EFFICIENT MANUFACTURING
VOL 06 | MAY 2015 www.efficientmanufacturing.in
EFFICIENT MANUFACTURING
Industry 4.0
MAY 2015 I VOLUME 06
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
The quiet revolution for India
www.efficientmanufacturing.in
FOCUS Composite machining
P. 50
SPECIAL FEATURE Design of experiments P. 88
EM - Interview Paul Ricard
President, DP Technology Corp
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RELIABILITY. PRICE. REPUTATION.
Haas VF-2SS Super Speed Vertical Machining Center
= TOTAL CUSTOMER VALUE. WE KNOW what it’s like. We’re MACHINISTS, too. We CUT METAL every day. Haas Factory Outlet
That’s why we’re driven to make sure that every Haas CNC machine is trustworthy, affordable, and always backed by the industry’s best after-sale service. | www.HaasCNC.com
Sales: Ahmedabad: 079-32405007, Bangalore: 080-41179452/53, Chennai: 044-65156052, Coimbatore: 0422-2413924 Delhi: 0124-4367619, Kolhapur: 0231-2677979, Mumbai: 022-39136041, Pune: 020-32935433 Service: North: 09312550550, West (Guj) and Central: 09376150150 West (Mah) and East: 09325150150, South: 080-41179452/53
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E D I TO R I A L
Building a brand India “It’s time for the industry to come forward and invest in R&D, innovations and new product development so as to build a brand India, vis-à-vis the `Make in India’ movement”
As the Indian government struggles to maintain investor confidence, FDI in India has surged by 56% in five months since the ‘Make in India’ programme was launched in September 2014, according to official data. The inflow into the manufacturing sector alone saw a jump of 45%. The recent Hannover Fair held in Germany was a classic example where every investor was excited and wanted to know more about the campaign to plan their investment in India accordingly. India was the Partner Country for this year’s Hannover Fair, where the ‘Make in India’ movement took a global dimension and also paved the path for several new investment avenues and stronger economic engagement with India. Interestingly enough, Indian companies had more visible and therefore prominent presence at the exhibition, with a noticeable participation from a few SMEs. But it was as much a time to introspect as it was to get our backs pat. Although the Indian manufacturing industry has a great potential, considering the current business optimism in the industry, its success will depend upon how soon the reforms will be in place from the government side and how fast the industry responds to the global technology developments. It’s time for the industry to come forward and invest in R&D, innovations and new product development so as to build a brand India, vis-à-vis the `Make in India’ movement.
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net
EDITORIAL ADVISORY BOARD Sonali Kulkarni President & CEO Fanuc India
N K Dhand CMD Micromatic Grinding Technologies
Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant
Dr K Subramanian President, STIMS Institute, USA Training Advisor, IMTMA
Vivek Sharma Managing Director Yamazaki Mazak India
S Ravishankar Managing Director Walter Tools India
Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan Dr P N Rao Professor of Manufacturing Technology Department of Technology University of Northern Iowa, USA
Satish Godbole Vice President, Motion Control Div Siemens Ltd Vineet Seth Managing Director India & Middle East Delcam Plc
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
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CONTENTS
Market
10
Management
NEWS
34
Focus
Composite machining
“WE WANT TO PARTNER WITH THE INDIAN MACHINE TOOL INDUSTRY�
16
CONCEPTS�
Interview with Paul Ricard, President, DP Technology Corp
Interview with Claire Kuo, Chairman & CEO, SEYI Taiwan
ROUND-TABLE
“WE ARE IMPLEMENTING SMART PLANT
38 CREATING JOBS WITH ‘MAKE IN INDIA’
The article discusses the substantial impact of ‘Make in India’ campaign on job creation in the country
PRODUCING ECONOMICALLY ATTRACTIVE COMPOSITE COMPONENTS
The article deals with how carbon composites are becoming more competitive & cost effective across industries
BUILDING MISSION-DRIVEN MACHINES
The feature discusses on the need of a PLM software to improve productivity of NPD process for consistent product quality & minimised lifecycle costs
MARKET TRENDS 20
50
MANAGEMENT STRATEGIES 44
Technology
IMPACT OF B2C EXPERIENCES ON B2B CUSTOMERS
The article details on the tools that will design & execute superior experiences, while addressing challenges faced by organisations to implement effective business strategies
POWER PRESSES 56
Enabling proficient troubleshooting
The article discusses the different press elements, their function, accuracy parameters, as well as checking & preventive maintenance for efficient trouble-shooting
Cover Story 26
THE QUIET REVOLUTION FOR INDIA
A read into how Industry 4.0 shows substantial improvement in Indian manufacturing application
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CONTENTS
Technology
INDUSTRIAL PARTS CLEANING 60
Ensuring quality with optimised use of resources
INDUSTRIAL BEARINGS 80
The article focusses on how SKF’s condition monitoring system used by ArcelorMittal Bremen GmbH helps to optimise production & simultaneously maintenance costs
The article highlights a new methodology model to make the Design of Experiments (DOE) easy WELDING 64
Investing in welding system
A read on the advantages of investing in a welding system and the benefits such systems offer for overall productivity
MACHINING 84
Making competitive shopfloor
A read on the investments made by GAT on Haas CNC machine tools for making efficient shopfloor run by well-trained operators
MANUFCATURING IT 68
Embracing faster innovation to adapt to new realities
SPECIAL FEATURE 88
72
Optimising induction heating
An application story on how Tata Steel is using COMSOL Multiphysics simulation to optimise induction heating COOLANTS & LUBRICANTS 76
Analysing bio-resistance system
The article details on the methods of monitoring concentration that leads to higher customer satisfaction
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Emphasising statistical approach The article highlights a new methodology model to make easier the implementation of Design of Experiments (DoE)
The article highlights the emerging trends in the automotive industry that are causing a fundamental change in vehicle technology
COUNTRY FOCUS: USA 94
Cover image courtesy: Hannover Messe
A steely resolve
Demand on solid ground
A read into the current performance of the machine tool industry of USA
New Products 100 Drilling tools for titanium & stainless steel; Vertical turning machine for small chucked components; Ring Saw with two head design; Hybrid linear bearings 101 Sealless compact pumps; Universal hydraulic chuck; Eddy current displacement sensors; High-speed CNC CMM 102 Miniature sensors for space constrained applications; Precision blanking and sheet metal forming press; Quick jaw change system; PCBN insert grade for rough machining
Columns 07 08 104 104
Editorial Contents Highlights – Next issue Company index
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MARKET | NEWS
New management for CII
Ford opens Sanand plant
Sumit Mazumder, Chairman & MD, TIL Limited, has been elected as the President of CII for 2015-16. He succeeds Ajay Shriram as the new President. TIL is the manufacturer of India’s largest range of material handling equipment in technical collaboration with Manitowoc Crane Group, USA; Hyster (a part of NACCO Materials Handling Group, USA); Astec Industries, USA; Paceco Corp, USA (a part of Mitsui Engineering and Shipbuilding, Japan) and Mitsui Miike Machinery Co, Japan (a part of Mitsui Group). Sumit Mazumder, Mazumder is also the Executive Chairman of TIPL Chairman & MD, TIL (Tractors India).The company is a distributor for Limited, is elected as Caterpillar, USA, in India, Nepal and Bhutan for the President of CII earthmoving, construction, mining equipment and power systems. Dr Naushad Forbes, Director, Forbes Marshall, has become the President-designate of CII for 2015-16. It is India’s leading steam engineering and control instrumentation firm. He chairs the steam engineering companies within the group. Shobana Kamineni, Executive Vice-Chairperson, Apollo Hospitals Enterprises Limited (AHEL), has been elected as Vice-President of CII for the year 2015-16.
Ford Motor company’s Indian arm inaugurated its second factory in Sanand, Gujarat. According to the company, it had planned to establish India as an export hub. Also, it wanted to triple its exports from here over five years. Anurag Mehrotra, Executive Director—Marketing, Sales & Service, Ford India, said, “Half The initial production would be for the of the combined production domestic market from their Sanand and Chennai units would be for export.” Nigel Harris, President, Ford India, said, “The Figo Aspire would be launched in the second half of the year. The initial production would be for the domestic market and the company would eventually focus on exporting the model. “The body shop is 95% automated and the paint shop almost fully. There are 125 stations along the production line that have been set up for quality checks. There were more than 437 robots at the facility,” added Mehrotra.
> MORE@CLICK EM01631 | www.efficientmanufacturing.in
> MORE@CLICK EM01632 | www.efficientmanufacturing.in
Klingelberg partners with Sandvik Coromant Klingelnberg GmbH has joined hands with Sandvik Coromant for the basic research & development of modern production concepts. Their latest project is a new tool concept for the Klingelnberg Zyklo-Palloid® gear cutting process, designed to establish dry processing with carbide indexable insertscin this process as well. Through intensive development work, they will join forces to offer customers endto-end solutions, which take into account and optimise the complete machine, comprising the machine, setting, cutting parameters and tool solution. “Our goal is to realise innovative Their latest project is a modifications, to enable our customers to new tool concept for the manufacture their products with maximum flexibility, Klingelnberg Zyklo-Palloid® shorter processing times and lower process costs,” gear cutting process explained Dr Tim Sadek, Head—Tool Machines product line, Klingelnberg. To accomplish this, both companies are blazing new trails in a joint effort. Together with Sandvik Coromant, Klingelnberg has been at work developing a modern tool concept for the Klingelnberg Zyklo-Palloid® gear cutting process, which will replace the proven system based on high speed steel materials. > MORE@CLICK EM01633 | www.efficientmanufacturing.in
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Rockwell Automation partners with Cisco Rockwell Automation with over $6.62 billion dedicated to industrial automation & information has further expanded its global footprint in India, China & South-East Asia. On the backdrop of hosting India’s largest Automation Event, the company recently announced its partnership with Microsoft & Cisco for joint solution development & integrated solutions & services. These collaborative efforts shall result in better asset optimisation and broader risk management for industrial companies. Dilip Sawhney, MD, Rockwell Automation India, The collaborative efforts shall result said, “Increasing awareness of automation in better asset optimisation benefits in manufacturing shows scope for automation in manufacturing as the industry is realising the vast benefits of automation. In the light of “Make in India”, manufacturing will get a boost, thus, giving scope to more adoption of automation in manufacturing for industry to remain competitive also. RAOTM (Rockwell Automation On the Move) is an annual event that brings together the best and brightest thinkers, practitioners, and innovators from business & academia to accelerate the market adoption.” > MORE@CLICK EM01634 | www.efficientmanufacturing.in
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MARKET | NEWS
Frost & Sullivan announces the launch of IMEA Frost & Sullivan recently announced the launch of its 12th edition of India Manufacturing Excellence Awards (IMEA). The awards assessment process brings out the consonance of strategic goals toward business growth, their derivative organisational objectives towards enhanced competitiveness and the facility’s operational performance towards manufacturing effectiveness. This is based on the global excellence model, which captures the facility’s operational performance across 12 parameters and business results across three parameters. Speaking on the occasion, Raghavendra Rao, Senior VP, Frost & Sullivan, said, “With the Government of India taking significant steps to boost the country’s industrial sector, companies are eyeing and preparing themselves for opportunities that the next big revolution is expected to bring. The “Make in India” program is both exciting and challenging and forward-looking companies are expected to make the most out it. IMEA has been a pragmatic approach toward identifying opportunities for improvement within the organisation”.
The best facility in each industry sector shall be presented with the “Future Ready Factory of the Year” award. The facility that has proven to be the best across all industry verticals shall be presented with “The Indian Manufacturer of the Year” award. In addition, the super achievers this year shall also be recognised at the growth, innovation & leadership banquet, a flagship event of the company. Also, there will be an opportunity for senior level executives to be a part of the world’s foremost member-driven, global business leadership network – The Manufacturing Leadership Council (MLC). Besides engaging with and being a part of global thought leaders and sharing opinions, the MLC provides international plant visits, interactive collaboration zones with industry peers and premium access to Executive Insight Webinars Research. It is a day-long event that serves as a platform for discussion and active industry interaction on industry relevant issues, and sharing of identified best practices.
Gleason Corporation opens new facility in Bengalaru
Renishaw bags Queen’s Award for Enterprise
Gleason Corporation recently announced that it has broken ground for a new manufacturing facility in the Bengaluru Aerospace Park Industrial Area. John J Perrotti, President & CEO, Gleason Corporation, said, “We continue our belief that the Indian market offers significant near-term & long-term growth opportunities, and we are pleased to take the next step to position Gleason to better serve the Indian market”. The facility will produce a wide range of products & services for aerospace customers and markets including The facility will produce a wide automotive, heavy truck, construction, range of products & services for agricultural equipment and energy. aerospace customers and markets Phase 1 of the new Gleason works India facility is planned for completion in the second half of 2016, and includes 50,000 sq feet space for manufacturing, sales, service and administration. The facility will continue the manufacture of Gleason Genesis® gear hobbing machines, gear cutting tools, workholding equipment, and aftermarket products and services, and will provide the space needed for continued expansion for other products. > MORE@CLICK EM01636 | www.efficientmanufacturing.in
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> MORE@CLICK EM01635 | www.efficientmanufacturing.in
Renishaw was recently felicitated with the Queen’s Award for Enterprise 2015 in the innovation category for the development & manufacture of its RESOLUTE™ family of non-contact, optical position feedback devices. It enables a step change in the performance of motion control systems, used in manufacturing and other environments. It can determine position to a resolution of one nanometre (one billionth of a metre) with motion speeds of up to 100 metres per second for linear position applications, and is The encoder system capable of 32-bit resolution at up to 36,000 RPM enables a step change in for rotary (angle) applications. It determines position immediately at switch-on and is the performance of motion control systems compatible with a range of ‘open’ and ‘proprietary’ serial protocols including Siemens DRIVE-CLIQ, BiSS®, FANUC, Mitsubishi and Panasonic. “RESOLUTE complies with our years of experience in optics, high speed image processing, system engineering and precision manufacturing. I am proud of our achievements to produce a globally successful encoder product that is a world-first in its field,” said David McMurtry, Chairman & Chief Executive, Renishaw. > MORE@CLICK EM01637 | www.efficientmanufacturing.in
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MARKET | NEWS
HaasTec 2015 attracts 3300 visitors to Haas factory According to reports from Haas Automation, the recent HaasTec open house axis rotary table. With a maximum speed of 1000° per second on both axes, attracted nearly 3,300 attendees to the the TRT100 provides high-speed, accurate, company’s headquarters and manufacturing 3+2 positioning for machining small facility in Oxnard, California. The 4-day complex parts. event drew visitors from around the world, “This was a great event. We are very with attendees from 48 countries, including appreciative of being given the opportunity China, India, Korea, Latin America, the to attend and exhibit. This gave us a great Middle East, and many European countries. opportunity to have our customers come More than 330 students attended the and look at the complete line of Haas event. products, as we would like nothing more The event included machine demonstrations, than to have our customers buy more Haas extensive tours of the company’s 1 million machines!”, said Joe Bailey, Sales sq foot facility, where 38 exhibitor booths Executive, Autodesk. with representatives from major CAD/CAM, Visitors witnessing the 20 machines on display and running “Overall, we found it to be very productive, demos at HassTec tooling and work holding manufacturers. and were able to meet with many existing There were 20 machines on display and customers, prospects, and HFOs. This event running demos at HaasTec, including the new UMC-750SS super-speed was valuable in that many of the people visiting were actual decision universal machining center. Also, there were the ST-55 large-through-bore makers. We spoke with many executives and managers who can actually turning centre, the new DM-1 drill/mill centre, a wide array of Haas VMCs, spend money,” added Bryan Jacobs, Communications Manager— and a Haas horizontal with pallet pool system. A number of Haas rotary Marketting, CGTech. > MORE@CLICK EM01638 | www.efficientmanufacturing.in products were also on display, including the new TRT100 high-speed dual-
Honeywell expands cyber security development capabilities
KBL’s LLC pumps felicitated with India Design Mark
Honeywell Process Solutions recently announced the opening of the Industrial Cyber Security Lab to advance its development and testing of new technologies & software to defend industrial facilities and operations such as refineries and manufacturing plants from cyber-attacks. According to the U.S. Department of Homeland Security’s Industrial Control Systems Cyber Emergency Response Team (ICS-CERT), reported cyber incidents on industrial targets in 2014 continue to increase and are up more than 25% since 2011. The Industrial Cyber Security Lab “We will be able to validate new defends refineries & manufacturing solutions faster in a variety of plants from cyber-attacks scenarios and increase our customers’ defenses against the growing threat of cyber attacks,” said Jeff Zindel, Global Business Leader—Cyber Security, HPS. The new Industrial Cyber Security Lab, located in Duluth, Ga, includes a model of a complete process control network that the company cyber security experts will leverage for proprietary research, hands-on training, and to develop, test & certify industrial cyber security solutions.
Kirloskar Brothers Limited has recently received national-level recognition for its LLC Pumps series. KBL’s LLC Pumps series has been granted the prestigious “India Design Mark” by the India Design Council. The India Design Mark is a design standard, a symbol that recognises a design that is useful and responsible. It symbolises product excellence in form, function, quality, safety, sustainability and innovation and communicates that the product is usable, Corrosion & natural erosion have durable, aesthetically appealing while been considered while designing the being socially responsible. Commenting pumping system at the event, Ravindra Birajdar, VP— Corporate Research & Engineering Development, KBL, said, “This award not just recognises our efforts to make our products more useful, but also motivates us to continue creating new, innovative & enriching products.” Factors such as corrosion and natural erosion have been considered while designing the LLCTM pumping system. The objective behind the pumps is to save on additional energy costs and reduce the degradation cost.
> MORE@CLICK EM01639 | www.efficientmanufacturing.in
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> MORE@CLICK EM01640 | www.efficientmanufacturing.in
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NEWS | MARKET
Strong participation by Indian industries at Hannover Messe 2015 Coinciding with Hannover Messe 2015, CII organised the Indo-German Business Summit in collaboration with BDI. The summit focused on highlighting new & emerging markets for trade between India and Germany. A strong 40 member CII CEO’s delegation led by Sumit Mazumder, President, CII, participated at the recently held Hannover Messe 2015. 350 Indian companies including the Tata Group, Reliance, Bharat Forge, State Bank of India and the Kirloskar Group showcased their strengths at the fair. CII had set up 3 stalls at the fair to showcase Brand India at the event, highlighting the industrial growth & business opportunities in the country. The delegation conveyed a powerful message for the global manufacturing industry to look at India as a major investment destination.
Towards Indo-Germany trade opportunities Coinciding with the fair, CII organised the Indo-German Business Summit in collaboration with BDI. The Summit was attended by the CEOs of prominent German companies. Hon’ble Prime Minister of India Narendra Modi and German Chancellor Dr Angela Merkel had addressed the session. The Summit focused on the “Make in India” campaign, which aims to increase the share of manufacturing in India’s GDP. With much of Germany’s economic success being credited to its focus on the manufacturing sector and on producing high technology sophisticated goods, the session generated a strong response. The overall approach towards India was very positive, from not only German companies, but also companies from other parts of the world as well. It also focused on the opportunities to collaborate especially in the high technology manufacturing sector as well as highlight new & emerging markets for trade and investment between India and Germany.
Indian participation The event witnessed participation from Punjab, Maharashtra
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and Andhra Pradesh. Separate sessions were organised for Gujarat. In addition, a seminar on “India-Germany-Towards a Strategy Skilling India” and “Indo- German Collaboration on Digital India” were also organised. In addition to Mazumder, the delegation included Dr Naushad Forbes, President Designate, CII & Director, Forbes Marshall; Chandrajit Banerjee, Director General, CII; Baba Kalyani, Chairman & MD, Bharat Forge Limited; Prashant Ruia, Group CEO, Essar Group; Ravi Parthasarathy, Chairman, Infrastructure Leasing & Financial Services Limited, Dr Raghupati Singhania, Chairman & MD, JK Tyre & Industries Limited, Deepak Puri, Chairman & MD, Moser Baer India Limited; Nikhil Meswani, Executive Director, Reliance Industries Limited; Sunil Mathur, CEO & MD, Siemens and Soumitra Bhattacharya, Joint MD, Bosch Ltd, among others. ☐ > MORE@CLICK EM01641 | www.efficientmanufacturing.in
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MARKET | INTERVIEW
“We are implementing smart plant concepts” Claire Kuo, Chairman & CEO, SEYI Taiwan, in an interview with Megha Roy, briefs on manufacturing execution solutions, while analysing the Indo-Taiwan trade relations in the manufacturing landscape SEYI Taiwan integrates machines with different automation, in factory into the students’ credits. This develops technical thus enabling solution-based products for customers. How personnel training program to send our senior engineers in are you transforming from a manufacturer to a total solution their junior semesters and then select suitable students for the provider? program. We provide smart production solutions, instead of single press machine by working with customers, to begin with the What are the challenges witnessed in manufacturing mechanical design of customised manufacturing solutions that raises the presses? How does R&D work in your domain? capabilities of customer production lines. The areas include The major challenge is the constant knowledge about the pressing machinery to robotic arms to feeding and conveying trends of metal stamping equipment development, integrating equipment. We change our business upstream and downstream industry resource practices into the service-oriented thinking to import comprehensive solution and to strengthen competitive advantage of the provide optimal production programme, customers, instead of only selling equipment assist our customers the best of profitable to the customer. That makes us a total production to create the win-win industrial solution provider. synergies. As such, the R&D team needs to understand customers’ requirements in What are the company’s initiatives towards the beginning to design the whole solution Industry 4.0? What developments are to precisely satisfy their business needs happening on this end? eventually. This trend will be a crucial For Industry 4.0, we are implementing turning point to win over customers who smart plant concepts. We adopt some need tailor-made solutions. programs from SAP and other vendors in manufacturing execution solutions, Keeping in mind the Indian demand scenario, integration and intelligence as well as what kind of product line is being offered by information management to gradually your company? form solutions such as shop connector systems, assembly Currently, the most popular products for the India market lines, equipment, products, monitor connected together all are small tonnage models. Along with the rapid grow of India production related processes into a complete network of market, especially in automotive sectors; our large tonnage intelligent production. As a machine tool plant, we have machines shall provider more value and meet users’ needs changes of technology and product development in the better. manufacturing sector, particularly Industry 4.0 waves. We will integrate with Taiwan’s ICT (information communication Can you elaborate on the industrial trade activities between technology) strengths to promote products in new areas. India and Taiwan? What are your future expansion plans for the Indian market? Given that the industry-academia activities have become The major trade activities are fine parts and equipment from important for the growth of the manufacturing industry, what Taiwan and assembling or manufacturing the end products steps are being taken by your company to promote this? in India to sell in the international and domestic markets. In We implemented the education cooperation with colleges future, some Taiwanese companies will also set up plants in and conducted employment-oriented programs to offer India to closely serve the customers. We will concentrate on several positions to students in electric machine department selling more high quality and larger tonnage products first, to practice for a month. We also sent our engineers to build and then build up an intensive dealer network to expand the up industrial-college classes to teach students related courses Indian market. ☐ > MORE@CLICK EM01642 | www.efficientmanufacturing.in and arrange them for internship or help to convert the hours
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MARKET | TRENDS
Creating jobs with ‘Make in India’ Corporate India across the spectrum wholeheartedly supports the "Make in India" initiative of the government. The idea that manufacturing can have a very substantial impact on job creation and hence needs adequate focus is widely accepted today after years of a narrow-minded focus on IT and services. The part-1 series of the article discusses that while it is possible to increase low-end manufacturing in the country in an effort to create jobs for all kinds of talents, the window of opportunity for the same is narrow and hence requires decisive action today. The vision of "Make in India" is to facilitate investment (both domestic and foreign), foster innovation, enhance skill development, protect intellectual property and to build a bestin-class manufacturing infrastructure in India. Targets for this initiative have been clearly spelt out. Manufacturing sector growth should increase to 12-14% pa over the medium term,
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Dr Wilfried G Aulbur Managing Partner India Chairman Middle-East Head Automotive Asia Roland Berger Strategy Consultants wilfried.aulbur@rolandberger.com
manufacturing's share in GDP should increase from 16% to 25% by 2022, and 100 million additional jobs should be created in the sector in the same time frame. These targets are ambitious. Adding 100 million jobs, for example, means tripling current employment in manufacturing. Enablers have also been identified. Unnecessary processes,
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TRENDS | MARKET
FIGURE 1
With a delayed effect, manufacturing jobs are seeing a drastically similar decline in % of people employed in most economies In all major economies (except China), manufacturing jobs as a % of labour force have declined Comments
% 40 35 30 25 20 15 10 5 1970
1975
1980
1985
1990
1995
2000
France
Italy
United Kingdom
India
Germany
Japan
United States
China (Mainland)
Source: Federal Reserve Bank of St. Louis , Roland Berger
2005
2010
2015
> Manufacturing technology has improved labour productivity and as a result reduced the need for additional labour > China's low cost labour has hampered further automation and productivity increases, however, current Chinese salaries are high > To deliver cost-effective products to customers, focus has turned once again on automation, e.g., Industry 4.0 and cyber-physical systems
jobs are seeing a drastically similar decline in % 20150421_Figures.pptx
laws and regulations will be eliminated. Time-bound clearances will be given to projects through a single on-line portal. Appropriate skill sets will be inculcated through quality education. The government will be made more transparent, responsive and accountable and we will increase domestic value addition and technological depth. All these points are laudable and timely. Is it then just a matter of consistent execution that will allow India to leverage her "demographic dividend" and become another factory to the world similar to China? Can we capture the space that China seems to be vacating by moving from "Make in China" to "Innovate in China"? While it is possible to increase lowend manufacturing in the country in an effort to create jobs for all kinds of talents, the window of opportunity for the same is narrow and hence requires decisive action today. Five major trends impact our opportunity to create the intended 100 million jobs by 2022: t Competition from other low-cost countries eager to establish manufacturing footprints of their own t Competition from established countries trying to reindustrialise and bring value addition and jobs back home rather than outsource them to China or an alternative t Increasing pressure for environmentally friendly production not only in developed but also in emerging countries due to the latter's significant influence on global GHG emissions t Need to invest in research and development to avoid creating knowledge gaps with competing economies such as China that turn out to be too large to be closed in a reasonable time frame
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Figure 1: With a delayed effect, manufacturing 1
of people employed in most economies
t
Non-uniform capability of Indian companies to compete at global levels of efficiency and quality due to internal reasons as well as lack of a manufacturing ecosystem In addition, globally manufacturing jobs have declined as a function of time as shown in Figure 1. The only exception here is China which has dramatically added jobs over the last few years as companies used low labor cost in China as an alternative to further investments in automation and productivity improvements. With relatively high salaries in China and a new focus on efficiency improvement in the Triad, this trend is likely to reverse itself.
Make in India – The background Corporate India across the spectrum wholeheartedly supports the "Make in India" initiative of the government. The idea that manufacturing can have a very substantial impact on job creation and hence needs adequate focus is widely accepted today after years of a narrow-minded focus on IT and services. Overall factors are also in India’s favour. Cost of capital has come down significantly since 1995 and is likely to reduce further. India's labour pool is set to be larger than China's in the mid- to long-term. Salary costs for skilled labour are already lower than Chinese labour costs. As a consequence, India's manufacturing competitiveness should improve v/s China as shown in Figure 2. The current economic environment is also supportive. After two challenging years, the Indian economy shows signs of a modest recovery. Inflation has fallen to single digits (backed in particular by a global reduction of oil prices), GDP growth is
21
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MARKET | TRENDS FIGURE 2
With the expected growth in economy and increasing competitiveness, Indian manufacturing is set to grow rapidly Key enablers and drivers 1 Decreasing cost of capital
2 Availability of cheap labor
Manufacturing competitiveness
Borrowing rates
Labor force [mn]
> India is increasing its manufacturing competitiveness vis-à-vis other emerging countries
919
China 16 14 12
Brazil
10 8 6
927 129 139
+7%
+17% 2013 2025
Skilled labor wages – 2013 (USD/year)
4 2
Beijing
0 1995
895 794
India
-3%
2000
2005
2010
2015
Delhi Rio de Janeiro
Index Score1)
Good
Bad 2
4
6
8
10
China India Brazil
6,200
Russia
4,800 18,600
2010
2015
With the expected growth in economy and increasing competitiveness, Indian
1) Based on Deloitte Global manufacturing competitiveness Index 2013 data Source: OANDA, World Bank, UBS, ACMA, Press reports, Roland Berger analysis
20150421_Figures.pptx
2
manufacturing is set to grow rapidly
inching up to a 7-9% range and interest rates are coming down and are now close to a factor 2 larger than corresponding wages albeit slowly. This revival of economic growth, if supported by in India. In principle, this opens up opportunities for India to consistent government action, should boost industrial activity, enter manufacturing plays that are no longer viable in China. increase income and rekindle consumption led growth. However, India is not alone. Manufacturing costs in Vietnam However, major challenges for “Make in India” remain. Poor are 60%, in Indonesia 64%, and in the Philippines 67% lower infrastructure, a tedious bureaucracy, labour law complexities than in China. In terms of labour availability, India leads the and corruption are some of the key investment risks in India. three other countries by a large margin, however, Indonesia Due to capacity constraints at major ports and their low and the Philippines trump India in terms of English speaking mechanisation levels, slow inland freight movement, lack of percentage of population. While India is the largest market last mile connectivity, etc, India's logistics performance has among the 4 nations that we are considering, the internal declined over the last 7-8 years. India's Logistics Performance market in Indonesia is also large and that of Vietnam and the Index (LPI) is now 54 down from a rank of 39 in 2007. According Philippines is relevant. to a Worldbank study, the ROS of heavily logistics dependent A number of global indicators are cause for concern. In the companies is 200 bps lower in India than in best-in-class global competitiveness report 2014-15, India scores a rank of countries. In terms of Ease of Doing business, India faces clear 71 out of 144 countries compared with 34 for Indonesia, 52 for challenges in Enforcing Contracts, Trading Across Borders, the Philippines and 68 for Vietnam. In terms of the Worldbank's Paying Taxes, Dealing with Building Permits and Starting a Ease of Doing Business index, India is again last with a rank of Business. Labor law complexities continue to drive companies 140 v/s 117 for Indonesia, 86 for the Philippines and 72 for to hire temporary rather than permanent labour. In many Vietnam. In terms of the 2014 International IP index, India manufacturing companies temporary labour makes up 30-70% ranks behind Indonesia and Vietnam (Philippines have not of the total workforce. been ranked) while its logistics performance index is such that China created a virtuous cycle as the "world's manufacturing India ranks 54 behind Indonesia (53) and Vietnam (48) but workbench" by, among others, leveraging cheap labour; creating ahead of the Philippines (57). world-class infrastructure; adapting and improving of Clearly, just because China is forced to vacate parts of the technologies developed overseas; achieving cost reductions manufacturing space, it does not imply that India is the only or through deployment at scale and achieving incremental process best alternative. As a consequence, the "Make in India" initiative and manufacturing innovation. While all these points can be needs to drive its agenda quickly in order to change key global achieved in principle, they require timely and consistent rankings. The latter are important, as global companies do take execution for India to follow in China's footsteps. them into consideration when evaluating their global manufacturing footprint and deciding on fresh investments.
India's declining performance in key KPIs – Ascent of low-cost competitors
A major consideration of the "Make in India" campaign is the observation, that manufacturing wages in China have risen
22
Market Trends Wilfried May15.indd 22 FORM-2.indd 10
Manufacturing is cool – The re-industrialiation of the Triad In the wake of the global financial crisis, Western nations
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FORM-2.indd 12
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MARKET | TRENDS FIGURE 7
Manufacturing companies can address sustainability concerns by focusing on incremental measures covering the entire value chain Transformation to Green Manufacturing – Framework
Green STRATEGIC PLANNING
0
1
2
• Energy procurement • Eco-friendly raw materials • Supplier management
3
Green PROCESSES
Green PROCUREMENT • • • • •
Eco-efficiency analysis Waste analysis Water conservation Efficient buildings Renewables
4
Green PRODUCTS • Innovation management • Recycled products • Lead user approach
Green MARKETING • Identification of values and sustainability needs of customers
5
Green REPORTING & RISK MANAGEMENT
Manufacturing companies can address
• Communicating and promoting Green initiatives and their benefits to all stakeholders • Reporting systems for eco-indicators (CO2 emissions) • Forward looking systems for relevant regulations
sustainability concerns by focusing on incremental measures covering the entire
Source: Roland Berger Product Development, Civil Economics Competence Center
20150421_Figures.pptx
re-discovered the charm of manufacturing as a driver of innovation, employment and services. The US, UK, France, and even Germany with a still healthy industrial base all embarked on various initiatives to ensure manufacturing employment within their own national borders. Rather than going through all the initiatives currently underway, we will focus on "Industry 4.0", the German avatar of the reindustrialisation drive. The basic premise of Industry 4.0 is that the introduction of intelligent machines, embedded cyber-physical sensors, collaborative technologies and networked processes will once again drive an efficiency revolution in industrial manufacturing. Initiated by the German BMBF ministry (Federal Ministry for Education and Research) and launched officially with a report "Securing the future of the German manufacturing industry" in 2013, Industry 4.0 aims to build the intelligent factory which is characterised by adaptability, efficiency and full digital integration. Some components of this factory are smart robots and machines, i.e. multipurpose, “intelligent” robots that are able to adapt, communicate and interact with each other and with humans. Big data will be leveraged via cloud computing, e.g. for mass customisation. Connectivity will reach a new level of quality via constant exchange of information between machines, work pieces, systems and human beings. Optimised production processes will ensure energy efficiency and allow for a decentralisation of plants. European companies, in particular, are positive regarding the potential of Industry 4.0. Expected cost savings of 14% on average over the next 5 years would negate a large part of the factor cost advantage that countries like India enjoy today vs. developed nations (typically in the range of 15-30%). Efficiency
24
Market Trends Wilfried May15.indd 24 FORM-2.indd 14
7
value chain
gains are expected to be even higher at 18% within the next 5 years. Industry 4.0 is a board room level topic for all European manufacturing companies with investments in the approach amounting to 3.3% of revenues on average. In comparison, a typical R&D budget of Western OEMs amounts to about 5% of revenue. Established players in the EU are changing their organisations, processes and capabilities in whole or in part due to Industry 4.0. As freedom and flexibility of the production process increases, it will become possible to create products tailored for segment-by-one customer needs at relatively low marginal cost. Also, distribution processes for spare parts or not too complex consumer goods may get easier. In terms of competition, traditional industry boundaries will become blurred as are the boundaries between industrial and non-industrial applications. Going forward the focus will be on industrial working methods, not only of products but also of services. The value chain will be redefined as well. In a complex and intertwined manufacturing network, the roles of designers, physical product suppliers and the interfaces with customers will change. Supplier hierarchies and pecking orders are likely to change. New companies (e.g. Amazon, Google, Apple) are increasingly integrating all parts of the value chain to enhance their core service offerings. In terms of skills, employees will need both enhanced social and technical skills. Corporate cultures with continuous training and development in the workplace will become a core competency. Last but not least, the need for off-shoring work will reduce as will the number of available jobs in manufacturing overall.
EM | May 2015
5/13/2015 5/15/2015 2:31:43 7:10:05 PM
TRENDS | MARKET
TRENDS | MARKET
Take Baxter, the world's first general purpose production robot as an example. Baxter's base version costs only $25,000, can be taught any task due to its learning capability, is not limited to single-tasking, can work alongside humans due to a range of built in sensors, communicates with humans via a visual interface, and can recognise and dynamically adjust to work interruptions, wrong parts, etc. The tendency to drive efficiency by leveraging intelligent software is not limited to manufacturing alone. In many service industries, software bots today are able to take over white collar, professional and creative jobs. Whether it is writing articles for newspapers, diagnostics of health problems, writing software or even writing of songs, software bots can replace human intervention quite effectively. Overall, experts believe that for a developed economy such as the US, 37% of all top 20 jobs can be automated easily. We will have to prepare for a future in which large sections of the population may be unemployable without any fault of their own. This trend has implications for job creation in India's software and engineering services industry as well. The next industrial revolution is hence upon us and like its predecessors it will lead to the introduction of new products and of new means of producing existing ones, the disruption of the competitive status quo both on a company and country/ region level, and new requirements for workforce and infrastructure alike. Unfortunately, India's automation and digitalisation levels are not adequate. Opportunities to leverage the country's pool of well-trained engineers and IT professionals to drive an Indian version of "Industry 4.0" clearly exist and should be pursued with the necessary drive and investments. � > MORE@CLICK EM01643 | www.efficientmanufacturing.in
EM | May 2015
Market Trends Wilfried May15.indd 25 FORM-2.indd 16
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C O V E R S TO R Y
TECHNOLOGY
Image courtesy: Hannover Messe
INDUSTRY 4.0 The quiet revolution for India
Industry is on the onset of the fourth industrial revolution, as digitalisation now follows after the automation of production. The goal mouths are to upsurge productivity and efficiency, speed, and quality. This feature details on how Industry 4.0 shows substantial improvement in Indian application. In the industry of the future, the product is expected to become an information carrier and pilot its own way through the production process. 26
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Dr JĂźrgen MĂśssinger Vice President Robert Bosch Engineering & Business Solutions
EM | May 2015
7:10:06 PM 5/15/2015 7:07:12
TECHNOLOGY
Industry brings the masses to work. Many industrialised countries in the past decades faced a reduction in the share of industry in GDP. The share of industry in GDP is going down close to 10% in France, UK; and Germany has stopped at 23%. India is above 30%, and China even higher. No industry, no work. Many technical innovations have come up in the last years, driven by higher integration of electronics, faster microcontrollers, higher bandwidth in communication, cloud service and the emerging of data analytics. Industrialised countries are using these technologies to setup up Industry 4.0 (I4.0), the next industrial revolution, to safeguard their competiveness in manufacturing. Their problem is that production costs are higher than in emerging countries, even taking their higher productivity, efficiency into account. They need to focus on efficient, flexible, high quality production. First projects showed significant cost reduction due to introduction of Industry 4.0 principles – 10, 20, 30% cost reductions possible. Industry is progressively playing an important role all around the globe and is considered a catalyst for innovation, growth, and social stability. Simultaneously, on the other hand, competition is getting stronger and fiercer. It is necessary to continually increase productivity while meeting the customers’ new demands for high quality and customised products within shorter time intervals. And only those who can make do with less energy and fewer resources will be able to cope with the growing cost pressure. To remain competitive costs have to be saved, as emerging countries offer cost advantages. In India, we have the symbiosis of classical manufacturing with IT. The country has a big IT strength. India now wants to go global with ‘Make in India’. The past focus was on IT. India has a well paid middle class, but the masses are struggling. The industry gets the masses into jobs, therefore Modi has taken the initiative for Make in India. Manufacturing gives millions
EM | May 2015
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C O V E R S TO R Y
of people a share in producing products. This is critical for India’s future. The starting point for India is excellent - broad knowledge in classical manufacturing, IT knowledge and a huge pool of highly motivated workers. Globally, traditional manufacturing industry is in the throes of a digital transformation that is speeded up by exponentially growing technologies. Companies and their industrial processes need to adapt to this change to stay ahead of the competitors or at least be in the same pace. The widespread adoption by the manufacturing industry around the world of ICTs is now creating the stone work to make way for disruptive approaches to development, production and the complete logistics chain.
Industry 4.0 Industry 4.0 is the fusion of the physical world of production with the virtual world of information technology and Internet of Things (IoT). Humans, machines, objects and systems are connected and communicate in a dynamic, real time, optimised and self-organised way. In these intelligent production systems, all instances of the added value chain from the supplier over logistics to the customer are connected across the companies. The industrial production can implement individualised customer requests on high-quality level, while increasing flexibility and robustness as well as optimal resource allocation. The ability of gathering and analysing the data from actual production and make an online or offline (e.g. improvement of processes, flow of manufacturing, stock) optimisation increases flexibility, reduces cost, e.g. by reduction of inventory, improves quality. Additionally, it also allows to horizontally optimise the value with focus on the customer. Big Data Analytics is the backbone to analyse the immense number of data collected. In the Indian context, beside cost reduction the improvement in quality is the major benefit. This will enable
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7:10:06 PM 5/15/2015 7:07:14
C O V E R S TO R Y
TECHNOLOGY
The total realm of manufacturing is going to renovate and become entirely networked with machines analysing almost every aspect of the manufacturing process in Industry 4.0
systems Energy management: Energy is frequently the second largest operating cost. IoT can help to understand patterns of utilisation and plan energy usage Internet of Things t Proactive maintenance: Lower cost sensors, wireless The term Industry 4.0 talks into the vibrant improvements the connectivity and big data processing tools make it easier to Internet of Things will bring about in engineering, production, collect actual performance and monitor equipment health and logistics processes in the future. Internet of Things is a t Connected supply chain: Real time information access will help manufacturers to lower their inventory costs and major enabler for Industry 4.0. It always goes with big data reduce capital requirements capabilities. The global data growth per day is about 8 Zetabyts Our world is rapidly changing. People are partaking cars, (10^21) per day. In manufacturing, the potential for cyberphysical systems to improve productivity in the production generating their own energy for their homes, and finding ways process and the supply chain is vast. Consider technologies to make machines communicate with each other. Key areas of that manage themselves, where smart products can take our personal and professional lives are becoming increasingly corrective action to avoid damages and where individual interconnected. And that makes things easier – both at home parts are automatically replenished. What opportunities and and at work. Everything need not be local. The correction challenges lay in the future for manufacturers and what will it required could be elsewhere. take to conquest? Like in other areas of our everyday lives, the Internet of India’s possibilities - case study Things is also becoming predominant in industry. An important aspect is the linking-up of factories to form a production A multinational manufacturer uses a piston, and matches a network that goes beyond individual companies and national product to it. The pumps are produced in India. With Industry 4.0 applied the stock can be lower by 90%, efficiency can go boundaries (global factory). up 3%. The crux of the problem is not local in this instance. What IoT means to businesses? t Factory visibility: IoT will provide production line However, the solution lay in connecting suppliers with OEMs information to decision makers and improve factory and the customers - $7 million to be saved in specific steps of efficiency the manufacturing process. t Automation: Manufacturers can use the information to Networked industry will help in global competition. The automate workflows to maintain and optimise production Germans have done it. With a focus on manufacturing, “Made us to compete with other emerging countries like China on the world market.
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EM | May 2015
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C O V E R S TO R Y
TECHNOLOGY
Industry 4.0 is the future topic with high relevance and big effects on entire value chain
in Germany’ has a good reputation. It costs more, but people still buy it. A networked industry will help countries like India improve quality, raise their profile in the global market. There will be mass products produced for the global market.
The 1% opportunity For Industry 4.0, high investment is needed. We are talking about plugging in sensors, and data analytics in the background. In discrete manufacturing you often optimise single steps. If you want to invest in a plant you need improvement of 20-30% in these steps to justify the investment. In batch manufacturing, however, lies the 1% opportunity across the whole process. Single events influence directly the product quality (and therefore the achievable price) and throughput of the plant. Introducing Industry 4.0 methods allows identifying unused production resources, reducing downtimes and improving product quality. If the turnover of a plant in batch processing is e.g. $1 billion, a 1% improvement gain is $10 million. Continuous detailed analysis of process parameters often leads to this kind of 1% improvements. Applying I4.0 in batch industry shows huge cost reduction potential and fast RoI. Putting this in a global context huge savings are possible, e.g. a 1% increase in oil & gas exploration and development will lead to a saving of capex of $90 billion.
The need to drive I4.0 If India wants to be successful in “Make in India”, it needs to become the hub for manufacturing. This requires a focus on
30
Untitled-1 30 26 FORM-2.indd
exports. It needs to bite the bullet and make this investment in improvement. So that the world market is not driven elsewhere like China or Indonesia. t The plant is only one piece. At present, India is at a lower level compared to other countries in terms of plant sophistication. It is many times at pure mechanical manufacturing level. The desirable level, or top of the pyramid, is a situation where 4.0 is adopted fully. We need to now tailor I4.0 concepts for India. Only this optimisation will give us the success in India. t That said, I believe we don’t have to be on top of the I4.0 pyramid. We will get easier ROI in the middle – with an India optimised I4.0 approach. t For the success in I4.0 beside a full ecosystem is required, users, enterprises, connected things and partners. In I4.0 not everything can be done by suppliers or OEM by themselves. The partners are key. Here is also a potential for India to be successful in being the right partner for the industry worldwide. The implementation of I4.0 has already started in industrialised countries like Germany, USA. Experts see in it the fourth industrial revolution. With good reason – not only is the Internet of Things transforming factory control and production structures, it also increases agility and flexibility in the production process. It will enable us to individualise even the smallest volumes to a high degree while retaining optimum productivity, thereby optimising multi-variant series production. It will allow companies to involve their customers more closely in the production process and to react
t
EM | May 2015
5/15/2015 7:07:14 7:10:08 PM
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5/15/2015 7:10:09 PM
C O V E R S TO R Y
TECHNOLOGY
The starting point for India is excellent - broad knowledge in classical manufacturing, IT knowledge and a huge pool of highly motivated workers
faster on changing market requirements. The ideal scenario envisages a self-controlling production process, in which production reacts autonomously to changes or faults and takes appropriate measures. We are currently at the beginning of such a development, which will gradually become established in industry. India needs to push I4.0 in order to participate from the beginning, not losing its exposed position.
The ultimate sample size of ONE This is the idealistic situation. It allows you to enter new markets with a higher number of variants. Manufacturing helps raise the standard of people and aids in increasing market size. Although customers are price sensitive and affordability is crucial, customers realise the importance of acceptable quality levels. At present, 4.0 is just gaining momentum in India.
Incorporating built-in communication Technology advances have distorted the boundaries between the digital and physical worlds. Intelligent, interconnected systems now seamlessly support activities along the entire value chain. This means reduced costs and enhanced efficiencies, greater speed and scale, and smarter products and services. It is to evolve into the disruptor. The industrial sector is in the primary steps of having a continuous or rounded network that has overall connectivity and visibility. Forward-looking equipment manufacturers are starting to incorporate built-in communication as well. They comprehend that by providing connectivity — as well as intelligence around energy states — they can moderate the total cost of ownership of their equipment, and help their customers
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optimise their operations at the same time. Industry 4.0 is the future topic with high relevance and big effects on entire value chain. Industry 4.0 concepts will be introduced in a stepwise approach. Key topics will be data security, data analytics (big data), cooperation, new business models and the usage of Industry 4.0 principles is not limited to high industrialised countries. Industry is on the onset of the fourth industrial revolution, as digitalisation now follows after the automation of production. The goal mouths are to upsurge productivity and efficiency, speed, and quality. As follows, companies can remain competitive on the path to the future of industry. Industry 4.0 concept shows substantial improvement in Indian application. In the industry of the future, the product will become an information carrier and pilot its own way through the production process. Appreciatively, Industry 4.0 is less of a revolution and more of an evolution in many small footsteps that will actually change how manufacturing and industry do business. The expedition of creating and developing smart factories will be a complicated and evolutionary process. Requirements for innovation are diverse as these will play an instrumental role in implementing Industry 4.0. The total realm of manufacturing is going to renovate and become entirely networked with machines analysing almost every aspect of the manufacturing process. With Industry 4.0 beginning, the Gen Z manufacturers will look downright different from what we see today and we can foresee a smart creation of the world with smart industries helping emerging nations to gain global competitiveness. � > MORE@CLICK EM01644 | www.efficientmanufacturing.in
EM | May 2015
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FORM-3.indd 1
www.emag.com 5/15/2015 6:37:22 PM
MANAGEMENT | INTERVIEW
“We want to partner with the Indian machine tool industry” Paul Ricard, President, DP Technology Corp, discusses the recent developments in the CAD/CAM industry with Maria Jerin. Excerpts from the interview... How has the CAD/CAM industry evolved over the years globally? What are the recent developments? In CAM software, the customers now demand solutions that work “out-of-the-box”. To simplify, CAM software is constituted of essentially two parts: a main program where endusers describe the machining processes, and a post-processor that creates the code instructions. These post-processors have always been a source of frustration for everyone. It is not common for a CAM vendor to spend 6 months at a customer’s site to get a post-processor to work with a 75% success rate or less. All of this is highly counterproductive. More progressive companies like ESPRIT have established strong relationships
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FORM-3.indd Interview_Paul 2 Management Ricard_ESPIRIT.indd 34
with machine-tool builders to provide them the ability to fully develop post-processors for their machines and test them in all conditions. In fact, at ESPRIT they are called ‘machine driver’ in reference to a ‘printer driver’ because they are made to produce near perfect output. Consequently, a customer becomes fully operational and productive as soon as the machine hits the factory floor. What are your company’s knowledge-based features that are unique in providing high-end solutions to users? We refer our CAM software as a ‘Manufacturing Operating System’. We are totally open and highly customisable. ESPRIT
EM | May 2015
6:37:23 PM 5/15/2015 6:36:27
INTERVIEW | MANAGEMENT
CANDID SIX
boasts an Application Programming Interface (API) which allows anyone to develop specialised functions for very specific customer needs. In addition, our patented Knowledge Based Machining (KBM) engine, paired with our Feature eXchange (FX) technology, allows customers to completely automate part programming, thus cutting programming time and drastically increasing machine utilisation. How is the CAM software leveraging cloud technology to benefit the manufacturing industry? The manufacturing industry has always expressed a serious interest in having a single source of access to product data from the manufacturers of cutting tools, machine tools and work holding that is complete and always up-to-date. Machining Cloud is a new comapany, in the process of addressing this need. Several CAM companies like us have implemented a connector to the Machining Cloud technology, thus, enabling the users to access catalogs of tool manufacturers and to automatically select tools based on features of the part they want to machine. This simplifies the selection of cutting tools, offers a list of recommended tools based on machining features and allows more precise simulation of the machining processes with accurate 3D models of tool components and assemblies. What are the essential factors to be considered by the shop floor officials, while choosing CAM software for machining complex models? The most important factor is the availability of machine drivers (post-processors) certified by machine tool builders. Next, in order to shorten part setup and avoid costly crashes, it is important to have full machine simulation with complete collision detection. In addition, one programming environment to handle all the CNC programming needs, will cut training and improve ease of use. The ability to read native models from any CAD systems is also very important. And finally, even the best of CAM software would be of little use without a highly competent technical support team. What can the customers look forward to in the 2015 ESPRIT World Conference? The ESPRIT World Conference is the annual gathering of the entire ESPRIT community. Customers, resellers, partners, sponsors, guests and employees from around the world get together for 5 days to listen to inspirational speakers, learn, network, exchange and also have some fun. There will be in
EM | May 2015
Management Ricard_ESPIRIT.indd 35 FORM-3.indd Interview_Paul 4
t If not in this industry, where would you be? "T B UFFOBHFS * EFWFMPQFE UXP QBTTJPOT TPGUXBSF QSPHSBNNJOH BOE NBSLFUJOH 4P * XPVME TUJMM CF JOWPMWFE JO TPNF PUIFS TPGUXBSF WFOUVSF t What is your favourite pastime? Football t What are you currently reading? #JPHSBQIZ PG "MCFSU &JOTUFJO t Which is your dream car? 5FTMB .PEFM 4 UIF POF * N ESJWJOH OPX t Your dream holiday destination? 5BK .BIBM t Uniqueness of India that appeals to you‌ 5IFSF BSF TP NBOZ UIJOHT JO *OEJB UIBU GBTDJOBUF NF UIF LJOEOFTT PG UIF QFPQMF UIFJS QPTJUJWF BUUJUVEF BOE PQUJNJTN UIF UIJSTU PG ZPVOH QFPQMF UP MFBSO BOE FYDFM UIF GPPE UIF WBTUOFTT PG UIF DPVOUSZ UIF EJWFSTJUZ PG MBOETDBQFT BOE DVMUVSFT UIF IFDUJD QBDF PG MJGF UIJT LJOE PG iPSHBOJTFE DIBPTw XIJDI JT GSVTUSBUJOH BU UJNFT CVU BMTP TP DIBSNJOH BOE BUUSBDUJWFy
excess of 120 hours of training for customers, sales training for resellers as well as presentations by our executives on various subjects. We are expecting more than 500 people to attend the conference this year. How are you viewing the demand trends across the world and in India? What are your future plans for the Indian market? Manufacturing around the world is growing at a rapid pace. Specific sectors are particularly vibrant such as commercial aviation, energy and medical. Fast developing economies, of which India is a part of, aren’t relying solely on export anymore. Due to their growing middle class, there is a strong need for infrastructure development: public transportation, roads, bridges, power plants, housing, etc. This drives local manufacturing, hence the need for more and better technology. We are committed to the Indian market. In the short term, we want to solidify our technical ability to support our customers as well as make sure that our current customer base is extremely satisfied with our products and services. Medium term, we want to expand our sales reach to other regions, while continuing to grow our engineering capabilities. In the long term, we want to partner with the Indian machine-tool industry, just like we did with European and Japanese builders, in order to offer the best solutions possible for the Indian market. � > MORE@CLICK EM01645 | www.efficientmanufacturing.in
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R O U N D - TA B L E | M A N A G E M E N T
Building mission-driven machines Increasing global competition, varying market demands and regulatory mandates require manufacturers of industrial machinery to continuously innovate, develop new products and optimise their production processes. To achieve these goals, manufacturing enterprises need a PLM platform that enables them to improve the productivity of NPD process, so as to operate faster, deliver better with consistent product quality and minimised lifecycle costs. A report on the round-table events on this topic, conducted recently, in Bengaluru and Pune. To be successful in today’s competitive global business environment, manufacturers need to build mission-driven machines that are smarter, more functional and easier to maintain. On the other hand, today’s new product development (NPD) process is comprised of hundreds of decision points and parallel work flows across multiple disciplines that take place in a global context. To balance this effectively, manufacturing enterprises need a product lifecycle management (PLM) platform that enables them to flourish in this complex business environment by making smarter decisions and better products. In this context, EM along with Siemens PLM Software had organised round-table discussion events in Bengaluru and Pune, to deliberate on this topic. IMTMA was the Knowledge Partner for the same. With the theme of “Building Mission-Driven Machines –
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Srimoyee Lahiri Sub-editor & Correspondent srimoyee.lahiri@publish-industry.net
Megha Roy Features Writer megha.roy@publish-industry.net
From bid to delivery”, the round-table discussion was moderated by Shekhar Jitkar, Publisher & Chief Editor, EM. The panelists of this discussion were S R Chandramauli, DGM - Design & Development (Special Products), Ace Designers; Raju Sagi, Head - Product Engineering & Development, BFW; Ganapathiraman G, Vice President & GM (South and South-East Asia), ARC Advisory Group; Mohini Kelkar, Managing Director, Grind Master Machines; Santanoo Medhi, Managing Director & CEO, Premium Transmission; and Srinath Koppa, Technical Director, Siemens PLM Software. T K Ramesh, CEO, Micromatic Machine Tools and Gautam Doshi, Advisor, IMTMA, delivered the keynote speeches in Bengaluru and Pune, respectively. Ramesh discussed the importance of knowledge to drive more business, recommending
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M A N A G E M E N T | R O U N D - TA B L E
“Sheer lack of technology and advanced tools has wiped out many companies in the past. Manufacturers should invest in region-specific customer feedback for a better understanding” Ganapathiraman G, Vice President & GM (South and South-East Asia), ARC Advisory Group
everyone to upgrade his own skills & knowledge levels, create collective value and deliver it to customer. “Creativity & innovation is the foundation of success for manufacturers. Competitive knowledge has a competitive advantage, for example, technical knowledge, market knowledge and process knowledge. PLM is all about managing this knowledge. It is extremely important to manage this knowledge and innovate,” he added. On the other hand, Gautam Doshi, Advisor, IMTMA, spoke on the challenges of generating quotations on time, meeting customer demands on time, along with offering precise commitment to delivery. “An appropriate speed & infrastructure are required to address these challenges.” He further stresses on what can be done to make the information-flow better, decisionmaking effective and ultimately bring speed in the operations.
Strategies for efficient manufacturing Industrial machinery manufacturers are constantly challenged to adapt to new circumstances. Many manufacturers find themselves facing an increasing number of new requirements such as demand for more flexible machines that can be rapidly adapted to new products as formats, as well as for machines that can be easily integrated into existing plants. To address these challenges, manufacturers need to create a highly efficient product development and manufacturing environment that fosters continuous and measurable product and process innovations. Jitkar asked the panel to suggest strategies to achieve these tasks in long term. Commenting on the same, Ganapathiraman opined that investments should be made on the latest technologies, be it for machine tool or electronic products manufacturing. “The need of the hour is consistent technology upgradation. Technology is one of the biggest factors driving the Indian manufacturing industry. Also, one of the ways to survive the competition is increasing the volume, which is a major challenge in India. We expect a CAGR growth of 9 to 11% in the economy in the next five years depending on market conditions. With this, technology is all set to take a huge leap in the coming years.” On the other hand, Kelkar opines the importance of being customer oriented. “We don’t have standard products in our company. We develop grinding, polishing and deburring
EM | May 2015
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“The industry should try to focus on innovating products, which are new to the market” S R Chandramauli, DGM - Design & Development (Special Products), Ace Designers
“Modularity, standardisation, cost advantage and building faster machines can bring the required benefits to manufacturing” Raju Sagi, Head - Product Engineering & Development, BFW
machines for various applications. So, we have been more customer-oriented from the beginning. Since we supply to a huge variety of industry sectors, customisation becomes important. Thus, modularisation is vital here. Also, we have created a databank that is easily accessible to the design, sales and marketing people, so that one can select the right module and thus customise and prepare the quotation fast. Preparing quotations should not take time in any company. If the relevant data is made available fast, one can offer customised solutions sooner,” she believes. How to improve the productivity of NPD process, so as to operate faster, deliver better with consistent product quality and minimised lifecycle costs?…..this is the question for every manufacturer today. In this context, Jitkar asked the panelists to brief on the innovative solutions for achieving success in NPD. On this, Chandramauli suggests, “Product development happens under two circumstances: when there is demand and when demand is created. The industry should try to focus on innovating products, to help create demand. To do this, we need to work closely with the user segment and know their requirements. A research on the latest developments on advanced tools is required. We should also focus on the development of high technology consumer products which should be cost effective. All these aspects need to be studied
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R O U N D - TA B L E | M A N A G E M E N T
“The feedback from the service is quite important. Transparency between the supplier and customer helps to plan a cost structure efficiently” Mohini Kelkar, Managing Director, Grind Master Machines
from the customer perspective and mapped down to design specification with a quality function deployment scheme.” He also underlined the importance of testing the products after assembly and development, which is not addressed strictly in the Indian market as compared to other global markets. In case of the Indian machine tool sector, over the years, the industry has witnessed a transition from small to big companies with the development of various products in different sectors. As per Sagi, the Indian machine tool industry has majored in developing standalone machines over the past few decades. “Over the period of time, manufacturers have received an improved feedback for accuracy, reliability and quality of products, while meeting customer requirements. Now, we have reached a stage when we should strategise a series of machines, from small to big, in the same configuration. Any product developed as a series will have a consistency in its quality, productivity, aesthetics and commonality between all the machines. This is one of the areas where we are falling short in India as compared to the global manufacturers. Modularity, standardisation, cost advantage and building faster machines can bring the required benefits to manufacturing” he averred.
“Condition monitoring system is a good solution. It gives an advanced warning to the machine, giving rise to smart machines” Santanoo Medhi, Managing Director & CEO, Premium Transmission
“Successful innovation requires companies to facilitate open innovation, enable collaboration both inside and outside of their organisational borders and instill discipline across their lifecycle processes” Srinath Koppa, Technical Director, Siemens PLM Software
lack of technology and advanced tools has wiped out many companies in the past. Manufacturers should invest in regionspecific customer feedback for a better understanding and then further invest in new technologies and tools”. Towards new product development Moving on, Koppa suggests that the examination of the According to Koppa, to understand the manufacturing innovation process quickly determines the need for process is important. By leveraging technologies such as 3D transformation. “Successful innovation requires companies to technology and product data management, the lifecycle level facilitate open innovation, enable collaboration both inside and can be reduced till the production level is achieved. “For outside of their organisational borders and instill discipline commissioning & servicing, there are ways to optimise the across their lifecycle processes. Siemens PLM Software provides entire process. So, virtual commissioning makes the supplier- a PLM platform, especially designed for industrial machinery customer transparency easy. Even before the person goes to the manufacturers that unify both the product and production commissioning level, it can be already practiced and proven. So, lifecycles,” he said. this shortens the commissioning process at the clients end and no resident engineer is required. For service management, we Product costing & bidding need to predict the parts which can go wrong. Predictive Mostly bidding of industrial machinery includes product maintenance is thus important,” he said. Constant technology innovation and customer demand for and lifecycle cost. The challenges faced by the manufacturers the latest technologies combine to play extra pressure on today’s are how to drastically reduce the time to develop new industrial industrial machinery manufacturers. These pressures require equipment, while ensuring that these machines can operate at manufacturers to add new features in their existing products at close to 100% uptime. Equally important, the basis of a very rapid pace. When Jitkar asked about improvising on competition is shifting towards delivering excellence in service existing products by adding more features, Ganapathiraman and parts management. When Jitkar asked, how to estimate the lifecycle cost said, “In today’s scenario for new product development, manufacturers can’t survive without having proper tools. Sheer accurately, Medhi opined, “If a manufacturer starts with QFD,
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EM | May 2015
PARAMETERS
CONVENTIONAL
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R O U N D - TA B L E | M A N A G E M E N T
“An appropriate speed & manufacturing infrastructure is required to address the current challenges” Gautam Doshi, Advisor, IMTMA
the design mode of failure can be easily found. Given that the machine will be obsolete someday, some module will die earlier, and some later. So, finding out the designed failure mode is important. Accordingly, over the long time, the spare or service parts can be accommodated. For example, for the car manufacturers, every 30,000 km, there are break-pads, and for every 5,000 km, there are air filters. This has come from designed failure mode, and that is how one needs to plan servicing. So, when an operation fails, he has to replace the machine. As such, every 1000 hours, the required parts should be changed. He also believes that through this process, one can estimate the total lifecycle cost, assuming the cycle time. “That is the cost per unit of our machines. One should make sure that the servicing of the machines should be done correctly. Also, the data should be kept updated. So, if it will be 3,000 hours of servicing, one can take out the defective component and it can be increased to 5,000 hours, further reducing the lifecycle cost. But replacing the filter and other parts becomes wastage of information source of knowledge. Manufacturers should take that part back and analyse it how far was it close to failure and then use it for improving the design,” he added. Speaking on the running cost, Kelkar avers, “In our machines, the running cost is much higher than the machine cost. Running cost is really important and if it is more than other machines, then the cost of machines is more than the other machines. So, the equipment cost doesn’t matter. Also, the feedback from the service is quite important. Transparency between the supplier and customer helps to plan a cost structure efficiently. At times, machinery manufacturers try to cut down the cost and figure out a margin. The companies ignoring this important factor face difficulty.” Suggesting a framework for these costs, Koppa opined that there are tools for all these costs, but extrapolating the costs can become a different business model. “Today, even the Indian air force is thinking of buying fighter jets. They are asking to buy 50,000 flying miles rather than buying the product. Thus, the concept of product as a service is an extrapolation. Once the framework is there, one can build the entire lifecycle cost. These are different business modules to push towards scalable growth,” he suggested. On the other hand, Sagi said, “Product cost is determined before the development of the machine. Off late, all MNCs are going into the product life cycle cost. They practice the analysis and knowledge of maintenance cost, running cost, consumable
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“Creativity & innovation is the foundation for becoming a successful manufacturer” T K Ramesh, CEO, Micromatic Machine Tools
“Manufacturers need to create a highly efficient product development and manufacturing environment that fosters continuous and measurable product and process innovations” Shekhar Jitkar, Publisher & Chief Editor, EM
cost, before making an investment. In India, we are yet to follow such practices. We have to get into the estimation of the product lifecycle cost scientifically. Based on the product levels cost per component is to be decided.”
Just-enough machines When asked about the concept of building mission-driven machines that are smarter, more functional and easier to maintain, Ganapathiraman opines, “Smart machines are expected to be the future by enabling the connectivity, directly to Internet of Things. It helps in closed loop PLM. Smarter machines are gaining momentum in Europe. We expect the same in India, where one gets connected to the manufacturers as well as the end user, that aids in a better product lifecycle design. It also helps the OEMs controlling the inventory with the smart machine information.” According to Chandramauli, the concept of smart machines is known as modularity. “How can we make the products modular is the main constraint. From manufacturers’ perspective, this helps in developing the product and ensuring cost effectiveness.” Adding further, Medhi informed that, today, modularisation is done by suppliers. They are adapting parallel processing which can reduce time. “Condition monitoring system is a good solution. It gives an advanced warning to the machine, giving rise to smart machines,” concludes Medhi. ☐ > MORE@CLICK EM01646 | www.efficientmanufacturing.in
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I M A G E C O U RT E S Y: Shutterstock
M A N A G E M E N T | S T R AT E G I E S
IMPACT OF B2C EXPERIENCES ON B2B CUSTOMERS The article details on the tools that will fashion, shape, design and execute superior experiences in B2C to impact on B2B, while addressing the challenges faced by organisations to implement effective business strategies Build a great product, work out a great price, get the right connections into buyers, land up at their factories, demonstrate the product, give the right customer references and you are well on your way to making that sale. Sounds familiar? This is how most organisations that sell to businesses (B2B)
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Anil V Pillai Director Terragni Consulting
think and do business even today. However, times are changing rapidly. The effects of such a change are beginning to manifest. All of the above are indeed important, but the challenge is that everybody has a similar approach. Such a similar approach means that most B2B
EM | May 2015
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M A N A G E M E N T | S T R AT E G I E S
Today, the challenge is to search for that ever elusive competitive advantage beyond price and specifications
vendors are competing on product specifications, price and reach; all fleeting advantages at best and those which can be replicated in the short to medium term.
welding rod vendor is secure in the perception that he has a superior product and is cheaper than competition by 10% and that the buyer is known to him since years.
The TEA experience
Delivering higher profitability
We tend to forget that B2B prospects are not some faceless anonymous departments. Buying decisions are taken by real people whose “thoughts, emotions and actions” (the “TEA” of experience) are shaped by the experiences that they go through, not just with what they encounter at their work, but significantly by the day-to-day experiences that they undergo in their own personal buying as consumers. One can make the argument that this has always been the case, and it would be right. But what has changed now is that while the shaping of superlative experiences is now an absolute imperative in the B2C industry, the B2B industry sadly lags significantly in this respect. A buyer of books on Amazon is impressed by the fact that Amazon remembers his preferences and also by the speed of response of both the buying portal and the delivery as also by the great condition of the books when they are delivered. Now all of a sudden, this buyer is wondering why he cannot get the same experience from his welding rod vendor from whom he has been buying since the last two decades. Meanwhile, the
What would happen if the buyer of welding rods came across a welding rod vendor who offered the same quality but gave an experience across all touch points that was Amazon like? Replace welding rods with CNC, waste heat boilers or gensets. The answers would still be the same. The product centric approach to create superior customer engagement is well past its sell by date. Our extensive experience with helping capital equipment manufacturers create engaged customers that deliver higher than average profitable buying behaviour has consistently demonstrated that increasingly the customers of such capital equipment expect and demand a customer experience that mimics what they as individual consumers undergo in their everyday lives. But, here is an interesting insight. Surprisingly, these customers are unable to explicitly articulate these deep desires when they give the mandatory yearly C-SAT /NPS feedback to their vendors. The result is that the buyers are dissatisfied, but they do not or cannot attribute this to their own enhanced
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expectations that are shaped by their individual consumer experiences. In turn, B2B vendors keep wondering what is it that they are not getting right and thus go back to the same old area, tinkering furiously all over again with the product, price, delivery and at best the packaging and so ironically losing both money and customers in the process! The B2B vendors unfortunately have little wherewithal to capture this customer insight nor compare what they offer as experiences with what a B2C brand offers as an experience.
S T R AT E G I E S | M A N A G E M E N T
This is because traditionally, being product centric, the B2B businesses have never looked at cross pollinating ideas from industries beyond their own and lack the internal expertise to do so. Should a genset manufacturer benchmark the experiences they offer only with other genset manufacturers? Why? If a prospect is looking for information for gensets, why do we think they will wade through the site with its numerous slow links and complex pages to get the information she desires? Remember the unit of measure of site responsiveness is now
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Today, the challenge is to search for that ever elusive competitive advantage beyond price and specifications
benchmarked with an Amazon or a Flipkart and not the competitor genset manufacturers.
Competitive advantage How do you compare? Who are we comparing against? What is our customer comparing us against? What kind of Omni channel presence do we have? What is the customer journey we offer when a customer tries to get a service issue resolved? How different would this journey be, if we benchmarked against the customer journey of a Toyota servicing a car instead of being fixated on bettering my immediate competition? These need to be the question that B2B businesses ask themselves across each customer touch point. It is heartening to note that many of them have just about begun to do so. When the country was an economy where B2B demand was sluggish and customers had very little choice, being excessively product focused was enough to thrive but, today, the challenge is to search for that ever elusive competitive advantage beyond price and specifications. Such a competitive differentiator comes in the form of shaping and creating “Experiences� across the entire buying and consumption journey as a formidable entry barrier. Yes, by all means do benchmark against
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competition when it comes to the product. For all other touch points, choose the best in class as your benchmark. For building an online spares ordering portal, one can use Amazon as the benchmark. For building a dealer network, Maruti can be a template, if so which elements. Getting ready to roll out a customer help line? Can battery manufacturers like Exide provide a benchmark? One should remember these are all organisations that touch the lives of each of the B2B buyers in their individual capacities. If there are ways, one can take the best-in-class and adapt it to the business touch points, resonance and affinity to the brand that is bound to follow.
Conclusion Get ready for what is sure to be a rather exciting journey and equip yourself with the insight and the tools that will fashion, shape, design and execute superior experiences as your competitive barrier against intense competition and margin pressures that is around the corner if not already here. �
> MORE@CLICK EM01647 | www.efficientmanufacturing.in
EM | May 2015
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COMPOSITE MACHINING | FOCUS
Producing economically attractive composite components Carbon fibre reinforced composites are widely used in multiple industries due to its high performance although the cost is higher compared to metals. However, recent advances in composites are driving carbon composites to be more competitive and cost effective. New technological developments in fibre reinforcements, resin systems, and production concepts are continuing to drive the future deployment. This article presents a perspective on how carbon composites are becoming more competitive and cost effective across industries. The influence of various advanced technologies in reducing the cost of carbon composites is also presented. Composites have been widely used across industries like aerospace, wind energy, automotive, industrial, marine, oil and gas. Advanced carbon fibre composites are comparatively more expensive than metals. The choice of composites is a tradeoff between cost and performance. As a result, carbon composites
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Shama Rao N Principal Consultant Infosys
Simha T G A Principal Consultant Infosys
Rao K P Principal Consultant Infosys
Ravi Kumar G V V Senior Principal & Head Advanced Engineering Group Infosys
have made their impact in high performance vehicles, such as jet fighters, spacecraft, racing cars, racing yachts and exotic sports cars. The global composites materials market is about $28 bn in 2014 and is growing at 15-20% per year. This market size will further grow provided the cost of composites is reduced. The
EM | May 2015
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FOCUS | COMPOSITE MACHINING
Figure 1: Cost comparison of materials
cost considered is primarily the composite manufacturing cost. However, for correct assessment entire life cycle cost needs to be considered including maintenance and operation. Composites provide a cost benefit particularly in respect of operation and maintenance which form a sizable percentage of direct operating cost. A typical cost comparison between various materials is shown in Figure 1 and Figure 2 which presents the worldwide market estimates for carbon fibre. Although, the cost of carbon fibres is high, the market for carbon fibre in non-aerospace structures is increasing at a rapid rate as shown in Figure 3. Cost of the product is the major factor prohibiting the wide spread use of carbon composites in industry. The factors that contribute to reduction of cost include reduction in cost of carbon fibre; availability of high performance resins meeting production automation requirements; cost effective product forms; cost effective production methods and automation with repeatable high quality; availability of relevant design and environment data on selected composite systems and highvolume processing. The effort to produce economically attractive composite components has resulted in several innovative manufacturing techniques. It is obvious that improvement in manufacturing technology alone is not enough to overcome the cost hurdle. It is essential that there be an integrated effort of key cost drivers as shown in the figure 4 for composites to become competitive with metals.
Raw materials The Main raw materials of carbon composites are polymeric resins and carbon fibres. Cost of carbon fibre is directly related to the cost and yield of precursor from which it is obtained and cost of conversion. At present carbon fibre is Polyacrylonitrile (PAN) based and its average cost of non-aerospace grade is around $21.5/kg, with a conversion efficiency of only 50%. The following advances are taking place to reduce the cost of carbon fibre: t Development of low cost and high yield precursors for manufacture of commercial (heavy-tow) carbon fibres,
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t
t t t t
Figure 2: Global consumption carbon fibre
which will significantly reduce the carbon fibre cost. Industrial grade fibres are expected to be available at $13.8/ kg by 2017. Figure 3 shows how the cost of carbon fibre is going to get reduced in future, till the year 2020, due to some of these advances in raw materials. Chopped carbon fibre/epoxy prepregs in Sheet Moulding Compound (SMC) form for structural applications with processing times in minutes with 3-D moulding capability that results in dimensionally controlled surfaces on both sides. Development of highly moldable fast cycle prepregs, unidirectionally arrayed chopped strand prepregs. Development of highly reactive resins to reduce cycle time. Combining fibres to create hybrids and weaving forms, reuse of waste fibres by combining and consolidating dry fibres into a mat. Development in preform technology-multiply curved complex preforms such as skin-stringer/frame intersections.
Production technologies Many advanced production technologies are in good state of development. These have potential to reduce the manufacturing and assembly costs while capable of meeting the production volumes of specific industries. Some of them are fast cycle manufacturing techniques; lay-up automation and automation of labour intensive activities; flexible automated composite laying processes; textile processes like braiding (3-D) and preform making and forming processes. A few other technologies include out of autoclave processes like resin transfer moulding and resin infusion technology; utilisation of fluid based pressure/heating/ cooling systems; high speed compression moulding and rapid cure resin technology combined with RTM for fabrics curing in 10 minutes.
Advanced software tools for composite product development Many advanced composite software tools and utilities are now available to automate many engineering processes and to
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COMPOSITE MACHINING | FOCUS
Figure 3: Trends & forecast of carbon fibre
Figure 4: Key drivers for cost reduction
reduce design cycle time. These tools identify feasibility of manufacturing and associated issues upfront during design stage. These advanced software tools are helping to perform many engineering activities concurrently while reducing the design cycle time and engineering cost. Few of these tools include advanced design, analysis and manufacturing simulation software tools and utilities; knowledge based engineering tools; design for part integration and co-cure methods and cost modeling software
carbon and glass; carbon/epoxy SMCs; new and faster curing resins; combination of material forms like chopped fibres with continuous fibres tailored to meet the requirement and stronger and durable adhesives t Design: Advances in CAE; change in mindset of designers and better integration methods with metals. t Manufacturing processes: High speed compression moulding; compression moulding of prepregs; high speed resin transfer moulding; resin spray transfer moulding and reactive injection moulding Marine industry: Carbon composites are considered in selected Industry specific advances in carbon composites areas of marine industry in order to achieve high performance Aerospace industry: Recent advances in aerospace structure are with least weight. Focused efforts are being pursued in the production of carbon fibres from Textile PAN and/or melt spun following areas: generation of design and process data comparable PAN likely (cost reduction by 15% to 20%); dry composite to design data sheets used for steel construction; development of preforms, woven structural braided reinforcements, complex material system and designs; total integration of technologies; textile based architecture associated with out- of- auto clave effective NDT techniques; cost effective and robust production curing such as RTM/Resin infusion and e-beam curing. methods; low cost hull mould concepts in large sized hulls (>100 Availability of high performance fast curing resins to meet meters long) and integrated approach in design, analysis, testing, the out-of- autoclave production processes; Automated Dry fabrication and assembly techniques. Material Placement (ADMP) - A newer approach to cut and Oil and gas industry: Carbon fibre composites are recognised as place ply patterns in one operation eliminating pick up and an enabling technology in deep-water and ultra-deep-water placement approach; CNC controlled contour tape laying/fibre (1500 m – 3000 m) drilling scenarios. Many developments in placement machines with high deposition rates. Manufacturing areas of design, manufacturing, NDT have taken place. Some of of large parts through Vacuum-Assisted Process (VAP) and the recent advances are a number of standards for design, combined infusion of the different parts (skin and stringers), manufacture and testing. Installation and maintenance were avoiding thousands of rivets and secondary operations; on-line issued by European committee of standardisation. Cost effective quality control during manufacturing process and designing routes for manufacture of load bearing composites (main vertical with heavy tows of uni-directional materials without and deck elements); alternate designs, for example, in the deck compromising properties. design, instead of sandwich construction a linked assembly of Automotive industry: Recent advances in different areas of pultruded cellular elements construction to achieve the necessary composites in automotive industry can be summarised into: degree of stiffness. Developments in low cost manufacturing t Raw materials: Technological advances in the area of low- processes, like pultrusion of deep box beam section with fibres in cost fibre precursors such as, cheaper polymers, inexpensive different orientations; development of resin infusion moulding textiles, low-quality plant fibres or renewable natural fibres processes for very large components with high quality and to meet auto requirements in terms of properties and novel reduction in carbon fibre costs using cheaper precursors and carbonisation techniques to produce useful, uniform fibre better conversion technologies. properties at low cost. Rail industry: In order to meet the demands of high speed rail t Materials and forms: Multi-material system and hybrids- industry prototype, vehicles are built using carbon composites.
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COMPOSITE MACHINING | FOCUS
Figure 5: Influence of production volume on various cost line items
Figure 6: Influence of production volume on overall cost
Recent advances in this area include standardisation of fire safety For example, Figure 6 provides information on how increase regulations and issuance of harmonised standards for fire, smoke in production volume reduces the product cost. In addition, the and toxicity (FST) requirements; reduction in cycle time for following technological improvements contribute significantly development and validation of non-linear FE models for to reduce the cost: composites; training of engineers on composites; cost effective t Availability of low cost commercial carbon fibres from cheaper precursors manufacturing techniques for industrial reproducibility at cost levels comparable to steel and generation of approved t Aero grade fibre from textile PAN/melt spun/PAN t Carbon/Epoxy chopped prepregs in SMC form performance requirements. Wind energy: Turbines blades are increasingly large to be cost t Textile processing, 3D/2D. All these technologies are in advanced stage of technology effective which necessitates the use of carbon fibres. Recent advances include development of an integrated approach, demonstration and are expected to be production ready in few combining processes, and material and design innovations. The years from now. These are likely to reduce the material cost by areas of advances include: multi-axial, multilayered matte/wove/ 15% to 30% and the manufacturing cost by another 15% to 20%. UD reinforcements; advanced pre-pregs to produce thick sections Considering these, a cost estimate in the current year and in of good quality eliminating the need for compaction; development 2020 is made for a medium sized structural carbon/epoxy of new core materials that are pre-preg compatible, suitable for component with same mechanical performance. resin infusion with low resin absorption characteristics & higher thermal stability; epoxy resin reinforced with carbon nanotubes Conclusion resulting in half the weight of fibre glass blade; special Carbon fibre reinforced composites (CFC) are becoming thermoplastic coatings with enhanced durability and sophisticated measurement, inspection, testing and quality competitive and cost effective compared to metals. At the current rates, CFC components are costlier compared to metal assurance tools components. Many advances in raw materials, manufacturing technologies, assembly techniques are influencing directly the Cost analysis cost of composites design & development. These advanced The manufacturing cost of a composite product is highly technologies will help reducing the cost of composites dependent on manufacturing process. For example, a stiffened substantially which will spur the demand for composites panel can be manufactured by autoclave process, resin transfer exponentially in coming years. Composites design, analysis, moulding or compression moulding. The major cost drivers are manufacturing tools will help in reducing the engineering cycle raw material, tooling, labour and equipment. Costs of these vary time, reduce costs and improve the quality while maintaining with the chosen process of manufacture and on volume of repeatability of parts being manufactured. This paper presents production. Figure 5 gives cost of the above parameters in briefly various advances in raw materials, manufacturing percentage of total cost for a typical hand layup process for processes and software tools which will eventually drive down aerospace parts and various production volumes. As seen, the the cost per kg of CFC in industry sectors such as aerospace, cost of raw material plays an important role in high volume marine, railway and oil and natural gas. � production. Production volume is a major factor in reducing the > MORE@CLICK EM01648 | www.efficientmanufacturing.in cost of the component.
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POWER PRESSES | TECHNOLOGY
Implementing proficient trouble-shooting The article discusses the different press elements, their function, accuracy parameters, as well as checking & preventive maintenance for an efficient trouble-shooting Most engineering industries need sheet metal components. Sheet metal components are formed or drawn on presses. Press shop is a very important division in auto industries and presses are needed in many manufacturing units, right from wrist watch manufacturing industry to automobile industry. Quality & quantity of pressed components largely depend on selection of right type of press. If care is not taken while selecting presses, time is wasted in trouble-shooting & maintenance. The staff engaged in selection, erection, operation and maintenance of presses must have a thorough knowledge of presses. As far as, trouble-shooting and maintenance is concerned, the approach in this article is not conventional, i.e. list some of troubles and give solutions that is always available in machine
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Anil A Gupte Industrial Adviser anilgupte64@rediffmail.com
catalogues. Unique and variety of problems are faced from industry to industry. So, effort has been made here to explain different press elements, their function, accuracy parameters, checking, preventive maintenance etc, so that maintenance staff should be able to troubleshoot themselves.
Mechanical press Advantages of mechanical presses include fast speed of 25 strokes/min for high productivity and less power consumption due to fly wheel i.e. 1/3rd of hydraulic press. The disadvantages are that the power varies with stroke position due to crank mechanism, power curve is sinusoidal. Also, maximum power
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TECHNOLOGY | POWER PRESSES
The sketch explains how many transmission elements are involved in slide adjustment system
is developed just 12 to 15 mm before BDC. Why tonnage capacity of the press increases as it approaches BDC can be explained this way: The energy transmitted to ram from crank is fixed for particular tonnage press. The energy is always expressed in units like K-joules, Kg-m, T-m, etc. As press approaches BDC, the linear distance travelled by ram reduces for same crank angle, energy being constant, the tonnage increases.
Hydraulic presses In a hydraulic press, full power is available throughout the stroke and is most suitable for deep drawing and critical draw operation. The proportion of mechanical presses to hydraulic presses in any press shop is generally 10:2. In mechanical presses, there are two types: single action & double action. Most presses nowadays are single action because blank holding in deep drawing is achieved by cushion also. Presses available with servo cushion further facilitates the operation of deep drawing. The link drive press is generally employed for draw operation and it is always the head press in press line. In link drive press, by mechanical linkage, the speed of ram is reduced as it approaches BDC to nearly 0.5 m/sec, which is the ideal speed for drawing operation. Two point press is the one where two cranks connect to the ram. Generally, presses having ram up to size 3x1.6 m are two points. Above this size, the presses are four points. Four-point presses give better parallelism as compared to two-point presses. The main advantage of hydraulic press as indicated above is it develops full tonnage (or set tonnage) as it comes across resistance. Its tonnage does not vary as per stroke position.
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They are, therefore, very useful for deep drawing operation & critical components. The maintenance crew always faces problem of parallelism of mechanical presses. The slide or ram is required to be adjusted up or down as per die height. To achieve this, ram is given drive by rotating nut in crank screw. The sketch above explains how many transmission elements are involved in slide adjustment system. If one of the points does not get proper drive due wearing out of one of the transmission elements, the parallelism gets disturbed. Generally, wearing of key ways, gears, threading of nut, etc affect the parallelism.
Press accuracies Maintaining press accuracies is one of the prime functions of maintenance department. Different accuracies are required to be checked and set within tolerances periodically at least once in two months as tabulated below: Moving bolsters: For better productivity, selection of moving bolsters and their configuration is important. Moving bolsters primarily help in reducing die setting time and releasing more time for stroke making. While purchasing the press, one has to ensure that it is with moving bolster. Moving bolster always facilitates for loading and unloading of dies by crane. Moving bolster configuration is either front-back or sidewise. Sidewise is better as it allows less gap between two presses. Less gap between presses helps in installing automation for loadingunloading. Clutch & brake: This element is of vital importance in mechanical presses. The drive from main motor is transmitted to the crank via clutch and brake unit. Proper selection of clutch
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POWER PRESSES | TECHNOLOGY
Different accuracies are required to be checked and set within tolerances periodically at least once in two months
and brake while buying the press is most important. Belts: The main drive is generally provided with V-belts, but many old presses are with flat belts. Flat belts have distinct advantage that they slip when ram is overloaded and this avoids breakage or jamming. The drive from crank to bolster is connected to ram by pressurised hydraulic pad. High pressure of the range 90 kg/sq cm to 150 kg/cm is maintained depending on tonnage required. If due to wrong setting press is overloaded, the hydraulic pressure in the pad increases, which actuates limit switch and press stops protecting against damage to any mechanical element. A small air actuated hydraulic pump is used to maintain pressure in hydraulic pad. This air pump gives many problems and one of the reasons for breakdowns of presses. Rotary pump with pressure switch and accumulator can be used in place of air pump which is relatively simple to maintain. Counter balance cylinders: Crank has to move weight of ram and die. To reduce load on drive motor, this weight is reduced by providing pneumatic counter balance cylinders. The main trouble that is experienced with counter balance cylinders is the breakage of counter balance rod, cylinder cover or connecting bracket. This happens due to the failure of slide adjustment end limit switches. When slide adjustment goes beyond limit, crank tries to move slide more than stroke of counter balance cylinder. The piston rests on end cover of the cylinder, when ram tries to move further, pressure is exerted on the cover and weakest element breaks.
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Cushion: Mechanical presses are generally provided with pneumatic cushion. The ram generally starts pressing down the cushion at 90° of crank angle when force of ram is 15 to 20% of full tonnage, so generally cushions are rated 20% of full tonnage of the press. Hydraulic cylinder is used as damping cylinder with pneumatic cushion cylinder to make return stroke of cushion smooth (vibration and shock free) when ram pressure on cushion is released during start of up movement of ram. The function of the draw cushion is to hold the blank during deep drawing operation, cushion prevents the formation of wrinkles. It also does ejection function, raises the parts to the transport level during the return motion of the slide. Cushions are either pneumatically or hydraulically operated. Majority of cushions are pneumatically operated. The cushions are incorporated with one or more cylinders. The problems faced with cushion are disturbed parallelism of cushion pad, cylinders becoming loose on frame mounting, seal or o-ring breakage, etc. Periodical preventive maintenance and check reduces the problem.
Preventive maintenance Preventive maintenance has to be carried out weekly, monthly and quarterly basis. Right type of tools and equipments are required for proper maintenance. For example, a moving trolley helps for carrying out work at height safely and efficiently. � > MORE@CLICK EM01649 | www.efficientmanufacturing.in
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I N D U S T R I A L PA R T S C L E A N I N G | T E C H N O L O G Y
Ensuring quality with optimised use of resources Cleaning has become an indispensable link in the production chain in component manufacturing. The quality and efficiency of this process are critically dependent on the choice of the right cleaning medium and process technology. This article details on the latest developments in industrial parts cleaning and how it has evolved into a key quality and value-adding factor in manufacturing. 60
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T E C H N O L O G Y | I N D U S T R I A L PA R T S C L E A N I N G
Wet chemical processes can accomplish virtually any cleaning task in the metal processing industry. The right choice of the cleaning medium and technology are key to an efficient process.
Parts inevitably get dirty during manufacturing and machining. In downstream processing machining and polishing aid residue, metal chips, burrs and abraded particles normally become a problem. Such contaminants may impair the quality, functionality and service life of finished products. Industrial part cleaning has become a key quality and value-adding factor in manufacturing.
Wet chemical cleaning Wet chemical processes can achieve almost every cleaning objective in many industries. The effectiveness of the chosen method and the quality, cost-efficiency and stability of the cleaning process are critically dependent on the dissolving capacity of the cleaning agent employed. Both aqueous detergents and solvents are commonly used. Solvents are distinguished in chlorinated, non-halogenated hydrocarbons and polar solvents. In selecting the right cleaning medium, the “like dissolves like” principle of chemistry applies. For removing mineral oil-based (non-polar) contaminants (machining oils, greases and waxes) a solvent is commonly the preferred cleaning agent. For water-based (polar) contaminations (coolant and lubricant emulsions, polishing pastes, additives, salts, abraded particles) aqueous cleaning agents are typically employed. Material compatibility and achievable results should be tested by cleaning trials. Aqueous processes should be subjected to
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regular process monitoring, with control of key parameters like detergent concentration, temperature, rinse water quality and filter condition to ensure consistent cleaning performance. Polar solvents and modified alcohols combine the benefits of aqueous and solvent cleaning, given their balanced grease and water solubility. Dürr Ecoclean‘s extensive portfolio includes machines for all kinds of cleaning fluids. In terms of dimensioning, process technology, fluid treatment and drying performance, these systems are adaptable to any cleanliness specification, throughput and part geometry. For an optimum process matching the company conducts cleaning trials at its own Test Centre in Pune.
Solvent-based cleaning To facilitate handling and fluid treatment in machining operations, the trend is to rely on cooling and lubricating oils. The choice of the ideal cleaning agent is not merely a function of the specific machining process but also depends on subsequent operations (e.g. grinding). Where this involves water-based emulsions, the main contamination type adhering to the parts is relevant and the cleaning agent must be matched to it. Punching and deep-drawing processes are often carried out with the aid of chlorinated oils followed by aqueous cleaning. This often leads to less-than-optimum cleaning results and
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I N D U S T R I A L PA R T S C L E A N I N G | T E C H N O L O G Y
In removing polar contamination such as salts, emulsions, polishing pastes and abraded particles, water-based systems operate very cost-efficiently. The Universal 81W manufactured in India covers a broad range of cleaning applications
high costs since the oil carried-in by the parts calls for frequent changes of the cleaning and rinsing fluids. For such applications, the use of chlorinated hydrocarbons is recommendable. The use of solvents is likewise recommended in the case of hardening processes where large quantities of oil remain present after quenching. Compared to aqueous methods, a solvent-based system offers advantages in terms of cleanliness, fluid lifetime and fluid treatment. This also applies where grease-free surfaces are required to optimise quality in downstream processes (coating, brazing or welding).
corrosion. Solvent systems are a reliable, low-cost alternative here. The solvent is mixed with a standard commercial (solventfree) concentrated preservation and applied to the part after cleaning. Thereafter, the solvent employed is returned into the process.
Energy and resource efficiency
From an environmental viewpoint, solvent cleaning does not enjoy the best of reputations. Such concerns were not unfounded with regard to open cleaning systems used in the past. They promoted the changeover to water-based cleaning Aqueous cleaning wherever oil carryover was involved. Specifications to this Apart from its ability to remove polar contamination, effect are still in place in some industries. This has remained aqueous cleaning processes hold some aces if parts are to be true irrespective of the benefits a solvent system would provide. phosphatized or activated as well. Likewise, aqueous media are Today, solvents are employed in closed circuits ensuring a safe preferred when removing rust or cleaning after thermal and ecological operation under vacuum. An integrated deburring or nitriding. Cleaning may be carried out in single or distillation train continuously reconditions the solvent ensuring multi-chamber systems. Another application is fine and ultra- a long solvent life and low consumption. Dürr Ecoclean fine cleaning to very high cleanliness standards (e.g. hydraulic machines feature heat recovery systems for reclaiming the system parts, before PVD/CVD coating of machine tools, thermal energy associated with distillation. These can provide indexable inserts). up to 50% cuts in energy consumption compared to conventional systems. If the water consumption, contaminated waste flows disposal and frequently inferior cleaning quality are taken into Corrosion protection account, solvent cleaning will prove not only a less costly but Parts often travel thousands of kilometers before reaching also a “greener” alternative in many cases. ☐ > MORE@CLICK EM01650 | www.efficientmanufacturing.in their point of use. Accordingly, they must be protected from
Dürr Ecoclean India A Division of Schenck RoTec India Ltd. 198/1 Genesis Building, Fourth Floor Dhole Patil Road, Pune 411 001
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Sales Contact: Phone: +9120 30585002-04 E-Mail: info.india@ecoclean.durr.com www.durr-ecoclean.com
EM | May 2015
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Industrial Automation Solutions
Achieving more flexible machine setting with complete electric motor / axis solutions Maximum productivity demands faster machine changeovers, quickly and repeatable. A complete, matched solution with simple control interfaces and superb set-up and diagnostics. For information on our complete range of innovative electric drives - contact us today!
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Festo Controls Pvt. ltd 237%, Bommasandra Industrial Area, %DQJDORUH +RVXU +LJKZD\ Bangalore 5 0099. 7ROO )UHH QR )D[ Web site: www.festo.in
5/15/2015 6:42:20 PM
WELDING | TECHNOLOGY
Investing in welding system Investing in a welding system may be a more expensive choice upfront, but in many cases, it can end up costing less in the long term. This article discusses the advantages of investing in a welding system and the benefits such systems offer for welding operators to help improve arc performance and overall productivity.
Mike Vandenberg Product Manager Miller Electric Mfg Co
Quality results and high productivity are important in every welding application. What many companies may not consider, however, is that the weakest part of a welding system is actually what determines its performance. If the welding gun, feeder or power source is performing poorly, for example, the resulting welds will also likely be poor. For this reason, it is important to have a welding system in which all the components are engineered to work together. Having parts that complement one another can help improve arc performance and overall productivity, while also reducing quality issues and minimising downtime. Such welding systems are available for many specific applications, including welding aluminium and/or pipe, to name just a couple.
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The importance of welding systems For many applications, welding systems can offer significant performance benefits. Designed systems offer compatible amperage and duty cycles—two of the most important considerations for achieving good weld quality and productivity. These systems also are scaled properly to each other to ensure their features provide the greatest advantage. These include preventing potential problems like poor arc performance or wire feeding issues, both of which can occur when piecing together equipment which is not specifically designed for compatibility. For example, when using a smart feeder that allows multiple parameter settings, communication signals must go back and
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TECHNOLOGY | WELDING
TECHNOLOGY | WELDING
forth between the feeder and the power source to make all of those features and functions work. Having a system designed with components that work together can provide synergic control benefits for which the system is intended. That may not be possible when using a wire feeder that has not been matched for a given power source. Similarly, if a welding operator uses a set of weld cables that are too small or undersized to work with a certain system or application, those weld cables may end up overheating or cause a voltage drop, which can greatly affect arc performance, especially when Pulse MIG welding. Using a welding system can also make regular service and maintenance easier from a troubleshooting standpoint. Technicians will know better what problems to look for and can often pinpoint issues more quickly with a performance-matched system compared to components that are not matched.
Welding systems available to meet various needs When selecting a welding system, there are many different types suitable for various applications and needs. A full welding system typically includes a power source, a wire feeder (for a Flux-Cored or MIG process) and a gun for MIG welding or torch for TIG welding. In some cases, the filler metal may also be included or recommended to improve performance on a given application. Welding systems are typically matched together based on the manufacturer’s knowledge of how their features will mesh and on how they can help minimise known welding operator challenges in the industry. Often at times, manufacturers design systems around a specific outcome, such as improving productivity, reducing downtime, completing welds faster or reducing burn-through on certain materials. More specifically, a welding system could offer processes for welding aluminium without burn-through or distortion, or provide processes for welding the root pass in a pipe joint.
Advantages One of the biggest benefits of a matched welding system is
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WELDING | TECHNOLOGY
Aluminium Welding System : Among the biggest benefits offered by using a matched welding system is ease of setup
the ease of setup. Welding operators can often be up and running within minutes — especially when using a system designed to be “plug and play”— versus taking hours or days to make unmatched components work together. Once running, welding systems are designed, in many cases, to offer synergic controls and a simplified interface design. When the components are specifically matched to work together, arc performance can also often be maximised through advanced processes or advanced features, such as Pulsed MIG welding. These performance benefits can be especially important in robotic welding. Features and functions can be lost in these applications — with larger financial consequences— if the feeder and the power source, for example, are not communicating properly with the robot. Robotic welding systems are also built to incorporate certain safety standards, which can make them a safer option than robotic systems that are put together piecemeal. To ensure all of the pieces are working optimally together in a robotic system, it is helpful to work with a reputable systems integrator who fully understands the system components.
feeder is most appropriate. These feeders typically have more powerful motors, are capable of running larger wire types and have more features than a less costly, smaller feeder. It is important to note that these feeders may cost more upfront, but they will generally pay for themselves in the long term. Along with the right feeder requirements, amperage and duty cycle capabilities are also key considerations. Be sure that the power source and gun offer the right duty cycles and amperage for the job, and that they are compatible in terms of their amperage capacity. Portability of the wire feeder might also be another important consideration, depending on the application. Next, it’s important to match the interconnecting cables to ensure they are compatible with the available features of the wire feeder and power source. Some systems are digital and others are analog; the interconnecting cable should be matched to the appropriate system type. This task may require assistance from the manufacturer or distributor during the selection process.
Key considerations for matching components
Investing in a welding system may be a more expensive choice upfront, but in many cases, it can end up costing less in the long term by eliminating downtime, improving quality and preventing lost productivity. Manufacturers research and design welding systems to work together to enhance equipment features, increase productivity and make them easier to use. For questions about the potential benefits of welding systems or assistance in selecting the right one for a given application, remember to consult with a trusted welding distributor or equipment manufacturer. ☐
In situations where companies or welding operators want or need to match off-the-shelf components rather than buying a welding system, there are a few tips to keep in mind. First, it’s always a good idea to consult a trusted distributor or equipment manufacturer when making the selections. It is important, too, to consider the various types of wire feeders available and choose one that’s most appropriate for the application or future applications. For example, if the job calls for eight hours of welding day after day, an industrial type wire
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Conclusion
> MORE@CLICK EM01651 | www.efficientmanufacturing.in
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Route tightly. New: Triflex速 RS
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plastics for longer life igus 速 (India) Pvt. Ltd. 36/1, Sy. No. 17/3 Euro School Road FORM-5.indd 4
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Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura, Bangalore -560048, Karnataka, India
Phone Fax
+91-80-45 12 78-00 +91-80-45 12 78-02
5/15/2015 7:21:28 PM
M A N U FA C T U R I N G I T | T E C H N O L O G Y
Embracing faster innovation to adapt to new realities The article highlights the emerging trends in the automotive industry that are causing a fundamental change in vehicle technologies which requires more innovation from automakers and suppliers in alternative propulsion, lighter vehicles and energy optimisation.
Jizheng Zhao Marketing Manager Asia Pacific Siemens PLM Software
The automotive industry faces stricter fuel economy and electronics and embedded software to keep up with an ever emissions standards around the world, with varying deadlines growing industry. These trends are causing a fundamental for achievement through 2025. These fuel economy and change in vehicle technologies which requires more innovation emissions standards, along with improvements to safety, from automakers and suppliers in alternative propulsion, growth of intelligent mobility and customer desires for lighter vehicles and energy optimisation. integrating their lifestyle into the vehicle, have automotive A 2014 Centre for Automotive Research report, entitled original equipment manufacturers (OEMs) relying more on Advanced Information Technology Solutions: An engine of
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
innovation summarises this sentiment by saying: “The industry is transitioning from a primarily mechanical-based industry to a software-based industry. In fact, some would argue that the industry is transitioning from a transportation focus to a technology focus.” Adopting these new technologies and product innovations drives more interaction across vehicle systems and components. As the complexity of vehicle systems increases with new types of technology, these innovations demand a fundamental increase in the sophistication of automotive systems. Suppliers must integrate mechanical, electronics and software capabilities
as well as system development knowledge to deliver more complex systems. That, coupled with the global growth of the industry, increases the pressure on automotive suppliers to expand their own engineering, manufacturing and supply chain networks around the world, which adds to program and operational complexity.
Staying in front In Asia, suppliers are facing pressure on two fronts - the need to respond to their local market and OEM quickly, because Advt
THE INDUSTRIAL LUBRICANTS DIVISION OF THE GROUP METAL WORKING FLUIDS SPECIALTY LUBRICANTS MAINTENANCE LUBRICANTS HIGH PRESSURE DIE CASTING QUENCHING FLUIDS
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Atlantic Lubricants & Specialities Pvt. Ltd. 301, Ketan Apts., 233, R.B. Mehta Marg Ghatkopar East, Mumbai 400 077 Tel: + 91 22 2501 1960/2501 1961 Fax: + 91 22 2501 1928
Motul 119, boulevard Félix Faure 93300 Aubervilliers - France Tél.: +33.1.48.11.70.30 69 Fax.: +33.1.48.11.70.38
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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
Suppliers must integrate mechanical, electronics and software capabilities as well as system development knowledge to deliver more complex systems
Asia continues to be the growth engine for the automotive tools and fixtures. industry, and, as the part of the supply chain, they need to t Integrated validation of manufacturing to optimise process productivity and efficiency to improve costs, quality and collaborate with global OEMs more efficiently and contribute flexibility in manufacturing while taking advantage of more actively than before. new innovations and platforms. For automotive suppliers to realise more profitable innovation, they need to achieve greater success in our t Integrated program planning and costing for predictable program performance and profitability to collaborate dynamically changing industry through a balance of traditional effectively in all stages of a program and achieve greater and technology-driven products, and the connected consumer visibility and transparency in program execution. lifecycle-centric and service-driven future. They need to execute program innovation through optimising design and improving validation in the early development process to Facilitating a enable cross-discipline development in a unified environment. dynamic environment This in turn will allow these suppliers to quickly adapt to a changing global structure and improve visibility to program Automotive suppliers are required to demonstrate and provide increased responsibility for the design, development, execution and risk management. In order to capitalise on the pressure for greater innovation, prototyping and final production of parts and systems. Today, suppliers should adopt a model-driven program to provide they are asked to do more project management with extensive early and comprehensive simulation and validation, fast and coordination, sourcing and qualifications, all at lower costs. efficient design creation, integrated manufacturing validation Suppliers need to demonstrate their ability to perform all these and predictable program performance and profitability. To tasks on time, on budget and with high-quality successful ensure success, the following key focus areas should be launches bearing in mind diversity, remote plant locations and multiple customers. considered part of the overall solution: t Comprehensive development of systems through modelAs a result, there is a great need for a standardised, driven simulation and validation, including integrated simplified process that will work across all product lines and controls simulation, and 1D and 3D simulation to enhance ensure that operations are profitable. Meeting these needs for a supplier’s ability to virtually model and validate the faster innovation combined with greater program control and performance and behaviour of the systems before physical risk management requires adoption of a model-driven prototypes are developed. approach to program execution. Suppliers who do not t Fast and efficient design creation through an integrated adequately adapt to these changes, will find themselves solution with an open and flexible modeling and design struggling for survival, while those that capitalise on the approach to reduce development time, capture greater innovation pressure to bring to market new technologies organisational knowledge and best practices, and increase and products while improving overall program visibility, the capacity to effectively integrate product design and control and risk management will carry the day. � > MORE@CLICK EM01652 | www.efficientmanufacturing.in validation with the manufacturing engineering of molds,
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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
Optimising Induction Heating Predicting the electromagnetic, thermal, and metallurgic phenomena that come into play during the induction heating process is challenging. The application story describes how Tata Steel is using COMSOL Multiphysics simulation to explore methods to optimise induction heating during the manufacturing of steel wire. In the steel industry, induction heating is quickly becoming a widely used technique for manufacturing a variety of metal products including blooms, billets, slabs, and many types of cables, wires, and ropes. This process offers faster and more precise heating control, uses less energy, and is more environmentally friendly than many other heating methods. Additionally, there is a decreased labour cost, the equipment is easy to maintain, and it offers better quality assurance and reliability. However, predicting the electromagnetic, thermal, and metallurgic phenomena that come into play during the heating
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process is challenging. Using multiphysics simulation software, Tata Steel, one of the top ten steel companies worldwide, is exploring ways to optimise induction heating techniques in order to improve the quality of the final product, as well as to increase the energy efficiency and cost effectiveness of their production processes.
Simulating induction heating of steel wires Ishant Jain, Research and Design Engineer at Tata Steel, has used COMSOL Multiphysics速 to simulate the induction
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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
Simulation result show the current density norm distribution (skin effect) captured by a tetrahedral (left) and boundary layer mesh (right), respectively
heating of Tata’s high carbon wire rods, strands, and ropes. mechanical properties for a particular application can be “Numerical simulations of temperature distribution are highly achieved.” beneficial for designing induction heating systems,” says Jain. “Choosing the correct shape and distribution of the heating Skin effect and furnace design coil and adjusting the electric current can greatly affect the In order to ensure that the correct heating is achieved quality of the manufactured product, and simulation can help to optimise this process to achieve the highest-quality results.” within the wire, only a small temperature gradient between the Jain has developed a model of Tata’s furnace system for surface of the wire and the wire’s center is permitted. However, producing structural rope, a wire that consists of six carbon this is complicated by a phenomenon known as the skin effect. wires helically spun around a steel core. These ropes are Alternating currents tend to be unequally distributed within a manufactured from individual wires, which are made by conductor so that the current density is highest near the surface of the conductor, and decreases closer to the center. drawing the end of a rolled rod through a tapered hole. “In order to stabilise deformation and elongation while the “Understanding how the skin effect influences heating within wires are in use, ropes and strands are typically pre-loaded to the wire was one of our key areas of study,” says Jain. In the manufacturing of the structural rope with a radius of about 55% of their breaking strength to increase the ultimate tensile strength (UTS) of the wire,” says Jain. “After pre-loading 6 mm, the skin depth is predicted to be about 0.03 mm. “We is complete, deformation becomes linear and predictable, wanted to implement a computationally efficient simulation that would allow us to visualise the induced current profile allowing the wires to be used for construction purposes.” This is achieved by stretching and heating the wire while over the surface of the wire while also letting us quickly obtain passing it through a coil carrying alternating current. The answers and easily revisit and modify our design,” describes magnitude of the alternating current and the distribution of Jain. “A typical tetrahedral mesh wouldn’t have allowed us to the induced magnetic field inside the wire can be used to investigate what happens at skin depth without increasing the precisely and accurately control the temperature of the wire as mesh density significantly. Instead, we implemented boundary layer meshing, which helped us to refine the calculation while it passes through the furnace. One of the aspects that make modeling this process so keeping the model at a reasonable size.” Once the mesh was refined, the furnace could then be challenging is the extreme changes that occur in the temperature of the heated material. “The temperature changes within the modeled in full. “We modeled the complete furnace as a 2D wire are so drastic that we had to implement non-linear axisymmetric model, with the helical structural rope temperature-dependent material properties in order to represented as a cylinder having the same power consumption accurately model the system,” says Jain. “By developing this per unit volume,” describes Jain. “This approach reduced the model, we want to verify that under the current operating complexity of the simulation and allowed us to model the conditions, we are heating the wire correctly in order to achieve variation in the wire’s surface temperature along the entire the desired mechanical properties. Additionally, we are looking length of the furnace.” The model was validated against to optimise the operating parameters of the furnace for the experimental results from an in-house developed pilot line production of different types of wires so that the desired furnace, and showed good agreement.
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T E C H N O L O G Y | M A N U FA C T U R I N G I T
T E C H N O L O G Y | M A N U FA C T U R I N G I T
Currently, the induction heating furnace at Tata Steel contains 104 coils, with areas of tighter and looser coil density. Jain’s current work is to understand how the different coil winding densities or cross-sectional areas can affect the heating of the wire. “The furnace is divided into areas where the coil windings are dense and areas where the coil windings are spread apart in order to ensure that the temperature in the centre of the coil increases along with the surface temperature,” explains Jain. “Using our model, we can determine if the furnace is designed according to a coil configuration specifically optimised for constructing structural rope, and eventually optimise the furnace parameters for the production of all different types of products.”
The future of induction heating techniques Tata Steel is constantly improving their range of products in order to meet industry demands such as lighter, stronger components for the automobile industry, and wire ropes for the oil and gas industry that can withstand harsher environments. “Simulation allows us to stay on top of market demands and ensures that we are continuously delivering high-performance products to our customers,” says Jain. Using the model produced in this study, Tata Steel will continue to deliver on this mission by manufacturing higher quality products at lower costs and with improved energy efficiency. “In the past, simulation was a sort of black box that we couldn’t adapt to our design needs,” describes Jain. “One of the unique features of COMSOL is that we can implement boundary conditions, material properties, and study parameters based on our requirements. Using the results obtained in this preliminary study will help us to further improve the products that we deliver to our customers.” ☐ Courtesy: COMSOL Inc > MORE@CLICK EM01653 | www.efficientmanufacturing.in
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COOLANTS & LUBRICANTS | TECHNOLOGY
Analysing bio-resistance system The concentration of any product is dependent upon the type of product and test methods employed. The part two series of the article details on the methods of monitoring concentration leading to higher customer satisfaction Screening tests are necessary to determine the efficacy of different bio packages designed for a product. Typically, a bioresistance test is conducted over an eight-week period and is designed to simulate field conditions as closely as possible. Each week, inoculations of the diluted metalworking fluid with high doses of microorganisms are made. The goal is to have no growth in any of the three microbial types-bacteria, fungi/yeast and mycobacteria during the eight-week period. Sometimes, a small growth may occur, which is often killed off in the following week. The drawbacks of these tests are that it is impossible to simulate plant conditions exactly. They don’t account for issues such as swarf, tramp oil, other contaminants or product chemical changes that will eventually occur over time. Therefore, while a “clean” eight-week bio-resistance test is useful, it may not go far enough to predict bio-stability in the actual plant environment. To give the customer more confidence, a multi-week plant test of the product can be carried out, in an actual metalworking system monitoring bacteria, fungi and mycobacteria weekly.
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Predicting bio-stability Bio-stable products are designed to work within certain parameters. Outside these limits, the product cannot be guaranteed to maintain its bio-stability. Carefully monitoring system pH and concentration to remain within recommended parameters is required. Consistent additions of fresh product on a routine basis are necessary to maintain proper levels of each functional ingredient. Controlling contamination through best practice protocols within the plant is essential. Customers today are stretching the limits of metalworking fluid life. Over the lifetime of a system, metalworking fluids change-via depletion and degradation mechanisms. Parameters such as contamination, changes in ionic strength, evaporation and volatilisation also change the fluid. Predicting ingredient depletion and degradation is not an easy task and requires sophisticated analytical testing. The change in a fluid over time means that after two or three years of use, changes in maintenance procedures will be needed to maintain bio-stability.
EM | May 2015
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A DVERTO R IA L
ESPRIT CAM Fulfills a Growing Need for Powerful CAM Software in India
DP Technology, creator of ESPRIT® computer-aidedmanufacturing software, has increased its ability to support diverse manufacturing demands throughout India. Specifically, the DP Technology team, which now serves more than 300 customers throughout the country, has seen a significant increase in the number of manufacturers who require a powerful CAM system in the disciplines of Swiss-style and multi-tasking machining. DP Technology supports a successful group of wire EDM customers, such Michelin, Escorts India, and Crompton Greaves. ESPRIT provides a universal EDM contouring cycle to machine any contoured mould, die, core, cavity, shape or profile. This versatile machining cycle supports any number of straight or tapered rough and skim cuts while optimising wire cutting paths. Strategies for all styles of EDM machining such as punch, die, multi-cavity parts, and unattended machining are included. Between cuts ESPRIT automatically handles all the necessary wire-cut and wire-thread instructions, and part-handling functions of the machine: flushing, tank fill, and tank drain. Like the rest of the world, India has the multi-tasking machine tool market grow as manufacturers strive to remain competitive while manufacturing increasingly complex parts. “Despite a recent slowdown in the Indian economy we see bright spots in manufacturers taking the time to implement more efficient manufacturing solutions. At the core of this is ESPRIT and its ability to provide the backbone for digital
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manufacturing pipeline solutions. We expect our sales growth to top 30% annually for the next several years,” says Mike Lauer , GM — Asia DP Technology. To better serve customers, DP remains appraised of the latest developments in machine tools & tooling, and works directly with major manufacturers. Among those manufacturers is Kenn ametal,Mazak,Tsugami,Hardhinge with which the DP Technology team collaborated for the IMTEX industry event, which took place this year in Bengaluru. “We have great relations with Mori Seiki, Makino, Agie Charmiles,Yamazen, Mazak, Tornos, Biglia, Galaxy, Hardinge, and more,” said Lauer. To provide a platform for greater support, DP Technology introduced the ESPRIT Engineer On-Site, or EEO, Program — a program through which engineers are placed within customer businesses permanently, where they act as their employees until the software is fully implemented and understood — and the customer is completely satisfied. “We thank you very much for your prompt support for training our team ESPRIT - CAM software. Also, for our new (and urgent) part development, you delivered “SolidMill and SolidMillTurn, both with 5 axis capability and post processor” well within time. We could deliver samples to our customer before the scheduled date of despatch. Once again, I thank you very much for your continual support and we expect the same for our future projects.” said a spokesperson from Orchid India Medisolutions Pvt. Ltd. ☐
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COOLANTS & LUBRICANTS | TECHNOLOGY
Controlling contamination through best practice protocols within the plant is essential
Overview Water-soluble metalworking fluid means that the fluid is mixed with water prior to use in the machine tool. However, unlike straight oils, water-soluble products must be monitored for appropriate concentration. What exactly is being monitored or measured? There are a number of different variables involved.
Methods The concentration of any product is dependent upon the type of product and test method(s) employed. Common test methods can be grouped into six different categories, without getting into intensive analytical procedures. Each method can be negatively affected by contaminants that will generate false positives and lead us to believe that more “product” is present when it is not. Laboratory conditions are used to determine the factors for these procedures. This means that each product will respond differently to each test and its “factor” reflects to what degree it is affected.
Ratio vs percentage A concentration is best expressed as a percentage, meaning parts of concentrate per parts of total dilution. If 5 parts of X are added into 95 parts water, then the concentration of X is 5%. This is because the total is 5 parts of X plus 95 parts of water for a total of 100 parts. Five divided by 100 yields 0.05. As a percentage, this equals 5.0%. Some people refer to dilutions in terms of a ratio. For that same 5% dilution from above, the calculation is to simply divide that number into 100. In this example, the dilution is referred to as 20:1.
Dry-down A dilution is dried down in an oven to remove the water. Like the acid split, it is necessary to remove the tramp oil first. Of course, other contaminants, likes chips and other debris must also be removed first via filtration. This is typically a very “quick
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& dirty” method when other methods are not available. Products that tend to have a small amount of active ingredients can be ashed by taking the temperature above 110o F in small crucibles. This causes all organic material to burn off leaving only inorganic materials behind. This only works for products containing inorganic compounds in the formulation. This should only be run under tightly controlled laboratory conditions.
Extraction An extraction involves the use of a specific solvent to extract or capture a specific component(s) in the product. The most common component involved is one of the esters of the company. Sometimes, it will be referred to as an ester extraction. After the component is extracted, additional analysis is performed to quantify the amount. This needs to be performed with very specific laboratory equipment, especially when handling solvents. The typical interference would be any compound that would be soluble in the particular solvent.
Refractrometer The optical refractometer was originally designed to measure the percentage of sugar, expressed as sucrose (% Brix), in solution for wine making. Today, this same device is used to monitor a wide range of “solids” in solution. A refractometer, in essence, measures the total actives of a product. A few drops of the dilution are placed on a small glass chamber, covered by a prism, and then pointed at a bright light. The light is refracted through the prism. When viewed through the eyepiece, a linear scale is read to determine the %Brix. That reading is then translated into concentration based on the factor for the product. There are many different manufacturers of refractometers with different scale readings. The most common are the 0-10 scale and 0-32. As long as one expects to run concentrations below a reading of “10,” a 0-10 scale unit should work fine. If a product has a reading of 4 on a 0-10, it should also read 4 on the 0-32 unit. However, just recognise that there will be fewer
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TECHNOLOGY | COOLANTS & LUBRICANTS
TECHNOLOGY | COOLANTS & LUBRICANTS
graduations on the 0-32 scale. This will affect accuracy of the reading. This device is also thrown off by the presence of tramp oil so, like the other methods, the tramp oil should be removed from the dilution prior to testing. This device is standardised to read “0” against distilled water. Each product will have its own refractometer factor. The level of active ingredients (i.e. those that refract) in the concentrate dictates the factor. If a product contains 20% water in the concentrate, then a 10% dilution will read 8.0 at best. This can confuse some end users not aware of this issue. Some people believe that a reading of “5” means 5.0%. It does only if the product is 100% active. Other raw materials can impact the reading as well.
Saponification Only fats and esters can be saponified. Saponification occurs when a caustic material is heated with the solution. The end mixture is then titrated to an endpoint. Fat-containing and ester-based products work best for this method.
Titration This is actually a simple acid/base titration. A titration can be conducted colorimetrically or potentiometrically. A colorimetric endpoint uses an indicator that changes colour when the endpoint (i.e. specific pH) is reached. A potentiometric endpoint uses the pH meter. Potentiometric is more accurate than colorimetric. A titration can be based on the acidity or alkalinity of the product. There are titrations for total, free, and reserve alkalinity. There is also a boric acid titration. A titration is very accurate but will be interfered by similar compounds. If one is conducting an alkaline titration and an alkaline cleaner is the contaminant, one will read both.
Conclusion When asked about concentration, one should now be able to handle this inquiry. By understanding the product and the process contaminants, one can choose the method of monitoring concentration that will lead to higher customer satisfaction. ☐ Courtesy: Quaker Chemicals > MORE@CLICK EM01654 | www.EfficientManufacturing.in
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INDUSTRIAL BEARINGS | TECHNOLOGY
A STEELY RESOLVE The article highlights on how SKF’s condition monitoring system used by ArcelorMittal Bremen GmbH helps to optimise production and simultaneously maintenance costs German steel manufacturer ArcelorMittal Bremen GmbH, part of the world’s largest steelmaking group, produces more than 3 million tonnes of steel each year. SKF has supplied the condition monitoring system to monitor its central compressed air system. The company’s facilities occupy a 7 square kilometre site outside Bremen. The steelworks provides jobs to 3,500 people, which makes it one of the largest
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Dietmar Seidel Communication Manager Press and corporate publishing, SKF Gmbh Dietmar.Seidel@skf.com
industrial employers in the Bremen ArcelorMittal Bremen produces a total region. The company has produced hot of 3.2 million tonnes of steel per year. All and cold rolled sheet steel with special facilities needed for production, from surface treatment on this site since 1957. pig iron output to sheet metal processing, Today, the steel is supplied to a variety of are located at the site. The company’s industrial sectors, including the plant equipment needs to withstand extreme conditions, regardless of automotive industry. whether it’s used for high-temperature Achieving optimum production applications in the red-hot heart of a works or has a peripheral role, such as With its highly automated production, supply utilities & equipment.
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T E C H N O L O G Y | C O N D I T I O N M O N I TO R I N G
Ralf Suhling, Head — Metrology, ArcelorMittal Bremen, believes that achieving optimum production means ensuring the reliability of all facilities. Condition monitoring has a key role in optimising production and reducing maintenance costs. One example of this is in the central compressed air system that supplies various production units in the plants via the compressed air network. The system consists of four turbocompressors, each operating at a pressure of 0.65 MPa (6.5 bar). “As a rule, there are always three compressors in operation. If one of these compressors suffers major damage, this is generally due to a bearing problem in the compressor’s motor,” he said. The motor operates with a gap between the rotor and stator, and as such there should not be any wear or tear. However, over time the clearance in the motor bearings may increase due to wear. As such, the gap between the rotor and stator is reduced. Stephan Sondermann, Sales Manager—Key Customers, Metalworking Industry, SKF Germany, explains that if the bearing clearance continues to increase, the rotor may drop down so much that it touches the stator and result in significant damage. “If this occurs, the damaged motor must be removed immediately, resulting in expensive repairs,” he said. To avoid such incidents, the company has for several years relied on SKF Multilog On-line System IMx-S for its central process air system. The online monitoring system enables the company to identify changes in good time and to better plan maintenance and motor replacements.
is simple: bearing damage results in increased vibration levels in defined frequencies that can be captured through sensors. “All things considered, the continuous monitoring also tells about
the efficiency of the machinery as there is a constant flow of information,” explained Sondermann. The system has helped the company noticeably reduce the number of expensive motor Advt
Reducing expensive motor replacements The system’s identification of changes
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INDUSTRIAL BEARINGS | TECHNOLOGY
The motor operates with a gap between the rotor and stator, and as such there should not be any wear or tear
replacements required in the central compressed air system. ArcelorMittal Bremen has always been innovative in terms of condition monitoring. In the mid-1990s, the company introduced systematic monitoring of its installations, although at that time the monitoring was routebased. A technician would regularly check the units in the central compressed air system using a portable measuring instrument. The data was recorded and then used as the basis for an analysis. Employees used the analysis to assess whether a component of the unit needed to be replaced or not. “This was a huge step forward from the traditional method in which a component was replaced immediately the moment the unit made strange noises. With the introduction of route-based offline monitoring, ArcelorMittal Bremen was better able to plan the replacement of bearings, motor and compressor parts,” said Suhling. It soon became clear that an online condition monitoring system was needed that continuously monitored the condition of the plant equipment.
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and his colleagues to respond on a more tailored basis. Instead of replacing many parts because a problem was suspected, as was previously the case, the company now knows, more precisely, when a replacement is actually required. Since introducing the SKF IMx-S units five years ago, ArcelorMittal Bremen has only had to replace one motor. The system can be optionally The Multilog On-line System equipped with 16 or 32 analogue signal IMx-S inputs. Each input can be configured. SKF supplied the SKF Multilog On- The data from the machines is line System IMx-S, which was installed, automatically & precisely transferred to wired and in use in just two weeks. The a host computer running the SKF system indicates the performance & @ptitude Observer software via availability of the machines. The unit permanently mounted vibration sensors. constantly checks all sensors, wiring and Thus, large amounts of complex electronics. System messages are information about the machines and generated automatically. installations can be rapidly, efficiently Suhling opined that motor repair and reliably stored and processed. This costs have decreased significantly, since in turn enables staff to detect faults early, the introduction of the system. Unlike or to avoid them. This is because the route-based measurements that only system automatically provides provide snapshots, permanent online recommendations on how to eliminate monitoring can distinguish between existing or impending problems. ☐ short-term fluctuations and a genuine, Courtesy: SKF > MORE@CLICK EM01655 continuous deterioration in condition. www.efficientmanufacturing.in This precise information allows Suhling Suhling further opined that fluctuations have repeatedly been observed in measurements from the route-based method. “If a value was extremely high, we replaced the component concerned immediately. But there were still doubts as to whether this action was really necessary,” he said.
EM | May 2015
7:04:40 PM 5/15/2015 6:57:27
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MACHINING | TECHNOLOGY
Making competitive shopfloor The article briefs on the investments made by GAT on Haas CNC machine tools for making efficient shopfloor run by well-trained operators producing high-quality precision parts. Located in a region which was once one of the most war-ravaged places in the world, the story of GAT is one of determination and triumph in the face of adversity Bosnia-Herzegovina is a country on the rise. It’s been 20 years since the conflict ended in 1995, during which time the nation has rebuilt and introduced liberal market reforms to help stimulate the economy. Many
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people who left to escape the war have since returned. Among them is Almir Gvožđar, who in 1996 came back from Germany, invested all of his savings in a second-hand CNC machine tool, and started making aluminium components
from the family garage, under the name of GAT d.o.o. During his time in Germany (citizens of war-affected countries such as Bosnia and Croatia had temporary refugee status in Germany), Gvožđar worked as
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TECHNOLOGY | MACHINING
Advt
a technician for ABM Fahrzeugtechnik GmbH, which is based at Breisach, close to the border with France. ABM is a leading manufacturer of highperformance parts for the motorcycle industry, and the company was later to be GAT’s first customer. “Working alone I started producing parts for tuning motorcycles,” says Gvožđar. “From here, we managed to pick up a few other German customers, and so our story began. Indeed, the German market remains our most important to this day, although we also export to countries that include Switzerland, Austria, and Slovenia.”
Machine tool investment In 2003, GAT purchased a facility measuring 1100 m² on a 5000 m² plot at Sanski Most, in the industrial northwest of Bosnia-Herzegovina. In parallel with investing in premises and the addition of more employees, the company also began to step up its investment in the latest CNC machine tools. “I first heard about Haas when I was at ABM; they had Haas machines,” says Gvožđar. “I knew the Haas CNC was easy to use, and that the service and
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MACHINING | TECHNOLOGY
Around 90% of the parts made on the UMC750 machines are cut from aluminium
support was good. Haas machines are also a good price – the best buy on the market!” GAT today employs 65 people and has 12 Haas models, including seven VF-2 vertical machining centres, two TL-1 tool-room lathes, and one TL-25. The company’s latest additions, however, are two UMC-750 five-axis universal machining centres, the first to arrive in the region formerly known as Yugoslavia (BosniaHerzegovina, Croatia, Macedonia, Montenegro, Serbia, and Slovenia). The machines have been set to work producing parts such as clutch levers, which GAT designed in cooperation with its customer. “We were seeing more and more demand for five-axis work, hence the investment,” adds Gvožđar. “Since using the UMC-750s, we’ve seen both productivity and quality increase. We are also achieving a better price for final products.”
the UMC-750 machines are cut from aluminium. Many of them are motorcycle related – such as components for fuel tanks, air filters, and speedometers – and many involve the generation of complex, freeform surfaces. The company also machines parts for other industries, such as the metrology and medical sectors, and is attracting increasing numbers of customers from Western Europe. Because the salary for a machine operator in Bosnia-Herzegovina is circa €400 per month, the company is extremely competitive. GAT adds value to parts by suggesting design changes that will lower the price further still. This is a big advantage, particularly for larger batches – the company produces in volumes up to 10,000 off. So impressed is Gvožđar with Haas CNC machine tools that he even bough a Haas Mini Mill for the local technical high school, to aid in the training of future machine operators.
Efficient shopfloor
Back on the map
Around 90% of the parts made on
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In a country once riven by war, the
story of GAT is one of determination and triumph in the face of adversity. A former refugee, the company’s owner returned home after the conflict in Bosnia and built a successful manufacturing business supplying his one-time employer in Germany. Walking into the company today, visitors are greeted by an impressive, architectdesigned building of blue glass, a mesmerising water feature in the lobby, and a clean, efficient workshop run by well-trained operators making highquality precision parts. The general presentation and standards could easily pass for that of a German or Swiss company. Located in an area of rapidly emerging modern infrastructure, few would guess that this region was once one of the most war-ravaged places in the world. Visionary companies like GAT, with high standards, ambition, and owners with a sense of urgency, are putting Bosnia-Herzegovina squarely, back on the map. ☐ Courtesy: Haas Automation > MORE@CLICK EM01656 www.efficientmanufacturing.in
EM | May 2015
5/13/2015 5/15/2015 8:24:16 7:04:41 PM
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S P E C I A L F E AT U R E | D E S I G N O F E X P E R I M E N T S
Emphasising statistical approach The article highlights a new methodology model to make easier the implementation of Design of Experiments (DoE), as an approach to bridge the existing gap between the technique and industries, also to tackle quality problems in key processes that they deal with everyday. Although experimentation is a frequent activity of engineers, they usually use primitive strategies to carry on their experiments. A survey identifies the needs of using an efficient and practical technique for the experimentation. Although Six Sigma improvement initiative emphasised the use of Design of Experiments (DoE) for
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experimentation, engineers still consider it a difficult technique to apply and interpret. Engineers do a variety of activities such as developing new products, improving previous designs, maintain, controlling and improving ongoing manufacturing process; maintaining and repairing products, among others. As
experimentation is a frequent task in those activities, engineers end up using statistics regardless of their background in it. Therefore the issue is not whether they use statistics or not, but how good they are at it. The following section stimulates the engineering community to apply an efficient technique to experimentation, the Design of
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D E S I G N O F E X P E R I M E N T S | S P E C I A L F E AT U R E
Frequency of experimentation
Experiments, to tackle quality problems in key processes that they deal with everyday. The Design of Experiments (DoE) is a methodology for systematically applying statistics to experimentation. It consists of a series of tests in which purposeful changes are made to the input variables (factors) of a product or process so that one may observe and identify the reasons for these changes in the output response. DoE provides a quick and cost-effective method to understand and optimise products and processes. Although these techniques are commonly found in statistics and quality literature, they are hardly used in industry.
Six Sigma and other approaches is the integration of a highly disciplined process with one that is quantitative and data oriented. Six sigma uses a five-step process known as DMAIC, named for the five steps in the process: Define, Measure, Analyse, Improve, and Control. Generally, after the project definition phase, key process characteristics are identified and benchmarked in the Measurement and Analyse phases; this is followed by the Improvement phase where the process is changed for better performance, then the Control phase aimed at monitoring and sustaining gains. The detailed contents and sequence of applications of DMAIC tools could vary from one organisation to another and from project to project. However, their integration DoE: Key tool of Six Sigma and logical flow is what makes possible Like quality management in general, the overall impact of Six Sigma. Six Sigma has penetrated most sectors of Experimentation, mainly in the today’s business world, still being one of phases of Analysis and Improvement, is the most popular philosophies in the often the best way to achieve the goals business world. A key difference between proposed for the project. Consequently,
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DoE as an efficient technique for experimentation constitutes the bulk of these important phases, making DoE a crucial technique.
Gap between DoE & industries In order to get first-hand information, a survey was designed to detect the need of DoE and the degree of implementation of this technique within industries. Questionnaires were sent to over 760 manufacturing industries, with over 50 employees, in The Basque Country. A total of 138 completed questionnaires were received, at a response rate of 18%, which leads to a survey-wide sample error rate of 7.7%. To be able to detect the need for specific experimentation techniques, the frequency of experimentation in industries must first be established. Results showed that 95% of industries in The Basque Country carry out experimentation, 50% of which do it frequently. Three types of experimentation
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S P E C I A L F E AT U R E | D E S I G N O F E X P E R I M E N T S
Extent of application of DoE
strategies exist: Best Guess, One Factor advantages over OFAT. The following At a Time (OFAT) and Statistical are the advantages of applying DoE over Designed Experiments (DoE). The first OFAT: one consists of using prior knowledge to t It requires less resources (experiments, time, material, etc) for the amount modify several variables and conduct of information obtained the experiment under conditions expected to give the best results. t The estimates of the effect of each factors (variable) on the response Secondly, OFAT strategy consists of are more precise modifying one variable at a time while keeping the others fixed. Finally, DoE is t The interactions between factors can be estimated systematically the most effective method for solving (Interactions are not estimable with complex problem with many variables. OFAT experiments) Results showed that 39% of industries follow Best Guess strategies, while 80% t There is experimental information in a larger region of the factor of industries conduct experimentation space. using the OFAT strategy. Furthermore, The respondents were asked to rate only 20% of industries carry out experimentation with a pre-established their knowledge of DoE on a scale from statistical methodology. Foreseeing the ‘1-not at all’ to ‘5-master’. The results to low usage of statistical methodologies, this questionnaire show that the majority the need for a methodology to help of respondents are unfamiliar with DoE, industries carry out their experiments as only 33% of industries claim to know was evaluated. This survey shows that at least ‘3-something’ about DoE. Afterwards, respondents were asked 76% of industries consider themselves in to rate the extent to which they used need of a methodology. Most engineers apply OFAT strategy DoE on a scale from 1 (not at all) to 3 to their experiments. They will continue (frequently). The results confirm that to do so until they understand the despite all efforts by specialists in quality
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and statistics, DoE is still not applied as widely as it could and should be. Only 20% of industries in The Basque Country have applied DoE and only 3% of those apply it frequently (representing 15% of total users). Again, there is a significant difference in the application rate when it comes to industry size, as is seen in the application rate of 18% at small and medium industries (SMI) and 29% at large industries, of which only 6% and 39% apply it frequently. In order to pinpoint the challenges that DoE faces in finding its niche in industries, respondents were asked to describe their view of DoE using one of several possible answers. Results showed that two biggest barriers in the application of DoE are: “Theoretical ignorance of DoE for real applications” (43%) and “Absence of a clear methodology to simplify its application” (37%). To sum up, although experimentation is a frequent activity, strategies used are quite primitive, leading to a very low usage of statistical tools. It can be concluded that DoE is little used in
EM | May 2015
7:04:51 PM 5/15/2015 5:34:13
D E S I G N O F E X P E R I M E N T S | S P E C I A L F E AT U R E
TOOLS THAT MAY BE USED IN EACH STEP OF THE METHODOLOGY DEFINE Fishbone Process Map
MEASURE
PRE-ANALYSE
EXPERIMENT
ANALYSE
IMPLEMENT
CONTROL
Brainstorming
Randomisation
Check Sheets
ANOVA
TRIZ
Procedures
Affinity Diagram
Software design Creative Tools
Poka-Yoke
aid Flow Chart
Contour plots
Analysis of Covariance
Gauge R & R
SPC
Goal Hierarchy Plot
Multivariate
Charts SIPOC
industries, although that trend seems to be changing. Results also showed that Six Sigma has a positive influence on the application of DoE.
Regression Fishbone
complex task whereas the scientific community continues to develop algorithms and designs with better mathematical properties, scant importance has been provided to solve industry’s real problems. DoE is too New methodology model important as to be left only to Hard work must be done to bridge statisticians. Taking advantage of the the existing gap between DoE and democratisation of statistics, partly industries. The following approach for thanks to software packages and the bridging the current gap between spread of Six Sigma thinking throughout industries and statistical methods was industries, this approach presents a to elaborate a simple, easy and thorough framework for the experimentation methodology from an engineering point process following the traditional DMAIC of view, without ignoring the complexity steps as a generic problem solving of this task and its statistical severity. methodology. The survey supports this decision, However, it was necessary to adapt showing that 76% of respondents the DMAIC model, in order to fit the believed that a methodology is truly application of DoE to a similar structure. needed and that the absence of a clear A hypothetical Analysis step from the methodology was one of the main DMAIC was divided into three, including barriers in the application of DoE. The the selection of the experimental design new methodology model has been in the Pre-Analysis step and the analysis validated theoretically at the DEMA of the data obtained from the Experiment conference and proved to be useful in an step and Analysis step. automotive engineering industrial Moreover, the model aims to transmit application. some more theoretical concepts. Firstly, Applying DoE in industries is a very the existing cycle stimulate not to
EM | May 2015
FORM-6.indd 20 Page _Special Feature DoE.indd 91
Control Plan Generalised Linear Models
conduct a one-shot experiment and make experiments in more than one stage. Consequently, the following experiments will obtain better results than the first ones. Secondly, the arrow connecting the Control and Define stages aims to establish experimentation as an inductive-deductive learning process. Experimentation must be understood us a tool to continuously improve the whole process. Every step of the model includes a series of activities that must be completed before continuing to the next step. The complete methodology uses some brief guidelines to explain and guide users through the different activities necessary to complete a DoE project. Furthermore, the guidelines mention the tools that may help users to fulfill their task. The guidelines are written without statistical jargon in order to reach those who have a weak statistical background. Finally, special worksheets were designed for each of the steps in order to recollect the information needed, the tools utilised and the results obtained in every activity.
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S P E C I A L F E AT U R E | D E S I G N O F E X P E R I M E N T S
ACTIVITIES FOR THE APPLICATION OF DOE ACTIVITIES
BRIEF EXPLANATION
Select team
Experimentation is a team process, so strategies and tools must be used for the best selection of the working team
DEFINE
Formulate problem State relevant background
MEASURE
Choose response
Once response is chosen, a measurable objective must be set with a deadline to achieve it
Identify factors
Every variable that can affect the response must be listed in this preliminary stage
Classify factors
The identified factors must be classified in primary ones that will be considered for experimentation, those which will be kept constant and those nuisance factors which hinder experimentation
Validate measurements systems Choose strategies for nuisance factors
State actual process knowledge
ANALYSE
EXPERIEMENT
PRE-ANALYSE
Characterise the factors Define characteristics needed for the design Choose experimental design
Measurement systems of primary factors must be validated in order to include those factors in the experimentation One strategy must be assigned to each nuisance factor such as blocking or randomization, in order to reduce or eliminate their effects on the response The ranges for the quantitative factors must be defined as well as the number of possible levels for each qualitative factor Based on previous knowledge, they must predict the effect of factors and its interaction on response, before selecting the experimental design Important characteristics of the factors must be listed in order to make a correct selection of the design The characteristics desired for the design must be defined for choosing the design A useful design must be chosen, suitable with the previous listed characteristics
Select levels
The design selected establishes the number of levels for each factor. So values, belonging to the range pre-established, must be defined for each coded levels
Outline experiment
It’s easy to underestimate the logistical and planning aspects of the experiment. Consequently, special care must be taken for arranging the experimentation
Evaluate trial runs
Before experimentation is carried out, it is recommended to make some trial runs. They permit one to check experimental error and assumptions made in previous steps
Perform the experiment and recollect data
The experiment must be performed carefully as planned and data must be recollected for further analysis
Determine factors effects
All possible factors effects must be calculated. These effects include interactions and second order effects if necessary
Determine significant effects
ANOVA analysis or probability plots must determine which effects are statistically significant
Model building Optimisation Evaluate new experiments
IMPROVE
The variable(s) that will measure the result of the process is called the response. This should be continuous, precise and related to the client’s perception of quality
State objective
Choose ranges and levels
Once analysis is validated it is possible to make a prediction model If it is required, once the model is obtained, response can be optimised throughout the studied region The possibility to carry out more experiments must be taken into account
Confirming testing
Once new condition are presented as the solution, it is convenient to make some confirmatory test to validate the result obtained from experimentation in those values
Draw conclusions and do recommendations
Once confirmation of the experimentation is obtained, conclusions and recommendation must be elaborated. Graphics are stimulated because they are the best way to present results
Implement new conditions
CONTROL
The problem that will be solved must be clearly defined and measured Information from experience, previous projects and control charts must be document as any information that may be useful for the project
New conditions are set in the process or product
Implement controls
A control plan must be set, in order to obtain the benefit proposed from the last activity
Validate results
A date must be established, for example one year later, in order to ascertain whether the expected benefits of the project were obtained or not
Evaluate iteration
Experimentation is an iterative inductive deduction learning process, so once the whole cycle is finished, new experimentation must be evaluated
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Conclusion Engineers perform experiments and analyse data as an integral part of their job. Whether or not engineers have learned statistics, the will use statistics. The survey confirmed that DoE is hardly used; however, this technique is necessary for the experimentation frequently carried out within industries. But, manufacturing industries need the Design of Experiments (DoE) technique to increase the effectiveness of their engineers and the efficiency of their processes. Moreover, Six Sigma has made DoE even more necessary, since it is a key tool of this widespread methodology. The modeled approach presents a validated methodology to simplify and clarify the application of DoE, guiding them through the entire project with structured steps and activities explained using special guidelines. ☐ Courtesy: TECNUN (University of Navarra) > MORE@CLICK EM01657 www.efficientmanufacturing.in
EM | May 2015
7:04:51 PM 5/15/2015 5:34:13
June 5th, 2015 | India
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FORM-6.indd 24
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COUNTRY FOCUS - USA | MARKET
Demand on solid ground While a strong dollar dampened growth last year in the United States, there was a strong ending to the year due to IMTS – The International Manufacturing Technology Show. In 2015, the Association - AMT expects to see another jump in production of machine tools, with forecasts estimating production of US machine tools to reach just under $6 billion. In the United States, the manufacturing sector played a key role in leading the country out of the recession, and it continues to be a strong foundation for sustained economic growth. New government initiatives have helped promote and expand the industry, leading to a positive runoff effect for the machine tools and cutting tools markets. Production in those two markets has risen over the past five years and the forecast for future growth is optimistic. As the manufacturing industry continues to grow, thanks to favourable labour and energy costs and a strong influx of foreign direct investment, AMT – The 94
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Association for Manufacturing Technology anticipates continued growth for the machine tools and cutting tools markets. A dramatic jump in the US production of manufactured goods had led to an increase in US production of machine tools. From 2009-2013, the US machine tool production increased every year, and AMT estimated that 2014 would see similar production numbers to the preceding year. In 2013, the United States produced $5.7 billion worth of machine tools, up from $3.4 billion in 2009. While a strong dollar dampened growth in EM | May 2015
5/15/2015 1:32:03 7:04:52 PM
MARKET | COUNTRY FOCUS - USA
US Production of machine tools
US consumption of machine tools
(Million of USD)
(Million of USD)
2014, there was a strong ending to the year due to IMTS – The International Manufacturing Technology Show. In 2015, AMT expects to see another jump in production of machine tools, with forecasts estimating production of US machine to could reach just under $6 billion.
gets almost half the number of exports China receives from the United States. Notably, India ranks fifth on the US list of exports by country, coming in ahead of countries like Japan, Russia, and South Korea. In fact, since 2003, overall trade between the United States and India has increased by over 400%, a testament to the importance of the relationship between the two countries. However, the United States still imports more machine tools than it exports, with Japan, Germany, and Taiwan being the largest source markets for the machines. Worldwide, the United States continues to be the second largest consumer of machine tools and – based on recently release US government data – has become one of the top 5 producers of manufacturing technology in the world.
Machine tools market Meanwhile, machine tool consumption has nearly doubled during the same period. In 2009, US machine tool consumption reached $4.5 billion, far below the $8.5 billion in machine tool consumption seen in 2013, and less than half of the $9.3 billion seen in 2012. Another rise in consumption is estimated to have occurred in 2014. The significant increase in US consumption of machine tools represents one of the largest expansions in manufacturing capacity over such a small period in the history of the United States. Regarding trade, the United States continues to be a large importer of machine tools; and while exports of machine tools rose during the same period, the per cent increase was not as substantial. The United States continues to send the largest number of machine tools to China, with exports to that country rising 130% from 2009 to 2014. Mexico, the second largest destination in terms of machine tool exports at $261 million,
EM | May 2015
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Cutting tools market Similarly, cutting tools have seen regular growth in recent years. In 2009, cutting tool production was measured at about $3.1 billion. In 2013, that number had risen to $4.8 billion, an increase of over 50 per cent. Consumption of cutting tools within the United States has also seen substantial growth, increasing from $3.5 billion in 2009 to $6.08 billion in 2013. Like in the machine tool sector, the United States imports
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/million $ 1 2 3 4 5
Country China Mexico Canada Belgium Germany
Value $ $ $ $ $
444 261 176 175 78
Main origins of 2014 US MT IMPORTS Country Value 1 Japan $ 2,044 2 Germany $ 834 3 Taiwan $ 400 4 Switzerland $ 368 5 Korea, South $ 348
C O U N T R Y F O C U S - U S A | /million M A R K $E T
s of 2014 US MT EXPORTS
untry of 2014 US MTValue EXPORTS antry $ Value 444 co $ 261 $ 444 176 oda $$ 261 um 175 a $$ 176 many 78 m $$ 175
any $ 78 f 2014 US MT IMPORTS untry Value 2014 US MT IMPORTS nntry $ Value 2,044 many $$ 834 2,044 an 400 any $$ 834 erland $ 368 n $ 400 a,rland South$$ 348 368 South $
South $ 46 f 2014 US MT IMPORTS untry Value 2014 US MT IMPORTS $ Value 332 ntry a 174 $$ 332 da 132 $$ 174 ia $ 78 a $ 132 68 Germany aandBelgium $$ 78 $
Main destinations of 2014 US MT EXPORTS /million $ Country Value 6 India $ 76 7 Germany $ 76 8 Japan $ 70 9 Russia $ 57 10 Korea, South $ 46
$450 $400 $400 $350 $350 $300 $300 $250 $250 $200 $200 $150 $150 $100 $100 $50 $50 $$-
China China
348
s of 2014 US MT EXPORTS untry of 2014 US MTValue EXPORTS $ Value 76 ntry many $$ 76 76 n 70 any $$ 76 a 57 $$ 70 a, South$$ 46 57
nd
$500 $500 $450
Mexico Mexico
Main origins of 2014 US MT IMPORTS /million $ Country Value 6 Italy $ 332 7 China $ 174 8 Canada $ 132 Canada Belgium Germany 9 Austria $ 78 Canada Belgium Germany 10 Thailand $ 68
$450 $400 $300 $200
$1,000
$150 $100
$500
$50 $China
Mexico
Canada
Belgium
Germany
Switzerland
$100 $50 India Japan
Germany Germany
Japan
Germany
Japan Taiwan Taiwan
Russia Switzerland Switzerland
Korea, South South Korea,
$Italy
China
Canada
Austria
Korea, South
Source:
Main destinations of 2014 US MT IMPORTS
US Census
$250 $200
$60 $50 $1,500 $50 $40
$200 $150
$40 $30 $1,000 $30 $20
$150 $100 $100 $50
$20 $10 $500 $10 $India
Germany
Japan
Russia
India Japan
Germany Germany
Japan Taiwan
Russia Switzerland
Korea, South Korea, South South Korea,
$50 $$-
Italy Italy
68
China China
Source: $350
Source:
Canada Canada
Austria Austria
Thailand Thailand
US Census US Census
$300 $250 $200 $150 $100
Russia
Korea, South
$50 more cutting tools than it exports. In 2009, $1.18 billion worth $of cutting tools were imported, compared to an export value of Italy China Canada Austria Thailand $808 million. Both of those numbers increased over the next Source: US Census several years, with imports reaching $2.5 billion in 2013 and exports reaching $1.3 billion. However, unlike machine tools, the largest export market for cutting tools was Canada, with China in fourth place behind Germany and Mexico. The Netherlands rounds out the list of the top five export markets for the United States cutting tool sector.
Optimistic growth The machine manufacturing industry employs approximately 1.14 million people in the United States, a number that has stayed relatively constant over the past several months. Meanwhile, unemployment in the industry has hovered around 5 per cent in recent months, remaining lower than the national average. Machine tools companies employ around 39,000 people in the United States, while cutting tools companies employ around 29,000. Geographically, companies in these sectors are focused near the Great Lakes, in the Ohio River Valley, and along the East Coast. Future growth for the two sectors remains promising as end-user industries, specifically automotive, continue to grow.
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Korea, Sout
$150
$300 $250
$2,000 $70 $60
Taiwan
$200
$- $-
$350
Germany
$250
$10 $500
$350 $300
Japan
$300
$2,000 $70 $2,000 $60 $1,500 $50 $1,500 $40 $1,000 $30 $1,000 $20 $500
$-
$-
Main destinations of $350 2014 US MT EXPORTS
$90 $2,500 $2,500 $80
$90
$- $-
$1,500
$250
$90 $2,500 $80 $80 $70
$2,000
$350
The aerospace and energy sector have both plateaued in recent months, but industry experts believe that aerospace is likely to pick up steam mid-year. An educated labour force and falling energy prices have helped keep the US market a competitive place for manufacturing. The government has been pushing STEM (Science, Technology, Engineering, and Mathematics) initiatives, and in the next 10 years, the United States is expected to be the largest producer of oil, gas and coal-based products. Although US workers are highly skilled, there continues to be a shortage which may be cause for concern. And while a rising dollar and falling oil prices may appear to dampen forecasts, experts that work with AMT believe the US economy will continue to improve and manufacturing will see a measure of restrained growth.
Advancements in manufacturing technology Positive expectations are supported by encouraging trends in the machine tools and cutting tools industry. Advances in 3D printing technology and additive manufacturing continue to make headlines, which bodes well for their continued adoption on the factory floor. For cutting tools, there is a push to adopt ISO 13399, which is a set of standards enabling cutting tool manufacturers to describe a product independent from a specific software system, allowing for better data
EM | May 2015
5/15/2015 1:32:06 7:04:53 PM
Thailand
FORM-7half.indd 1
5/15/2015 7:02:36 PM
COUNTRY FOCUS - USA | MARKET
“We expect the industry to hold steady with a push-pull between strong domestic investments in manufacturing”
Douglas K Woods, President, The Association for Manufacturing Technology - AMT
transfers that will lead to improved productivity and decreased costs.
from March 2014. “As we close the first quarter of 2015, strong cutting tool shipments in March prove that this year’s economic outlook remains solid for our industry,” said Brad Lawton, Chairman of MT orders AMT’s Cutting Tool Product Group. “This increase is on track The recent March, US manufacturing technology orders with the positive trend in machine tool orders and durable totaled $399.83 million according to AMT. This total, as goods manufacturing. There is a possible caution in the industry reported by companies participating in the USMTO program, regarding the increasing value of the dollar and the potential was up 30.3% from February’s $306.96 million but down 18.7% impact on exports.” when compared with the total of $491.73 million reported for March 2014. With a year-to-date total of $1,052.29 million, Conclusion 2015 was down 12.7% when compared with 2014. Overall, the momentum seen in manufacturing toward the “There are many indications that our end-user customers are making significant investments in their manufacturing end of 2014 is fueling optimism for 2015, with major facilities to increase capacity, including GM’s announcement manufacturers saying they plan to invest more throughout the that it will invest billions in its US plants,” said Douglas K coming months. Although, there is some concern among Woods, President, AMT. “Overall we expect the industry to business in the United States regarding high corporate taxes hold steady with a push-pull between strong domestic and regulatory restrictions, the overall business environment investment in manufacturing but a drag on foreign trade due to in the country remains strongly favourable for manufacturing. In fact, foreign direct investment in key US sectors continues to the dollar’s strength.” grow, creating new opportunities for manufacturers and companies producing machines for use in those factories. AMT Cutting tool consumption is confident that the United States will continue to serve as an The recent March US cutting tool consumption totaled innovative leader where the world’s most advanced technology $197.6 million, according to the US Cutting Tool Institute is developed and produced. ☐ (USCTI) and AMT. This total, as reported by companies Courtesy: AMT participating in the Cutting Tool Market Report (CTMR) > MORE@CLICK EM01658 | www.efficientmanufacturing.in collaboration, was up 9.8% from February’s total and up 4.6%
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EM | May 2015
5/15/2015 1:32:09 PM 5/15/2015 7:02:38 PM
FORM-7half.indd 4
5/15/2015 7:02:39 PM
technology | news
Drilling tools for titanium & stainless steel
Vertical turning machine for small chucked components
Dagger Master Tool Industries has recently extended its EAZYDRILL range and enabled the precise and efficient drilling of holes in titanium and stainless steel. The powerful tools have been carefully crafted with polished flutes and matched coating, all of which ensures superb chip flow and ideal processing results. The self-centering with exact positioning easily turns precise drilling into a child's game. Whether in the short robust version or with internal cooling – the new range offers machine operators the right drill for a wide range of applications. The diameter range spanning 0.3 mm to 3 mm which means EAZYDRILL that the tool focus is on precision. The short, robust design of the EAZYDRILL SHORT drill makes the tools particularly suitable for precisely creating planet and core holes in Torx machining. The NC spot drills in the MICRO series are normally employed for general micro-level applications. The special configuration of the cutting geometry makes it ideal for centering drill holes from 0.1 mm upwards.
EMAG with their VL 2 vertical turning machine, has opened up new opportunities for the machining of a wide range of small chucked components. Small gearwheels, planetary gears, sliding sleeves, pump components, synchroniser rings, chain gears or flange components – with a maximum diameter of 100 mm and a length of up to 150 mm – are machined on the VL 2 vertical turning vertical pick-up lathe with great efficiency. The machine machine design focusses on providing for the application of a variety of manufacturing technologies for soft and hard machining and a complete automation system at a very favourable price-performance ratio. The machining area includes 12 turning or, alternatively, up to 12 driven drilling and milling tools can be employed to carry out a large number of operations in a single setup. The machine can also be equipped with optional Y-axis. The automatic measuring cycle takes place after machining and before the workpiece is returned to the conveyor belt, acting as an in-process quality control measure. Productivity levels of the VL 2 are approximately 15 percent higher than those of comparable automated horizontal turning machines.
Dagger Master Tool Industries Limited | Mumbai Email: mawate@daggermaster.com | Tel: +91-22-2494-3840
EMAG India | Bangalore Email: HAshwini@emag.com | Tel: +91-80-4254-4400
> MORE@CLICK EM01659 | www.efficientmanufacturing.in
> MORE@CLICK EM01660 | www.efficientmanufacturing.in
Ring Saw with two head design
Hybrid linear bearings
Everising has introduced a new ring saw – RV2007DH, a unique two head design to produce twice the cutting speed of two machines while only using the floor space of one. Each saw head will operate independent of each other with the blades running in the down direction but at different speeds to account for one head climb cutting while the other is chase cutting. Blade speeds will range from 15 – 105 m/min. The saw heads are designed Ring Saw - RV2007DH to use hydraulic actuated carbide blades with blade speeds controlled with a constant torque vector drive system. The saw heads will feed into the cut on precision ball screws with cutting forces being precisely controlled through a servo control. The ball screw feed system will also detect part out of roundness and will ensure that the blade will not overfeed into the material. The special design work holding chuck will accommodate a large variation of material sizes eliminating the need to waste time changing out jaws and chucks. The chuck rotation drive is 5 HP and is fed to precise positions through a ball screw and servo controls.
igus has expanded its range of double roller hybrid bearings with two new sizes. The range of hybrid bearings will now be completed with sizes of 10 and 16 mm. The quiet and smooth-running hybrid linear bearings from the company are used not only in camera technology, sliding doors or machine tool doors, but increasingly in cabins for construction machinery, or even for the individual hobbyist's needs. To facilitate the design engineer in their selection, there is the option of two additional sizes of hybrid carriage. The innovative concept of this bearing is the combined advantages of plain and roller bearings. For extremely smooth and almost silent Drylin double roller hybrid operation, the concept provides two angularly bearings opposed rollers made of maintenance-free high performance plastics. The rollers take the weight in the main load and ensure low driving forces for manual operation. When misuse or moment forces occur, these will be absorbed smoothly over the sliding element, thus eliminating the risk of the carriage leaving the rail at the same time the movement of heavy loads becomes possible with minimal effort - all absolutely free of lubricant.
Everising Machine | Taiwan Email: evrs@everising.com.tw | Tel: +886-4-23505300
igus (India) | Bangalore Email: vinayak@igus.in | Tel: +91-80-4512-7800
> MORE@CLICK EM01661 | www.efficientmanufacturing.in
> MORE@CLICK EM01662 | www.efficientmanufacturing.in
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EM | May 2015
6/4/2015 3:42:41 PM
news | technology
Sealless compact pumps Kirloskar Brothers Limited (KBL) has announced the launch of highlyadvanced i-CAN series of pumps that is designed to dramatically reduce maintenance time and total cost of ownership (TCO) for the small-scale industries. The new cutting-edge product by the company will help customers install, operate and maintain their systems more efficiently and reliably. The seal-less and gland-less mono-block design of the pump enables it to cater to industries like ice-making plants, cold storages, air-conditioning plants, dairies and some small scale industries involved in i-CAN series of pumps refrigeration-related businesses. The pump’s compact, lightweight yet sturdy design with less number of components helps it to minimise assembly and dismantling time and occupy less space. The pump is hailed as a step-up from the conventional mechanical seal pump category which requires heavy maintenance. The pumps are capable of handling toxic, explosive, expensive, hazardous, cryogenic and corrosive fluids without any possibility of emissions into the environment and will be suitable for vacuum-tight application and for fluids which react when come in contact with the atmosphere.
Universal hydraulic chuck Kennametal has introduced the new HydroForce HT universal hydraulic chuck, a cost-effective chucking solution that simplifies inventory while maximising tool life and machining results for milling, drilling, reaming, and other rotating applications. The universal chuck provides the increased rigidity necessary for improved cutting parameters and better results. Clamping force is up to three times better HydroForce HT than regular hydraulic chucks, and with improved vibration dampening, runout is three microns at 2X diameter overhang. Balance quality of G2.5 is achieved at speeds up to 25,000 rpm. Direct clamping is available for 20 and 32 mm (0.75 and 1.5 in) diameters and reducer sleeves are applied for all other diameters. The HydroForce HT universal chuck can work directly with the Kennametal KM4X™ spindle connection to not only transmit higher levels of torque, but also provide maximum resistance to bending loads. The combination of the KM4X™ system’s high clamping force and interference level lead to a robust connection and extremely high stiffness and bending capacity for greatly improved performance in titanium machining.
Kirloskar Brothers Limited | Pune Email: pune@kbl.co.in | Tel: +91-20-2444-0770
Kennametal India | Bangalore Email: bangalore.information@kennametal.com | Tel: +91-80-2219-8444
> MORE@CLICK EM01663 | www.efficientmanufacturing.in
> MORE@CLICK EM01664 | www.efficientmanufacturing.in
Eddy current displacement sensors
High-speed CNC CMM
Micro-Epsilon has introduced new M12 eddyNCDT 3001 eddy current displacement sensors that provide 2 mm measuring range. The eddyNCDT 3001 sensor series includes powerful eddy current sensors for measuring displacement, distance and position. To date, the M12 design has only been reserved for inductive proximity sensors. These compact sensors come with integrated electronics including temperature compensation, offering an excellent price/performance ratio. The high measurement accuracy and M12 eddyNCDT 3001 sensors linearity as well as the high frequency response rate of 5 kHz are outstanding characteristics compared to other sensors in the same price class. The sensors are factory-calibrated for ferromagnetic and non-ferromagnetic metals. An additional sensor with a 2 mm measuring range completes the eddyNCDT models. The sensors are protected to IP67 and are therefore universally applicable in automation, machine building and machine design. As the sensors are easy to use and cost-effective, they are particularly suitable for standard production in OEM applications.
Mitutoyo has developed CRYSTA-Apex S Series, a new high-speed CNC CMM that is manufactured using lightweight materials and has an innovative machine structure. The CMM comes with a maximum error of MPEE = (1.7+3L/1000) µm (L= measuring length in mm), that improves its overall measuring range. Additionally, it features a number of advanced features like high-speed (max 519 mm/s), high acceleration (max 2,309 mm/s2) and scale resolution of 0.0001 mm. Its lightweight innovative structure makes it to deliver high motion stability, accuracy and affordability. Its compatible vision and scanning probe technologies gives flexible and effective CRYSTA-Apex S Series measurement capabilities. It has a flawless machine construction that helps it to maintain its accuracy over a long period of time. The Y-axis guide rail is integrated into one side of the granite surface plate. Even during high-speed, highacceleration operations, its precision air bearings located on the bottom, front, rear and upper surfaces of the X-axis slider minimises vibration and ensure stability. This results in higher throughput for greater productivity and lower total owning and operating costs.
Micro-Epsilon India | Pune Email: pragnesh.mori@micro-epsilon.com | Tel: +91-20-2674-1009
Mitutoyo South Asia | New Delhi Email: nmathur@mitutoyoindia.com | Tel: +91-11-2637-2090
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Miniature sensors for space constrained applications
Precision blanking and sheet metal forming press
Renishaw’s associate company RLS, has announced the launch of high performance miniature encoder sensors for embedded OEM motion control applications. With their small size and lightweight design the new sensors are highly suited to a wide range of applications including medical products, optics positioning, robot control, 3D printers, gimbals and hand held devices. The miniature sensors come in four different shapes and offer linear and rotary performance at resolutions to 0.244 µm for linear applications and to 753,664 cpr for rotary applications. The RoLin™ rotary incremental new encoders consist of a miniature magnetic encoder system sensor and a magnetic scale or a ring. The sensors are available either in a potted housing or as PCB board level sensors. The position information is output in incremental quadrature TTL or RS422 and parallel in SSI and BiSS-C formats with the option of a unique or periodic reference mark. The proven RLS non-contact sensing technology brings high reliability and performance in harsh applications.
Schuler subsidiary Gräbener Pressensysteme has developed PSK precision blanking and forming presses to facilitate the economic production of progressive or transfer dies with varying material strengths. First, a pre-form shape of the component is produced in a classic sheet metal forming process. Next, one area is thickened or embossed by means of cold forging, e.g. to increase rigidity. Such parts can be produced with a high level of repeat accuracy and close tolerances. For components requiring a higher degree of deformation, the company offers hot forming processes. With the aid of additional PSK precision blanking functions integrated into the press – so-called and forming presses ServoModules –a smooth blanked surface is created which is free from fracture and tearing and which can fulfill functions without the need for reworking. As a result, the manufactured components are ready to install and the combination of precision blanking and sheet metal forging reduces number of process steps as well as material and energy costs.
Renishaw | Pune Email: samina.khalid@renishaw.com | Tel: +91-90-4900-1589
Schuler India | Mumbai Email: info@schulerindia.com | Tel: +91-22-6680-0300
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Quick jaw change system
PCBN insert grade for rough machining
SCHUNK has designed the PRONTO quick jaw change system particularly for conventional lathe chucks with screw connected chuck jaws. It lowers set-up time of a complete jaw set to 30 seconds, which is about 95% faster than conventional solutions. It optimises the set-up process from the storage of the quick-change set to the jaw change on the machine. It combines fine-serrated supporting jaws (1/16’’ x 90° or 1.5 mm x 60°) with special quick-change inserts, and extends the clamping diameter up to 45 mm in seconds. This is eight times PRONTO quick jaw more than with conventional lathe chucks. To change system achieve a fast and highly repeatable jaw change the locking of the changing inserts are loosened with an Allen key, the insert is removed and replaced with another one. This prevents an incorrect positioning. In locked condition, a six-sided form-fit clamping ensures maximum process stability, and provides high force and torque transmission. This system is suitable for clamping raw and machined parts. It can be used on every fine-serrated lathe chuck in sizes 200, 250, and 315, and is independent from the manufacturer.
Seco Tools has developed new CBN600 PCBN insert grade for grey cast irons and high-chrome iron that provides high-volume, cost-effective rough machining performance. As a universal rough-turning grade, CBN600 endures abrasive workpiece materials, heavy cutting forces and high levels of thermal shock for varying depths of cut conditions. The grade encompasses nine standard products, and inserts are available in round, rhombic and square styles. The new grade complements the company’s existing CBN300 and CBN500 premium Secomax™ CBN600 grades for similar materials. Secomax™ CBN600 with 90% CBN content, multi modal grain size and Al ceramic binder comes together in a product which offers great toughness high wear resistance and a wide application window machining of grey cast iron, chilled cast irons and high manganese steels. Secomax™ is a range of high performance cutting tool grades based on PCBN - Polycrystalline Cubic Boron Nitride and it achieves a large reduction in production costs.
SCHUNK Intec India | Bangalore Email: info@in.schunk.com | Tel: +91 80 4053 8999
Seco Tools India | Pune Email: seco.india@secotools.com | Tel: +91-21-3766-7300
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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights - June 2015 IMPRINT Publisher / Chief Editor Shekhar Jitkar shekhar.jitkar@publish-industry.net Sub-editor & Correspondent Srimoyee Lahiri srimoyee.lahiri@publish-industry.net Features Writer Megha Roy megha.roy@publish-industry.net
» Metal Forming Metal forming tends to have more uniform characteristics across its sub-processes than its contemporary processes, cutting and joining. It enjoys industrial importance among various production operations due to its advantages such as cost effectiveness, enhanced mechanical properties, flexible operations, higher productivity and considerable material saving. The next issue highlights the recent developments in the metal forming processes.
» PLM/Digital Manufacturing Digital manufacturing represents an integrated suite of PLM tools that supports manufacturing process design, tool design, plant layout and visualisation. The next issue will feature upgrades and innovations in this sector. » Surface Treatment Surface treatments often are used to prolong tool life. These treatments increase surface hardness and wear resistance while reducing the coefficient of friction. The next issue will talk about the broad range of industrial processes that alter the surface of a manufactured item to achieve a certain property.
» Safety & Security With technology driving the manufacturing sector, major industrial installations, R&D units are now looking at enhanced solutions to ensure safety & security of machinery, people and data. Catering to these challenges through indepth articles, the next issue will feature system safety and availability, industry safety and health & fire prevention.
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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 Ace Designers . . . . . . . . . . . . . . . . . . . . . 38 Ace Micromatic Group. . . . . . . . . . . . . . . . . 73 Altair Engineering India . . . . . . . . . . Back Cover AMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 ARC Advisory Group . . . . . . . . . . . . . . . . . . 38 Benign Enterprises . . . . . . . . . . . . . . . . .36,37 Bharat Fritz Werner . . . . . . . . . . . . . . . . 38, 53 Blaser Swisslube . . . . . . . . . . . . . . . . . . . . 31 CG Tech . . . . . . . . . . . . . . . . . . . . . . . . . . 41 CII . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 15 COMSOL. . . . . . . . . . . . . . . . . . . . . . . . . . 72 Dagger Master Tool. . . . . . . . . . . . . . . . . . 100 Drass Mechatronics & Machinery . . . . . . . . . . 6 Durr Ecoclean . . . . . . . . . . . . . . . . . . . . . . 60 EMAG India . . . . . . . . . . . . . . . . . . . . 33, 100 Esprit . . . . . . . . . . . . . . . . . . . . . . . . . 34, 77 Everising . . . . . . . . . . . . . . . . . . . . . . . . . 100 Exito . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Faro . . . . . . . . . . . . . . . . . . .Back Inside Cover Femco . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Festo Controls . . . . . . . . . . . . . . . . . . . . . . 63 FLIR Systems. . . . . . . . . . . . . . . . . . . . . . . 29 Ford Motor . . . . . . . . . . . . . . . . . . . . . . . . 10 Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 12 Ganro . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 GF Machining. . . . . . . . . . . . . . . . . . . . . . . 17
Features Writer Maria Jerin maria.jerin@publish-industry.net
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Gifu Enterprises . . . . . . . . . . . . . . . . . . . . . . 4 Gleason Corporation . . . . . . . . . . . . . . . . . . 12 Grind Master Machines . . . . . . . . . . . . . . . . 38 Haas Automation . . . . . . . . . . . . . . . 1, 14, 84 Haimer India . . . . . . . . . . . . . . . . . . . . . . . 45 Hannover Messe . . . . . . . . . . . . . . . . . . . . 15 Honeywell Process Solutions . . . . . . . . . . . . 14 Hong Ji Precision Machinery . . . . . . . . . . . . 71 Hyundai WIA India. . . . . . . . . . . . . . . . . . . . 49 igus . . . . . . . . . . . . . . . . . . . . . . . . . 67, 100 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . 38, 55 Infosys . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Ingersoll Rand . . . . . . . . . . . . . . . . . . . . . . 43 Jainnher Machine Co . . . . . . . . . . . . . . . . . 65 Jyoti CNC Automation . . . . . . . . . . . . . . . . . . 5 Kaifeng Machinery Co . . . . . . . . . . . . . . . . . 75 Kennametal . . . . . . . . . . . . . . . . . . . . . . . 101 Kirloskar Brothers . . . . . . . . . . . . . . . . 14, 101 Klingelnberg. . . . . . . . . . . . . . . . . . . . . . . . 10 LK Machinery Corp ( Taiwan ). . . . . . . . . . . . 81 Marox Tools Industrial . . . . . . . . . . . . . . . . . 79 Micro-Epsilon. . . . . . . . . . . . . . . . . . . . . . 101 Micromatic Machine Tools . . . . . . . . . . . . . . 38 Miller Electric . . . . . . . . . . . . . . . . . . . . . . . 64 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . 59 Mitsubishi Heavy Industries. . . . . . . . . . . . . . . 2
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Mitutoyo South Asia . . . 101, Front Inside Cover MMC Hardmetal . . . . . . . . . . . . . . . . . . . . . 23 MotulTech India . . . . . . . . . . . . . . . . . . . . . 69 Omron Automation . . . . . . . . . . . . . . . . . . . . 3 PMT Machines. . . . . . . . . . . . . . . . . . . . . . 11 Premium Transmission. . . . . . . . . . . . . . . . . 38 Quaker Chemicals . . . . . . . . . . . . . . . . 13, 76 R3 Events . . . . . . . . . . . . . . . . . . . . . . . . . 93 Renishaw . . . . . . . . . . . . . . . . . . . . . 12, 102 Robert Bosch. . . . . . . . . . . . . . . . . . . . . . . 26 Rockwell Automation. . . . . . . . . . . . . . . . . . 10 Roland Berger Strategy Consultant . . . . . . . . 20 Royal Precision Tools Corporation . . . . . . . . . 85 Schuler . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Schunk . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Seco Tools. . . . . . . . . . . . . . . . . . . . . . . . 102 SEYI . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Siemens PLM . . . . . . . . . . . . . . . . . . . 38, 68 SKF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Sofimu . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 TECNUN (University of Navarra) . . . . . . . . . . 88 Terragni Consulting . . . . . . . . . . . . . . . . . . . 44 Triune Exhibitors . . . . . . . . . . . . . . . . . . . . . 97 YG1 Cutting Tools. . . . . . . . . . . . . . . . . .18,19
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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2015 India Altair Technology Conference July 14 – 15, 2015 | The Ritz-Carlton | Bangalore
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