MART OCTOBER 2012 by MART INFOMEDIA PRIVATE LIMITED

October 2012

industrial business MART

October 2012

industrial business MART

October 2012

industrial business MART

October 2012

industrial business MART

October 2012

NEWS MART

Hypertherm Inaugurates Cutting Technology Center in India Hypertherm, a leading manufacturer of advanced metal cutting systems, officially opened the doors to its first cutting technology center (CTC) in India last week. Located in New Delhi, the center is the first and only Hypertherm CTC in India, and one of just 3 Hypertherm CTCs in Asia. The facility will serve as a gathering point where channel partner employees can train up their technical skills and sales expertise to enhance their capabilities when introducing Hypertherm products to end-users. Soo Kam Tatt, Director, Hypertherm Asia, said, “At Hypertherm, we recognize the significance of our OEMs (original equipment manufacturers),

A theory session on the MAX200.

Participants had the opportunity to try out manual and automated cutting using Powermax systems and the MAX200. system integrators and distributors. They are our key sales channels in India and are our end-users’ main point of contact. That is why we believe in investing effort and resources in training all channel partners, and we have reinforced this commitment with the new CTC.” From 11 to 14 September, a total of 9 employees from 3 channel partners gathered at the CTC to acquire technical knowhow and sales techniques related to the Powermax range of manual plasma systems, and the MAX200 oxygen cutting system. These instructional sessions will be extended to Hypertherm’s entire network of 40 channel partners over the coming months. The following photos

were taken during last week’s four-day training. The CTC is co-located with Hypertherm’s new office, which has been operationally ready since August 2012. This larger premise houses an increased number of associates who work to meet the needs of the company’s ever-expanding local customer base. “Business in India has been growing since we first entered the country in 1999,” shared Soo. “With the new office and CTC, and with the addition of more local associates, we are confident that Hypertherm India will be able to better cater to the demands of our customers, both current and potential.”

Online Turnkey Solutions Platform for Construction Sector www.machinebank.in to help organized and unorganized sectors make right decisions A unique online platform promoted by alumni from IIM and ISB, that will enable its customers achieve Effective, Efficient and Economical Project Management solutions (e3PM) was launched today. The portal, www.machinebank.in, provides advisory services (transaction, strategic and operating phase) to buy, hire, sell or auction new and old machinery and spare parts. “If you are looking to access latest tenders (domestic or globally), realize best

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value for your assets, have faster utilization time for your assets, reach out to largely spread set of customers, access that specific manpower, avail finance at best IRR etc – www.machinebank. in is the solution you had been looking for,” said Mr. Keerti Kumar Jain, MD and CEO, Machine Bank. MachineBank will offer end-to-end solutions to various stake holders like EPC, contractors, subcontractors, manufacturers, financial institutions, job seekers, government departments of the infrastructure indus-

try. Machine Bank is being patronized by India’s leading Equipment Banking Company; Quippo Construction Equipment Ltd, a SREI Infrastructure Ltd subsidiary. The USPs of MachineBank are – realization of best value for asset with least lag time, access right machinery or spare parts at right value and at the right time, auction platform, Smart Search Engine and being able to receive target applications for manpower needs and also access industry specific resumes.

October 2012

industrial business MART

NEWS MART

Your own college to train young aspirants, to manage your Enterprise. There is belief that most of young recruits do not have required expertise and zeal to perform. The blame is fixed on the values of young generation & falling standards of education in general. How much responsible, the Industry has been in this regard? Most of it is satisfied with three rounds of interviews and Campus recruitment. The solution is to understand the holistic value chain. You want to hire someone to help you perform better. How can a College or University understands this? Can they modify their syllabus to include the demands of each Industry? Obviously No. They are working under a system that takes 15 years to change or modify anything. The young aspirant is confused

that what has been taught, is not helping him to cope up with the demands of Job. It is time to change and Industry has to be more responsible for developing it’s own HR. SaaRaa Learning Centre (SLR) in partnership with KIMS, Management study wing of Karnatak University, has developed a Customised Industry Specific Suitability Certificate Management program. Industry is offered with a list of fresh graduates for selection to sponsor the candidate to undergo this program. SaaRaa Edge Level. 1 is of 6 month’s duration. During this period the candidate will attend the class at SaaRaa campus in mornings (4 hours) and work as Intern with the sponsoring Industry post Lunch.

Industry has to offer a stipend during this period. The syllabus of the training will be designed in consultation with the Sponsoring Industry. After completion of the training the student is awarded the certificate by the University.The candidate is employed by the Sponsoring Industry. Candidate clearing level.1 are eligible for Level. 2 course thereafter. To take this Idea further minimum 100 Industrial units are required to enrol with SaaRaa as sponsors, by paying a fees. The amount collected from the enrolment fees will be used to advertise this course to get the quality candidates. Industries can communicate on saraa. lc@gmail.com with Vivin Agarwal, the Mentor of this Program.

Raman Koul - New GM in Chicago Pneumatic Chicago Pneumatic has announced the appointment of Raman Koul as General Manager of the company’s Chicago Pneumatic Compressors in India. He will be based in Pune. Raman holds a degree in engineering and an MBA in financial management. Raman joined Atlas Copco as a management trainee in 1991 and has held positions like sales engineer, senior sales engineer, assistant manager sales, manager sales, regional manager and product marketing manager. He was appointed as Business Line Manager - Af-

Raman Koul 14

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termarket in 2006 and has been working as Business Line Manager - Compressor Technique Service upon the formation of Compressor Technique Service in 2008. “Raman’s considerable experience within Atlas Copco will strengthen our business and contribute enormously to growing Chicago Pneumatic Compressors into vibrant business, improving the brand’s operating and financial performance” commented Peter Wagner, President, Atlas Copco Gas and Process Applications.

“I am proud and thrilled to take up the position of general manager of Chicago Pneumatic Compressors. As I take on my new responsibilities, my priorities are to achieve maximum efficiency, accountability and concrete result.” October 2012

SKF receives SNCF Suppliers Excellence Award SKF has received a suppliers excellence award by SNCF in the category Parts and Service. The award was given during a ceremony at InnoTrans 2012 in Berlin and SKF was rewarded for its high level of excellence throughout the life cycle of the equipment.

Rybicki, Manager SKF Railway BU Europe South.

SNCF measured the performance of SKF according to a multi-criteria evaluation procedure. The final grade, high-level, has been obtained thanks to two major indicators: Reliable delivery and Quality.

To serve its strategic development objectives, SNCF expects its suppliers to deliver high levels of excellence and innovation. Standards of SNCF rolling stock division require operational excellence throughout the life cycle of the equipment in terms of Quality, Time, Cost control and Fulfillment of commitment related to sustainable development of SNCF.

“SNCF has been an important customer for SKF for many years. We are proud of this award which reflects our continued commitment to contribute significant resources and investment “, says André

SKF has been a supplier to SNCF since the 1950’s and supplies the company with wheelset bearings, housings, bearing solutions for traction motor and gearbox applications and is considered

October 2012

as a strategic partner of SNCF. SNCF Group is the main player of railway transport in France and one of the leading transport and logistics groups in Europe. In India, the SKF Group started its trading operations in Kolkata in 1923. Since then, the group’s operations have been consolidated into SKF India Ltd. SKF India Ltd also has associate companies called SKF Technologies (India) Pvt. Ltd. and Lincoln Helios (India) Ltd. providing Sealing solutions, Industrial bearings and Lubrication systems. The company has manufacturing plants in Bengaluru, Pune and Haridwar.

industrial business MART

NEWS MART

RESOLUTE™ True-absolute Encoder debuts at AMB Metalworking Show, Germany RESOLUTE true-absolute linear and rotary (angle) encoders with new compatibility for Siemens DRIVE-CLiQ will make their debut at the AMB international exhibition for metalworking in Stuttgart, 18th – 22nd September. (32 bit on rotary) even at speeds up to 100 m/s (36 000 rev/min on rotary). Advanced optics mean the detection scheme also has intrinsic low SubDivisional Error (SDE) and very low noise (jitter), so users can benefit from lower velocity ripple and rock-solid positional stability. Such high-fidelity motion control performance is normally only associated with much more fragileRESOLUTE montage encoders, but RESOLUTE adds ruggedness and reliability, with sealed readheads and scales constructed from dependable shatter-proof engineering materials. DRIVE-CLiQ is the innovative, powerful communications interface to connect encoder and direct measurement systems with SINUMERIK and SINAMICS drive components. Allowing machine builders to achieve higher performance and greater reliability, this product conforms to Category 2 in accordance with EN ISO 13849 and so is suitable for use in safety-related axes such as linear motors and direct drive rotary (DDR) torque motors. Outstanding Performance Visitors to hall 1, stand H72, will be able to see the outstanding motion control performance of RESOLUTE with the DRIVE-CLiQ interface. RESOLUTE’s unique operating principle is analogous to an ultra-high speed digital camera, capturing images of the scale, enabling resolutions up to 1 nm to be achieved

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The non-contact format eliminates bearings, seals, couplings and guideways from the encoder design, thereby also eliminating the most common causes of shock / vibration-induced encoder failure. Even if the main seals on the axis fail, RESOLUTE readheads are sealed against ingress of oil and coolant; simply wipe the readhead and scale, then start working again. Downtime is minimised and servicing /repair is simplified. The non-contact format also helps improve system metrology. RESOLUTE rotary encoders read a solid stainless steel scale that is locked to the axis shaft so the encoder does not suffer from the mechanical backlash, wind-up and coupling losses that affect traditional enclosed encoders. Rotary scales include options with accuracy better than ±1 arc second, low-iner-

tia versions and sizes from 52 mm to 550 mm, with custom sizes also available. Furthermore, the large through-hole allows the encoder to be mounted much closer to the point of interest without complicating the routing of services to payloads. The result is a system with greater dynamic capability, faster settling times and improved repeatability. Linear encoders, with both stainless steel and ZeroMet™ (low expansion nickel-iron alloy) scales share many of these advantages, mounting direct to the machine’s structure or track guided. With precision-graduated unique singletrack absolute code, linear scales include options with accuracy better than ±1 micron, or tape scales up to 10 metres long. Functional Safety The functional design of RESOLUTE’s operating system paves the way for certification to EN ISOImage: Functional safety logo 13849, Category 2, performance level ‘d’. The detection scheme is inher-

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ently dependable, featuring advanced cross-checking and high levels of redundancy. Position is calculated every time the encoder receives a position request, so true absolute position is determined every time, meaning miscounting or ‘runaway’ is impossible. Safety is also enhanced by RESOLUTE’s unique built-in position checking algorithms. Each time the encoder receives a position request, RESOLUTE determines position using one algorithm, then verifies that result using an independent position checking algorithm. Any errors can therefore be flagged to the controller before the axis enters a dangerous condition. As a true-absolute encoder, RESOLUTE determines position immediately at switch-on, so complete control of the

October 2012

axis is achieved without any movement, reference returns or battery back-up. Proof of the effectiveness of these safety features is that RESOLUTE is being used in a variety of medical, defence and aerospace applications where reliability of position data is of primary and critical importance. Quick and Simple Installation For the machine builder, RESOLUTE offers a quick and simple installation experience. The scales are designed for easy installation, the readhead has large set-up tolerances and the readhead features a unique set-up LED that provides a very simple and intuitive indication of optimum installation. This LED (repeated on the remote DRIVE-CLiQ interface) provides simple diagnostics throughout

the life of the encoder too, without the need for specialised set-up boxes. Please note that the RESOLUTE range is available with several other serial protocols, allowing connection to a variety of industry-standard drives and controllers. DRIVE-CLiQ is a registered trademark of Siemens

industrial business MART

NEWS MART

Enhanced Laser Scanning: ROMER Absolute Arm now up to 66% faster Hexagon Metrology is further developing its laser scanner technology for portable measuring arms. The integrated laser scanner for the ROMER Absolute Arm is now significantly faster. Also, laser scanning can now be carried out wirelessly. sions, offering an acquisition speed of up to 50,000 points per second. This enables users to move the scanner over the measurement object faster than before, while achieving the same high data quality that ROMER users have come to expect, even on difficult to scan surfaces like high-gloss carbon-fibre. This means that users can now scan up to 66% more surface area in the same amount of time as with previous versions of the ROMER Absolute Arm with integrated laser scanner.

The enhanced ROMER Absolute Arm with integrated laser scanner is now more rapid compared to previous ver-

Along with this development, Hexagon Metrology is also launching a wireless scanning option for the ROMER Absolute Arm with integrated laser scanner. This new Wireless Scanning Pack allows any arm with integrated scanner to be operated completely wirelessly, and at the same data transmission speed as with a traditional cable. Furthermore for unlimited wireless operation in the field, the Wireless Scanning Pack also includes

a dual â&#x20AC;&#x2DC;hot swappableâ&#x20AC;&#x2122; battery system where one battery can be charged continuously, while the other is in use. The Wireless Scanning Pack is offered as an accessory and is compatible with all new and existing ROMER Absolute Arms with integrated laser scanner. Installation can be completed by the user and in just a few minutes. These new laser scanning capabilities are available immediately. Hexagon Metrology will debut them at the IMTS exhibition in Chicago from September 10th-15th, 2012 (booth E-5202). The ROMER Absolute Arm with integrated laser scanner is a portable CMM for both tactile and non-contact 3D measurement. The laser scanner is completely integrated into the arm, which allows the measuring arm to be certified as complete system according to international standards such as B89 or VDI/VDE.

Heatex Heat Resistance Paint from SPOI cutta for Star Heatex Aluminium Paint Heat Resistant upto 600degree C as per I.S. Specification No. 13183-1991, Grade I.

Star Paint & Oil Industries is 66 years young paint manufacturing company who has recently obtained certificate from National Test House, Alipore Cal-

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The Specification was recently published by Indian Standard Institution, New Delhi and Star Paint was the first manufacturers to obtain certificate from laboratories. The said Heatex paint is used for protection of Blowers, Boilers, Burners, Chimneys, Driers, Engines, Exhausts, Furnaces, Gensets, Heaters, Incinerators, Kilns, Manifolds, Muttlers, Ovens, Radiators, Silencers, Transformers, Auto- Claves, Cooking- Ranges, Driver-

Racks, Engine- Heads, Flare- Stacks, Heat Reactors, Lab- Equipments, Light- Reflectors, Oven- Trays, Solar- Heaters, SteamPipes, Steel- Structures, Studio- Lights, Tail- Pipes, Etc. This paint is reported not to crack or peel off at temp upto 600 degree C. They are also manufacturing Industrial Paints & Enamels, Insulating Varnishes, Chemical Resisting Paints, Fire Proof & Fire Retarding Paints, Etc. For more information visit www.starpaintindia.com October 2012

Orbitz gears up for HANNOVER MESSE 2013 Hannover Messe is the premier technology event and decision-making platform for investing in global markets. It affords a unique opportunity to develop new fields of business and discover new perspectives with the ground-breaking technologies and innovations. The world‘s most important technology event will present a complete array of solutions designed to streamline production processes and reduce costs. Hannover Messe 2013 to be held from 08—12 April, 2013 at Hannover, GERMANY, will feature 11 leading international trade shows that will be more attractive than ever before. This transforms Hannover Messe into an accurate indicator of

October 2012

future business trends. When it comes to trade fair tours, Orbitz is unmatched. That’s because its Business Tours division comprises a team with the expertise and vast experience of having led India’s largest delegations to Hannover Messe in all its earlier editions. Orbitz offers Independent Travel Plans and Group Travel Packages for exhibitors & visitors for Hannover Messe 2013. They include premium airline, 3 star hotels located within city limits and in city suburbs, apartment stays, fair ground transfers with group, packed lunches for exhibitors on trade fair days and Indian

dinner in hotel as well as at selected Indian restaurants. Moreover, the attractively priced packages include German Schengen visa with overseas Mediclaim and experienced tour managers to make sure the delegates have an absolutely relaxed trip. Industry professionals should therefore plan a visit to Hannover Messe 2013 with Orbitz expertise and excellent track record. After all, it pays to attend the world’s biggest technology event with India’s premier trade fair travel company. For further details write to Sandeep Panwar at sandeep.p@orbit-star.com or book online: www.visittradefairs.com/ go/hannover2013

industrial business MART

COVER FEATURE

The Perfect Gear When engineers and management at California-based Haas Automation decided they wanted to become the world’s largest machine tool manufacturer by volume, they knew they had to master the art of gear making. Nearly 30 years later, more than 1200 Haas machines and hundreds of rotary products are built every month, and every Haas gear is machined in-house to exacting and uncompromising standards. According to Bill Tandrow, Vice President of Mechanical Engineering at Haas Automation, “More than any other type of machining, gear making relies on a perfect mix of science and art. “I have a lot of respect for anyone who makes gears,” he adds. “In many ways, the quality of gear making at Haas helps to define the quality of our final product.” The art of gear making, claims Tandrow, lies in careful observation and skillful control of the machining process itself. There’s no “black magic” required, only complete and careful attention to detail.

Bill Tandrow Vice President of Mechanical Engineering at Haas Automation 20

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Haas Automation approaches gear making seriously. The company machines every high-precision spur gear, worm, and worm gear for its extensive product line in-house at its huge manufacturing facility in Oxnard, California. Out of more

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than 600 skilled machinists and assembly specialists, only a handful of machinists are assigned the task of making these demanding parts. Haas machinists Boris Klebanov and Edik Beginian have been with the company for about as long as anyone can remember. They learned most of what they know about gears from company founder Gene Haas. “Years back, when we first started making mills,” recalls Edik, “Gene wasn’t completely happy with the gears we were getting from vendors, so he purchased a Reishauer RZ-80 and started making the gears himself. He did a lot of experimenting and testing to figure out exactly what was going on. He not only solved all of the performance problems, but he learned how to repair and maintain the machine himself. Then he taught us.” “We use those same perfected techniques today,” Boris adds. “We’re making essentially the gears that Gene evolved, along with 70 or 80 other kinds October 2012

of gears. We’re still doing everything in-house, and we’re still solving all of our problems ourselves.”

produce an oil-film fit. We manufacture smoother running gears than anyone could even have imagined back then.

With schedules demanding different machine setups daily, maintaining process control is just one of many demands facing these highly talented machinists – but it’s a big one.

Why does Haas insist on making its own gears? “Because, ”says Tandrow, “it allows us to precisely control the outcome. There are so many little tricks and subtleties in the hobbing and finish grinding, that we just would not succeed by having them done externally. We build our own gears to get exactly the

“Spur gears were never intended to be precise, ”Tandrow remarks. “Until recently, nobody had equipment to make them precise. Machinists were often happy if they just fit together. If you open a Machinery’s Handbook to the section on spur gears, you’ll find a lot of tables for backlash, etc. Those tables weren’t based on a desire to make a bad gear, ”Tandrow says. “It’s just that when those tables were written, back around the late ’30s, that was the state of the art. CNC gear-hobbers and grinders obviously didn’t exist then. You just couldn’t expect to hold 30 millionths of an inch on a grind. But now we have equipment and processes that can hold down in those ranges repeatedly. We can

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“But when you make a gear in-house, you can build things into it that they can’t do across the street. For example, you can preassemble the gears in a rough state on a single mandrel, put them into a hobber or a grinder, and finish-grind them perfectly. The gears are as exact as you can measure them, and they’re already on the shaft they’ll run on. ‘Across the street’ is just not close enough to ensure this kind of quality, ”Tandrow says. “For most of our gearbox operations, the operator who hobbed or finish-ground the gear is literally within a hundred yards of where we assemble the gearboxes. “For a manufacturing environment, that’s the ideal. We can make the gears in very tight batches of 10 or 20, and quickly process them through. It’s more cost-effective than ordering big batches, and if there are any issues, we’re only looking at a small number of reworks to

right thing for us, at the highest precision possible.” Straight-cut spur gears are the basis for all of Haas Automation’s gearboxes. The company started out buying complete assemblies, but they just weren’t as good as the engineers wanted them, explains Tandrow. “Finally, we just designed our own gearbox. Now we make every part ourselves.

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“When you buy gears from someone else,” he continues, “you effectively have to buy through a middleman. Even if their shop is just across the street, you have to build a relationship with them. You have two different companies, two different cultures, and you probably have a pretty big disjuncture between the process of using the gears and the process of making them.

get production flowing again. That’s if there are any issues, ”Tandrow emphasizes. “Honestly, we’ve not had one since we adopted this approach.” In the same area where the spur gears are cut and ground, Haas also machines precision worm gears and worms for its rotary products. This is where the dedication to tight process control really pays off. “The aluminum-bronze worm gears at the heart of our rotary products are ac-

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is translated into actual product accuracy through the skill of these machinists, and through their careful control of the process. “Every third or fifth one is checked on a Wendzel WGT500 CNC gear analyzer against a master worm,” notes Velasquez. “We can verify toothto-tooth and overall pitch accuracies on both the worm and the gear at the same time. We also have special worms that we use to check the gears as we’re cutting them, for more immediate feedback. We need to know that they’re coming out of the machines right.” “That’s another very important aspect,” adds Tandrow. “You can’t compete at the level just described without having some of the best equipment in the world: like the Reishauer RZ-362A hobber, the Studer S40 grinders, and the exceptional inspection equipment we have on the floor. You have to have the best tools to generate these results repeatedly.” “We also have Mitsubishi GC15 and GE20A, Koepfer 300, and Gleason 130H gear hobbers,” adds Velasquez, “as well as high-quality carbide hobs, and a real passion for maintaining the equipment so that it stays accurate.” tually quite mature concepts,” explains engineer Thomas Velasquez, who has been designing these products for nearly two decades. “The inherent accuracy is assured by the single-lead hobbers that we use, and by the preassembly we do before cutting. We place the shrink-fit

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gear blank onto the spindle, mount it on the fixture, and actually tram it in, ensuring that the pitch diameter of the finished gear is perfectly concentric with its mounting diameter.” Again, the inherent accuracy of the setup

Another factor critical to the accuracy of the gears is the careful process of heatshrinking the worm gear to the spindle before cutting it. “That all but eliminates concentricity errors,” says Velasquez, “and it simply could not be done if the

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Misha Brkic, uses a proprietary inspection setup to verify the accuracy of each final product. With his years of experience, he can tell almost as much with his hands during the assembly process. He knows perfectly the subtle feel of an exactly machined worm and gear, and can stop the assembly process almost before it starts if he finds anything unusual.

gear was jobbed out. In a nutshell, we keep tabs on everything.” “We have an assembly staff that can inspect as they build,” adds Tandrow. “Since the parts are made in a controlled

October 2012

process, and the assembly staff knows all aspects of it, including the tolerance bands for testing the parts, we have complete control of the quality.” A key member of that assembly staff,

“This level of skill and experience is the final key to the success of the process,” says Tandrow. And while Brkic performs his duties on the opposite side of a long wall separating the machine shop and assembly areas at Haas, he’s still only a hundred yards from Boris and Edik. There’s a large doorway conveniently located midway between them. “It’s perfect!” smiles Tandrow. “Just like the gears.”

industrial business MART

COVER STORY

â&#x20AC;&#x153;Electronic Industryâ&#x20AC;? Towards Greater Sustainability

J R Mahajan President, Mechatronica Cluster (Indian Cluster of Mechatronics)

industrial business MART

October 2012

industrial business MART

October 2012

industrial business MART

FEATURE ARTICLE

Returnable Dunnages Dunnage is a critical component in material handling applications where part protection and/or storage efficiencies are required. A reusable and returnable dunnage for holding product therein during shipment and then being returned for reuse comprises a body having at least two opposing and moveable side structures. Why returnable dunnage? • To save nature by avoiding wooden/corrugated paperboard packing. • To reduce the packing expenditure. • To protect &phospeted critical components. Working procedure of Returnable/ Collapsible Systems Fill returnable binin your warehouse and have them returned in closed-loop distribution applications. Durable containers stack and collapse; you can utilize the full cube of outgoing trailers to get the most product out in the least space. These dunnages help you prevent product damage; standardize the trailer loads, and more.

C M Nagaraj Managing Director Right Engineers & Equipment India Pvt Ltd 32

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October 2012

Advantages/ Disadvantages of Returnable Systems General saving advantages of returnable dunnages; • Reduces long-term reccurring cost • Improves product protection • Improves workers safety

A well-designed returnable dunnage can often provide more handling and storage protection then an expendable packaging. Improves workers safety Returnable dunnages and pallets provide handles and smooth grasping areas for ease of use and reduce worker injuries.

Cost for the returnable; Rs 20000 Total packaging material weight saving would be; 5000 x 20 – 1 x 20000 = Rs 80000 General disadvantages of returnable dunnages;

• Improves housekeeping • Improves space utilization • Improves environmental impact

A returnable can often be fitted with material-handling features, like handles, storage & transports that would not be economically feasible with an expendable container.

Reduces Long-term recurring cost Export packaging is typically used once and then thrown away. The cost of this package is added into the product unit cost. Returnable packaging eliminates this recurring cost. If your packaging will remain constant for a long period, returnable containers and dunnage are frequently lower in annual cost than expendables. The Initial investment will be much higher, however. Over a period of time, the cost of a returnable dunnage system is typically much less than that of expendable one-way packaging. Improves product protection Returnable dunnages are constructed to support heavy loads and to provide excellent resistance to impact, resulting in better protection of the product carried inside.

October 2012

Improves housekeeping

• Large capital expense or high Initial Investment.

Returnable dunnage eliminates dirt, dust, and the trash clean-up associated with expendable packaging.

• Increased transportation expense, mainly for the returns.

Improves space utilization

• Cost for tracking and accounting and sometimes cleaning.

Returnable dunnage is typically built to support heavy loads and stack high in the warehouse and trailer, saving space and eliminating the damage from crushed product. Improves environmental impact Returnable dunnages reduce the amount of trash going into the landfill. A package reused is one less package that will wind up in the solid waste stream. With fewer returnables going into landfills over a given period of time, the cost of packaging material disposal is greatly reduced. An example; 1 returnable with a lifetime of 20cycle replaces 20 expendable containers. Cost for the expendable; Rs 5000

• Storage space for empties. Large capital expense Initial cost is probably the largest deterrent to the wide use of returnables. Savings over time have to be significant to justify the capital expense. On the other hand, by the experience we have had, Pay-Off-time for the Investments are normally <1 year, which means the Investment is quickly covered. Increased transportation expense Returnables have to be returned and the return trip is usually not free. The cost must be factored in. Our experience shows that the return cost is normally dominating over other costs. The degree of “collapsibility” or “nestability” of containers and dunnage is of key importance

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and increases with shipping distance. Cost for tracking and accounting

• Auto mobile components & parts. • Gearbox, Gear shafts & Rolled components.

Because returnable packaging is relatively expensive, it´s important that they don´t get lost in the return system. A loss rate of 10% losses per trip will give the result of complete system loss in just 10 cycles (10% loss x 10 cycles results in 100% loss). On top of this cleaning might sometimes be an issue.

• Provision to handle with four way forklifts and manual pallets jack.

Storage space for empties

• Lifting hook to lift by crane

It typically takes more space to store empty returnable packagingthan to store expendable packaging due to strength and design.

• Resting pads are designed with finger holes for easy removal of product.

Additional features of Returnable dunnages

• Pistons cylinder, Cylinder Heads & Hydraulic equipment. • Sheet metal parts, door panels etc.

• Additional polyester ratchet belts to arrest the component falling during transportation. • Foldable sheet enclosure or door panels to protect from rain, sun lights etc. • Large label areas on each bulk container provide easy identification and improved inventorycontrol. Applications:-

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• Non-metallic, porcelene, plastic moulds etc. Concepts to use in:1. Internal process flow line 2. Dispatches 3. Assembly Line 4. Storage 5. Stock yard etc. Scope of work:1. Construction: a. Cold rolled MS hallow tubes, MS gusset plates,Pre – Formed

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Stackable cups, pre â&#x20AC;&#x201C; casted nylon mounting with metal claddings, pivot pins& fasteners. b. Foldable enclosure made out of MS sheet with handles. c. Plastic latches will be provided for covering gaps. 2. Process: a. Fabricated & welded by CO2 welding. b. Phosphated & pre treated with anticorrosion. c. Powder coated with pre decided color. 3. Labeling & identification: a. Pallet name. b. Part number.

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c. Manufacturing date.

what sets us apart from the competition.

d. Any special required data.

We have designed to have the heads rest on a series of TPU (thermoplastic urethane) or Nylon rest pads that are exchangeable for 2 or more cylinders.

We have designed and fabricated very simple to very complex dunnage systems used to transport and protect a wide variety of items. Our engineering expertise, thorough understanding of the critical role your dunnage will play, creativity and attention to cost-effectiveness is

We have design tool like solid works to provide 2D & 3D drawing & also practical design presentation for customer to better understanding.

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Below are just a few design of the dunnage we’ve provided to the automotive, Assembly & manufacturing industries… Presently, Right engineers &equipmentIndiaPvt ltd has designed some returnable dunnages for following customers…

weather-proof doors, so that the parts can be store even outside the building. The pallets are designed to be weather proof conditions it can be used in sun lights, rainy seasons etc. 3. Customer- WIPRO INFRASTRUCTURE

1. Customer- CATERPILLAR INDIA PVT LTD (TRANSMISSION BUSINESS UNIT)

Role- The collapsible pallets are designed

Roles- The gearbox has manufacture in Hosur plant being packed in returnable pallet and closed in sea worth material & fit into container. The same is being shipped to states & the empty pallets returned back in collapsible condition with same container. 2. Customer- CATERPILLAR (MACHINE DIVISION) Role- The hydraulic cylinder & parts which manufacture by Wipro infrastructure are being transported in collapsible containers. The cylinder are in painted condition, are packed neatly in each pallets padded with non-metallic wedges & fitted tightly by using polyester belts &ratchets. The pallets are fitted with

The interactive took by Wipro by keeping in view environmental policy & also bring down the packing cost. The idea really to hold hydraulic cylinders housing, piston and heads are being transported to the end user like- JCB. Caterpillar, Komatsu, Schwing stetter, Volvo etc.

Hook for Belt Foldable Handle

Nylon pad-big

Right engineers and equipment India pvt ltd are the leading manufacturer for above customers, they have in-house design facility to design customized product.

Fixed leg

Lifting hook Bottom cup

worked well & they have started implementing for all parts & all customers…

Galvanized hinges Collapsible pin

For more details please visit www. rightengineers.com or contact us on rightengineers@airtelmail.in Ph: 080 41108328/29

Related returnable dunnage designs 36

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October 2012

PRODUCT MART

Hitachi Variable Speed Drives from Strategi power savings when used in such applications with paybacks in many cases being within a year. These drives also incorporate a special Hitachi algorithm to ensure higher energy savings in fan/ pump applications.

Hitachi of Japan brings a wide, rugged range of AC drives upto 400 Kw ratings. These are available as simple v/f drives and also sensorless and flux vector drives. Simple v/f drives (L300 and X200) are suitable for fan, pump, compressor applications and are available upto 132 Kw. Variable Speed drives offer significant

October 2012

The SJ700 series vector control drives have a industry leading starting torque of 200% at 0.3Hz in the SJ700 series. It can maintain 150% torque at 0Hz also. These drives can be used for position control applications with the addition of a feedback option card. The SJ700 series has an inbuilt braking circuit upto 22Kw and a built in EMC filter upto 55Kw. These drives have a built in Over current and Over Voltage suppression. The new latest WJ200 drives has many class leading features such as 200% starting torque. It has special algorithms

to improve low speed regulation. It can be used for simple positioning applications with encoder feedback without the use of any add on card. It can be controlled with a pulse train input also. It incorporates a built in USB port for programming. The same drive can be used for both induction motors as well as brushless motors. All the drives are compliant with International ratings such as CE, UL, C-UL etc. For further details please contact Strategi Automation Solutions Pvt Ltd Plot # 25/B, Doddanakundi Industrial Estate, Off Whitefield Road, (Behind Graphite India), Bengalooru â&#x20AC;&#x201C; 560 048 India Ph: +91-80-32329798/32467879 Fax: +91-8041163047 Email: sales@strategiautomation.com Website: www.strategiautomation.com

industrial business MART

CORPORATE MART

Uniline- 20 years in Power Continuity Uniline, incorporated in the year 1989, ventured to manufacturing in to offer quality products that is reliable, priced rightly backed with service and today it has emerged as Numero Uno - Largest Indian Manufacturer of UPS and the fastest growing UPS companies in India in IGBT technology. “Your life changes the moment you make a new, congruent, and committed decision”, which is how it goes with the very dynamic and diligent Mr.RK.Bansal, the Founder and Managing Director of Uniline Energy Systems Private Limited. Over 22 years of electrifying experience is employed at the company in the design and manufacture of high quality UPS’s, Inverters and other Power Conditioning Products. Its branches are scattered all over India with factories covering 100,000 sq. feet modernized sales & service area at Delhi and Parwanoo (HP). Along with that, the company’s strong R&D innovates timely to offer latest customers with more features, green power, low distortion and energy conservation, high Input Power Factor for greater efficiency.

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The company proudly stands as the most innovative, highest quality, cost effective, energy efficient and rationally priced UPS systems and Power Conditioning Products available in the Indian market today. Custom designed problem solving by the company’s engineering personnel is recognized and widely used by the industry. The wide ranges of products include D SERIES (High Power IGBT UPS up to 1000 KVA), GIGALINE (IGBT UPS Up to 200 KVA), MAXILINE (IGBT UPS Up to 100 KVA), GREENLINE (Online UPS Up to 6 KVA), SMARTLINE (Offline UPS Up to 3 KVA), POWERLINE (CTV - SERVO Up to 1000 KVA). Adopting high frequency full bridge topology for high steady performance, high input power factor connection, selectable various output range and operational mode and cold start function are the unique features of Uniline’s OnOctober 2012

line Green Series UPS. The company’s first UPS factory was set up in 1996 at Okhla in Delhi and now the company operates its offices in almost every corner of the country and has distinction in providing power conditioning solutions to all the industry segments viz. PSUs, Banking, Ministry, Medical Institutions, Telecom, SMEs, Single Head Customers, etc. “The company is aggressively strengthening its support network while forming partnerships with reputable, honorable distributors and retailers who are aggressive in their approach to the market and who maintain a high sense of values. Our distributors are our partners in profit and we work directly with our distributors to maintain price competitiveness, while continuing to supply the highest degree of quality and reliability and ensuring the highest of margins”, clearly affirms the energetic Mr.Bansal who is awarded with National Quality Gold Star Award, Udyog Patra Award, Laghu Udyog Bharti Excellence Award, Udyog Pragati Award, etc. for his contribution to the power management industry. The company has left no stone un-

turned in entering into high capacity UPS system. Uniline has introduced high frequency IGBT rectifier & inverter based UPS system also called the Green UPS. The efficiency of the system is less than 94% and less than 98% in eco mode as against conventional efficiency of 90% which result in large saving per day. The UPS systems are available up to 300 Kilo Volt Amperes (KVA) with a provision of paralleling upto 7 units. The UPS systems are supplied with user friendly touch screen display with further facility of management by remote monitoring/

control by RS 232/ RS 485/ SNMP/ web based. In their recent press meet, Uniline launched its D-Series which is purely unbeatable, highly efficient, environment friendly power saving green product. It has been mainly designed for the Telecom domain applications at all levels of operations and it fits into any architecture, scalable, run parallel in dual redundant manner. The most important feature of the product is that it has indigContinued to Page 60

“The products are manufactured in ISO 9001 and ISO 14000 certified facilities and in conjunction with experienced engineers, maintain quality control and our continued in-house state-ofthe-art Research and Development department maintain high-end, cutting edge and energy efficient technology to ensure that we continue to meet and exceed international standards”

R K Bansal MD, Uniline - Sumeet Sawhney October 2012

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QUALITY MANAGEMENT

Successful Implementation of TQM:

Integration of Core Values, Techniques and Tools “TQM is a management system in continuous change, which consists of values, techniques and tools. The overall goal of the system is increased customer satisfaction with a reduced amount of resources.” -Hellsten and Klefsjo (2000) Another quote from a TQM specialist adds further insight: “For an organization to be truly effective, each part of it must work properly together towards the same goals, recognizing that each person and each activity affects and in turn is affected by others… The methods and techniques used in TQM can be applied throughout any organization.” -Oakland Total Quality Management (TQM) is an excellent way to develop quality focus at the strategic level and improve all-round organizational performance. However, implementing TQM is far more complex, and takes much more time, than putting in place a quality management system like ISO 9001:2008.

Saravjit Singh CEO, www.10xQuality.org

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Large companies that have successfully implemented world-class TQM include IBM, British Airways, and Motorola. However, many others have found it difficult to successfully adopt TQM despite years of trying. This is particularly true of SMEs engaged in manufacturing. They have failed to see that the implementation of TQM is a comprehensive organizational change, and not just applying quality tools in the manufacturing area. What is missing is a strong focus on the applica-

tion of the wider concept of total quality. In most cases, inability to adopt TQM can be traced to poor implementation strategies and processes. Companies that want to embrace TQM must recognize that when TQM is successfully implemented it brings about a comprehensive change right across the organization. Implementation work can be seen as a transformation made by actors in a human activity system (Pidd, 1999). When starting on its journey towards TQM, the first essential for an organization is to build the right culture, as reflected in the core values internalized by all its employees. This takes time. You must recognize that TQM just cannot happen unless everyone in the organization first embraces six essential core

October 2012

Core Values Top Management Commitment

Focus on Customes

Everybody’s Commitment

Focus on Processes

Continuous Improvement

Base Decissions on Facts

The core values of TQM according to Hellsten & Klefsjo

Exhibit 1 values that are shown in Exhibit 1. Do a study, how many of these six core values exist in your organization? In some traditional organizations, it is seen that not more than two out of these six core values is present in all the employees. When starting on the TQM journey, we should focus on organizational change. “The process of change involved in integrating the TQM philosophy into an organization is complex and wide ranging...At the same time there have to be changes in organizational structure,

values, attitudes, management style and the adoption of new working practices” (Dale et al., 1997). We need to pay special attention to training, coaching and developing all employees to adopt all six core values as given in Exhibit 1. This effort has to be seriously led by the company’s CEO. Furthermore, top management must promote TQM as a company-wide management system; nothing less will work. The message must go out that everyone is responsible for creating and main-

taining TQM. Berry (1991) defines the TQM process as a total corporate focus on meeting and exceeding customers’ expectations and significantly reducing costs resulting from poor quality by adopting a new management system and corporate culture. When TQM is fully implemented, the company finds that there is a big increase in the satisfaction level of all internal and external customers. At the same time fewer resources are needed and the byproduct is a healthier bottomline and sustained growth. For TQM to become a reality, the right tools and techniques must support company-wide enabling culture and the six core values. As shown in Exhibit 2, at system level, TQM consists of three interdependent entities, namely core values, techniques and tools. All three have to be integrated in order to effectively develop TQM. It is like fitting together a complex three dimensional jig-saw puzzle. Most companies would need an

Aim: Increase external and internal customer satisfaction with reduced resources

Tools

Core Values

Control Top Management Relation Focus on Charts Commitment Diagram Factorial Processes Focus on Improve Criteria of Design Customers Continuously Ishikawa MBNQA Let Everybody Diagram Process Base Decisions be Committed Maps Tree ISO on Fact 9000 Diagram Quality Function Deployment Quality Employee Supplier Circles Development Partnership Process BenchDesign of marking Management Experiment SelfPolicy Assessment Deployment Total Quality

Management

Techniques

Source: Hellsten and Klefsjo (2000)

Exhibit 2: Three interdependent units of TQM October 2012

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experienced practitioner to show them the path towards TQM and to help them overcome all the hurdles they will face when implementing TQM. As we have already said, TQM implementation work should begin with the universal build-up of the sixcore values. The next step is to continuously choose techniques that are suitable to shore up these core values. Finally, suitable tools have to be identified and used in an efficient way in order to implement the chosen techniques. We will now show how the six core values contribute to creating TQM. Focus on customers Customer focus is the central theme of TQM. This ensures that quality is compatible with customer needs and expectations. The effort is long-term and continuous; to ensure that ever-increasing customer expectations are taken care of. The organization needs to be dedicated to satisfying customers. To focus on the customer means that the organization must find out what its customers need and value;and then fulfill these expectations by systematically developing and

offering the desired productsto these customers. Top management commitment Top management must initiate and itself work on planning for implementation of TQM. A strategy for TQM must be built on the management’s continuous commitment for questions concerning quality. The management must establish a quality policy and support quality activities morally and by providing resources. Management also has to set a good example by actively taking part in the practical work of TQM implementation. All senior managers must be role models and create customer orientation and set clear and visible quality values. They have to serve as advocates, teachers and leaders of the TQM initiative. One necessity to achieve a successful implementation is that all functional managers must discuss and explain why the TQM way of working is better than the present one.The new way of working in the organization has to be implemented by means of systematic procedures based on properly chosen tools and techniques that are understood and

Permanency of TQM 6. World class 5. Award winners 4. Improvers

accepted by all involved personnel.It is also necessary to set visible goals toward which the implementation is directed. Base decisions on facts This core value underscores the fact that we should make decisions based on facts that are well founded. We should not allow random factors to be of decisive importance. This calls attention to the importance of knowledge regarding variation and ability to handle and control variation. Focus on processes A process is a repetitive sequence of activities. Much of the work in an organization is done through processes. The goal of the process is to produce products or services that satisfy the customer. The result comes from whatever process is followed. Processes drive results. So, redesign of processes to bring them in line with core values is a necessary building block of TQM. Continuous improvement External demands are continuously increasing as customers’ expectations rise because of their experiences with competing products and services. Consequently, an organization needs to continually try to improve the quality of its products and processes. Continuous improvement of the process leads to customer satisfaction due to external quality improvement. Fewer defects that happen when the process is improved result in an internal quality improvement and greater internal customer satisfaction. Everybody’s commitment

1. Uncommitted

2. Drifters

3. Tool- pushers

Levels of TQM adoption

Exhibit 3 42

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Levels Source: Lascelles and Date

For TQM to succeed, all the employees should be engaged in satisfying the customer with a continuously improved quality. Everybody’s commitment means that continuous improvement is practiced everywhere in the processes and

October 2012

that the involvement of all employees at every level is facilitated. This core value also includes commitment of suppliers and dealers, all of whom become partners by working with empowered employees to benefit the organization and its customers. Educating and training all employees provides the knowledge needed on the mission, vision, direction, and strategy of the organization as well as the skills that they need to secure quality improvement and resolve problems. Keys to commitment are information, delegation and training. Maturity levels of TQM TQM can be considered as a management system with different maturity levels of adoption. Lascelles and Dale describe six different levels of TQM

October 2012

adoption. These are shown in Exhibit 3. TQM maturity levels are not necessarily the stages through which organizations pass on their TQM journey. These levels show characteristics and behaviours that organizations display in relation to TQM. The levels described in Exhibit 3 are intended to support organizations in identifying their weaknesses and addressing them, as a challenge of continuous improvement throughout the organization. TQM is to be considered as successful when the organization reaches Level 5, termed as “Award Winners”. Organizations at this level have reached a point in their TQM maturity where they have achieved a very high level of maturity with regard to culture, values, trust,

capabilities, relationship and employee involvement in their business. This is a point where quality improvement has become “Total” in nature. We find that most organizations get stuck in Level 3, i.e., they are Tool-pushers. They single-mindedly pursue the path to quality by implementing only quality tools. This is a very low level and persistence with it cannot give sustained growth in quality. If and when an organization sees it stuck at Level 3, it must combine core values, techniques and tools in an integrated manner to achieve higher levels of TQM maturity. Aim for Level 5. The author Sarvajit Singh is the Chief Executive Officer of 10x Quality.org and he can be contacted at saravjit@10xquality. org

industrial business MART

MACHINE DESIGN FUNDAMENTALS

Strength of Material Aspects In this thirty fourth series of articles on machine design fundamentals, let us discuss about one of the most important aspects of machine design which is strength of material and rigidity aspects. Machine elements are subjected to several types of loads i.e. pure tensile, pure compressive, bending and torsional. By proper designing there is considerable scope of saving material in most of the structures, building materials and machinery components used. It is wrongly assumed by the vast majority of the people that by simply increasing the weight or the thickness of the material used a higher load carrying capacity could be achieved. It is not always so.

A S Shetty CEO, Sedvik Industries

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Engineers efforts all along from time immemorial has been to make the best use of the available building materials. If the members in a structure or the machine elements could be formed or shaped in such a way that the maximum area of their cross section could be subjected to the maximum allowable stresses, the material utilization is most efficient. In practice, pure tensile, shear or compressive loads are rarely applied. They are invariably combined with bending or torsional loads. As soon as bending or torsional loads are applied, it is well known

in the field of STRENGTH OF MATERIALS that the distribution of stresses over the cross section of the member is not uniform. They are highest at the farthest portion of the area from the Neutral Axis and lowest or almost zero at the nearest portion of the Neutral Axis. See Fig. 1a &1b. Hence if we could form or shape the Section in such a way that material near about the Neutral Axis could be minimized, great economy in material utilization could be achieved. That is the reason why ways and means of producing I Sections, Channel, Angle or hollow closed Sections are being encouraged. With these measures savings up to 60% in weight as compared to the use of solid, rectangular, square or round Sections are achieved (see Fig. 1c & 1d). There are still further methods of optimum usage of steel. Following are some of the methods that could be adopted:

October 2012

1. Shaping the Sections: Figure 2 shows how the same weight of sheet could be used for carrying higher loads. Let us consider how we could increase the strength of sections. Fig.2a to 2f. show how the starting material of plain sheet progressively get increased stiffness/ strength by shaping the sheet as shown from left to right direction. In Fig.2b. the plain sheet is bent into a channel shape, getting increased strength. By providing lips on the legs (single lipped C section) the strength increases considerably. By further providing lips, i.e double or treble lips as shown the strength increases much more. In Fig. 3a & 3b it is shown how plain sheets get increased strength by providing corrugations (Roofing sheets). Here also still deeper corrugations give much higher strength. The technology used for producing such different shaped sections is called Roll forming technology. In the years to come this material saving technology is going to get increased prominence. Al-

ready the author had extensively explained about this technology in his forty series of articles earlier published in this magazine. 2. Closed Sections: Go for closed sections and shapes. A closed hollow section as shown in Fig. 4a &4b gives the highest torsional rigidity. A further rigidity is achieved by providing ribs on the closed sections as shown in Fig.4c &4d. In the field of bus-body building the trend is to use more and more of welded hollow sections instead of open sections like channels, angles and hat sections. Even in the case of other automobile industries the trend in the advanced countries is to go for specially shaped welded hollow sections. Apart from this, stiffening of the unsupported sheets and plates could be best achieved by welding stiffeners in such a way that a closed section is achieved as shown in Fig.11 thereby increasing the rigidity several times. 3. Tapered Shapes: Go for tapered or conical shapes. In case of lighting masts/street lighting masts (Fig.5) tapered shaped construction is economical. Here, where the load is maximum, the cross section is more i.e.

October 2012

at the bottom of the mast and it goes on decreasing towards the top. The nature itself in its profound wisdom shows how the material utilization could be made optimum. For example bamboo plants grow to very great heights because its cross section is circular and hollow; it is decreasing from bottom to top. Further, to get greater stiffness and rigidity thick membranes are there at each and every node. See Fig.6a. The cross section with ribs of sand grass is shown in Fig.b. From the above cited examples it could be seen that by proper shaping the cross sections of the components material could be conserved and consumption reduced ultimately leading to stable prices in the long run. We will discuss more about improving the strength of material aspects in our next article. The author Mr. A.S.Shetty, CEO of Sedvik Industries, manufacturer of Rollforming machines, Bangalore can be contacted : 080-25452669 or E-mail: sedvik@vsnl. com

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MANUFACTURING EXCELLENCE

Understanding Expectations of Customer Part 5 In the last four articles under the same heading, we dealt about SWOT analysis of sourcing from India and expectation from customer related to quality, technology & cost management. We will continue the topic further here on understanding customer expectations. 6.0 Managerial ability (continued from previous article) Customer would like to see involvement of the management in the company. It does not mean that management takes all decisions as typically seen in many SMEs. They should guide people and delegate so that day to day things of company goes on without their involvement. 6.5 Marketing

P S Satish Mentor and Consultant Saraswati Industrial Services

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One of the areas where suppliers are weak in India is marketing. It is taken for granted. There seems no efforts to develop people in marketing skills. Marketing does not just mean selling something. Their job also includes building relationship with customer which is a pre-requisite for long term sustenance. No customer is expected to come to the door of supplier to give the order.

Supplier need to put in efforts to increase their visibility in the market. Supplier should become members of associations like CII, ACMA, ALUCAST etc. where it gives them opportunity to know other suppliers, information about the market and access to customers. As per one of statistics, I saw in one of tradeshow in Hannover, Germany; participation of Chinese was 15% whereas from India it was 1%. It does not mean that Indian suppliers cannot afford. It is only a mindset in not believing in marketing. Whenever I meet a supplier as a customer, first thing I see is what they are projecting in their presentations against what they are. Typically, not emphasis is given for correct presentations and marketing persons are not trained to present properly. It is high time SMEs spend some re-

October 2012

source to focus on their presentation material to focus on their strengths. After all, customer is interested in looking at strengths which he can exploit to his benefit. Another marketing tool is usage of website in internet. My experience says that many companies do not have websites though they can afford one and those who have had outsourced to somebody to develop contents. Information is not updated. You would never know when customer looks at website and what conclusion he draws without asking anybody. So it is important that websites are always updated with all correct information and made as customer friendly. It is also recommended that companies use emails under domain name rather than using gmails, yahoo. This will increase credibility of the company. I came across a company who was seeking my support for marketing. After few interactions I found that his customers are not happy. He is simply jumping to find new ones without focusing on the one who is available. Marketing does not meant to be with new customers alone. It is also to be used with existing customers to continuously update them on new developments, performance and to seek new opportunities. 6.6 Continuity of Business This is applicable for family owned businesses. We find hundreds of SMEs started by one generation as an Entrepreneur and second generation is not trained or sometimes not keen on continuity of business. Concern for customer is about continuity of business should something happen to the owner. If the owner foresees an issue of continuity, he should put an effort to bring a professional in the business or reorganize the structure so that cusOctober 2012

One of tradeshow in Hannover, Germany; participation of Chinese was 15% whereas from India it was 1%. It does not mean that Indian suppliers cannot afford. It is only a mindset in not believing in marketing. It is high time SMEs spend some resource to focus on their presentation material to focus on their strengths. After all, customer is interested in looking at strengths which he can exploit to his benefit.

tomer is given confidence of continuity. 7.0 Logistics From the customer angle logistics are important not only from the delivery angle but also the cost involved. Compared to other countries, logistic costs are high in India. Costs need to be optimized in various elements of logistics like transportation, packing, handling etc. 7.1 Packing If you have made just beginning to export, my suggestion is start looking at packing first. Packing is a area which is often neglected. It is taken for granted. Packing industry in India to a great extent is disorganized. When developing a new product to a customer, without he asking for it, if you provide packing proposal with photos, sketches you are demonstrating professionalism. I have seen many of big corporates as well have given less importance for packing. But scenario is changing for the good. Packing is getting due importance with pressure for cost reduction. Because of increase of awareness on environment, emphasis is on increase in green packing like non usage of wood, recyclable packing, less usage of plastic covers, less oil

and so on. Normal tendency in package is overdoing. I will give you an example to elaborate this point. When I was in charge of export there was an item of machined cast iron from a supplier from India. We had given enough warnings on chances of rust in sea transport, long travel days etc. I do not know how message was peculated to the person who did the packing. When the box reached customer in Germany, I got a photo showing parts were almost soaked in oil and wooden boxes were nailed in all directions so much so that customer had difficulty in opening the box and had to clean parts again to remove excess oil. Expectation from customer is environmentally packing, suited for the product, easy handling and at economical cost. Too much is too bad. Too less may be inadequate. I will continue this article with additional points on expectations of customer in the next issue. Please send your inputs,remarks,suggestions to P.S.Satish,Mentor and consultant, M/s Saraswati Industrial Services, Q-103,Mantri Paradise Apartments,Bannerghatta Road, Bangalore-560076. Email : gotopssatish@ gmail.com . Wishing good day to you all.

industrial business MART

INDUSTRY UPDATE

Demech Esscano Power India Pvt Ltd Unleashing productivity in industrial damper design with SolidWorks solutions SolidWorks has helped DEMECH in quickly responding to the demands for complex dampers with its ease of use and automated design. The need to restrict gases and liquids makes industrial dampers a necessity in many actories and plants, including power plants, steel mills, cement plants, petrochemical facilities, and other process-related operations. Fulfilling the challenging requirements for damper technology led to the formation of DEMECH Esscano Power India Pvt. Ltd. (DEP), a joint venture of Esscano Power A/S Denmark and Deccan Mechanical & Chemical Industries Pvt. Ltd. (DEMECH) in India. DEP designs and manufactures many types of industrial dampers, including multilouver dampers, butterfly dampers, sliding dampers, and other variants. By combining Esscano Powerâ&#x20AC;&#x2122;s expertise in shaft-sealing arrangement design with DEMECHâ&#x20AC;&#x2122;s quality product manufacturing capabilities, the company has quickly attained a prominent role in the industrial damper market, introducing

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October 2012

new concepts that offer performance and cost advantages. From the company’s beginning, management realized it would need a parametric 3D design system to support design automation, checking, and validation needs. “The requirement for 3D was driven by our customers,” explains Swapnil Yele, Executive, Design & Engineering Costing. “The first order that we received required parametric design because we needed to release layout and detailed fabrication drawings for 44 different damper varieties quickly. We had to submit the general arrangement layout within a short time of receiving the order, and then deliver all 44 dampers in just three months. That was a daunting challenge for which we needed 3D.”

October 2012

® ® DEP evaluated Solid Edge and SolidWorks 3D design solutions. According to General Manager Subhash Bidwai, DEP chose SolidWorks because its solutions are easy to learn and use, include integrated design validation and ® eDrawings communications tools, and are supported by a reseller with a proven record of success: Pelf Infotech. After first implementing SolidWorks Professional design software, DEP added SolidWorks Simulation Premium advanced analysis and SolidWorks Flow Simulation computational fluid dynamics (CFD) analysis software. “Although DEMECH has operated for more than 30 years, manufacturing industrial dampers is new,” Bidwai says. “Considering the cutthroat nature of our competition, we needed design software that not only helps us design faster but

can also allow my design engineers to validate the strength of our damper mechanism upfront, enabling us to lower design costs. We found that software in SolidWorks.” Configurations increase automation By implementing SolidWorks solutions, DEP has realized benefits that increase design automation. Detecting interferences, gaps, and clearances within complex assemblies; customizing the SolidWorks Toolbox to support DEP standards for components; and incorporating design configurations all serve to boost automation and shorten design time. “With the automation that we have achieved with SolidWorks, we deliver production and layout drawings to the customer within hours,” Bidwai notes. “Using 2D, that step would take

industrial business MART

Challenge: Accelerate the development of design and production layouts by increasing design automation and by leveraging design simulation technologies.

Solution: Implement SolidWorks Professional design, SolidWorks Simulation Premium advanced analysis, and SolidWorks Flow Simulation computational fluid dynamics (CFD) analysis software.

Using SolidWorks Simulation, DEP has eliminated the need to prototype and test its systems, producing dampers that are 99.95 to 100 percent efficient. us at least three days.”

Results: • Reduced production layout time from three days to a few hours • Eliminated prototypes using thermal expansion analysis • Increased design automation • Realized repeat business

“The ability to automate the generation of new designs and drawings using ® Microsoft Excel-driven design tables is phenomenal,” adds Design Engineer Vinod Biradar. “With the help of configurations and the SolidWorks autodimensioning scheme—and all of the capabilities for adding different views, annotations, and the correct BOM (bill of materials)—we can more quickly release error-free drawings for production.” Validation eliminates prototypes

“With the automation that We have achieved with Solidworks, we deliver Production and layout Drawings to the customer Within hours. Using 2d, that Step would take us At least three days.” Subhash Bidwai General Manager

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Using SolidWorks Simulation Premium and SolidWorks Flow Simulation software, DEP has eliminated the need to prototype and test its systems. The company relies on SolidWorks simulation tools to support its goal of producing dampers that are 99.95 to 100 percent efficient. “We started using SolidWorks simulation for calculating thermal expansion of the blades while working under extremely high temperatures,” Bidwai stresses. “We need to provide adequate clearances to account for this expansion

while still preventing leaks that hamper efficiency. With the accurate simulations provided by SolidWorks, there’s really no need to build a prototype and test.” Delivering better designs faster equals more business SolidWorks solutions have helped DEP quickly become a major player in the industrial damper market. With customers like Thermax, M.E. Energy, and Ansoldo, the company’s consistent record of timely, quality delivery has enabled DEP to successfully enter and thrive in a highly competitive industry. “The first project that we completed in SolidWorks was the design of multilouver dampers for M.E. Energy,” Bidwai recalls. “By the time that we had successfully completed that first order, we had received repeat business from the same customer. In just the first year of our SolidWorks implementation, we have completed more than 100 different damper designs and released fabrication drawings. With SolidWorks, we have realized the design automation, productivity, and efficiency that we need to grow our business.” October 2012

Greater Noida to host HANNOVER Milano Fairs India For the first time in Greater Noida, HANNOVER MILANO FAIRS INDIA PVT. LTD., one of the world’s leading industrial trade fair organizer is all set to hold 5 concurrent and Industrial Trade Fairs in the city from 21st to 24th November, 2012.

With Over 400 participating companies from across the globe, the industry will witness to more than 4000 products on display along with the latest technologies from - Germany, Italy, Spain, China, Japan, Hong Kong, Taiwan, Vietnam & Sweden. The events are the most sought after Business-to-Business events covering

the manufacturing, automation, materials handling, surface technology and laser technology industries. The success of HANNOVER MESSE 2012 confirms once again that the shows are one of the world’s most important technology shows and forms a powerful driver of investment in new technology and automation.

al delegations supporting the show, our shows will be a platform to build new investment and business opportunities for exhibitors to find potential partners. On the other hand the visitors have an opportunity to see integrated technologies in a single visit. This synergy effect is a well proven concept at the world renowned Hannover Messe”.

This time, Greater Noida has been chosen by Hannover India Fairs to host these concurrent trade fairs – CEMAT INDIA (Materials Handling, Warehousing, Storage System and Logistics), MDA INDIA (Motion Drive and Automation - Hydraulics & Pneumatics, Electro Mechanical Transmission), Industrial Automation INDIA (Process and Production Automation and Industrial Building Automation), SURFACE INDIA (Surface Technology) and LASER INDIA (Laser Systems and Laser Technology for Manufacturing).

Hannover Milano Fairs India Pvt Ltd (HMFI) is a wholly owned subsidiary of two of the world’s leading trade fair organizers Deutsche Messe AG, Germany and Fiera Milano, Italy. HMFI have been bringing world class trade fairs into the Indian market for Indian and international enterprises since 2007. The strong international contacts and the vast expertise and best trade fair practices of its parent companies are deployed in the fairs in India which is the USP of fairs of HMFI. Exhibitors and visitors will gain from the professionalism of the international leaders. Looking forward to hear from you.

Mehul Shah, Director, HMFI, said, “With the response received, we hope to have the best show in India. Our joint presentation and international presence has a major advantage for the industry, both exhibitors and visitors. With internation-

For further details Visit: www.hmf-india. com

“With the response received, we hope to have the best show in India. Our joint presentation and international presence has a major advantage for the industry, both exhibitors and visitors. With international delegations supporting the show, our shows will be a platform to build new investment and business opportunities for exhibitors to find potential partners. On the other hand the visitors have an opportunity to see integrated technologies in a single visit. This synergy effect is a well proven concept at the world renowned Hannover Messe”. Mehul Shah Director, HMFI October 2012

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TECHNO ARTICLE

Reciprocating Grinding Reciprocating grinding is the oldest form of surface grinding. It is characterized by low depths of cut between 0.005 and 0.03mm and fast reciprocating table movements of around 15 to 30m/min Reciprocating is a very cost effective method for easy-to-grind materials, low number of work pieces and low stock removals. Also, the initial investment for such a grinder is relatively low. These machines are typically found in tool mould making shops. There are, however, some serious disadvantages inherent in the reciprocating process. The low depths of cut prevent proper chip formation and rapidly lead to wear flats on the abrasive grit resulting in wheel glazing and a high level of friction. This generates excessive levels of heat often causing thermal damage and micro cracking. Low depths of cut result in short arcs of contact.

V Nagesh Founder Directors of COSMOS

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This, in combination with hard grades of grinding wheels and low machine rigidity, may cause detrimental chatter and vibrations. Furthermore, with each reciprocating movement, the grinding wheel impacts on the edges of the work piece

and suffers and increasing loss of form. Valuable production time is subsequently wasted on redressing. Additional time is wasted in air-grinding at either end of each reciprocating table stroke. Creep-feed grinding, on the other hand, eliminates the disadvantages listed above. It requires, however, a considerable investment in a sophisticated machine tool and its ancillary equipment such as rotary dressing units, large capacity coolant supply and filtering units Etc. We were needed in between solution where affordable cost with enhanced performance, with that in mind we have introduced the same technology on normal conventional machines . with extension to the creep feed capability , we can perform profile grinding as well as normal surface grinding which makes our machine a must have tool for your machine shop . October 2012

For example: A customer manufacturing Chuck Jaws wanted a solution for machining of the serrations. Before they would use a vertical machining centre for premachining the serrations, and then using reciprocating grinding machine for finishing. So to finish one jaw, minimum of two setups were required and an the operator would have to clamp the premachined jaws very carefully on the machine. Now with our creep feed grinder, the serrations can be finished in a single setup , with only three passes. 1 pass for roughing and 2 for finishing. “like this there are several components in the engineering industry which may be large or small that can be machined in the least time in a single setup on our machines” say Mr. Nanda Director Grinding Division. Earlier in 2011, when we introduced this concept at Imtex, it was appreciated by the Indian Machine tool manufacturers and we were also awarded the prestigious FIE Foundation Award. Our machines come equipped with an operator friendly control panel, which is easy to operate and use conversation programming along with standard G and M code programming.

Coming future the industries will prefer single machine for multiple application without compromising quality and expecting value for money, we feel this is the solution. Established in 1987, COSMOS was founded as a basement operation with Cutting Tools. Today, COSMOS’sMetal Cutting Machine Tools are widely recognized nationwide with13 Branch Offices in all major states. In 2011, COSMOS was the proud recipient of FIE Award for manufacturing High Tech Creep Feed Grinding Machine with Innovative Design

and Concept. “The COSMOS brand has consistently been synonymous with quality products and as a company we are very fortunate to have reached this milestone,” said V. Nagesh, one of the Founder Directors of COSMOS. “It is quite an accomplishment to be in business for a quarter of a century. This landmark achievement represents COSMOS’sresilience in an ever-changing and highly-competitive Capital Goods industry, and only lays the foundation for a more prosperous future in the market.”The business has certainly gone from strength to strength over the years and continues to grow and perform strongly in the current challenging economic times. Over the past 25 years, COSMOS has played a key role in CNC Machine Tools solution providing and has become an industry leader in metal Cutting & Grinding solutions; offering a comprehensive product selection and a wide-variety of solutions for our customers. The company’s broad spectrum of products offers innovative technology and Business solutions. Visit www.cosmos.in to learn more about the complete line of COSMOS Business solutions.

October 2012

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INDUSTRY UPDATE

Self-Contained, Battery-Powered Wireless Photoelectric Sensor New SureCross Wireless Q45 Series from Banner Engineering provides dependable, economical communications in multiple industries The first self-contained wireless photoelectric sensing solution for multiple monitoring and control applications has been introduced by Banner Engineering (www.BannerEngineering.com), the company reports. The new SureCross Wireless Q45 includes a sensor, radio and internal battery power supply in a single compact and robust housing. interfaces with all common PLCs, HMIs and other industrial control systems. Basic gateways control two and six sensors, and the flexible system can be expanded for larger scale applications. Using a simple binding procedure, new sensors can be added to the network in minutes since there is no need to install any cabling.

Self-contained SureCross Wireless Q45 Photoelectric Sensors from Banner Engineering allows easy installation and dependable operation in challenging industrial applications. A variety of sensing modes are available in the new self-contained wireless series, allowing for functions including presence/absence, alignment, position, counting, monitoring and detection. Battery life is up to five years depending on sensor model and application, and the housing is IP67/NEMA 6 rated.

bearings. Food & beverage. Cargo handling. Material handling. Port operations. Mobile machinery. Vehicle detection. Waste management. Water supply. Tank level monitoring. Agriculture. Pump/flow control. Security/perimeter guarding. Signals from the sensors are received at a wireless network gateway that

The wireless sensors are designed for rapid, low-cost deployment and dependable operation in a wide range of situations. These include providing remote input for dry relay contacts, replacing failed cable runs, adding sensors to mobile applications, replacing complex festooned or ribbon cabling and connecting locations that were previously impractical or impossible. The secure, proprietary SureCross radio provides PLC level functionality and reliability over a long range of 1km/3,000 ft. Data is transferred reliably by using frequency hopping and a proprietary

Compared with wireless solutions requiring a separate sensor connected by wire to a radio, the self-contained units make it more economical to add the benefits of wireless communication for both OEMs and end users. They are suitable for many industries including automotive, food and beverages, material handling, waste management, water supply and mobile equipment. Applications include: Factory automation. Automotive. Motor

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Each DX80 Gateway can support a network of up to 47 self-contained SureCross Q45 Photoelectric Sensors.

Call-for-parts systems can be effectively supported and rapidly updated using self-contained wireless photoelectric sensors. October 2012

Precise position monitoring for quality assurance in assembly operations is facilitated by self-contained wireless photoelectric sensors. protocol; malicious hacking is impossible. The system does not affect other wireless devices in the 2.4GHz ISM band. An alarm output is available in case the radio link is lost.

October 2012

Wireless sensor supports facility management, shown here indicating whether a door is open or closed

Banner Engineering is a leading manufacturer of vision, photoelectric and ultrasonic sensors, fiber optic assemblies, machine guarding systems, mea-

surement and inspection systems and wireless network products. The company provides local application support worldwide.

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INDUSTRY UPDATE

Safety Sensor Technology on New Grounds The history of the safety-related sensor technology starts with one industry and one technology: the electromechanical safety swit-ches, which were used in the entire machinery and plant construction, appeared to be unfit for the hygiene-critical fields of the food-processing industry, considering that impurities and contaminates can deposit in the dead spots, e.g. in the inlet opening of the actuator.

The start: an alternative to the classic safetyswitch was needed for the hygiene-sensitive areas in food production 56

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Sensor technology offers advantages

sor technology is wear-free.

As a result, the idea of using sensors came up. The safety sensors and their actuators, which Schmersal subsequently developed on the basis of magnetic switches, had completely smooth surfaces without any dead spots. The design of this switchgear is oriented either to-wards the familiar cylindrical sensors or to the electromechanical safety switches (compare to image 1). Alternatively, extremely compact designs with rectangular flat enclosure are used and special variants for the hygienic areas in the food-processing industry are available, amongst which the brandnew BNS 40, which is now presented by Schmersal (image 2).

The switchgear furthermore is extremely compact and can be smoothly integrated in the surrounding construction, if necessary even in concealed mounting, for instance on safety gu-ards or protective covers in non-ferromagnetic materials such as (thermo) plastic or stainless steel.

It soon became apparent that these sensors of-fered not only advantages for food-processing machinery. Due to the non-contact operating principle, the sen-

New technology with additional functions The list of advantages was all the more exten-ded when the Schmersal Group developed a new patented operating principle, the so-called CSS (Coded Safety Sensor) technology. With this principle, the sensor and the actuator exchange signals, thus generating additional information, which the machine user can utilize for instance for diagnostic purposes.

October 2012

Safety sensor on the basis of a magnetic switch in food-safe design with stainless steel enclosure and protection class IP 69K The safety sensors equipped with the CSS technology can also detect the misalignment between the machine casing and the safety guard and emit a warning, requesting the operator to realign the safety guard. This “premature warning signal” increases the availability of the machine. Another advantage of this technology is that up to 31 sensors can be wired in series and evaluated through a single safety-monitoring module (image 3). This saves costs, installation effort and space in the control cabinet. These sensors are also available in different variants, both in cylindrical and square form (image 4). Optionally, a variant with paired coding is available as well (CSP 34 series), which guarantees a higher protection against tampering. The next step in the evolution A few months ago, the next step in the

Up to 31 safety switchgear with CSS technology on board can be wired in series and evaluated through a single safety monitoring module. October 2012

evolution of the safety sensor technology was taken. At SPS/IPC/DRIVES 2010, the Schmersal Group presented the RSS 36, an electronic safety sensor, which is, just like the other sensors with CSS technology, is suitable for series-wiring in Performance Level e safety circuits to EN 13849-1 (SIL 3, control category 4) and can be combined with all components of the CSS fami-ly, for instance with the AZ 200 safety switch or the AZM 200 and MZM 100 solenoid interlocks. Different coding variants through RFID technology As the latest generation of safety sensors is using the RFID technology, different variants can be generated, which differ from each other by their respective coding. In the basic version, the sensor will accept any target. The second version will only accept the target, which has been taught during the first startup. With the third version, the teach-in process can be repeated any number of times. In this way, the user can choose the most adequate coding va-riant and therefore determine the desired level of availability and protection against tampering. Schmersal moreover could already acquire comprehensive experience with the RFID technology: the machinery safety programme includes key selector switches with integrated RFID systems, which are used for instance as operating mode selector. In this case, the person setting up the machine is entitled to use the set-up mode, whereas the machine ope-rator can only start the machine in automatic mode. The new series is characterised by universal mounting possibilities. Optionally, an integra-ted magnetic latching can be supplied, which enables using the sensor as end stop when fitted on smaller safety guards. The materials used for the enclosure have been tested in accordance with the Ecolab directives and are

Perfect for fitting on profile kits in mechanicalengineering: rectangular-shaped safety sensor with CSS technology resistant to aggressive cleaning agents. With their protection class IP 69K, they can be used under very unfavourable circumstances. Also new safety sensor with “Hygienic Design” The Schmersal Group has developed another innovation in the safety sensor programme, the BNS 40S series, which is especially designed for hygiene-critical areas. The design and the chosen materials meet the “Hygienic Design” requirements. The sensors resist to detergents and chemicals and perfectly withstand cleaning procedures with steam jet cleaners (protection class IP 69K). The cables of the BNS 40S are FDA approved and the safety sensor is current-ly submitted to the UL and ECOLAB approval procedure. The BNS 40S is also suitable for use in hygiene-sensitive areas of food-proces-sing machinery. Increased industry-specific focus, more intensive consulting This new development underlines the increa-sed industry-specific focus from the Schmersal Group: the BNS 40S is part of a complete portfolio for the safety of machinery in the food-processing industry. For more details: please contact us at: info-in@schmersal.com

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INDUSTRY UPDATE

High-speed Synchronization with EPOS3 70/10 EtherCAT The digital positioning controller EPOS3 70/10 EtherCAT meets the highest demands in real-time positioning of synchronized multi-axis systems. Extremely compact in size, the EPOS3 possesses a wide nominal power supply voltage range from 11 to 70 VDC and delivers a continuous output current of 10 A, during acceleration and deceleration even up to 25 A. Designed for DC and EC mo-tors with a power range up to 700 Watt, it provides outstanding uniform running for motors equipped with incremental encoders. The EPOS3 70/10 EtherCAT easily integrates as slave into real-time EtherCAT protocol-based Ethernet networks, and, with the provided device description file and device-specific configuration guide e.g. in a Beckhoff-TwinCAT environment. A multitude of operating modes allows efficient, flexible use in a wide range of drive systems in robotics, automation, and mechatronics. The positioning controller supports a broad bandwidth of encoders. In the typical EtherCAT modes «Cyclic Synchronous Position (CSP)», «Cyclic Synchronous Velocity (CSV)», and «Cyclic Synchronous Torque (CST)», the EtherCAT master calculates the trajectory points and sends the target parameters cyclically and synchronous via EtherCAT network to the EPOS3. Thereby, the corresponding control loops for position, speed, and torque/current take place in

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the EPOS3, which, in turn, delivers the measured actual values (position, speed, current) to the EtherCAT master. For the actual drive control, the EPOS3 70/10 EtherCAT is equipped with superb motion control functionality. For example; in «Profile Position Mode (PPM)», the calculated path is being followed highly dynamic and with high accuracy. A bundle of additional features, such as speed control with given target velocity in «Profile Velocity Mode (PVM)», «Homing» to a defined mechanical position using numerous implemented methods is available. The same applies for the generous number of inputs and outputs, which makes the extra EtherCAT I/O module obsolete. Digital inputs/outputs (11/5) can be configured as reference or limit witch as well as Capture or Trigger, or can be used to activate holding brakes with definable ON/OFF switching delays. October 2012

Additionally, analog inputs/outputs (2/1) are at free disposal. Perfectly tailored for servo motors, the EPOS3 70/10 EtherCAT offers likewise built-in motor filters with motor chokes for EMCconform operation. Prefabricated cables and perfectly matching accessories help to make installation and commissioning easy. The controller offers comprehensive circuitry against overcurrent, excess temperature, undervoltage and overvoltage, against voltage transients and against short-circuits in the motor cable. Furthermore, it is equipped with adjustable current limitation to protect motor and load as well as protected digital inputs and outputs. The «EPOS Studio» serves as user interface for efficient parameterization employing a lot of smart and clever functions and intuitively designed Wizards. Tasks, such as, Firmware download,

October 2012

EPOS3 70/10 EtherCAT – EtherCAT-capable digital positioning controller for DC and EC motors within-cremental encoder up to 700 Watt automatic controller commissioning, I/O configuration, test & data recording becomes little more than child’s play. Alternatively to the Ethernet interface, a USB 2.0 port is available for commissioning and diagnostics. A comprehensive documentation set,

inclusive Firmware specification and application examples, as well as the graphical user interface «EPOS Studio» are available for free download from the Internet: www.maxonmotor.com For further details Visit: www.maxonmotor.in

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Continued from Page 39

enous software and is consumer friendly. To maintain the utmost quality standards in manufacturing, the company undergoes rigorous testing processes to ensure productivity. The company guarantees that all UPS’s and Power Quality Products manufactured will continue to be manufactured to meet the highest degree of performance our customers have come to expect and demand. “We love accepting challenges and with our never-ending spirit and determination, we will stand as one of the complete power solution providers in the entire segment in the coming five years” concludes Mr. Bansal. Uniline’s yet another initiative in Solar Energy Solutions is a promise to the ever growing demands amongst the Indian Consumer, mainly targeting Enterprise level markets where it sees great potential in the coming years. Products like inverters and High power UPS up to 1000 KPA are something also to be assumed to work upon in the company’s R&D section. The storyline has just begun and yet to bring out some more wonders in India’s Power segment.

Coca Cola Reduces Downtime Losses, installs Uniline UPS The Coca-Cola bottling plant in Faizabad, UP has become the country’s first FMCG to install the highest capacity UPS of 500 KVA for uninterrupted process continuity of their plant. A 500 KVA UPS manufactured by Uniline, a leading UPS and Solar Energy in India. Mr. SK Pandey Chief Engineer, CocaCola, Faizabad says “Due to poor power condition of the state, our production line gets held up and we lose about 4 lac bottles each time we stops, a tremendous wastage of value & downtime, failure of electronic opponents is yet another reason” When margins fall, one has to tie ends. FMCGs are now closely looking at this aspect to keep their losses at bay and well in controlled to keep afloat and rolling. Despite increase in power generation in the country , the demand for power far outstrips supply and therefore in the foreseeable future, the demand for Process Continuity - UPS systems role is bound to increase.

Uniline seems to be in the right place at the right time with its range of sophisticated, hi-tech UPS systems for a wide variety of needs in different commercial, industrial sector and service sectors. For more details pls contact- R K Bansal – 0 98101 12487 – rkb@uniline.in Indraneel Bose – 0 98100 449870 – indraneelbose@gmail.com Uniline Energy Systems, New Delhi. Tel – 011 4666 1111 www.unilineindia.com, uniline@uniline. in

Uniline Empowers Punjab Schools and the Prestigious India’s Smart UID Project Under various state government led Rajya Shiksha Yojna & Sarva Shiksha Abhiyan educational infra projects “Uniline”- India’s No 2 UPS Manufacturing Enterprise was chosen to empower more than 30,000 primary and high secondary schools across Madhya Pradesh, Gujarat, Haryana, Rajasthan and Maharashtra putting them on a path of imparting

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education, uninterruptedly. , Continuing its endeavour to strengthen India’s next generation, Uniline has recently empowered the northern state of India - Punjab as well as certain additional of Haryana that shall allow these states to receive power for 5 – 6 hours / day in addition.

October 2012

INDUSTRY UPDATE

The quick trough for hall Cranes Energy chain supply can be installed 80% faster than standard solutions The energy supply specialist igus GmbH Cologne, introduces a guiding trough for energy chains, that is easy and simple to install. “guidefast” has been developed especially for a lateral mounting to standard carriers of industry and hall cranes. The modular design and a reduced number of components significantly reduce the installation time: Up to 80 % compared with standard energy supply solutions for hall cranes. The cheap guiding trough is available in different materials and sizes. Brackets, trough, clips - ready The elaborate concept simplifies the work of the installer with every step: Special brackets that are mounted via screw/thread or welding bolts allow simple vertical fine-adjustment. Furthermore, the static cables can be directly fixed to the integrated strain relief of the bracket – this considerably simplifies electrification and additional installation as, for example, cable clips or hose clamps, become needless. To connect guiding troughs with a standard trough length of 2 m easily and without shearing edges, special clips are available.

Every 500 mm the trough elements dispose of a cable supply as well as prefabricated bore patterns for the connecting elements of the energy chain. The energy chain is directly inserted into the guiding trough including cables. Through the cable supply, the installer can flexibly connect consumers or feeds wherever the situation of installation requires it. The prefabricated bore patterns accelerate installation, because time consuming measuring, drilling or cutting is unnecessary. All savings sum up to 80 % less installation time. For this reason, “guidefast” does not only contribute to reduce costs, above all, it also allows faster commissioning. Customers, that like to save additional installation time, can order pre-harnessed and readymade “readychain” energy chains from igus. At www. igus.eu/guidefast-video, igus branch manager Christian Strauch demonstrates the fast and simple installation of the new system. Complete construction kit –

October 2012

thoroughly tested Like any other igus products, “guidefast” has been thoroughly tested in the company’s own 1.030 m2 test laboratory. In long-term tests the guiding trough has proven its strength and resistance against vibration also under harsh environmental conditions. “guidefast” is part of the complete package for crane applications and consists of trough, the E2/000 energy chain and “chainflex” cables. The trough is available in different designs such as galvanised steel, stainless steel or black powdered steel versions. An aluminium version is planned. For further details visist www.igus.in industrial business MART

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October 2012