Volume 11 Issue 12 June 2015 ` 100
Production
Metrology
& Cost Efficient Manufacturing Production metrology is a key technology for quality assurance of products and processes. It helps to secure the leading global status. Fundamentally, everything can be measured. The challenge for production metrology, nowadays, is to implement the technology concerned in industrial manufacturing operations, so that acquisition of product quality data can be cost-efficiently achieved.
Optical Metrology
Big Data Analytics
How to Boost
CUSTOMER ORIENTATION
SUPERIOR VALUE
FOR MANUFACTURING AUTOMATION
WITH INDUSTRIAL METROLOGY
CHECKWEIGHING EFFICIENCY
MANAGING SME IN INDIA
FOR SUCCESS AT MAKE IN INDIA
June 2015
www.martupdate.com
1
2
www.martupdate.com
June 2015
Meistermacher. Made in Germany.
Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding.
German champion with Borussia Dortmund 2002 English champion with Arsenal London 2004
The first pro goalkeeper with headed goal qualities
© 2015 SCHUNK GmbH & Co. KG
Jens Lehmann, legendary German goalkeeper
Rainer Scholl, Master – Gripping System Components
The world’s first gripper with multi-tooth guidance PGN-plus, universal gripper from SCHUNK
www.gb.schunk.com/pgn-plus
June 2015
www.martupdate.com
3
4
www.martupdate.com
June 2015
Pressure Range
Capacity
Discription
Sr No
M3/Min
CFM
Bar
1
Lubricated SCREW Compressor
0.23 to 43.70
8 to 1545
8 to 13
2
Oil Free SCREW Compressor
5.30 to 51.40
187 to 1815
8 to 10
3
Lubricated PISTON Compressor
.125 to 6.20
4.5 to 219
8 to 40
4
Oil Free PISTON Compressor
.156 to 1.30
6 to 45
8 to 40
5
BOGE FLEXPET
1.55 to 17.9
54 to 634
40
BOGE AIR. THE AIR TO WORK.
BOGE India , No. 216, Third Link Street, Industrial Estate, Nehru Nagar, Kottivakkam, Chennai - 600 096, india@boge.com* www.boge.in Chennai Mr. F C Jayakaran
: +91 9600041656 : fc .jayakaran@boge .com
/ Chennai Mr. Muthu Ganesan : +91 9003172111 : muthu.ganesan@boge.com
Hyderabad Mr.W.Narendra
: +91 9704770930 : w. narendra@boge.com
/ Mumbai Mr. Hasan Hasware : +91 9840956161 : h.hasware@boge.com
Delhi Mr. Deepesh Upadhyay June 2015
: +91 9818556732 : d.upadhyay@boge.com www.martupdate.com
5
VINTECH AIR CONTROL ENGINEERS AND CONSULTANTS “Sai Raghavendra”, 207, Dr.Radhakrishna Salai, Ramakrishna Nagar, Valasaravakkam, Chennai - 600087 Phone Nos: 044-2486 6221, 044-2486 6821, 044-6563 1221 Fax: 044-2486 6321 E-mail: vintechair@gmail.com | vintechchennai@yahoo.co.in 6
www.martupdate.com
June 2015
foreword Technology, Growth! Hi Readers, The leading organizations in the world invests good amount of resources in their Research and Development, advancing the technology to benefit the mankind by producing greater efficiency and saving time. Is there any possibility someone can disregard the modern technology in this digital world? I was discussing with one of our reader about ease of doing business in India, which we are featuring in our next edition of MART. He shared his experience with the Legal Metrology division’s inspectors in various part of our country not agreeing to accept the latest technology with international standards, just because it’s not written in the book of rules. He had himself written to the top hierarchy in the department a couple of times but no constructive measures are taken. This mismatch can be found in different working levels between the industry and Government machineries, which make a big difference in ease of doing business in our country. Constructive measures should be taken by all the stake holders to bring better co-ordination which will result in better productivity and entrepreneur encouragement. PM’s dream of making India one of the largest manufacturing destinations can happen only with changes from the ground level, the way we do our day to day business and a change in our attitude towards growth. When it comes to manufacturing, metrology plays a major role in quality assurance in different processes of production. In this edition of MART, we are featuring Metrology as our main focus and included several articles from diversified fields of measuring and calibration. In our tech talk section Dirk Bettels, Senior Product Manager from Mettler-Toledo Garvens talks about boosting checkweighing efficiency. Anup Verma, Managing Director of Hexagon India shares their latest plans with our readers in the On Face Column. With this edition we are completing 11 years serving the engineering manufacturing sector, turning difficult economic conditions as the learning curve, MART is getting better with each issue, understanding the changing needs of our valuable readers and business associates. We look forward your valuable suggestions and comments to make MART more industry friendly.
June 2015
Hari Shanker hari@martinfotech.in
www.martupdate.com
7
10 INNOVATIONS 54 58 62 66 68
Columns
First Step to Leadership.
Develop Customer oriented mindset in the Organization Deliver Superior Value for Success at Make In India When Zero Defects are the Norms, Why Not Zero Customer Complaints? The Informality Principle in Leadership
CORPORATE MART 72
Quality Leaves a Lasting Impression Globally and Locally Volume 11 Issue 12 June 2015 Annual Subscription `1200 Member INS Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre Kabre P S Satish J R Mahajan LD Bhakre
MediaMart Infotech
Siji Nair
Sandeep Hingne
Digital Edition at
313, Dorikal Byelane, Jheel Avenue, Dum Dum Road Road, Kolkata - 700 04, 041,India. India.Tel: Tel:+91 +9133 332560 25604052 4052
Mob: +91 9038000711 Email: info@martinfotech.in Visit www.martupdate.com
Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business Mart is a monthly journal published from Thiruvananthapuram.
8
www.martupdate.com
Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every effo June 2015 employees accept any responsibilities for any errors or omissions. Š All Rights Reserved
CONTENTS 22 Production Metrology and Cost Efficient Manufacturing
40 Noncontact Temperature Measurement in Heat Treatment Processes
MAIN FEATURE
COVER FEATURE
26
Optical Metrology for Manufacturing Automation
30
Big Data Analytics with Industrial Metrology
34
Harmonics - A Power Quality Problem
38
Significance of Calibration
SUCCESS STORY
50
40
Replace manual gauges with new INTUOTM software for EquatorTM
42
Noncontact Temperature Measurement in Heat Treatment Processes
Case Study 3T uses FLIR camera to detect temperature differences on PCB components
78
82 Feature articles
80 84 97
FAIR MART MART UPDATE THE LAST LEAF
Managing Editor Hari Shanker hari@martinfotech.in Associate Editor Hiya Chakrabarti hiya@ martinfotech.in Editorial Assistant Riti Banerjee riti@martinfotech.in Creative Assistant Arnab Chowdhury Amitava Sinha Roy martcreative@gmail.com Circulation & Subscription Knowledge Partner Devjeet Biswas devjeet@martinfotech.in +91 9038005670
Advertisement General Manager
Priya Kundu +91 98301 22946 priya@martinfotech.in Marketing Bangalore Chennai Delhi Mumbai
Madhurima Bhattacharjee +91 9038888277 Adrita Baidya +91 9038002340 Sumithra Krishnaswamy +91 9845388869 Subramaniam V +91 93827 48296 C R Sathyanunni +91 9910727307 K Ravindranath +919820417240
IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from�Tharangam�, TC 37/2029, Kodunganoor Post. . Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614
ort has been made to ensure the accuracy of the information published in this edition, neither the Publisher no any of its June 2015
www.martupdate.com
9
PRODUCT MART
I N N O VAT I O N
LumaSense’s Industrial Grade Infrared Pyrometer
With the ISR6-TI Advanced, manufacturers have more temperature sensing capability per dollar than ever before.
LumaSense Technologies, Inc. ®introduced its integrated ISR 6-TI Advanced. The ISR6-TI Advanced is a major breakthrough combining an infrared thermometer (also known as a pyrometer) with infrared imaging capabilities to open new sensing opportunities for heatdependent manufacturers. With temperatures approaching 1800 °C, normal “contact” based methods of temperature measurement such as thermocouples
will disintegrate. Thus, manufacturers of metals, glass, and other materials manufacturers have long relied on infrared technology. Infrared technology allows manufacturers to capture precise temperature readings without making physical contact. Such temperature readings are crucial to manufacturing processes affecting product quality, energy consumption, asset life, and personnel safety. Thermal imagers produce
temperature-based “pictures” to show the temperature across an object. The ISR6-TI Advanced achieves the same result more affordably by producing a “relative” thermal image. A “relative” thermal image is made by combining the temperature of a center spot by a highly accurate 2-color pyrometer and an image from a video camera containing a short wavelength infrared filter resulting in an auto calibrated thermal image. The ISR6-TI Advanced is an integrated system that operates
in a short wavelength (around 1 μm) for accurate and reliable temperature measurements between 700°C and 1800°C. The analog video output signal is converted to USB and fed to a PC where LumaSense’s InfraWin software generates the “relative” thermal image. InfraWin also provides temperature, data logging, and analysis features. For more information about LumaSense Technologies, visit www.lumasenseinc.com
“Materials industries have very small margins and manufacturers constantly have to make the trade-offs as to what will improve production versus adding cost. Now with the ISR6-TI Advanced, manufacturers have more temperature sensing capability per dollar than ever before.” Steve Abely CEO, LumaSense
10
www.martupdate.com
June 2015
June 2015
www.martupdate.com
11
PRODUCT MART
I N N O VAT I O N
New IND570 Industrial Terminal for Weighing in Any Environment
METTLER TOLEDO offers a new industrial terminal, the IND570. Accuracy, durability and versatility are the hallmarks of the IND570. It is constructed and approved for the harshest industrial environments and offers flexible control options for simple to complex weighing applications.
Its versatility in form and function make the IND570 a standard solution for weighing in any environment. Consistency across processes supports better quality and gains in production efficiency, leading to lower costs and increased profits. The new terminal maximizes process efficiency with advanced features, including:
Selectable interfaces and programs that allow users to customize features to match application requirements—adding costs only when needed. Real-time communications via serial, Ethernet and PLC interfaces can be tailored to a customer’s specific needs. Performance monitoring and proactive alerting help to avoid
expensive down time and keep the weighing system running at maximum potential. In manually controlled weighing applications, the highly visible, graphic display shows real-time weighing status and can be programmed with plain language routines to step users through operations, simple or complex, to improve efficiency and avoid costly errors. If automation is the
goal, the IND570 offers a high potential for cost-savings when functioning as a standalone process controller. The terminal’s digital I/O options and the easily programmable software applications take control of your process to produce accurate, repeatable results. For more details visit: www.mt.com/ind570
I N N O VAT I O N
Jyoti CNC’s Vertical Line Series machines
The concept of moving the inverted vertical spindle head in all axes and keeping the front space of base open for customisation of tooling requirement make this machine series unique. Vertical Line Series machines with automated job feeding feature and special high speed electro spindles are quite suitable for mass production
12
www.martupdate.com
jobs. The concept of moving the inverted vertical spindle head in all axis and keeping the front space of base open for customisation of tooling
requirement make this machine series unique. Some special features of ATM are Turret option for turning and
milling both, Auto job feeding arrangement, Multifunction station for Customisation in turn mill and Pickup stations for the same. There is Y axis on headstock which provides high rigidity while performing off the centre machining operations. For further details contact Jyoti CNC Automation Limited Tel: +91 2827 306100, 287081 Email: sales@jyoti.co.in Web: www.jyoti.co.in
June 2015
June 2015
www.martupdate.com
13
PRODUCT MART
I N N O VAT I O N
High Speed – Innovative 3D Scanners from STEINBICHLER
Steinbichler unveils the new high-speedsensor COMET 6 8M. The new variant of the high-end sensor series excites with a stunningly short measuring timewhich even in maximum resolution mode is less than one second Equipped with a broad range of fields-of-view and unique, extremely bright projection optics, this innovative fringe projection system sets new standards due to its sensational speed. Thus, maximum efficiency is guaranteed for data acquisition featuring highest data quality and precision. The tried-and-tested singlecamera technology in the COMET 6 8M allows the measurement field size to be quickly adapted to the measuring task at hand. The new handling system makes
sensor positioning with respect to the measurement object extremely easy, highly convenient and fatigue-free. Thanks to its extremely easy and comfortable sensor handling, and the projectoriented software colin 3D, COMET 6 8M guarantees fast measurement processes for a multitude of applications, e.g. in quality control, design and reverse engineering. 3D Digitizing – T-SCAN: HighEnd Scanning Technology for Handheld/Intuitive and Automated 3D Data Acquisition
Allowing to adapt the light quantity projected onto the relevant object surface, the new and unique “3D ILC – intelligent light control” functionality reduces undesired effects such as glare to a minimum. The T-SCAN complete solution for laser scanning and optical tracking is a high-performance measurement tool in both handheld and automated configuration. With its extremely high dynamic range, the compact scanner permits the data acquisition on a wide range of object surfaces without the need of any time-consuming surface
preparation. Independently from the robot accuracy, the system precision is guaranteed by an optical tracking unit. Adapting the T-SCAN laser scanner onto an industrial robot for sensor guiding, recurring measurement tasks can be carried out with maximum efficiency and data quality. For further details write to Steinbichler Vision Systems Pvt Ltd, #307, 1st Floor, 18th Cross, 6th Main, Malleswaram, Bangalore – 560055 Tel: +91 80 40909839/ 38 Visit: www.steinbichler.in
Matrix Introduces 2MP IP PTZ Cameras INNOVATION
IP PTZ cameras are used in the Outdoor purposes where large distances are to be covered
Matrix SATATYA IP PTZ cameras come with a varifocal lens of 4.3-129mm which can cover an IR range of 100m. Also, this camera has 30x optical zooming capabilities which allow closer inspection. These IP PTZ cameras are used in the
14
www.martupdate.com
Outdoor purposes where large distances are to be covered. The features are 2MP, 1/2.8’’ Progressive Scan CMOS, Edge Analytics like Motion Detection, Traversing Virtual Plane, Intrusion Zone detection. 30x Optical
Zoom, 16x Digital Zoom, 4.3-129mm Varifocal Lens, 6 Piece IR Array LEDs with IR Distance of 100m, 1 Audio Input & 1 Audio Output, H.264/MJPEG, Dual Streams. Smart IR, PoE, 64GB SD Card, 2 Privacy Masks Programmable, Wide
Dynamic Range and Digital Noise Reduction and IP66, TVS 4,000V Lightning Protection, Surge Protection and Voltage Transient Protection For further details visit www.matrixsecusol.com
June 2015
New AMETEK Taylor Hobson Talysurf i-Series
High resolution Talysurf i-Series instruments deliver simultaneous surface and contour inspection for automotive, bearings, gears and many other applications.
A new series of high resolution instruments offering automated simultaneous surface and contour inspection has been introduced by Taylor Hobson, a unit of AMETEK Ultra Precision Technologies. The low noise axes and high resolution gauge of the Talysurf i-Series instruments assure measurement integrity, and a choice of gauge ranges provides versatility for a variety of applications. The instruments are available in 1mm, 2mm and 5mm gauge ranges with an 18 bit gauge for improved resolution in surface detail, contour and 3D measurement. Powerful software for analysis of surface finish and form is included. Ultra precision machining and FEA (Finite Element Analysis) optimized design combine to provide low noise and high accuracy mechanical execution of the measuring axes. Balanced beam design allows the instruments to be used in any orientation. Traceable standards and exclusive algorithms effectively eliminate instrument influence from the measurement results. A unique temperature compensation system monitors and feeds back changes in ambient temperature, ensuring consistent system performance and high measurement integrity, regardless of environmental effects. Taylor Hobson is a leading manufacturer of ultra-precision measurement instruments for a wide range of markets including optics, semiconductors, manufacturing and nanotechnology research. It is a unit of AMETEK, Inc., a leading global manufacturer of electronic instruments and electromechanical devices with annual sales of more than US$3.6 billion. For further details visit www.taylor-hobson.com
June 2015
Conveying Safety for Bulk Material Handling Plants
AN ISO 9001-2008 COMPANY
Jayashree Safety Switches for monitoring conveyor safety in Bulk material handling plants
SPEED MONITORS
LEVEL MONITORS
PADDLE LEVEL SENSOR
DIGITAL DISPLAY RM E261
RM E211
PROXIMITY SWITCHES
RF POINT LEVEL SENSOR
TILT SWITCH TILT PROBE RM 2211 FP
BELT LOAD MONITOR
RF LEVEL SENSOR
Making in India for more than 35 Years
JAYASHREE ELECTRON PVT. LTD.
Works : EL-34, `J’ Block, MIDC, Bhosari, Pune - 411026 (India) tEL. : 020-27130295 / 46901301 Fax : 020-46901357 E-mail : sales@jayashree.co.in Web : www.jayashree.co.in
www.martupdate.com
15
PRODUCT MART
I N N O VAT I O N
ElMeasure’s 3 in 1 Prepaid Meter (Dual Source)
ElMeasure has developed a unique 3 in 1 Contactless Prepaid Energy Meter were in process parameters such as water, gas etc can be integrated and its consumption can be monitored along with electrical parameters
Recovering electricity dues remain one of the major challenges in the power sector. Most distribution companies face serious problems in recovering electricity bills especially from government departments / apartment blocks / commercial complex etc. ElMeasure has developed a unique 3 in 1 Contactless Prepaid Energy Meter were in process parameters such as water, gas etc can be integrated and its consumption can be monitored along with electrical parameters. The design is completely microcontroller based thus providing an effective and
reliable solution to the service providers. The service provider needs to just install the meter and further activities involve the consumer. It is sufficient for the service provider to have just one manpower to recharge the card as per the consumer’s request. The consumer will have to display the card in the front fascia of the meter for three seconds. The advanced microcontroller electronics inside the meter stores the number of units recharged and measures the energy consumption. When the purchased units are used up by the consumer the meter disconnects the power supply
until the next recharge. The main features are compact wall mounting design, dual Source Measurement (EB & DG), 3 in 1 meter with option to integrate process parameters. Pre-paid metering system using contactless smart cards, accuracy Class 1.0 and cost effective ‘Pay as you use’ three phase electricity metering The advantages are upfront payment for electricity and hence low over heads for service providers. Advanced RF card technology, tamper proof construction. Cost of manpower for billing / collection is substantially reduced. This avoids the hassles of human
intervention as there is no need to enter the data into the meter. This makes the system more user friendly. Displays balance energy in the meter, thus enabling the consumer to plan when to recharge. No billing disputes, allows consumer to budget electricity expenses, helps consumer to contribute towards energy conservation. Available in single phase and three phase system. For further details write to ElMeasure India Pvt Ltd, No. 764, 4th Phase, 707, Yelahanka New Town, Bangalore - 560 106 Tel: +91 80 28461777 E-mail: marketing@elmeasure.com Web: www.elmeasure.com
“The flourishing realty business coupled with high energy prices has increased the demand for Prepaid Energy Meters. ElMeasure being in the energy management field has seized this opportunity and has developed Prepaid energy meter with three in one solution- Electricity, Gas and Water. Prepaid meter with multiple options are demonstrated below which will give you the spectrum we cover.” Babu T K CEO, Elmeasure India Pvt Ltd
16
www.martupdate.com
June 2015
June 2015
www.martupdate.com
17
PRODUCT MART
INNOVATION
USB Pen Drive based Data Logger for Humidity and Temperature
The low cost Pen Drives offer very large storage memory space making this product very economical and easy to use for factory personnel.
Countronics offer a USB Pen Drive based Data logger for Humidity and Temperature. This state of the art logger automatically creates a data file compatible with MS Excel on the pen drive storing the Humidity and Temperature values along with the date and time stamp making it very simple to use. Just unplug the Pen drive and take it to your PC to view all the data. The unit allows the user to set the rate of logging from 1
second to 99minutes. No need of any additional complicated software installations. The low cost Pen Drives offer very large storage memory space making this product very economical and easy to use for factory personnel. Capacitive sensor (Dry/Wet sensor also available on request) for humidity and Platinum based temperature sensor provide accurate values for humidity and temperature.
Internal Real Time Clock allows data to be time stamped in real time. Available as a panel mounted version with 96x96mm front facia and front loading USB Pen Drive in an ABS cabinet and aesthetically designed front panel. For further details write to Countronics, M-95, Connaught Circus, New Delhi 110001 Tel: + 91 11 23418487, 09810536887 Email: info@countronics.com Web: www.countronics.com
INNOVATION
Ha-VIS eCon Switches Stand for High Efficiency and Performance
The compact, cost-effective Plug & Play switches can be easily and quickly put into operation.
Optimized and designed for jobs in harsh industrial environments, unmanaged HaVIS eCon Ethernet switches equally enable the cost-effective expansion of existing network infrastructures, as well as the development of new industrial networks. The compact, cost-effective Plug & Play
18
www.martupdate.com
switches can be easily and quickly put into operation. Two different compact, space-saving housing designs guarantee the best possible use of available space in the switch cabinet. Powerful Power over Ethernet Plus (PoE+), full Gigabit Ethernet and an industrial tem-
perature range of -40째 C to +70째 C broaden the wide product portfolio with additional functionality. Thanks to their approval for use in industry as well as the maritime market and transportation technology, the switches can be optimally selected for each application. For further details visit www.harting.com
June 2015
Kusam-Meco launches Multifunction Power Quality Analyzer Model KM-2100 is a new Power Quality Analyzer introduced by “KUSAMMECO”, an ISO 90012008 certified company. This Power Quality Analyzer has an Auto Power off &LCD Backlightdisplay function.It has safety features CAT III 1000V / CAT IV 600V & standards: IEC61000-4-30 (2008) S class, EN50160 (2007). It can be easily operated to capture the power quality problem.
It can be used in Single-phase 2W / Single-phase 3W / 3-phase 3W / 3-phase 4W system. It displays Run Chart, Bar Chart, Vector Graphic, Waveform, Event List, Readings& 8G Memory Card to make the longterm measuring data storage.It support USB port to connect to PC and analyze the data/ screen shots copied by U-disk & also supports LAN port to make the remote control available, transfer the measuring data. It measures Voltage range (0~1000Vrms), Current range (1~3000Arms), Frequency range (42.5~57.5Hz & 51~69Hz), Harmonics range (0~50). It can also measure Active power range (1.0~20MW), Apparent power range (1.0~20MW), Reactive power range (1.0~20MW), Power factor range (0~1), Energy (0kWh~200GWh), Inrush current measurement range (0.5~400 Arms), DIPS & SWELLS range (0~200% for
PRIMO™ revolutionises automatic setting of parts and tools...
Vrms/Arms) with Programmable threshold in % of nominal voltage Event detection based upon ½ cycle rms voltages Captures Dips, Swells Interruptions and Rapid Voltage Changes. This model has Data Logger function, System monitor (Record time upto 7 days & Record Event number >10000). It has adapter input AC 220V (1±10%),50Hz(1 ± 5%), ≤ 10VA. It is supplied with Voltage Test Lead 3 meters long x 5, Alligator Clips x 5, External DC Adaptor, Flexi CT Clamps 300A / 3000A X 4, Software CD & User Manual. For more details write to Kusam Electrical Industries Limited, G-17, Bharat Industrial Estate, T.J. Road, Sewree (W), Mumbai :- 400015 Tel: +91 22 24156638 Email :- kusam_meco@vsnl. net, sales@kusam-meco.co.in Web: www.kusamelectrical.com
Y
X
• Simple to learn and use • Faster to payback and increase profits • Easy to justify compared to manual alternatives
Don’t get behind – get in front call +91 20 6674 6200 or visit www.renishaw.co.in/primo
Renishaw India [Pune] S.No.282, Hissa No.3, Raisoni Industrial Estate, Village Mann, Tal:Mulshi, Pune 411057 T +91 20 6674 6200 F +91 20 6674 6211 E india@renishaw.com
www.renishaw.co.in June 2015
www.martupdate.com
19
PRODUCT MART
INNOVATION
Unipunch Offers High Speed Pipe Cutting
Apart from saving of material very high production rates ranging from 3000 to 5000 pieces per hour can be achieved.
Cutting pipes and tubes is a well established requirement with fabricators in that field. Pipes are generally cut by band sawing, circular sawing, lathe cutting or compression flow cutting. New technology is now available to cut the pipes by
shearing and without loss of materials in cutting. This method is highly suitable for cold rolled pipes and is good for stainless steel also. Pipes from 9 Dia to 100 Dia can be cut on different models that are available. This machines
can be conveniently coupled with automatic bar loader, end finisher, wire brush deburring, washing of components, inspection of components, etc. All operations can be controlled by one person.
US based Haven Manufactur-
Unipunch Toolings represents
Email: unipunch@gmail.com
ing Company to market their products in India. For further details write to Unipunch Toolings Pvt Ltd, Chennai. Tel: +91 9941905061
Biological Microscope Model RXL-5B INNOVATION
Right handed, co-axial, low positioned stage with double slide holder. LED Light source operated on 220 Volt/ 50 Hz.
Robust, ergonomically designed with stability having anti-mould and hard coated design. All objectives, eyepieces, optics & observation tubes are having anti fungal treatment with universal
20
www.martupdate.com
“Launched in 2012, our Biological Microscope Model RXL-5B is an economical and well designed microscope, containing most of the features available in high end research microscopes. Ergo design, High point eyepieces, Plan Objectives, LED illumination system are some unique features of this model. A wide range of optional accessories can be utilized with this microscope. In just three years, more than 2500 units have been sold out. “ Manoj Mankotia Technical Director, Radical Scientific Equipments Pvt Ltd
infinity corrected optical system. Sidentopf Binocular Head inclined at 30º & 360º rotatable. Inward facing nosepiece with click stops mechanism. Right handed, co-axial, low
positioned stage with double slide holder. LED Light source operated on 220 Volt / 50 Hz. Suitable for Pathology Laboratories, Medical Colleges, Hospitals, Research Centres etc.
For further details contact Radical Scientific Equipments Pvt Ltd, 9th Milestone, AmbalaJagadhri Road, Khudda Kalan, Ambala Cantt. – 133104 Tel: +91 171 2891500, 6600500 E-mail : info@radicalscientific.com Web: www.radicalscientific.com
June 2015
June 2015
www.martupdate.com
21
MAIN FEATURE
Production Metrology and Cost Efficient Manufacturing \
Riti Banerjee riti@martinfotech.in
Metrology comes from the Greek word “metron” and “logos” which means the study of measurement. The study of measurement is a basic requirement in any field of science and technology, most importantly in engineering and manufacturing. Metrology, being the study of measurement, is expected to validate predefined standards for traceability, accuracy, reliability, and precision. All of these are factors that would affect the validity of measurement. Although these standards vary widely, these are mandated by the government, the agencies, and some treaties. Consequently, these standards are verified and tested against a recognized quality system in calibration
22
www.martupdate.com
laboratories. Our focus however is on Applied Metrology. Applied metrology is rather specific in its applications, which are primarily various industrial processes including manufacturing among others. This metrology subfield intends to establish the importance of measurement in the industry. Moreover, it also ensures the appropriateness of measurement instruments including the maintenance, quality control, and proper calibration of these instruments. If we look at the application of Metrology today, we find that Metrology is used for the purpose of measurement mainly in four fields: • Measurement in manufactur-
ing industries • Measurement in navigation and communications • Measurements in medical diagnosis and therapy • Global climate studies Looking at the future of manufacturing metrology: The term ‘manufacturing metrology’ is most commonly used in the German language, while the term ‘production metrology’ is also typically found outside of Europe to refer to metrology within the context of production. ‘Faster, safer, more accurately and more flexibly’ is the title of the ‘Manufacturing metrology roadmap’ issued by the VDI/
VDE (The Association of German Engineers and Association for Electrical, Electronic & Information Technologies) Society for Measurement and Automatic Control. The document, drawn up by a group of German experts from research and industry, presents a view of the development of metrology for industrial production over the next ten years. Production metrology is a key technology for quality assurance of products and processes. It helps to secure the leading global status of German technologies. Fundamentally, everything can be measured. The challenge for production metrology, nowadays, is to implement the technology concerned in industrial manu-
June 2015
Lift Thrust
Drag
Weight Process Control & Assembly
Production
Fully Automated Inspection
Troubleshooting
Metrology assisted methods in aerospace manufacturing has led to the integration of metrology in everything from production, to process control and assembly, to fully-automated inspection, and troubleshooting.
facturing operations, so that acquisition of product quality data can be cost-efficiently achieved. Mr. V. S. Bansal, Managing Director, Banbros Engineering, observes, “Metrology in the manufacturing process is often seen as being a cost factor and very seldom as value adding activity, whereas production metrology is very essential in today’s manufacturing process, as it helps in producing the right quality. Production metrology helps in improving the productivity by minimizing or practically no rejections
resulting in consistent product quality.” It is quite an interesting fact that Metrology and Aerospace go hand in hand. The use of composite parts is integral to the future of aerospace manufacturing in order to build lighter, more efficient planes. While the operating costs of airplanes constructed of composite parts are lower, the manufacturing costs of such airplanes are typically higher. Composites—lightweight, strong, and durable—are more expensive than steel and aluminium, and metrology-assisted assembly is
“Production metrology is very essential in today’s manufacturing process, as it helps in producing the right quality. Production metrology helps in improving the productivity by minimizing or practically no rejections resulting in consistent product quality.” V S Bansal Managing Director, Banbros Engineering
June 2015
critical to making the manufacturing process cost effective. As composite parts become more extensively used, the role of metrology is becoming more widely recognized as a valueadded component. Metrology isn’t just a check on a process. In many factories now, it’s integral to the process and in terms of value, and often helps to use metrology to set things, to fabricate more accurately and eliminate tooling. To say measurement is a check or a balance on a process, is giving it short shrift. There are a great number of measure-
ment systems out there that aren’t measuring as a check but are integral to the process of fabricating something. Regarding value, if you are eliminating a lot of things that you used to have to design, that’s a huge cost saving. Compared to metal, composite is hard, unforgiving material; so accurate assembly adhering to very narrow tolerances is absolutely necessary to get it right the first time. In addition to helping manufacturers avoid costly scrap and rework, the use of metrology software saves time and money by
“In order to bring out excellence in our services, we have taken initiative by adopting modern technology to international standards of techniques & quality in our entire activities. In today’s increasingly competitive business environment, better quality translates into better value for our customers and, subsequently, this is the very essence of competitive differentiation.” Supriyo Ghosh Managing Partner, M/S Girish Ch. Ghosh & G.G.S. (Govt Approved Licence of Legial Metrology Dept)
www.martupdate.com
23
replacing hard tooling with 3-D models. Instead of being limited to fixed tooling structures, 3-D models can serve as flexible tooling, allowing users to react more flexibly to engineering changes.The growing acceptance and application of metrology-assisted methods in aerospace manufacturing has led to the integration of metrology in everything from production, to process control and assembly, to fully-automated inspection, and troubleshooting. This has basically brought metrology, and therefore quality, fully “into the fold” of the entire manufacturing process. When fully integrated in the manufacturing process, metrology and quality become not only value-added but required. Mr. Supriyo Ghosh,Managing
Partner, M/S Girish Ch. Ghosh & G.G.S., Storage Tank Calibration Consultant comments, “In order to bring out excellence in our services, we have taken initiative by adopting modern technology to international standards of techniques & quality in our entire activities. Our equipment matches all parameters of performance owing to their higher power and sophisticated design. This ensures smooth performance even in complex situations. As Quality is the primary determinant of customer satisfaction and loyalty, and we are dedicated to our valued customers we have to take this initiative. In today’s increasingly competitive business environment, better quality translates into better value for our customers and, subsequently, this is
the very essence of competitive differentiation. This new technology is covered under the following rule. He also says that the advantages of using modern optical metrology in calibration method are, • Much safer method • Much faster method • Much accurate data & result • Less man power needed • Simple process to calibrate a tank • Less Power consumption • Possible to calibrate in difficult weather In foreign countries this technology is adopted so many years ago but in India this
method is not adopted in all places. For example, Haldia in West Bengal is a city having different industries. But here the Govt. officials (Inspector) are not at all ready to accept this technology & are thus creating problems in different manners & forcing to work in old procedure. This type of mentality of certain people cause problems in the “Make in India” project declared by our hon’ble Prime Minister. This is against the process of “Ease of doing business in India”. A few people, for their personal incapability, are trying to stop the growth of our country. This should be stopped at any cost for global interest. For the success of this project, different initiatives must be taken & co-operation in all levels is required too.”
Global Climate studies
Measurement in navigation and communications
METROLOGY Measurement in medical diagnosis and therapy
Measurement in manufacturing industries
24
www.martupdate.com
Application of Metrology today is for the purpose of measurement, mainly in these four fields.
June 2015
June 2015
www.martupdate.com
25
MAIN FEATURE
Optical Metrology for Manufacturing Automation Due to the zero error rates requirement, 100% part inspection has become more common these days. Inline metrology with contact free measurement techniques is an ideal solution considering the high volume uninterrupted production rate of goods. Since the result of measurement is directly fed back into the process for corrective measures, it is considered to be an integral part of efficient and competitive production. Speed, measurement accuracy, reliability and appropriate measuring principal are the key features of an inline optical metrology.
Usha S usha.cmti@nic.in
Optical Metrology for Manufacturing Automation Automation continues to grow as an important tool in any industrial process chain. Innovative solutions enable metrology to be integrated seamlessly in the automated processes. Metrology offers solutions for characterizing a new process or monitoring high-volume manufacturing processes and supports in analysis and process optimization. This gives manufacturers the ability to maintain tight control of their processes. Quality and throughput are the two critical factors that determine the profitability of industrial production processes. In this respect, quality assurance implemented using rapid, automated and robust inspection technology greatly facilitates both throughput and quality of products. Due to the zero error rates requirement, 100% part inspection has become more common these days. Inline metrology with contact free measurement techniques is an ideal solution considering the high volume uninterrupted production rate of goods.
26
www.martupdate.com
Since the result of measurement is directly fed back into the process for corrective measures, it is considered to be an integral part of efficient and competitive production. Speed, measurement accuracy, reliability and appropriate measuring principal are the key features of an inline optical metrology. Manufacturing automation with optical metrology offers: •Increased efficiency in quality control •Higher productivity •Higher accuracy •Major cost reductions The designs of optical metrology systems vary widely, depending on the application. Lens image sensor, and camera play the key role in all classic optical inspection systems. Each of these elements influences the performance of the system both in quantitative and qualitative aspects. Quantitative parameters include the measurement accuracy as well as the time required to capture and measure an object. Also one needs to take into account whether the target is stationary or in motion (e.g. mov-
ing on a conveyor or handled by a robot). A qualitative parameter is the reliability of a measurement system. The measurement results must be consistent and reproducible irrespective of varying environmental conditions, like temperature and lighting. Following discussions highlight how the application influences the inspection requirements. High Speed Inspection For Quality Control Industrial production testing requires measurement cycle times of only a few microseconds. This poses a stiff challenge as the pass/fail analysis must be done within this time frame. Both Area scan cameras and Line scan cameras can be used. While using area scan camera , in order to get a crisp image of a fast moving object (“freeze motion’’), one needs to choose short exposure times as well as high speed shuttering, powerful light source, strobe illumination in sync with image acquisition. All these add to system complexity and usually make it harder and more expensive to get good images.
June 2015
Fig.1 (left) Dripper under inspection (middle) Image captured (right) result of image analysis.
In contrast line scan cameras lend themselves well to imaging high-speed objects where continuous inspection is demanded in line with the production such as fabric inspection, web inspection, inspection of printed circuit boards, quality inspection of food products, wafer surface inspection, defect detection in textured materials. Figure 1 shows result of one such high speed inspection developed in-house wherein drippers used in irrigation are being inspected for various defects along the periphery at the rate of 600 parts per minute using line scan camera. 3D Metrolgy For decades, CMMs were dominating the dimensional metrology market. However, during the past 10 years, 3D laser scanners, white-light scanners, laser trackers, and
multi-sensor systems have become widely accepted in dimensional metrology. Newer technologies continue to capitalize on the user confidence by showcasing flexibility and portability apart from demonstrating high-precision results. Optical solutions introduce innovative concepts like automatic alignment or dynamic referencing, which enables the measuring device to be continuously locked to the part by an optical link. It is possible to continuously monitor any deviations from the reference part by fixing markers on the part being measured. This significantly improves the accuracy of portable CMMs that work in challenging shop floor environments subjected to intense vibrations 3D shape measurement technologies have seen a significant growth over the past few decades. Numerous techniques have
evolved to recover 3D objects with different principles. The structured light method has become one of the most important 3D shape measurement technologies for both scientific research and industrial practices mainly because of its simplicity and speed. Fig.2 shows the 3D point cloud data captured for some of the sample components using fringe projection technique developed in-house. The system consists of one camera and a digital light projector which projects fringe patterns onto the object which needs to be modelled. The projected pattern deforms according to the shape of the component. The deformations of the patterns are captured by the camera and analysed to capture the 3D point cloud data and derive the CAD model. This finds application in reverse engineering, measurement of 3D features and design simulation.
Fig. 2 3D Point Cloud of Captured by the Fringe Projection System of a (left) lower human jaw bone (right) Tyre Mold
June 2015
www.martupdate.com
27
NanoMetrolgy There is a great demand for process control of feature dimensions below the resolution limit of visible wavelength microscopy. Semiconductor device fabrication is one such manufacturing process that is most sophisticated and complex. Advances in the manufacturing processes have brought down the feature size of gate to as low as 22 nm. As the feature size of the semiconductor device continues to shrink, the minimum feature size to be fabricated brings in lot of pressure on the process as well as the ability to detect micro defects in the semiconductor devices. Lot of research has been focused on increasing the resolution of the metrology tools. However most of them are standalone inspection systems like Scanning Electron Microscope (SEM), Atomic Force Microscope (AFM), Near Scanning Optical Microscope (NSOM) that are not tied to the process for in-line correction. Also if the time taken for inspec-
Micrscope Setup
tion is long, it affects adversely the performance of the resist. Scatterometry is one of the few types of metrology that has true in-situ potential for deep submicron CD and profile analysis. Scatterometry needs a powerful analysis of the optical signals in order to extract geometrical characteristics on the patterned wafer.
is used to evaluate change in dimension of two targets in nanoscale. Fig.3 depicts the concept of TSOM technique for identifying 100nm variation in line width and line depth in single line grating on a silicon wafer. Conclusion
‘Through focus Scanning Optical Microscope’ (TSOM) is an innovative in-house development to identify nanoscale dimensional variation. This new metrology method achieves nanoscale measurement sensitivity comparable to scanning electron microscopy (SEM) and atomic force microscopy (AFM) using simple inexpensive optical microscope for in-situ application in manufacturing production line.
The idea of smart factories, although not new, is constantly evolving. Today, it is well accepted fact that the industrial revolution is driven by the factories of the future. With increased acceptance of optical metrology systems on robots in plants, the role of repetitive manual operation is reducing. Automation is expected to be a key driver for the metrology market across various industrial applications. Also there is a great demand for advanced metrology tools to cater to the nano manufacturing challenges.
It captures set of through focus image. Extracted optical intensity profiles are stacked to form TSOM image. TSOM image
The author Usha S is the Joint Director of Central Manufacturing Technology Institute, Bangalore.
Through Focus Scanning of Line Grating
Intensity Plot
3D Optical Data
TSOM / DTSOM Image
28
www.martupdate.com
June 2015
June 2015
www.martupdate.com
29
MAIN FEATURE
Big Data Analytics with Industrial Metrology In our industry big data solutions will be key to scaling solutions to finer levels of control and diagnostics. However the main impact will be to better enable more effective predictive technologies such as predictive maintenance (PdM), virtual metrology (VM) and yield prediction.
Rajesh Angadi rajesh_angadi@hotmail.com
Metrology is the science of metrology. It is the science of measurement which includes units of measurement and their standards, measuring instruments and their field of application, and all theoretical and practical aspects relating to measurement. Metrology is the science that covers all theoretical and practical aspects related to measurements, regardless of the uncertainty on everyfield of science and technology. Thus, Scientific and Industrial Metrology is an important tool for growth and technological innovation, fostering competitiveness and creating a favourable environment to the scientific and industrial development of every country.The Future of Manufacturing Industry, is on the threshold of the fourth industrial revolution, as digitalization now follows after the automation of production. The goals are to increase productivity and efficiency, speed, and quality. In this way, companies can remain competitive on the path to the future of industry.
30
www.martupdate.com
Metrology is classified in three main fields:
metrology dealing with measurements in chemistry
•Scientific Metrology •Industrial Metrology •Legal Metrology
Industrial Metrology is that part of metrology which deals with measurements in production and quality control. It covers calibration procedures, calibration intervals, and control of measurement processes and management of measuring instruments in industry to ensure that they are in a state of compliance with requirements for their intended use.
Scientific Metrology is that part of metrology which deals with aspects common to all metrological questions irrespective of the quantity measured. It covers general theoretical and practical problems concerning units of measurement, including their realization and dissemination through scientific methods, the problems of errors and uncertainties in measurement and the problems of metrological properties of measuring instruments. There are different specialist areas of metrology, for example: Mass metrology dealing with mass measurements; Dimensional metrology dealing with length and angle measurements; Temperature metrology dealing with temperature measurements; Electrical metrology dealing with electrical measurements; Chemical
Legal Metrology is that part of metrology which is subject to legal/regulatory control. It is defined in the International Vocabulary of Legal Metrology as that part of metrology relating to activities which result from statutory requirements and concern measurement, units of measurement, measuring instruments and methods of measurement and which are performed by competent bodies. Legal metrology provides regulations for the control of measurements and measuring instruments. Legal metrology
provides protection of public safety, the environment, consumers, traders and is critical to fair trade. Legal and Industrial Metrology Legal and industrial metrology both have the same demands in terms of metrological traceability. This means that the measurement process must be defined and controlled. Under the specified conditions, the measurement process must produce a measurement result that the user can trust. The approach to the measurement process is the same in both disciplines: definition of the measured, selection of the most suitable measurement method, determination of the influencing parameters. All of these factors produce a result and an uncertainty that are compatible with the requirement. But the results of the metrological operation are put to different uses. In legal metrology, they are used to achieve regulatory conformity and to guarantee the conformity of the instrument with this regulatory requirement, so that
June 2015
it can continue to be legally used. If the requirement is industrial then users set their own limits of acceptability in order to meet a functional need. The end user must be capable of implementing the process as planned and analysed, since it often makes a significant contribution to the uncertainty of measurement. The concept of legal metrology encompasses the various aspects of the design, certification and inspection during operation of measuring instruments covered by a regulation. Big Data Analytics with Industrial Metrology At first glance, the move to big data analytics might appear to be just another evolutionary change in the Industrial Metrology. After all, engineers have always measured, and techniques such as fault detection and classification (FDC), statistical process control (SPC) and run-to-run (R2R) control are certain requirements of what is to come. But the move to big data, at the very least, is an inflection point, if not an outright revolution, as the industry shifts from reactive techniques to predictive approaches that involve major changes in how data is gathered, stored, and— most importantly—managed. Engineering groups at equipment suppliers and semiconductor manufacturers will need to share data to an unprecedented degree, experts agree, though how to do so remains a work in progress.As requirements on data volumes, rates, quality, merging and analytics rapidly increase in semicon-
June 2015
ductor manufacturing, we need new approaches to data management and use across the fab. A number of industries are facing this problem and, in response, the “big data” effort has been emerged. In our industry big data solutions will be key to scaling solutions to finer levels of control and diagnostics. However the main impact will be to better enable more effective predictive technologies such as predictive maintenance (PdM), virtual metrology (VM) and yield prediction. In semiconductor manufacturing, metrology — the science of measuring things — is an absolutely vital part of the manufacturing process. Much of this analysis is handled by CDSEM (Critical Dimension Scanning Electron Microscopy) equipment. As process nodes shrink and manufacturing difficulty increases, the amount of data being collected per wafer has increased. Foundries now collect more data per wafer than ever before, and they need to be able to analyse that information quickly and compare it to other readouts from different pieces of equipment. While big data solutions can be any solution approach that addresses one or more of the four V’s, (Volume, Velocity, Variety, and Variability) a typical big data solution contains the following components: •Real-time collection and analytics: In addition to increased data collection rates (velocity), analytics are being implemented that function in timecritical environments, providing
www.martupdate.com
31
analysis to support real-time decision-making. •Apache Hadoop: an open source software framework for storage and large-scale processing of data sets on clusters of commodity hardware. Hadoop leverages parallelprocessing and scalability capabilities to provide solutions tailored to large time-series data sets such as trace data. •Hadoop Distributed Filing System (HDFS): a distributed file system designed and optimized for processing large data volumes and for highest availability. •MapReduce-type frameworks: A programming model for large-scale data processing such as MapReduce (which originally referred to the proprietary Google technology but has since been genericized). Proper implementation of big data solutions can provide for more efficient data storage and processing. •Data warehousing: An extensible storage capability that relaxes limitations on volume of data.
•Analytics: Addresses the “value” component of big data. Analytics, particularly predictive analytics, leverage capabilities to organize and analyse large quantities of data quickly. These big data solutions will likely still require a transactional component probably best suited to a relational database; however the vast majority of data volume and processing can be relegated to a Hadooptype infrastructure. As more sensors are added to tools and data is collected at higher rates, at Fabs and Foundries, there will be an absolute explosion in the volume of data. Of all the four Vs, the volume one is the most problematic, because that potential data explosion could drive-up costs. The benefits of implementing these types of big data solutions include: Lower COO of data solutions, More efficient data storage, Improved analytics performance and Better enabling of predictive analytics. Predictive Analytics with Big Data
Predictive analytics represent the latest layer of capabilities being added to the factory automation infrastructure. These capabilities can be leveraged in a collaborative fashion for yield optimization and overall equipment effectiveness (OEE) optimization. While the former is largely a proprietary fab effort, the latter requires the user and predictive analytics supplier to cooperate so that equipment, process and analytical knowledge can be leveraged together to achieve cost-effective, optimized solutions. This means that both a technical and business foundation is in place to deliver effective services. Prediction is the Future The advent of big data solutions combined with recent successes in predictive solutions in our industry opens the door for significant opportunities in yield optimization and improvement. These opportunities come with challenges such as migrating from a reactive to predictive culture of operations, enabling cooperative (user, OEM and analytics sup-
CONTROL
Engineering DB RDBMS + Hadoop
MES
Automation
APC w/VM
REACTION
COLLECTION
Events/ Commands
Primary Port SECS/GEM
32
www.martupdate.com
The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.
OEE OPTIMIZATION
YIELD OPTIMIZATION PREDICTION
plier) solutions while protecting intellectual property, and addressing key big data topics such as data quality (variety) and data merging (variety) to enable cost-effective and repeatable solutions. However, the level of success currently being achieved is a clear indication that these issues are being addressed, paving the way for prediction to become much more pervasive in the fab of the future with the backbone of industrial metrology.
Yield Prediction
PdM
Yield Analysis
Post PM Recovery
Inhibit Tool, Lot, Recipe,etc.
MWBC Optimization
SPC
EHM FDC
OEE FDC
EDC Data
Trace Data
Trace Data
Interface A
DTC
Tools
June 2015
dry-tech: ®
dry-tech® [ˈdraɪ]-[tekˈ] The lubricant-free, low-cost way to swivel, rotate, oscillate, move and achieve linear motion ... construct sustainably with dry-running polymer bearing solutions from igus . ®
.in/dry-tech24h
®
igus (India) Pvt. Ltd. 36/1, Sy. No. 17/3 Euro School Road Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura, Bangalore - 560048, Karnataka, India Phone +91-80-45127800 Fax +91-80-45127802 info@igus.in plastics for longer life ®
®
June 2015
www.martupdate.com
33
MAIN FEATURE
Harmonics - A Power Quality Problem Power Quality is defined by any problem manifested in voltage, current or frequency deviations that results in failure or mal functioning of customer sites or equipments. For quality performance of various power system devices it is necessary to understand the problems due to harmonics deeply and take further remedial measures for improvement and better performance.
Haren Shah haren.shah@mecoinst.com
Power Quality is defined by any problem manifested in voltage, current or frequency deviations that results in failure or mal functioning of customer sites or equipments. Bureau of Energy Efficiency (BEE) plays a key role in creation of professionally qualified energy managers and auditors with expertise in energy management, project management, financing and implementation of energy efficiency projects as well as policy analysis. It is a Law to force firms to make more profit and not an Act to control and monitor Energy Consumption of Industry. Under the BEE’s PAT Scheme (Perform, Achieves & Trade) for Eight Industrial Sectors like Aluminum, Cement, Chlor – Alkali, Fertilisers, Iron & Steel, Pulp & Paper, Textile and Thermal Power Plants, it is mandated to compulsorily improve their Energy Efficiency by adopting all the available measures including replacement of their old Equipments with New and Energy Efficient Equipments. For quality performance of various power system devices it is necessary to under-
34
www.martupdate.com
stand the problems due to harmonics deeply and take further remedial measures for improvement and better performance. Harmonics – A Power Quality Problem The power quality may defined as any problem manifested in Voltage, Current or Frequency deviations that results in failure or misoperation of customer sites or equipments. Harmonics, voltage flicker, voltage regulation, voltage sag, voltage swell and transients usually characterize the quality of electric power. Harmonics is one of the major factors due to which none of these conditions are fulfilled in practice. The presence of harmonics distorts the waveform shape of voltage and current increases the current level and changes power factor of supply, which In turn creates so many disturbances. Sources Or Causes Of Harmonics Rapid use of energy conservation devices in both domestic sectors and industrial sectors such as electronics chokes for tube lights, electronics energy controllers for
the motors and electronic fan regulators etc. also inject harmonics substantially. Large use of the shunt capacitors to improve power factor and stability has significant influence on harmonic level. Related to the supply system converters and traction are the major causes of generation of harmonics. More use of solid state power converters for industrial furnaces for mini steel and non-ferrous metal plants, use of thryistors for locomotives, extensive use of single phase electronic loads in domestic sectors are causes of harmonic generation. A growing power quality concern is harmonics distortion that is caused by the non - linearity of customer loads. Impacts Of Harmonics On Various Equipments Transformers: The Primary effect of power system harmonics on transformers is the additional heat generated by the losses caused by the harmonics content of the load current. Magnetic loss increases due to higher
June 2015
“Technology is changing every moment, in the electronic field and new solutions are developed in the measuring instruments field due to application of advanced micro circuits and software solutions. MECO’s in house R & D is continuously developing solution for easier, efficient, reliable and accurate measurement at affordable cost.”
“Our target is to increase our market share & sales by 25% - 30% every year. Major challenge that our organization and this sector is facing is competition and over capacity. In the next five years we want to make competitive product for global requirement.”
Premchand Goliya Chairman & Managing Director, MECO Instruments
frequency level of harmonic current. Copper loss increases in winding due to third harmonic current present with load current. Also copper loss increases in the delta connected transformer windings due to extra circulating zero sequence currents. Rotating Machines: An increase in motor, Generators, Turbine operating temperature will cause reduction of the rotating machine’s operating life. Extra audible noise is produced during the operation due to the difference between the time harmonic frequencies. Also harmonics cause variation of mechanical resonance speed of adjustable speed drives, which may do damage due to amplification of the pulsating torques. Capacitor: The effect of the Harmonic component is to cause extra power loss due to decrease of impedance by increasing frequency; which in turn increases the temperature level and shortens the life by early equipment failure. Also it increases the dielectric stress inside the capacitors. Circuit Breakers: The Harmonic distortion of the current can affect the interruption capability of the circuit breakers and thermal magnetic breakers. The extra heat due to losses for frequencies above the fundamental raises the temperature of the thermal device, which in turn may reduce the trip point of the circuit breaker.
June 2015
Measuring Meters: Wattmeter and watt-hour meter, Electronic Energy meter shows error from the frequency characteristic of the voltage and current waves affected by harmonics. Linearity of the meters can be degraded when the power factor is low or waveforms have large crest factor caused by the Harmonics. Absolute average responding meters calibrated in RMS and peak responding meters give erroneous result under the presence of harmonic distortion. AC/ DC Drives: Voltage surges due to harmonics can damage the power diodes connected at the input of an AC variable frequency drive. Under sustained over voltage and under voltage condition the equipment may be shut down. Input voltage waveform containing of harmonics may have multiple zero crossing, which may change the firing angle of the thyristors. Conductors: There are two mechanism is which harmonic currents can cause heating in Conductors that is greater than for the RMS value of the current. The first mechanism is due to current redistribution within the conductor and includes the skin effect and the Proximity effect. The second mechanism causes abnormally high current that is due to excessive third harmonic current in the neutral conductor. Cables:
Kamal Goliya CEO, MECO Instruments
Harmonics cause extra heating which in turn causes a degradation of dielectric, production of cable jacket both inits dielectric role & its mechanical protection role, reduction of life span due to oxidation and a possible overall reduction of maximum operating capacity of the cable. Computer Networks, Control Room, SCADA: Presence of Harmonics effects can cause nuisance tripping of sensitive loads. Some Computer controlled loads are sensitive to voltage distortion. Data acquisition through SCADA System may get effected due to Power disturbance like Voltage sag, swell, Transient events, and presence of harmonics. Protective Relays: Waveform distortion does affect the performance of protective relays and may cause relays to operate improperly, or not to operate when required as in ground Relays due to zero sequence third harmonics and dual input relays by the phase relationship between the respective input harmonics. Changes of operating points operating torque and time of static relays may happen due to distortion of waveform, which in turn causes improper high speed operation of difference relays. Controls & Remedies For Harmonics Limit harmonic current injection from nonlinear loads Transformer connections can
www.martupdate.com
35
be employed to reduce harmonics in three phase system using parallel delta-delta and wye delta transformers to yield net 12-pulse operation or delta connected transformers to block triple harmonics. The Harmonic distortion in adjustable speed drives can be controlled will within IEEE 519-1992 limits by drive design modification, switching from 6 pulses to higher pulses converters, connection of series reactor. Modify system frequency response to avoided adverse interaction with harmonic currents. This can be done by feeder sectionalizing adding or removing capacitor banks adding shunt filters or adding reactors to detune the system away from harmful resonances. Applying Harmonic like Filter harmonic current at the loads or on the system with shunt filters or try to block the harmonic currents produced by the loads. There are number of devices to this. Their selection is largely dependant on the nature of the problems encountered. Solution can be as simple as an in-line reactor (i.e. a choke) as
in the PWM based adjustable speed drive applications or complex as designed active filter. In the Reactor (i.e. Choke) as in the PWM based adjustable speed drive applications or complex as designed active filter.
With the move towards deregulation within the Power utility industry, customers are demanding superior Power quality and reliability of Supply. Many utilities have responded to the needs of their customers by establishing Power Quality Divisions within their marketing departments.
Monitoring problem manifested in V, I, Hz. Data acquisition is the primary step for both the situations. The requirement is the data on the current and voltage distortion both as it exists.
Analyzing the spectra and knowing the size of systems planned, different solutions can be deduced and incorporated in the design that will lessen the disturbances or possibly eliminate them entirely.
For Quality performance of various Power system devices it is necessary to understand the problems deeply and requires further remedial measures for improvement and better performance. So for Quality performance of various Power System devices it is necessary to understand the problems deeply and requires further remedial measures for improvement and better performance. Data acquisition is the primary step for both the situations.
Providing solution to Power Quality problems, cost plays a major role. Hence it is always necessary to find cost effective solution to resolve Power Quality issues to minimize equipment downtime and loss of production by using Handy and Easy to use Instruments for Monitoring, Measuring and Recording all necessary values in three phase like TRU-RMS value, Voltage, Current, Frequency, Apparent & Reactive Power, Energy, Power Factor, Phase Angle and above all Harmonic Analysis with Transients events.
Planning & Designing For Harmonic Suppression
MECO “Power & Harmonics Analyzer – Model 5850” is a state of art versatile
Power & Harmonics Analyzer – Model 5850 Useful to Analysis for 1 & 3 Phase Quality Power System. Large Dot Matrix LCD Display with Backlight of 35 Parameters in screen to monitor Energy, Active Power, Apparent Power & Reactive Power, Power Factor, Energy, TRU RMS Value, AC Current, and Average & Maximum Demand with Programmable Time Interval & CTR & PTR. Displays Individual Harmonics of Voltage & Current upto the 99th Order, THD with Waveform & Peak value. For more details please visit www.mecoinst.com
36
www.martupdate.com
June 2015
instrument using micro controller technology, Ideal to carry out Vigilance checks, Surveys, Audits and Periodic Visits for checking at Industrial and Consumers end.
or 10/100/1000A or 300/3000A & 120/1200A (Flexible CTs) as per application.
The measurements can be done on Live loads. It do Analysis for 1 & 3 Phase Quality Power System. Large Dot Matrix LCD Display with Backlight of 35 Parameters in screen to monitor Energy, Active Power, Apparent Power & Reactive Power, Power Factor, Energy, TRU RMS Value, AC Current, and Average & Maximum Demand with Programmable Time Interval, CTR & PTR. Displays Harmonics upto the 99th Order, THD with Waveform &Peak value. Has inbuilt memory of 512K for 17000 records & Optical Isolated RS-232 ~ USB Interface with users friendly Software with facility to retrieve Power Data & Harmonics on Meter Screen at site. Available with Clamp on CT having Multiple Range of 1/10/100A
Objective of is to provide steady state Harmonic Limits that are reasonable to both Electric Utilities & the Users.
Objective
• The power provider should limit Harmonic voltage since they have control over the system impedance • The users should limit Harmonic Currents, since they have control over loads. • Both parties share the Responsibilities for holding Harmonic levels in check. The author Haren Shah, a Commerce Graduate from Mumbai University, is associated with MECO Group for more then 20 years. Premchand Goliya and Kamal Goliya of Meco
Instruments inspires Haren Shah penning down these technical articles. Meco Instruments Pvt Ltd at Mahape, Navi Mumbai is one of the market leaders in the field of Testing and Measuring Instruments for over four decades. Technology is changing every moment, in the electronic field and new solutions are developed in the measuring instruments field due to application of advanced micro circuits and software solutions. MECO’s in house R & D is continuously developing solution for easier, efficient, reliable and accurate measurement at affordable cost with this in mind having target is to increase their market share & sales by 25% - 30% every year. Some of the write-up, example or case study taken from various articles in Magazine for the awareness and knowledge of the Public issued herewith without any prejudice. E. & O.E.
More than just a pretty face. Expand your options with Graphite® HMIs.
Connect more devices with plug-in modules and support for 300+ protocols.
Red Lion’s Graphite advanced operator panels are the industry’s first rugged HMI solution to combine flexible plug-in modules with built-in protocol conversion, data logging and web-based monitoring. From factories to extreme remote locations, Graphite HMIs enable customers worldwide to connect, monitor and control processes across a broad range of industries to meet all of your industrial automation needs.
+91-9844876540 I india@redlion.net I www.redlion.net © 2015 Red Lion Controls, Inc. All Rights Reserved.
June 2015
www.martupdate.com
37
MAIN FEATURE
Significance of Calibration
For the advancement of technology and science measurement plays an important role. The countries those who have better measurement capability are in better position, economically and technologically.
B N Guha nutech_cali2006@rediffmail.com
Customer demands quality products along with quality services. The advanced countries like USA, China, Japan, Russia, France, Germany, UK, Switzerland etc are very much advanced in their metrological systems. Metrology is the science of measurement. Measurement activity was prevailing in the ancient days also but the methodology was different and it was backdated, for example Emperor of Rome used to measure the land by his feet as made measurement. Now question comes if Emperor’s foot size changes, accordingly measurement changes.
38
www.martupdate.com
There was no consistent reliability as well as repeatability of measurements.
prosper. For example a nut made in India must match with bolt made in other countries.
With the advancement of civilization, the methodology of measurement changed through decades. A technical person from Sweden realized that to maintain consistency and repeatability in measurement a device is to be developed. He invented gauge blocks for the first time as length standard.
Most common objective of every organization engaged in production of goods or services is to attain excellence in its economic performance, by providing better quality products/ services with competitive price.
Since then we are using slip gauges of various accuracy in the metrological field for manufacturing industries as for calibration or measurement. Inter changeability is a must without which trade cannot
Globalization of the market and tough competition forced to set up International Standard Organization (ISO) body having its head quarter at Geneva in Switzerland established in 1947 with the objective of unification of International Standards. First quality standard was published in 1987 (ISO 9000). Since then calibration became
mandatory for those who want to have ISO 9000 certification for the manufacturing and export of their products to the global market and also for internal market. Necessity demands invention. Invention needs R & D. R & D needs measurement and calibration. EDM machines were developed in Switzerland for the manufacturing of interchangeable watch components. Calibration is a process of measurement in which an instrument (DUC) reading is compared with known measurement (calibrated) results of higher accuracy to lower accuracy instrument result to
June 2015
With the advancement of civilization, the methodology of measurement changed through decades
know the deviation or drift occurred. Which will speak the status of the DUC (Device Under Calibration). To perform calibration following criteria has to be followed: S = System (Methodology for performing calibration and technology to be implemented) W = Works (Where calibration has to be performed) Should have environmental condition such as a) Temperature b) Humidity Level c) Dust Proof d) Vibration Proof e) Illumination f) Sound level etc to be maintained strictly. I = Instruments (By which calibration should be performed) Instrument means Master / Standard instrument by which calibration shall be performed having at least 5:1 accuracy than DUC (Device Under Calibration). It will be further better if the ratio is 10:1 P = Personnel (By whom cali-
June 2015
bration to be performed) Calibration personnel who will do the calibration must have proper qualification, sufficient training, experiences and knowledge about the instrument to be calibrated, its functioning and other technological aspects about the master instrument and the DUC and the ability to calculate Measurement Uncertainty. The author B N Guha is the CEO of Nutech Calibrators & Engineers. Nutech Calibrators & Engineers is engaged for the calibration of various Mechanical, Electro-Technical & Thermal measuring instruments for small, medium & large scale industries including Government Organization all over India, Nepal & Bhutan. This Organization is registered under Govt. of West Bengal as an SSI unit and it is enlisted with Kolkata Municipal Corporation. For more details visit www.nutechcalibrators.com
www.martupdate.com
39
MAIN FEATURE
Replace manual gauges with new INTUOTM software for Equator TM
The Renishaw Equator™ flexible gauge is now offered with the new INTUOTM gauging software, combined with a range of industry standard Renishaw probes. INTUO simplifies and automates the gauging of a wide variety of parts, removing dependence on the skill of manual gauge users. Reducing gauging inconsistency reduces scrap, whilst ensuring parts that are out of tolerance are always identified.
Samina Khalid Samina.Khalid@renishaw.com
Highly repeatable process control on the shop floor - create simple gauging routines in minutes and eliminate user error. Renishaw is also launching the Equator Button Interface (EBI), with simple push-button controls for shop-floor operators, removing the need for a mouse and keyboard. Replace manual gauges, reduce ongoing costs INTUO with Equator is an ideal alternative to multiple manual devices such as vernieror digital callipers, micrometres and plug gauges. Equator is highly repeatable and runs fast
40
www.martupdate.com
automated routines, meaning significantly reduced labour costs. With many workshops using hundreds of manual gauges this cost saving can be considerable. INTUO, with minimal training, uses intelligent functions to help the engineer set up gauging of parts in a matter of minutes. Shop-floor operators then select and run those programs using the user-friendly Renishaw Organiser front-end software.
ing drawing. With the Feature Predict function activated, the programmer uses the joystick to take points on each feature while INTUO does most of the work, by predicting the type of feature, the nominal value and a possible tolerance band. It is then easy to adjust the program to change the number of points taken or to space them evenly, and match nominals and tolerances to the engineering drawing.
Gauging routines in minutes
Easy manual input of master part actuals
INTUO allows the programmer to create gauging routines using just a part with an engineer-
It is a simple task to input the actual values for features on the master part, which does
not need to be a ‘perfect part’. In fact it is preferable that a production part manufactured with the same method and material is used. First the features required are measured on a certified device, like a calibrated manual gauge or any co-ordinate measuring machine (CMM). The values from this master part inspection report can be manually added to a table in Organiser or to the corresponding field in INTUO – changing one will update the other. Programmer training in one day INTUO has gone through extensive development to
June 2015
INTUO allows engineers to create simple gauging routines on Equator in minutes, with easy input of master part values. With Equator Button Interface shop floor operators can start routines with a single button, and control other basic functions
make it as simple to use as possible, which means that programmers only need a training course lasting a few hours. Training is ‘hands-on’, using the joystick to take points while interacting with icon based menus and a graphical workspace to rapidly build up the features to be gauged. In just a few hours programmers will learn the four stage INTUO process of Align – Measure – Dimension – Report, and be ready to inspect production parts. Equator Button Interface In many shop-floor environments simple operator controls are essential. Customer feedback has shown that an alternative to the keyboard and mouse is required, so Renishaw has introduced the Equator Button Interface (EBI), which works directly with the Organiser software. EBI uses large push buttons
June 2015
which can be operated by operators wearing gloves. It is not affected by shop-floor contamination and can be mounted on the front of the Equator or on the framework of a table or enclosure. At the most basic level it can be used to start gauging programs, but can also be used to stop those programs mid-cycle, select other programs and navigate the Organiser environment. Equator can be moved using the jog keys if necessary and there are buttons for initial alignment, switching between master/measure modes, changing view screens and easy error recovery. Control your process Equator has various reporting options, including simple pass/ fail, a more detailed view in Process Monitor (a process monitoring window for the user interface), or automatic data capture for updating machine tool offsets.
Process Monitor provides a chart showing the history of feature measurements, and an easy graphical view of proportion of tolerance for each feature. Being able to view the inspection data history of a part is an invaluable function for controlling manufacturing processes. This is not possible when using a Go/no-go gauge, which can only indicate the state of each feature.
take advantage of Renishaw’s extensive network of Equator support engineers. Projects initiated in one country or region can be easily transferred and locally supported in multiple locations. Renishaw now has over 70 regional support offices and multiple approved partners, covering every industrialised area of the world.
Process Monitor also enables shop floor management of the mastering process according to temperature, time or number of parts measured. Use of a calibrated master part allows the system to be re-zeroed whenever shop-floor conditions change, meaning Equator can cope with a rapidly changing thermal environment.
Equator is unique in its design and method of operation, and has already changed the thinking of thousands of production engineers, making it their new gauge of choice.
Global support Reflecting the international nature of many modern manufacturing organisations, Equator customers have been able to
The versatile gauge
The versatility and repeatability Equator offers is re-defining the world of gauging, and now with INTUO and the Equator Button Interface an even wider range of capabilities is offered to manufacturers globally. For further details on gauging, visit www.renishaw.com/gauging
www.martupdate.com
41
MAIN FEATURE
Noncontact Temperature Measurement in Heat Treatment Processes Raytek and Ircon at METEC-THERMPROCESS 2015 Berlin – At this year’s METECTHERMPROCESS exhibition, infrared temperature measurement experts Raytek and Ircon will present their comprehensive pyrometer program for the metal working industry. By detecting infrared radiation from a distance to determine an object’s temperature, pyrometers reliably monitor products and processes with temperatures up to 3,000 °C.
Exhibition highlights range from robust handheld devices to fixed pyrometers with rugged accessories, from OEM sensors with record-setting compact dimensions to highly precise thermal imaging systems. The team will be happy to advise visitors on the best way to tackle their particular application. Raytek and Ircon provide capable solutions for all scenarios involving digital or analog signals and automation environments featuring a variety of different fieldbuses or Industrial Ethernet protocols. The latest addition to the product family, Raynger® 3i Plus handheld infrared thermometers are designed for highly demanding hot environments, measuring
temperatures up to 3,000 °C. A high optical resolution allows for accurate temperature readings from longer distances. A heatresistant “Red Nose” warning detector ensures operator safety and efficiency. Dual laser and scope sighting, visible even against red-hot backgrounds, make this infrared thermometer a perfect choice for primary and secondary metals processes. A wide range of spot pyrometers for fixed installation includes one and two-color (ratio) pyrometers as well as fiber-optic models suitable for extreme industrial environments. Installation in remote or hard to reach places is not a problem since the accompanying software allows for PC-based sensor configuration. Integrated automatic self-diagnosis functions ensure consistent
Rugged pyrometers for use in high-temperature environments
42
www.martupdate.com
accuracy. Through-the-lens, laser, and/or video sighting facilitate orientation. Motorized focus control enables remote sensor re-focusing. Cooling accessories open up applications in ambient temperatures up to +315 °C. The Raytek MI3 line includes the world’s smallest stand-alone pyrometer, 28 mm long and 14 mm wide. MI3 sensors are capable of withstanding ambient temperatures up to +180 °C without cooling. Two shortwave models accurately measure reflective surfaces and are therefore better suited for metal sheet processing than longwave infrared sensors. MI3 sensors are also available with ATEX and IECEx certificates for use in potentially hazardous areas. Raytek and Ircon line scanning systems generate thermal images of live processes for continuous or batch production as well as for discrete manufacturing. The systems have a wide 90° field of view. Featuring built-in laser sighting, water-cooling, and an air purge housing, they withstand even the most demanding conditions. With a maximum optical resolution of 200:1, a scan speed of up to 150 lines per second, and up to 1,024 measurement points per line, they are among the most precise and fastest thermal imaging systems in the market. Even minimal temperature anomalies and hot spots are detected and displayed in real time. For further details visit www.raytek.com
June 2015
June 2015
www.martupdate.com
43
ON FACE
Along with more than 20 production facilities and 70 Precision Centers for service and demonstrations, and a network of over 100 distribution partners on five continents, Hexagon India has an assembly plant in Noida, since 2008 as well as 5 technical centers in west and south. Their team in India is very well equipped and trained to offer the Hexagon Metrology solutions to the customers.
Mr. Anup Verma, Managing Director of Hexagon Metrology India reaches out to the readers of Mart on how they are in the forefront in all the sectors that they are in and are recognised as the technology leaders in these segments.
“Legacy of Brands & theTechnology is our Strong Leverage�
Since last two centuries Hexagon has been into Metrology. How are you able to take this legacy in your Indian operations? Very prestigious and well-known brands come under Hexagon Metrology fold. These have over a century of history of innovation and cutting edge technologies. This is also recognised by the Indian market. Our work in India has been to represent these brands in terms of offering the right solution and after sales service to the satisfaction of our customers. The legacy of the brands and the technology is a strong leverage we have in the
44
www.martupdate.com
Indian market.
tions and capabilities to cater to that
Globally we are witnessing a lot of changes and developments in the field of Measurement Technology. Can you please share your experience?
Can you brief about Metrology Automation? How Indian manufacturing is adapting to this modern technology?
Measurement now not only has to be accurate, repetitive and reliable but also fast. The challenge now is to have fast and accurate, reliable measured data. Also, the data is used locally as well has to move around the globe. So it has to be faster and compatible data.This we see as the demand in the market and our products: Sensors, Machines and Software have the innova-
We have very good products in automation with products like 360° SIMS, Laser Tracker based robotic solution, White Light based robotic solutions etc. We offer solution in line, near the line, contact and contactless sensors for right automation solutions. At this moment, we see some interest in the market for this automation and we are presenting our solutions to potential users in automotive and aerospace segments.
June 2015
360° Smart Inline Measurement Solutions (360° SIMS)
Leica Absolute Tracker AT960
While coming to its global counterparts, how Hexagon India is competing in terms of applying high-end technologies? In India, we have an assembly plant in Noida since 2008 as well as 5 technical centers in west and south India. Our team in India is very well equipped and trained to offer the Hexagon Metrology solutions to our customers. We are in the forefront in all the sectors we are in and are recognised as the technology leaders in these segments. What are the latest products offering in the Indian market from Hexagon’s end? We are constantly offering new products and solution in the market. To name a few, the new Automation Solutions in portable machine like Laser Tracker, White Light Scanning is introduced in India. The probing solutions in our CMM new Indexing Heads, enhanced capability on scanning probes, etc. are on offer. What are the application sectors of your products? Broadly, our products cater to segments
June 2015
like Automotive, Aerospace, Electronics, Energy, Medical Metrology, today, is one of the key factors in manufacturing. Can you please brief about the application of this particular field of science in manufacturing? Our goal is to provide accurate and dependable data to our users so they can apply it to understand the quality of product as well as the manufacturing process. For this we have product portfolio that enables them to acquire the data in accurate and reliable way and use our versatile software to get smart data for improving their process and products. What do you feel about Mr. Modi’s initiative towards ‘Make in India’? In this regard, any particular plan to expand the Indian manufacturing facility? It is much needed push and high time that we had this push in India. This will not only generate the employment to start with but improve our manufacturing capabilities and hopefully prepare us to move towards
innovations so that we are not only manufacturing hub but also technology leaders. It is very encouraging to see the government making this push. As far as Hexagon Metrology is concerned we recognised the potential of manufacturing in India and were the first International Company to open an assembly plant in Noida for our certain models of Coordinate Measuring machines. In India, there is a huge gap when it comes to the pragmatic approach towards the course material in engineering. What is your view in manpower enhancement and skill development here? While we do have good things going on in terms of training the human resource we do find shortage of skilled manpower. With the make in India push this will beone of the greatest challenges. I believe much greater dialog is required between Engineering institutes and industry to have curriculums that prepares the student to face the challenges of the industry as he enters it.
www.martupdate.com
45
TECH TALK
How to Boost Checkweighing Efficiency Dirk Bettels Senior Product Manager, Mettler-Toledo Garvens
On food and pharmaceutical production lines, as elsewhere in life, the smallest expenses can soon add up into something insurmountable. Even seemingly trivial errors in portion sizes on filling lines can result in costly levels of product waste, making the installation of advanced checkweighing systems crucial to keep this waste to a minimum and maximise manufacturing output. Dirk Bettels, Senior Product Manager at global checkweighing manufacturer, Mettler-Toledo Garvens, answers our questions about how to ensure optimum efficiency.
What do we need to consider at the specification stage? Before making a purchasing decision, it is crucial that you think about the environment the checkweigher will be
operating in. Humidity, high temperatures, draughts, excessive vibration and airborne dust can all negatively impact on weighing precision, while moisture and dust can prematurely age the system by damaging
the conveyor belt or weigh cell. Selecting checkweighing technology with sealed casings, milled from a single piece of plastic or metal, and sloped surfaces for ease of cleaning for example, can help overcome
these issues by preventing the ingress of particles or moisture and protecting the delicate mechanisms within. You also need to consider whether there will be excessive
Granulate_conveyor
46
www.martupdate.com
June 2015
Rejection Pushers
movement or vibration near the checkweigher. Even tiny vibrations can be detected by sensitive checkweighing systems, which can distort measurements. Training staff about these potential correlations and other simple precautions can prevent these problems, ensuring precision weighing. How does the type of product impact the choice of checkweigher? When selecting the correct checkweighing technology, it is important to consider the nature of the product to be inspected. In addition, packaging format, height, weight, whether the product is solid, powdered or liquid, for example, will affect pack stability in transit, potentially impacting on weighing accuracy. The installation of timing belts, screws or wheels can help to ensure each pack is correctly spaced so that only one at a time passes over the weigh cell. Side grips and transfer units act to keep each pack stable, optimising weighing accuracy and guaranteeing rejection of the correct pack in the event of
June 2015
an inspection failure. The product and its packaging will also determine the type of reject device that should be used to remove the pack from the production line. Small, sealed packs can be rejected by a simple air jet device, whereas open containers may require a sweep-off rejecter. The nature of the product will also affect the choice of conveyor mechanism. Granulate foods, such as salt, flour or sugar, overtime without precise cleaning, can cause corrosion damage to the conveyor system thereby producing friction to the moving parts. Selecting a checkweigher with a conveyor specifically designed to accommodate powdered products, featuring wide belts with minimal openings where grains could enter the machinery, will reduce the need for maintenance and ensure optimum weighing accuracy. What role does the checkweigher set up play and how can we ensure the system is set up properly? Ensuring the checkweigher is
set up correctly is critical to the success of the entire purchase. Proper calibration of your checkweigher to remove packs, that fall significantly above and below your product’s target weight, not only ensures you meet metrology regulation requirements, but also reduces wasteful product giveaway. In order to guarantee that the average weight of your product batch is within legal limits, your target weight should be slightly above that stated on your packaging label. Precision checkweighers will enable you to set tighter tolerances above and below your product’s target weight, allowing you to further reduce giveaway and minimise the risk of underweight products reaching consumers. You should also make sure your checkweigher has been fitted in accordance with the weights and measures legislation governing your target markets. For example, in the case of compliance with the European Union’s (EU) Measuring Instruments Directive (MID), your equipment supplier must engage an independent
metrology certification body to assess whether the machine conforms to weight regulations and tolerances. The original test products must be available onsite indefinitely for future testing and verification, the responsibility of which rests with you, the manufacturer. In addition, innovative data monitoring software should also be sourced to incorporate the checkweigher with the rest of the line’s product inspection equipment. This will enable you to identify consistent product over- or underfill and locate the source of the error. What is more, it can also alert your filling machines earlier in the production line to any adverse filling trends, allowing them to adjust portions to rectify the issue and reduce the future incidence of costly product giveaway. How important is operative training? A properly set up checkweigher with trained staff will help you to avoid weighing errors due to improper set up or even from physical damage. Every machine operative should receive
www.martupdate.com
47
basic training on the system software as well as appropriate care and maintenance of the machine and conveyor. An understanding of correct product set up and changeover procedures should be communicated to every operative, as well as that for false rejections or unexpected machine stoppages. Many checkweigher manufacturers offer support for food manufacturers to enable them to optimise checkweighing accuracy on their lines. MettlerToledo, for example, provides extensive training for machine operatives through its Product Inspection Training Course, helping them understand the capabilities of their checkweighing and other product inspection technologies and how to operate them effectively.
fied and rectified as quickly as possible. As part of your training regime, line operatives must be educated to pay attention to the system’s output so that any differences in weighing accuracy are spotted early. A regular vision inspection routine should also be put in place as part of this procedure. This will identify any problems and enable you to put the corrective action into effect as quickly as possible. Establishing a regular performance testing programme can help to guarantee accurate weighing. Atmospheric changes can affect weighing accuracy, so it is vital that the weigh cell’s sensitivity be regularly checked. This will safeguard against false rejects and help prevent overweight products from continuing on the production line.
Would you recommend setting up a monitoring protocol? Standardised procedures in the event of a weighing error Yes – periodic monitoring of should be implemented as well. the checkweighing system can Operatives should know what ensure that any issues that to do and be able to respond could affect weighing sensitiv- quickly, to minimise disruption ity and line efficiency are identi- to the production process.
What advice can you give regarding maintenance? If a component on your checkweigher begins to wear over time, early detection and rectification is paramount to boosting the uptime of your production line as a whole. It is vital that you undertake preventative action to replace worn components, such as conveyor belts, before they cause a malfunction. Much of this can be carried out by your operatives. Alternatively, you can take advantage of your supplier’s service technicians to ensure that maintenance is carried out correctly and that all components in need of work are identified. Some checkweigher suppliers offer a remote maintenance service, using secure cloud computing to continuously monitor system performance. This service can pinpoint potential causes for concern that may not be visible or obvious to operatives on site and in many cases correct them remotely, further reducing maintenance downtime
for you. In addition to maintenance, you should implement regular testing procedures of your checkweighing system to monitor performance. This includes scheduled service intervals with the technology supplier’s technicians testing the precision of your system’s weigh cells. Between these service intervals, you can also “self-test” by passing a packaged product of an established weight several times through the checkweigher to monitor the system’s performance. Today’s checkweighers feature easy-to-use Human Machine Interfaces (HMIs) to facilitate quick, straightforward recalibration of the weigh cells and rejection criteria, enabling you to correct many problems yourself. To demonstrate due diligence and compliance with legal metrology regulations, you should ensure that all testing and maintenance records are comprehensively logged as proof of good practice.
Remote Service Support
48
www.martupdate.com
June 2015
Total Solution in Precision Gauging
What other advice can you give? Ensuring the product is the correct weight is not just about complying with legislation, but safeguarding product quality as well. The reputation of your brand depends on the correct checkweigher specification for your production line, and on the maintenance and monitoring procedures you set in place after it is installed. As such, before making a purchasing decision, it is crucial to seek guidance from checkweighing experts. They will be able to offer support on system selection and set up, as well as training and maintenance. This advice will ensure your production line benefits from minimised downtime due to unscheduled repairs and reduced costly product giveaway, maximising efficiency and profits, allowing your brand to grow. Dirk Bettels has been working for Mettler-Toledo for over twenty years. In that time, he has been responsible for the company’s electronic developments and, for the past seven years, has held the position of Senior Product Manager for checkweighing and checkweighing combination machines, such as metal detection, x-ray, marking, vision and labelling devices. Due to his extensive experience in industrial automation, he is one of the driving forces behind Mettler-Toledo’s innovations. He introduced the first x-ray checkweighing combination machine to the market, as well as the inaugural serialisation stand-alone machines.
June 2015
More recently, he developed the XS2MV TE, 4 in 1 serialisation station, with marking, camera inspection, tamper evident sealing and checkweighing on a footprint of below 2m. Mettler-Toledo Garvens is the world’s leading supplier of checkweighing solutions for the food and pharmaceutical industries. Together with Safeline, CI-Vision and Pharmacontrol Electronic GmbH (PCE), Mettler-Toledo Garvens forms the Product Inspection Division of Mettler-Toledo. Mettler-Toledo develops, produces and sells precision instruments worldwide. The company is one of the largest suppliers of weighing systems in the world, whose high-quality products are used in laboratories as well as industrial and pharmaceuticalretailing applications. Renowned producers of all conceivable everyday products rely on MettlerToledo’s weighing technology as an important aid to product development. These producers reap the benefits of the global company’s innovative products and global presence. Mettler-Toledo’s corporate philosophy centres around quality and tailored solutions. The company forms a true partnership with its customers, working together to develop unique solutions, providing support during the selection of appropriate systems and offering a reliable service. For general information on Mettler-Toledo Product Inspection, visit: www.mt.com/pi.
www.martupdate.com
49
SUCCESS STORY
Creaform Extends its Presence in India Specialists in 3D Portable Measurement Technologies and 3D Engineering Services
The multidisciplinary Creaform team of experienced applications engineers and metrologists work very closely with their clients, both big and small, to get a clear understanding of their needs, and they come up with the most effective 3D measurement technologies and work methods. The Creaform Metrology Services division is fully committed to fulfill their customers’ needs and help them improve their process and maximize their investment.
Creaform develops, manufactures, and sells 3D portable measurement technologies and specializes in 3D engineering services. The company offers innovative solutions, such as 3D scanning, reverse engineering, quality control, non-destructive
50
www.martupdate.com
testing, product development, and numerical simulation (FEA/ CFD). Its products and services cater to a variety of industries, including automotive, aerospace, consumer products, heavy industries, healthcare, manufacturing, oil and gas, power generation, and
research and education.
Singapore.
With headquarters and manufacturing operations in Lévis, Québec, Creaform operates innovation centers in Lévis and Grenoble, France, and has offices in the United States, France, Germany, Brazil, China, Japan, India, Korea and
Creaform is a unit of AMETEK Ultra Precision Technologies, a division of AMETEK Inc., a leading global manufacturer of electronic instruments and electromechanical devices, with 2014 annual sales of $4.0 billion.
June 2015
Creaform took off in May 2002, in Canada. In February 2005, they opened in France, and in June 2005, they launched their First Handyscan 3D laser scanner. Gradually, they started opening their offices in different parts of the world including India. Over its 7-year presence in the Indian market, Creaform has supplied major Indian industrial and Government sectors with metrology solutions including Tata, JBM, Ashok Leyland, Daimler India, Hyundai Motor India Ltd, Royal Enfield, IIT, and DRDO etc. They are now completing their fourth year with direct offices in the country. With more than 10,000 metrology services projects to its credit, Creaform has earned a reputation for effectiveness, quality and professionalism. Their experts provide metrology services worldwide 24/7, with quick turnarounds and under strict quality standards. The multidisciplinary Creaform team of experienced applications engineers and metrologists work very closely with their clients, both big and small, to get a clear understanding of their needs, and they come up with the most effective 3D measurement technologies and work methods. As expert users of advanced portable 3D measurement technologies, they know that seamlessly integrating these tools into the business process is the key to success. The Creaform Metrology Services division is fully committed to fulfill their customers’
June 2015
“India offers tremendous opportunity” Carl Mercie Vice President Sales, APAC Creaform’s heightened presence in India is significant news for customers in the region. They can now gain access to an unprecedented level of services and training. Our significant investment in India make our technologies readily available to Indian manufacturers.
Please brief us about the journey of Creaform? Creaform is a world-class company founded in 2002 with offices around the globe. The Canada-based company is recognized as a leader in the development and manufacturing of innovative portable 3D measurement technologies. Its wide range of products and services are being used worldwide by more than 5000 clients from various industries such as automotive, aerospace, manufacturing, consumer products, research & education, NDT, heavy industries and power generation. What has been the Scenario of Creaform in India? Over its 7-year presence in the
Indian market, Creaform has supplied major Indian industrial and Government players with metrology solutions including Tata, JBM, Ashok Leyland, Daimler India, Hyundai Motor India Ltd, Royal Enfield, IIT, and DRDO, to name a few. We are now completing our fourth year with direct offices in the country. As a result of Creaform’s recent acquisition by the American company AMETEK, we now have three direct offices in Chennai, Pune and Delhi allowing us to better support ourclients. How do you plan to expand your business in India? Our direct sales and support team are in constant expansion. We are actively recruiting for two strategic sales and technical positions
to increase our capability and to keep up with the growing Indian market. Creaform’s heightened presence in India is significant news for customers in the region. They can now gain access to an unprecedented level of services and training. How well has the Indian market adapted to Creaform? India’s growing manufacturing market will give Creaform tremendous opportunities in the coming years. The increasing demand for cutting edge and world-class quality control metrology instruments has positioned Creaform at the fore front of preferred vendors worldwide. Our significant investment in India make our technologies readily available to Indian manufacturers.
www.martupdate.com
51
needs and help them improve their process and maximize their investment. Their knowledgeable productionoriented applications engineers integrate 3D measurement technology into the customers’ work process seamlessly and efficiently. • Integration of metrology and scanning technologies • Development of custom software and user interfaces • Development and implementation of integration strategies
• On-site counselling and integration process • Creation of application capabilities and specifications manual. Creaform’s expertise covers the following sectors among the others: • Aerospace • Power Generation • Automotive and Transportation • Heavy Industries / Oil and Gas
One of the recent developments for the company is its Joint Marketing Agreement with Stratasys, another market leader in 3D printing and 3D scanning. This new partnership empowers users to leverage cuttingedge 3D scanning technology and world-class 3D printing technology designed to streamline the process across various industries and applications. With a professional-grade solution, the user is able to accurately scan any 3D object and quickly generate print-ready files or even perform direct 3D-scan-
to-print. Moreover, Creaform has won the venerable Red Dot Award: Product Design for 2015, which benchmarks and recognizes the innovation efforts of forwardthinking companies in product development and design. In its 60th year, the Red Dot is the largest and one of the most influential independent product competitions in the world. For more details, write to creaform.india@ametek.com or visit Web: www.creaform3d.com
How to get highly accurate measurements on the shop floor Nowadays, measurement needs often sits on shop-floor—far from the comfort of expensive metrology labs— where qualified inspectors operate digital CMMs on stable granite tables. Operators of portable measurement solutions in production environments are faced with many issues such as vibrations, rigid parts set-ups, changes in temperatureas well as user experience. In addition to benefiting users from major cost savings, Creaform’s optical technology offers anefficient solution to the above challenges: Creaform’s TRU accuracy technology features dynamic referencing. It enables the measurement device to be continuously locked onto the part by an optical link. Tests in situ have demonstrated the advantage of dynamic referencing: where HandyPROBE has shown no notable lossof accuracy, the measuring arm has shown an increase in errors—by a factor of three.
52
www.martupdate.com
Operator-independent measurements
eliminate operator-induced errors.
Studies have clearly shownthat human error is a major factor in poor quality measurements. Dynamic referencing contributes to reducing such errors. When using the right tools, optical CMMs enable the positioning of targets on specific points regardless of skill levels in order to improvethe quality of the alignment and
Shop-floor optical metrology solutions ensurefaster reactivity to absorb increases in production, earlier drift detection, and faster identification of the cause of defect. This results in significant productivity gains without the need for costly equipment or a measurement lab.
June 2015
June 2015
www.martupdate.com
53
TALENT MANAGEMENT
First Step to Leadership
When do you need to start being a leader? The answer is simple: Sooner than you think! The practice of leadership is a continual process. You start leading as soon as someone starts following.
Pavan Sriram pavan@ittige.com
In an organisation, the very act of engaging someone else in your cause is a clear signal that you are now in a leadership role. This act of explaining, of making sense of things, is a core element of leadership. And while there are no easy solutions, your growth as a leader will be impacted by how you take your first steps. Many people think leaders are born, not made. They automatically associate leadership with heroic figures like politicians, celebrities, or great humanitarians - but the reality is that virtually every single person has the potential to be a leader. Leadership is simply a learned set of behaviours, and the
ability to lead is a skill that almost anyone can develop. People perform leadership actions every day at home, in the society and at work without even recognizing it. Warren Buffet once said, “The most dangerous myth is that leaders are born – that there is a genetic factor to leadership, that people have certain charismatic qualities or not. This isn’t true. Leaders are made rather than born.” While this perspective is a larger topic for future columns, the point here is that if you are afraid or unwilling to lead, some magical leader will not appear to do it for you. Even if you hire great team, your abilities will always be looked upon to lead. If you
don’t meet this challenge, you forfeit an enormous opportunity to help the organization stay connected to its roots. At ITTIGE Learning, having worked with scores of aspiring leaders, here is our suggestive list of five steps to successful leadership:1) Self-Awareness: The first step in becoming aneffective leader is recognizing your own value. The trinity of selfawareness is: know thyself, improve thyself, and complement thyself. Without self-awareness, you cannot understand your strengths and weakness and it is selfawareness that allows the best leaders to walk the tightrope of leadership: projecting
Why leadership should be forward thinking? 54
www.martupdate.com
June 2015
Leadership is all about developing the skills, values, attitudes and beliefs that help you do a better job of helping others accomplish shared goals. Leaders are made, not born
conviction while simultaneously remaining humble enough to be open to new ideas and opposing opinions. 2) Integrity: There is a theory of leadership known as “servant leadership.” I like the term “custodial leadership.” It means striving to be the best caretaker, the best guardian, and the best keeper and protector you can be for those you lead. Servant leaders, or custodial leaders, govern with integrity. It comes from intrinsic core values and a cognizant choice of service over self-interest. This essentially means, seek the best for others. Leaders with integrity ignore self-interest and personal gain, and reach out to do the best for those they lead. 3) Accountability: A willingness to be held accountableis the key factor every leader must have. Without a willingness to put them-selves in this position, any other method will be met with scepticism and cease to work. An accountable leader allows themselves to be exposed to criticism, checks and balances, and the full responsibility of their actions and intentions. 4) Sense of Humour: In leaders, humour
June 2015
and humility seem to go hand in hand. They’re like a counter balance for selfconfidence, something that keeps their feet on the ground and their egos in check. A leader should come across as someone who is ‘approachable’. A good sense of humour therefore plays a big role in ensuring that a leader is perceived as someone with whom employees and subordinates can share their concerns and discuss their problems. It not only allows free flow of ideas, suggestions and creative inputs within the team but also encourages employees to move beyond the hierarchical structure in the organization and openly share their thoughts within the team. Good sense of humor helps to ease out the nerves in today’s high pressure job environment and creates a happy work environment which is directly proportional to the productivity of their employees at work. 5) Understanding the Ecosystem: Every organization is a living ecosystem in which everything and everyone is connected, directly or indirectly. So everything that happens within that system has an impact. The closer to the source, the more directly the impact is felt. And just as every drop
of water is an integral part of the entire pond, everyone within the organization is an integral part of the entire organization. Hence leaders now need to think about and influence their business ecosystem. That means your job is about convening, connecting, encouraging, and enabling. It’s rarely about doing something by yourself. So leaders need to pay very close attention to their “responsibility pond”. Put simply, leadership is all about developing the skills, values, attitudes and beliefs that help you do a better job of helping others accomplish shared goals. There’s no denying the fact that being a leader is hard work, and it requires a lot of emotional and physical stamina. I look forward to hear from you at pavan@ittige.com on how you are helping your leaders take their first steps to leadership in your organisation and unleashing the enormous human potential to advance both their career and their life’s leadership opportunities. The author Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance based training company that works with c-level executives to improve learning outcomes.
www.martupdate.com
55
ASCENT
Collaboration Can Really Happen- Need is to Change the Mindset Industry-Academia interface has been always a topic of discussion and still there is no exact method clear to any of them to bridge the gap. While talking about the industry, there is a huge need for the proper manpower and be it from the large level manufacturers to small scale industries, they are not happy with the talent. On the other side, one-sixth of all Indian students are enrolled in engineering programmes every year. So, why is this mismatch?
Hiya Chakrabarti hiya@martinfotech.in
To go deep, our MART team has recently visited B.P.Poddar Institute of Technology, one of the premier institutions in Kolkata. While having a conversation with Mr. Pramathes Das, H.O.D. Electrical Engineering Department, we have found out that though this year their placement record reached 88%, most of the recruiters are from IT sector. According to Mr. Das, “We teach our students with all kind of reference to the latest technologies and updates from the industry. But when it comes to the scenario of placements,
companies from the core sector are coming very less and also, they take in less number. So, being compelled by the situation, we have to shift our focus to the IT majors.” Now when a student is becoming an engineering graduate spending a lot of money, surely he/she will look for a job opportunity and where the opportunity comes, he/she goes. According to him, “This year, by God’s grace, out of the 40 companies we have seen, 20 are from the core engineering sector.” To our surprise,
we often see a chemical engineering graduate learns Java script, and other coding languages to bag a job in IT, while on the contrary, industry is waiting for efficient manpower. When a student comes to study engineering, he/ she dreams to invent newer technologies suitable for the industry. Slowly, their inner drive loses its focus seeing the current unemployment scenario in the core sector. Here, we must address the issue with more prominence. If at the very beginning, we are killing the enthusiasm of an engineer, where from will
“Industry is going through a rough patch. But in our college, this year placement records 88% approximately. But, yes, core sector recruitment is really less.” Prof. Pramathes Das H.O.D. Electrical Engineering B.P.Poddar Institute of Management and Technology
56
www.martupdate.com
June 2015
Bi-cycle driven Mobile Charger, if implemented successfully, can solve a lot of problems in rural areas where there is no electricity
the manufacturing happen? Mr. Modi during his ‘Make in India’ speech, has announced different schemes for rural employment and approached every engineer from our country to become an entrepreneur. This needs a total shift in the mindset of the people. Most of our parents want their kid to become an engineer to bag high profile white collar jobs in the IT industry and to visit abroad. Then what will happen to this country? As Mr. Das has pointed out, “No matter how much we try to give practical classes to the students, until and unless they are going to the industry and learning with experience, they cannot excel in the core industries. Students have a tendency, nowa-days: to follow notebooks and from the 1st standard, they are following the same pattern. Notebooks can fetch you good result, but cannot give you the in depth knowledge that is needed in an engineer.” Collaboration between the industry and the academia can be seen from the perspective of a producer-consumer. Engineering colleges are producing engineers every year and the industry is consuming but the balance is improper. This relationship necessitates some collaboration as the consumer has to ensure that the output
June 2015
of the producer satisfies the needs to a large extent. In India, due to the lack of skilled man-power, this collaboration can reach the next step. Engineering education system is not in the best of shape and along with the Govt initiatives, private sector also has to focus on the upgrading the whole system and to facilitate the engineers with more practical learning and first-hand experience. B.P.Poddar Institute is continuously striving hard to help their students to reach a better platform in the field of engineering. They organise ‘Present around the World’ competition to inspire their students to come up with newer ideas and projects. According to Mr. Das, “Our students have reached till the national levels”. They also organize Tech Fest to showcase the talents of their students in the national and international level. Recently, Professor Das has come out with a new idea of bi-cycle driven mobile charger. In the rural areas, where the electricity has not reached yet, if to charge a mobile, one can easily use a bicycle to charge it. B.P.Poddar Institute has already received Rs.three lakhs from the AICTE for development of Entrepreneurship. Now, Mr. Das’s dream is that one day his innovation can help the industry as well.
Many engineering institutes are offering education at high-end and have the courseware and ability to provide training for the high-end manpower development. These can be areas interesting to the industry as well. Another basic field is the area of research. When an engineer wants to do research it is advisable to find out how much that specific industry in which his concern is interested to have a research. R&D departments can be a real help in the collaboration. Also, industry in India often looks for ‘consultants’ from the academic community to facilitate the problem solving part. But, often we see these consultants are of less experience from the industry perspective and therefore, common issues can be identified by joint research. Lastly, to conclude with Mr.Das’s comment, “Transparency and dedication is required in all fields in India. You can see the mismatch everywhere. How can India excel in performance with its global counterparts?” The focus that is needed is to change people’s mindset. We must have more projects encouraging entrepreneurship among the engineers and young graduates should inspire more young talents to become engineers in the core sectors. The output is only a matter of time.
www.martupdate.com
57
MANUFACTURING EXCELLENCE
Develop Customer oriented mindset in the Organization Managing a SME in India - Part 30
Customer is the centre point of business today more than ever before. So much being said and taught in various forums on customer delight, customer satisfaction and ways and means to make Customer return. There is a saying, ‘The whole purpose of business is to keep Customers happy. All other things are details’. As a continuation of last article, we will discuss on few more points to manage SME’s better in India.
P S Satish gotopssatish@gmail.com
I recently visited a wildlife sanctuary along with my family and stayed in a resort. Booking this hotel and feedback from others who stayed there earlier were not so encouraging but still we decided to stay in this resort because of its location and convenience of approach. During our stay, an employee of resort was taking care of our room service. I was really amazed with this boy’s customer orientation and the amount of care he took on us. In fact, I learnt from other co-visitors that customer orientation of room boys are excellent in this resort and is one of the reason why Customers are coming back in
58
www.martupdate.com
spite of many other drawbacks with respect to customer experience. One of the areas that Organizations need to focus on is how to make each and every employee orient all his actions towards the satisfaction of Customers. Customer is the centre point of business today more than ever before. So much being said and taught in various forums on customer delight, customer satisfaction and ways and means to make Customer return. There is a saying, ‘The whole purpose of business is to keep Customer happy. All other things are details’. This sentence shows importance of knowing Customers and to ensure that all
in the organization is oriented towards needs and wants of the Customers. The market place today is drifting from seller to Buyer. The Customer is now in charge. The Customer has choices and has access to good information to make those choices. Thanks to vast development of Internet, computerization and communication. With smartphone in everyone’s hand, Customer is becoming impatient to wait for anything. Smartphones use is expanding with lot of specific business applications. Unless Customers are delighted, there is no way to succeed in Business. To manage current time, there is a
change in management mindset required.Bureaucracies of last century or decades no longer cope with the speed and complexity of the marketplace where Customer wants and needs are changing very fast. We need to find ways to delight them and also develop customer oriented mind-set in every person working in the organization. We need to develop team delivering value to Customers, interact with them constantly and take feedback for improvements. The Customer instead of being kept in periphery should be in the centre of organization universe so that all in organization has a
June 2015
Customer Proximity Through Performance
Delivery
Customer Contact by Personnel Other Than Sales
Flexibility
Customer Orientation Behaviour with Customer
Customer Related Processes
Customer Proximity Through Interaction
Service Quality
Tranparency
Product Quality Openness to Feedback by Customer
The Two Phases of Customer Orientation
clear sight of Customer. With increased trend of customer centric goals the organization structure is tending towards horizontal. Vertical organizations with always directions from the top is difficult to grow and survive long. Customer orientation among employees can be a differentiating factor to stay above competitors. Unlike products/services, it is very difficult for the competitors to copy Customer orientation aspects and company need to do lot of efforts to bring in culture and spirit of customer orientation. A. Customer orientation There are two phases of Customer orientation a) Customer proximity
June 2015
through performance like product quality, service quality, customer related processes, flexibility, delivery etc.
but everyone in Organization is oriented towards Customer and gets into problem solving mode.
b) Customer proximity through interactions like openness to feedbacks/suggestions by Customer, transparency, behaviour with Customer, Customer contact by personnel other than sales & marketing etc.
TQM (Total Quality Management), one of the thought process towards business excellence insists that starting point of any action is whether it will satisfy or help Customer. In this, Customer is the central theme and every action is oriented towards Customer. Top management plays a key role in driving this thinking and is done by involving all employees.
One of the definitions of management is “The systematic pursuit of desired conditions by utilizing human capabilities in an effective way to manage dynamic, unpredictable conditions and to satisfy changed demand of Customers”. The focus and orientation towards customer changed needs are spelt out clearly here. The challenge would be that not only the management and marketing
See the words of Jim Womack on Customer orientation, “True Customer focus demands true flexibility to be able to solve Customer’s problems completely, when they want it how they want it and how they want it without wasting their time and without wasting their
time and without asking them to do more work”. Bringing this culture in the Organization is much more than having a Key account manager for Customer and using slogans on Customer focus and orientation. I came across one company recently where Customer focus and satisfaction is written as part of Quality policy but the CEO never bothered to give full attention to hear Customer’s problem during one of the recent visit of an important Customer. B. Leadership to develop Customer orientation Three dimensions that control Customer orientation in the organization are – o Leadership o Organizational Culture
www.martupdate.com
59
o Information
towards Customer.
Leadership
The Leader with high focus on employees & Customer and little on Performance cannot deliver results. He will not make employees accountable for the results. In this soft approach, Customer needs will get low priority.
The Leader plays an important role in building a mind-set of Customer orientation among Employees. He can demonstrate his behaviour in three dimensions – Customer orientation, Performance orientation and Employee orientation.Customer oriented Leader will have equal degree of focus on all of above three dimensions. Authoritative Customer oriented Leader focus is on Customer & performance and very less on employees. Though this works well, it is difficult to sustain in the long range. Care towards employees to take their inputs, ideas and making them part of decision process goes a long way in building culture of customer orientation. It is seen that motivated and happy employees with good empowerment have high focus
We see one more degree where some Leaders work like Bulldozer with high focus on Performance neglecting Customer and Employees. His focus would be on company results overlooking what Customer wants. This is dangerous for the Organization. Organization Culture Culture is the way the organization is doing something in a particular way over years. Customer orientation in the company is a culture that needs to be nurtured so that any new person joining will
In fo rm at io n
Le LEADERSHIP to develop CUSTOMER Orientation
Organizational Culture
60
www.martupdate.com
automatically starts following. I have seen companies where they want to change overnight by bringing a new aggressive Leader. This would be like replacing the Engine of an old Ambassador with high powered Ferrari Engine. You cannot make Ambassador Car a Ferrari race car just by changing Engine without looking at the changes and redesigning required in other parts of the Car. Information How quickly and frequently Information flows across the company among all levels? Is the flow only one way? How needs and wants of Customer percolated to everyone and each one knows what exactly he or she has to do to keep his next customer as well as end Customer satisfied? Suppose if there is any Customer complaint, is there a mechanism to make known immediately to all concerned to
act upon quickly? Collection of bunch of Data related to Customer satisfaction, response, complaints are not enough without analysis of the same to convert into a valuable Information upon which actions can be initiated. In the second part of this article, we will discuss on ways and means to develop oriented mind-set among employees of the Organization. Please send your inputs, remarks, opinions and suggestions to P.S.Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103, Mantri Paradise Apartments, Bannerghatta Road, Bangalore-560076. Email:gotopssatish@gmail. com;www.linkedin.com/ pub/satish-cp-pii/35/153/85b; www.satishps.com; Mob: 9845043202.
ad
ers hip
Three dimensions that control Customer orientation in the organization
June 2015
June 2015
www.martupdate.com
61
QUALITY
Deliver Superior Value for Success at Make In India
Make In India is here. It opens India to agile engineering companies from around the world. They serve through unique, innovate offerings. Get ready to compete!
Saravjit Singh saravjit.singh@gmail.com
Manufacturing accounts for 34% of China’s, 31% of South Korea’sand 15% of India’s GDP. Make In India, launched on 25thSeptember 2014, is a Government of India initiative to make India a manufacturing hub. Its aim is to cut red tape and accelerate setting up of world class engineering
ventures. The slogan can be expanded for better communication:“Make in India, supply in India and across the world.”
Meanwhile, by 2022 China will be losing 8 Crore jobs because of their rising labour costs. China is countering higher labour costs by shifting to robotics on a very large scale.
Expected results of Make In India by 2022: Manufacturing Jobs created: 100,000,000
www.makeinindia.com website is superb. It gives concise information about attractive
Manufacturing sector
▶
▶
What
▶
Customers
search engine that allows internet users to find relevant
Make In India is already attracting large multinationals. When they come, they will make superior, high quality, value for money products for global and Indian markets alike. India is getting ready
Value
▶
▶
▶
information quickly and easily www.martupdate.com
sectors and the windows available to quickly set up business in India.
Unique
Google is the world’s largest
62
contribution to GDP = 25%
Figure 1: Value Proposition of Google
June 2015
Value Proposition of Genentech “At Genentech, we use human genetic information to discover, develop, manufacture and commercialize medicines to treat patients with serious or life-threatening medical conditions”
Slogan of Genentech Making Medicines That Matter Note: A Slogan is not a Value Proposition Figure 2: Value Proposition of Genentech for accelerated growth. Indian companies must make strategic plans to sustain growth in a highly competitive environment. Learn from history. Recall the downfall of Standard, Premier Padmini and Ambassador Mark IV – these outdated products fared badly after Maruti Udyog set up shop in 1983. Another example. When LG and Samsung arrived, Indian manufacturers of white goods (consumer durables such as refrigerators, washing machines and air conditioners) rapidly lost market share to them. Recently, Samsung and LG are also dominating the emerging LED TV segments. Indian consumers have
Customer Value
Functionality
become choosy, having experienced quality products and services. Their loyalty cannot be taken for granted. Now they want to buy only world-class,innovative, reliable, lifestyle products. To participate in the Make In India opportunity, Indian companies must benchmark Samsung. Samsung enters a market by first defining a value propositions for particular target segments. Then it creates and delivers unique product offerings to the targeted customer. John Cusimano says, “We provide great customer service” or “We build quality products” are not value propositions. Such statements are general service factors used
by all companies.
to the target customer.
Marketing Experiments adds that a company risks “becoming lost in a sea of similar businesses” if it does not have a unique value proposition. Are Indian manufacturers listening?
4. Uniqueness of the product and the way it is delivered.
A value proposition is a statement of the unique benefits delivered by the product/service offering to the target customer. A value proposition has four basic components: 1. The product itself. Performing the basic function reliably is a must. 2. The target customer. 3. The value company provides
Price
Attributes that create value for retail customer are: Usability, aesthetics, safety, status, impact on the environment,
Image
Product & Service Attributes
Quality
The value proposition statement must identify at least one unique value. Miguel Prazeres explains this with examples of Google (Figure 1) and Genentech (Figure 2). Value has different components. These are shown in Figure 3. Customers in each target segment experience product value uniquely. What is unique for one segment may be a given, or even an undesirable, in another segment.
Time
Relationship
Convenience
Responsive
Figure 3: Components of Customer Perceived Value
June 2015
www.martupdate.com
63
mental satisfaction and so on. For organizational buyers, value creators are: Usability, quality, lower risk, money and time saving, and customization. Practically, customer estimate value by weighing benefits to costs. This is shown in Figure 4. As a part of Make In India, Sweden’s IKEA may make a big entry into India. It’s value proposition:“IKEA offers a wide range of well-designed, functional home furnishing products at prices so low that as many people as possible will be able to afford them.”
Today, HMSI dominates the scooter segment with a 55% market share. In May this year, Honda announced its intent to make India its largest two wheeler operation globally. HMSI is investing Rs,1,775 Crores in new plants and products. This will raise HMSI’s production capacity to 6.4 million units within two years.Their fourth plant, coming up in Gujarat in 2016, will be the world’s largest scooter manufacturing hub.
Are Indian home furniture majors - Godrej Interio, Usha Lexus Furniture, Zuari Furniture, and Durian - ready to take on IKEA?
Indian two-wheeler manufacturers will face the heat. Honda and Yamaha are expected to take full advantage of Make In India. After all, India is the largest growing two wheeler market in the world.
Another success story is Honda Motorcycle and Scooter India (HMSI). They entered India in 2001 with Activa Scooter. It became an instant hitas it delivered value for money.
In our quest for Make In India, what kind of world beating companies should Indian entrepreneurs create? Which is the best company to benchmark?
The unique supply chain and alliances of Apple Inc. gives an idea of what is possible these days. Apple is the richest company in the world, with a market capitalization of $749 Billion (03-June-2015). Apple’s financial results for quarter ended March 28, 2015 show recordrevenue of $58 billion and net profit of $13.6 billion for the quarter. Gross marginisreported at 40.8%. Sales outside USA accounted for 69% of revenue. Is Apple made in USA? Apple does most of its styling, concept creation, product design, software development, product management and marketing in USA. Thereafter, procuring components and assembling its products is outsourced, mostly to China. The country of origin and number of Apple suppliers are: China 349; Japan 139; USA 60; Taiwan 42; South Korea
32; Phillipines 24; Malaysis 21; Thailand 21; Singapore 17; Germany 13; Vietnam 11; Indonesia 6; Israel 6; France 5; Czech Republic 5; Belgium 3; Italy 3; Ireland 3; UK 3; Brazil 2; Costa Rica 2; Austria 2; Netherlands 2; Canada 1; Portugal 1; Spain 1; Morocco 1; Puerto Rico 1; Malta 1; Hungary 1. There is no Apple supplier in India. The new Apple iPhone 6 is being assembled in China by FOXCONN and PEGATRON, with volumes divided equally between the two. Together they employ 130,000 workers to assemble iPhone 6. It is reported that FOXCONN has also deployed 10,000 “Foxbot” robots to assemble iPhone 6. FOXCONN and PEGATRON are Taiwan based companies. However, most of their manufacturing operations are located in China. Overall FOXCONN employs 1,200,000 employees across the world. In China, 99% of its workforce is
Customer Perceived Value
Total Benefits
Total Costs
Product Value
Monetary Cost
Service Value
Time Cost
Relationship Value
Energy Cost
Image Value
Psychic Cost
Value
Benefits
Costs Figure 4: Customer Perceived Value
64
www.martupdate.com
June 2015
from mainland China.
chairman Terry Gou said.
Mr. Rassweilier, Senior
The company could spend
Director of Materials and
a “few billion dollars” on
Cost Benchmarking at
developing its facilities in India,
IHS technology, a global
said Gou.
information company, says that an iPhone 6, as made from parts procured worldwide and assembled in China is estimated to cost $190. IHS technology estimates that an iPhone 6 fully made in USA would cost $740,and probably retail at $2,000. Obviously, made in USA iPhone is not feasible. China’s suppliers for iPhone mainly make low cost, small value add components. High tech components are sourced from USA, South Korea, Japan and Taiwan. Some of these suppliers are: • LG Display, South Korea – Largest supplier of display panel
Gou is also reported to have said in his Guiyang interview, “A lot of our customers, especially Chinese customers, need us to manufacture ... in India, to make phones, tablets, TVs, as soon as possible.” Gou elaborated that FOXCONN is aiming to cooperate with local companies such as Micromax Informatics, which ranks second to Samsung Electronics as India’s smartphone maker. FOXCONNiscoping with rising expenses at its 25 manufacturing sites in China. So, we can expect that by 2020, India could also become a manufacturing hub for Apple
• Sony, Japan – Front and rear
products, at India’s FOXCONN
cameras
facilities.
• GT Advanced Technologies,
Indian companie swill need
USA – Sapphire crystal
large investments in R&D,
components
supply chain, new-age training
• TSMC, Taiwan– A8 Chips Make In India is gaining
and lean manufacturing facilities to succeed in the changing environment. Unless
momentum. Smartphone company XiaomiInc, announced plans in March, 2015, to begin manufacturing in India.
all the pieces fall into place,
On 26th May, 2015, Reuters reported from Guiyang, China: Taiwan’s Foxconn Technology Group, the world’s largest contract electronics manufacturer, is aiming to develop 10-12 facilities in India, including factories and data centres, by 2020, company
no short cuts.
June 2015
B/2, Alaukik Flats, Nr. Dwarkesh Tower, Judges Bunglow Road, Bodakdev, Ahmedabad - 380015 Mob: 99251 11749 Telefax: +91 79 26870311 Email: sales@kwedos.com kwedos@vsnl.net, mail@kwedosbeltdrives.in Web: www.kwedospulleys.com
Indian companies will struggle – and even stumble – when striving to provide superior value to customers. MADE IN INDIA is demanding. There are
The author Saravjit Singh is Principal Consultant (Automotive and Farm Equipment Verticals) with Pushkarna Consultants. You can seek his advice on Make In India at http://saravjit-singh.strikingly.com
www.martupdate.com
65
CUSTOMER VALUE
When Zero Defects are the Norms, Why Not Zero Customer Complaints?
There was a time that there was no such phrase like ‘zero defects’. It was accepted that some defects would always remain. But management Gurus convinced management that zero defects were possible and also created competitive advantage.
Gautam Mahajan mahajan@customervaluefoundation.com
Today, it is accepted that customer service is necessary, and good customer service creates competitive advantage. Unfortunately, customer service efficiency is measured by customer satisfaction that measure transactions and not embedded feelings over
a period of time, measured by customer value. Another measure is complaints per thousand interactions. Many companies are happy to have 10 or less complaints per thousand, or 1%. Some company’s achieve 0.1% complaints. And they rest on their laurels.
Whenever a complaint gets escalated upwards to management, the general thought is to solve the complaint (and not always to the customer’s satisfaction). No one thinks about systemic means to change processes and set procedures.
Much of this happens, because the job of the managers is to solve the problem. They do not, or are not asked to reach zero customer complaints. If they were to look at the problem from this view point, not only would the problem be solved, but also in future the
Embrace the concept of zero customer complaints and work on reducing problems for customers
66
www.martupdate.com
June 2015
complaint or customer problem should not happen. Let me give you an example from some of the most admired and large Indian companies. I just bought overseas travel insurance on the net. Unfortunately, I had to extend the length of stay and consequently the number of days of insurance. The insurance was due to start a month from this time. I got on the phone, and found one number did not exist. The other one was difficult to get and when I would get on, and was made to answer many questions and listen to many unnecessary “ads�, I would
June 2015
be put on hold for the next available agent. And then I would get disconnected. I had to go through a few iterations before I got to talk to an agent. No, the policy could not be extended (he did not know how). The best would be for me to cancel the policy and get a new one for a longer time period. So I requested cancellation. The agent could not tell me when I would get my refund. Almost 20 days later, I managed (through influence) to get the number of a senior executive. He was very apologetic. A few days later, I still did not have refund. So I sent an email again. This time an executive working for the company called me because his
boss had asked him to help me get a refund. I had to fill a form for a refund. I told him I had not filled any form for getting the policy, and why now, and why the call centre had not told me about the form. To cut a long story short, he said he would arrange for a refund. The executives would never go back and get the problems corrected using software, processes and procedures so that others would not have a problem, which would lead to zero customer complaints. I urge companies to embrace the concept of zero customer complaints and work on reducing problems for customers. What a different
customer experience zero customer complaints would be! The author Gautam Mahajan is an internationally acclaimed expert in strategy, general management (including Customer Value) and globalization. He is President of Customer Value Foundation and Inter-Link an International Consulting Firm in operation since 1987, working with clients from America, Europe, Asia, Australia and India. Gautam is also the Founder Editor of the Journal of Creating Value, an international journal focused on Customer and Value Creation (see jcv.sagepub.com). He has also taught at IITs in India and abroad.
www.martupdate.com
67
LEADERSHIP
The Informality Principle in Leadership Developing an informal persona as a business leader allows for openness and honesty to emerge through dialogue, essential aspects of any environment which hopes to increase the flow of information and communication. Emphasis is placed on the modus vivendi of the management’s interactions, that is, the practical compromises which must be made in order to fully comprehend problems, opportunities and the key decision-making duties senior staff are tasked with carrying-out.
Dr Kevin Sludds drkevinsludds@gmail.com
Background C-suite executives are all too often surrounded by yes men, people who believe that by simply being the senior people their intuitions, ideas and strategies must be best or, at least, must be considered the best. At ECTi we have developed a training programme around what we call The Informality Principle in Leadership, a potent means of tapping into the selfreflective power of humility which senior staff can utilise in order to gain access to all relevant information and make truly informed and balanced decisions. For this principle to be made
68
www.martupdate.com
manifest in behaviour means executives must engage in a dialogue with staff at all levels. The word dialogue literally means a welcoming of difference, so that, where there is uncertainty about how one should proceed a clear view of all issues can be discerned. The underlying virtue of informality is that it allows decision-makers to explore contrary perspectives, new understandings and tap un-mined experiential knowledge. When managers encourage their people to see them as colleagues who they can work with rather than for, they create a freedom for each individual to play a constructive role as soundingboard for the other. As a result, challenges and opportunities are
seen in-the-round and a more effective response to decisionmaking can unfold. “Leadership isn’t something you do writing memos. You’ve got to appeal to people’s emotion. They’ve got to buy in with their hearts and bellies, not just their minds” Lou Gerstner (fmr. CEO IBM). A Changing Emphasis among Business Leaders Recently executive search firm Russell Reynolds analysed 4,000 executive assessments in their database and determined nine differentiating attributes for those who become CEOs as compared to those who did not. The CEO differentiators
were: Calculated Risk Taking; Bias towards Action; Efficient Reader of People; Optimistic; Measured Emotion; Pragmatically Inclusive; Constructively Tough Minded; Forward Thinking; Willingness to Trust. Within a traditional topdown management structure employees are routinely assigned roles without their input (i.e. without dialogue) and are often discouraged from querying choices or offering opinions. Accordingly, in relation to ethical matters in particular, little scope exists for red-
June 2015
flagging to occur. This is most important for companies who wish to ensure their ethical, whistle-blowing and CSR policies are seen to be more than window-dressing. The fundamental values which underscore this type of structure are adherence to instructions and obedience. In the usual course of events leaders within business are not accountable to their juniors and ethical concerns are often left to the judgement of individuals or small groups. Consequently, if key protected disclosure information is missed a vacuum is created which is frequently filled by inappropriate or illegal behaviour. In concrete terms, little can be learnt through management training if it occurs within the shadow of such a hierarchical structure, as information will constantly be stifled from flowing upwards.
June 2015
Having interviewed over 1,700 CEOs for their Leading through Connections survey in 2012, IBM identified that CEOs from 64 countries and 18 industries believed the top orgainsational attributes in drawing out the best from their workforce were; Ethics and Values (65%), Collaborative Environment (63%) and Purpose and Mission (58%). The study further found that, “CEOs differentiate their organisations through ‘new and deeper connections,’ driving outperformance by empowering employees through values, engaging customers as individuals, and amplifying innovation with partnerships.” Many businesses over the years have been misled by the belief that if they work strictly within directives there is no need to reflect further on ethical or social responsibility matters. Unfortunately, when one is faced with reputational
challenges, legal ordinates and guidelines prove to be of little pragmatic assistance. Managing responsibility through regulation forms a corporate mentality whereby rules and red tape inevitably multiply and, over time, replace leadership responsibility for deciding what is right. This situation is exacerbated by the fact that decision-making is considered simplistically one-dimensional, that is, either one abides or does not abide by the law. It should be remembered that no matter how many controls we create we will never reach a point where every possible unethical scenario can be imagined. Nevertheless, and despite the very many corporate and political scandals that have occurred globally since 2000, governments around the world have reacted to these very
scandals by enacting more and more laws rather, than, addressing the underlining working cultures which produce such behaviour in the first place. “The more corrupt the State, the more numerous the laws” Tacitus. Leadership as a Modus Vivendi (Practical Compromise) To offset the danger of isolation created by a yes men atmosphere, successful leaders foster a cohesive climate in which employees feel invited to participate. In other words, the correct emotional tone of collaboration is set. To that end, such progressive leaders strive to have around them a management team capable of improving corporate culture. The outcome of such an engagement policy is fourfold: •Heightened employee morale
www.martupdate.com
69
•Greater levels of trust •Enhanced transparency •A capacity to promote specific ways of doing business as distinguishing features from competitors Developing an informal persona as a business leader allows for openness and honesty to emerge through dialogue, essential aspects of any environment which hopes to increase the flow of information and communication. Emphasis is placed on the modus vivendi of the management’s interactions, that is, the practical compromises which
must be made in order to fully comprehend problems, opportunities and the key decision-making duties senior staff are tasked with carrying-out.
engaged value) and through example instilling an attitude of free exchange of ideas, knowledge and opinion within employees.
Informality as a guiding principle has for too long been underestimated, “The story of GE that hasn’t been told is the value of an informal place. I don’t think people have ever figured out that being informal is a big deal” Jack Welch. Creating a pro-active and positive atmosphere of informality within an organisation means breaking the chain of command from topdown. Executives must learn to communicate across all layers of their organisations by treating others with overt respect (a vital
“If I only had a little humility, I’d be perfect,” Ted Turner. ECTi’s Informality Principle in Leadership allows Executives to: •See business challenges and opportunities in-the-round •Tap into their staffs’ full potential not merely as they know them through a workmask •Increase levels of dialogue – a welcoming of open exchange
to embrace distinct viewpoints •Heighten listening skills - develops awareness of sensitive social and ethical scenarios which directly affect crucial non-financial assets such as goodwill and reputation •Builds rapport with key personnel, enhances teamwork, boosts morale and generates trust The author Dr Kevin Sludds is Head of Dept. General Studies, Baze University, Abuja, Nigeria and MD of ectiethics.com. He has worked in India, Africa and Europe and is respected globally for his innovative and engaging training on ethics and CSR.
A capacity to promote specific ways of doing business as distinguishing features from competitors
Greater Levels of Trust
Enhanced Transparency
Heightened Employee Morale
70
www.martupdate.com
June 2015
June 2015
Innovative Automation Products
B/24, MIDC Satara 415004 India
+91 2162 246509 +91 2162 245966 sales@innovativedro.com www.martupdate.com 71
CORPORATE MART
Quality Leaves a Lasting Impression Globally and Locally
HELLER 2014: positive trend continues
As expected, 2014 was a year of two very different halves. Development during the first six months was below average. The pickup noted in the second half of the year exceeded our forecasts in terms of both business volume and results. The 2014 order intake is also above plan with a correspondingly positive impact on the current financial year.
Order intake: strong increase The increase in order intake noted by the German machine tool industry continued throughout 2014. On an annual basis, this resulted in 4% growth. In 2014, HELLER recorded a 35% increase in orders received to a total volume of EUR 558.1m,
72
www.martupdate.com
resulting in the second highest order inflow in the history of the HELLER Group. In particular, project business with automotive customers contributed to growth with an increase of approx. 60% on the previous year, so that we were able to exceed our forecasts for 2014.
Origin of orders: Germany and the rest of Europe as main drivers The most substantial changes in the geographical distribution of order intake in 2014 were noted in overseas markets. Germany continues to hold the lion share, followed by the rest of Europe with 69%
(previous year 66%) due to strong domestic automotive project business. At 23%, North and South America are above the previous year (15%). Here again, project business developed above average. Due to the development in China, Asia’s growth has slowed down significantly to 8% compared to
June 2015
HELLER Heavy Machine Shop
HELLER Heavy Machine Shop
the previous year (19%). Turnover: strong second half-year At EUR 434.4m, the turnover achieved by HELLER in 2014 was approx. EUR 98.3m below that of the previous year. As expected, development of sales split the year 2014 into two distinct halves. Due to the fact that order intake picked up strongly in the second half of 2013, and considering the usual lead times until revenue recognition, especially in project business, we had already anticipated that the weaker first six months of 2014 would be followed by a significantly stronger second half of the year. As a result, 62% of group sales were realised during the second six months of the year. Capital resources: overall above average Increase in inventories and capitalised services included, the total operating revenue amounted to EUR 462.5m, which is above average
June 2015
in multi-year comparison. The result from ordinary business activities significantly decreased year-on-year due to the heterogeneous business development throughout the year. However, the strong second half-year was not able to fully offset the shortfall in the first six months. The group’s equity capital increased to EUR 108.8m, resulting in a strong equity ratio of 34.5% by the end of the year. Investments and developments: at the previous year’s level The total investment volume in 2014 reached EUR 8.1m. The majority of this was invested in machinery, plant, operating and business equipment. New product development and product refinement as well as the enhancement of our machine series remained focal points in 2014. With a total of EUR 13.5m, expenditure in this area was approximately at the previous year’s level. Product range: comprehensive development programme
contributes to success In 2014, the focus remained on the expansion and modernisation of our product range, enabling us to better serve our existing customers and to expand business into new target customer groups and industries, attracted by the traditional strengths of HELLER such as productivity, reliability and availability. At the same time, we continued working on the expansion and intensification of our regional business. Our current product spectrum of 4-axis and 5-axis machining centres and mill/turning centres enables machining of components of up to 10t in weight and 1,800mm in height at high productivity and process dependability. The newly added large machining centres are ideally suited for the machining of large pumps and housings for power generating and continuousflow machinery. Other areas of application are general mechanical engineering, the oil and gas industry or aerospace.
HELLER CBC: HELLER and Daimler receive R&D 100 Award In terms of its turnkey competence in crankcase manufacturing systems, HELLER for some time has been offering systems for the coating of cylinder bores on the basis of a twin-wire arc spraying technology. The process named HELLER CBC (CylinderBoreCoating) is a new addition to the crankcase manufacturing process chain. This process technology helped us to gain numerous manufacturing projects again in 2014 in different countries, including Germany, France and Japan. In November 2014, the coating process received an award from US trade journal R&D Magazine, naming it one of the 100 most important high-tech products. For this technology, HELLER and Daimler also received the R&D 100 Award, also known as the Oscar of Invention. HELLER 2015: excellent
www.martupdate.com
73
prospects Based on the current order situation and expected utilisation, 2015 is expected to develop significantly better than 2014. There will be a substantial increase in turnover and we also expect a far more homogeneous utilisation throughout the course of the year and a noticeably improved profit situation. Recovering markets Provided that escalation of the crises in the known troubled regions can be prevented, we expect a very positive development in the coming years. Asia was, is and remains one of the great hopes for the future, although the Chinese
market shows slight signs of consolidation. In South America, especially Brazil, the economic climate remains fragile and characterised by a significant investment backlog, which, however, is expected to clear in the medium term. Europe, too, seems to be stabilising. The current favourable economic climate in the US is expected to persist. As far as the general business situation in our industry is concerned we agree with the leading industry associations, predicting a positive development based on the current order situation. Domestic machine tool production is expected to see another slight increase, thus reaching a new record level.
Consistent further development in all areas We will be starting the year 2015 with an order backlog exceeding the previous year’s level by approximately 50%. We also expect further lucrative contracts from project business, single machine sales and service business and anticipate a satisfactory business performance throughout 2015. The effects resulting from ongoing improvement projects will also be contributing to this development. HELLER’s most important asset in this context remains the valuecreation network of the group companies, enabling the HELLER Group to respond
flexibly to fluctuations in business volumes of individual business areas or regions. We also expect added impetus from R&D, currently in the process of developing new machine types and optimising the cost of the current product range. Furthermore, systematic personnel development programmes are being implemented throughout the entire group. In our submarkets in Europe, South America and Asia we will promote both project business and single-machine sales. For this purpose, suitable sales and service capacities have been established in target markets. Our current product range also enables us to address a growing number of customers
HELLER Shop Floor
Heller5 Axis Mill Turning
74
www.martupdate.com
June 2015
HELLER Cbc Process
HELLER 5-Axis Machining
from outside the automotive industry in the regions mentioned.
we will create up to 160 new jobs, most of them at our parent company.
Additionally, we are further expanding our now sizeable service and spare parts business in a targeted manner. This includes strategic further development of traditional markets and targeting new business in underrepresented markets.
Our aim is to set down a marker for our headquarters in Nürtingen by increasing staff levels to offset future losses due to retirement, building up capacities in production and assembly and developing expertise in 5-axis business.
All in all, we believe that the HELLER Group is wellpositioned in terms of markets and products with a good earnings situation at the moment and therefore expect a gratifying development of business throughout 2015. HELLER employees: workforce expansion, also at Nürtingen headquarters Since 2011, there have been 180 new additions to the workforce of the HELLER Group. In 2015,
June 2015
Independent of the location, the high quality of the HELLER products and services is backed by dedicated and qualified staff everywhere. That is why we remain committed to not only maintain the high quality level but to globally promote and enhance it through special measures and qualification programmes. Mastering this challenge is one of the most important tasks of the HELLER organisation as a whole, also for the current business year 2015. Training and personnel development at HELLER are
key to tomorrow’s success. That is why the company is proud that, throughout the world, the name HELLER has for a long time been synonymous with excellent products and services as well as outstanding, renowned and sophisticated vocational education and advanced training – at all production locations. HELLER quality: prerequisite for customer satisfaction Today, HELLER counts among the leading suppliers worldwide in the most important markets of metalcutting manufacturing – with complete solutions comprising state-of-the-art machine tools and manufacturing systems, intelligent applications and comprehensive service solutions. We believe this to be a fundamental requirement to be perceived as an important partner in the global market by
our customers. HELLER global footprint: quality anytime, anywhere, in any area We are committed to delivering the same high level of service to our customers anywhere in the world, meeting the same high quality standards and enabling them to be optimally prepared for changes in the market or in manufacturing requirements and to operate their core business successfully. To achieve this, we have implemented a convincing concept: globally consistent quality assurance for all products and in all areas – from the machine and application through to our service network. This principle of a consistent global orientation and a strong regional presence is what we refer to as HELLER Global Footprint. HELLER Lifetime Productivity:
www.martupdate.com
75
quality to last a lifetime Investing in a machining centre means investing in the future: increasingly smaller batch sizes, shorter delivery times and growing complexity of components require continual optimisation and streamlining of the manufacturing process. Today, there is a growing trend towards complete machining on a single machine. Machines for complete machining allow to reduce loading times, part handling times, measuring requirements, cycle times etc. and, as a rule, increase the achievable accuracies. The possibility of complete machining is supported by multitasking, i.e. the intelligent combination of a standard
machine with process and control expertise. To achieve this, HELLER is offering Lifetime Productivity: our machining centres not only meet current requirements. They also provide the capability to be used efficiently and productively throughout their entire life cycle. By adding specific technology and process know-how, a standard machining centre can be transformed into an effective asset for efficient complete machining. To achieve Lifetime Productivity we have built up comprehensive expertise in application engineering. Often, consistently implemented complete machining requires
the use of manufacturing technologies atypical for machining centres. This includes complementary technologies such as turning, grinding, shaping, honing or the machining of gears. As an integrated solutions provider we are integrating numerous additional technologies into the core process of milling, creating future-oriented solutions implemented on standard HELLER machining centres for processes otherwise requiring specialpurpose machines or complex manufacturing systems. To achieve this, we use a smart mix of technologies: the goal is not to upgrade a machine with the maximum range of functions. The key is to
configure it in a way to provide the right combination of machining processes tailored to the customer’s range of workpieces, keeping the effort involved within adequate and reasonable limits. Lifetime Productivity also requires a fair partner, able to provide transparent and clearly structured services for adapting existing machinery to the new technological challenges whilst ensuring maximum availability. HELLER machines and the services provided by HELLER Services go hand-in-hand. A global presence, rapid response times and qualified customer care from HELLER Services help to ensure maximum machine availability over many years.
HELLER Founded in
:
1894 in Nürtingen
Workforce 2014
:
2,470
Order intake 2014
:
EUR 558m
Turnover 2014
:
EUR 434m
Chairman of the Board
:
Berndt Heller
Managing Directors
:
Manfred Maier, Klaus Winkler
Fields of business
:
Horizontal machining centres, 5-axis machining centres, mill/turning centres, flexible
manufacturing systems, crankshaft and camshaft machines, CBC systems, services
Production locations
Germany (Nürtingen), United Kingdom (Redditch), USA (Troy/Michigan),
:
Brazil (Sorocaba), China (Changzhou)
Sales/Service locations
:
EUROPE, Germany (Hattingen, Salem, Goslar, Saarbrücken, Nürnberg, Nürtingen), Italy
(Verona), France (Paris), Poland (Posen), Spain (Barcelona, Santander),
Sweden (Värnamo), Switzerland (Niederbüren), Slovakia (Vráble)Russia (Yekaterinburg)
NORTH/SOUTH AMERICA, Mexico (Querétaro), Brazil (Belo Horizonte, Gravataí, Joinville)
ASIA, China (Beijing, Chongqing, Shanghai)India (Pune), Thailand (Bangkok), Singapore
76
www.martupdate.com
June 2015
June 2015
www.martupdate.com
77
CASE STUDY
3T uses FLIR camera to detect temperature differences on PCB components The design of a Printed Circuit Board (PCB) can be very complex. Dutch embedded electronics specialist 3T sometimes develops PCBs that have over 2,000 different components. But what if something is wrong with one of those components? How can you see tiny faults in PCB components of less than a millimeter that might be the cause for a bigger PCB failure? Very often, thermal imaging will be the answer. 3T has been using thermal imaging cameras for many years throughout its different activities to detect hot spots of less than 125 microns.
3T is a leading Dutch developer of electronics and embedded systems. With an all-round team of approximately 50 employees, 3T is one of the larger providers in the Netherlands. The company has offices in Enschede and Eindhoven and has been active for 25 years in a number of demanding market segments, including machinery, professional equipment, instrumentation for measurement and testing, communications systems, innovative consumer products, and medical products. “We are using thermal imaging cameras throughout our entire process,” says
78
www.martupdate.com
Ronald van der Meer, hardware engineer at 3T. “When something goes wrong in a PCB, be it improper soldering of a circuit or a failing component, the PCB will heat up. Therefore, thermal imaging is a very good way to diagnose PCB boards in an early stage of a problem. We use it in the design phase of a PCB, to test it before it is supplied to the customer or in the qualification stage.” Benefits of thermal imaging for microelectronics 3T recently opted for the FLIR T420 bench test thermal imaging camera with 50μm close-up lens. “This close-up lens was absolutely necessary, because without it the focus distance was too
big,” says Ronald van der Meer. “We are dealing with microelectronics here at 3T. The mass of the PCB components that we need to research is so little, and possible temperature changes are so small, that we really need that detail.” The alternative for thermal imaging in the field of PCB electronics is the use of thermocouples, a temperaturemeasuring device consisting of two wire legs that contact each other at one or more spots. “Although thermocouple measurements are still required by certain regulatory bodies, the problem with thermocouples for measuring micro-electronics is that these devices can actually disturb the measurement,
June 2015
The PCB inductor is clearly visible in the thermal image through the PCB’s epoxy layer
because they need to make contact with the tiny components on the PCB board,” says Ronald van der Meer. “Thermal imaging on the other hand is a non-contact technology, so you don’t have that problem.” FLIR T420 bench test thermal imaging camera 3T has been convinced of the power of thermal imaging for many years. And now that prices of thermal imaging cameras are dropping, thanks to high unit shipment, owning a thermal imaging camera becomes even more attractive for research and electronics design companies. The FLIR T420 is a high-performance, yet affordable thermal imaging camera. It combines excellent ergonomics with high image quality of 320 x 240 pixels. The FLIR T400-Series come with a tiltable optical unit which makes it possible to measure and take images of objects in all angles, still
A heated PCB trace PCB resistors are sometimes laser trimmed in orderto achieve a certain value. This thermal image shows hotspots near the resistor as a consequence of this trimming process. in a comfortable working position. “The T420 camera is very robust and easy to carry,” says Ronald van der Meer. “That is very convenient, because we sometimes use our camera on the customer site. Especially with the close-up lens, the image detail is very good, so this allows us to see the smallest faults. PCB boards are also usually multi-layered. Sometimes, due to a production error, the different layers come apart. These delaminations then form small air bubbles, which can be discovered, as the FLIR thermal imaging camera picks up small temperature differences located around these bubbles.” FLIR software for R&D applications For 3T, FLIR’s ResearchIR software for R&D applications was an essential part of the thermal imaging package. ResearchIR allows researchers to make high speed recordings and perform advanced thermal pattern analysis.
“Sometimes, we need to capture the precise response of a one-time thermal event,” says Ronald van der Meer. “This would be difficult to capture in one still image. That is why the ability to make high-speed video images is critical for us. Recording a certain event helps us to reconstruct and analyze the problem more accurately. We also import our video images obtained with ReserachIR into MATLAB, a software package for data visualization, and programming that we use.” ResearchIR allows 3T engineers to better analyze PCB hot spots and find thermal peaks. The software gives users complete colorization control, so they can change the color palette, color distribution, contrast and isotherms, zooming and panning. For further details visit www.flir.com
The FLIR ResearchIR software allows researchers to make high speed recordings and perform advanced thermal pattern analysis.
June 2015
www.martupdate.com
79
FAIR MART
The 6th IMTOS: All Set to Generate a Record Breaking Success IMTOS 2015 will follow the international counterparts and would establish the brand all over the world by ensuring maximum participation from international companies. Several international and local industrial giants will rub their shoulders against each other in the four-day mega event. Several national and international companies have already confirmed their participation.
India Machine Tools Show 2015 is the 6th of the biannually organized Industrial machinery, machine tools, automation exhibition with MHWE 2015 (Material Handling World Expo 2015) and INDIA Tools 2015 as concurrent exhibitions. Some of the leading companies from around the world and India have already secured their participation. Based on the feedback received from
leading participants of IMTOS exhibitions:
•International venue Delhi, Pragati Maidan
•India being a large country, exposure in north is required
With a huge demand base emerging as a result of the foreseen growth in the CG sector, the quantum of industrial output is estimated to be much heavier than the augmented. And hence, the 4th India Machine Tools Show, IMTOS 2011 in New Delhi is slated to be the best business platform, this time around.
•Huge buyers of machine tools, automation, and material handling equipment in north •More than 40,000 visitors of IMTOS ensure good penetration and exposure to north India.
IMTOS 2015 will cover entire India including the states of Haryana, Punjab, Uttar Pradesh, Himachal Pradesh, Rajasthan and Jammu & Kashmir. IMTOS 2015 will follow the international counterparts and would establish the brand all over the world by ensuring maximum participation from international companies. Several international and local industrial giants will rub their shoulders against
More than 40,000 visitors of IMTOS ensure good penetration and exposure to north India
80
www.martupdate.com
June 2015
“We are confident that IMTOS is all set to repeat the success story at the four day event which will showcase the latest trends and technologies available in the world machine tool market. Manufacturers, Suppliers of machine tools, machinery and services would come together and make it an exposition where besides business, transfer of knowhow will also take place.” Kamlesh Gohil Managing Director, K and D Communication Limited
each other in the four-day mega event. Several national and international companies have already confirmed their participation. IMTOS 2015 Exhibitors profile includes Machine Tools, Heavy Machinery, CNC Machines & SPMs, Sheet Metal Working Machineries of all categories, Small Light Workshop Machineries, Hydraulic Press, Press Brake, Shearing Machines, Cutting Tools, Hand Tools, Power Tools, Industrial Pumps and Valves, Hydraulics and Pneumatics, Air Compressors, Electrical, Electronics & Industrial Automation, Instrumentation, Industrial Robotics, Wires And Cables, Testing and Measuring Instruments, Energy Conservation Products, Gears, Motors &Drives, Newly Launched and Specialized Industrial Products, Welding and Welding Consumables & many more. IMTOS is already making news through electronic
June 2015
media. The good news is that already participated by some of the leaders of the industry, exhibition is expected to accommodate as many as many national and international companies in an area of 14000 sq meters. International visitors from countries like USA, Germany, Korea, New Zealand, Taiwan China, UAE, Cyprus, Kenya, Ghana etc., will be on their maiden visit to the exhibition. With last 5 editions of IMTOS exhibitions generating over 2000 crores worth business for the participants, 6th IMTOS is all set to cross all boundaries and generate a record breaking success. K and D’s journey is driven by values; those which have led them this far and which will lead them further ahead. At K and D, they practice ethical value-based conduct in business. K and D is actively involved in organizing national and international level trade fairs and exhibitions for a
diverse industry spectrum. It is also one of the most reputed names in India. K and D has been known for connecting the dots together, dots that mean dreams values, success, growth and future. With a humble beginning in 1997, with just a few companies and a strong desire to be the best in the business, today K and D Communication has earned its name as India’s leading exhibition organizer with a tremendous success story. Through committed endeavor and a no-compromise attitude to quality, K and D Communication Limited is on a drive to expand the scope of exhibitions-to expand to truly global platforms. K and D offers an ideal launch pad for new ideas, products and services, conducive platforms for forging joint ventures and collaborations and open marketplaces to source ideal solutions. In sum, K and D Communication is
opening the doorway to the global marketplace. Through its worldwide networking, pre-emptive planning and execution, intelligent space management and meticulous control of macro and micro level logistics, the group ensures that every participant gains from such platforms. The extraordinary care that foes into every aspect of the event and the gains that participating companies have garnered in real terms, have made K and D Communication a permanent name in corporate calendars of hundreds of companies across India and abroad. K and D Communication has taken an initiative to build India’s largest, technologically superior, ultra-modern and state-of-the-art exhibition center. The Exhibition centre in Gandhinagar, Gujarat will have 1,25,000 sq mtr of exhibition & convention area for hosting large scale exhibitions and trade shows.
www.martupdate.com
81
FEATURE ARTICLE
FastMig X: The New Standard of Professional Excellence
KEMPPI assembled the perfect setup in FastMigX, flexible enough to adapt to the fast-changing needs, and capable enough to handle demanding materials like aluminium and special alloys.
KEMPPI provides Superior Productivity, Limitless Flexibility, Phenomenal Quality and Outstanding Durability. They offer high-quality MIG/MAG pulse welding for robust workshop use, high-quality pipe welding, plate and root welding from one side without backing for pipe welding, high strength steel, special alloys and aluminium welding for demanding welding applica-
82
www.martupdate.com
tions. They even offer 40% lower shielding gas costs at multi-material workshops, for example in the offshore industry or in aluminium ship and boat building, where they need high-quality welding for various demanding tasks. They assembled the perfect setup, flexible enough to adapt to the fast-changing needs, and capable enough to handle demanding materials like
aluminium and special alloys. See welding is at its finest with KEMPPI. FastMigX welds with 25% lower heat input. Robust workshops, for example in heavy machinery manufacturing and rolling stock manufacturing, need reliable MIG/MAG welding for various plate thicknesses. KEMPPI assembled the perfect setup
June 2015
for high-quality pulse welding that saves energy, time and money. FastMig X welds 5 times faster than TIG. In pipe welding, the quality demands are high and productivity expectations can be even higher. When we are talking about thousands and thousands of welds in oil & gas pipelines, water pipelines or pressure vessels, even a small increase in quality and productivity will count – and they promise us a big one. FastMig X is a modular system; therefore the final setup is always configured to meet the customer’s needs, whatever they are: materials from mild steel to special alloys, from thin sheets to thick plates, conditions from hot to cold, working environments from workshops to shipyards. Amazing range of welding curves, easy adjustability and upgradability allow fast response to changing needs, leading to less waiting, less adjusting and more profitable welding. Rashmi Ranjan Mohapatra, National Sales Manager, Kemppi India, comments, “The latest welding machine from KEMPPI is in the black series known as Fastmig X. With the introduction of this “black” series the KEMPPI offering is complete across the segment. We have now the HiArc (Grey colour) for the basic needs. The FASTMIG
June 2015
M series in Orange colour comes in the mid segment for the industrial customers. The black range is for the Quality conscious customers and positioned at the high end of production and quality. FASTMIG X is unique in its position and offering. Some interesting point for the “Quality” conscious customers: 1. All rounder / Versatile: This machine will take care of any welding need. Be it for special material and process – FASTMIG X will do it with utmost ease. 2. Modular structure: This helps in creating your own package as deemed fit for the application.
“With the introduction of this “black” series the KEMPPI offering is complete across the segment. We have now the HiArc (Grey colour) for the basic needs. The FASTMIG M series in Orange colour comes in the mid segment for the industrial customers. The black range is for the Quality conscious customers and positioned at the high end of production and quality.”
3. Pipeline: Changing from TIG to Mig by increasing the productivity by 500%. 4. Plug and Play: Communicate through an android device and enjoy the settings done from your phone /tab. 5.
40% less shielding gas cost.
6.
Increase welding speed by 30%.
7. It’s a mix of special processes, welding management software and welding programs and functions.” For more details visit www.kemppi.com
Rashmi Ranjan Mohapatra National Sales Manager Kemppi India
www.martupdate.com
83
MART UPDATE
Delcam’s Latest video shows Vortex High-Efficiency Roughingon DMG DMU 65 The latest video added to the Delcam.tv website shows the high metal-removal rates that are possible with theVortex high-efficiency areaclearance strategy in Delcam’s PowerMILL CAM system for high-speed and five-axis machining. The demonstration shows Vortex in use on a DMG 65 monoBLOCK five-axis machining centre fitted with Seco tooling. Other strategies shown in the video include fiveaxis drilling, sawmill slot milling and five-axis engraving. To watch the video, please go to www.delcam.tv/DMGMORI Delcam’sVortex strategy gives the fastest safe metalremoval
from solid carbide tooling, in particular from designs that give deeper cuts by using the full flute length as the cutting surface. The strategy, which is also included in Delcam’s FeatureCAM feature-based machining software and the PartMaker system for the programming of turn-mill equipment and Swiss-type lathes, can be used for two- and three-axis roughing, three-plus-two-axis area clearance and for rest machining. It gives significant time savingsregardless of the material being machined,whether that be titanium, tool steel or alloys such as Inconel.
Vortex produces toolpaths with a controlled engagement angle to maintain the optimum cutting conditions for the toolpath that would only be possible only for the straightline moveswith conventional roughing. As a result, much higher feedrates are possible so the cutting time isfar shorter, while cutting is undertaken at a more consistent volume-removal rate and at an almost constant feedrate, so protecting the spindle and the machine. The consistent feedrate possible with Vortex is a fundamental difference from other high-speed roughing techniques. Delcam has
Delcam’s latest video shows the Vortex roughing strategy on a DMG machine with Seco tooling performed trials showing that this approach gives more reliable results as it can often be difficult to predict exactly how machine tools willreact to constantly changing feedrates.
Haas DM-1 High-Speed 40-Taper Drill/Mill Center the DM-1 from Haas Automation is the solution.
To compete in today’s economy, machine shops must produce parts quickly and accurately, while optimising their floor space. Whether you’re a high-mix production business looking to increase throughput, or a sub-contract machine shop looking for a small, fast 40-taper machine,
84
www.martupdate.com
The DM-1 is a high-speed, lean-style machining center with a compact footprint that allows multiple machines to be placed side-by-side to make the most efficient use of valuable shop floor space. Its high acceleration rates, fast axis speeds, and short tool change times – combined with a 40-taper inline spindle – make the DT-1 an attractive high-productivity machining center. The DM-1 has a 508 x 406 x 394 mm work cube and a 660 mm x 381 mm T-slot table. The 40-taper inline direct-drive spindle turns to 15,000 rpm,
and allows high-speed rigid tapping, with up to four times retract speed. The spindle is coupled directly to the motor to reduce heat, increase power transmission, and provide excellent surface finishes. A 15-hp vector drive system provides 62 Nm (peak) of cutting torque for milling and boring operations. The DM-1 provides cutting feedrates to 30.5 m/min for high-speed milling, and the machine’s 18+1 side-mount tool changer swaps tools quickly to reduce non-cutting time. Highspeed 61 m/min rapids combine with high acceleration rates to shorten cycle times and increase throughput. For efficient chip removal, the DM-1 features steeply sloped internal sheet metal. Optional
twin chip augers transport chips to exit at the rear of the machine, allowing multiple machines to be placed close together. A 170 L flood coolant system is standard, with options for a programmable coolant nozzle and high-pressure through-spindle coolant systems. A wide selection of options are available to further boost productivity, including high-speed machining software, wireless tool and work probing, 4th- and 5th-axis capability, and much more. Built in the USA by Haas, the DM-1 Drill/Mill Center is backed by the worldwide network of Haas Factory Outlets – the most extensive system of support and service in the industry. For more details visit www.HaasCNC.com.
June 2015
Indo-MIM creates history again at MPIF Design Excellence Awards Small parts can ease the manufacturing complexities with panacheand this has been proved again by Indo-US MIM Tec. Pvt. Ltd (IndoMIM). Indo-MIM, a leading global supplier of precisionengineered products using Metal Injection Molding (MIM) has received six out of 14 MPIF PM Design Excellence Awards at the recently concluded 2015 International Conference on Powder Metallurgy & Particulate Materials (POWDERMET2015) at San Diego, California. Four MIM components developed by Indo-MIM— catcher, tensionbar and new base cap & body—earned the Grand Prize in the Lawn & Garden/Off-Highway Category. The components are used in proportional valves found in hydraulic circuits of off-highway and farm equipment. The two parts forming the new base are made of MIM 17-4 PH stainless steel, while the catcher and tension bar are formed of 4605 lowalloy steel. All dimensions of the two parts forming the new base are achieved in the as-MIM condition, including the internal thread in the body.
Krishna Chivukula Jr. CEO, Indo-MIM
June 2015
By completely re-designing the parts to maximize the advantages MIM offers, the customer obtained savings estimated at 65%, with annual production of 350,000. The Award of Distinctionwas received in theAutomotive— Chassis Category for a MIM 4605 low-alloy steel top plate. Thecomplexity of the part—with its 18 holes and six thin ribs that connect to a ring around a centralhole— presented a challenge to complete filling. The gating and venting system played a keyrole in producing this part defect free. It is produced close to net shape, with surface grinding toachieve flatness and a facing operation to achieve height tolerance being the only secondaryoperations performed. This application is a new design for MIM and delivers increasedrepeatability/ accuracy of the shock absorber over the previous machined version, with estimatedsavings of 25%. In the Hardware/ Appliances category, Indo-MIM received the Award of Distinctionfor two MIM 17-4 PH stainless steel
“MPIF is an extremely competitive platform and Indo-MIM’s continuous achievement at the global arena confirms that we are par excellence. Winning parts at MPIF aptly demonstrate that Indo-MIMhas given a platform for innovative thinking and being recognized globally in such a platform proves again and again that history can always be repeated with such creative czars. This is definitely a boost to the morale of Indo-MIM!”
parts—front and rear keepers that go into industrial electrical locks. The parts’ complexity, with many cross holes and sharp knurl features, required the use of multiple slides, some moving at different angles. The parts are made close to net shape requiring only a final coining to adjust a small distortion and a tapping operation on the front keeper. Annual quantities are 20,000 per part. The second Award of Distinction in the same category was received for a 4605 low-alloy steel bolt used in the Crickett 22LR rifle. Made via MIM, the part replaced one produced by brazing together three machined parts, delivering an estimated 35% cost savings in the process. The part’s design features many cross holes and undercuts, requiring complex side core matchings in the molding cavity. The fabricator delivers 60,000 pieces annually. Not only the Hardware and Automotive; but Indo-MIM received recognition in the Electronic category also. The
company received two Awards of Distinction for developing a MIM 17-4 PH stainless steel shell and a male fool-proof device and a female polarizer. The shell goes into a charging assembly for mobile phones. The complex geometry of the part, with thin cross sections and internal undercuts, was achieved with a slide-in-slide mechanism moving on specially designed cam tracks. The MIM part replaced an earlier design that used sheet metal processing and welding, with an estimated 20% cost savings. Two million of the parts are delivered each month. Made via MIM from 4340 low-alloy steel, the male fool-proof device and a female polarizergo into an electricconnector assembly made for Airbus. Both parts are fabricated to net shape, with all dimensionsachieved in the as-MIM condition; this includes the threads, which are formed through auto unwinding in the tooling. The fabricator delivers 320,000 pieces annually. For more details visit www.indo-mim.com
www.martupdate.com
85
MART UPDATE
Red Lion’s Rugged Graphite HMIs receive Global ATEX and IECEx Approvals Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced that its rugged Graphite®Human Machine Interface (HMI) operator panels have been certified to operate in global ATEX zone 2/22 and IECEx zone 2 environments. Following Underwriters Laboratories (UL) Class I, Division 2 Listed status received last year, these approvals certify that Graphite HMIsare safe for use with industrial control equipment in potentially explosive,
hazardous locations around the world. Red Lion’s touchscreen Graphite HMIsare now able to provideorganizations with powerful monitoring and control capabilities regardless of operating environment, even locations subject to potentially explosive atmospheresthat may result from gas, vapor, mist and/or dust. This enablesindustrial customers in markets such as oil and gas, flour and grain, mining, chemical, painting and metal processingto benefit fromruggedaluminum construction, wider operating
temperatures and high shock/vibration tolerances. From factories to extreme locations, Graphite HMIs enable customers to connect, monitor and control processes across a broad range of industries to meet varying industrial automation requirements. Since its launch in July of 2013, Red Lion’s Graphite platform has received numerous global accolades, including Automation World’s “First
Team Supplier, HMI Hardware” award, the “Industrial Control Award” from Plant Engineering China and “Best Product of the Year” from Control Engineering China. For more information on Red Lion’s modular Graphite HMI platform, visit www. redlion.net/Graphite
Compact Powerhouses with Integrated Intelligence enlarged its mechatronic product line with the series SCHUNK PR 2, PDU 2, and PSM 2, and offers three particularly compact, intelligent drives with a very compact performance, optimized for robust applications in the field of industry. The complete power electronics of the modules has been fully integrated into the modules, no external controller is needed, and cabling as well as error susceptibility are minimized.
The intelligent SCHUNK high-performance rotary modules PR 2, PDU 2, and PSM 2 (shown here), convince with maximum performance in confined spaces. Control and power electronics are integrated in the module. For many years, the SCHUNK highperformance rotary modules have been successfully used in laboratory, research, and industrial applications. SCHUNK, the competence leader for clamping technology and gripping systems has now
86
www.martupdate.com
Fast and easy commissioning The modules are available in three each standardized unit sizes. Equipped with standardized plug connections, they can be quickly and easily connected. Optionally, control is done by Profibus (up to 12 Mbit/s) or CAN-Bus (up to 1 Mbit/s). For commissioning and parameterization by PC with the SCHUNK motion tool, the modules are equipped with USB connection, and can be manually addressed
by means of an easily adjustable rotary encoding switch. Initial module movements can be manually realized via a DIP switch. The status of each module can be seen on an LED display. Due to the integrated Harmonic Drive, the PR2 rotary module, and the PDU 2 drive for linear axes achieve enormous torques between 16 Nm and 184 Nm - depending on the module size. The directly driven PSM 2 module can be used for fast movement of small masses. It is compact and achieves at a torque of 1.8 Nm up to 4,320 rpm. Position, speed, and torque of all the three modules can be individually controlled. An incremental encoder ensures high position and repeat accuracy. The integrated holding brake is activated as soon as the target position is reached. For evaluation of the sensor signals, the module is equipped with two digital inputs. For further details visit www.in.schunk.com
June 2015
June 2015
www.martupdate.com
87
MART UPDATE
New Real-Time Monitoring System for Metrology Environments Hexagon Metrology unveiled MMS PULSE, a monitoring system that offers realtime insights into external and environmental factors impacting upon metrology environments. Designed to ensure data integrity while also improving safety and security in modern shop-floor inspection conditions, MMS PULSE uses a network of sensors to record variations in temperature, vibration and humidity in the vicinity of a coordinate measuring machine (CMM). Also offering equipment status alerts and crash notifications, it creates a central hub of information to support the metrology data gathered by the machine. The sensor package can be customised to specific requirements and
the information reconciled with anomalies in output data to make compensations as necessary, giving MMS PULSE the potential to improve productivity. In the coming months, MMS PULSE will add compatibility with various data management systems and offer the scalability to gather data from multiple machines around the factory. All the information collected is displayed directly on an easy-to-understand dashboard accessible locally or remotely via PCs, smartphones or tablet devices, supporting the fast pace of lean manufacturing environments. The MMS PULSE interface is visually reminiscent of current consumer electronics technology, offering intuitive and user-friendly controls.
Users can also set up environmental thresholds that, when breached, alert the operator via instant messaging services. “MMS PULSE really taps into the Internet of Things concept, creating a network of physical objects which communicate and interact via real-time connectivity,” explains Milan Kocic, Business Development Manager at Hexagon Metrology. “The information it provides effectively gives our metrology hardware and software the ability to learn from their surroundings and informs future decisions. This can help optimise processes
and remediate issues quicker – that’s where we really drive productivity.” Initially available for the Hexagon Metrology 4.5.4 SF and 7.10.7 SF CMMs, MMS PULSE will be available in the US from June 2015, with worldwide rollout to commence later in the year. For further details visit www.hexagonmetrology.com
TurnLine: T515, New CVD-Coated Grade for Cast Iron Turning
T515, with the specially designed substrate and coating structure, is the highly versatile CVD-coated grade most suitable for machining
88
www.martupdate.com
cast iron. The adhesion strength between the substrate and coating layer has been drastically improved, which will strengthen the chipping and peeling resistance and offer stable machining. Excellent wear resistance in high-speed machining is another strength of this new grade, and, with the thickness of alumina (Al2O3) layer increased by
1.7 times to our conventional products, remarkably long tool life is achieved. Also, Tungaloy’s special surface technology, PremiumTec, plays an important role to improve the surface roughness, leading to strong resistance to chipping and edge-buildup. To simplify the chipbreaker selection, 2 main types will be stocked: all-round type and flat-top type. The new CVD-coated grade,
T515, for cast iron turning delivers reliability and stability in the application area from general machining to highspeed machining. Together with the Tungaloy’s existing T5100 series, T515 will complement all operations of cast iron turning and provides manufacturers in various industries with outstanding productivity. For more details visit www.tungaloy.co.jp/in
June 2015
Designed for corners: Curved linear Guides from Igus Individual requirements and space optimisation calls for new ideas in the field of design. In the instance of linear plain bearings, the straight structured rail guide has caused certain limitations. Now the plastics expert igus also offers curved drylin rails, which give the designers more freedom such as, in the cabins of construction and agricultural equipment. Utilising the already proven and tested drylin W linear plain
bearings, igus has developed a new offer for linear guides that provide a functional reliable and cost-effective solution even for curved travel paths. The curved guide rails are made of aluminium and have an exceptionally resistant hardanodised coating. Customised guide carriages thereby implement cornering without tilting or seizing. In addition, appropriate hand clamps can be added. Low installation effort and
Examples for the versatile use of curved section rails in the driver’s cab of an agricultural machine: lubrication-free mobility in all directions, even in the most confined of spaces
maintenance-free operation are the strengths of the new system, which like all drylin systems combine low friction coefficients with dirt-repellent dry operation. The drylin aluminium rails are also easy to machine individually and are characterised by their light weight. Use in driver’s cabs The driver’s cab of an agricultural machine is a good example of how curved guide rails can increase flexibility in the adjustment of monitors, seats or fittings and ideally adapt to the general design of the machine. Every agricultural machine has its specific frame sizes and design requirements. Adaptable, modular components create the necessary leeway to achieve custom solutions. The curved drylin rail can be configured. Within certain physical limits,
The curved guide rails are made of aluminium and have an exceptionally resistant hard-anodised coating. In the maintenance-free application, cornering becomes trouble-free without tilting or seizing
users can choose their own bending radius and therefore optimally fit in the driver’s cab. igus manufactures the section rail according to these specifications and provides the individual rails and linear bearings from the range of drylin W and drylin T. For more details visit www.igus.in
The Shoulder Milling Cutter becomes an All-Rounder The Xtra•tec® F4042/F4042R shoulder milling cutter is one of the most universal representatives in its category. The 90 degree approach angle tool is capable of shoulder milling, ramping, pocketing , facing and interpolating. Now, with a new wiper indexable insert which is fitted instead of a conventional indexable insert, the F4042 has extended its field of application once again.
June 2015
The main features of the new wiper insert: precision-ground, double-edged, has positive geometry, axial projection and requires no adjustment. As a result, the F4042/F4042R becomes not only a roughing and finishing face milling cutter that enables the production of outstanding surfaces (Ra down to 0.2μ) , when fitted with the wiper indexable insert, it also fulfils all the prerequisites
necessary for turn-milling. And let’s not forget that at the end of the day, the user is spared the effort and expense of additional work steps and tools. On occasion, he will be able to perform complete machining operations on just one machine, while also enjoying an overall reduction in expenditure. A variety of different cutting tool materials allow the tool
to be used for machining steel, cast iron difficult-tocut material workpieces. The F4042/F4042R is consequently suitable for all metalworking industries. For further details visit www. walter-tools.com
www.martupdate.com
89
MART UPDATE
Brand-new Bright Minds for NORD Drive Controllers Integrated basic PLC capability due to faster CPU and firmware upgrades. Featuring an integrated PLC, frequency inverters from NORD DRIVESYSTEMS combined with geared motors become a full-fledged intelligent system solution. All distributed SK 180E and SK 200E controllers and the cabinet inverters SK 520E and above now offer an integrated PLC. The PLC enables straightforward free
programming of driverelated functions according to IEC 61131-3 in “Structured Text” and “Instruction List” using the free-of-charge NORD CON programming and parameterization tool. The intelligent inverters can thereby manage sophisticated tasks such as autonomous process monitoring or dynamic operation without an external controller. This allows for very economically priced solutions. Moreover, these new-
Grundfos India launch ‘i Save Energy’
Build Differentiated
This forum aims to discuss and encourage energy efficiency, by highlighting the challenges faced as well as the solutions and steps that an individual, organization or community can take to become more energy efficient.
troubleshooting
Mahathi Parashuram, Head – Public Affairs & Marketing, Grundfos India said, “Grundfos being a company where energy efficiency is at the core of our product, we truly believe
www.martupdate.com
size 11, with 160 kW rating, later this year. For more details visit www.nord.com
Kollmorgen Introduces KDN
Grundfos India marks World Environment Day with the launch of ‘i Save Energy’, a forum on Facebook to promote Energy Efficiency in India.
‘i Save Energy’ also highlights the power of an individual in creating a cleaner and greener future.
90
generation inverters control a wider range of motors: support for IE4 synchronous motors is currently being tested in the field. In addition to their outstanding functional versatility including position control, the distributed SK 200E units also provide exceptional overload tolerance and are available for a wider power range than usual in this product class – up to 22 kW. The highly compact control cabinet inverters from the SK 500E line will be available up to
Machines, Faster, with Help from the Kollmorgen Developer Network KDN is an online knowledgebase that helps OEMs spend less time that being energy efficient is the solution to a cleaner environment. Through this forum we hope to help create and strengthen the practical awareness about energy efficiency. It’s not just about sharing facts and information; i Save Energy is about creating a community where we can provide members a platform for dialog and action on the subject. Ultimately, creating ambassadors for energy efficiency in India” Follow i Save Energy at: facebook.com/ISaveEnergy
and more time developing superior performing machines. KDN is an interactive knowledge base where Kollmorgen customers can learn from one another, receive expert advice from Kollmorgen application engineers and customer support staff, and delve into rich technical information with just a few clicks. KDN content focuses on AKD® servo drives series, AKD®
BASIC drives, AKD® PDMM, Kollmorgen Automation Suite™ (KAS), and Kollmorgen servo motors. The site also provides information and support for Kollmorgen legacy products. For more details visit www.kollmorgen.com/ kdn
June 2015
Matrix Comsec Awarded by TEMA as the National Apex body to represent telecom Technology Providers, Global and Indian, Private and Government owned companies. This award, instituted by TEMA, acknowledges the most outstanding technological innovation that has brought prestige to India. It is awarded to technology that
Matrix, a leading manufacturer of enterprise telecom and security products, is awarded for ‘Excellent Innovation in Telecom Technology and Products’ by TEMA. This award has been conferred upon Matrix for its exceptional efforts in bringing about technological innovations
June 2015
and quality engineering in its products. In a function at BSNL headquarter in Bangalore the award was presented by TEMA and CMAI Association of India in association with BSNL QA at Bangalore. Telecom Equipment Manufacturers’ Association of India (TEMA) is recognized by the Government of India
is developed in the country by Indian innovators and meets the highest global standards. TEMA selected the winner after rigorously evaluating several Indian technology companies through a careful analysis of a variety of parameters including technology innovation, commercial success, execution of strategy and dedication to research and development.
“We are very honored to receive the TEMA Award for ‘Excellence in Innovation’. This is a great recognition for the outstanding team of Matrix that has consistently delivered world-class products to its customers.”
Ganesh Jivani Founder, Matrix
www.martupdate.com
91
MART UPDATE
OMRON Automation sets up an Office in Ahmedabad Following its regional expansion strategy, OMRON Automation India, part of OMRON Japan- a global leader in factory automation technology, announced the opening of its new office in Ahmedabad. Situated in Shahibaug, the office is Omron Automation’s 6th office in the country. Speaking on the occasion, Mr. Sameer Gandhi, MD, OMRON Automation India said, “The move indicates the importance of Gujarat in Omron’s business strategy. The state is one of the major industrial hubs in India and this expansion of our infrastructure
would contribute a lot in strengthening our presence via servicing current & potential customers in a better and more efficient manner. This would also serve as a centre to cater to adjoining regions namely north and south Gujarat such as Gandhidham, Kutch, Morbi, Rajkot, Jamnagar and the industrial belts of Waghodia, Jhagadia, Hajira and Dahej falling under Baroda and Surat regions.” The current focus areas of the company are the large and medium manufacturing enterprises from Packaging, Pharma, Special Purpose Machines (SPM), Batch Mixing
OEM’s & Automotive sectors in these regions.Currently, OMRON Automation’s network comprises of 05 offices, 9 RE locations, 1 Automation Centre,
2 repair centres, 3 training centres, 1 logistics centre and a workforce of around 160 people spread across the country.
phase version (200 ÷260 V / 47 ÷ 63 Hz) with a motor power between 0.25 and 1.5 kW, and in three-phase version (360 ÷ 480 V / 47 ÷ 63 Hz) with a motor power between 0.25 and 5.5 kW.
The electronic part, available in 10 power sizes, is located in two different chassis sizes, one for power up to 1.5 kW and the other for power up to 5.5 kW.
DRIVON to feature at HISPACK and SPS Italia
DRIVON, designed to be used in different types of applications (especially pumps, fans and conveyor belts) consists of extremely reliable components and is controlled by our software that provides
92
www.martupdate.com
excellent performance with special attention to the system energy efficiency. Its Vectorial Check, besides ensuring a constant motor torque throughout a wide range of frequencies without requiring the use of the servo-ventilation at low rpm, provides fast and precise output according to the application dynamic conditions allowing high torque overload of the motor. Conceived for extremely different and variable supply conditions, Drivon is available both in single-phase/three-
For further details visit www.motovario.com
“The different functions of this software provide a wide range of standard and optional interfaces for a simple and flexible use.” Partha Prathim Sen Managing Director, Motovario India
June 2015
IXXAT Safe: TÜV-Certified Solutions for Safety Implementations With the IXXAT Safe portfolio of ready-made safety I/O modules and safety protocol software, HMS Industrial Networks offers TÜV-certified solutions for implementing secure communication into industrial devices. With the IXXAT Safe offering, HMS offers an extensive portfolio of solutions for safe communication according to IEC 61508. The solution includes TÜV-certified safety protocol software for CIP Safety and Functional Safety over EtherCAT (FSoE), as well as certified and ready-to-use PROFIsafe I/O modules for integration into customer devices. Implementing safety functionality can be complicated, which is why the HMS safety development team offers support to customers during their safety implementation. HMS also offers development of customer-specific OEM solutions.
IXXAT Safe T100 A highlight within the IXXAT Safe offering is the ready-made IXXAT Safe T100 module – a complete solution for easy and fast integration of safe I/Os using a safe communications protocol. The Safe T100 module is integrated directly into the customer product or system – for example welding systems, drives, counter terminals etc. Thanks to the comprehensive architecture of the safety hardware and software, pre-certified by TÜV Rheinland, the use of the IXXAT Safe T100 considerably simplifies the development of devices and systems with safe communication. It also reduces development time, cost and risk. The IXXAT Safe T100 is designed to work together with HMS’s Anybus CompactCom modules for fieldbus and industrial Ethernet communication. In this solution, CompactCom acts
as the pathway through the unsafe network and safe communication is implemented using the “black channel” principle. In addition to the first version now released – the IXXAT Safe T100/PS for PROFIsafe on PROFINET – additional variants will soon be available, such as for CIP Safety on EtherNet/IP or FSoE. Special requirements in terms of form factor, connectors, or the number of I/Os, can also be met through specific OEM implementations offered by HMS. Safety protocol stacks In addition to the ready-made Safe T100 module, HMS also offers protocol stacks for FSoE and CIP Safety on EtherNet/ IP or SERCOS. Just as for Safe T100, the protocol stacks are also certified by TÜV,
enabling easy implementation of safe communication on suitable hardware. By using a pre-certified safety protocol stack, customers benefit from significantly faster development time as well as lower costs and risks. Integration of the stacks can be carried out by the device manufacturers themselves, but HMS is ready to assist with implementation, porting, and certification services. For more details write to HMS Industrial Networks India Private Ltd, “Corporate Plaza”, Unit 1A & 1B, Ground Floor, Senapati Bapat Road, Near Chaturshrungi Temple, Pune - 411016 Tel: +91 20 2563 0211 Email: in-sales@hms.se
Full Metal Proximity Switch Series SW 4041 Jayashree full metal body (SS) Inductive Proximity Switch is very usefull for working in harsh aggressive environment. The front SS cap is abrasion proof
June 2015
The sensor can sense metallic object like a normal Inductive Proximity Switch. The full metal Proximity Switch is very useful for process industries, bulk material handling plants and steel Industries. The features are all metallic enclosure, available in M12/M18/M30 sizes. IP-67 Grade ,Corrosion Resistant
construction, chances of mechanical damage minimal and no limitations of Flush/ Non-flush mounting. For more details write to Jayashree Electron Pvt Ltd, EL-34, ‘J’ Block, MIDC, Bhosari,Pune – 411 026 Tel: +91 20 46901300 E-mail: sales@jayashree.co.in Web: www.jayashree.co.in
www.martupdate.com
93
MART UPDATE
Stainless Steel is Positively Turning for Dormer Pramet A new range of inserts with positive NF geometry has been developed by Dormer Pramet for turning of stainless steel. The double-sided inserts, marketed under the Pramet brand, are available for finishing to medium turning of stainless steel, low carbon steel and super alloys. More than 110 variations in insert shapes (C, D, S, T, V and W), sizes and grades have been developed. The new inserts will be of interest to companies performing general turning applications, thanks to the low values of radial cutting force, making it suitable for unstable machining.
Meanwhile, Dormer Pramet has announced new wiper inserts for turning with W-MR geometry. Available in CNMG12, DNMG15 and WNMG06 and 08 inserts, W-MR is suitable for longitudinal and face turning of steel, stainless steel and cast iron. The double-sided inserts have a positive chipbreaker and a new shape on the smoothing edge to achieve low roughness in turning. This enables reduced cutting forces and higher feeds, increasing productivity while retaining the same surface finish as with standard
inserts. If used correctly, their use can completely eliminate the need for grinding. Both NF and W-MR geometry further strengthens Dormer Pramet’s portfolio for machining stainless steel, with a wide range of indexable and rotary products now available. Dormer Pramet’s additions to its turning range forms part of a wider product launch in
April 2015 – the first combined unveiling since Dormer and Pramet merged last year. For more details visit www.dormerpramet.com
Doosan Bags the Red Dot Design Award for the Second Year Running
The FM 200/5AX Series wins Doosan Infracore Machine Tools the Winner Award at the Red Dot Design Awards for the second year running
Doosan Infracore announced that it had received the winner award in the category of product design at the Red Dot Design Awards 2015 for its FM 200/5AX, a high-speed, high-precision machine tool series. The company has now
94
www.martupdate.com
won the Winner Award in Product Design at the Red Dot Design Award for a second consecutive year following its receipt of the award in 2014 for its PUMA SMX series. The Red Dot Design Award is widely regarded as
one of the top three design recognitions in the world along with the iF Design Awards and the IDEA Design Awards. For each award in three main categories – product, communication, and concept – candidate products/ideas are
subjected to a comprehensive evaluation in terms of design, creativity, practicality and ecofriendliness. The FM 200/5AX, this year’s recipient of the Winner Award, is the highest-speed 5-axis machining center on the market. Based on the concept of ‘hexagonal edges,’ the external design of the series is characterized by visual stability while symbolizing the robust performance of the machine tool. The design excellence of the machine tool series had already been recognized in Korea with its receipt of the Good Design Award 2014.
June 2015
June 2015
www.martupdate.com
95
96
www.martupdate.com
February 2015 November June 2014
THE LAST LEAF Dear Readers,
Our Prime Minister Mr.NarendraModi completed one year of his tenure. He has been actively traveling across the globe soon after his resuming as PM.Summarizing his recent visit to South Korea and discussions with their President Park Geun-hye, Mr.Modi expressed that there is much that India can learn from South Korea given that both countries were at similar levels of development half a century ago. But South Korea emerged as a miracle economy, successfully making the transition from a backward Third World nation to a veritable First World player. South Korea’s manufacturing sector is a powerhouse. With India now seeking to make a similar transition from a backward agrarian nation to one with strong manufacturing and services, there’s huge scope for cooperation between New Delhi and Seoul. South Korea decided to provide $10 billion to India for infrastructure, development of smart cities, railways, power generation and other diversified areas as the two countries agreed to upgrade their bilateral relationship to a “Special Strategic Partnership”(Courtesy : Timesofindia.com) During the earlier visit of Indian Minister to China, an idea of establishing a consortium of higher educational institution as a part of greater collaboration between India and China besides mutual recognition of academic degrees, is being solicited. China will be the key knowledge partner in the Mahatma Gandhi National Institute for Skill Development and Entrepreneurship being set up in Gujarat. Under the MoU, China will provide curriculum in various trade and industry sectors. According to officials, China has trained over 13 million people in skill development in focused areas for better employment against a million by India.A conscious effort is being put in applying Information and Communication Technology’s (ICT) application to grassroot education. Japanese investor Teruhide ‘Teru’ Sato is an investor with a difference. He started his first venture in 1997, a JV with Softbank and CyberCrach, and then BEENOS (formerly Netprice), one of the biggest Japanese conglomerates that is working in the space of e-commerce, marketplace and payment. From its seed accelerator division, it has invested in over 50 companies in Japan, and from its investment division, it has invested in over 85 companies globally. Recent investment has been in Tokopedia, one of the biggest marketplace businesses in Indonesia, that drew a funding of $ 100 million from Softbank and Sequoia Capital. He feels that India is playing a very key role in the international growth, in a way to present bigger opportunities. According to him, there might be large investments from his side happening in India, and hence has based a colleague out of Bengaluru, who is on a lookout for interesting ventures. Graphene is the new buzzword in the global electronics industry and scientists at the Indian Institute of Engineering Science and Technology (IIEST) have applied its unique properties to sniff out a deadly cancer-causing food toxin with high sensitivity, just like finding a needle in a haystack. The modified form of graphene (reduced graphene oxide) can easily bind to the protein-like structure of the toxin and give an enhanced signal compared to other materials. It is 100 times more sensitive than conventional sensors and displays certain interesting electrical characteristics which imparts additional selectivity to the sensor. (Courtesy: Ndtv.com) We need your input on any industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our readers about a better tomorrow. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board
June 2015
www.martupdate.com
97
98
www.martupdate.com
June 2015
June 2015
www.martupdate.com
99
KEMPPI INDIA PRIVATE LIMITED Lakshmi Towers, 2/770, Kazura Garden 1st Street, Neelankarai, Chennai - 600 041 Phone: 044-45671200 Email: sales.india@kemppi.com Web: www.kemppi.com
100
www.martupdate.com
June 2015