MART February 2013

Volume 9 Issue 8 February 2013 Pages 68 `100

CARBOLOY

Global launch at IMTEX from Dormer

Automation, walking the talk in Manufacturing Machine Vision to keep India’s manufacturing industry globally competitive

Gemba Kaizen Implementation Managing a SME in India Mandatory CSR- The Road Ahead Haas Makes Light Work

Dear Readers, Time is trust in Journalism. Timely news has the power to make people trust on it, making it the ‘burning topic’ of debate @Prime 9 and then by one ultimate day the ‘burn’ smears away by timely order.

Now, it is the time to go digital and so people trust! ‘Apps’ are in vogue.

Reading online, purchasing online are today’s ‘smart’ talk. God forbid, we can experience some day that people will trust sleeping online! The ‘smart’ machine in your pocket is your best pal-serving you all the time downloading ‘apps’ on how to measure your heart-rate, what to include in your diet, how to memorize your lessons. A recent study reveals that by 2013-end, mobile devices will outnumber humans. Good riddance from brain-storming! But if the question is not of ‘where’ then ‘how’ to use your brain to “get idea Sirji?”

Foreword

Survival of the Fittest

Well, time will tell. As of now, ‘apps’ are apt at the race of ‘survival of the fittest’.

To fight with the current economic slowdown, the Commerce & Industry Ministry is batting for lower taxes on companies, arguing this will improve higher investment in corporates. Over the last five years, India’s economy has nosedived from over 8.5% to 5.5%. Now it’s time to look upon a budget somehow different- a budget for the common people, talking of funds for social and infrastructure development, accelerating implementation of reforms.

Trust is crucial to enhance any relationship- be it personal, professional or public. Sarcastically, trust between Indian Government and the people, this year is dependent on the budget proposal and thereby, Election!

Countdown begins for the UPA’s political strategy. Let time speak the last word.

In our February edition of ‘MART’, we are featuring Automation & Robotics. Robotics, today is progressing rapidly in India in sectors like Automobile, Aerospace as well as Medical engineering. We have done exclusive interviews of the people from this industry to update you with the latest technologies and happenings in Automation.

Along with the regular columns on Quality Management, Manufacturing Excellence, Industry Updates, we have done a quick wrap up of IMTEX in the Fair Mart section.

We look forward to your sincere feedback on our quality and quantity of MART. You can reach me at +91 85530 12371 or email me at hiya@ martinfotech.in. Your reviews help us to make MART, SMART!

Hiya Chakrabarti Associate Editor

February is a month full of events on manufacturing. By January-end, IMTEX has stimulated the trust and optimism among people and the flow of enthusiasm has been noticed in the concurrent shows of IATF (Mumbai), Weld India and Aero Show in Bangalore. We trust, maximum investments will happen and this will accelerate the Indian economy.

Volume 9 Issue 8 February 2013 Annual Subscription `1200 Member INS

10 Cover Feature

Automation, walking the talk in Manufacturing Leader Speak

16 L R Katrat

12 Satish Sadasivan

Managing Director, Felsomat India

Articles

Regular Columns

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22 Safe data transfer for robots 40 24 How to connect robot cells to any industrial network

26 Automated Storage and Retrieval Material Handling Systems

28 Machine Tool Runoff Cutting

Titanium Confirms Advantages of ‘Ultimate Tuned System’

30 MultiCon = Meter + Controller

Gemba Kaizen Implementation Saravjit Singh Machine Design FundamentalsProfit Improvement A S Shetty

42

Managing a SME in India P S Satish

44

Green machining initiatives from Felsomat G P Bhat

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Mandatory CSR- The Road Ahead J R Mahajan

+Recorder + HMI in one package

51 Ascent

Case Study

32 Haas Makes Light Work

63 Mart Update

53 Fair Mart

34 NORD supplies powerful drives for the European brew house

Associate Editor

Hiya Chakrabarti hiya@martinfotech.in +91 85530 12374

Editorial Advisory Board

18 K P Chander

14 A K Menon

Managing Director, Strategi Automation

manufacturing industry globally competitive

Hari Shanker hari@martinfotech.in +91 9743 181818

Managing Director, Katlax India

Managing Director, Schunk India

20 Machine Vision to keep India’s

Managing Editor

65 The Last Leaf

A S Shetty Saravjit Singh Manoj Kabre P S Satish

J R Mahajan LD Bhakre Mahesh R P

Siji Nair

Content Editor

V Viswanath

Art & Creative Head

Baiju G Nair

Accounts

Suresh accounts@martinfotech.in

Manager Customer Support

Prathibha Prakash +91 9964 181818

Sushama Prakash +91 8553012372

Circulation Officer

Mamatha S Mallapur +91 8553012374

Regional Directors Ahmedabad

Narendra Vora +91 8734999636

Bangalore

John Heston +91 98451 42405

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Balu G +91 9840918972

Pune

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MediaMart Infotech No:217, 3B Main, OMBR Layout, Bangalore – 560 043 Tel: +91 85530 12375 Fax: +91 80 25426934 Email: info@martinfotech.in Visit www.ibmart.in

Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, Bangalore – 560 043.

Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed in the journal are not necessarily those of the Publishers.

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COVER FEATURE

Automation, walking the talk in Manufacturing

Hiya Chakrabarti hiya@martinfotech.in

How do you feel when you get your works done through multi-tasking? Less people, less time, maximum work- these are the primary conception of a layman when it comes to Automation. Well, the scenario, though more or less the same, the inside story is more on hard work, accuracy, efficiency and quality. Most of the Automation solution needs workers on site.

India, being one of the states for the rapidly growing Machine Tools, Aerospace, Medical engineering and Automobile sector, Automation is playing a big role in Manufacturing Industry.

“Automation or Robotics in a labor intensive market would have expected limited relevance but the unlimited capability of automation has quickly translated into success with a significant

demands. These include asset management, production engineering and simulation, energy conservation, material handling and packaging, mechatronics, material and human safety, quality of work

1947, when General Motors established the automation department. At that time automation technologies were electrical, mechanical, hydraulic and pneumatic.

Between 1957 and 1964 factory output nearly doubled while the number of blue collar workers started to decline.

Recently, in the Automation facilities, the machines often do their work autonomously through sensors; thus making the production cost as well as time effective, reducing the hiring cost of manpower. However, in some plants, the machine can only execute by the instructions given by an engineer. It is helpful for boosting up economy. Two countries, Germany and Japan increased its income due to automation during 20th century.

“Most automation component manufacture requires huge capital investments in plant and machinery.

Most of these are imported today.

Festo’s New T-Gantry and H-Gantry Herald a New Era in Packaging Handling Systems with Packing Cycle Times of 670 Milliseconds. Festo delivers the systems directly to the packaging machine, ready to install and adapted to all required machine interfaces.

role in the Indian Industry. Today, robotic or automation is not limited to the regular task but rather used for reliability, multitasking and higher productivity.” said Mr.Satish Sadasivan, MD, Schunk India Pvt Ltd. India is investing on its infrastructure to promote the industries and Industrial Automation is required for almost every industry to compete with the Global speed and accuracy.Leading academia and industry stalwarts emphasize that understanding the principles of automation will enable engineers across various industries to demonstrate new competencies that global leadership

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and environment, and tracking and tracing systems. Automation catalyzes the safety and reliability of the industrial products, thus making them globally competitive.

Worldwide, the lesson of automation is expanding rapidly at retail operations.

From product display and promotion to shelf stocking, Automation is being used effectively. Here, India is still in a very nascent stage. However, the changes are happening and growth will surely hit the Industry with a positive note!

The term automation, inspired by the earlier word automatic (coming from automaton), was not widely used before

“Small industries do not generally spend on R & D, since they work on very low margin.Some of the control electronic hardware, with a high reliability is either not available or not known for the brand image.

Therefore, Industrial Automation has not been expanding in a big way in India, though there is a marginal progress.”

R Seshagiri Managing Director, Gears & Gear Drives (India) Pvt Ltd

February 2013

Robotic surgery is used in cancers that include gynaecological, kidney and prostate, colorectal, thyroid, lung and esophageal.

The government must offer attractive incentives to manufacturers who would like to set up local manufacturing facilities”, claimed A.K.Menon, Secretary, ISA Bangalore & Director, Strqategi automation solutions Pvt Ltd. Like automated manufacturing, waste management can also be done through Automation technologies. The costs of automation to the environment are different depending on the technology, product or engine automated. There are automated engines that consume more energy resources from the Earth in comparison with previous engines and those that do the opposite too. Oil refining, manufacturing of Industrial chemicals and “Introduction to Robotic surgery is a boon to the cancer patients. So far the technical support was limited to imaging. The experience, skill and efficiency of a surgeon used to play the major part, and he had to perform 10-11 hours of nonstop surgery every day. In place of humans with two hands turning around 90 degree, with possible tremors, is now replaced with a state-of-the-art advanced computer system integrated robot, with four arms turning around 360 degree, removes all tremors, gets the highest precision and quality on surgery.”

Dr. Somasekhar S P Robot Surgeon, Manipal Hospital

February 2013

all forms of metal working consume much energy. However, R&Ds are happening to make the process more environmentfriendly.

Recently on a report, we have seen the world’s first bionic man REX, created with synthetic blood, organs and tissues, thanks to the robotics team of UK. Again, Nasa is planning to launch a spacecraft to an asteroid in 2016 and use a robotic arm to pluck samples from a Near Earth Asteroid which will help understand the solar systems in a better way.Here, how far the India has progressed on the latest technologies of Robotics& Automation?

able to perform precision surgery to our patients. We call it infusion to precision” said Dr. Somasekhar S P, Robot Surgeon, Manipal Hospital, Bangalore. Robotic surgery is used in cancers that include gynaecological, kidney and prostate, colorectal, thyroid, lung and esophageal.

India is progressing and the Machine Tools industry is playing the catalyst in Automation sector. What is needed is more R&Ds in premium technological institutes, implementation of latest world-class technologies and overall, the support from The Government. Let’s not only hope, but execute it.

“Traditionally Indian Industries work on the basis of lesser cost on end products.

Instead of using Automation, they prefer the man power. Indians are successful in Frugal Engineering (Juggad). Any Automation Design and Development costs investment; hence many a times takes a back seat” commented R Seshagiri, Managing Director, Gears & Gear Drives (India) Pvt Ltd, Bangalore.

We can say, it is not much of other global giants, but on health, Robotics, indeed is helping to beat Cancer. Robots are helping in surgeries related to Cancer treatment and in Manipal Hospital in India; the technology has already been implemented. “Surgeon can sit anywhere in the world, gets the 3 dimensional images with 15 times magnified view, can perform the surgery with the robot. Every second the robots checks for 1600 errors which gives zero error and zero tolerance. Now with a surgeon’s brain and skill, we are

Rex worlds first bionic man www.ibmart.in

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LEADER SPEAK

Automation has optimized Reliability, Multitasking and Higher Productivity Schunk India, one of the world wide subsidiaries of SCHUNK GmbH & Co. KG in Lauffen / Germany since 2001, is today the largest manufacturer of clamping technology worldwide and European market leader of grippers for industry robots. Quality, efficiency, service and particularly reliability are the priorities at Schunk. Excerpts from the interview with Mr. Satish Sadasivan, Managing Director, Schunk India:

Automation and Robotics has taken a leap in the manufacturing industry. Tell us what are the latest technologies and new inventions hitting the Robotics Industry?

Automation or Robotic in a labor intensive market would have expected limited relevance but the unlimited capability of automation has quickly translated into success with a significant role in the Indian Industry.

Today,robotic or automation is not limited to the regular task but rather used for reliability, multitasking and higher productivity.

Right from part handling and assembly, automation has optimized reliable productivity with post operations incorporated within the limited cycle time. For example, Metrology, quality assurance, de-burring and more, are tasks which can be encapsulated within a part handling cycle, which otherwise would need separate stations and further time to realize.

Moving Robots also enhanced their utility considerably.

Where does India stand in Robotics

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Sector? How Schunk is going to help in progressing in manufacturing?

to innovate its program to add greater meaning to automation and robotic.

While a Robot is a machine that allows controlled motion with a predetermined payload, the usability, application and optimization is rather a lot dependent on the end effectors which is the core competence of SCHUNK. In the last 10 years, SCHUNK offered to the Industry, end effectors that changed the way robots were expected to work.

Schunk is the European leader for supplying grippers to Robots. What are the plans for India?

Robot tool changers got the robots absolutely flexible and multitasking. The tool changer ensured that several tasks could be undertaken within the least time and with a maximum number of varied end effectors and with great sense of security and reliability.

Pneumatic and electrical grippers ensured regular gripping options combined with possibility for quick programmable stokes with options to regulated stroke time and forces using the electrical gripper. This in turn offered possibility to grip variety of work pieces without the change of grippers.

SCHUNK Dextrous Hand allows complicated and almost near human hand capabilities with a robot.

The 6 axis force torque sensors from SCHUNK, allows the sensitivity and feel from a robot that makes it possible for tasks like distant robotic surgeries, dexterity study and more.

SCHUNK , the family owned company ensures

The company sets standards worldwide and so there are no second thoughts that in India too, we would like to be the most preferred automation provider. We work very closely with our OEM partners and already have a sizable market share for Grippers and we wish to further capitalize in industries where a potential to grow further, remains. With products which offer life time warranty, like the PGNplus grippers, I am sure the market understands and recognizes the reliability and security we offer.

Which are the sectors Schunk India is now focusing on to apply its Robotics solutions?

Food & Beverage and Phrama sector will be very interesting for us in the next years apart from the every important automotive Industry.

As mentioned earlier, SCHUNK is ready with automation solution in strict adherence to international standards.

For example, we offer grippers made from food grade stainless steel and lubrication free moving parts which are the right fix for the F&B and Pharma industry.

Obviously we are very keen to upgrade the knowledge of educational institution and R&D centres by providing the latest technology available today

February 2013

and have the engineers and research scientists ready at an international technology level, from the start.

Schunk is holding ‘6th International Expert Days- Service Robotics’ in Germany. Can you please brief us about this?

SCHUNK Expert days is a unique initiative from the SCHUNK family to bring the most advanced development in robotic, automation and artificial intelligence, under the SCHUNK roof every year. The program runs purely on highly advanced technology with high quality subjects and research papers presented during the program that allows the participants and audience to exchange views and share the high level of innovative knowledge.

SCHUNK is known for its competence and innovation and the expert days is just a signature of the organization’s endeavour in this direction. The program is open and brings the best brains in artificial intelligence,

February 2013

automation and robotic under one roof and from across the globe.

Schunk India to bridge up the gap between Industry and Academia?

What are the future market plans of Schunk India for Robotics Industry? How in over all can it boost up the economy?

As mentioned earlier, one of our immediate focuses is to work with the educational institution and R&D centres to have knowledge ahead of its implementation. In this direction, we already have partnership with engineering community and educational institutes to offer all the knowledge that can be available.

Automation could be perceived as an antonym in a tired and slow economy.

However, SCHUNK with its innovative ideas and solutions will ensure cost and process optimization with its automation solutions and we are geared up to push the needful energy into the industry to a feel the urge to own competence.

We have plans to take up promotions and training programs throughout the year and we look forward to spending more time and focus on the industry and users.

Industry more often talks about the shortage of talents. In Robotics, one must have the proper skill to work in plant. What are the developments happening inside

Obviously, one must know the possibilities and on the other hand our own R&D facility in Germany is in focus to build systems that needs little manual interference. The win-win situation is expected to have our systems and products go without much of human indulgence though.

We also have initiative to start a high technology training and demonstration centre in Bangalore to train all those who have an appetite for premium technology.

Overall, we believe in offering the best in terms of product, service and knowledge.

www.ibmart.in

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LEADER SPEAK

Simplification and Uniformity of Regulations are the Urgent Need in Automation Since 1996, Strategi Automation is among the pioneers of Automation & Robotics. Specialized in motion control solutions, it offers solutions to various industries like Packaging, Printing, Machine Tools, Instrumentation, and Robotics etc. From a small conversation with Mr. AK Menon, Director, Strategi Automation Solutions Pvt Ltd, excerpts: in particular by reducing the number of statutory compliances for manufacturers.

The myriad rules and regulations sap the energy of entrepreneurs in trying to comply. Simplification and uniformity of regulations are the urgent need of the day.

Which are the segments in Indian manufacturing where application of Automation is a necessity?

What are the changes India witnessed in last 10 years in Automation sector?

India has been benefitted by the availability of high reliability and performance automation components at economical prices in the last 10 years. Every major automation player has a presence in India today.

Knowledge about the applications and benefits of automation has percolated into many industries. India is adopting automation technology and processes rapidly.

Automation is already adopted in a big way in the Auto sector and auto ancillary sector in India. The need for automation is already felt in many segments for its benefits in repeatability, accuracy and quality control.

The food processing segment is likely to see large scale adoption of automation in the near future and is an urgent necessity wherein we are likely to see a lot of packaged foods in our store shelves.

Could you please brief about the Factory Automation Division of Strategi Automation?

Strategi Automation provides positioning solutions. We design, manufacture and instal positioning systems like XYZ positioning stages, gantries, pick and place mechanisms and machine loading, unloading mechanisms. We have provided custom built positioning solutions to several of India’s leading companies.

What is the role Strategi Automation is playing in bringing the latest Automation processes in Indian Manufacturing?

Strategi Automation has always been at the forefront of innovative solutions in motion control. We pioneered economical positioning solutions with PLCs and also propogated digital network positioning solutions.

Latest international offerings like direct drive motors and BLDC motors for power saving have been introduced to progressive customers. Our strategy has been to differentiate our product and service offerings while providing the maximum value to our customers.

The Factory Automation Division (FAD) of

Comparing to the other leading manufacturing nations, India is still in a very nascent stage. What are the measures industry as well as the Government should initiate to transcend this backlog?

Most automation component manufacture requires huge capital investments in plant and machinery. Most of these are imported today. The government must offer attractive incentives to manufacturers who would like to set up local manufacturing facilities. This will not only generate employment but will also give the opportunity for consumers to access products at reasonable prices.

The government must encourage manufacturing in general and automation

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Strategi Automation is the System Integrators for Adept Robots in India February 2013

February 2013

www.ibmart.in

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LEADER SPEAK

Automation is more about Accuracy and Speed Katlax, established in 1993, is completely dedicated to the offerings in latest Sensors & Automation. In following 9 years it added more than 200 products to its portfolio, thus making ‘innovation in action’. A small conversation with Mr. L.R.Katrat, Managing Director & Chief Executive Officer, Katlax Enterprises Pvt Ltd is as follows: industries. How much emphasis is being given to promote automation in the industry?

Tell us about the present Automation scenario in India. What is the global market position?

Automation in India is way behind developed countries but certainly picking up. The low cost labour which is illusion and low investment are some of factors deterrent to growth of automation.

The major reason for poor use of automation technology is low volumes and inconsistency in products and process. The attitude towards quality and conservation either resources or environment are casual hence there is no pressure on voluntary enforcement of automation in many industries.

Whereas in developed countries such as Europe, US, Japan & Canada there is acute shortages of skilled manpower and quality and conservation conscious society is compelled to use of automation to optimum level. In India automation means Industry whereas in developed world automation has far reaching applications such as Agriculture, Security, Building, Banking, Retail, and Healthcare and so on.

I think India will take few more decades to reach level of automation these developed economies have attained and it is huge opportunity for automation vendors for robust and sustainable growth.

Automation is needed in almost all the

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In India automation is picking up in Banking, Stock Markets and in a small way in Process and factory automation but lot needs to be done in areas such as security, building, power sector, utility, municipal services, health care, infrastructure, law and order administration, judiciary and so because most of present days problems which lead to slow action, poor delivery system leading to corruption is result of non-transparency and too much dependent on human intelligence which is vulnerable to manipulation can be avoided through transparent automation. Automation is process defined with consistency in operation and behaviour of tested components and free of human bias.

The components and system that carry automation follow protocol and consistent without abrupt behaviour and without any fatigue, emotions and controlled by any person following defined protocols. With increasing cost of labour and inconsistency in performance, pressure on quality and timely deliveries and competition as result of market economy now automation is only Mantra to face these challenges and to remain in business. Apart from these considerations there are some process and tasks which cannot be done by Human where automation is only remedy.

‘A robot is doing maximum work in lesser time’ - that is what the common perception about Automation. How will you define Automation in a larger

perspective?

Robots are not only performing complex tasks that human being cannot perform but also with lot of accuracy and speed. There are processes which involve hazardous nature of operation like welding, painting, powder coating and chemical process that Robot alone can carry out. Robots is ultimate form of complex automation but there is automation with basic components such as sensors, actuators, conditioners and data loggers which can replace good number of manual operations with lesser cost and with consistent and efficient performance.

Take a small example of Detergent Pouch packaging case.

You need to pack 500 gm of detergent and say 10000 packs for 8 hours shift.

With normal manual operation it will need sizeable number of manpower to carry out these operation but it is possible with simple pouch filling line with bear minimum automation.

There is hopper with say 100 Kg Detergent capacities which is filled by conveyor belt from Silo which carries detergent powder produced or sourced from manufacturing unit. By using Load Cell and the volume and weight of Hopper will be detected by level sensors.

There are 2 sensors one for lower (Empty) and second for full (top) level. These sensors will control hopper filling by controlling conveyor feeding. The quantity of 500 gm pouch is controlled by flow

In automation systems various elements play an important role, interface products connect these parts.

February 2013

What is the role Katlax playing in bringing the latest Automation processes in Indian Manufacturing?

While I discussed broad areas of automation and possible opportunities, Katlax has consciously decided to remain in very tiny spear of automation confining to Factory, Process, Machine , Logistics and Assets tracking automation. Our focus is to address conservation of resources and energy with affordable price and reach to lower strata of society. We believe that any initiative we introduce in automation is primarily help common man by way of availability, affordability and accessibility and it should be user friendly with no barriers in use and maintainability.

using timer or weight using load cell. For every 500 gm the hopper outlet will open and fill pouch which in turn will count using counter and it will seal bag.

The bag is moving on conveyor and by simple photo sensor each pouch passing on conveyor is counted by counter. The preset counter for set value/number will give signal which can operate hopper filling from silo and stop whole operation. The signal after every pouch filling will operate cutter of pouch bag and also provide signal for label carrying details of batch and Serial Number. The automated process will also transfer pouches in stack form to packing and with lot of 50 or 100 as required will be packed in corrugated box.

From raw detergent powder from Silo to Loading in vehicle can be done by using Low cost automation components such as sensors, load cells, cutters, solenoid valves, conveyor belts, motors and controllers like Relay Logic or advanced PLCs and HMIs. Automation is concept and the limits are endless in terms of speed, accuracy, reliability and reports. The most important thing in deciding automation process is to study existing process and analyse on basis of what is required from automation. It is like system analysis in building software solution.

What are the major changes in the Automation Sector we can see for India in the near future?

Automation has made definite impact in

February 2013

factory, process and machine automation but it is long way to go in Building automation which is fast growing. Then with privatization of Highways and Pay and Park facilities there is need for automation on movement of vehicles and duration for usage and charge the toll.

Then there is automation like public utilities such as street lights, municipal water supply and vigilance. Then there is automation in traffic both regulating by using signaling system and check traffic offenses by installing vigilance cameras and logging data of traffic violators.

Entries to public places such as parks, auditoriums and places where entries are regulated on chargeable basis. Airport services where Entries, Luggage trolleys and other services including use of Toilets have to be regulated for authorised users.

The other major area where automation is very much needed is disaster managements such as floods, cyclones or natural calamity where warning has to go automatically and people are warned for evacuation.

In short whatever human intelligence can do, the same can be done more reliably with less manpower and for low cost is sum total of automation reach. Indian is learning fast to explore possibilities and soon we will see automation everywhere including data on visitors to temple and melas by using simple sensors, counting devices and data loggers.

We through our 4 SBUs have launched series of automation solutions from component to system level. From Sensors and Field Devices (SFDG) we offer basic sensing elements or sensors for sensing position, interruption, motion, presence, absence, level, speed, colour, pressure, direction etc. These sensors are like membrane of Human body.

To connect these sensing devices or to transfer sensors intelligence, we have Interface Products (IPG) which provide vital link between sensors to intelligent controller and to controlling device. It is like nerves of Human body. We offer wide range of connector cable assemblies with I/O Junction Boxes which are Highways or artery roads moving sensor data to controllers and to actuating devices.

Then we have Control and instrumentation (CIG) which accept intelligence from sensors through cable/ connectors and process and take appropriate action of controlling, storing, analysing action.

These controllers act like Human brain and they communicate to sensors and output/ actuating devices like nerve system of Human body.

Then we provide integrated solution of asset tracking of valuable cargo and provide solutions such as pilferage, adulterations, theft by using sensors and GPS technology. We have implemented this solution using patented technology in India and now in US, EU and Israel for Energy sector. We are Company known more for innovative solutions with less emphasis on commercial exploration which make us unique Indian Company on Globalised Indian map of automation vendors. www.ibmart.in

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LEADER SPEAK

Manpower Shortage is the Root Cause of India Lagging behind in Automation From global innovation leader to global system provider – Felsomat is on top in quality, reliability and energy efficiency.

Felsomat has started a new era in production technology,leading the way with powerful, cutting-edge technology and automation that provide you with the perfect, total solution. From a small conversation with Mr. K P Chander, Managing Director, Felsomat India Pvt Ltd, excerpts: necessity. Already, automation is widely accepted in critical areas like welding etc. and many companies are in the mode of experimenting with automation. Those who have made the first investment correctly are coming for repeat requirements.

Felsomat, being a German company, has strongly shown its presence in USA, UK as well as Asia. Tell us which the best market is for Automation.

Tell us about the present scenario of Automation Industry in India. What is the global market position?

Globally, in the context of developed countries, automation is at a very advanced stage. Automation is used in these countries not only for replacement of costly manpower, but also for achieving high quality and flexibility to handle multi products / models in manufacturing with quick set up changes.

The best markets for automation for Felsomat continue to be Europe and US. The demand for productivity, quality and Flexibility are highest in these markets and Felsomat continuously develops new and innovative products to meet complex requirements of these markets.

Felsomat offers Assembly and Heat Treatment which was an unobtainable goal. Please brief up about the procedure.

Felsomat has developed flexible assembly systems for transmission assembly in automotive industry. These are conceptually totally different from

the conventional assembly lines used in the Industry with many features to eliminate errors in Assembly. Unlike the conventional lines where assembly stations are positioned serially in the sequence of assembly, in Felsomat systems, assembly stations are positioned flexibly as required to maximize manpower utilization and to suit requirement of logistics.

Each and every activity in the assembly stations is monitored by cameras and suitable operators prompts etc are provided so that the assembly will leave that station only if it is OK. A programmable transportation system moves the parts between assembly stations as per the assembly sequence.

Today, heat treatment is a process for which the continuity in manufacturing line is interrupted. Parts are transferred in lots to heat treatment section, creating inventory pile up. Felsomat is working with a heat treatment system manufacturer to develop automated, in line heat treatment system that can be integrated into gear manufacturing lines directly for single piece flow manufacturing

In India, automation Industry is just coming out of the nascent stage and is poised to grow rapidly in the coming years. One factor that is going to drive this change, surprisingly, is manpower shortage. Even though we say we have abundant manpower and labor cost is still considerably low in our country, availability of quality manpower, their reliability and ability to achieve required output with consistent quality are issues ofconcern faced by many companies.

The second factor is, manufacturing Industry is rapidly adapting latest machine tools and cutting tools for increasing productivityand productive use of these expensive machines makes automation a

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February 2013

Felsomat - Market Leader with integral automation platform

What are the R&D developments happening in Felsomat, India. How is it going to help the manufacturing sector?

Automation solutions from Felsomat Germany are targeted towards the requirements of mature markets for automation, especially towards car industry. Today, these solutions are very sophisticated and expensive for the Indian market.

At Felsomat India, we are working on adapting that technology to the requirements of Indian market. For example, we have indigenously developed

February 2013

smaller Gantry systems for the 2 wheeler and small component industry and today they are widely used. Our focus is on developing affordable solutions for the Indian market to promote the growth of the automation in Industry in the Indian market.

Where you see India in Automation manufacturing industry in the next 5 years?

I would say automation Industry in India today is at the same stage where CNC machine tools were 10 to 15 years back. In those days, buying a CNC machine tool was

expensive and was a major decision, but today no one raises a question.

Today, companies are feeling the need for automation, but are hesitating to invest even though they feel the need for the same. I see that in the nest 5 years, automation becomes an integral part of manufacturing and will be widely used in many areas by many companies. The challenge for the automation suppliers is to make automation systems affordable for many, the way CNC machines are today.

That I would say is the key to the growth of the automation Industry.

www.ibmart.in

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FACTORY AUTOMATION

‘Machine Vision to keep India’s manufacturing industry globally competitive’

Didier Lacroix vaggu.sunil@cognex.com

India ranked as one of the fastest growing markets and has seen an upsurge in the number of manufacturing facilities across the country. Despite this, it remains grossly underinvested in factory automation – necessary for long-term competitive success in both domestic and foreign markets. material and labour costs coupled with process inefficiencies are dulling Indian’s competitive edge.

India’s future depends on adopting appropriate automation, innovation, technology and empower its talented, English-speaking workforce.

India, Automation, and Global Competition

DataMan 300

India’s Manufacturing Success Story During the past decade, India has emerged as one of the key manufacturing hubs for global manufacturing companies in the automotive, pharmaceutical, packaging, food processing, and textiles industries.

In 2010, Deloitte Touche Tohmatsu ranked India as offering the second best global manufacturing platform in the world, above traditional manufacturing countries such as the U.S., Germany, and Japan.

Innovation combined with a talent pool of scientists, researchers and engineers is more critical to manufacturing growth on the global stage rather than low cost energy, labour and regulations, it stated.

Within the country, the domestic manufacturing sector accounts for nearly 17% of India’s total GDP and employs nearly 100 million people (per ASSOCHAM estimates). Frost & Sullivan’s IPC Practice predicts that by 2020, this would generate 25% of the country’s GDP. However, Frost & Sullivan analysts add

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that this growth will only be realised through adoption of factory automation that enable greater efficiency, productivity, sustainability, global competitiveness and standards compliance.

Cognex’s Machine Vision Enhance Factory Automation

Automation in India has always been a shop floor tool rather than a “business performance enabler.” When it comes to core manufacturing processes, manufacturers rely on labour-intensive methods. Even with factory automation in place, the technology threshold is fairly low, when compared to world standards, due to lack of knowledge and awareness.

Based on their prior experience, significant investment is being done by established manufacturing hubs in the US and Japan in India to increase efficiency and flexibility of their supply chains while improving upon product features and quality in the

Cognex Corporation is a leading supplier of machine vision systems. It’s ID and Vision systems address all three critical areas in the manufacturing process: inspection, identification and guidance for industries including automotive, electronics, pharmaceutical, food processing & packaging, and consumer goods, Cognex’s image-based ID systems can meet all the 1-D barcode and 2-D code-reading requirements. Since its inception in 1981, Cognex has shipped more than 500,000 machine vision systems representing more than $2.5 billion in cumulative revenue.

Despite all this, the domestic manufacturing industry is facing competition from emerging manufacturing hubs in Asia and South America. Increasing

In-Sight7000 February 2013

Machine vision systems can be broadly categorized into two different types of systems that use the same underlying technology: • Identification (ID) Systems: When used separately or together help manufacturers improve their manufacturing process and cut costs.

DataMan50 for consumer products

automotive, pharmaceutical and food processing industries. An increase in the demand for such solutions is already being witnessed in the Asian region.

Automation technology providers offer variety of factory automation technologies, including machine vision. Manufacturing equipment and robotics “make” products, while machine vision provides quality assurance, product tracking and documentation for standards compliance.

Machine Vision: Key to Improving Quality, Productivity Machine vision systems address three critical areas in the manufacturing process: identification, inspection, and guidance.

Identification refers to tracking and tracing raw materials, components, and products throughout the entire production cycle.

It tracks any industrial code, including engraved or embossed serial numbers placed on a product, tells manufacturer how, when, and where it was produced and raw materials used to manufacture the product, supplier identification, and any number of other important production data.

Inspection refers to presence or absence checking and dimensional checking where manufacturers make sure that a part is manufactured to critical dimension.

Guidance is the use of vision to locate a part, feature, or pattern to automate the mechanical handling of that part during assembly, material handling, and packaging processes.

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• Create total visibility and measurement by automatically retrieving codes and other identifying marks on raw materials, components, and products as they move through the manufacturing supply chain.

• Enable accurate, timely information about a specific item, which can be stored, retrieved, and analyzed in easyto-use manufacturing databases that, in turn, help manufacturers with: • Removing hidden inefficiencies in material handling productivity • Tracking the flow of operations One such company is Proteck, a Chennaibased leading manufacturer of printing equipment. Its printing operations use a variety of printing presses from different manufacturers, each with its own unique set-up and quality needs.

To streamline operations Proteck installed two Cognex In-Sight Micro cameras to detect registration marks on printing plates and automate the set-up process.

Cognex’sPatMax and In-Sight Explorer software handled different positioning requirements in the same machine, while Vision View terminal provided a way to view information such as plate positions, before-and-after position correction and the presses’ operating status.

At P&G India, Cognex’s In-Sight Vision System verified that right packaging and manufacturer’s recommended price

(MRP) were used for 50 detergent variants, each with similar color and features.

Previously, quality checks for the detergent packaging, was done manually in two separate rounds of inspection and verification. After deploying Cognex InSight Vision System along its packaging line, P&G has increased the line speed and bottom line as both inspection and verification are done simultaneously, eliminating packaging errors.

These show how Cognex’shelped Indian manufacturing companies reduce costs while improving throughput and quality.

For more information, please visit www. cognex.com.

The author Didier Lacroix is the Senior Vice President International Sales & Marketing with Cognex Inc. - He is responsible for Cognex worldwide marketing and training activities. These include positioning Cognex as the number one supplier of machine vision and industrial ID systems in all markets, running a lead generation engine to identify new projects at all major manufacturing companies and providing product training to the ever-growing customer base.

Peter has a great depth of experience, having been with Cognex for over 10 years and has worked in the machine vision industry for more than 20 years. For further details write to Cognex Sensors India

In-Sight Micro

Pvt. Ltd., Level 6: Pentagon Towers P II, Magarpatta City, Hadapsar, Pune - 411028 Tel: +91 20 66280011 Email: vaggu.sunil@cognex.com Web: www.cognex.com

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ROBOTICS

Safe Data Transfer for Robots

Sreejith Menon

Twistable optical fibre cable for 3D movements in energy chains

sreejith@igus.in

The “Chainflex CF Robot-LWL” has a fibre diameter of 50/125 µm and is suitable for almost all high-speed buses provided that suitable converters are used. This covers a wide range of uses in torsional applications, such as in energy chains on robots and machine handling where vision technology plays an exciting role.

Bus system problems often occur during twisting applications in energy chains, particularly with shielded data cables if the shields get damaged or open up.

This is not the case with glass fibre optic cables: These do not have a mechanically vulnerable shield braid, and they are insensitive to EMC whilst transferring highspeed bus signals up to a length of 400 m.

Following comprehensive tests, the Cologne-based company igus GmbH has now developed a new twistable fibre optic cable for all 3D movements in energy chains, to keep bus systems working reliably.

The twistable TPE fibre optic cable “Chainflex CF Robot-LWL” makes high data rates possible and can be routed directly alongside high-capacity electrical power cables. The special design uses twist-optimised compensating elements, and the mechanically strong fibre optic

cable is absolutely robust even with rotary angles of +180° eg on a robot arm.

One million cycles, 360° torsion angle The new fibre optic cable has been running on a test set-up 1 m long in the igus technical centre for more than 1 million double cycles. There is no change to the excellent data transfer rates even at a torsion angle of 360°. The fibre optic cable has a 2-fibre optic core, is resistant to oil, bio-oil and UV light and remains flexible in the cold.

The FOC wires with high-tensile aramid fibres and dampers are stranded firmly around a GRP core. The pressure-extruded outer sheath is made of a halogen-free TPE mixture. Highly dynamic in continuous movement, the cable can be used for indoor and outdoor applications at temperatures from -20 to +60°C. The “Chainflex CF Robot-LWL” has a fibre

diameter of 50/125 µm and is suitable for almost all high-speed buses provided that suitable converters are used. This covers a wide range of uses in torsional applications, such as in energy chains on robots and machine handling where vision technology plays an exciting role.

This helps to meet the requirements on moving quality control monitoring, which are becoming ever more demanding. The new fibre optic cable is a solution suitable for industrial applications for image transmission for GigE, FireWire IEEE1394a/b and USB. For further details write to Sreejith Menon, Product Manager - Chainflex®, igus (India) Private Limited, 36/1, Sy. No. 17/3 Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage, Mahadevapura Post, Bangalore – 560048 Tel: +91-80-39127815 Cell : +91-9342828642 Visit: www.igus.in

“Chainflex CF Robot-LWL” for energy chains – new 2-fibre gradient fibre optic cable for all torsion applications.

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23

ROBOTICS

How to connect Robot Cells to any Industrial Network

Anders Mandorsson anybus@ulepl.com

SVIA in Sweden use Anybus X-gateways to connect their DeviceNet-based robot cells to any network that their customers are using.

Seeing robots

able to determine how to pick it up.

Svensk Industriautomation (SVIA) is a fast-growing automation company in

Connecting DeviceNet and PROFIBUS

robots can easily communicate with another DeviceNet network, but if they are to be connected to another network, for example a PROFIBUS network (with a PLC from Siemens) or an EtherCAT network (with a PLC from Beckhoff) a “translator” is needed. Anybus X-gateways handle the conversion between the two networks through built-in software which restructures the telegrams from one side and make them understandable on the other side. The configuration is made in a matter of minutes by using the Anybus Configuration Manager software which means that no programming is necessary.

As most advanced automation systems, SVIA’s robot cells need to communicate with some kind of plant-wide industrial network and this type of communication is not always hasslefree. “A couple of years ago, we built a robot cell for a customer who Flexibility promised me access SVIA Anybus X-gateway installed to their PROFIBUS SVIA’s robot cells are very flexible and can system, but after easily be adjusted to cater for different a while, it became clear that our system customer applications such as mounting, Jönköping, Sweden, developing robot was only to be a separate node in their packaging, drilling and lathing. Through systems for customers in the Nordic network. That’s when we found Anybus Anybus X-gateways, SVIA can also be very countries, Germany, U.K., the Netherlands, X-gateways from HMS. We tried installing flexible when it comes to the network and the U.S. The systems are put one into our cabinet and it handled the they can connect to. “To be honest, we together to robot cells which are able conversion between our DeviceNet based don’t really think much about networking to communicate with other systems in a system and the customer’s PROFIBUS anymore,” says Anders Mandorsson. factory for example. system in a very elegant way,” says Anders “When we create a robot system, we The core of the robot cell is SVIA’s own Mandorsson. vision system called Pickvision, which Since then, SVIA has used Anybus detects exactly how a particular object X-gateways in many of the robot cells is placed on a conveyor belt and thereby they deliver to customers around the enables a robot to pick up the object. In world. Once again, simplicity is key. simple terms, you could say that SVIA “DeviceNet is the standard we use enables robots to see. This revolutionary in most of our cabinets and instead technology has become very popular on of handling the conversion to other the automation market and has enabled networks ourselves, we simply install SVIA to double its turnover during the past an X-gateway from HMS. It is cheaper, few years. but above all, it makes it easier for “Our strength lies in the simplicity,” says the customer since he gets a clear Anders Mandorsson, Designer and Project segregation between our system and Manager at SVIA. “It is very easy to tell the his own factory network,” says Anders robot what to pick from the carrier belt, Mandorsson. and then you are ready to go.” By using the How it works Pickvision software, users take a picture of the object which is to be picked from the SVIA’s robot cells usually come with belt. The software automatically detects robots from ABB which operate on the shape of the object and every time this In Pickvision, the operator decides what to pick from the conveyor belt. A photo is taken of each item and a DeviceNet based network. The shape shows up in the camera, the robot is the software identifies the shapes.

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Development and manufacturing takes place at the head office in Halmstad, Sweden. Local sales and support is provided by the HMS branch offices in Chicago, Beijing, Karlsruhe, Milan, Mulhouse and Tokyo. HMS employs over 240 people and reported sales of €42.5 million in 2011. HMS was formed in 1988 and is listed on the NASDAQ OMX Nordic Exchange in Stockholm in the category

When the robot cell is in operation, a camera in the ceiling monitors the belt...pick from the conveyor belt. A photo is taken of each item and the software identifies the shapes.

An Anybus X-gateway handles the conversion between the robot cabinet’s DeviceNet system and the end customer’s PROFIBUS network.

simply order the X-gateway which converts to the customer’s industrial network — we plug it in and it works.”

HMS Industrial Networks is the leading independent supplier of embedded network technology for automation devices. HMS develops and manufactures solutions for interfacing automation devices to industrial networks.

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Small Cap, Information Technology with ISIN SE0002136242.

...and makes it possible for the robot to know exactly what to pick, and how to pick it up.in the ceiling monitors the belt...pick from the conveyor belt. A photo is taken of each item and the software identifies the shapes.

For further details write to UL Electrodevices Pvt Ltd S.NO. 6/9/6, Bhairavnath Nagar Nahre Gaon, Tal Haveli 411 041 Pune Tel: +91 20 269 60040 Email: anybus@ulepl.com Visit www.ulepl.com

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STORAGE

Automated Storage and Retrieval Material Handling Systems from PARI

Team PARI

sales@parirobotics.com

Warehousing and distribution are about moving as many products to the market as possible, in the shortest amount of time and storing the material with maximum utilisation of the space and other resources.

While there are a variety of methods available, it is becoming increasingly necessary for companies of all sizes to replace manual methods with innovative Automated Storage and Retrieval Material Handling Systems (AS/RS).

Traditional manual systems have limited throughput of approximately 10 load movements per hour. This is in stark contrast to the average of 40 and more load movements an hour that are performed by our Automated Storage and Retrieval Material Handling System (AS/ RS). In addition to increasing throughput, it optimizes the utilization of labor.

Why AS/RS? Space Optimization Because an AS/RS removes ‘dead space’ in a facility by using very high density storage and fully utilizes the vertical space in a warehouse, the ‘footprint’ needed for storage can be drastically decreased.

In comparison with conventional storage, ASRS can utilize vertical space 3 times. This can have a significant impact on the initial cost of a project whether you are leasing, buying, or building a new facility.

Reduces Mobile Material Handling Equipment As the AS/RS performs most of the ‘travel’ necessary to put away and retrieve products, the need for mobile material

PARI is amongst the largest global automation companies with over 1000 + employees.

The solid engineering strength enables PARI to be a complete “Solution Provider” from conceptualizing, designing and manufacturing to implementing and supporting advanced factory automation systems. It provides its customers with the solutions www.ibmart.in 2626 www.ibmart.in

handling equipment such as fork trucks can be greatly reduced or eliminated altogether. If fork trucks are eliminated, so are battery costs, maintenance personnel, maintenance training, and floor space for them.

Product Security/ Safety

Many companies are finding it imperative to have accurate inventory information to be able to conduct timely replenishment operations and fill orders without “short” picks. The more touch points a product has with workers, the more likely an error can occur. AS/RS reduces the number of touches and improves inventory accuracy as the system knows where it put the product each time, every time and there is the added benefit that product can be pulled from any location at any time.

With automated storage and retrieval, product is stored in a secure, fenced-in area around the AS/RS. The only way product is delivered is via electronic pick commands through a WMS/WCS solution. Pick commands to the AS/RS system automatically track the SKU from storage location to a goods-to-person picking workstation, and back to the AS/ RS inventory after completion of the pick. This gives 99% or more traceability in the solution. Adding enclosed picking workstations for high-value goods can further increase the level of security.

Product is also safer with an AS/RS because of the reduced need for fork trucks moving product (and potentially damage the product or the facility) and the fewer touches on the product.

Order Accuracy

Ergonomics/Worker Safety

In this solution the SKU is delivered to the picker and presented to the operator ONLY when there is a requirement for that particular SKU. This, if integrated with an ERP, eliminates any chances of order pick discrepancies.

AS/RS bring products to an ergonomicallydesigned work station so that every pick is at the ideal ergonomic pick height to reduce the overall stress to the worker over the course of a shift.

Inventory Accuracy

they need to enhance productivity and achieve their manufacturing goals.

The company began operations in 1990, and has experienced business growth exceeding 50% year on year, through innovative solutions and focus on complete customer satisfaction. PARI has provided over 1500 automated solutions

Redundancy/Work Balance

worldwide. PARI was founded by technocrats with the knowledge and experience to understand the needs of the manufacturing industry.

Striving for excellence in every step of the process from sales to commissioning has allowed PARI to attain success. This excellence can be seen in their products, people and solutions.

PARI is in the field of ROBOTICS &AUTOMATION. The company has got a strong financial and infrastructural customer base in India. PARI is a leading global automation solutions provider with export of 33% of company turnover. PARI provides wide variety of industrial robotics solutions to a broad spectrum of the industry.

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bases that move in lateral direction, eliminating the need for fixed racks.

The aisles open up on operator request through the HMI provided for the operating the system. The required aisle is opened the case and remaining aisle/racks remain closed. This results in effective space utilization. The mobile bases have motors, slides, sensors etc. to ensure complete safety while operating it.

Truck Loading/Unloading Automation Material loading/unloading in the truck can be automated with proven technology at PARI. In this way, we can increase the overall efficiency in the warehousing activities. Truck loading/unloading automation can be interfaced and connected with AS/RS and internet data server for inventory management as well as dispatch order execution.

AGV — Automated Guided Vehicles Automated Guided Vehicles (AGV s) increase efficiency and reduce costs by helping to automate manufacturing facility or warehouse. The AGV can tow objects behind them in trailers to which they can autonomously attach.

The trailers can be used to move raw material or finished product.

The AS/RS places the same unique SKU into multiple storage locations spread across multiple aisles of the AS/RS, creating a highly redundant solution. This allows the WCS/WMS solution to choose the required SKU from multiple locations based on congestion within each aisle and quantity of available product SKU. This allows the WCS/WMS more options for delivering the correct tote to the workers during picking operations providing a balanced workload to them throughout the picking cycle.

The ‘Green’ Factor An AS/RS can easily be part of your February 2013

company’s overall ‘green’ strategy and initiatives. Reduction in your facility’s footprint means less building materials and less overall area to heat/cool and light so that your energy bill is reduced.

COMPACTOR SYSTEM — More Storage using Mobile Racks In this concept of storage automation the storage racks are mobile/collapsible type.

Loading/unloading of material is done semi automatically using either forklifts or reach trucks depending on the height of the storage. The storage racks are installed over guided rails mounted mobile

The AGV can also store objects on a bed. The objects can be placed on a conveyor and then pushed off by reversing them. Some AGVs use forklifts to lift objects for storage.

AGVs are employed in nearly every industry including pulp, paper, metal, newspaper and general manufacturing. Transporting materials such as food, linen or medicine in the hospitals is also done.

We have AGVs with battery, with Contactless Power Supply technology (without battery), with fixed path and flexible path options.

For further details contact Precision Automation And Robotics India Limited, Narhe Works, S/No 38/2, Village Narhe, Off Pune Sinhagad Road, Pune - 411 041 Tel: +91 20 66462300 Email: sales@parirobotics. com Web: www.parirobotics.com

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MACHINE TOOL

Machine Tool Runoff Cutting Titanium Confirms Advantages of ‘Ultimate Tuned System’

M S Satish

Info.india@widia.com

When it comes to sourcing capital equipment for machining specialty materials, many organizations would do well to remember the 10-speed bicycle analogy. People shop and buy a 10-speed bike for recreational or workout goals, but when riding rarely go beyond two or three of the most comfortable gears. Tour de France riders and other finely tuned athletes both size and operate all their components (frame, pedals, shifters, wheels, etc.) to get the absolute most out of their equipment, whether climbing mountains or racing in the flats.

Machining high-strength, high-temperature alloys like titanium is a significant mountain to climb for many shops. Machine tool builders have responded with milling and turning centers that feature improved

test cut on a titanium (Ti-6Al-4V) workpiece on the Mitsui-Seiki HPX63 CNC horizontal machining center equipped with four Kennametal tools, each using the KM4X 100 spindle connection.

utmost stiffness, its box way axis slides are hardened, ground, and hand-scraped.

Positioning accuracy and repeatability is 0.001mm. The spindle, Mitsui´s own, automatically compensates for thermal changes and does not require a »warm up» period. The company offers several spindle options to meet user needs for direct or gear drives and the amount of torque and rpm requirements.

Overall, the ruggedness, rigidity, and precision of the HPX-63 make it ideal for machining titanium, Inconnel, tool steels, stainless steels, and aluminum for the aerospace, energy, compressor, mold and die, fixtures and tooling, automotive prototyping, and general precision machining industries.

stiffness and damping on spindles and sizable machine structures and motors, all to provide the significant cutting forces required while minimizing undesirable vibrations that deteriorate part quality and tool life.

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The Machine

Achieving the ultimate system for machining titanium for maximum metal removal means paying close attention to the machine tool that provides the force, the cutting tool characteristics where the cutting edge meets the workpiece, and the spindle connection - the ´handshake´ between the machine tool and the cutter.

Key design criteria of the HPX63 include a large work capacity featuring a swing diameter up to 1050 mm and available work height (Y axis) up to 1050mm. Axis stroke is 1000mm in X and 900mm in Z. Pallet size is 630mm. The B-axis rotary table offers 12 rpm and high-torque, highacceleration availability. Rapid travel rates are 32m/min with 0.5G acceleration/ deceleration, and the cutting feed rate is 12m/min.

In April 2012, machine-tool builder Mitsui Seiki (Franklin Lakes, NJ) in connection with tooling and tooling systems provider Kennametal Inc. (Latrobe, PA) conducted a

Made for precision work, its castings are metallurgically configured for the

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A spindle connection that makes the best utilization of available power possible is an important consideration to achieving the ultimate system. Most tools in the market are solid and the spindles have relatively low clamping force. Connection stiffness is limited, as radial interference needs to be kept to a minimum. The required tolerances to achieve consistent face contact are thus very tight, leading to high manufacturing costs.

The Spindle Connection KM4XTM from Kennametal represents the next generation of KM. Some systems may

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309 cc/min. material-removal rate at a spindle speed of 171 min-1, 101.6 mm/min. cutting feed, 40 mm depth of cut and 76.21 mm cutting width. be able to transmit a considerable amount of torque, but cutting forces also generate bending moments that will exceed the interface´s limits prior to reaching torque limits. By using three-surface contact for improved stability and optimized clamping force distribution and interference fit, KM4XTM engineering results in three times the bending moment resistant capacity compared to other tool systems.

In the test cut, the HPX63 was equipped with a high-torque, high-power spindle with maximum 26/22 kW power and 1081 Nm torque. The KM4X100 spindle connection generated 85kNm clamping force, more than twice an HSK100 and three times that of a BT50 (40kNm and 25 kNm, respectively).

The Cutting Tools The four different cutting tools employed in the test were (1) a 203.2 mm diam. face mill with seven square indexable inserts, (2) the same diameter face mill with seven round inserts, (3) a 76.21 mm diam., 228.6 mm long helical (HARVI UltraTM) cutter with five helical rows of 11 inserts each, and a flat-bottom indexable (FBI) drill unit at 125 mm diam. with six indexable inserts.

With the power of the machine tool and spindle and superior clamping force of the spindle connection, test cut results were phenomenal across the board. For the square-insert face mill, the materialremoval rate reached 88.74 cc/min. at 64 min-1 spindle speed, 12 mm depth of cut, and 45 mm cutting width, feeding at 164.3 mm/min.

At 73 min-1 spindle speed, 177.8 mm cutting width, 3 mm depth of cut, and 88.9 mm/ min cutting feed, the round insert face mill achieved a 47.42 cc/min. material-removal rate.

The HARVI UltraTM helical cutter, cutting in X and Y directions simultaneously, topped February 2013

The FBI drill made a flat-bottomed hole in the titanium workpiece at 102 min-1 spindle speed, 10.2 mm/min. feed, and 125 mm hole diameter at 125.2 cc/min. materialremoval rate. Following the first hole, the workpiece was rotated 45 degrees away from the spindle and an angled hole was drilled pushing through the edge of the previous hole. In spite of the heavy interrupted cuts, both machine tool and drill performed well.

To the Max Compared to commodity or generalpurpose machine tools, the HPX63 is able to reach between 1.5 and two times the materialremoval rate in machining titanium alloy. And the KM4X spindle connection had enough clamping force and interference fit to allow a customer to use the higher RPMs and torque levels the machine tool and spindle can provide.

About Mitsui Seiki Mitsui Seiki’s machines are built for the utmost in durability and longevity for day-in, day-out, heavy-duty machining.

Our solid reputation is based on that.

Your productivity shines because of it. The better built a machine tool is, the less it costs in the long run because downtime is minimal. Further, we can provide long-term accuracy and uptime guarantees for you to consider when purchasing our equipment.

That is just one of the ways Mitsui Seiki distinguishes itself from other machine tool manufacturers. Ask us for the details or visit www.mitsuiseiki.com.

Kennametal Inc delivers productivity to customers seeking peak performance in demanding environments by providing innovative custom and standard wearresistant solutions. This proven productivity is enabled through our advanced materials sciences and application knowledge. Our commitment to a sustainable environment provides additional value to our customers.

Companies operating in everything from

More productivity potential is gained from the machine tool and more cutting performance is gained from the tool.

Moreover, a KM4X100 spindle connection will reach performance levels of an HSK125, but makes unnecessary the longer spindle, bigger tool-changer arm, larger tool magazine, and all the related increases a larger-footprint machine would require. Sizing the right machine tool with the right tools and connection can result in an ultimate productivity system for cutting titanium and other difficult-to-machine alloys. The connection can stay viable right up to the machine tool´s performance potential, which will drive the most out of the cutting edge, Milling, drilling, and even turning just got more productive.

airframes to coal mining, from engines to oil wells and from turbochargers to construction recognize Kennametal for extraordinary contributions to their value chains.

In fiscal year 2012, customers bought approximately $3 billion of Kennametal products and services - delivered by our approximately 13,000 talented employees doing business in more than 60 countries - with more than 50 percent of these revenues coming from outside North America. Visit us at www.kennametal.com

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MEASUREMENT

MultiCon = Meter + Controller +Recorder + HMI in one package

Arvind Gupta india@simexcontrols.com

The MultiCon series devices are advanced meters,controllers and recorders closed in one compact case.

They havebeen designed for both advanced and less demandingapplications in industrial automatic control engineering. Theyfeature a colour TFT display with a touch screen (3.5 or 5.7 inch,depending on version).

Such a GUI is a pleasure to work with, and the operation of the MutiCon playing the HMI role isintuitive and comfortable. The kernel of the software is LINUXoperating system, which ensures stable operation and enables installing advanced software.

Possibilities At first glance, the absence of any keys on the instrument front panel comes as a surprise. However, operation using the touch screen is much more efficient and comfortable. The operation philosophy is analogous to generally known windows systems: hitting (clicking on) appropriate menu keys, sliders to move the screens, etc. If, however, you are not happy with the touch screen, a traditional keyboard and a mouse can be connected to the instrument through USB ports to make the operation extremely simplified.

Despite its compact dimensions the instrument has huge application possibilities. A well-thought-out modular design allows precise adaptation of the CMC to various specific needs and requirements of all customers. Available is a wide array of input and output modules (current, voltage, universal, thermocouple, RTD, digital, counting, relay, SSR and other).

In its most expanded version, a single, compact CMC-99 instrument can include modules which provide in total up to 48 physical inputs and outputs (analogue,

digital and relay). Its slightly bigger brother, CMC-141, can have fifty percent more inputs and outputs. Figure 2 shows the CMC-99 rear panel for one of the most typical configurations often ordered by our customers.

You do not need to use all slots; what’s more, when a modification becomes necessary all you need to do is send the instrument to an authorized distributor who will introduce the changes, adding, removing or replacing modules.

The most demanding users, for whom a single RS-485 interface in the standard version is not enough, can choose the ACM (Advanced Communication Module) with additional communication interfaces: Ethernet, USB, RS-485 and RS-232 shared with another RS-485.

Using the Modbus RTU, the MultiCon CMC can read data and control outputs of other devices in the network. External inputs/outputs (i.e. inputs and outputs for other devices) are particularly useful when there is a need to control a large number of physical execution units or collect data from distant sources.

The number of these inputs/outputs is counted independently of the inputs/ outputs available onthe built-in modules.

This additionally augments the potential of MultiCon which is powerful already. In this way, using a MultiCon CMC you can build an advanced network system where you can monitor the operation of the whole from any place on the planet,e.g. via Internet.

Possibility of operation via a touch screen, a keyboard or a mouse

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Each MultiCon can work also as a data recorder. Its internal memory of 1.5 GB is sufficient for over 125 million of samples,

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The device system is based on Linux, which allows –with suitably thought-out software -to use MultiCon to implement even many independent tasks at the same time (also in large multi-channel systems).

For detailed description of more interesting software functionalities (including logical channels, mathematical operations on channels, timers, profile generators, single and multiple PID controllers, etc.) please refer to part III of the articles on MultiCon CMC.

Fig. 2: Example of input/output hardware configuration meaning that even in the intensive sampling mode (every second) you can record data, for example, from 24 channels for 2 months.

Block internal design In order to understand why such a small device meets so many different requirements, it is necessary to have a closer look at its internal design.

The heart of the device is a powerful, 32-bit ARM9 processor to which typical peripherals are connected: flash memory with firmware, flash memory for data recorder, RAM, TFT graphic display with a touch screen, power supply systems, basic communication interfaces, etc.

expanded internal firmware of the modules ensures very good accuracy and stability of measurements.

Such a design solution allows also an easy introduction of a very important element: galvanic separation of all external connectionsin all modules to significantly increase the device functionality and flexibility.

Software After powering on, the operating system is loaded from the flash memory to RAM, followed by the application software. The before-mentioned, specially designed bus connecting the modules, including an

Please note, however, the way the I/O modules are connected. To reduce the load on the CPU and ensure fast implementation of system tasks, including immediate response of the TFT display (thelaboratory tests of hardware possibilities have proved that e.g. viewing films or cooperation with aUSB internet camera with advance processing and image displaying in real time is not a problem), all optional measurement and communication modules are equipped and supported by their own efficient RISC processors (AVR family) and they are connected with the main processor via a fast serial bus.

Therefore, all tasks related to e.g. A/D processing, calibration, transmission frames support, etc. are performed directly on the modules. As a result, even with the maximum number of modules connected, the device speedis not affected, and

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As a result of cooperation with the users, the softwareis constantly developed and new, useful functions are added.

Interesting additions or solutions are quickly implemented asfirmware updates.

A free update feature is provided so that allMultiCon CMC users always have the latest firmware versioninstalled on their devices. The update procedure cannot besimpler: just download the latest files from our website, writethem on a pendrive, connect the pendrive to CMC and start theprocess - the rest is fully automatic.

More articles This article presents only the MultiCon generalfeatures - modular design concept and outline of the devicepossibilities. The next article will be published next month and itwill show the software potential

Fig. 3: Block diagram of the device internal communication protocol, allows an immediate detection, identification and recording of each newly installed module.

Suitable configuration modules are activated simultaneously which ensures full implementation of the PnP function.

using the TFT touch screen,results presentation in the digital data format or as analogueindicators, colour graphs displayed on the screen in real time,bar graphs, etc.

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31

CASE STUDY

Matt Bailey

Haas Makes Light Work

press@mbmc-uk.com

Haas customer, Thorlabs Inc., has evolved to become a leading global player in the supply of photonics products to customers conducting light-based experiments – viz., the people who are creating the light-based technology of tomorrow. The company has written-the-book (a shelf-busting 12lb catalog in fact) on how to run a successful mail order, high-tech component business. Needless to say, while Thorlabs innovates, it’s Haas CNC machine tools that are doing the metal cutting, at the company’s US headquarters in Newton, New Jersey.

So much modern technology is light-based, from supermarket checkout scanners to life-saving medical imaging equipment. For engineers and scientists developing the next generation of such technology, Thorlabs offers a staggering 20,000 different photonics products, including optomechanical components, motion control equipment, optics, fiber, light analysis equipment, and imaging devices: in other words, all the building blocks needed for laser and fiber optic systems are available through its online store.

In all, Thorlabs has 15 design and production facilities located in eight countries around the world. In Newton, New Jersey, there are four buildings, one of which is a few miles from the other three that form a campus.

The company’s imposing new headquarters is in the center of town and houses, amongst other things, engineering staff, assembly and administration.

The former headquarters on Route 206 is now dedicated to the company’s machine shop and contains six Haas VF3SS high speed machining centers with automatic pallet changers, three EC400 horizontal machining centers (two with six station Pallet Pools) and a DT-1 drill-tap center.

At present, Thorlabs manufactures a portion of its products in-house, but there are plans to bring this figure up considerably in the coming 3-5 years.

Now that most of the non-

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technology allows Thorlabs to perform its component loading and unloading off-line while the spindle is still cutting.

Using tombstone fixtures on the EC400 Pallet Pool horizontals, Thorlabs says it can complete even highly complex parts in a maximum of two set-ups, while the four-axis verticals are also able to replicate some of the processes performed on the EC400s.

The Haas machines have proved to be extremely worthwhile assets to Through the use of pallet Thorlabs, holding tight tolerances, are user friendly and can accommodate pools, Thorlabs has taken a lot of tools, which helps minimize set-ups. advantage of “unmanned or lights out machining” in number of different manumanufacturing operations have order to stay competitive facturers,” Patrick Mulvoy been moved from the Route in its respected industry. explains. “We decided to 206 building, there’s ample standardize and Haas stepped space for new equipment and Workpiece materials range up to the plate – they’ve the organisation has plans from aluminium to stainless been a great partner for us to double its machine shop steel, and volumes vary widely. ever since. The machines are capabilities. Patrick Mulvoy, of A typical part, such as a mirror relatively low-cost and are very the company’s Mechanics Busimount is produced in numbers productive. We have Haas 4th ness Unit oversees the machine of around 40,000 units a year. axis rotary tables on all the VF shop and explains his vision for However, some components machines, as well as pallet loada bigger, expanded manufacare made in annual volumes of ing systems.” turing operation. up to 110,000 units and more.

“As you can see,” he says, “we’re not short of space now that the rest of the business is relocated in the new building. I can see us having 100+ machines in here in the future, which is probably what we’ll need if we’re going to meet our business goals.”

That’s particularly good news for Haas, since Thorlabs has committed to a predominantly one-make shop.

“Five years ago we were using machine tools supplied by a

The use of pallet change

The company has different Haas machines set aside for

Thorlabs offers a staggering 20,000 different photonics products, including optomechanical components, motion control equipment, optics, fiber, light analysis equipment, and imaging devices February 2013

The company’s machine shop contains six Haas VF3SS high speed machining centers with automatic pallet changers, three EC400 horizontal machining centers (two with six station Pallet Pools) and a DT-1 drill-tap center one off prototypes, families of parts, and high volume components. Pointing at one particular EC400 Pallet Pool, Patrick says: “This one will only make two components for the rest of its life. We bought it for a specific high volume purpose.

We foresee a life expectancy of up to 15 years, which is a very impressive ROI.” Having machines set-up for certain tasks and volumes also aids personnel deployment.

“Operators can switch from one job to another without problems or assistance from senior staff,” explains Patrick.

“One particular Haas machining center produces a family of 12 different parts. Here, several components are loaded on to a 36 inch work-holding bar – we can flip the whole row and cut the back-side off. In fact, this particular set-up yields about 70 parts per load, which allows the operator to walk away and do something else for an hour.”

All of the Haas machines at Thorlabs are fitted with Renishaw probes, which are particularly useful when machining some of its stainless steel parts, as the company can use broken tool detection capabilities between spot drilling, drilling and tapping. “If a tool breaks, the others don’t follow,” says Patrick.

Company President, Alex Cable, founded Thorlabs in his basement, back in 1989 and February 2013

named it for his dog, a black Labrador. Today, the firm has 850 employees worldwide, half of which work in New Jersey.

Most of its sales come via the website, and when orders are placed, customers can count on the part being in stock and available for immediate shipment.

The responsibility for making sure this happens for the Mechanics Business Unit falls on the shoulders of Rick Chiong, Mechanics Business Unit Leader, who claims to be a “recovering accountant” and is based at the new Thorlabs headquarters. With an eye for figures and accuracy, he’s also an expert in lean enterprise and Six Sigma: know-how he applies rigorously to get the very most from the Haas machine tools.

“Haas machines have proved to be extremely worthwhile assets,” he says. “They hold tight tolerances, are user friendly and can accommodate a lot of tools, which helps minimize set-ups. They are also fast, which is important because everything we do has a bottomline impact.

eed on our site, it is very easy for them to web-search for similar products elsewhere, so we have to have the product on the shelf all of the time and be able to deliver without delay.” This is what Rick refers to often as the company’s ‘customer centric’ approach and it is, he says, “a large part of why we are successful.”

“We need the Haas machines to be extremely agile,” he adds, “which also matches the Thorlabs business model. We offer our customers a wish list of every conceivable part and product for light-based experiments. However, if someone doesn’t find what they neend-

“I must say, the Haas machines have really fulfilled the potential we saw when we bought the first, back in 2007. I remember being very impressed when the machines and their various productivity enhancing features were demonstrated.

Also, they are made in the US,

which is particularly good for us: a company with a large part of its manufacturing based here. It’s also very refreshing to see that Haas invests in its own in-sourcing, which is what we plan to do even more of as we get bigger and carry more product lines.”

It’s difficult to imagine just how many more products the company could offer. But, given that the plan is to have a total of 100+ CNC machine tools, the online catalog could be an order of magnitude bigger than it is currently. What the already tome-like printed catalog would look like is anyone’s guess! www.ibmart.in

33

CASE STUDY

Nord supplies powerful drives for the European most modern brew house

Jyoti Mishra jyoti.mishra@nord.com

During 40 years of continuous around-the-clock operation, the tanks and vats in the Forst specialty beer brewery´s old brew house (Italy) produced 25 million hectoliters of beer. Now, since brewing technology has progressed, especially with regard to energy aspects, the management decided to construct a completely new brew house which was to operate highly efficiently, comply with the latest safety requirements, and produce the lowest possible emissions. In the very 1st week after start-up, the brewery reduced its primary energy consumption by 30 %. loosens this layer in order to ensure an optimum flow of the beer wort. Thus, the wort quality improves and raw materials are used efficiently. Pressure sensors at the bottom of the vessel detect the spent grain´s consistency, and the drive adjusts the machine´s speed accordingly.

This intelligent control system enables flow rates between 9 and 14 liters per minute and square meter. Next, the spent grain is removed: the machine is gradually lowered and the flat bars mounted on its six arms push the spent grain out of the tun through a hatch. This step is also fully automatic. If too much mass accumulates, the lowering process stops, and the speed is adjusted.

Each drive unit was tailored to the individual requirements of the application, pictured: a helical bevel gear motor powering the mash tun.

Five large vats, including the technology and piping systems, a newly designed water supply, and a malting plant with twelve silos as well as three separate storage vats - the engineers and technicians had just 16 months to construct the main components from scratch for the 154-year-old Forst brewery in Algund, South Tirol. The 4,800 m² glass facade offers a view of the plant, which is considered a model of modern European brewing. Up to twelve brews per day can be produced, each with a volume of 630 hectoliters. The annual production capacity is 900,000 hl.

Each drive unit tailored to its task NORD DRIVESYSTEMS assembled the geared motors for all the vessels according to the specific requirements of the various applications, from the grinding mill, which gently grinds the malt at the start of the brewing process, to the screw conveyor removing the spent grain. In the first stage of the process the malt is mixed with

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spring water from the nearby mountains in the mash tuns.

The mixture is then heated to various temperatures by means of thermally optimized conducting surfaces at the bottom and the frames of the mash tun. A frequencycontrolled NORD helical bevel gear motor, equipped with a temperature sensor, drives the agitator inside the vessel. Subsequently, the liquid is pumped into the lautertun.

Thus, the tun can be emptied in as little as six minutes. In order to process the material as gently as possible, the spent grain is loosened at a low speed. But when the spent grain is removed, high speeds are required so the vessel can be emptied as quickly as possible. Thus, the clouding of the spent grain is minimal, and the flow is very efficient. To check whether the system is running smoothly, the speeds, current consumption, and the motor temperature are centrally monitored continuously. Both

Smooth lauter speed adjustment Measuring 8.6 m in diameter and weighing close to 21.5 t, the lautertun is the heart of the brew house. The liquid and solid parts of the mash are A parallel shaft gear unit drives the screw conveyor. separated in a fully automated process. As the spent grain tasks are handled by a custom-tailored settles on the floor of the vat, it forms a NORD drive unit based on a splined hollow natural filter layer. A special raking machine shaft.

February 2013

feature oil expansion tanks to prevent lubricants leaking from the vent valves at high temperatures. A special sealing system on the industrial gear unit ensures that there is always an adequate lubricant film on the shaft.

target is to reduce steam consumption by at least 47 percent», he adds.

NORD Drivesystems develops produces and sells drive technologies with around 2,800 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example

Due to the design, the lifting cage does not require With an 8.6 meter diameter, the lautertun is the heart of the brew house. Here, the mash is automatically additional oil separated from the spent grain. reservoirs, which elimiThe drive is a combination of a motor, an nates the problem of industrial gear unit, and a helical bevel gear sealing. Following the unit. It has a maximum torque of 96,000 UNICASE principle develNm and can continuously regulate the oped by NORD, all the circumferential speed from one to one hunbearings are integrated dred meters per minute - while providing a into a single housing block constant torque. which provides excellent strength and rigidity.

Accurate to the millimeter UNICASE housings have A single drive unit actuates the lautering process, both loosenno sealing surfaces that Inside the lautertun, the raking machine ing the spent grain and clearing out the tun. The combination could deflect under the is lifted and lowered by up to 500 mm. of geared motor and industrial gearbox achieves torques of up effect of torque or radial The lifting device works accurately to the to 96,000 Nm. forces. The compact and millimeter, even under full load. A limit with energy-saving drives or explosionlight gear units run very quietly and have switch and an optical sensor were installed protected systems. a longer service life and lower energy for exact positioning. The height can be consumption than multiple-part gear unit adjusted during standstill, in an idle phase, NORD produces a wide variety of drive housings. and during operation. To this end, both the units for torques from 10 to 200,000 Nm, helical gear unit and the oil-hydraulic lifting electric motors with powers from 0.12 Modern technology reduces steam conunit are designed to withstand the axial kW to 200 kW as well as the necessary sumption by 47 percent Dr. Walther Unand radial loads which occur in the process. power electronics in the form of frequency terthurner, Technical Director at the Forst inverters and servo controllers. For further brewery, points out, »Constructing the new The drive motor has an 18.5 kW power ratdetails contact NORD Drivesystems Pvt brew house, we wanted to ensure that the ing and provides output speeds of 0.04 to Ltd, 282/2, 283/2, Village Mann, Tal. Mulshi, resources would be processed as gently as 4 rpm. To ensure that the required speed is Adj. Hinjewadi MIDC II, Pune 411057 Phone: possible.

Furthermore, we wanted to use maintained, the motor has been equipped 09765490890 Visit www.nord.com these modern technologies to considerably with an encoder. An external fan cools reduce energy consumption and emisthe motor at low speeds. Both gear units sions.» Therefore, in addition to efficient facilities in the brew house, a new heat recovery system has been integrated into the vapor condenser. The heat required for the production of the beer wort is stored in a large energy reservoir in the form of hot water tanks at the rear of the building and is reused for subsequent brewing processes.

According to Unterthurner, these various measures The new brew house is a showpiece project designed have already reduced the The helical bevel gear motor is combined to operate reliably for at least 40 years», says Dr. Walter consumption of primary with an industrial gear unit based on a Unterthurner, Technical Director at the Forst brewery splined hollow shaft. energy by 30 percent. »Our (left; with Master Brewer Manfred Biechl).

February 2013

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35

QUALITY

Gemba Kaizen Implementation

Doing breakthrough improvement in five days

Saravjit Singh saravjit@10xquality.org

“Japanese management practices succeed simply because they are good management practices. This success has little to do with cultural factors. And the lack of cultural bias means that these practices can be – and are – just as successfully employed elsewhere.” A – Masaaki Imai, Father of Kaizen Continuous improvement is a drive towards excellence. Excellence is not a destination.

It is anon-going journey.There is a saying, “If you’re not getting better, you’re getting worse”.

Exhibit 1 shows different types of improvements that you can undertake, from simple to complex. In this column we will deal with Gemba Kaizen, which are small, week long, improvement

based on companywide workers’ suggestions, give enormous results related to better productivity and less waste.

7. Kanban (Pull Systems)

Gemba Kaizen is also known as Kaizen Blitz or Kaizen Event. We will use these terms interchangeably in this column. Gemba Kaizen is different from Quick Kaizen, except that both require a Kaizen Mindset.Gemba kaizen is a focused project, undertaken by managers to look at one issue at a time.

Exhibit 1: Improvements – Simple to Complex When doing Gemba kaizen process improvement tools projects that have a major impact on are used to achieve dramatic benefits. It the performance and competence of a is usually completed within a week, hence company. the name kazen blitz.

Kaizen is ongoing improvement involving everybody, without spending much money. Kaizen is used to make the work environment more efficient and effective by creating a team atmosphere, improving everyday procedures, ensuring employee satisfaction and making a job more fulfilling, less tiring and safer.

Before it embraces Kaizen, your company should adopt the five point agenda of a Kaizen Mindset, as shown in Exhibit 2.

Kaizen, also known as Quick Kaizen or Easy Kaizen,is an evolutionary technique where a process is reviewed and incremental improvements made continuously. Here, workers themselves make changes, usually through their own Quality Circles and then their manager monitors the improvements.

Numerous small continuous improvements,

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Exhibit 2: The Kaizen Mindset

Gemba kaizen is aligned with the company’s strategy for remaining competitive through innovative breakthrough improvements in strategically important areas. The motto of gemba kaizen is “Creativity before capital”.

8. Kaizen Office / Lean Office (Streamlining office and Administrative Processes) A kaizen event is too short for handling complex problems that involve detailed analysis and experiments. These are done as full fledged, traditional projects.

However, many gemba events can be undertaken as part of a major project. This gives very good results. We will talk more about this sibsequently.

Doing a gemba kaizen Gemba kaizen implementation is based on observing processes, trying new things out and measuring the results.

The common elements of gemba kaizen are: 1. Use of a cross-functional team.

2. Emphasis on quick action.

Areas targeted for gemba event Implementation include:

3. Improvement focused on the gemba (actual work place).

1. Process Redesign

4. Decisions are made based on facts through direct observation of current process.

2. Layout Redesign (Manufacturing Plant, Office Layout) 3. Work Cell implementation

Three phase kaizen event process

4. 5 S (Office, Store, production floor)

Kaizen event is done sequentially in following three phases:

5. Quick Changeover (SMED)

1. Kaizen preparation phase

6. Total Productive Maintenance (TPM)

2. Kaizen week phase February 2013

3. Kaizen followup phase.

Kaizen Preparation phase. In this phase we define the problem, set targets and defining the scope of the project. Then we select a 4 to 10 member project team, ensuring a good cross-functional mix. We also coordinate for resources needed for the project, and communicating with the stakeholders.

Kaizen week phase. The team is assembled.

This team observes, redesigns and tests new methods by following the PDCA cycle and applying various lean tools to get rid of waste.

The steps taken in Kaizen week phase are: 1. Finalize pre-event preparation findings.

2. Kaizen kickoff, lean/ kaizen training, and specialized training.

3. Go to the gemba where each member of the project team does the actual work – measures present state.

4. Identify waste and categorize it in the 7

February 2013

types to make sure you understand them.

5. Write this down on A3 Report, orkaizen form.

6. Identify the root causes.

7. Brainstorm and apply countermeasures.

Exhibit 3: Typical Kaizen Event Schedule

8. Test results.

1. Team Training in project room

9. Standardize new method.

• Explain what is kaizen and its requirements

Typical schedule of a kaizen event is shown in Exhibit 3. This gives a fair view of what actually is done during a kaizen event and when.

We will now show you, on day to day basis, how a typical team handles an engineering project during a kaizen week.

Day 1: Monday

• Project and goal background explained.

• Available project data presented.

• Specialized training related to project goal.

2. Area discovery • Team spends afternoon in project area

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• They gather insights from personnel

performance

• Observe issues and conduct studies

3. Team presentation to management

• Keep detailed notes

4. Celebrate completion of project

Day 2: Tuesday

Kaizen follow-up phase. We continue to monitor the new process until it stabilizes.

We then hand over the day to day sustaining and continuous improvement of the target process to function area managers.

1. Continue area discovery • Team Spends Morning in project area • Gather more insights from personnel • Observe more issues and conduct studies 2. Brainstorm issues • What was learned?

• Write down ideas • Evaluate studies (Use all tools needed for brainstorming and evaluation) Day 3: Wednesday

1. Over production due to unclear requirements 2. Waiting time for information before work can be completed 3. Inventory of project tasks under process

1. Continue to brainstorm issues

4. Motion of switching from one multi-task activity to another

• Capture ideas and solutions

5. Defects and rework loops

• Evaluate studies

6. Transportation, delays and loss of information due to hand-offs

2. Reduce and prioritize ideas • Consolidate ideas and solutions • Utilize effort vs. impact matrix • Assign numbers based on effort and impact 3. Midweek status meeting Day 4: Thursday 1. Implement solutions • Each team member acts on their assignments 2. Review progress • Morning: Review of assignments • Noon: Review of progress • Afternoon: Review of progress Day 5: Friday

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In initial training session there must be emphasis in explaining to the team the seven types of waste as applicable to project work. These include:

7. Over processing by duplicating what another project member has already done, and not sharing knowledge to make each other more effective Masaaki Imai is the foremost authority in the world on kaizan. It helps to keep in mind his following ten basic tips to start Kaizen activities. These tips are:

10. Kaizen ideas are infinite.

Using kaizen events within projects Kaizen events are a good way to give a “boost” to a traditional project by rapidly accomplishing some core sections of work in a short period of time while improving communication and clarifying customersupplier requirements.

Kaizen events and traditional projects gain by working together. A kaizen event complements a regular project team well because a regular project team typically lacks speed and a bias for action. On the other hand, while kaizen events can fail due to a lack of follow up and structure, traditional project management can effectively do this follow up.

For our readers who are interested in effectively doing kaizen events in their organizations, we suggest you read Masaaki Imai’s book Gemba Kaizen: A Commonsense, Low-Cost Approach to Management. The low cost paperback edition of this book is published by Tata McGraw-Hill, New Delhi. This book is an easy to understand definitive guide to continuous improvement in the workplace.

It shows how to implement cost-effective, incremental improvements in your most critical business processes. This book also has twenty interesting and insightful case studies of projects based on Gemba Kaizen.

1. Discard fixed conventional ideas.

2. Think of how to do it, not why it cannot be done.

3. Do not make excuses, start by questioning current practices.

4. Do not seek perfection, do it right away even if for only 50% of target.

5. If you make a mistake, correct itright away.

1. Continue to implement solutions

6. Do not spend money for kaizen, use your wisdom.

• Each team member acts on their assignments

7. Wisdom is brought out when faced with hardship.

2. Establish metrics to monitor

8. Ask ‘why?” five times and seek root causes

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9. Seek the wisdom of ten people rather than the knowledge of one.

Masaaki Imai

February 2013

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39

DESIGN

Machine Design Fundamentals Profit Improvement

A S Shetty sedvik@vsnl.com

In this thirty sixth series of articles on machine design fundamentals let us discuss about the various cost reduction aspects in the design stage itself. Engineering economists say that the main aim of business enterprise is to make a satisfactory return on capital employed on a continuous basis. They are also of the view that for sustaining a business it is the future cost which is important.

With the rising costs and a competitive market, there is a limitation to cost control by traditional methods. They should be supported by a radical change in technology which is possible at the engineering design stage which is the starting point for all engineering activities.

A good engineering design means the creation of an appliance which under given conditions in each case fulfils its purpose in the most simple, safe and economical way without affecting operational efficiency.

A well designed product can increase the market potential well beyond the achievements of the most ambitious sales promotion. Good selling designs are the reason why many of the companies stay in business.

During the initial stages of technical development preference to a solution is given which gives the highest technical advantages. But as soon as the product has taken a standard shape, for its further development, the cost advantages will be the main consideration.

The earlier designers tended to consider themselves more responsible for performance rather than cost but in fact, the two are indivisible. The truth is that, nobody has a greater influence on product costs than the engineering designer though he is rarely provided with the facilities or sufficient feedback to be aware of the cost of his decisions.

that exists is a general assembly drawing with materials, production processes and surface finishes required. Hence alterations can be made in the software stage without costly remachining or scrapping the whole part which might be required once the design is released for manufacture.

Let us go through some of the important cost reduction areas and techniques which the engineering designer adopts for profit improvement.

A rotary motion can be achieved using spur gearing or chain drive or belt drives or worm gearing or planetary gearing.

1. Functional Cost Approach This is the recent concept of tailoring design and specifying tolerances to get the needed function at the lowest cost.

Hence a number of alternative solutions are thought of for attaining the same function without reduction of quality or performance.

The ideal time to carry out this type of exercise is at the software stage when all

To cite a few examples;

A linear motion can be achieved using one of the following systems: Rack and pinion system, a hydraulic cylinder, a pneumatic cylinder, a linkage mechanism, a screw-down mechanism, a sprocket and chain system or a linear motor.

A support bracket can be made out of C.I. housing or steel casting or a fabricated one or a forged one.

A prime mover can be one of the following—A.C. Squirrel cage motor, an A.C. slipring motor, an A.C.synchronous motor, a single phase motor, a D.C. motor, a hydraulic motor, an- air motor, a diesel engine, a petrol engine or a steam /gas turbine.

In the above cases if the approximate relative costs of various alternatives are known, a quick decision can be taken on the best alternative solution.

We will discuss some more areas/methods of cost reduction in our forthcoming series of articles.

A rotary motion can be achieved using spur gearing or chain drive or belt drives or worm gearing or planetary gearing.Planetary Gear Box, Courtesy Bosch

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The author Mr. A.S.Shetty, CEO of Sedvik Industries, manufacturer of Rollforming machines, Bangalore can be contacted at Tel: 080-25452669 or E-mail: sedvik@vsnl. com February 2013

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41

MANUFACTURING

Managing a SME in India - Part 2

P S Satish gotopssatish@gmail.com

Journey towards excellence for February 2013

As a continuation of last article, we will discuss on few more points to manage SMEs better in India 5.0 Follow good cost accounting It is often argued that cost accounting is not important for SMEs as it needs lot of effort to manage this. It is wrong. Any company irrespective of the size should develop discipline of accounting every rupee spent.

There are simple soft-wares like Tally available in the market which does not need high skill to operate. The analysis of expenses every month or quarter under the heads of personnel expenses, travel, consumables purchase, electricity, rent, direct material etc. will give an idea of controlling. All these can be linked to ratio of sales volume done in that period. What is not measured cannot be managed. This discipline also creates unawareness on the importance of spending properly and budgeting.

The number of headings should not be too many but less than 10 should be okay to manage. There should be an eye on efforts required for collection of figures to auto-

mate the process as far as possible. The comparison of analysis period over another the next should be a part of management review. The process can be started with simple excel sheet before deciding on a software for accounting system.

Along with accounting system for expenses, it is also important to have a system for product accounting. I have seen companies where offer for a product or component is given based on thumb rule without any accounting behind. I had this good experience when I was sourcing from China.

I saw cases where there was no link between raw material cost and sales price. If you are a component or product supplier to OEM or Tier1, many times buyer wants to know split up of cost at-least under main headings of material costs, labour charges, overheads and profit. Having clear split up of product cost also helps when customer is approached for price increase say for reasons of wage hike.

The discipline of cost accounting as ex-

plained earlier helps to calculate realistic overheads.

Typically in SMEs overheads are assumed which might or might not be right. It is a pre-requisite to initiate cost reductions and to have cost control to be competitive in the market.

6.0 Financial performance – Keep a watch How many SMEs really measure their financial performance regularly other than looking at turnover and notional profit? It is seen that notional or assumed because real profit many time differs.

The financial performance is the result of many operational decisions taken and gives an answer to know how much debt company is having and what the actual return on assessment is. It helps to take better decisions for long term sustenance of the company. Many SMEs are started by Technocrats and their main focus will be on technical matters on the company with little focus on financial management.

It is the high-time that the owners and CEOs are start understanding financial terms like debt, equity etc. and to study balance sheet. Quarterly or half yearly measurement of key financial performance indices like Debt days [accounts receivables* 365/ (annual sales)], Inventory turnover = Inventory/sales, liquidity ratio (cash and equivalent/current liability) and many others. This measurement helps to focus on actions needed in the next period. It is also important to link returns to the capital employed which is measured by parameter EVA ( economic value addition). The logic behind EVA is that business should make more profit than the case if capital were invested in a safe investment. I got a shock when I saw in a SME that revenue was treated like a profit.

The cost of no training is more expensive than cost of training

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7.0 Do not miss training February 2013

Unfortunately many SMEs consider training as a cost and not as an investment.

Sometimes, I understand that training could be seen as expensive. See what Peter Drucker, management guru said, ‘ The cost of no training is more expensive than cost of training’.

If you look at the success of big corporate and companies who have sustained for long term, you will observe that on their high emphasis on training. One of the expert studied companies concluded that for the growth of the company, 3 things have to be focussed namely Hardwork, Discipline and Training.

All three to be focussed equally. Typically focus is high on hard work. Our logic on training is when I have been doing a job for a long time why do I need training? The emphasis of training is not only to learn a new job but also to do the current job better.

Imagine the extent of mobile phone usage if we take training on how to use the mobile phone fully. Since we are using for

February 2013

long, we think we know everything. Study reveals that users only have few features of mobile phone though it offers innumerable options to use.

Where to start on training? Focus on simple hard trainings like how to use a gauge, maintain a machine etc. as well as soft trainings like time management, communication skills etc. Come over of fear that trained persons will leave the company for a better job. Overall, you can retain persons long if you focus on their learning.

Giving opportunity to learn is one of the motivational factors.

Training does not mean that you have to call an expert always. You can start with an in-house training where one expert in a domain teaches others on hand. Bringing outside expert will enhance learning as he or she brings a new perspective. One of the companies having realized importance of training asked me recently which trainings to be focused first. I suggested three trainings as building block namely Time management, communication skills and

presentation skills.

These 3 blocks help everybody in the company irrespective of jobs they are doing.

Time management will give lot of tips to manage their time better helping employees to perform better in official as well as in personal front. This answers CEO who put me a question,’ where is the time for training when I am running so fast all the time?’.

Do not neglect training.

Let us learn from Germany and Japan where sweepers are trained on how to sweep best and not just sweep. Ensure that training covers lot of practical aspects relevant to company so that participants start implementing. Even if they focus 10% of what trainer says, it is fantastic.

I will continue the article in the next issue.

Please send your inputs, remarks, suggestions to P S Satish, Mentor and Trainer, Saraswati Industrial Services, Q-103, Mantri Paradise Apartments, Bannerghatta Road, Bangalore - 560076. Email : gotopssatish@ gmail.com . Wishing good day to you all.

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GREEN IN

Green machining initiatives from Felsomat

G P Bhat bhat@felsomat.in

From global innovation leader to global system provider - Felsomat has started a new era in production technology. Complete process chains with standardized machine platforms which create extremely flexible and highly efficient manufacturing systems.Felsomat has developed two modules widely used in Gear manufacturing to make the manufacturing process environment friendly.

In automotive industry, Gears are manufactured in very high volume involving lot of machining and grinding with coolant.

The chips and coolant sludge that are generated are harmful to environment and disposal of these as per the prevalent regulations is expensive and adds to the cost of the product.

Further, cycle times are very low in machining and loading / unloading of the part takes considerable amount of time out of total cycle time in the existing machines.

steel chutes with smooth surfaces ensures that chips fall freely without getting stuck.

• These special design features enable gear blank turning without coolant.

• This totally eliminates the need for coolant and coolant disposal requirements.

• Twin spindle design gives the advantage that while part is machined in one spindle by the turret, loading / unloading takes place in the second spindle, either manually

As a result, machines are not fully utilized for chip removal, resulting in inefficient use of the energy and other resources.

2. A hobbing machine that can hob the gears without coolant/ oil and also combine deburring and chamfering operations, thereby eliminating the need for a separate deburring machine.

Both these machines are newly developed from the start keeping in view the above requirement and conceptually differ from the existing machines used in the industry.

Turning machine: • It is configured as a twin spindle vertical turning machine with single turret • Because of vertical configuration, when gear blanks are turned without coolant, chips fall directly below into the chip conveyor and are carried away.

• Specially designed base with stainless

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Hobbing Machine: • The design of this machine is made totally different from the machines available in the market to make it suitable for dry hobbing of gears.

• It is a twin work spindle machine with work spindles arranged horizontally so that chips fall directly into the chip conveyor • Above design feature together with the use of latest cutting tools, enable dry gear hobbing, making the machine environment friendly.

• While hobbing is going on in one spindle, loading / unloading, deburring and chamfering take place on the second spindle

Felsomat has developed two modules widely used in Gear manufacturing to address these issues and make the manufacturing process environment friendly.

1. A Turning machine that can do both soft and hard turning in dry condition, substituting conventional turning and grinding machines

automotive industry.

• With the above feature, chip to chip time is reduced to 1.5 sec.

or automatically, without losing time on machine.

• This ensures efficient and high energy utilization as the machine produces parts

• A chip to chip time of 1 sec is achieved as the turret has to travel a short distance to start machining on the second spindle.

• This ensures efficient and high energy utilization as the machine is always producing chips without waiting for loading / unloading of parts.

• The machine is rigidly designed with mineral concrete base, short overhangs to do hard turning of gears in dry condition after heat treatment.

without loss of time for load / un-load operations.

• The turret can be equipped with a HF grinding spindle to do bore and cone grinding with CBN wheels in dry condition.

• Provision of deburring and chamfering in the same machine eliminates the need for a separate machine for these operations.

• All these features make the Turning machines from Felsomat eco-friendly machines designed for the future needs of the

• These features make the hobbing machines from Felsomat very eco-friendly.

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CORPORATE

Jagdish R. Mahajan

Mandatory CSR- The Road Ahead

mahajanj@gmail.com

The Ministry of Corporate Affairs , after an exhaustive consultative process, has published Voluntary Guidelines on Social, Environmental and Economic Responsibilities of Business, 2011 {www.mca.gov.in} in line with the above international developments. The practices and precepts outlined in these Guidelines take into account the realities of Indian business and society as well as global trends and best practices adapted to the Indian context.

A company’s performance has been traditionally judged by its financial results. It has now become equally critical to evaluate its performance in relation to the society in which it operates and to its impact on the environment for its ability to operate effectively.

In simple language, (CSR) is a concept whereby companies integrate social and environmental concerns in their business operations and in their interaction with their stakeholders on a voluntary basis.

There are a number of compelling reasons that awareness about CSR is increasing in the corporate world.

Globalization, greater ease of mobility, rapidly growing availability of instant communication mean that individuals and organizations around the world are finding it easier to know about the decisions and activities of organizations at different locations almost immediately.

The global nature of environment and health issues, recognition of worldwide responsibility to combat poverty, economic interdependence and geographically dispersed value chains and several international agreements on these issues emphasize worldwide interdependence.

Consumers, donors, investors and owners are exerting financial influence on organizations in relation to social responsibilities.

This means that a company’s decisions and activities are subject to increased scrutiny and influence by a wide variety of groups and individuals. In response to rising expectations of the society about performance of the companies on societal issues, a growing number of companies are communicating with their stakeholders and are publishing social responsibility reports.

This is a reflection of the growing recognition of the need to ensure a healthy ecosystem, social equity and good corporate governance. It is realized that in the long

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run the health of all companies depends upon the health of the world’s ecosystem.

The overarching objective of CSR is then to contribute to sustainable development.

Mandatory CSR: The Ministry of Corporate Affairs , after an exhaustive consultative process, has published Voluntary Guidelines on Social, Environmental and Economic Responsibilities of Business, 2011 (www.mca.gov.in) in line with the above international developments. The practices and precepts outlined in these Guidelines take into account the realities of Indian business and society as well as global trends and best practices adapted to the Indian context.

world-over.)

Since then there has been a lot of debate whether companies should be asked to spend some minimum amount for CSR activities. There has been a lot of resistance from the industry against introduction of any mandatory system or expenditure on CSR activities.

After getting delayed for several years, the Companies Bill that has been finally passed by the Lok Sabha on 18 December 2012l aims to bring the management of the corporate sector in line with global norms.

It has also introduced the following novel mandatory provision on CSR in Section 135 of the Bill.

It urges businesses to embrace the “triple bottom-line” approach whereby their financial performance can be harmonized with the expectations of society, the environment and the many stakeholders in a sustainable manner. The adoption of these National Voluntary Guidelines should improve the ability of businesses to enhance their competitive strengths, improve their reputations, increase their ability to attract and retain talent and manage their relations with investors and society at large.

“Every company with a net worth of Rs. 500 crore or more, or turnover of Rs. 1,000 crore or more, or net profit of Rs. 5 crore or more in a financial year will have to form a corporate social responsibility (CSR) committee, consisting of three or more directors, of which at least one would be an independent director. This committee will have to ensure that the company spends, in every financial year, at least two per cent of the average net profits made during the three immediately preceding years, towards CSR activities.”

(The work on formulation of international norms for CSR has resulted in the publication of ISO 26000 Guidance for Social Responsibility to bring about a common understanding of language used in defining social and environmental responsibility the

The bill also makes it compulsory for the company to specify reasons if it fails to spend the amount. The mandatory expense is to be made in the 9 CSR activities outlined in the Fig.1.

Activities covered in the CSR policy

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Why Mandatory?

CSR & Value Creation:

CSR for VALUE CREATION:

There has been a lot of criticism to the mandatory provisions for CSR from the industry and several planning and CSR experts. Such a provision probably does not exist in Companies Act of any major economy of the world.

The essential characteristic of social responsibility is the willingness of an organization to incorporate social and environmental considerations in its decision making and be accountable for the impacts of its decision and activities on society and environment. This implies that a company should display both transparent and ethical behavior and comply with all applicable laws , industry standards and international norms.

However, it would be in the interest of comparatively large companies that are now covered by the mandatory CSR to rise to the occasion and integrate CSR into their strategies for improving their performance and move from compliance and auditing to value creation.

Many experts feel that there were simpler ways to motivate Companies to contribute to CSR than to add bureaucratic mechanisms like CSR Committees and mandatory CSR. It is opined that a simple tax incentive scheme should work much better.

Another argument is that the Government just wants to transfer a part of its responsibility of welfare and economic empowerment over to the companies. Adding another committee to an already complex set of requirements is not going to make life any easier for companies.

Those advocating such a provision feel that CSR in developing countries is more crucial which face huge challenges of poverty, education, health, water, sanitation and equity. Developing countries also represent rapidly expanding economies which will present increasing challenges for tackling social and environmental impacts.

They are of the opinion that such challenges can be tackled only with the cooperation of all concerned. They emphasise that multinationals and Indian private sector companies have a significant role to play in tackling such problems and should embrace their rightful responsibility for such issues.

Now that a decision has been taken, the government should ensure that this amount invested towards CSR is made eligible for tax deduction. Moreover there should be a provision to carry forward the unspent portion so that such accumulations can be used to build a strong CSR network and/or address larger issues.

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At this level a company should institutionalise its CSR strategy and look at building a strong code of conduct, anti-corruption policy, stakeholder dialogue, community involvement, responsible political involvement, promoting social responsibility in the value chain etc.

An innovative approach should aim at developing new products that are environment friendly or reduce energy consumption or optimise consumption of materials or lead to improved processes creating additional value for the company and society.

Integration of Social responsibility in the company:

Fig. 3 - CSR for Value Creation Compliance with local laws and international norms: When laying down a provision for mandatory expense, it is presumed that the enterprises are willing to go beyond complying with government and local regulations and complying with international norms. This implies that a company complies with legal requirements in all its locations even if the regulations are not adequately enforced; keeps itself informed of all legal obligations and reviews its compliance periodically.

Such regulations relate to labour practicesstandards and working conditions (ILO), human rights (International Bill of human rights and associated instruments) - discrimination, gender equality, child labour, civil and political rights, freedom of association and industry standards and environment etc.

Social & Environmental Auditing: The next level of Human Minimisation is where a company opts for environmental, safety or energy certifications/compliance like ISO 14001, OHSAS 18001, ISO 50001, CE, RoHS, REACH or social audits like SA 8000, BSIC, EuRep or other private voluntary standards of companies or independent organisations.

The mandatory provision of expenditure has one significant positive aspect as every company will now appreciate that its performance in relation to the society and environment is as important as its financial performance.

Now that a company will be bound to earmark a minimum amount for social responsibility, it is in the interest of a company to accept social responsibility in all its aspects and work to improve its performance on social parameters gradually. The best way to do it is to embed CSR into its Vision, Mission and Strategy along with its other values and goals.

This will help it to design its governance system so as to integrate social responsibility throughout the organisation. Effective governance will entail adherence to the principles of accountability, transparency, ethical behaviour and respect for stakeholders and the law.

This system will help in laying down strategy, objectives, short and long term targets at corporate and functional levels and reflect commitment to social responsibility.

A suitable organisation structure designed to integrate social responsibility throughout the organisation with an appropriate system of reward for performance on social parameters will demonstrate leaderFebruary 2013

Recognition by a company of its social responsibility and its Identification and Engagement with its Stakeholders. The recognition of social responsibility involves identifying the issues arising from the impact of its decisions and activities as well as the way these issues are addressed .

Note: Stakeholders may have an interest that is not consistent with the expectations of society

The above figure depicts the relationship between an organisation, its stakeholders and society.

Sometimes a company its stakeholders and society are likely to have different perspectives on some issues because their objectives may not be the same. Similarly, a company should examine whether a group

Figure 2 – Relationship between an organization, its stakeholders and society ship commitment and accountability.

Fundamental Practices of CSR: The two fundamental practices of CSR are :

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A basic principle of social responsibility is that it should respect and consider the interests of its stakeholders that may be affected by its activities while respecting the expectations of the society.

claiming to speak on behalf of specific stakeholders or advocating a specific cause is representative and credible.

Stakeholder engagement may be formal or informal & should provide opportunities for stakeholder’s views to be heard to arrive at balanced decisions.

The mandatory provisions of CSR should propel a company to embark upon a structured framework for CSR with a view to embed all aspects of CSR into its systems for seamless integration into its practices at all levels. It is suggested that performance on various issues/ aspects of CSR is communicated to stakeholder in a suitable format at regular intervals to display transparency of its system and encourage it to continually improve its performance on all aspects of CSR. This will help improve company brand, product reputation, customer loyalty, risk management besides improving productivity and employee retention.

Jagdish R Mahajan, Author is a senior CSR Consultant and Trainer (CBI-Trained) & President of Indian Cluster of Mechatronics and President Institute for Export Development.

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ASCENT

IEEE CONECCT – International Conference for Academia & Industry IEEE CONECCT was the outcome of a collective desire of the IEEE Bangalore Section Executive Committee, in June of 2012, to organize an International Conference relevant to academia and industry. It was felt that the current day electrical engineer is being confronted with complex problems, which requires a multi-faceted approach to solve them.

Several modern systems have become a confluence of Electronics, Computingand Communication technologies, embedded with Control strategies.Hence a broad based conference was envisaged to attract the attention. We tried to get a suitable acronym and after a few iterations on a late evening, the Executive Committee came up with the name CONECCT. IEEE CONECCT received an overwhelming 457 papers for review. Papers were received from 18 countries. A total of 40 TPC members and more than 150 reviewers assisted in the review process. Each paper had at least 2 reviewers per paper and finally, selected 46 papers for ORAL presentation which will beincluded in the

IEEE Xplore database. Selected 26 POSTER papers which will not be included in Xplore but will be included in the conference proceedings.

The technical programme comprised of Distinguished Plenary Lectures and technical sessions of peer-reviewed papers. Prof.

M.Vidyasagar, Fellow of the Royal Society, University of Texas at Dallas, USA, Prof.

SadaokiFurui, Tokyo Institute of Technology, Japan, Prof. Paul Berger, The Ohio State University, USA,Dr. K. K. Ramakrishnan, AT&T Research Labs, USA, Prof. Jeff Bilmes, University of Washington, USA, Dr.ShekharKirani, Accel Partners and Prof.

D. P. Sengupta, National Institute of Advanced Studies were the speakers.

Over 150 engineers and scientists participated in the IEEE CONECCT Conference.

Over 100 engineers and scientists participated in the following tutorials:Zerovelocity Aided Foot-mounted Inertial Navigation byProf. Isaac Skog & John Olof Nilsson, KTH-Royal Institute of Technology,Stockholm, Sweden. Topics on Storage Systems and Networks, Prof. K. Gopinath (IISc), Durga Prasad Allada (Mahindra Satyam), Udayan Singh(TCS), Microsoft Windows 8, SabaHalem, Microsoft, Android – A serving plate for Embedded Domain, Satish Patel, Texas Instruments, Next Generation Network (NGN) – Technology, Architecture and Applications, Satya N. Gupta, NGN Forum, India. The next edition of IEEE CONECCT is planned in 2014.

AIA partners with IIT Madras The Automation Industry Association has tied up with IIT Madras to enhance research projects in the field of industrial automation. It is eyeing a similar tie-up with IIT Mumbai.After signing up the MoU with IIT Madras, Automation Industry Association successfully organized a short-time training programme for the first time on “Manufacturing Excellence through Relevant Automation” from 6th to 8th December 2012. The batch was consisted of 20 students.

The institute has set up a Centre of Excellence in Industrial Automation at its campus. The collaboration will enable the institute to get industry inputs in developing curriculum and a modern lab, and formulate industry-relevant and need-based research projects, said the association’s president, K. Nandakumar. The centre has been set up by the institute’s Design Engineering Department, he said.

Each participating member company of AIA will bring a ‘mentor’ and a subject matter (or domain) expert. There will be joint development of curriculum, research projects, individual technology demonstrations, and training workshops under the agreement. The idea is to infuse contemporary technology and content into the educational system.

Leading players in the field of automation, such as B&R Automation, Larsen & Toubro Control and Automation and Siemens Ltd, www.ibmart.in 5050 www.ibmart.in

have announced immediate participation in the project with their technologies, said Nandakumar, who is also the chairman and managing director of the Mumbai-based Chemtrols Industries Ltd. The association is a forum for all automation companies in India spreading knowledge and creating awareness.

The objective of the proposed course was to introduce the state-of-the-art technology & products in automation to practicing engineers and academicians to enable them to take up challenging assignments in the future & spread the learning to the pears and creating a professional environment.

Background theory of products & technology in automation as well as practical hands on technology have been introduced and deliberated upon during the programme. The course specifically addressed the following topics relevant

to the Indian Industry.Different Components of Automation:Sensors, Actuators, PLC& HMI(Human Machine interface), SCADA and DCS. Introduction to RoboticsRobot classification, work cells, applications, robots for Indian Industry. Discrete Machine Automation, Batch and Continuous process, Plant wide automation and control system strategy, The Automation Pyramid – from Shop floor to supervisory control in real-time and Operations visibility- Maintenance & condition based Asset Management.

The teaching faculty constitutes experts from Department of Engineering Design and other departments of IIT Madras and guest speakers from reputed Industries. To fully realize the objectives of the course, the lecture notes were made available to the participants at the time of registration at IIT Madras. Classes were held in the Centre for Continuing Education and Engineering Design department, IIT Madras.

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Wrapping up IMTEX 2013

Prathibha Prakash prathibha@martinfotech.in

The seven-day metal cutting exhibition started from the 24th January 2013 at BIEC in Bangalore was inaugurated by, Mr. S. Sandilya, President, Society of Indian Automobile Manufacturers, Mr. Harish Lakshman, Vice President, Automotive Components Manufacturers’ Association and Mr. VikramSirur, President, IMTMA. During seven days of exhibition, closely one lakh visitors have experienced ‘Live Technologies’@ BIEC.

With 25 countries in the segment of machining toolsexhibiting, IMTEX 2013 focuses on high end metal cutting technology for sectors like defence, automobile, medical engineering and others. It will showcase the latest trends in metal cutting along with innovations which are imperative for companies to adopt in order to keep ahead of competition.

mobile industry may produce automobiles, it is however a process that brings together the most diverse of industries. The machine tool industry plays an important and impartial role, catering to the need of both, small and large automakers alike. Forming the backbone of many major sectors of industrial activity in India in the traditional manufacturing context, the machine tool industry in India has played and will continue to play a key role in enhancing competitiveness and enabling development of quality and excellence in the output of the manufacturing industry and of the Indian economy as a whole”.

Addressing the inaugural ceremony, Mr. S. Sandilya, President, Society of Indian Automobile Manufacturers said, “The auto-

Expressing his thoughts, ACMA Vice President, Harish Lakshman said: “Auto component industry is catering to ever

2013 marks a positive hit in the manufacturing sector and readies it to the next league of expansion through IMTEX 2013. India, to become one among the top global machine tool markets over the next five years.

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expanding domestic market and exporting to external replacement market. The automobile industry globally is the single largest customer of the machine tools industry.

There is a huge need for the machine tools industry to expand production capacity exponentially to meet the demand of the original equipment manufacturers (OEMs) and their ancillaries, including small and medium enterprises in the supply chain.”

Sharing his views on India’s global ranking, Mr. VikramSirur, President – IMTMA said,“For the Indian machine tool industry, it marks the beginning of a new era of hope – to take on challenges of tomorrow with courage and confidence. I am proud to mention that this edition is the largest ever IMTEX fair in its 44 years of existence.

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Over 900 exhibitors are showcasing the very best machines and manufacturing solutions, as well as potential futuristic metal-cutting technologies. This exhibition, clearly, will reinforce what we feel is a step-

the-art facility”, added Jadeja.

Talking with some of the global giants in Machine Tools, it is optimism and a ray of hope everywhere that surpassed the current economic slowdown and eventually

The growth prospect of machine tool industry in India: Demand growth expected to hold steady at 15% CAGR The production projected to grow at 25% CAGR Exports is likely to grow at 25% CAGR during the 12th Five Year Plan Imports are estimated to grow at a CAGR of 6.7% Total Sales turnover in LFY 2011-12 is 955US $ Million Total Orders Booked is LFY 2011-12 is 983US $ Million Global Position of India in 2011 is seven, China being the first

sharing his experience, said, “Customers have really appreciated our display which has so many new products. The quality of visitors have been quite good during the show.”

Mr. K. Chander, Managing director of Felsomat India while sharing his experience about IMTEX 2013 said, “Conventionally, automation solutions are engineered to meet individual customer needs, using the standard modules. We have displayed for the first time at IMTEX standard automation products that can be readily used for the automation of 2 machines. We have targeted these products at small and medium scale industries and the response during IMTEX was very good. These products have generated a lot of interest from both end users and OEM`s as a readymade automation solutions for their machines.”

International exhibitors from Japan, China, Taiwan, Korea, Germany, France has also received huge response from the show.

IMTEX 2013 paves the way for the Machine Tools Industry on a right track for another two years. Now it is time to execute and to see how the Government in its budget plan takes measures to accelerate growth of Indian economy.

ping stone towards Indian machine tool industry’s journey on ‘VISION 2020’. ” IMTEX 2013featured over 900 exhibitors and 600 machine tools weighing 6,000 tonnes with a total value of Rs. 1500 crorein their premises. The inauguration was followed by Ribbon cutting ceremony and the prestigious award programme.

The IMTMA VinodDoshi Outstanding Entrepreneur Award was won by Mr. P G Jadeja, Founder, Jyoti CNC Automation Pvt ltd. The company produces all of its own components, including spindles, turrets and rotary tables, said Jadeja. A recent addition has been a mechanized foundry with a capacity of 1,000 tons/month. “We can handle castings from 150 kg to 15 tons in our state-ofFebruary 2013

kick-started the growth.

Talking to Mr. Satish Sadasivan, Managing Director, Schunk India, he said “Imtex 2013 has surely been a kick off to a dynamic economy for the foreseeable time. I amsure that the following days will be busy and we have our own experience from the 7 days at Imtex that the industry is up and ready once again.”

Walter, the German Cutting tool supplier said India is among four countries from which it expects the most sales over the next few years. Mr. ProtyushDebnath, Marketing Manager at Walter Tools India, while

“IMTEX 2013 is indeed good hope for industry professionals. But a significant mindset needs to be changed by the Govt.of India.

Being the election year ahead, the budget will not be as good as to withstand and take tough measures. We have received a very good amount of enquiries and delivery is in essence of order at our company” Sridhar Ramisetti Managing Director, DMG Mori Seiki India

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MILLTAP 700 - First corporate development of DMG/ MORI SEIKI enthralls IMTEX Visitors

With the MILLTAP 700, DMG and MORI SEIKI present an outstanding example of focused innovative power The compact machining centre MILLTAP 700 as the first joint development of DMG/ MORI SEIKI documents their high standard to always offer the customers significant added value to suit all applications. The MILLTAP 700, displayed at the IMTEX 2013 in Bangalore, achieves absolute top values in all processes and with its combination of impressive work capacity and chipping performance, it also achieves a so far unrivalled performance on the tapping centre market.

Productivity and efficiency were at the core for development of the new MILLTAP 700.

For this reason, DMG and MORI SEIKI have concentrated their innovative power and equipped the compact machining centre with a series of outstanding technical details.

The high machining speed usual in the field of tapping centres is thus supported by a high-speed tool changer which achieves tool change times of 0.9 seconds and chipto-chip times of less than 1.5 seconds and so enables a highly efficient process.

There is also a special feature: The complete drive of the magazine – it takes 15 or optionally 25 tools – is integrated into the spindle head. Key features in this context are the impressive dynamic response of up to 1.6 g in the linear axes as well as fast axis movements up to 60 m/min, which significantly increases productivity.

Furthermore, the MILLTAP 700 considers aspects like process reliability and maintenance costs. Its triangular bed design

due to the optimised table design. The footprint of the MILLTAP 700 is 10 % less compared with the competition.

Despite all this compactness, the work area with 700 mm in the X-axis and 420 mm in the Y-axis (with a Z-path of 380 mm) is generously dimensioned and above all designed ergonomically in such a way that perfect accessibility is ensured. The sturdy machining table and the wide distances between the linear guideways enable the machining of workpieces up to 400 kg. Furthermore, a number of clamping options promises highest flexibility.

On the spindle side, the MILLTAP 700 impresses with a high-torque 10,000 rpm spindle, whereby the machinable material spectrum can even be increased with the optional high-speed spindle with 24,000 rpm. With a spindle drive of 25 kW the new development of DMG and MORI SEIKI is complete top of the range. Furthermore, the symmetric spindle head ensures extreme rigidity and high thermal stability.

The rigidity of the machine is also helped by the C-frame design and usage of robust castings. The user benefits with highest surface quality of the workpiece and long tool life.

Apart from the manufacturingand process-relevant features, the MILLTAP 700 also presents itself with an outstanding control performance. The adapted Siemens 840D solutionline Operate with Sinamics 120 Cijo Mathew James, Application Engineer compact inverter and 10” moniexplains in details about Milltap 700 to Visitors tor ensures simple and efficient as well as the static cover of the X-axis programming. The system guarantees optimise the chip flow and enable parallel highly dynamic contour accuracy and efdisposal of the chips. Users can either ficient program sequences. Optionally the position the cooling system on the machine MILLTAP 700 can also be equipped with the from the front or back.

PROGRESSline, which clearly displays the remaining time and quantity of a complete All in all the innovative machine concept machining order as status control. impresses with a width that is 30 % less compared to the competition, which is The topic of energy efficiency is dealt with

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by DMG / MORI SEIKI with a perfected energy management. Here, the CNC control, combined with efficient drive technology, ensures an energy consumption that is up to 30 percent reduced in direct comparison with competitor machines.

The MILLTAP 700 impresses with a high-torque 10,000 rpm spindle.

Highlights – MILLTAP 700 • Large work area with small footprint of only 4 m² • Exceptionally sturdy design as a basis for perfect surfaces, maximum precision and high contour accuracy • Fast rapid traverse and feed speeds up to 60 m/min •High-tech spindles with 10,000 rpm and (optional) 24,000 rpm •High dynamic response and acceleration up to 1.6 g •Short downtimes: tool change time of 0.9 seconds and chip-to-chip time of less than 1.5 seconds •Tool magazine with 15 positions (optionally 25 positions) •Optimal chip flow due to 2 axes on the spindle-side and X-axis in the table, optional chip conveyor •Siemens 840D solutionline Operate with 3D programming software and integrated tool management •High energy efficiency: up to 30 % less power consumption •Expansion options for multi-axis machining and automation solutions February 2013

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Global launch at IMTEX The innovative history of Carboloy dates back all the way to the 1920s, when a General Electric scientist started experimenting with tungsten carbide. In 1928 a special Carboloy department was formed making breakthrough advance in cemented carbide technology and their metalworking applications. In the following decades Carboloy’s innovation flourished, which further strengthened Carboloy’s good reputation in the market for solving customers’ ever-increasing demands for greater productivity, quality and costeffectiveness.

“It is with pleasure that we announce the global launch of our new brand Carboloy for tools and inserts, which is a perfect match to our offer of rotating tools, says Fabrizio Resmini, President of Dormer Tools, on the occasion of the IMTEX 2013 fair in Bangalore.

Carboloy is today a member of the international Dormer Group, and is now taking the next step in its ambition to offer customers the best possible tooling solution in manufacturing. “Our common success is built on five pillars,” explains the Brand Manager and President Lars-Erik Lindgren.

“Consistency in terms of product quality, Durability in terms of tool life, Versatility by offering a focused tool assortment with a wide application coverage, Security in the delivery performance and most importantly: Simplicity in every aspect of working with Carboloy. This is really our soul and blood.”

Carboloy secures a consistent product quality through rigid methods and quality standards in its production facilities in Europe. “Top durability is critical from a large number of aspects,” underlines R&D

Gautam K Ahuja, the Managing Director, Dormer Tools India Pvt Ltd with Lars-Erik Lindgren, President Carboloy Manager Anders Fältenhag.”That’s not new, but how we achieve it is. In short by improving wear resistance through special coating combined with a treatment that improves toughness and security.”

Gautam K. Ahuja, the Managing Director of Dormer Tools India Pvt Ltd since early 2013 and with a long experience in the cutting tool industry in India, confidently says that “Carboloy will present a perfect fit for most of the manufacturing industries in India requiring metal cutting tools, and the combination of Carboloy and Dormer represents a strong offer for our distribution network in India”.

Starrag launches new Centres at IMTEX Starrag India Pvt Ltd, a whole-time subsidiary ing Centers (HMC) on 24th January at Imtex Fust.

Announcing the launch, Dr. Frank Brinken, President & Chief Executive Officer of Swiss Headquartered “StarragGroup”, said “WMW is one of our 10 heritage brands globally renowned for long-term accuracy, long-termperformance and long-term reliability. The other well known brands are SIP, Dorries, Heckert, Starrag, Drop + Rein,Bumotec, Bertheiz and Scharmann.

India has several installations of SIP jigboring of many generation technologiesand their durability and longterm accuracy is the hallmark of our ten brands.”

“The new range of high performance machining centers for developing markets offer very productive solution formachining ferrous parts for Trucks, Tractors, Earthmovers & Construction equipment, Windmills, Compressors,Textile Machinery, Machine tools, Power Generation Diesel engines, Oil & Natural Gas, Gearboxes, Aerospace,Valves, Hydraulics, Turbine Blade Root and General engineering.These 4 axis machining centers have many unique features for High Performance Milling of Ferrous and hard metalusing time tested Heckert High Torque Gear box spindle technology, using heavy duty tooling for a highproductivity”, said Dr. Frank Brinken.

Starrag became the first European company to set up Machining Center manufacturing plant in India as its 100% subsidiary- at KIADB Aerospace Park, Devanahalli, Bengaluru- the first company approved under Global Investor Meet in 2010, inaugurated Manufacturing plant in Aerospace Park on

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range of high performance WMW Horizontal Machining of Starrag Group Holding AG, a Swiss Public Limited Company, launched their new range of high performance WMW IWK HorizontalMachin2013. Starrag India also inaugurated their new factory to produce machining centers at Bangalore on 25th Jan 2013 by its ChairmanMr. Walter

25th Jan 2013.

Speaking about this venture, Mr. A.N. Chandramouli, Managing Director, Starrag India said “The Greenfieldmanufacturing facility with a 12 Mn Swiss Francs or Rs. 60 croreinvestment has come up in Bengaluru at KIADBAerospace Park; Devanahalli. It was approved by Karnataka UdyogMitra during the Global Investor Meet in June2010.

Indeed, Starrag India is the first factory to

integrated turnkey solutions and above all competitive prices;Already Since Oct 2010, in order to support the machines imported from Germany, the company had set up atPeenya, Bangalore, a state of the art Technology Center which is now relocated and integrated within the newmanufacturing plant. The purpose of this Tech-center is to support Indian customers in Application and Turnkeysolutions. Here Turnkey

milling, turning, boring and grinding work pieces of metallic andcomposite materials.

Our customers are primarily in machining applications in the Power Generation, Aerospace,Transport, Industrial, Watch &Jewellery, Medical sectors. In addition to its portfolio of machine tools, Starrag Groupprovides integrated turnkey (value added technology) and after sales/reconditioning services that significantlyenhance customer value.

Starrag India has placed several Turbine blade machines, SIP Jig boring machines in the Indian market. In India, they enjoy the patronage of premium Indian customers and their Tier1/2 suppliers in Power Generation (BHEL), Defence(OF), Aerospace (HAL, ISRO), Transport (MAHINDRA, LEYLAND), Wind Energy (HANSEN, WINERGY) and Machinery(ACE). For further details visit www.starrag.com

launch in this new industrial park. Employment of 300 highly skilled technicians will be generatedover time directly by this investment. In the new factory, a apprentice training center has been commissioned usingSwiss Vocational Education and Training (VET) programs already tailor-made in collaboration with SWISS-MEM.” “The new factory will now give the Indian customers advantages of currency protection, locally adapted features,faster delivery, quick response to customer support,

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Projects are undertaken involving Proposal engineering, Application Engineering, Fixtureand Tool engineering, Application and Fixture manufacturing for various customers in Aerospace,Transport/Automobile, Power generation equipment, Agriculture equipment & Construction equipmentmanufacturers.” said Chandramouli.

Starrag Group, headquartered in Switzerland and listed on the SIX Swiss Exchange is a global technology leader inmanufacturing high-precision machine tools for

“The factory will rollout 4 popular size models of WMW Horizontal Machining Centers from July 2013 to Dec 2014. A cost reduction program through local supply chain is in advanced stage and there will be a national road show of the localized product by July 2013. The two phased manufacturing program (60~120 units per year) will mainly be absorbed by Indian market which is now on its economic revival after a slow down in 2012”.

A N Chandramouli Managing Director, Starrag India www.ibmart.in www.ibmart.in

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Hikari Kikai exhibits Japanese solutions at IMTEX, plans to enter Indian market Since last sixty five years of its existence as one of the leading machine tool players in Japan, Hikari has participated in IMTEX 2013 for the first time, finding possibilities to enter into the Indian market with more than 20 products. They are looking for exclusive dealers and distributors to supply CNC grinding machines to cutting tool insert manufacturers.

Hikari manufactures special purpose grinding machines achieving a high level of efficiency, operation and maintenance performance. Some of their products targeted for India are CNC Double Disc Grinding Machine – Planetary Type (with complete unmanned operation) and Oscillation type.

Their CNC Single Disc Grinding Machine is good for complex shaped works in cutting tools. CNC Brush Honing Machine is designed to perform radius honing on the top edge of tungsten carbide inserts.

Operator friendly CNC Chip Breaker Grinding Machine, Diamond Tool Grinding Machine, 4 stationed CNC Rotary Grinding Machine are some of the other offerings from Hikari Kikai. All Hikari machines come

Pursuing High Rigidity and Operability with Diamond Toold Grinding Machine

Read this article online at http://issuu.com/mediamart

Founded on May 1946, Hikari Kikai believes in being professional. Professionalism is setting no limits on the possibilities of each career, which leads each person to his or her self-achievement. Since its foundation, Hikari Kikai has been growing based

upon its technical expertise particularly in grinding. In their history of over 65 years, they have achieved technical innovations in manufacturing special-purpose machine tools with different specifications on every order.

CNC Chip Breaker Grinding Machine with an Operator Friendly Design

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In order to invite an “A-ha” reaction from their customers, Hikari gives utmost importance to develop products through continuous R&D and human training. Their in-house Manufacturing Training Center and Management School train staff, so that each one of them acquires technical knowledge as well as management skills.

“People are enquiring about our products.

We are optimistic. This is for the first time we are participation at IMTEX. Indeed, the experience is fabulous.”

Akito Yasui Director, Hikari Kikai Seisakusho Co. Ltd with one year guarantee system, after sales service available as long as machines are used and their spare parts and consumable parts are made available.

Saraswati Industrial services, Bangalore headed by P S Satish (www.satishps.com) and Cocoroworld co ltd, Japan, supported Hikari Kikai in Imtex 2013 to meet right people. For further details and dealership enquiries contact Mr. Akito Yasui, Director, Hikari Kikai Seisakusho Co., Ltd, Japan Tel: +81-59-227-5511, Email: vasui-a@hikarikikai. co.jp, Web: www.hikarikikai.co.jp

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Renishaw Exhibits Process Control at IMTEX 2013 Renishaw, the global engineering technologies company,has,over many years, developed expertise in the area of process control for manufacturing using precision measurement systems. At IMTEX 2013, the company exhibited a range of process control solutions, from pre-process machine calibration, to online and offline post process control. This included a range of new touch probes and software that increase machine tool automation, a new rotary axis calibration system, and new additive manufacturing machines.

Renishaw, the global engineering technologies company, has,over many years, developed expertise in the area of process control for manufacturing using precision measurement systems. At IMTEX 2013, the company exhibited a range of process control solutions, from pre-process machine calibration, to online and offline post process control. This included a range of new touch probes and software that increase machine tool automation, a new rotary axis calibration system, and new additive manufacturing machines.

On show in hall 3A stall G102 – the RLP40 and OLP40 lathe inspection probes, which offer a choice of signal transmission technologies – radio or optical – to make part set-up and inspection on turning centres accurate, simple and reliable. Measuring just 40 mm (1.57 in) in diameter and 58.3 mm (2.30 in) long, the probes provide unidirectional repeatability of 1 µm (0.00004 in) and can be used to reduce set-up times, scrap, and fixture costs, while improving process control.

Visitors to IMTEX 2013 witnessed products for machine tools that help increase

speed of manufacture. These include the Renishaw TRS2 tool recognition system, which takes typically less than one second to detect broken tools. Also being demonstrated was Renishaw’s twin-probe system which uses a single optical receiver for tool setting probes together with a spindle-mounted touch probe for component inspection, offering fast integration.

This twin system comprises the OMP40-2 touch probe and OTS cable-less tool setter, which is particularly suitable for machines with twin pallets or rotary tables.

system. Equator can switch between parts in seconds, perfect for flexible manufacturing processes or accepting parts from multiple machines.

For visitors to IMTEX who were looking to source machine tool testing systems, Renishaw exhibited the QC20-W wireless ballbar system which assesses machine tool positioning and servo control performance, and includes a volumetric testing capability.

Visitors to IMTEX 2013 also seen a new range of Renishaw demonstrated a new additive manufacturing Also on show was the surface finish probe option for technologies. Renishaw’s Renishaw Equator™, a its revolutionary REVO® five- laser melting systems lightweight, fast and highly axis measurement system. utilise a pioneering, addirepeatable gauge that operative manufacturing process tors can use with ‘push-button’ simpliccapable of producing fully dense metal ity. Equator’s innovative flexible gauging parts direct from 3D CAD, using a hightechnology is based on the comparison powered fibre laser. Parts are built from a of production parts to a reference master range of fine metal powders that are fully part, which can greatly increase throughmelted in a tightly controlled atmosphere, put and reduce scrap rates at a fraction of in layer thicknesses ranging from 20 to 100 the cost of an equivalent custom gauging microns.

WIDMA Wins FIE Foundation Award for Hydraulic Fixture at IMTEX 2013 The FIE Foundation recently recognized WIDMA TM Machining Solutions Group with its prestigious FIE Foundation Award for an innovative hydraulic fixture exhibited at the 16th Indian Metal - Cutting Machine Tool Exhibition (IMTEX) 2013 in Bangalore. The award acknowledges the latest technical innovations in machine tools exhibited at IMTEX, and aims to appreciate and encourage ideas, innovations, and vision in machine tool technology.

Ongoing innovation and quality control on standard increased knowledge of machining centers. how machine tools, tooling, The complete hydraulic and the fixtures that hold fixture provides proper the workpiece all interact averaging, location, orientais required to address tion, part support, and the increasingly complex clamping to locate and hold challenges of 21st Century a workpiece rigidly in place manufacturing. The awardon a horizontal machining winning WIDMA innovation center (HMC). By acis a hydraulic fixture that commodating a complex serves as a turnkey solution two-component rear axle for fixture tooling, sigWDMA FIE Award copy housing for first operation nificantly upgrading process (OP10), this innovative fixture design was optimization, cycle time efficiency, and

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shown to significantly improve productivity. The fixture has a unique configuration by design and features internal hydraulics for easy chip flow.

According to the foundation, »Pursuing excellence is the ambition of every human nature. It is an eternal journey - a journey replete with the rich canvas of experience.

People who pursue this journey have all exhibited certain canonical attributes, creativity, motivation, hard work, discipline, determination and dedication. Such people serve as great motivation to individuals and corporations all over.»

February2013 2013 February

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With the last nine years of networking and publishing of MART, we were successfully made a place in the Indian Manufacturing industry. Our growth was always triggered by the changes undertaken as per the needs of the industry.

The contents of MART is unique, with regular columns by industry experts in the diversified fields of engineering manufacturing, technical features, news updates, interviews, case studies, trade fair informations etc.

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IATF 2013 brings Innovative and Inspiring Growth in the field of Automation Automation is no longer a dream for the industry, from SMEs to large scale enterprises; everyone today is using automation to increase their productivity and competitiveness. India’s automation industry is operating in a fast changing and dynamic environment. The first edition of the India Automation Technology Fair, IATF 2013, organized by Automation Industry Association (AIA) and MesseMünchen International India (MMI India), was launched at Bombay Exhibition Centre, Mumbai as a three day event, starting on 1st February and ending on 3rd February, 2013. place applications and for precision manufacturing were showcased by Kuka Robotics,Mitsubishi Electric Industries and Titan Automation Solutions.

The event witnessed the presence of eminent personalities from the industry.

Emerson Process Management displayed among other products smart perceptive technologies like Smart wireless, Forbes Marshall, a major player in the area of process efficiency and energy conservation, exhibited steam and water analysis systems. and other products, L&T Electrical and Automation displayed its integrated end to end automation solutions for power plant engineering.

Over 100 products suitable for adoption by the SME sector were on display.

Baumer Technologies recent launch ‘clever level switch’ was given the AIA award for the most innovative technology solution for SMEs. The next best solution award went to Base Automation for ‘Automation enabled poka-yoke’. A group of young engineers from Axcend Automation, B&R Automation, Rockwell, Siemens and Schneider were given commendation certificates for exemplary teamwork in launching the PackML global standard in machine communication.

Siemens Industry Automation Division, showcased solutions that integrate product development with manufacturing automation to power the digital enterprise and enable companies to improve productivity, optimize manufacturing, and get products to market faster. Also, robotics based solutions for pick and

The Innovation Exchange Programme at IATF 2013 gave importance to the automation sector as a catalyst for the growth of Indian economy. As manufacturing facilities move towards the smart factory concept, there will be a need for real-time performance management across multiple facilities. IT will be the major facilitator of this mega

trend. A thin line between automation and IT is testament to the growing role that IT will play in being a part of the future evolution of automation. This automation-IT amalgamation was very well complimented with a presentation by Rockwell Automation on “Future Trends in Industrial Networking” Traditional adopters of automation solutions will continue to grow but it is important for India that other industries that form a significant share of the economy do not lag behind. IATF 2013 laid a perfect platform for bringing SMEs and MNCs together to drive the next phase of the Indian manufacturing growth.

“Chemtrols is proud to participate in the very first edition of India Automation Technology Fair 2013. I am overwhelmed with the success of IATF 2013 and hope that it will lay the foundation for the next phase of Innovative and Inspiring growth in the field of Automation” Nandakumar Chairman and Managing Director, Chemtrols Industries Ltd.

Quaker Chemical Launches QAdvantage Platform Quaker Chemical Corporation has launched QAdvantage, a new enterprise designed to better serve industrial manufacturing customers in North America who are currently served through distribution channels, and to ensure their easy and complete access to Quaker’s robust product portfolio and industry-leading expertise. QAdvantage is supported by a dedicated team of professionals who will work with existing distribution partners and end-users to strengthen Quaker’s position in the industrial manufacturing market.

Quaker’s process fluids are used in critical manufacturing processes by global industry leaders, in automotive, aluminum, steel, heavy equipment, aerospace, tube and pipe, and bearing manufacturers.

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“We have routinely demonstrated the value of Quaker’s products and services in helping to improve process control, efficiency and quality in our core markets,” said Karl Kunkel, Quaker’s Business Director for Metalworking in North America. “QAdvantage will expand our reach and deliver that same value to the underserved customers in targeted industrial

manufacturing niches.”

Quaker Chemical is a leading global provider of process fluids, chemical specialties, and technical expertise to a wide range of industries, including steel, aluminum, automotive, mining, aerospace, tube and pipe, cans, and others.

For further details visit www.quakerchemindia.com February2013 2013 February

Igus completes successful 10 years in India Announces major initiatives to meet India’s burgeoning market for Polymer Energy Supply Systems and Bearings India will emerge to be a key growth market for German based igus GmbH, the world’s leading manufacturer of energy supply systems including cables and all accessory components. T he company also pioneered research in the field of Tribopolymers and today leads the world market in the field of high performance polymer bearings.

In its first ever Press Conference held to mark completion of 10 years of its successful operations in India, the company announced a slew of significant initiatives and growth plans for the India market, a decade which also marks igus efforts of having introduced, educated and grown the Indian market for innovative use of plastic technology in dry-tech bearings, high flexible cables and energy supply chains.

Today igus supplies to diverse and fast growing sectors such as automotives, machine tools, robotics, medical, packaging, steel, food, textile, material handling, ports, cement, mining, energy, etc.

is continually investing in India, to both enhance its sales organization as well as infrastructure for assembly, storage and distribution. It looks to expand its current network of 11 offices to over 16 across regions in the coming year and will double its sales force to support the growth plans. igus India from day one since its inception has remained debt free and on a strong growth path, continuously investing into the local operations and the availability of the large igus’ delivery program for our customers in India from 24 hours. To further support our growth plan and maintain the leadership position igus GmbH in the near future would look at investing in a state of art factory with the highest production standards based on Lean methodologies” said Marc Poensgen, Head, International Group Development - Asia, igus GmbH. Elaborating on the significance and potential applications of igus innovative technology, Antony P. Kurian, Managing Director, Igus (India) Pvt Ltd said, “Modern energy chains and chainflex® cables from igus help to design and operate machines that

are efficient in terms of energy and costs.

Energy consumption can be drastically reduced by using the igus ready chain systems® as is proven by the over 5000 cranes running across India. Metal chains are being increasingly replaced by lighter yet rugged plastic energy chains even in the toughest of working conditions, be it in a simple clean room application of a pharma company or in the extremes of molten steel handling ladle crane or in machine tool with 850°C hot metal chips.” “igus products and cable management systems can be deployed right from small workshop to the cable management system of telescopes installed on the Himalayas at -30 degree centigrade. The Chandrayanproject telescope was also equipped with igus cable management system which eventually was part of the discovery of water in Moon. Thousands of gallons oil in lubrication and millions of man-hour in maintenance has been saved by the use of our dry-tech bearings which run without lubrication and maintenance be it in an auto rickshaw or a packaging line.”, he added.

igus India grew nearly 25 times in the Indian market in the last 10 years and close to 40% growth in the last financial year- net sales in the country is expected to close at an estimated 60 crore at the end of FY 2012-13. igus India ranks first among its subsidiaries in growth percentage continuously for the last couple of years and top 10 fast growing markets for Igus globally.

The company expects to double its growth in the country over the next three years to establish its undisputed leadership in the market for plastic bearing, high flexible cables and polymer cable chains. igus

Team Igus India

Carbide Burnishing Drills from BILTZ BILTZ CUTTING TOOLS COMPANY offers Solid Carbide Burnishing Drills with Coolant holes for Drilling in short chipping materials such as cast iron, malleable cast iron, etc where accurate and correctly aligned Drilled holes are demanded.

BILTZ Burnishing Drills, straight fluted with two flutes in Solid Carbide have higher torsional strength compared to spiral fluted

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tools.

BILTZ Drilled holes have close diameter tolerance and excellent surface finish at high cutting rates resulting in high productivity.

These are available in diameter ranging from 1 mm to 80 mm also for Drilling depths up to 10 times diameter.

Range of Solid Carbide Tools supplied includes 2/3/4 fluted End Mills, Reamers,

Through Coolant Reamers, High Helix End Mills, 3 Flute Standard Drills, Through Coolant Drills, Centre Drills, Step Drills for tapped hole, Solid Carbide, Special Tools.

For further details contact Biltz Cutting Tools Company, S-3, Rahul Chambers, Kasarwadi, Pune – 411034 Tel: 020 46761015 Email: biltz@vsnl.net Web: www.biltzindia. com

www.ibmart.in www.ibmart.in

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MART UPDATE

Fluke Corporation introduces the Fluke® VT02 Visual IR Thermometer New-format Fluke VT02 Visual Infrared Thermometerfills the gap between thermometers and thermal imagers Fluke Corporation introduces the Fluke® VT02 Visual IR Thermometer, a troubleshooting camera with an infrared heat map. Until now, electriciansand industrial, HVAC, and automotive technicians have had to choose between singlepoint infrared thermometers and high-resolution thermal imagers (infrared or “IR” cameras).

The Fluke VT02 Visual IR Thermometerfills the gap, for when a single-spot temperature reading isn’t enough and a high-resolution thermal image is more than users need.One tool combines the visual insight of a thermal imager, the visual images of a digital camera, and the point-and-shoot convenience of an IR (infrared) thermometer.

Conducting inspections for electrical, industrial, HVAC/R and automotive applications is far faster with the VT02 than an infrared thermometer, which requires multiple

readings and manually recordedresults.

The VT02 instantly detects problems using blended thermal and digital imagery. It will display and save images as full visual, full infrared, or in three blended modes (25, 50, and 75 percent).

Markers pinpoint hot and cold spots indicating the hottest temperature with a red box and the coldest with a blue box.

A temperature reading is provided at the center point. Images are saved to the micro-SD card, eliminating the need to write down single or multiple measurements.

Developing a tool that is easier to manufacture than traditional thermal imagers required significant innovation. Using hyper-thin pyroelectric technology, engineers discovered a way to push the limits of the tech-

nology, pioneering an array dense enough to create an infrared heat map.

Affordable, compact, and intuitive, the VT02 operates with focus-free simplicity, expanding the user base from senior to junior technicians and broadening the applications for in-house staff as well as creating new business opportunities for service contractors. Images from the VT02 can be imported into SmartView® analysis and reporting software, included with the VT02, to produce professional reports that document problems detected or repairs made for management and customer review.

Pricing and Availability The VT02 Visual IR Thermometer is available now. For more information, visit: www.fluke.com/blending.For information on Fluke tools and applications, or to find the location of the nearest Fluke distributor, contactHelpdesk – 1800 209 9110, Email – Info.india@fluke.comor visit the Fluke Web site at www.fluke.com/india.

Hypertherm introduces new 3.0kW HyIntensity Fiber Laser cutting system Hypertherm, announced first week of this month at Singapore, the release of a new 3 kW fiber laser system—the HyIntensity® Fiber Laser HFL030 with a recommended cut capacity of 3/4 inch (20mm) for mild steel, a 1/2 inch (12mm) for stainless steel, and 3/8 inch (10mm) for aluminum.

Like all HyperthermHyIntensity Fiber Laser systems, the HFL030 is specifically optimized for cutting applications. It comes complete with pre-developed cutting processes, and all the needed components for significantly simplified table integration and operation.

As a result, the system can cut thicker materials in some cases much faster than many higher powered competitive systems. In other words, Hypertherm’s 3 kW system has the cut capacity of other 4 kW fiber laser systems without sacrificing cut quality.

When compared with CO2 laser systems, the fiber laser cutting process significantly www.ibmart.in 6464 www.ibmart.in

simplifies table design requirements and integration. Operating costs, thanks in part to the high energy efficiency of the fiber laser, and maintenance requirements which are virtually nonexistent are also much lower than with CO2 laser for lower total cost of ownership.

All of the HyIntensity systems were developed and manufactured by Hypertherm in the United States, making Hypertherm the only company to offer both laser and plasma cutting expertise.

Readers can learn more by visiting www.fiberlasercutting.com.

February 2013 February 2013

THE LAST LEAF Dear Readers, Self-reliance is today the buzz word in the industrial atmosphere. It helps accomplish greater freedom and hence, lower lead time to accomplish success. There have been significant endeavor made today across our country to initiate and sustain self-reliance.

Countries such as India and China are developing their own ‘home grown’ talent to meet the demand of the automotive industry, given the shortage of skilled engineers reported in both Europe and US. There are companies who have been showcasing and demonstrating how they work to deliver training and education to the communities where their plants are located, and reap benefits of the surroundings.

The training (localized) being given to the people helps them to get employed with such companies and in the event these companies are unable to employ them, they help them getting placed with another company based on the training that has been given to them.

Its one of the great effort taken by such elite companies of creating a local pool of skilled workers and hence building a strong bond with the local community, to keep at bay the possibility of an industrial unrest.

Complimenting this effort, is the IT industry support to such an initiative, assisting the communication and data transfer challenges. It is clearly evident in India that there is a increased use of IT systems – be it a tailor-made software or an ERP module – to control operations at the manufacturing industries. This includes every aspect of production workflow, assembly line, supply chain, etc. with little or no human intervention so as to offer dramatic productivity enhancements and increased equipment utilization.

Meanwhile, recently there was an effort by Audi in form of Audi Production Award 2012 Competition, to give a fitting recognition to the values like passion and emotion in production, as well as competence.In a similar way, in India, VW’s Pune plant was adjudged the plant with greatest reduction in energy compared to previous year. These are endeavors to delight the customer and save our planet, as a whole.

Give customer what they want and get it to them faster than any one else. These are the two basic rules on which Amancio Ortega Gaona has built the empire Zara, the world’s largest fashion brand. He is the world’s third richest person, after Gates and Slim, now worth $ 56 billion, ahead of Warren Buffet. Zara has a total of 6000 stores in the world and a new store opens every day on average. While the entire Spain is in recession, this enigmatic Spaniard shows no sign of slowing.

As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions.

Till then, Happy Technology!

Manoj Kabre Member - MART Editorial Advisory Board

February 2013

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February 2013

Looking for Sales Representatives in Europe and Asia

RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012/2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month