Autodesk India . . . . . . . . . . . . . . . . . . . . . 108 B&R. . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Honda Motors . . . . . . . . . . . . . . . . . . . . . . . 7 igus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Schunk Intec India . . . . . . . . . . . . . . . . . . 125 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Siemens PLM Software . . . . . . . . . . . . . . . . 76
Blaser Swisslube . . . . . . . . . . . Back Cover, 56 Bohler. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indian Institute of Welding. . . . . . . . . . . . . . . 98 Insergoll Rand . . . . . . . . . . . . . . . . . . . . . 125
Siemens Ltd . . . . . . . . . . . . . . . . . . . . 5, 106 Starrag Group Holding AG . . . . . . . . . . . . . . 70
Bharat Fritz Werner . . . . . . . . . . . . . . . . . . 102 Blum Novotest. . . . . . . . . . . .Back Inside Cover, 58 BFW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
JMTBA . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Kawasaki Motors . . . . . . . . . . . . . . . . . . . . . 5 Kennametal . . . . . . . . . . . . . . . . . . . . . 13, 18
TechSolve . . . . . . . . . . . . . . . . . . . . . . . . 118 Tyrolit . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Tague Tec India . . . . . . . . . . . . . . . . . 18, 127
CMTBA. . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Crouzet Motors . . . . . . . . . . . . . . . . . . . . 125
Kirloskar Brothers Ltd . . . . . . . . . . . . . . . . . . 7 Lien Chieh Machinery Co. Ltd. . . . . . . . . . . . 17
TMTBA . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Tyrolit India Superabrasive Tools . . . . . . . . . . 95
CECIMO . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Delcam Plc . . . . . . . . . . . . . 18, 62, 108, 110 Da Jie Electricity Machinery Industrial . . . . . . . 9
Lucas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Marposs India . . . . . . . . . . . . . . . . . . . . . . 11 Makino India . . . . . . . . . . . . . . . . . . . . . . . 15
United Grinding GmbH . . . . . . . . . . . . . 47, 66 UCAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 UCIMU-SISTEMI PER PRODURRE. . . . . . . . . 90
EMAG. . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Faro Technologies. . . . . . . . . . . . . . . . . . . 126
Micromatic Grinding . . . . . . . . . . . . . . . . . . 30 Mitsubishi Materials. . . . . . . . . . . . . . . . . . . 64
VDW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Wendt India . . . . . . . . . . . . . . . . . . . . 12, 127
Femco . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Ferromatik Milacron India . . . . . . . . . . . . . . 121 Fresmak Arnold . . . . . . . . . . . . . . . . . . . . . 14
Nickunj Eximp Entp. . . . . . . . . . . . . . . . . . . 38 Optical Gaging (S) Pte Ltd . . . . . . . . . . . . . . 21 PTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Walter Tools . . . Front Inside Cover, 18, 60, 124 Wohlhaupter . . . . . . . . . . . . . . . . . . . . . . . 16 Worldwide Industrial Machinery Ltd.. . . . . . . . 23
Faurecia Interior Systems . . . . . . . . . . . . . . . 18 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 24
Pragati Automation . . . . . . . . . . . . . . . . 36, 77 Pepperl + Fuchs . . . . . . . . . . . . . . . . . . . 126
YG-1 Co Ltd . . . . . . . . . . . . . . . . . . . . . . . 50 Yamazaki Mazak Corporation . . . . . . . . . 52, 98
Ganro Industrial Corp. . . . . . . . . . . . . . . . . . 75 Grind Master Machines . . . . . . . . . . . . . . . . 46
Quaker Chemicals . . . . . . . . . . . . . . . . . . 105 Renishaw Plc . . . . . . . . . . . . . . . . . 6, 68, 124
Design & Layout Sovan Lal Tudu (Senior Designer) sovan.tudu@publish-industry.net Editorial & Business Office publish-industry India Pvt Ltd 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001, Maharashtra, India Tel: + 91 - 20 - 6451 5752 Board of Directors Kilian Müller (CEO - Worldwide) Hanno Hardt (Head - Marketing & Business Development) Frank Wiegand (COO - Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `1000 em.india@publish-industry.net Tel: +91-20-6451 5754 Printing Kala Jyothi Process Pvt Ltd, S.No: 185, Kondapur, R R District, AP 500 133, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of editorial contributions is only allowed with express written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet http://www.efficientmanufacturing.in
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When the coolant becomes a liquid tool.
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