Volume 11 Issue 11 May 2015 ` 100
ARTIFICIAL LEAF TECHNOLOGY A playing-card-size coated-silicon sheet is taken, that, when placed in a glass of tap water and exposed to sunlight, split the water into hydrogen and oxygen and the gas could easily be collected and either burned or used to power a fuel cell.
Productivity Efficiency
Big Data Analytics
HEART OF MOTION
VALUE ENGINEERING
LEADERSHIP E.I.
IN THE AUTOMOBILE INDUSTRIES
IN THE AUTOMOBILE INDUSTRIES
MOTOVORIO SUCCESS STORY
EXPLOITING BENEFITS
TALENT MANAGEMENT
May 2015
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May 2015
Meistermacher. Made in Germany.
Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding.
Thilo Schumacher, Master – Chuck Jaws
German champion with Borussia Dortmund 2002 English champion with Arsenal London 2004
www.gb.schunk.com/chuckjaws
SCHUNK standard Chuck Jaws 1,200 Jaw Types from a single Source
50%
Up to larger clamping range
SCHUNK claw jaws
SCHUNK standard chuck jaw program. The world’s largest selection , for every conceivable use, of power chucks and toolholders from a single source for higher productivity in your machining center and your lathe.
Universal base jaw Power chuck
May 2015
Quick-change jaw system
© 2015 SCHUNK GmbH & Co. KG
Unbeatable when high torques have to be transmitted.
Stepped jaws
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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 4 www.martupdate.com
: +91 9818556732 : d.upadhyay@boge.com
May 2015
TRIDENT
engineering quality air & gas
India's Largest Exporter of Compressed Air Treatment Products
Refrigeration Compressed Air Dryers
Microprocessor Controller Anti Freezer Anti Recycle Controller Advanced 3 in 1 Integral heat exchanger and plate heat exchanger Large condenser for high ambient temperature
Heatless Air Dryers
Manifold construction Shuttle valve for low pressure drop Microprocessor based controller Pre filter with borosilicate glass element Point of use : Auto coner, Lab testing etc. Ranges from 5 CFM to 375 CFM
For OTHER PRODUCTS see our website :
www.tridentpneumatics.com May 2015
Submircon Filters
Oil Removal (Coalescing) and Particulate Flow from 15 to 2000 scfm Particle Removal 0.01 (Micron) Max. Oil carryover 0.003 (mg/m3 )
Trident Pneumatics Pvt. Ltd.
5/232, K.N.G. Pudur Road, Coimbatore – 641 108 Ph : +91-0422-2400492 | Fax : +91-422-2401379 | Mobile : 8220019925 Email : sales@tridentpneumatics.com, j_noelraj@tridentpneumatics,com www.martupdate.com
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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
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May 2015
foreword Ease, Tough! Hi Readers, Narendra Modi government completed its first year in office this month. With different progress cards doing rounds rating the government’s maiden year performance, Modi was able to make the right noise with his popular schemes like Make In India, Swatch Bharat, Pradhan Mantri Jan Dhan Yojana with the industries as well as the common people, inspiring to believe for a better tomorrow under his leadership. The Associated Chamber of Commerce of India awarded 7 out of 10, industry keeping their confidence in the current leadership but reminding to address issues on tax as well as improving the ease of doing business. When it comes to “Ease of doing business” we are ranked 142 among 189 countries for a long time. We never discussed about this subject till the PM appealed to the world to Make In India during his first speech at Red Fort last Independence day. It’s a fact we should understand that the situation cannot be changed overnight, moreover we are a country who reacts emotionally over media hypes, a lot of blame games but no actions. To start with focus is on Delhi and Mumbai, the government has directed the local administration to initiate a series of measures to reduce the time taken to set up a business, bring online registration for EPFO, ESIC, Shops & Establishment acts etc. Also, the government must take initiatives to support the established manufacturing companies in India to produce more or expand under Make In India, which will further boost the image of our country. In our July 2015 Anniversary edition, we are planning to feature industry stories on Make In India, for which we look forward to your contributions. It’s also well appreciated that Modi chose to visit China during their first anniversary. We always watch China with suspicion, but a larger co-operation with them is essential today. Within the last fifteen years we have seen steady growth in our neighbouring country, and now China is the world leader in global manufacturing outsourcing. From Apple iphone to the diwali crackers, our market is flooded with Chinese products, and there is a great imbalance in trade deficit, which the PM is expected to address during his visit. He is also expected to seek investments under Make In India, also take up the issues of lifting trade barriers to Pharma and IT exports, which will further boost our economy. Research for an alternative fuel technology is going for long and scientists have been pursuing artificial technology, a green approach to making hydrogen fuel, which is featured as our cover story. As our main focus in this issue, stories on “Adopting sustainability measures in the Automotive Industry” and “Productivity Efficiency in Automobile Industry” are featured. Motovario is celebrating its Golden Jubilee this year, and we feature them in the success story. Apart from our regular inputs, an interview with Cyril Periera, Managing Director of Triune Exhibitors, who is organizing AMTEX at Mumbai for the first time, is published in the Fair Mart. MART is also exhibiting at the show. Your opinions and suggestions help us to improve MART. Do write to us, and let’s catch up next month.
Hari Shanker hari@martinfotech.in May 2015
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34 Main Feature
10 INNOVATIONS
Columns
48 Leadership E.I. 50 The Way to Heaven is Only Through Hell 52 Exploiting Benefits from Value Engineering 56 On Face 58 Bridging the Gap Volume 11 Issue 11 May 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.
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Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every effo May 2015 employees accept any responsibilities for any errors or omissions. Š All Rights Reserved
CONTENTS 22
40
Artificial Leaf Technology
Adopting Sustainability Measures in the Automotive Industry
COVER FEATURE
MAIN FEATURE
26
Japanese Innovation for Better productivity
32
Productivity Efficiency in the Automobile Industry
36
Big Data Analytics Impact on Automobile Industry
SUCCESS STORY
42
Case Study 62
Back on the Map - GAT
64
Yili Industrial Group
66
Five-axis CMM Inspection
72 Feature articles
70 78 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 Rajiv Saini rajiv@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
Monalisa Chakraborty +91 9038 003210
Madhurima Bhattacharjee +91 9038888277
Adrita Baidya +91 9038002340
Bangalore Chennai Delhi Mumbai
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 May 2015
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PRODUCT MART
I N N O VAT I O N
Rexnord Q Motors for Refrigeration Applications
Q motors are designed specifically for OEM’s of refrigeration applications in constant search of quality goods
Rexnord Electronics & Controls Ltd, a global leader in manufacturing of high quality Compact Cooling Fan & Single Phase Shaded Pole, Q Frame & C Frame Motors offers Q motors, which are designed specifically for OEM’s of refrigeration applications in constant search of quality
goods. The wide range of motors and accessories, able to ensure the best performance in any application and market. The products are CE approved. Both shaded pole motors and energy saving motors are single phase AC input 115V / 230 V, 50/60 Hz. Shaded pole motors are 4 pole constructions,
Insulation Class B, IP 42. Motor with output power of 5watt, 10watt, 16watt, 18watt, 25watt & 34watt are available. Energy saving motors are electronically commutated type motors. With logical microprocessor control, a single motor can use three different
blade size 200mm, 230mm & 254mm with a constant Speed of 1300 it is designed to replace shaded pole motors without any changes and saves 60% in energy consumption. For further details write to sales@rexnordindia.com or visit www.rexnordindia.in
“Our Q motors has won the confidante of many International OEM, which assure you the quality & reliability of our product” Kishorechand Talwar Managing Director, Rexnord Electronics & Controls Ltd
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May 2015
May 2015
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PRODUCT MART
Mehta Cad Cam offers Fiber Laser Metal Cutting Machine
I N N O VAT I O N
Fiber laser technology has many advantages over traditional Co2 laser cutting technology like maintenance free, long life of around 1 lakh hours and give very clean cutting with nitrogen and oxygen
As we all know Co2 Laser Technology is very famous for SS/ MS metal cutting & give good quality of cutting with nitrogen and oxygen gas. Co2 laser source require maintenance time to time. Before 3 to 4 years fiber laser technology came into the market for thin metal cutting like 1 mm, 2 mm SS or MS. With the time more wattage of
fiber laser source like 500 watt, 1 KW, 2 KW came into market and they can cut upto 8 mm of SS. Fiber laser technology has many advantages over traditional Co2 laser cutting technology like maintenance free, long life of around 1 lakh hours and give very clean cutting with nitrogen and oxygen. In this few years many manufacturer of fiber laser source have come into the
market from different parts of the world and time to time the fiber laser source price also keep on reducing. Mehta Cad Cam believe fiber laser technology is most low cost, trouble free and long life, it is like a revolution in metal process industries. Ahmedabad based Mehta Cad Cam Systems Pvt Ltd well known in manufacturing and supplying
Co2 laser cutting machine and CNC routers have also jumped into manufacturing of high quality CNC, laser metal cutting machine equipped with 300 watt, 500 watt, 750 watt, 1KW, 2KW, fiber laser source. For more information contact Mehta Cad Cam Systems Pvt Ltd at +91 9227985717, 9033000150.
“I believe Mehta Cad Cam will bring revolution in metal processing industries with the introduction of maintenance free and very low cost fiber laser metal cutting machine.� Shailesh Mehta Managing Director, Mehta Cad Cam Systems Pvt Ltd
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May 2015
May 2015
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PRODUCT MART
I N N O VAT I O N
New Generation Permanent Magnet DC Motors
PMDC motors are ideal for applications like Printing, Textile, Plastic, Packaging, Pharmaceutical and Welding Machines, Treadmills and Fitness equipment requiring low maintenance and long brush-life
Rotomag Motors & Controls Pvt. Ltd., an ISO 9001 company, offers new generation Permanent Magnet DC Motors which are more Reliable, Compact, have higher Starting Torque, and superior Efficiency. Over 200 models in various ratings from 15 -3350 watts, voltages from 12 - 180 Volts and speeds from 750 - 5000 RPM
are available. Geared PMDC Motors with worm and helical gear-boxes also form a part of their range. Their in-house design expertise enables to develop Custom-built motors as per customer specifications in almost the same time and cost as a standard motor. Rotomag’s range of Battery Operated PMDC Motors for
Electric Vehicles and Battery operated equipment are designed for traction duty and have long brush-life, Class F/H insulation and higher torque-toweight ratio resulting in lower battery drain.
replace Universal motors due to lower noise and totally enclosed construction. For further details write to Rotomag Motors & Controls Pvt Ltd, 2102/3 & 4, Vittal Udhyognagar, Anand, Gujarat-388121 Tel: +91 2692 230430, +91 9227110023/ 24/ 25 Email: sales@rotomag.com Website: www.rotomag.com
Rotomag’s Micro PMDC Motors are also being used successfully in Circuit Breakers, Conveyors, Domestic appliances and can
I N N O VAT I O N
Cycloidal Reducer from N S Engineering
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“Some reducers are bought, installed and promptly forgotten. When looking for high performance and reliability in speed reducers, torque is what really matters.” Madan Bhatia Managing Director, N S Engineering
TRISONS NSCD series cycloidal pin wheel with reducer adopt the principle of planetary gearing transmission and the construction gear meshed with pin wheel, confirm to standard , with features of big ratio, high
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efficiency, compact structure, Small volume , long life, little break down , strong ability against impact and so on. Widely applicable to Ceramic Tiles, Drink, Food, Textile, Mineral, rubber, Cement, Wire , Glass ,
Pharmaceutical , Plastic , Printing , Dyeing , Metallurgical, Lifting & Transportation and many other industries. For further details write to N S Engineering, 3, Dharnidhar
Industrial Estate, Behind BOC Gas, Panna Road, Rakhial, Ahmedabad-380 023 Tel: +91 79 22777399 , +91 9825474366 E-mail : nsengineering@ rediffmail.com Web: www.nsengineering.co.in
May 2015
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SEW-EURODRIVE MOVI4-RU®:The smart, intuitive sustainable solution to a simple application
“Outstanding innovation, a strong commitment to sustainability and a clear focus on customer benefit characterizes SEW-EURODRIVE and this product showcases all three elements.” M J Abraham Managing Director, SEW-EURODRIVE India
SEW-EURODRIVE presents the ideal solution for simple applications in drive technology; MOVI4-RU® frequency inverters. This nofrills application comes without any unnecessary additional features. It focuses only on the essentials: the simple open-loop speed control of asynchronous motors with a new, simple, and intuitive operating concept. Besides, the high degree of protection from IP54 further allows for the use of MOVI4-RU® outside the control cabinet, like, for instance, close to the application for controlling conveyor belts. Some of the essential features of MOVI4-RU® frequency inverters are as follows. • Basic requirements: Fulfilling basic drive technology needs
May 2015
• Intuitive operation: Very easy start-up and innovative operating concept • Sustainability: Recyclability, high energy efficiency • Assembly concept: Logistic advantages for a worldwide production and assembly concept Some of the Target applications of MOVI4-RU® are as follows: • Material handling (eg., continuous conveyor). • Auxillary drive systems • Stand alone & portable applications (eg., agriculture sector, small food production facilities) • Replacement of line-powered drives for customers who start applying with AC drives • Replacement of drives with
motor starters or soft starters MOVI4-RU® is designed for easy Designed to be easy, intuitive, sustainable. MOVI4-RU® is designed for easy and effortless operatability. Its high-quality control knob/push button, LED-display, two simple menu levels and user-friendly display of menu items, status values (eg., speed) and errors make it simple and intuitive to work with. With its degree of protection IP54 as standard, it can be wall-mounted outside electrical enclosures, thus making its installation easy and costeffective. The device is designed with a sustainable raw material concept: • Reuse of aluminium housing •Return of product after usage • Closed raw material cycle
Thanks to four basic tenets, MOVI4-RU® is energy efficient: Intelligent use of materials; innovative and eco-friendly production; resource efficient utilization phase and reintegration into material and raw material cycles. Advantages of MOVI4-RU are intuitive operating concept for short start-up times and simple handling, modular design for fast unit replacement, degree of protection IP54 for wallmounting outside the cabinet control, guaranteed integration into cycle of materials: MOVI4RU® is based on a sustainable product concept that allows for reintegration into material and raw material cycles. For further details write to SEW-EURODRIVE India Pvt Ltd, Plot No. 4, GIDC Por, Ramangamdi, Baroda 391 243 Email: marketing@ seweurodriveindia.com Visit: www.seweurodriveindia.com
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PRODUCT MART
I N N O VAT I O N
Matrix Launches COSEC ARC: IP based Access Control Panel with PoE
Matrix COSEC is a comprehensive and flexible access control solution designed to meet access control needs of any organization irrespective of its size, locations, layouts and timings.
Matrix COSEC allows controlling access on all three simultaneous dimensions – user, zone and time by answering the three fundamental questions about who, where and when. All modern organizations need to protect their physical and IP assets and ensure human safety by controlling movement of people as per predefined policies. COSEC ARC is an intelligent compact IP panel with PoE for a single door. ARC dramatically simplifies access deployment and enhance security in multifold. It works in two
modes – standalone with COSEC PANEL or centralized with COSEC CENTRA application server. The stateof-the-art COSEC ARC can control 2 readers on wiegand or RS-485, door lock and other auxiliary devices making it an ideal solution for any access control installation. Key Benefits: Scalable: Matrix Access Control is scalable in the smallest factor of one door controller. It is scalable up to 255 devices with COSEC PANEL LITE or 65,000 devices with COSEC CENTRA server without worrying on
future investment. Flexible: Matrix access control architecture offers flexibility to install door controller near the door to reduce excessive and complex wiring compare to traditional access control installation. Cost Effective: COSEC door controllers can be directly connected with the COSEC PANEL LITE. COSEC PANEL LITE manages 255 devices and 25,000 users directlywithout any server installation. Highly Secure: Matrix offers biometric readers with
fingerprint and palm vein readers along withhigh-end access control features. This ensure foolproof security compared to traditional RFID card based access control solution with basic access control features. Reliable:COSEC Access Control solution is a single door and distributed architecture with standard IP wiring that ensures continuous and reliable access control without any security breach. For further details write to Matrix Comsec at email: inquiry@matrixcomsec.com
“Matrix has a rich innovation lineage. The company has acquired a formidable reputation for quality and engineering of its products. In line with our legacy of introducing new innovations, we are presenting two new security solutions designed and engineered keeping in mind the needs of enterprises. These solutions with their value added functionalities will surely strengthen the security cover of enterprises. These solutions have already gained interest of system integrators and consultants offering technology solutions for large projects and enterprises. We are launching these solutions in seven cities across India”. Ganesh Jivani Managing Director, Matrix Comsec
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The new control system PNOZmulti 2 with up to 80% less energy consumption ‌
‌ than comparable products. The power consumption of the new base unit PNOZ m B0 is a minimal 0.8 W with 20 safe inputs and 4 safe semiconductor outputs (PL e, SIL CL 3) and a width of just 45 mm. Rely on 10 years of innovation from the market leader in safe control technology! Count on the configurable control systems, the worldwide safety standard for all machine types. The simple, graphics configuration tool saves engineering costs because you can create your safety circuit simply and intuitively on the PC. Visit us at the Hannover Messe, Hall 9, Stand D17.
Further information about the PNOZmulti Configurator: www.pilz.com + Web code: web10522 Pilz India Pvt. Ltd Office NO 102 & 202, Delite Square, Near Aranyeshwar Temple, Sahakar Nagar NO 1, Pune - 411009 Telephone: +91 (0) 20 24213994/95, Fax +91 (0) 20 24213996, Web: www.pilz.in, Email: info@pilz.in
May 2015 1AD_PNOZmulti_2_222x285_EN_IND_2015_03.indd 1
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23.03.15 12:07
PRODUCT MART
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Delcam launches new FeatureCAM for feature-based programming
Turning-head holders have been added to the range of machining accessories supported by FeatureCAM . Full details on the new release, including video demonstrations of the main enhancements, are on the FeatureCAM Learning Zone – www.delcam.tv/fc2015/lz
Delcam has launched the 2015 R3 release of its FeatureCAM feature-based CAM software. This includes a range of enhancements to give highquality results on all types of machine tool, including complex mill-turn equipment and five-axis machining centres, while retaining the rapid programming times for which FeatureCAM is renowned. FeatureCAM was the world’s first feature-based programming software when it was launched in 1995. Constant development since then has ensured that the system has retained its leadership in programming speed and ease of use, while an increased range of strategies has been added to provide more efficient toolpaths that give greater productivityon a wider range of machinery, including mill-turn
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machines, five-axis mills and wire EDM equipment. The most significant new option is the ability to duplicate the physical constraints of the machine tool in simulations in FeatureCAM. Machinetool limits can be added to the models to be used in the simulation for three-, four- and five-axis milling machines, for turning equipment, and for mill-turn machines, including those with multiple turrets and/or multiple spindles. It is then possible to check that the chosen machine tool is capable of completing the proposed program for all types of equipment, from the simplest lathe to the most complex multi-tasking machine. The simulation will pause whenever the program attempts to move the machine beyond the specified limits. In many cases, simply changing
the position of the part on the machine bed will allow the whole operation to be completed. Alternatively, modifications to the fixturing or to the length of the cutting tools may be required. Whatever changes are made, the computer simulation can then be repeated to check that the modified program will run successfully. Proving out the program on the computer will save time and money on the machine tool, as well as checking that the part can be cut safely. In another improvement to FeatureCAM simulations, more accurate representations can be created of shanks and holders. These allow three-axis and five-axis collision checkingto be undertaken more reliably. Two enhancements have been made to five-axis machining with FeatureCAM. Firstly, more control is available with the ability to set the C-axis
orientation about the Z axis so helping to avoid machine collisions and to make the program more efficient by avoiding over-travel. Secondly, support for five-axis operation is possible in 2D spiral operations, giving better control of the tool axis. This can ensure uniform depth of cut and cross-section when engraving onto complex surfaces, including parts with undercuts. Additional accessories that are supported in the new release include turning-head holders and mini turrets. Turninghead holders allow turning to be undertaken on a milling machine, while mini turrets allow more flexible positioning of the tooling and faster tool changes. In both cases, the new options can be simulated on the computer before being sent to the machine.
May 2015
May 2015
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PRODUCT MART
New High-Performance WIDIA VSM490™ Family o Achieves True 90 Shoulder Milling
I N N O VAT I O N
Excellent cutting and extended tool life mean more parts at higher quality
The new VSM490 double-sided shoulder milling platform from WIDIA is a powerful advantage for achieving true 90-degree shoulders and floors with superior surface finish
Numerous precision parts in transportation, moldmaking, general engineering, and more require true 90-degree shoulders and floors with superior surface finish. Economic and competitive pressures require manufacturers of all parts to maximize metal removal and tool life. The new VSM490 double-sided shoulder milling platform from WIDIA is a powerful advantage for achieving all this and more. Designed for low horsepower draw and free machining, VSM490 delivers an effective one-two punch of reduced horsepower at the machine and higher speed and feed rates that get jobs done faster and/or with an improved surface quality.
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State-of-the-Art Design With four cutting edges and multiple corner nose radii available, the robust VSM490-15 inserts provide added stability and reliability in addition to delivering true 90-degree shoulders and floors. Two insert geometries are available: MM (universal), making it the first choice for a range of work materials; and ML (light) with sharper cutting edges resulting in lower cutting forces for mild steels and stainless. VSM490 cutter bodies made with tight tolerances to ensure minimum run-out have an integral chip gash design for excellent chip evacuation along with hardened-steel construction and hardened
pocket seats for improved resistance to deformation. They are available in shell, screw on, cylindrical shank, and Weldon shank models with internal air and coolant capability. Featured in NOVO Moreover, VSM490 is available through NOVO™, WIDIA’s digital process knowledge application. With powerful process knowledge available on iPad™ and other digital devices, NOVO helps users define machining features, such as shoulder milling in specific work materials, and then immediately reduces the product set to those like VSM490 that can do the job, taking into account constraint requirements such as material, tolerance, and
machining sequence for both single tools and multi-tools. NOVO then ranks the results— based on knowledge-based rules—to best meet the challenges of the application as defined by the customer’s operating environment and user preferences. This provides far more useful process knowledge than any online catalog alone, all obtained in a fraction of the time. VSM490 Starter Kits in both metric and inch, including cutter bodies, end mills, and WIDIA Victory™ grade inserts covering a variety of applications are available by contacting your WIDIA distributor. To locate a WIDIA distributor, contact: WIDIA Products Group +91 80 2219 8341 or visit www.widia.com
May 2015
May 2015
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MAIN FEATURE
Adopting Sustainability Measures in the Automotive Industry Rigorous changes have been made in the industrial policy of India Government with the initiation of major economic reforms since 1991. Relaxing of licensing rule, reduction of tariff rates, removal of restrictions on import etc. are among those which have been initiated at early stage. After delicensing of the sector, with the enhancement of purchasing power of common masses in India, the Indian automobile market is flourishing gradually.
Riti Banerjee riti@martinfotech.in
Pricing Pricing of automobiles is a complex issue as it is dependant on fixed cost, economies of scale, technology and other aspects. Competition and consumer demand also play important role in this. Currently, most of the automobiles companies consider price reduction as major strategic move for survival. For price reduction, companies need to take series of decisions at every stage of production and selling; starting from managing factors of production and supply chain to negotiation with dealers. Price is one of the factors that influences sales variability of products and services significantly. Companies require appropriate policies
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to be played intelligently for managing the series of decisions. Interestingly, reducing prices does not always generate profits. It should be in combination of other decisions regarding maintaining quality and marketing of the product. One undesired consequences of considering price reduction as the main means of obtaining customers, is attracting disloyal customers, who are attracted by the offer but do not see any other value in the company. Their life-cycle in the end is short, and they receive a much greater return from the company than the company can even make up the cost for obtaining them. Many companies take strategy of different pricing policies for different product segments of the considering
the expected value to the customers through the offered products. Companies develop innovative strategies to maximise profits without hurting customers. Pricing is adjusted to the qualities, purchase volume, development potential, loyalty and profitability factors
Market condition in India India is an emerging market for worldwide autogiants. Due to low cost of labour many multinational companies are investing in India. Its automotive industry has grown very rapidly from the middle of 1990’s. Recently, there are two big investments expected to boost the sector further, one is from Maruti and the other is from Honda Siel. Tata’s investment to manufacture
cheap car is also expected to boost the industry. India is the second most populated country in the World, and the growth rate of Indian economy is very high, which indicates the presence of huge demand in different industrial sectors. Automobile industry is not the exception in this regard. Indian automobile sector has huge demands from its own country. This demand also attracts the 19 giant automobile suppliers throughout the world to come and invest in the Indian automotive industry. Due to the contribution of many different factors like sales incentives, introduction of new models as well as variants coupled with easy availability of low cost finance with comfortable repayment options, demand and sales
May 2015
Market Share of Passenger Car Manufacturers Jan - June 2013
Jan - June 2014 7%
Others
Others
8% 3%
Chevrolet
46% 16% Maruti Hyundai
9%
8%
Mahindra
4%
3%
44%
3% Ford 4%
5%
Tata Motors
16%
Toyota Honda
Chevrolet
4%
Maruti
Hyundai
11%
4%
5%
Ford Tata Motors Toyota
Mahindra
Honda
*Approximate Figures
of automobiles are rising continuously.
Temporary and permanent workers problem Auto companies hire temporary workers when demand picks up and release them when sales slump, thus saving labour costs. On an average, about 40% of the industry’s workforce is temporary, up from 30% a few years ago. Tata Motors, Mahindra & Mahindra and Maruti Suzuki, for instance, have together laid-off almost 4,000 temporary workers recently. Even as the industry calibrates its temporary workforce in tune with consumer demand, worker angst is also increasing. So is there a win-win solution that can avoid ugly conflicts between companies and their workforce? Companies are trying to find one.Companies employ diploma holders to work on production line (on par with permanent workers) as trainees and
May 2015
pay them as low as Rs 8,000 odd per month and lay them off in a year, A permanent employee, working on the same assembly line, could earn Rs 14,000 to 22,000 a month. These result in lockout, unrest, illegal strikes and wide-scale rioting in the industries like Maruti Suzuki saw twice in 2012.
Knowledge of customers Customers are becoming increasingly sophisticated and impatient. Manufacturers and dealers no longer hold the monopoly on information about the vehicles and services they supply. In tandem, the prevalence of social networks and Web 2.0 technologies means that customer-to-customer interaction has become the norm. Customers know what they want and they know how and where to get it – at the best price and with a minimal wait. Easy access to endless rich multimedia content means that fewer people feel the need to spend hours at
dealerships in search of a car. Those who do make it into the dealership have done their homework and are better informed than ever, which means they are far closer to purchase when they arrive than may have been the case before.
spaces is about generating incremental sales and margin from existing customers by re-capturing their attention with new offerings—such as in-vehicle infotainment—that create personalized customer experiences at all stages of the car ownership lifecycle.
Since there are fewer customer interactions, it makes each contact between dealer and customer even more crucial – dealerships will need to offer more than stock information, brochures and price tags.
Government Regulations
Ways to succeed To succeed in the new normal, automakers need a customer-centric sales and marketing capability that focuses on new faces, places and spaces. New faces means acquiring new customers by engaging them in innovative ways, such as marketing campaigns that use digital media, social networking sites, smart phones, YouTube videos and online advertising. New places is about entering new markets. And new
The Indian government has made significant shifts in its policy towards the automobile industry. Ever since independence, the government considered the passenger car to be a luxury item, and imposed very high tariffs. Since the economic liberalization launched in 1991, the Government of India’s automobile policy announced in June 1993 has changed. The Government of India has reduced its direct control on the automobile industry following the announcement of the new automobile policy. Entry of MNCs is permitted, either as joint ventures or on their own. However, the indirect impact
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of government policies on the industry still remains far from insignificant. The government has levied 110% customs duty on completely built units (CBU) and 50% on CKD and parts. Prior to the mid 1990’s, the Indian automobile sector comprised of indigenous companies. The automobile market in India was however, opened up to foreign investors in 1996. International names like Ford, Hyundai, Toyota, Volvo, Daimler Chrysler and GM Honda were thus, able to make their foray into the Indian automobile sector. Furthermore, the auto emission rules issued by the government in recent years ensured that the vehicles manufactured in India, catered to international
standards. At present, the automobiles sector contributes 4 % to the GDP. About 9.7 million automobiles were manufactured in 20052006. Export figures had crossed the magic figure of one billion during 2003-2004. A reduction in the tariff imposed on car exports has been effected by the Indian government. There has also been a removal of the minimum capital investment required from new investors. The new policy is also in favor of reduction in excise duty for small automobiles and low emission and multi utility cars. The tariff policy is also to be reviewed on a regular basis in order to affect a balance between domestic industry and international trade. There has also been a proposal for tax relaxation on investment
of more than Rs. 500 Crore. The Indian government is also urging the state governments to ensure continuous power supply to the automotive manufacturing units as well as granting them with the preferred plots of land. Captive Generation for the automobile sector has also been proposed. The auto policy of the Indian government also includes the promotion of vehicles which are run on alternative energy resources. The policies adopted by the Indian government for the growth and development of the automobile sector, has led to a large number of foreign investments and India is becoming the ultimate outsourcing destination for global automobile companies like Ford, Mitsubishi, Toyota, Hyundai etc.
Green Methods Adopting sustainability measures is becoming a major driver of differentiation and competitiveness in the auto industry. Manufacturers and suppliers that don’t embrace “greener” practices will not survive in the long term. Many consumers are clamouring to drive more fuel-efficient, sustainably produced vehicles. Apart from using CNG and other eco-friendly methods, scientists are also coming up with other innovative ideas that will be miraculous in the field of automotives. One such invention is the “Artificial Leaf Technology” and we have discussed the details of it in one of the following articles of this issue.
Manufacturers and suppliers need to embrace “greener” practices to survive in the long term
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MAIN FEATURE
Japanese Innovation for Better Productivity
Uttam Bose Managing Director, Hindustan Motors Company who focus on Productivity & Business Performance and increase labour productivity will initially improve profitability, but the relationship between productivity and profits is more complicated over the long term.
Background of Global Automobile Industry The automobile as we know, it was not invented in a single day by a single inventor. The history of the automobile reflects an evolution that took place worldwide. It is estimated that over 100,000 patents created the modern automobile. However, we can point to the many firsts that occurred along the way. The Automotive Industry in the United States began in the 1890s and, as a result of the size of the domestic market and the use of mass-production, rapidly evolved into the largest in the world. The motor vehicle
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industry began with hundreds of manufacturers, but by the end of the 1920s it was dominated by three large companies: General Motors, Ford, and Chrysler. With the invention of the automobile and the mass production techniques of Henry Ford, which made the machine affordable, the American economy has been transformed by this key element in its prosperity. However, the United States was overtaken as the largest automobile producer by Japan in the 1980s, and subsequently by China in 2008. The first Japanese car
manufacturing companies at a full scale was established by Nissan Automobile in 1933 and by Toyota Automobile in 1937. In the fifties and more years since the Japanese began producing cars domestically, Japanese automotive technology has made remarkable progress and come to be one of the international leaders. In 1980, Japan became the top automobile-producing country in the world. The domestic auto industry has grown to the point where it is today one of the key industries supporting the Japanese economy. Today, looking further toward
the twenty-first century, utilizing new materials, high-tech electronics, new power sources, and artificial intelligence, the type of car which automakers are capable of producing cannot even be imagined. Look back of Indian Automobile Industry: The Automobile Industry of India has come a long way since in 1898 the first car rolled out on the streets of Mumbai. For nearly three decades the total production of passenger cars was limited to 40,000 yearly. Even the production was confined to three main manufacturers Hindustan
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Indian Automobile Growth 18000
Sales in units (000)
16000 14000 12000 10000 8000 6000 4000
2014-15
2009-10
2005-06
2000-01
1995-96
1990-91
1985-86
1980-81
1975-76
0
1970-71
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Graph - 1 Motors, Premier Automobiles and Standard Motors. There was no expertise or research & development initiative taking place. Initially labour was unskilled and had to go through a process of learning through trial and error. In the 1950’s, The Morris Oxford, became the Ambassador, the Fiat 1100 became the Premier Padmini. Then in 1960’s nearly 98% of the product was developed indigenously. There were significant changes witnessed by the end of 1970’s in the automobile industry. Strong and huge initiatives like joint ventures for light commercial vehicles did not succeed. Contessa, the Rover and the Premier 118NE, which were the new models, hit the market. Till later part of 1980’s India by and large followed a socialist system which is basically the UK automobile
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working style. The actual transition took place, post opening up of foreign OEM investments in Indian market which is initiated by Mr. Manmohan Singh (exPrime Minister). Then on, lot of OEM giants such as Suzuki, GM, Hyundai, Toyota, BMW, VW, Ford, Mercedes-Benz, etc started investing in India seeking the automobile future in India with high skilled labour at lower cost of production. Currently, all the OEM’s are focusing on ‘export of vehicles’ in larger scale. The first step towards productivity was that none of these foreign players went for Total Integrated Manufacturing plants. Rather they concentrated on just Welding Shop, Paint Shop and Assembly. Rest all operations like Body Shop, Engine Shop,
etc was made into a bought out items and supply on JIT basis. This also kept the investments at a very low level, making the payback in a very samll period. They brought in world class equipments and technology to India, which were very efficient in nature. The automobile industry in the country is one of the key sectors of the economy in terms of the employment opportunities that it offers. The industry directly employs close to around 0.2 million people and indirectly employs around 10 million people. The prospects of the industry also has a bearing on the auto-component industry which is also a major sector in the Indian economy directly employing 0.25 million people. The automobile industry in India is gradually evolving to
replicate those of developed countries. The trends are emerging in the industry across segments, namely, passenger cars, multi-utility vehicles, commercial vehicles, twowheelers and tractors. The qualitative analysis of the various trends reveals that the industry offers immense scope even for allied industries and those looking at investing in the auto industry. The Indian automobile industry is undergoing a revolution of sorts. The vehicle war is on. And it’s a fight to the finish. Within the span of a few years, the vehicle market has displayed an array 84 of models that were hitherto undreamt of. Ford, General Motors, Toyota, Volvo are household names today. Launch of a vehicle in one category spawns a war for the throne.
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Productivity in Automobile industry The first Japanese car manufacturing companies at a full scale was established by Nissan Automobile in 1933 and by Toyota Automobile in 1937. In the fifties, Japanese began producing cars by mass production. In 1980, Japan became the top automobile-producing country in the world. They introduced all small practices, which resulted in manufacturing excellence. They introduced JIT, SMED, TQM, TPM, AB costing, etc. These initiatives resulted into very high output and mind boggling
cost savings. Today, looking further toward the twenty-first century, utilizing new materials, high-tech electronics, new power sources, and artificial intelligence, the type of car which automakers are capable of producing cannot even be imagined. Japanese “good practices” are potentially applicable to any market and today, they are followed worldwide by all automakers. Terms such as ‘just-in-time’, ‘quality circles’ and continuous improvement would go on to become part of the management lexicon, and even words such as ‘kaizen’ and ‘kanban’ are now heard in factories across the world.
Several studies published in the 1980’s indicated that Japanese firms, have achieved the highest levels of manufacturing efficiency in the world automobile industry. Physical productivity, which reflects the “throughput” speed for completing products and the amount of labour required, has been significantly higher than in other nations. Graph 1 clearly showcases the automobile growth in Indian market over the decades, created desire (demand) amongst the buyers which in turn made all the OEM companies to practice best productive plans to meet the supplies for the demand.
High productivity and other aspects of process efficiency, such as rapid inventory turnover, help solve a problem as old as mass production itself that the conventional factory tends to produce huge lots of standardized components. Looking for the reasons Japanese companies have managed this problem so well. However, the performance of Japanese firms in auto production depends not on the employment of Japanese workers but on Japanese innovations in technology and management. Perhaps the most important innovations challenged fundamental assumptions about mass
From the Team Gather Information Describe The Present Process Analyze the Process Develop, Design and Process Concepts Evaluate Select
Continuous Improvement
Prototype/ Simulate the best alternative Evaluate / Select
Effective Acceptable
No
Yes Cost Justification Analysis Implement
Flow Chart - 1 28
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production. The major objective for me in sharing this article was to explain how Hindustan uses the Japanese innovations in production management by exploring the reasoning behind them as well as their evolution over time, while simultaneously documenting observable improvements in productivity and inventory levels. Being the Indian manufacturer & partner of Japanese brand “Mitsubishi” in India, we are obvious in line that we follow the procedure & best practices carried out in Japan counterpart. We are privileged to have a Japanese auto maker “Mitsubishi” association which bought now drastic change in the management style of normal Indian manufacturer’s culture, which is basically replicated the old culture of operation which is sporadic in nature. We inculcated the Japanese culture of continuous improvement in our production facility. The implementation of TQM made our process very robust and quality assured rather than quality controlled. Company who focus on Productivity & Business Performance and increase labour productivity will initially improve profitability, but the relationship between productivity and profits is more complicated over the long term. The dynamic relationship between productivity and profitability can be explained using a simple example. Imagine a situation where two companies compete in
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the same regional market with access to the same factor inputs. Both have similar levels of productivity and profitability. If one company is able to increase its productivity, it will be able to produce the same quantity of goods and services at the same quality level with less labour, or materials, and/or hours. In this case, higher productivity will create a cost advantage, and the company can use the resulting profits for new investments, or it can distribute these profits to shareholders. The company may also choose to offer lower prices in order to gain market share or pay higher wages in order to attract higher-skilled labour. A one-time increase in productivity, however, will usually not lead to a sustainable advantage in profitability. In order to stay competitive, the other company will have to follow suit and improve its productivity. Once the two companies reach the same level of productivity, they will compete primarily on price until any advantages in profitability have disappeared. The implementation of lean manufacturing strategy allows strengthening the phase sequence that leads to operational excellence, a continuous improvement and the elimination of non-value added activities. Thus, the influence of lean practices contributes substantially with the operating performance of plants and use of lean tools allows the improvement of
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results. The tool kaizen is applied as a way to progress toward lean manufacturing and as a formula to lead the activities of improvement. It has been increasingly adopted as a potential solution for many organizations, particularly within the automotive manufacturing industries. This work addresses the implementation of the lean tool kaizen in an automotive component manufacturing company with a focus on tube sub-assembly line. The main objective is to develop several strategies to eliminate waste on the shop floor. We in HMFCL, applied the
kaizen technique & following the process continuously, which over the years resulted a significant increase in quality and productivity is confirmed and the production flow was smoothened by elimination of several non-value added activities. For example, I will illustrate how the change-over time reduction during “bending process” in the production as an objective, the kaizen procedure which we followed is shown in flow chart 1: Also, the process improvements in the automotive segment are key tool for success of many
Automobile OEM’s and it’s the largest contributor to auto sector growth. Illustration shows how the value added per hour growth is defined in flow chart 2. Outlook: Even after the spectacular growth in recent years, the Indian automobile market still has considerable room to grow. While the potential is impressive, there are challenges that could pull down future growth of the Indian automobile industry. Since the demand surge for automobiles in recent years is directly linked to overall economic growth and rising
personal incomes, industry growth will slow if the economy weakens. Despite these challenges, the long-term outlook for the automobile industry in India remains bright. In most countries, the automobile industry historically has been one of the sectors leading the economic growth and development. Available indicators suggest that it will be no different in India, which is likely to remain one of the fastest growing economies in the world for which the increase in productivity efficiency will be the key tool to meet these growing demands from any automobile market.
Process Improvements were largest contributor to Auto Sector Productivity Growth Description Change in Model mix
Contribution of Market share shifts from lower to higher value added models.
Improvement of models
Increase in value of existing models through • Added functional features • Improved quality • Higher performance
Process improvements
Effect of process improvements within existing plants most importantly, adoption of Lean production
Market share and max shifts
Effect of shift in Market share to more efficient producers and changes in production mix
Value added per vehicle growth
Value added per hour growth
Hours per vehicle decline
Flow Chart - 2 30
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MAIN FEATURE
Productivity Efficiency in the Automobile Industries Sujeet Kumar Head – International Business & Strategic Sourcing Kinetic Green Energy & Power Solutions Limited Economic reforms and deregulation have transformed the scene. Automobile industry has written a new inspirational tale. It is a tale of exciting multiplicity, unparalleled growth and amusing consumer experience - all within a few years. India has already become one of the fastest growing automobile markets in the world. This is a tribute to leaders and managers in the industry and, equally to policy planners. The automobile industry has the opportunity to go beyond this remarkable achievement. It is standing on the doorsteps of a quantum leap.
The Indian automobile industry is going through a technological change where each firm is engaged in changing its processes and technologies to maintain the competitive advantage and provide customers with the optimized products and services. Starting from the two wheelers, trucks, and tractors to the multi utility vehicles, commercial vehicles and the luxury vehicles, the Indian automobile industry has achieved splendid achievement in the recent years. Growth Story From 1998 through 2010, its GDP has grown at an average of more than 7 percent per year. Moreover, its contribution to world GDP is expected to increase from 2
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percent in 2007 to 17 percent in 2050. Being one of the largest automotive industries in the world and one of the fastest growing globally, India manufacturers over 17.5 million vehicles (including 2 wheeled and 4 wheeled) and exports about 2.33 million every year. It is the world’s second largest manufacturer of motorcycycles, with annual sales exceeding 8.5 million in 2009. India’s passenger car and commercial vehicle manufacturing industry is the seventh largest in the world, with an annual production of more than 3.7 million units in 2010. According to recent reports, India is set to overtake Brazil to become the sixth largest passenger vehicle producer in the world,
growing 16-18 per cent to sell around three million units in the course of 2011-12. In 2009, India emerged as Asia’s fourth largest exporter of passenger cars, behind Japan, South Korea, and Thailand. A report presented by the Society of Indian Automobile Manufacturers, intimates that the passenger car segment has reached 33 per cent growth in domestic sales at 1,53,845 units in February 2010. An overall sale across the industry has grown up to 35 per cent. Meanwhile the Commercial vehicle segment has seen 87 per cent growth. The two wheeler and three wheeler segments has risen to 33 and 32 per cent, respectively. So automobile industry has become a motor of Indian economy and the contribution of the automobile
industry to overall Indian economic growth is significant as it provides 4.2 percent of the GDP. In 2010, India became home to 40 million passenger vehicles and more than 3.7 million automotive vehicles were produced in India in 2010 (an increase of 33.9%), making the country the second fastest growing automobile market in the world. According to the Society of Indian Automobile Manufacturers (SIAM), annual car sales are projected to increase up to 5 million vehicles by 2015 and more than 9 million by 2020. By 2050, the country is expected to top the world in car volumes with approximately 611 million vehicles on the nation’s roads. The Government is confident that with the above
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Advanced forging techniques High speed data communication and data management
Supercomputing Near-Net Castry
Programmable machines and tools
Virtual manufacturing and complex visualization techniques Advanced Manufacturing
interventions, the Industry will achieve the target of 75.3 billion US$ in turnover and 8.97 billion US$ of exports by the end of the Eleventh Plan period 2012. Employment Generation Not only this, the sector has also tremendous potential of providing employment which will increase the present figure of employment in manufacturing sector which is quite low at 12% as compared to the countries like Malaysia (50%); Korea (62%) and China (31%). “The opportunity is staring in your face, it comes only once. If you miss it, you will not get it again� Automobile Technology & Innovations shaping Up with Market Demands: In the early 21st century,
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with the original four Asian Tigers at or near to fully developed status, attention has increasingly shifted to other Asian economies such as China and India, which are experiencing rapid economic transformation at the present time and are thus leading a sort of redistribution of the epicenter of global innovative activities. Not only so, it is also being widely contended that these emerging new economies that have already shown capacities to alter the balance of the international division of labour in their favour i.e. demonstrated capabilities which might drastically change the world’s technological map. The apparent tendency is conjectured to have risen from some substantial amount of cumulative deepening and technological upgrading of the
enterprises. The positive demographic factors, stable macro-economic environment and pro-reform policies of the government saw almost all major global auto players making their way into India. The intense competition has compelled the manufacturers to launch the latest global offering in India as early as possible. It has also enabled to keep the prices of the vehicles under check. The consumers, in turn, have benefited from wide choice of models, technologically advanced cars and better service from the car manufacturers. Thus pushing all the manufacturers in the market to inject best technology available to contain their waste, reduce their cost of production, make their processes more efficient if they have to sustain in
such cut-throat competitive environment. Only with the largest possible degree of automation will the automotive industry be able to effectively reduce costs and therefore survive in an international market that becomes more competitive every day. The key factor to higher productivity, greater efficiency, and complete quality assurance is intelligent machine vision systems. To improve product quality and efficiency in production, automakers invest a large amount of time and money into developing and improving the manufacturing process, and rely heavily on research and technological innovation. Over the last 75 years, significant technological development has taken place, changing and reinventing how motor vehicles are produced.
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Technology has increasingly altered the manufacturing process for motor vehicles. While cars are produced at faster rates, automakers must continue to balance increased productivity and efficiency with quality and innovation. Modern technologies used in advancing manufacturing for the automotive industry include: • Programmable machines and tools; • Near-Net Castry; • High speed data communication and data management; • Supercomputing; • Virtual manufacturing and complex visualization techniques; • Advanced forging techniques. In looking at trends in global automobile manufacturing, Japanese automakers have been leaders in stream-lined manufacturing process systems. These methods have been adopted by manufacturing plants worldwide. These efforts were pursued in order to increase productivity and product quality. U.S. and European automakers initially showed considerable gaps in manufacturing plant productivity, however the gap in productivity with Japanese automakers’ assembly plants have been narrowed substantially in the last several year. Government Fillip Indian Government
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Automotive Mission Plan 2016, the bumper-to-bumper traffic of global automobile biggies on the passage to India has finally made government sit up and take notice. In a bid to drive greater investments into the sector, ministry of heavy industries has decided to put together a 10-year mission plan to make India a global hub for automotive industry. “The ten year mission plan will also set the roadmap for budgetary fiscal incentives” The Government of India is drawing up an Automotive Mission Plan 2016 that aims to make India a global automotive hub. The idea is to draw an innovative plan of action with full participation of the stakeholders and to implement it in mission mode to meet the challenges coming in the way of growth of industry. Through this Automotive Mission Plan, Government also wants to provide a level playing field to the players in the sector and to lay a predictable future direction of growth to enable the manufacturers in making a more informed investment decision. Growing As Automotive Hub The Indian automotive Industry is now working jointly with foreign auto giants, in terms of both financial & technical aspects. Also a considerable number of joint ventures have been founded in the auto-components sector and the pace is expected to go up further. India government is slated to render a suitable & stable infrastructure and economic and business
environment that is conducive to the success of the established and prospective foreign partnership ventures. Hyundai Motors alone exported 240,000 cars made in India in 2008. Nissan Motors plans to export 250,000 vehicles manufactured in its Indian plant by 2011. Similar plans are for General Motors as well. While other key car makers, such as Italy’s Fiat and France’s Peugeot, are looking for alliances to improve efficiencies and increase production. Not to forget Indian auto manufacturers who are also stretching their presence globally, and looking for more investments in the automotive industry from the international companies. All these augur great for Indian automobile industry. Some Key Challenges Faced Fuel Technology is significant and needed to ignite the growth of auto industry. Whether it’s a two-wheeler or a car, technology drives the growth. The challenge of alternative fuel technology ensures a brighter vision of the auto industry in the country. The increasing environmental pollution has become a concern for manufacturers and all associated with the industry. All of them are struggling hard to come up with a holistic and integrated approach to reduce carbon dioxide emission. Nurturing Talented Manpower: Manpower and human resources has always
been a key growth driver in any industry including the automobile industry. Though India has a vast pool of talented and skilled professionals, the country needs initiatives and support to treasure these resources to excel in all arenas of the industries as automobile industry is no exception and highly skilled manpower will further become the most reliable source of competitive advantage across the global as well as Indian automobile industry. Dream coming True So the substantial growth of economy marks the prosperity of Indian bourgeois that has attracted global auto makers. Growing income levels and return of buoyancy in the economy have made way for the middle class to drive luxurious, Small & medium cars. New launches of cars have become order of the day, some low cost cars – all customized in a manner so that the common man is not left behind. All that has made Indian automobile industry happen to become the ninth largest in the world following South Korea, Thailand, and Japan, and emerges the fourth largest exporter of automobiles. The author Sujeet Kumar is Head – International Business & Strategic Sourcing – Kinetic Green Energy & Power Solutions Limited and he can be reached at at Kinetic Innovations Park, 18/2, D-1 Block, MIDC, Chinchwad, Pune – 411019 Email: sujeet.kumar@kineticindia.com
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MAIN FEATURE
Big Data Analytics Impact on Automobile Industry Businesses are entering a new era of customer-centric computing fueled by big data—the automotive industry is no exception. Big data and analytics solutions can help automotive manufacturers, suppliers and dealers use big data to increase competitive advantage and success. Businesses of all kinds are entering a new era of computing that is customer-centric and fueled by big data.
Rajesh Angadi rajesh_angadi@hotmail.com
The big data era is characterized by the growth of social media, an explosion of mobile devices and a physical world being outfitted with millions of networked sensors connected through the Internet. These factors have resulted in unprecedented growth of all types and volumes of data available to businesses. The automotive industry is no exception. In fact, it is estimated that the auto industry will be the second-largest generator of data by 2015. This estimate is not surprising, considering that some plug-in hybrid vehicles generate 25 GB of data in just one hour. While big data affects nearly every industry, specific market forces are driving change in the automotive industry. For example, new alliances are being formed as consumer and environmental requirements create the need for collaborative partner ecosystems. Increased globalization is driving more integration within and between automotive OEMs and their suppliers. And rapidly integrating automotive enterprises with high numbers of joint ventures imply increasingly dynamic operations. Areas in the automotive industry impacted by Big Data include:
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Conceptual Design - From data gathered throughout the life cycle of the vehicle, auto manufacturers will use Big Data to shape future vehicle designs. Every part of the vehicle can be tweaked and tuned. Real-world data collected from billions of miles driven will undoubtedly influence safety, aerodynamics, performance, power algorithms and other fundamental elements of the vehicle. Drawing Board- Consumer sentiment and information gathered from actual driver usage will affect the features included in new car designs. Efficiencies gained in design, production volumes and manufacturing through Big Data in the auto industry will make it economically feasible to make today’s options tomorrow’s standard equipment. Analysis of service and in-field performance will influence which components are chosen, and will pinpoint when selected parts should be redesigned for specific tasks. Procurement - Supply chain management optimized by Big Data will help manufacturers continue to wring new efficiencies from the procurement process. Manufacturing - On the assembly line,
data gathered throughout the building process will be used in predictive analytics to improve manufacturing simulations and keep tabs on machine performance, making the next assembly line even more efficient and flexible. Marketing - Big Data is already having a major influence on vehicle marketing. Social sentiment will play a growing role in manufacturers’ plans to design new vehicles. Customer feedback on current models also helps marketing experts identify key themes and messages for new campaigns. Finance - Understanding consumer habits, preferences and buying power across market segments gives manufacturers insights needed to develop more-effective financing programs. But that’s just the first step. New insights from Big Data analyses of sales and in-field use data will help captive financing companies develop new services and new revenue streams. Performance - Real-world vehicle performance will both influence and benefit from Big Data. Information gathered from the field — from vehicle systems, driver inputs and external
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The big data era is characterized by the growth of social media, an explosion of mobile devices and a physical world being outfitted with millions of networked sensors connected through the Internet. The automotive industry is no exception!
conditions — will exert a major influence over the design of components and the characteristics of future vehicles. Service- Like performance, service will benefit as both a contributor and a user of Big Data in the automotive industry. Information gathered through millions of service events will provide invaluable feedback to designers. On the other end, predictive analysis will help identify problems before parts and systems malfunction, simplifying the service process and saving drivers from a nerve-wracking roadside breakdown. Aftermarket- With manufacturers acting as a conduit, aftermarket services to drivers, based on insights gained from a combination of Big Data and location-based capabilities, are expected to explode. Travel services, insurance, petroleum, maintenance and entertainment are just a few of the industries that will benefit by developing partnerships to leverage data and reach willing drivers with special offers and features. Just as new manufacturing techniques and technology innovations led to the industrial revolution a century ago, the automotive industry is again experiencing dramatic shifts in its core business model. Technology-led advances are transforming not only the vehicle itself but also the way it is developed, produced, sold and serviced — to serve changing customer preferences in an ever more competitive world.
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IT-powered customer value is dramatically transforming the auto industry. Consider features such as hands-free trunk opening, which integrates the vehicle’s on-board computer, location-aware key, locking system and motion-detecting sensors in the rear bumper. Or the extensive social media presence of original equipment manufacturers (OEMs), who feature “Follow us” accounts on Facebook, Twitter, Google+ and more. Or the in-car integration of tablets preloaded with apps.These and many other IT innovations pointing to the auto industry’s future direction are all the more reason why CIOs need to elevate their roles. IT leaders, more than any other functional executive, have the technical understanding and crossfunctional views to fully understand IT’s impact in transforming their companies and the industry as a whole. Cloud as a Driver In the auto industry, CIOs will have to assume this new, more strategic role quite rapidly. They will also have to shed their old role as reactive IT managers. That role was fine when the industry’s way of doing business was not as IT driven, but not now — not with so much changing. A big contributor to the change is the emergence of cloud computing. The cloud empowers CIOs to move many core IT solutions out of the data center and into the hands of Internet service providers (ISPs), onto a public or enterprise private
cloud. This enables CIOs to focus on more strategic matters and helps the enterprise improve quality and control costs, shifting expenditures from capital to operating and enjoying the flexibility of pay-as-you-go billing models. By transforming software, storage and even application development into cloud-based services, the cloud empowers automotive CIOs to dramatically improve their organization’s agility and speed to market. For the auto industry, the next few years will be exciting times as we see the ongoing development of self-driving vehicles and car-to-car and car-to-infrastructure communications, as enhanced “socialwatching” strategies unfold to connect OEMs with their customers and prospects, and much more. In all these developments, one essential component will be IT. For automotive IT leaders who adopt this new, strategic and business-focused role, the road ahead is brightly lit. Car services in the cloud Carmakers such as BMW or VW expect to have mass-produced vehicles as “Internet nodes on wheels” rolling off the assembly line in just two years. Transportation research shows that this level of connectivity could significantly improve traffic conditions by easing the “shock waves” responsible for stop and go traffic. Everyone has experienced this phenomenon: the first car in the traffic jam brakes suddenly and the next drive
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also must come to a halt.As a rule these maneuvers come in waves. However, if there is sufficient distance between cars, there is no shock wave and vehicles continue forward without braking. Police cars frequently perform this function and slowly break up congestion. In future, this will be done by networked onboard computers. Linking to the Internet also provides a range of possibilities for additional services. These include, for example, regular updates of the software used in the vehicle but also access to electronic remote maintenance that can replace some visits to the shop. That is because in many cases errors in the electronics can be solved by resetting the corresponding control units. A cloud-based service also offers the option of unlocking vehicle performance settings on-demand. For example, in principle many automakers use chip settings to set power for identical engines. A driver who wants to go on vacation with a trailer and needs more traction power for the vehicle would be able to quickly access extra horsepower via the Internet. Location-based services Drivers currently prefer supplemental services that have no direct impact on vehicle technology. For example, three out of four Germans want their car to be able to compare gas prices on the Internet and recommend the quickest route to the cheapest gas station. About two thirds of potential customers value information on the closest free parking space. That particularly requires integration into Car IT. Many of these services already exist via smartphone apps.As a result manufacturers are moving away from isolated technological solutions, creating links for conventional consumer endproducts instead. Ordinary Smartphones can also replace expensive features such as navigation systems with inexpensive apps. For these reasons, many customers are reluctant to pay more for these
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technologies. Linking mobile devices The industry is using two current developments to put Car IT and mobile devices on a joint platform. On the one hand, Long Term Evolution (LTE) already provides high-performance transmission technology. On the other, automakers have long been cooperating with the manufacturers of control devices and control software.The goal is to uniformly program functions such as power windows, windshield wipers, radios or seat adjustments for all manufacturers. Emerging location-based mobile services enable drivers to share their location with preferred companies in exchange for discounts. Such services also raise questions about information privacy. Companies are working with leading automakers on analytics technology that will unlock customer and prospect data from a variety of sources – online vehicle configurators that customers use to pick out the model, color and options, social media mentions on Facebook and automotive blogs, and dealership sales and maintenance records. Customer analytics, in the hands of sales teams connected by cloud-based tools such as saleforce.com, can result in higher sales of cars and more visits to the service department by loyal customers. Exploration: Defining the business case and road map the focus of the exploration stage is on developing an organization’s road map for big data development. Key objectives include developing a quantifiable business case and creating a big data blueprint. This strategy takes into consideration existing technology and skills, and then outlines where to start and how to develop a plan aligned with the business strategy of the organization. Engagement:
Embracing big data in the engagement stage, organizations begin to prove the business value of big data, as well as perform an assessment of their technologies and skills. A proof of concept (POC) can help validate the requirements associated with implementing big data initiatives, as well as articulate the expected returns. Execution: Implementing big data at scale big data and analytics capabilities are more widely implemented within the organization during the execution phase. Organizations should be prepared to implement big data solutions at scale as the threshold for advancing to this stage. Organizations offers a full breadth of big data platform solutions to support analytics needs across the enterprise and across multiple business use cases. Realizing the benefits of big data Automotive companies are entering a new era in which they can capitalize on new sources of data to achieve their business objectives quickly, efficiently and at minimum cost—if they have the necessary knowledge, experience and solutions. With big data and analytics, companies can meet these needs at each stage of the big data adoption process. Organizations can realize concrete benefits of big data with key auto industry use cases ranging from optimizing the data warehouse to leveraging the connected vehicle. 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.
May 2015
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COVER FEATURE
Artificial Leaf Technology
A playing-card-size coated-silicon sheet is taken, that, when placed in a glass of tap water and exposed to sunlight, split the water into hydrogen and oxygen and the gas could easily be collected and either burned or used to power a fuel cell.
Riti Banerjee riti@martinfotech.in
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From the very primitive age, human beings have been in awe of the capacity of plants in making their own food through the process of photosynthesis with the use of sunlight, Carbon Dioxide, water and other minerals. For years, scientists have been pursuing “artificial leaf” technology, a green approach to making hydrogen fuel that copies plants’ procedure, rather ability to convert sunlight into a form of energy they can use.
also be used at homes and businesses.
Scientists note that splitting water with the help of sunlight to yield hydrogen is one of the best ways to achieve clean and green energy. Producing hydrogen at low cost from water using the clean energy from the sun would make this form of energy far more environmentally friendly as well as cost effective as a result of which this could
The new study comes from the National Institute of Standards and Technology (NIST), which has proposed a silicon-based PEC, in which a layer of silicon dioxide insulates the semiconductor. The top layer of this “sandwich” is an array of tiny electrodes made of titanium and coated with platinum. As described by NIST, the
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Photosynthesis in plants consists of two stages, Oxidation and Reduction. In the first stage, water is oxidised to give oxygen and protons while in the second stage, the Carbon Dioxide is converted into Glucose. For making the fuel, both these processes are required to be execute separately, and scientists have thus created photocatalysts.
protective layer of silicon dioxide is thin enough to admit a sufficient amount of light to get the job done: “…photons will travel through it to the semiconductor, and the photo-generated electrons will “tunnel” in the opposite direction to reach the electrodes, where the platinum catalyzes the reaction that produces hydrogen. ”Nocera decided in the early eighties that the chemistry of green plants was the likeliest place to seek an answer to civilization’s long-term energy difficulties. At the 2011 national meeting of the American Chemical Society, he announced a tangible breakthrough: a playing-card-size coated-silicon sheet that, when placed in a glass of tap water and exposed to sunlight, split the water
May 2015
into hydrogen and oxygen. A video he made shows gas bubbles streaming from the sheet. He said the gas could easily be collected and either burned or used to power a fuel cell. He called the device an “artificial leaf.” The JCAP group hopes to solve the other side of the artificial photosynthesis problem: processing CO2 to convert its carbon into fuel and to help reduce levels of CO2 as a greenhouse gas in the atmosphere. So far, though, the group has not made it over the catalyst hurdle. Nocera’s discovery has generated interest from Tata Group which announced that it was investing $15 million to fund Nocera’s research with the aim of using water to produce hydrogen as an automobile fuel. Tata’s announcement says that the
May 2015
company and Nocera plan to organize a startup company to build a specialized “can” -- a container “that can store hydrogen in a compressed form and fit it into a car for [use] as an alternative fuel cost-effectively.” The company, which includes auto manufacturing in its many businesses, wants to use the technology to develop cars that will run on water. Toyota is also planning to implement this technology in their cars. With further companies trying to implement this technology in the near future, we can hope to see a greener world that exhausts the non renewable resources lesser than it does now. Before this sort of technology can become mainstream, significant hurdles still need to be overcome. In addition to offering alternatives, the artificial leaf
is being designed keeping in mind both sustainability and cost-effectiveness. Addressing future needs in ways that are both clean and inexpensive are the very hallmarks of alternative energy and fuel research. As it stands, every predictive scenario we have today indicates that demands for energy will rise while resources simultaneously exhaust, due to increased consumption and climatic change. As such, relying on conventional means of energy-production (i,e coal, oil and natural gas) will not give substantial outcomes. As the saying goes, “necessity is the mother of inventions”, and there are few things more necessary than making sure that our future generations have enough resources to live and survive.
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SUCCESS STORY
Driving Industries for the last 50 years
For the last 50 years the ability and the pace to be in the surviving belt of providing engineering solutions in the transmission components sector, Motovario has shown that there is no slow but there is always a steady way to win the race. Installing gear motors in screens to move the screen forward or backwards placed on cricket field at Bellerive Cricket pitch in Tasmania in 2013, or giving the solution of bulk material handling conveyor belts in august last year to Shakti Pack Pvt Ltd in India, Motovario group has come a long way in the field of proving the tailor made custom solution of gear motors.
Starting from its genesis in 1965 in the town of Formigine, at the heart of the Modena industrial district when it was set up, Motovario has established & grown to become one of the most important Italian and European manufacturers of gear units for industrial and
civil applications. Since 1965 it has provided technologically advanced solutions in the transmission components field for industrial and civil applications worldwide. Synonymous with innovation, quality and service, as one
“Our current strategy is to address all segments and all class of customers so that Motovario products are affordable for all, at a shorter lead time with our improved supply chain.”
Suresh Chinnasamy General Manager South, Motovario India
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of the World’s leading manufacturers of industrial gears and electric motors, it is well placed to serve its customers. This year, it is celebrating 50 glorious years as a successful designer and manufacturer
of innovative motors and gears. At the company’s Italian factory in Formigine, it boasts a production plant spanning 50.000m sq. and employing 500 people. Tailoring the product to the customer’s requirements is one of Motovario’s key benefits.
“Starting Component Assembly in the near future will be another key factor for the company’s benefit on the long run since there we can work in a better range with low inventory planning, which of course demands less volume of space considering the present semifinished components storage.”
Swarup Kumar Dutta AGM – Production Planning & Execution, Motovario India
May 2015
Its main fields of application are - Mechanicalelectromechanical industry, Food agricultural and oenology industry, Amusement industry, Machine tools and Steel industry, Transport and logistics industry, Energy industry, Chemicals and pharmaceuticals industry where it has proved its mettle in the journey of making milestones. One such example is having specialized in the field of packaging machinery for over 30 years now, ever since the British company Cpack Ltd. installed Motovario NMRV worm gear reducers on its Gift Wrap 3000 automatic wrapping machine, packaging 50 packs per minute of chocolates, cakes, gift boxes, and bathroom products has never been easier. The need was to render the synchronization of the packaging machine’s
May 2015
axes more efficient, and the solution came from Motovario, with whom CPACK Ltd has maintained a fruitful partnership since 2008. Another such important application is Cricket screen sight. The purpose of the sight screen is to create a background colour contrast in order to aid the batsman see the ball being pitched at him. In night time games and whenever a red ball is used the screen is white and black in case of a white ball. Motovario’s range of geared motors includes (started in 1999), the H Series Helical gear reducers, B Series Helical Bevel gear reducers and S Series shaft mounted gear reducers. Each has been designed to meet varying working conditions and all offer high reliability and performance with a 2 year warranty.
The technological content of B-Series gear reducers allows for an extraordinary performance/lifespan ratio. These highly versatile gear units are successfully used in a vast number of industrial and civil applications. B-Series units offer excellent value for money and output torque/ weight ratio, especially considering that they need very limited servicing. Within an active market like that of India, the Motovario Indian subsidiary continues to acquire new partnerships, successfully offering technological solutions to numerous customers and meeting a wide range of production requirements. Considering the growing demand during 2011 it came up with a subsidiary in India named Motovario Gear Solutions Pvt. Ltd. which was converted into an assembling center eventually during 2012.
For the distribution of products and the related technical support service, they count on a network of over 100 dealers, working in close relationship with their subsidiaries and MAC (Motovario Assembly Centres) located worldwide. Suresh Chinnasamy General Manager (South), Motovario, comments,” When we started our business in India in 2011, we had a clear segmented strategy to address the niche markets where our brand are already well known and proven. Down the line we enhanced to manage new products and new segments based on our strengths and today we are into more or less all segments starting from Steel, Power, Food , Electro mechanical etc. We are now focussed to reach a broader network this year, thanks for the support from new enhanced product lines and launch of energy efficient
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“Motovario is focusing on serving to higher level of consumer needs, to which the future of Indian manufacturing would largely relate to. This will help us in achieving new heights by providing customized solutions in terms of non-standard products in a short lead time.” Muninder Bhargav General Manager West & North, Motovario India
products. Our current strategy is to address all segments and all class of customers so that Motovario products are affordable for all, at a shorter lead time with our improved supply chain.” Motovario’s production system has been quality-certified under standard UNI EN ISO 9001:2008 – an international recognition of the company’s quality system as a whole. Procedures are under way to obtain the OHSAS (Occupational Health and Safety Assessment Series)
18001:2007 certification, which specifies the requirements of the management system controlling safety and health in the workplace. Recently Motovario has taken over Pujol Muntalà, one of the most renowned Spanish companies for the designing, production and distribution of geared units and elements for power transmission. The takeover, concluded by way of the foundation of a new company called Gear Solutions ES SI, will not require any
“Even if brand is relatively high priced, that high price, per se, need not be a problem as long as people believe our brand provides value for money. A successful brand is built on the bedrock of a great brand experience, no compromise on quality.” Arunima Ghosh Sr. DGM-Business Development, Motovario India
integration with the production and business structures of Motovario.
improvement and focus is shifting towards multi country operations.
As per Muninder Bhargav, General Manager (West & North), the core strength of Motovario lies in “Off the shelf availability of product” and “providing immediate response to the customer”. Since the inception of Motovario Indian subsidiary, we have strived hard to maintain these basics, which helped us to maintain a good relationship at market place. There are signs of
With “Make In India” approach, the Hon’ble PM of India aims to give global recognition and also place India on the world map as a manufacturing hub. Also implementation of GST will help improve competitiveness of Indian manufacturers. Motovario is focusing on serving to higher level of consumer needs, to which the future of Indian manufacturing would largely relate to. This
Motovario is at the heart of the production processes that drive industries worldwide. Quality and reliability are the company’s fundamental assets.
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From MAC to Motovario Component Assembly Centre Partha Pratim Sen Managing Director, Motovario India India is a huge market with vast product potential but at the same time it is price sensitive. Within a couple of years we will be able to start a full-fledged manufacturing unit catering to the Indian market, and also exported globally starting with our neighbouring countries.
Can you share the journey of Motovario India? Motovario was selling its product in India for a long time as per the OEM requirements through distribution chain. At that point we had pricing issues with currency exchange fluctuations as well as logistics issues of availability. I started liasoning for their products from 2010 to generate a dealer/ distribution chain and have a stronger presence of Motovario Brand in India. With the growing demand Motovario Gears Solutions India Pvt. Ltd. was established during 2011 as a subsidiary to MotovarioSpA based at Kolkata. In 2012, we were able to convert it into Motovario Assembly Centre (MAC), to penetrate the Indian market with competitive pricing for our products with ex-stock delivery of the Helical range. Motovario is celebrating its golden jubilee this year, and we are initiating to upgrade our facility into component assembly centre, which will further help us to expand our market both being competitive in price and also more flexible in delivery. The growth of Motovario India in terms of
May 2015
its sales network?
new technologies.
When we started in 2011 we were able to sell around 940 units worth around 48 Lakhs and now it expanded to 19750 units with a turnover of 15 crores during 2014. During the current year we are targeting to sell 25000 units with a revenue target of 20 crores. We have our sales team across all regions with pan India dealership network.
What are the future plans of Motovario India?
Products offered by Motovario India? For Motovario India is a huge market with vast product potential but the same time its price sensitive. As the name suggests Motovario started with Motovariators and currently we sell more of our Patented NMRV Worm units alongwith modular concept HBS Series products – Helical, Bevel and Shaft mounted gearmotors. We were able to expand our product portfolio time to time by acquiring industries, the latest one being Pujol, Spain renamed as Gear Solutions SA. In 2014 we developed invertor-motor “DRIVON�, a great innovation, but we are not able to sell in India due to the pricing as well as the industry yet to grow with adapting
Within a couple of years we will be able to start a fully fledged manufacturing unit from the proposed component assembling centre. It will not be only catering to the Indian market, but those products manufactured here will be exported globally starting with our neighbouring countries. Revenue wise, by 2020 we are expecting to reach revenue of 50 Crores. What are the basic driving force behind converting your currentassembly plant into a component assembly plant? The main driving force being again price sensitivity of the market where indigenous sourcing will save the import duty costs of standard components though the main heart of our drive system will be always manufactured at our parent plant Italy. The other main reason is the more flexibility of delivery of all ranges when we will only need the assembly time and can maintain the smaller components inventory level to the optimum.
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will help us in achieving new heights by providing customized solutions in terms of non-standard products in a short lead time The Company’s purpose is (I) the production, design, maintenance, painting and repair of transmissions and electric motors, parts and spare parts, (II) the wholesale trade of these products and machinery for the engineering, repair and maintenance of systems, machinery and equipment in general, (III) technical coordination activities for the Companies or Organizations in which the Company participates.
the market. Swarup Kumar Dutta, AGM – Production Planning & Execution, observes, “Motovario Gear Solutions Pvt Ltd is working as a MAC Assembly centre since end of 2012 where we wanted to serve the Indian Market demand for Ex-stock deliveries since we get the goods in semi-finished condition directly from our Italy Head quarter.
The vision of Motovario is to provide technologically advanced solutions in the transmission components field for industrial and civil applications worldwide.
However, to minimise this type of obligation, we are planning to start Component Assembly in near future, which is subject to Management approval because we can then supply the ratio combination of our gear reducers we want to, on Ex-stock basis and we do not have to be so much dependant on the long time Sea shipments for the semi-finished short components.
Its mission in corporate philosophy aims to promote the company’s brand and products at an international level with determination and transparency, while constantly striving to offer innovative solutions for satisfying and anticipating the demands of
We assume it will be another key factor for the company’s benefit on the long run since there we can work in a better range with low inventory planning , which of course demands less volume of space considering the present semifinished components storage.”
Innovation, quality, service, ethics are the company’s core values ever since its foundation in 1965. The Code of Ethics applied by Motovario states the responsibilities and ethical and social obligations that must inspire the conduct and behavior of those who act in the interest of Motovario, both within and outside the Company’s organization. Arunima Ghosh, Sr. DGMBusiness Development, suggests, “During Recession, the key to success during is maintaining focus by keeping wits on four things: competition, customers, communication and brand. Increasing marketing spend during times of recession can produce long-term gains that more than compensate for the investment required. Even if the brand is relatively high priced, that high price, per se, need not be a problem as long as people believe our brand provides value for money. A successful brand is built on the bedrock of a great brand experience, no compromise on quality. On the other hand, the strategy during upsurge is to keep track of those customers
we cannot service, for reasons whatsoever and invest in them to be top – of – recall. Ensure we service them at the next possible opportunity” The Drivon unit (new inverter motor) is designed for use with different types of applications (especially pumps, fans and conveyors), and is controlled by software that guarantees excellent performance, all above in terms of energy efficiency. An App dedicated entirely to the new Drivon inverter motor that allows the user to easily consult and request documentation, view the available accessories, and discover the product’s technical specifications. To know more, visit www.motovario.com that provides all the links necessary for substantial understanding. The videos regarding their production, R&D and Quality concept can be viewed on Youtube. For further details, write to Motovario Gear Solutions Pvt Ltd, C S Plot No:512, Mouza Hanspukuria, Diamond Harbour Road, Thakurpukur, Joka, Kolkata – 700104 Tel: +91 33 24381357/ 97
At the core of Motovario lies an evolved production process based on technological solutions that convert power into movement.
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TALENT MANAGEMENT
Leadership E.I.
Why You Need Emotional Intelligence (EI) to be a Successful Leader? It was once thought that the components of EI were “nice to have” in business leaders. But now we know that, for the sake of performance, these are ingredients that leaders “need to have.”
Pavan Sriram pavan@ittige.com
Much has been discovered in the past 30 years on EI and countless studies show its incredible role in an individual’s success. It was Daniel Goleman who first brought the term “EI” to a wide audience with his 1995 book of that name, and it was Goleman who first applied the concept to business leadership. It would be foolish to assert that good-old-fashioned IQ and technical ability are not important ingredients in strong leadership. But the recipe would not be complete without EI. It was once thought that the components of EI were “nice to have” in business leaders. But now we know that, for the sake of performance, these are ingredients that leaders “need to have.” Research has proven that the most effective leaders are alike in one crucial way: They all have a high degree of EI. It’s not that IQ and technical skills
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are irrelevant. They do matter, but mainly as “threshold capabilities”; that is, they are the entry-level requirements for executive positions. But EI is the sine qua non of leadership. Without it, a person can have the best training in the world, an incisive, analytical mind, and an endless supply of smart ideas, but he still won’t make a great leader. It has been shown that EI can be even more critical than the power of the cognitive brain usually measured with IQ. Let’s examine the human brain for a bit - EI is born largely in the neurotransmitters of the brain’s limbic system, which governs feelings, impulses, and drives. Research indicates that the limbic system learns best through motivation, extended practice, and feedback. Compare this with the kind of learning that goes on in the neocortex, which governs analytical and technical ability. The neocortex grasps concepts
and logic. Not surprisingly but mistakenly, it is also the part of the brain targeted by most training programs aimed at enhancing emotional intelligence. Today companies worldwide routinely look through the lens of EI in promoting and
developing their employees. For instance, Johnson and Johnson found that in divisions around the world, those identified at mid-career as having high leadership potential were far stronger in EI competencies than were their less-promising peers.
Understanding Emotions
Perceiving Emotions
Emotional Intelligence Managing Emotions
Using Emotions
Whats is EI?
May 2015
You would become a much more effective leader if you obtained a better understanding of what you feel, when you feel it.
To help you get started, here are five of my critical EI boosting strategies for leaders. Acknowledge Other People’s Feelings Assertive, action-oriented managers don’t exactly ignore other people’s feelings. What they tend to do instead is to marginalize them or “fix” them so that they don’t get in the way of action. People who fail to acknowledge other people’s feelings fail to realize that lingering emotions inhibit effective action. So the next time you notice someone on your team expressing a strong emotion, ask him or her about it. Then listen intently and play back what you have just heard in summary form. By validating their emotions, you’ll help them feel understood so that they can move forward without hindrance. When You Care, Show It This might be the easiest thing you can do - as long as you actually do it. Good leaders always notice when people on their teams are doing good work, but they don’t often show it. When you appreciate
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something or recognise what another person does, let him or her know about it. Even a quick email or pat on the back goes a long way in this regard. There are people who do great work around you every day. Don’t put off letting them know how you feel about it. Your praise will build fierce loyalty and inspire your people to work even harder.
raises stress hormone levels on its own, even without a stressor present. The pressure that leaders are under often makes them feel as if they don’t have time to sleep, but not taking the time to get a decent night’s sleep is often the one thing keeping you from getting things under control.
Watch Your Emotions
A big step in developing EI involves stopping negative selftalk in its tracks. The more you ruminate on negative thoughts, the more power you give them. Most of our negative thoughts are just that—thoughts, not facts. When you find yourself believing the negative and pessimistic things your inner voice says, it’s time to stop and write them down. Literally stop what you’re doing and write down what you’re thinking. Once you’ve taken a moment to slow down the negative momentum of your thoughts, you will be more rational and clear-headed in evaluating their veracity.
You would become a much more effective leader if you obtained a better understanding of what you feel, when you feel it. Practice this by taking notice of your emotions, thoughts, and behaviours just as a situation unfolds. The goal is to slow yourself down and take in all that is in front of you, so that you can understand how your emotions influence your behavior and alter your perception of reality. Rest Your self-control, attention, and memory are all reduced when you don’t get enough mental rest. Mental and physical rest deprivation also
Suppress Negative Self-Talk
For Leaders - It’s important to emphasize that building one’s emotional intelligence cannot andwill not happen
without sincere desire and concerted effort. But it can be done. “Nothing great was ever achieved without enthusiasm,” wrote Ralph Waldo Emerson. If your goal is to become a real leader, these words can serve as a guidepost in your efforts to develop high EI. For Organisations - To enhance EI, organizations must also refocus their training to include the limbic system. They must help people break old behavioural habits and establish new ones. That not only takes much more time than conventional training programs, it also requires an individualized approach. I look forward to hear from you at pavan@ittige.com on how you are helping your leaders to develop their leadership EI to manage their connections with teams and stakeholders in every corner of the organization. Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to improve learning engagement with measurable business outcomes.
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ENTREPRENEUR SPIRITUALITY
The Way to Heaven is only through Hell Spirituality for SME’s- 4 In this fourth series of articles on spirituality let us discuss about another principle which explains that struggling and suffering actually makes one stronger to face life boldly.
A S Shetty sedvik@vsnl.com
Jesus Christ said: Blessed is the man who has suffered; he has found life. Osho said: In life there are no short cuts; only illusions are short cuts. Life is arduous because only through arduous struggle does growth come to you; it never comes easily. You cannot get it cheaply, anything that is cheap cannot help you to grow. Suffering helps, the very effort, the very struggle, the long path that gives you sharpness, growth, experience, maturity. Only one who has never tried to live , who has been avoiding life, can remain without suffering. That is why, in very rich families, only idiots are born, because they are protected so much. And when you protect somebody so much it is not protection against death, it is protection against life.
With easy and lazy life one will never grow in awareness and maturity; and he will not have higher layers of consciousness because those higher layers come into existence only when you suffer, when you are challenged. When there is a problem you are challenged. In Sanskrit, they have a beautiful word for suffering. They call it Vedant, and vedant has two meanings; one is suffering, the other, knowledge. Vedant comes from the same root as Veda. Veda means source of knowledge. Those who coined this word vedant, came to know a fact, that suffering is knowledge. Hence they used the same word for both. If you suffer, immediately you become aware. The stomach comes into existence only with a stomach-ache. Before, it may have been there but it was
not in your consciousness. Suffering is a challenge: when you suffer you are challenged. When there is a problem, you are challenged. When you encounter a problem, only then you grow. Our mother nature shows fine examples of how pressure transforms anything. It is pressure that transforms sand in a shell turn into a perfect white shining pearl. It is extreme pressure with which coal is transformed into sparkling diamond over a period of time. Napolean has said: “only a fight is lost, only a battle is lost, not the war’. But if you want to win the war you will have to lose many wars. It has been observed that generally the first generation
Thomas Edison failed 1000 times before creating the light bulb. Albert Einstein didn’t speak until he was four years old. Einstein didn’t have the best childhood. In fact, many people thought he was just a dud. But he kept thinking well, he eventually developed the Theory of Relativity.
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entrepreneurs grow to greater heights once the initial hurdles are overcome. The second generation entrepreneurs generally grow slower and the third generation entrepreneurs generally encounter total failures. Because, the second generation entrepreneurs at least have the opportunity to watch how their parents have struggled hard to overcome problems. But the third generation entrepreneurs don’t have that opportunity to watch the struggles of the first generation entrepreneurs. During my working and consultancy experience I had watched in some business families the parents had seen to it that their heir is exposed to various levels of responsibilities step by step. I have watched also one business person who allowed his son to occupy an air conditioned room immediately after his
engineering graduation and not allowed to get involved in the shop-floor problems. After a few years of running the factory I heard the business had wound up. There is a saying that business is like a large tree with a big trunk with several branches. One has to struggle to climb up the trunk portion but once one reaches the branch levels he can move from one branch to another easily. There are several examples how some people started small and went on to achieve great things. Benzamin Franklin dropped out of school at age ten. That did’nt stop the great man from persuing his education. He taught himself through voracious reading and eventually went on to invent lightening- rod and bifocals. He became one of America’s Founding Fathers.
Bill Gate’s first business failed. Yes, the richest person in the whole world couldn’t make any money at first. Gate’s first company, Traf-O-Data failed miserably. When Gates and his partner, Paul Allen, tried to sell it, the product wouldn’t even work. Gates and Allen didn’t let it stop them trying again though. The author A S Shetty, with vast industrial experience of more than 28 years is a mechanical engineering graduate from IIT BHU and a Post Graduate in Welding Technology from Germany. He is one of the leading experts in Rollforming Technology in India. Apart from steering the growth of his company Sedvik Industries Pvt Ltd, he is also helping companies to promote Rollforming Technology as a consultant. In this new series on SME Entrepreneur Spirituality Article series, he is penning down his experiences.
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
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MANUFACTURING EXCELLENCE
Exploiting Benefits from Value Engineering Managing a SME in India - Part 29 Value analysis can be applied for any process. Process is mapped first and then each of the activities are analyzed to see if it is adding value. Looking at values from the customer angle and initiating actions may enhance value by systematic approach of VE and VA. This is one good mantra to stay competitive.
P S Satish gotopssatish@gmail.com
Exploit benefits from Value Engineering Competition has become order of the day. In the era of liberalization, privatization and globalization only the fittest can survive. Being in the race chasing costs alone is not sustainable. Companies need to think on how to increase the value to Customer. Value engineering and Value analysis is an effective tool for cost reduction of a product without sacrificing the quality, safety and efficiency. The emphasis is on providing over all functional reliability at the lowest cost. As a continuation of last article, we will discuss on few more points to manage SME’s better in India. Many industrial experts have identified the importance of
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value to Customer. See here saying on value from Bob Allen of AT&T, “Be better than your competitors in providing Customer value”. Larry Bossidy from Allied Signals said, “Premier companies are serious about delivering value to Customers”. Value analysis (VA) is typically referred for existing Products or service and Value engineering (VE) focus is at prototypes and new product developments. During initial stage of product cycle, cost involved to change product design is much less compared to doing at later stage of product life cycle. What is Value? Many times value is confused with cost or price of the product or service. Value is always defined by the Customer or end user and enhancing value is one the best
ways to beat competition. Value can be defined as ratio worth to us over what we pay. When we feel that what we get is worth less than what we pay, then we say that there is no or less value. Value can also be defined as ratio of perceived benefits over price paid by Customer. Within Value engineering, Value is defined as the ratio of function a product or service supposed to do and cost involved. That means, to enhance value for the same function, cost incurred has to be reduced. Aristotle identified 2000 years ago many values like moral value, social value, political value, religious, judicial value, economical value etc. The emphasis of Value engineering is enhancing economic value.
Value Perception The perception of Value is subjective and changes from person to person and changes over time. Customer perceived value is the difference between all the perceived benefits minus all the costs associated in the offering and alternatives. An old car is perceived as a bunch of scrap by someone and other one perceives same car to have high antique value. When the company is able to increase perception of Value in the mind of Customer, they can afford to sell products at higher price. Take for example Apple Products. They are able to create a Value of Innovation, benefit of image and psychological comfort in the Customer’s mind and able to sell at premium price though many competitors are able to
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Assessment & Conclusions Target
Performance
Value Analysis
Brand
Competition
Value Chain
give the same features at a better price. Higher quality or service does not necessarily mean that value will be perceived. All dimensions from customer’s perspective to be viewed to enhance value. The first step to enhance perception is to understand what is important for the Customer and not what is important to the company. What is Value Index? Value index is ration of Function-worth over Functioncost. The least cost that is required to perform a function is called worth. Value gap is the difference Function-cost and Function-worth. The focus would be on increasing the Value Index Reasons for Poor Value There are many reasons why poor value is perceived by the Customer from the product or service.
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Focus on confirmation and not going beyond,with old habits and attitudes, reluctance to change, lack of creativity, lack of time, reluctance to take advice from others, not adopting to changing circumstances, prejudices, lack of experiences, poor communication on products, not aware of importance of Value. Touch Points of Customer in looking at Value The Customer perceives Value at various stages during usage of product and interaction with the producer of product or service Product Performance– Features, Ease of use, Reliability, Performance, Life, Safety Product Price – Initial cost, Distribution cost, Maintenance cost Delivery, Installation and
Related Products
Service – Product availability, Lead time, Ease of Installation, Ease of Service Customer Relationships– Contacts, Reachability, Response, billing, Payments, Brand image Subjective – Appearance, shape, esteem, styling, satisfaction Objective – Price, Weight, Quality, Worth, Color, Use, Efficiency When to initiate VE Projects? •When profitability of the product is getting eroded •Lack of Customer appeal and product not moving in the market •Non-competitiveness of product •Products having repeated Customer complaints or quality issues
•Import substitution •When cost seems not worth for the function •At the early stage of product life cycle •For high value items •For high volume items, where small reduction can bring good benefits •When brand image of product has to be enhanced •To beat competitors Principles of Value Engineering •The VE is a multidisciplinary approach • Team has specialists in their field • The team identifies key functions for lowering costs without sacrificing performance • It is an organized and
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systematic review • Everything will be viewed from functional angle • Involves creative thinking process • Value is viewed always from customer perspective Types of functions Key questions to ask – What is the item supposed to do? What functions it does and what is not required? In the context of Value Engineering, function means not only what it does but also what it is to be and its purpose. For example an iron box does – create heat,consume energy,iron clothes (What it does ?); Be portable, Be decorative ( what it is ?) ; Remove wrinkles ( what is the purpose) Primary functions – Must to keep. Cannot be sacrificed Secondary Functions – To be debated whether this is
required and be compromised; Desirable but not must.
Function Analysis Phase
Orientation
This phase is also called function-cost-worth analysis phase. List down all functions of the main item and it’s constituent parts.Calculate basic cost of providing basic or primary functions called ‘Function-Cost’. If it has one basic function, whole cost will be included for this function.
Form a team with persons from cross functions. They should be knowledgeable in their domain. Identify a Leader to lead the Project. Create awareness to the team by training on the methodology. Define objective of the project, targets and time frame
If it has more than one function, present cost will be apportioned based on relative importance of the functions. Here total cost including taxes, overheads to be considered. It is a difficult job some time and better to include a costing person in the team.
Information
Next step is to calculate ‘Function-worth’. It is the lowest cost of providing the basic function without sacrificing quality. Example, Function-worth of ‘providelight’ is the cost of candle, though ‘Function-cost’ of same is by expensive electric lights. Then, Value gap (difference between function-cost and function-worth) and Value index (function-worth divided by function-cost) is calculated.
Aesthetic Functions – That pleases Customer Steps in Conducting VE Following systematic steps will give better results from Value engineering project –
Collect Information and data about the product that may include technical aspects, costs, quality, manufacturing, competitor activity & their product, market share, Customer feedbacks etc. Identify Customer needs & wants, voice of Customer and things that are critical to quality & value perception.
Value index below 0.6 is a good candidate for value engineering. Creative Phase Brainstorm among team members to create alternatives where cost reduction is possible for all functions with lower value index. Never neglect even silly ideas. Cultivate open and inquisitive mind approach. Watch for mental blocks. Focus on value with respect to cost and ways for reducing costs. Also compare with competitor ways and question everything. Encourage positive approach and innovativeness. Some obstacles for creativity are negative attitudes, resistance to change, playing safe, fear of failure, lack of confidence, tendency towards confirmation etc. Evaluation Phase Combine ideas and establish costs for all ideas. Three points to ask for each idea is – will it work, will it lower cost? & can it be implemented?Paired comparison method can be used to identify top few
Brainstorm among team members to create alternatives where cost reduction is possible for all functions with lower value index. Never neglect even silly ideas.
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best ideas. Few criteria for selection of ideas are better quality, reduction of costs, better aesthetics, ease of maintenance and service, better marketability, faster implementation etc. Investigation Phase Investigate again to check whether proposed solutions will work. Aspects of design, quality, manufacture and service are rechecked. Any quick trial needed to be completed to ensure proposed solution works. Pre-present to team for review. Recommendation Phase Give final recommendations to the management including proposed solutions, expected results, savings, time line and efforts needed. Implementation Phase Make a detailed action plan with clear responsibilities. Start implementation. The Team leader has to co-ordinate all actions Follow up Management will review in between to check the progress and any support needed Benefits of Value EngineeringOne or few benefits can be expected from VE and VA – Decrease of cost and hence increase of profit, improvement of quality, increase of market share, effective usage of resources, achieving target costs, standardization, work simplification. Pre-requisites for success of VE and VA Top management support,
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training of members, cross functional co-ordination, encouragement of creativity,
reward for VEVA efforts, positive attitude culture, proper selection of Project and Team, good selection of team leader who can drive, continued monitoring and support. Value analysis can be applied for any process. Process is mapped first and analysed each activities to see if it is adding value. If not either, the step will be eliminated or simplified. VE and VA are powerful tools which can be used by the industries and there is lot of scope in MSME’s for it’s application. Start looking at values from the Customer angle and initiate actions to enhance value by systematic approach of VE and VA. This is one good mantra to stay competitive. I acknowledge with thanks author Mr.M.S.Vittal from whose book, ’Achieving competitive edge through Value Engineering’, I derived a lot. I will continue the series of article in the next issue. 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. Have a nice day.
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ON FACE
EEPC to Mend the Top-Up System and Focus on SME’s
Suranjan Gupta Additional Executive Director, EEPC What the Government should do essentially is to be an enabler and create conditions in term of externalities. There are too many negative externalities, we need to build positive externalities. In terms of infrastructure, we need to have good roads, good ports. We need to have good institutional transmission mechanism in the sense that banking and revenue system should gel well and there would be less of transaction problems then.
What is your take on our PM’s “Make in India” campaign? Well I think the concept is good in the sense that he is trying to do is revive the manufacturing sector in India and in some ways it is a continuation of what the previous Government has also been attempting, which is to raise the share of the manufacturing sector from 15% to 16% of GDP to about 25% of GDP and also create employment avenues for about 100 millions. I think it is a good initiative. He is also linking it to areas
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where India is importing, like the defence sector, to try and control our import bill on defence and become an exporter of defence goods as well. In that sense it is a great initiative to give a boost to the manufacturing sector.
transaction cost in terms of various forms of digitalisation, lowering of documentation to only three documents now, what has been substantially reduced is the duty incentives (they are calling it reward now).
Can you please brief about the Foreign Trade Policy 20152020?
So what they have done is that they have consolidated it into two schemes, which is a good thing to do in terms of the architecture of the scheme and the administration of the scheme. They have done away with the clutter and streamlined it and modified what used to be earlier called
From the Industry’s perspective and from the exporters’ community it has been a dampener in the sense that even though the attempt has been made to reduce
the MLFPS scheme and categorised the countries into A, B, C. The major problem is that they have drastically reduced the duty credits that they were giving earlier and done that suddenly without giving a transition period. The exporters need some time to adjust to this sudden change because when you have a drop of about 3-4% of your FOB value or thereabouts in certain cases, you do take a hit because you have already contracted certain long term contracts as engineering,
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unlike shoes or textile, is such where you work on long time contracts and there are difficult issues with costing.
of technology. In this world of production networks, you have to pitch as to where in the value chain do you fit yourself.
We need to remember that Indian engineering is primarily low to medium value added, a lot of profitability arises as a result of the fact that you are giving them a certain incentive.
Increasingly we are at the lower end of the value chain and we need to gradually move up. In the developing countries, you have logistic problems, you have asymmetric information problem. These are the major problems that we face in building global partnerships.
While the objective to gradually phrase out incentives is a great idea and in line with our WTO obligations as the Government has pointed out, what is also critical is that you don’t give them a shock therapy. Perhaps it could have been handled better. What are the major setbacks that you face while trying to build global relationships? The greatest thing in building Global Partnerships is adjustments and it all depends on which part of the globe you are targeting the partnership. We have certain types of problem in the developed world, essentially of a non-tariff barrier type, which is in terms of standards of your technology and their technology. They are coming up with all sorts of sanitary and phytosanitary measures in the technical barriers to trade rather than their duty. There is also a lot of green technology. So, they are trying to dump their dirty technologies in our country and use good green technology in their markets. Therefore there is that contradiction and there is this mismatch. So the greatest challenge is to have a similar wavelength, in terms
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How was India’s growth in the Export market in engineering in the year 2014-15? April to February engineering was done relatively, on the average it was about 16% though February figures were negative, a negative 0.9%. The growth in the first half was very good but it was bad in October as a result of too many holidays. November was very good, where we had about 30% growth basically taking off from the October slide. Again February was bad and you can see a slackening there with Europe not reviving too much. Therefore, I think 16% when the overall exports were negative is a good thing for engineering but things could have been better had the external conditions been far more contusive and interest rates had not fallen down so much. Being a Government sponsored organisation and catering to the Engineering sector, what steps do you think the government should take to empower manufacturing in India?
What the Government should do essentially is to be an enabler and create conditions in term of externalities. There are too many negative externalities, we need to build positive externalities. In terms of infrastructure, we need to have good roads, good ports. We need to have good institutional transmission mechanism in the sense that banking and revenue system should gel well and there would be less of transaction problems then. The other thing of course is to ensure that there is credit accessibility. In fact the Prime minister has launched the “Mudra”- new bank for the micro unit, which is a great initiative. You need to ensure that risk taking becomes more acceptable to the Government or the bank. Without credit no one knows small businesses. There is a disproportionate credit that goes to the large sectors and very little to the smaller sectors. Those are the things that the Government should do for manufacturing. And of course the issues like land are already there. Otherwise, you would be essentially allowing a system where it would be only a system of risk taking and arbitrary, and no manufacturing would take place. Rather than U.S.A or Germany investing in India, wouldn’t it have been better if we had concentrated on the SME’s of India? Yes, from EEPC that is what we
are stressing because we are a SME based organisation and that is one of the reasons why you see Mudra coming in. We have been saying that there is no focus on the SMEs and it’s too top up. It’s good that we have large units coming in, we will have horizontal and vertical link! EEPC’s offering in the automobile companies? Automobile export is one of the key export sectors of India comprising about 18-19% of total export. One of the things that we do is that we take part in all kinds of auto exhibitions. We take a lot of auto companies to Automechanika in Dubai, Frankfurt and U.S.A. The other thing that we do is try and protect their interest when the Government negotiates in cases of the free trade agreements. There are a lot of regional trading agreements happening, including the one that is stuck with Europe where the Europeans are demanding that we lower down our tariff rates considerably for the auto sector. Here we have been protesting a lot on behalf of the automobile companies so that cheap models do not come here, I mean, the models that are discarded in the completely built up units. What we are essentially doing is trying to protect the interest of domestic auto manufacturing companies and also helping them to promote their wares and parts in the various countries.
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ASCENT
Bridging the Gap!
As the very title itself is self explanatory, the need arises to address the issue of such plight of the industry and the academics which has a set of characteristics and different nuances to be considered. The gap as seen in this aspect has many reasons in its arena which needs to be segregated on many platforms to be understood explicitly.
Rajiv Saini rajiv@martinfotech.in
In this issue we will focus on what exactly is the gap and what are the crucial facets/ factors contributing to its persistence? To answer this let us take a look at the statistical data first- 3,50000 engineering grads who pass out every year in our country are not totally employable. If we see the employability scenario, not more than 20% of
Engineering Graduates, 20 to 25% of Management students and only 8 to 10% of other Graduates are employable. In this given scenario, how can companies and educational institutes interact to make individuals more industry ready!? There is a need of creative thinking of how academia and corporate can interact more.
Moreover when 5 million remain unemployed, there tends to be a maximum of 3 lakh trainees only per year in this field. Thus the satiating rate of employability is quite low. The gap as seen is on many fronts and levels and to overcome this various efforts have been initiated and taken to cope up with the existing faux pas.
As put by India VP & Global Head of Corporate Communications at HCL, Mr. Ajay Davessar, the academia should understand the concerns & expectations of the industry. What are the concerns and what is the main driving force? Akhilesh Mishra, Senior Scientist Deptt. Sci & Technology, New Delhi, said that ‘‘research should be
Countries around the world are forecasting a shortage of engineers in the coming years and there is speculation that today’s engineering graduates are lacking the necessary skills and abilities needed to be successful in current and future engineering environment
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Creating, finding, and retaining workers in the contemporary manufacturing environment are already becoming critical factors in the success of advanced manufacturing
translated into commercial products that could generate wealth for the country’’. The viability that the tie ups provide are the important factors that are crucial to assess the gap or the distance pervading in the present situation. Countries around the world are forecasting a shortage of engineers in the coming years and there is speculation that today’s engineering graduates are lacking the necessary skills and abilities needed to be successful in current and future engineering environment. “The industry academia tie-up has always been a need more so now, than ever before. The Question is why is this Unison of Prime Importance today? India is a growing economy today and it has the attention of the world players for investments and expansions. This creates a requirement of employable resources. On the other hand, there is a large set of employees, who need to be skilled, re skilled and up skilled to meet the needs of the changing dynamics of work. This is possible only through
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the active role of industry in sharing the know-how and of the academia in developing the programs and solutions to fill the void”- Manpower Group. The present situation is a consequence of a number of factors that helped widen the gap. To put them at a glance - No job-ready skills cultivated in the young brigade, no exposure to the industry insights because of differently oriented goals, inadequate professionals in the academia, non negotiable point of views where the academy finds it below their standards to be with the industry happenings and no direct communication are such contributing factors. Additionally the shortage of ‘required’ skills as technical or non technical to be categorized specifically has added to the need of niche employees as well. 90% of manufacturing managers agreed that they view their workforce as partners in solving, improving processes & satisfying our customers. The rise of computers has led to the need
of sophisticated technical staff for the analysis and application along with production and operation. “Today, however, a third group has emerged apart from the white and blue collar jobs in the contemporary manufacturing environment, and is poised to eclipse at least one of the two traditional groups in importance. It is also a category that has grown, even in a manufacturing context, that has seen the shrinking numbers of workers. Creating, finding, and retaining workers in this third category are already becoming critical factors in the success of advanced manufacturing.” – Manpower group. It is however noteworthy that the distance maintained by both the sectors makes both of them indispensable & interdependent on each other and they are bound to be with each other in the long run. The following scenario can be categorized as ‘producerconsumer collaboration’, ‘collaboration in continuing
education’ and ‘collaboration in research’. The role of the students, universities, industries, internships, workshops, creating a sharing culture are some of the crucial and decisive factors for the amalgamation of both of them to work in unison. But more is never enough as there are rapid technological advancements and both need to pace up because it is an ever changing process. They both are the junctures for each other to carry on the baton of innovation, scientific progress and the technological upliftment of a nation by contributing in the GDP by their joint efforts. There are numerous points to throw light upon but here we shall confine to its existence and reasons only. 73% of manufacturing managers agreed that “The manufacturing process/ technologies we use in our operations have become much more sophisticated and complex in the past several
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years.” – 2012 Manpower Manufacturing Workforce Survey. As we see that the needs and requirements have changed so is the basic structure of the employers and the employee. The gulf countries are also under the same situation where they are finding it extremely difficult to bring up skilled and non skilled both on the tech front. Similarly one of the challenges in bridging the gap between academia, industry, and government is finding a neutral, supportive environment in which all of the players feel encouraged to participate, work through their differences, and reach consensus to produce a variety of shared results. The IEEE Standards Association (IEEE-SA) provides a globally recognized framework for
developing consensus standards through an open process that engages industry and brings together a broad stakeholder community. Engineering colleges will have to look at ways to bridge the gap in education by providing sufficient exposure to live projects, by increasing collaborations with the industry,” said Srikantan Moorthy, vice-president and head, Education and Research, Infosys Technologies. Soft skills have always been in demand especially in the areas of leadership and team management. “When Infosys recruits, apart from the basic qualifications, they focus on the learning ability of the individual, which effectively means how efficiently an individual is willing to learn and then use that knowledge in any given context,” Moorthy added. Through its partnership with the Indo-US Collaboration
for Engineering Education (IUCEE), Infosys has conducted two Faculty Leadership Institute programmes at Infosys Mysore since 2008 to prepare over 1,200 engineering faculty members across India,” – Moorthy, Infosys. NASSCOM report highlights shortage of 500,000 knowledge workers by 2015. Chemical engineering professor Raghunathan Rengaswamy said if the issue was about the gap between research and academia, one of the issues may be the lack of excitement on the part of industry. “The moment we present an idea before industry, question is whether the product is global or local. That is the target of industry when there is an innovative idea.”- TOI. In a nutshell we can summarize the whole de facto as types of gaps which can be elaborated as employability gap, skilled
and non skilled tech workers gap, gap of mentality between the industry and academia regarding the manufacture, goal driven gap as some of the major faux pas. As a major initiative in his first budget, the Finance Minister had promised employment to the youth of this country with funds allocated to various schemes, especially the manufacturing sector as a part of Make in India campaign. As industry is the best place for applying the knowledge of science, perhaps students should be exposed to experience in industry on a mandatory basis. Both industry and university will be benefitted in this process. The need of the hour is that students need to imbibe the skills to think like leaders. This could only happen if there is awareness of industry environment and if they were application – oriented.
“As a teacher of science in India and abroad for about four decades, my feeling is that the syllabus which the student go through is really out of touch with the real world. The Indian picture is that students are supposed to read some topics, memorise and then write it down on paper during the examination. In countries like USA, they are not expected to memorise, but use them in solving problems (the open book kind of examination). In both the cases, the knowledge and its applications are book bound.” Prof.(Dr.) Papiya S Nandy Centre for Interdisciplinary Research and Education (CIRE)
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CASE STUDY
Back on the Map In a country once riven by war, the story of GAT is one of determination and triumph in the face of adversity. A former refugee, the company’s owner returned home after the conflict in Bosnia and built a successful manufacturing business supplying his one-time employer in Germany. Today, the company he created employs 65 people and is home to 12 Haas machine tools, including two recently installed UMC-750 five-axis universal machining centres.
Bosnia-Herzegovina is a country on the rise. It’s been 20 years since the conflict ended in 1995, during which time the nation has rebuilt and introduced liberal market reforms to help stimulate the economy. Many of the people who left to escape the war have since returned. Among them is Almir Gvožđar, who in 1996 came back from Germany, invested all of his
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savings in a second-hand CNC machine tool, and started making aluminium components from the family garage, under the name of GAT d.o.o. During his time in Germany (citizens of war-affected countries such as Bosnia and Croatia had temporary refugee status in Germany), Mr. Gvožđar worked as
a technician for ABM Fahrzeugtechnik GmbH, which is based at Breisach, close to the border with France. ABM is a leading manufacturer of highperformance parts for the motorcycle industry, and the company was later to be GAT’s first customer. “Working alone I started producing parts for tuning
motorcycles,” says Mr. Gvožđar. “From here, we managed to pick up a few other German customers, and so our story began. Indeed, the German market remains our most important to this day, although we also export to countries that include Switzerland, Austria, and Slovenia.” In 2003, GAT purchased a
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facility measuring 1100 m² on a 5000 m² plot at Sanski Most, in the industrial northwest of Bosnia-Herzegovina. In parallel with investing in premises and the addition of more employees, the company also began to step up its investment in the latest CNC machine tools. “I first heard about Haas when I was at ABM; they had Haas machines,” says Mr. Gvožđar. “I knew the Haas CNC was easy to use, and that the service and support was good. Haas machines are also a good price – the best buy on the market!” GAT today has 12 Haas models, including seven VF-2 vertical machining centres, two TL-1 toolroom lathes, and one TL-25. The company’s latest additions, however, are two UMC-750 five-axis
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universal machining centres, the first to arrive in the region formerly known as Yugoslavia (Bosnia- Herzegovina, Croatia, Macedonia, Montenegro, Serbia, and Slovenia). The machines have been set to work producing parts such as clutch levers, which GAT designed in co-operation with its customer. “We were seeing more and more demand for five-axis work, hence the investment,” says Mr. Gvožđar. “Since using the UMC-750s, we’ve seen both productivity and quality increase. We are also achieving a better price for final products.” Around 90 percent of the parts made on the UMC750 machines are cut from aluminium. Many of them are motorcycle related – such as components for fuel tanks,
air filters, and speedometers – and many involve the generation of complex, freeform surfaces. GAT also machines parts for other industries, such as the metrology and medical sectors, and is attracting increasing numbers of customers from Western Europe. Because the salary for a machine operator in Bosnia-Herzegovina is circa €400 per month, the company is extremely competitive. GAT adds value to parts by suggesting design changes that will lower the price further still. This is a big advantage, particularly for larger batches – the company produces in volumes up to 10,000 off. So impressed is Mr. Gvožđar with Haas CNC machine tools that he even bough a Haas Mini Mill for the local technical high school, to
aid in the training of future machine operators. Walking into GAT today, visitors are greeted by an impressive, architectdesigned building of blue glass, a mesmerizing water feature in the lobby, and a clean, efficient workshop run by well-trained operators making highquality precision parts. The general presentation and standards could easily pass for that of a German or Swiss company. Located in an area of rapidly emerging modern infrastructure, few would guess that this region was once one of the most war-ravaged places in the world. Visionary companies like GAT, with high standards, ambition, and owners with a sense of urgency, are putting Bosnia-Herzegovina squarely, back on the map.
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CASE STUDY
Dairy Automation : Asia’s most advanced milk Processing Facility chooses Daifuku Inner Mongolia Yili Industrial Group Co Ltd, is a top dairy producer in China headquartered in Huhhot, the capital city of Inner Mongolia. In July 2005, Yili built the largest and the most advanced milk processing plant in Asia, with a coexisting distribution center, inside the Huhhot Main Factory premises. With high-capacity production systems and AS/RS, the new plant increased production capacity and achieved a fast supply system.
Complete automation of material handling system from production Yili processes dairy products including milk, butter, cheese, and powdered milk in dozens of manufacturing plants throughout China. Products are mainly distributed domestically but are also exported to neighboring countries, such as Mongolia and Vietnam. With the diversification of dietary habits and the health conscious trend of recent years, milk consumption has rapidly increased especially in metropolitan areas, and is expected to grow even more significantly in the future. With the anticipation of such growth in demand, Yili built the new Milk
Processing Plant along with a Distribution Center. The Distribution Center Yili chose Daifuku to consult, design & implement the state of the art distribution center - the unit load AS/ RS with 21,024 pallet-storing capacity, and a load handling area. The factory produces about 1,500 tons of fresh milk daily with 18 production lines. Processed milk is poured into paper cartons and transported to the packing line in the distribution center via conveyors. Palletizing robots then stack them onto pallets. These pallets are temporarily stored at the AS/RS by a loop-type high-speed STV. At the time of shipping, STV transports the pallet that has been retrieved from the AS/RS to the shipping area. The shipping volume
per day is about 2,000 tons, including products coming from other plants. With cutting-edge automation technologies, no manual handling is involved from production, to packing to shipping. The construction of five more new plants is planned for increased production Yili is projecting to continue increasing production volumes into the future. The plan includes building fine new plants in locations such as Xinyang, Hefei, and Hebei by 2007, introducing the same leading-edge material handling systems as in Huhhot. For further details write to asim_behera.da2@ha.daifuku.co.jp or visit www.daifukuindia.com
3 palletizing robots automatically stack milkcartons onto pallets
Unit load AS/ RS (11 S/Rs) and STVs: Loop-type STV has a transport capacity of 247 pallets/hour
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Innovative Automation Products
B/24, MIDC Satara 415004 India
+91 2162 246509 +91 2162 245966 sales@innovativedro.com www.martupdate.com 65
CASE STUDY
Five-axis CMM inspection - lets “good times roll” in QC department at small engine plant
Scanning probes speed form-data collection and feedback to machining cells, reduce CMM fixturing and cut probe calibration time from hours to minutes at Kawasaki’s Maryville, MO plant. Increased measurement throughput and flexibility allow faster feedback to manufacturing and R&D department, while scanning CMMs may ultimately eliminate inspection systems for gears and cam lift.
Kawasaki encourages motorcycle enthusiasts to “let the good times roll,” but good times of another sort are rolling at the company’s Maryville, MO small engine plant, where two 5-axis scanning probe systems are slashing CMM inspection and probe calibration times, and speeding up QC feedback for machining of small engine components. The 5-axis Renishaw REVO systems, installed on Mitutoyo CrystaApex 121210 CMMs, replaced two PH10 articulating heads using SP25 scanning probes on traditional 3-axis CMMs. The REVO-equipped CMMs have cut inspection times by half or more on scanning intensive applications, eliminated the need for custom probe configurations, cut
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probe calibration times from six to seven hours to about 45 minutes, and added new capability to collect large amounts of form measurement data, improving part quality. Of primary importance, the REVO systems have greatly increased inspection throughput, data quality and flexibility of the QC department, enhancing its value as a strategic support asset to both manufacturing and R&D. The Kawasaki Production System Kawasaki’s 800,000 squarefoot Maryville plant, opened in 1989, produces single and twin-cylinder air-cooled or water-cooled engines, 1000 cc or smaller, for commercial and consumer lawnmower
OEMs, as well as for a sister plant that manufactures ATVs and Mule™ utility vehicles. Operations at Maryville include aluminum die-casting, plastic injection molding, extensive amounts of machining, painting and assembly. All engines – approximately 500,000 per year – are run-off before shipping as well. “We use the Kawasaki Production System (KPS),” said JC Watts, Quality Control Technical Group Supervisor at the Maryville plant. “Our quality and engineering requirements are comparable to the best in the automotive industry, though our manufacturing is focused on lower volumes of many different kinds of products.” The plant has 50 machining
lines, typically arranged in a U-cell pattern with start and end machines across from each other. “Primarily, it’s one-piece production with machining lines running a part through multiple processes at a high rate,” Watts explained. Kawasaki utilizes automation in many die cast and some machining operations, accomplished through the integration of Kawasaki robots. On one of the crankcase lines, robots load raw materials and unload finished parts that are placed into inventory for assembly to draw upon. Machined parts include aluminum, cast iron and steel. “We’re running similar tolerances that automotive powertrain uses for highend products, and there are
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REVO in action
probably four or five critical processes for our aluminum parts and 15 for the steel parts,” Watts added. It is not uncommon to find tolerances “in single digits in microns” for form, and 0.05 mm true position. The QC lab is responsible for inspecting 125 different mass-produced parts, as well as vendor parts and those produced for engineering development. The environmentally controlled lab is located adjacent to the machining lines, and parts intended for routine inspection are delivered on carts or via train (an electric vehicle towing several trolley carts). Critical components may be hand delivered for priority inspection during a line changeover or if an operator suspects a problem. 5-axis scanning advantage “When I started here, we had a couple of 3-axis CMMs with
May 2015
PH10 articulating heads and SP25 probes, and another CMM with a fixed probe head,” Watts explained. “We were frustrated with having to make probe configurations and being limited to what we could do even with the articulated heads. We had so many different probe configurations that calibration times of six to seven hours took a bite out of our inspection throughput, too. We wanted to do better than what the industry considered the norm, so we looked at several options and the 5-axis REVO system appeared to be the fastest and most flexible available. It was the best fit for our requirements.” Kawasaki bought a new Mitutoyo Crysta-Apex 121210 in 2009 with the REVO system installed from the factory, and retrofitted an identical machine in 2010, after the first machine was up and running with all the part programs.
The REVO 5-axis scanning probe head can collect up to 6000 data points/sec. It is engineered for high-speed precision measurement of contoured surfaces and complex geometries requiring high-volume data collection to validate fit and form with high accuracy. It uses two rotary axes, one in the vertical plane and one in the horizontal, for infinite rotation and positioning. Five-axis software drives the measuring head and synchronizes its motion with the linear axes of the CMM. Look-ahead algorithms drive the probe path and CMM in coordinated continuous motion. The head adapts position while measuring on the move, maintaining stylus tip contact with changing contours at scanning speeds of up to 500 mm/sec. “Though our SP25s were scanning probes, we were doing 95 percent touch probing because scanning was
too slow with a 3-axis CMM,” Watts explained. “Our cylinder and crank bores are probably the best examples of where we believed touch probing was inadequate. To accurately collect enough data points to measure the geometry of a bore 80 to 100 mm in diameter and 150 mm in length, the SP25 probe took so long we limited those inspections to machine set up or special requests from our design department. Now on every crank case we measure, the REVO does a spiral scan of bores and the system outputs the values to software. We also send a graph of the data points to our network that can be used by anyone in QC, engineering or production, and it really helps troubleshoot problems. You can VISUALIZE the problem. What would take 3-4 minutes with an SP25, we’re measuring in 10 seconds with the REVO.” The REVO scanning heads have all but eliminated the need for
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touch probing. Now 95 percent of inspections utilize scanning, with no “time penalty” as before, allowing Kawasaki to collect so much data that it challenges the speed of computers doing the analysis. The REVO probe can also do “head touch” probing or be used for traditional machinetouch probing when the situation calls for touches. “With scanning inspections, our production and engineering people have a lot more confidence that the data is valid,” Watts added. “With touch probing it is easy to get one speck of dirt that causes an out-of-round condition if you’re only sampling seven or eight points. It can throw the location of that circle off. We have specific documented examples of where there were flatness errors we would not have caught with touch probing, and cylinder bore
geometries that would not have been caught with touch probing because of the amount of data sampled with the touch probe. We still caught these problems before they left the plant, but the parts were scrap. The REVO scanning capability allows us to catch form errors much more quickly, without a time penalty on our inspections. It has definitely made us more proactive in catching quality problems early in the game.” Fewer probe configurations, more flexibility With REVO, the Maryville operation now has two probe configurations that measure all of its mass production parts, reserving custom probes in a changing rack for a few special applications. Special configurations for vendor parts have also been eliminated because the infinite positioning angles of REVO allow measuring
of a part without special fixturing or consideration of which probe to use. With so few probes, calibration time has dropped to around 46 minutes. Now QC technicians monitor the calibration instead of calibrating every shift. “We are now able to measure all our mass production parts with just two probe configurations,” said Watts. “We were able to eliminate the large ball stylus configurations because of the large approach angle the REVO creates between the stylus and the work piece. During scanning the REVO maintains the approach angle which allows a large cylindrical feature such as a cylinder bore to be measured with the same stylus used for measuring a 5mm bore, with no chance of shanking the stylus.” Flexibility of the REVO system has also proven to be a time-
saver for Kawasaki. “We can measure any part on either machine with a limited amount of fixturing and no special calibrations,” said Watts. “We measure all our parts on three types of fixturing. The REVO probe orients itself to the part after it’s initially aligned. The utilization of special fixtures has almost been eliminated, without concerns of measurement error due to part alignment.” Kawasaki programs all of its inspection routines in-house using Mitutoyo’s Mcosmos 3.1 software. The upgrade to REVO instigated a shift to parametric and modular programming of inspection routines through in-house development of coding. This allows a program to be used for a part family. “We might have 30 different crankshafts, for example, but because everyone has the same features, only in a
Revo-equipped CMMs at Kawasaki’s Maryville
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May 2015
Revo head inspecting a FX series small engine flywheel
different size or location, we can use the same inspection program to measure all the parts,” Watts stated. “That’s one of the big advantages we gained.” Infinite angles of the REVO system make it simple to create parametric programs because there is no concern about the stylus interfering with a part feature, due to size or orientation of the feature. The probe automatically aligns normal to the feature being measured, simplifying programming. Faster inspection, better data from QC to R&D Watts says the transition from 3-axis to 5-axis programming is not difficult, and a programmer with limited ability can still program REVO inspections as 3-axis. However, when it comes to optimizing speed of inspection, it is critical to use head motion as much as possible. “This allows you to scan parts the quickest,
May 2015
without inducing measurement error,” he added. “REVO opens up a lot of possibilities, with few limitations, so speed gains are obtainable for both the higher and lower skilled programmers.” Inspection results may be relayed to the machining lines manually or they can be accessed locally by line operators over a computer network. “Some of our inspection reports supply offsets directly back to the machining centers coordinate system; this allows the CNC operator to read the offset adjustment right off the report, allowing no misinterpretation of what offsets the operator needs to input,” Watts explained. “We take advantage of some of the ‘best fit’ algorithms and work with our production engineers, especially on parts that require more complex algorithms to get the adjustment right, and to utilize multiple process
adjustments simultaneously. We had limited ability to do this before the REVO; the REVO allowed us to utilize parametric programming, which in turn allowed us to expand our capability across the board more easily.” Five-axis CMM scanning has been a game-changer for QC at the Maryville plant in terms of speed, data quality, and inspection capacity, according to Watts. “We’ve enjoyed big gains from having two machines that are completely redundant, so if one machine breaks or is down for calibration, it’s no problem to measure critical parts on the other machine. That’s a big advantage in the QC lab, because we were the ones who, in a pinch, had to get the large part on the small CMM, or the part requiring the odd angle probe on the machine that didn’t have it. We used to get requests from R&D
to measure certain geometries, and it was next to impossible to achieve in the time allotted. Now we can provide the data much quicker and, being scanned data, our people have greater confidence in it. This new flexibility, the reduced fixturing, form measurement, the parametric programming – these are all collateral advantages, in addition to the raw inspection speed.” The Maryville facility has run more than 50,000 parts through the two REVO equipped CMMs, and Watts indicated there are plans to expand the use of the REVO system to gear inspection and cam lift if it proves feasible. “We’ve developed our own algorithm and sub-routine in our software for cam lift, and, that’s something that would have been more difficult to do without the REVO system due to the angle the probe requires to measure the lift on the lobes.”
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FAIR MART
AMTEX 2015: Podium for Latest Manufacturing Technology
Cyril Periera Managing Director, Triune Exhibitions Pvt Ltd AMTEX exhibition holds tremendous significance for all levels in manufacturing organizations – be it CEO’s & entrepreneurs, senior executives, corporate planners & strategists, manufacturing managers & executives, shop-floor engineers & technicians, agents & dealers. AMTEX with its experience of more than a decade is providing a platform for the first time in Western India to meet the requirement.
How would you define Triune Exhibitors & Reed Exhibitions for AMTEX 2015 ? What were the leading factors for such a joint venture? TRIUNE formed in 2000 a 15 year old company is one of the largest Exhibition organizer in the country today. REED Exhibitions is the world’s leading event organizer with 50 years experience and a
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growing portfolio of more than 500 events in 40 countries with 34 offices worldwide. The JV will enable international presence and analyze markets, industries and stakeholders closely and accurately as well as providing proximity to Exhibitors in the country and abroad. AMTEX - 2015, Mumbai, The place to be for the machine
tools and engineering industry. Please elaborate on its focus and uniqueness this year to make it succinctly clear? It will be positioned as the premium machine tool event offering high quality infrastructure and visitors, addressing the gap present in the market. AMTEX shows provide the perfect platform for any company looking to tap the machine tool sector
in India. While exhibitors and visitors perceive that the regional exhibitions in North and in the South cover the hotspots in those regions. They feel that there does not exist a quality large scale machine tool event in the West in general and in the vicinity of PuneNashik belt in particular. Our upcoming AMTEX Mumbai event will be positioned as one of the premium machine
May 2015
tool event offering high quality infrastructure and visitors, helping international players tap the production and consumption hotspots of Western India. Mumbai- The city of dreams! What significance does it hold regarding its importance in the manufacturing technology at present; please share your views in the context of AMTEX? Our upcoming Machine Tool event in Mumbai is perfectly located in the business capital of India and is in close proximity to key production and consumption centres of Western India. Western region of India is one of largest consumption centres of machine tools in India. It is one of the key hubs of the top 3 machine tool consumption sectors in India.
Mark your dates!
AMTEX Mumbai is a professionally organized show which will be promising a higher return on your investment while targeting the auto (largest machine tool consumer), consumer durable
and engineering hubs of Western India.
Defence, Railways, Aerospace etc.
How many participants are expected to join the event this year? Additionally how many new international pavilions have shown up this time?
Association Support: The National Small Industries Corporation
200 exhibitors (30% International participation) and 12,000 – 15,000 visitors expected. Key Exhibitors : Ace Group, BFW Ltd., Tsugami, Keyence, Jyoti Ltd, Siemens, Muratec, Cosmos Impex, Sahajanand, Ravik Engg., Magal LVD, Fibro India, Accurate, Pinacho, Mahr, Golden Laser, Jinagoudra, etc. Key Visitors : Visitors from key production and consumption centers of Western India such as Mumbai, Nasik, Pune, Aurangabad, Nagpur, Surat, Vadodara, Ahmedabad, Rajkot, Sanand and Goa will be present at the event. Target industries will include Auto and Auto Comp, Textile, Capital Goods, Power & Electrical, Consumer Durables,
Concurrent Shows Automation Asia & Elasia. Exclusive pavilions from Taiwan and China in AMTEX-2015 will be showcasing themselves this year. What are the highlighting aspects which AMTEX wants to be seen by the participants this year? The machine tool hubs of North India and with the first edition of AMTEX in Mumbai from 29th May to 1st June 2015 at Bombay Exhibition Center in Mumbai, we plan to repeat our success of the past (AMTEX Delhi 2014) and help the exhibitors in targeting the production and consumption hotspots of Western India. Additionally as we are having an experience of 15 years of organizing such events we are hoping for the participants to make the maximum out of it, which shall serve the purpose
mutually. Post AMTEX 2014 results showed-64% were very likely to recommend AMTEX to industry associates. 66% strongly agree that it had the right visitors for Exhibitors. 68% were very satisfied with the event. 60% agreed that it is fully representative of the industry. Guaranteed 3 – 4 meetings with the desired buyer group is one such aspect too we want to highlight. ‘MAKE IN INDIA’ Does this slogan account for AMTEX 2015? MAKE IN INDIA is very relevant to AMTEX exhibitions. Seeing the import figures in say 2007 and in 2014/15 there is considerable reduction in terms of figures. Fostering innovations, build best-in-class manufacturing infrastructure and facilitating investment are the key targets of MAKE IN INDIA initiative and our AMTEX events are dedicated to support this initiative by offering a platform for national and international exhibitors within the machine tool sector to meet their respective customers.
AMTEX 2015
India Machine Tools Show 2015
12th International Surface
Asian Machine Tool Exhibition
A Cutting Edge Platform for the Global Marketplace
Engineering, Paints & Coating
29 May – 01 June 2015 Bombay Exhibition Centre
4-7 July 2015
7-9 October 2015
Pragati Maidan, New Delhi
India Expo Centre, Greater Noida
A confluence of exciting business opportunities, world-class technologies and enthusiastic participants from across the globe.
India’s Premier Machine Tools
An ideal platform for display and
& Automation Exhibition having
launch of new initiatives, products and
participation from 40 sectors and
technologies, establishing joint ventures,
20 countries.
developing new contacts.
www.kdclglobal.com
www.surfaceengineeringexpo.com
www.amtex2015.com
May 2015
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FEATURE ARTICLE
Time is Money! The “quick openers� from TSUBAKI KABELSCHLEPP Cable carriers for simple and quick cable laying The cable carriers from the EASYTRAX, QUICKTRAX and UNIFLEX Advanced series from TSUBAKI KABELSCHLEPP have one thing in common: they are designed to be opened quickly. This makes installation and replacement of cables and hoses particularly easy, saving users time and money
Depending on the series, various design features allow quick cable laying. The EASYTRAX and QUICKTRAX series, for example, use the 2K design. 2K stands for the two connected design components: chain links made of hard material and crossbars with flexible film hinges or flexible lamella crossbars. This allows the construction of cable carriers which combine the seemingly contradictory properties of stability and flexibility.
QUICKTRAX: crossbar with flexible film hinge The QUICKTRAX series features crossbars with flexible film hinges. They allow fast opening and easy lay in of cables and hoses with a high fill level and therefore full use of the inner space. Depending on the application, the crossbars can be opened in the outer radius (model 030) or inner radius (model 040). The crossbars are connected to the chain with a film hinge and remain fixed to the chain link even
when open so they cannot get lost during lay in of cables and hoses. The flexible material and the special shape allow the crossbars to be opened easily with just a simple movement: The crossbars are under slight tension which lets them spring open when they are unlocked. This means the cable carrier is ready for lay in of cables and hoses in no time at all and can be closed again just as quickly. No additional tools are required for loading the cable carrier, but handling is also very easy with a screwdriver.
Fast cable laying: made possible by the EASYTRAX series featuring flexible lamella crossbars into which the cables simply snap in Invisible and innovative: State-of-the-art cable carriers are hidden underneath the 30 check-in desks at Nuremberg airport
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The computer and the printer for check-in are housed in mobile trolleys. The required cables are placed in a KABELSCHLEPP cable carrier
EASYTRAX: Flexible lamella crossbars The EASYTRAX series on the other hand features flexible lamella crossbars into which the cables simply snap in. A very high fill level can be achieved as the crossbars swivel to the side and not into the cable space. The inner space of the cable carrier remains fully available and none of the cable carrier cross sections is wasted. The lamella crossbars swiveling to the front additionally allow the use of divider systems for repairing cables. The special wrap-around design seats the stays firmly in the chain link to ensure secure cable routing. The EASYTRAX chain links are made of glass fiber reinforced plastic. This fiber plastic compound provides stability, allowing extensive unsupported length. Compared to cable carriers made of non-reinforced material, the unsupported length can be nearly doubled with EASYTRAX. The fixed chain links are placed next to each other and pressed together. This simple assembly process creates the individually desired length. Ideal for numerous applications EASYTRAX as well as QUICKTRAX are equipped with an integrated noise damper to ensure especially quiet running of the cable carrier. The small division also means that both series run very quietly: Advantages which play an important role for applications in the logistics field, for example. But the innovative cable carriers
May 2015
also prove successful in other areas of application, for example at the check-in terminals at Nuremberg airport. Computers and printers are housed in mobile trolleys here. Cables and connectors are therefore constantly at risk of being damaged or disconnected accidentally. With EASYTRAX, the engineers at the airport were able to remove this source of error to optimize availability of the computers at check-in. The cable carriers are used at all 30 check-in desks of Nuremberg airport. This trolley is stored underneath the table of the check-in desk when it is not in use and is pulled out on the casters which run along a rail on the floor when it is required. The EASYTRAX cable carrier with a clear inner width of 38 millimeters guides the cables safely and without contact to the floor. Tangled cables and loose connectors during movement of the trolley are prevented. UNIFLEX Advanced: crossbars with ball joint mechanism The UNIFLEX Advanced series is extremely quick to open, but the design is different: The crossbars connecting the two side bands are fitted with a ball joint mechanism. It ensures fast cable laying and also makes the cable carrier especially stable in the closed state. When open, the crossbar remains on the chain link or it can be removed completely by unscrewing. A special tool is available for fast and gentle opening. It can also be used on UNIFLEX Advanced models with cables installed.
The UNIFLEX Advanced is extremely quick to open: The crossbars connecting the two side bands are equipped with a ball joint mechanism. Using the optional opening tool, the cable carrier can be opened extremely fast and without great effort
Users can open one meter of cable carrier in only two seconds with this tool The low noise, solid plastic cable carrier is lightweight and at the same time very robust. Reinforced wear areas on the outside additionally ensure a very long service life for applications laying on their side. Light, robust and highly resilient – it is exactly these features that make the UNIFLEX Advanced the right choice for the multi-functional formwork robot from Sommer Anlagentechnik GmbH. The company based in Landshut manufactures and assembles production systems for the pre-fabricated concrete industry and selected TSUBAKI KABELSCHLEPP for its cable carriers. “Our multi-functional formwork robot is a highly developed solution. We guarantee especially careful handling of formwork and highest precision for our customers,” explains Rainer Braun, Development Manager at SOMMER Anlagentechnik. “The cable carriers also have to meet the highest requirements so our machine can carry out its various tasks without problems.” The cable carrier type UNIFLEX Advanced 1555 is used on the Z-axis of the formwork robot. High additional loads and extensive unsupported lengths are no problem for the cable carrier, with fast cable laying as an added bonus. For further details write to Kabelschlepp India Pvt Ltd, B-14, ITI Ancillary Industrial Estate, Mahadevapura Post Bangalore – 560048 Tel: +91 80 41158997 Email: sales@kabelschlepp.info
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FEATURE ARTICLE
More Efficient Production Thanks to Tool Presetting
Attractively priced and professional – the tool presetters of the new UNO series from DMG MORI Microset convince with innovative features
Where the UNO series is concerned DMG MORI Microset relies on proven technology in tool presetting plus consistent further development. So the latest
models combine optimum ergonomics with extensive technical equipment. “The diverse options ensure the UNO series a level of
individualisation that is unmatched in this price category”, explains Lothar Sommer, Managing Director of DMG MORI Microset GmbH.
In addition to a touch display, RFID chip system and post processors for all standard controls the range of potential equipment now also includes completely
Fully equipped UNO 20|40 in the “automatic drive” version
“The release-by-touch operation in particular and the large touch display for even better handling of the MICROVISION software make work so much easier.” Lothar Sommer Managing Director, DMG MORI Microset GmbH
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Comfort system cabinet with ample storage space, optimum accessibility and internal oil trough
new options such as the autofocus and automatic drive. The UNO autofocus differs from the manual UNO in that it automatically focuses the cutting edge to be measured. This option proves enormously timesaving in particular for tools with several cutting edges around the circumference. In addition the UNO automatic drive positions the cutting edges automatically. No special knowledge is required of the user because the machine carries out fully automatic measurement of complex tools with several cutting edges and steps at the press of a button. In other words the UNO automatic drive constitutes an additional worker in tool presetting. The same manual operation as in the standard version is also possible with both equipment configurations if needed. The
May 2015
UNO autofocus and UNO automatic drive from DMG MORI Microset come with a comfort system cabinet and a 22” touch display in their standard versions. The models of the UNO series are available in two sizes. The UNO 20|40 kicks off with a 400-mm traverse path in the Z-axis while the UNO 20|70 has a travel of 700 mm. Both versions are available as tabletop devices with a 19” screen. There is a 22” or 23” touch display available as an option as well as the comfort system cabinet. Unique here is the possibility of measuring tools with diameters up to 100 mm with the snap gauge principle even with the standard version thanks to a traverse path of +200 mm to -50 mm in the X-axis. And of course all conventional tool interfaces such as HSK, Capto, VDI, KM or BMT can be realised by adapting the
spindle in addition to the SK 50 that comes with the standard version. Lothar Sommer goes on to explain the solid basis of the UNO tool presetting devices: “You can only get this class of FEM-optimised and thermally stable grey cast iron construction from DMG MORI.” The inherently rigid bed with 3-point support not only ensures safe footing but highest flexibility in the workshop as well thanks to simple setup. The integrated infinite fine adjustment in both axes and the segment incident light for visual control of the cutting edge are also outstanding features included in the standard version. The UNO “sets new standards in the entry class of tool presetting”, claims Lothar Sommer. “The release-by-touch operation in particular and the large touch display for
even better handling of the MICROVISION software make work so much easier.” The high-performance software enables simple and operatorindependent measuring in all equipment configurations. Lothar Sommer highlights the benefits of the latest generation of this software: “MICROVISION offers intuitive operation for the user and with its helpful functions quickly achieves highly accurate measuring results. Accuracy is aided by a focusing window, which enables exact positioning even for highly complex tools. A thermal label printer, vacuum clamping, a second camera for setting the centre of rotation and a multitude of other options round off the latest UNO series. For further details visit www.dmgmori.com
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FEATURE ARTICLE
Welding – Efficient and in the Highest Quality
With the new PRI7000 software, Rexroth simplifies all commissioning, handling, and diagnostics tasks. Up to 10,000 welding programs can be stored and will help to accelerate manufacturing processes. Operations and diagnostics can be done via smartphone and tablet PCs (WLAN). Welding PC and operating interfacecan be physically separated from the welding cell.
Welding processes in
much more than a proven
the automotive industry
control and monitoring
have to meet the strictest
concept: Users benefit from
requirements regarding
quicker commissioning,
process safety and the
maximum availability and
quality of welding spots.
energy efficiency, simple
With the new welding control
handling and maximum
PRC7300, Rexroth offers
flexibility. Thanks to a broad
range of interfaces.
Different combinations
welding spots
of sheet thicknesses and materials such as steel and
By means of adaptive control
aluminium are possible. With
algorithms, the new Rexroth
the precise adjustment of the
welding control PRC7300
welding current, spatter and
is optimally prepared to
• Mains voltage range: 400 V-480 V, 50/60
(Weld Interface Controller)
Hz or 500 V-690 V, 50/60 Hz
• Digital inputs: 16
• Required wire size: 35 mm²
• Digital outputs: 8
• Max. secondary current (at ü=55): 30 kA
• Digital E/A expansion via integrated
• Rated net current: 110 A
real-time bus WIC
• Max. primary current: 550 A
• Cooling: Air cooling
• Data interfaces: USB, ETH
• Protection class: IP20, control cabinet
Net, EtherNet/IP, DeviceNet
• Electrical servo-gun front-end: via integrated real-time bus WIC
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welding spot quality.
Extraordinary quality of
• Field bus interfaces: selectable, e. g. Profi
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provide repeatable high
installation
• Control dimensions: 315 x 260 x 180 mm
• Control weight: 14.4 kg
May 2015
expensive reworking can be avoided efficiently. Even today, handling, processing control, and monitoring functionalities are ready for future requirements of welding processes. 90 percent faster commissioning Innovative software tools and modular design facilitate up to 90 percent faster commissioning in comparison to other systems. An electric servo-gun front-end and open interfaces for communication, the welding process, and robot integration allow the flexible integration of PRC7300 into customerspecific automation systems – even into Industries 4.0 environments. User-friendly software With the new PRI7000 software, Rexroth simplifies all commissioning, handling, and diagnostics tasks.
May 2015
Intuitive Windows and web applications allow the handling of several welding controls on one hardware platform. Up to 10,000 welding programs can be stored and will help to accelerate manufacturing processes. Energy-efficient and compact design The system uses up to 30 percent less energy when welding and up to 80 percent less energy in idle mode. During production breaks, the higher level controller can switch the welding controllers to standby mode via field bus and activate them again if required. With its new performance electronics, Rexroth has also managed to reduce power loss and apply smaller, more compact cooling systems. Compared to the previous version, the volume of the PRC7300 welding control has
been reduced by 30 percent. Highlights • Up to 90 percent faster commissioning • Efficient handling and diagnostics with PRI7000 software • Integrated web server facilitates operation and diagnostics via smart devices • Optimized programming, control, and monitoring functionalities for maximum welding spot quality • State-of-the-art performance electronics for maximum energy efficiency •Open system architecture with integrated application layer and servo-gun functionality For more details about the product www.boschrexroth. com/welding Ready for Industry 4.0
The PRC7300 control facilitates the realization of horizontally and vertically networked welding systems according to connected industry: The dual-processor architecture for process control and communication allows especially high data transfer rates without affecting the welding process control. The fast information exchange with the higherlevel controller can be easily realized using all common Ethernet protocols. All data are being centrally stored on a production server – this helps to reduce the number of required operating computers. An integrated web server allows wireless operation and diagnostics via smartphone and tablet PCs (WLAN). Welding PC and operating interface can be physically separated from the welding cell. For further details visit www.boschrexroth.com/ industry-4-0
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MART UPDATE
Smart Switching – Adapted Braking New electronic braking torque regulation for ROBA-stop® safety brakes With the new, intelligent braking torque control module, mayr® power transmission offer an economically attractive solution for the generation of a variable braking torque for ROBA-stop® safety brakes.
The new, intelligent control device makes targeted braking torque regulation possible. The device can be operated with 24V or 48V DV and can control brakes with a coil nominal current of 10A or 5A
The new, intelligent braking torque control module by mayr® power transmission makes it possible to decelerate devices and machines evenly and gently. This innovative and economically attractive solution is pre-destined for application in smart, interconnected machines. Nobody would even think of using the handbrake or parking brake when a car is going at full speed. In order to decelerate the car as required, a driver would use the foot brake. Gradual, even deceleration is also often desired for devices and machine applications with dynamic braking actions. However, as safety brakes – in contrast to car brakes – can only distinguish between two operating conditions due to their design, namely “braking torque present” and “no braking torque present”, every
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braking procedure is carried out with the maximum braking torque available. With the new, intelligent braking torque control module, mayr® power transmission offer an economically attractive solution to generate a variable braking torque for ROBAstop® safety brakes, making it possible to decelerate machines evenly and gently. Continuous braking torque changes when in operation Up to now, brakes have been dimensioned with regard to the maximum load where devices with variable loads, for example forklift trucks, are concerned. However, it is not always expedient to work with the full braking torque. In case of partial loads, a stronger deceleration than necessary can lead to damage to the transported goods or
even to sliding of the wheels. If, however, the system detects the operating conditions and converts this information into a default signal for the new, intelligent control module by mayr® power transmission, electronic braking torque regulation is possible. Using the new system, the brake specialists have succeeded in continuously changing the contact force on the brake linings and therefore also the braking torque during operation. In this way, machines can be decelerated gently, adapted to the respective system requirements. \Furthermore, the new braking torque regulation makes it possible to compensate for negative influences on the braking torque consistency in applications requiring a
constant braking torque within narrow tolerance limits. Prerequisites for a smart machine The new, intelligent switching device by mayr® power transmission, which is operated with 24V or 48V DC voltage, can control brakes with a coil nominal current of 10A or 5A. In addition, the resulting clamping force for the brake rotor can be specified to 25%, 50% or 75% of the nominal spring force by means of two digital inputs. Alternatively, a continuous, analogue default signal from 0 to 10V is possible. The switching device determines without using a sensor whether the armature disk is attracted or has dropped. This makes it possible to adjust the overexcitation time automatically as desired. Due to the fact that the intelligent switching device
May 2015
registers the switching condition of the brake, no microswitches or proximity sensors including the respective cabling are necessary as would normally be the case. The device also takes possible wear reserves
into account, and, if required, recognises unpermitted high temperatures. With its compact dimensions of 30 mm in height, 69 mm in width and 103 mm in length, it can easily be integrated into control cabinets.
With the new braking torque control module, mayr® power transmission provide the possibility to build up control circuits and brake movements intelligently – ideal prerequisites for application in the smart, interconnected
machines of the future. For further details write to National Engineering Company (NENCO), J-225, MIDC Bhosari, Pune 411026 Tel: +91 20 27474529 Email: nenco@nenco.org
AV Multimedia “LSZH” Ethernet cabling simplified with HARTING Ha-VIS preLink®!
AV Multimedia “LSZH” Ethernet cabling simplified with HARTING Ha-VIS preLink®
jacket sizes up to 9mm can be handled.
HARTING’s recently launched Ha-VIS preLink® simple, fast assembly Ethernet cable connectors are ideal for Cat 5, Cat 6 and Cat 6EA AV Multimedia Public Building (Theatres, Concert Arenas, Schools & Universities and Conference and Exhibition Centres), Marine (Cruise Ships and Luxury Superyachts) and also Outside Broadcast Vehicle installations or any other confined space application where the latest fire regulations now demand the use of “LSZH” cables. The Ha-VIS preLink® is
May 2015
designed to terminate solid or stranded conductors allowing optimum cost efficient use for both fixed and flexible cabling installations. They can accommodate a conductor range AWG 27 to 22 allowing maximum Ethernet cabling lengths for the complete Ethernet infrastructure. The simple, repeatable, vibration-proof IDC contact termination design can handle conductor + insulation material diameters of up to 1.6mm, which supports the typical LSZH cable specifications. In addition overall cable outer
HARTING’s Ha-VIS preLink® high reliability pre-terminated IDC terminal module design concept make it ideal for use in difficult confined space installations, pre-assembled patch leads fitted with replaceable protection covers allow easy trunking dragthrough. The terminal modules are then finally clicked into the connector housings to complete the job. The rugged male & female cable connector metal housing construction ensures fully screened secure Ethernet data transfer up to 10 GBit and a long service and maintenance life. The Ha-VIS preLink® design concept allows the most cost effective, fully flexible
future-proof installation, when higher Ethernet performance cable system upgrades become necessary, as the connectors can be re-used by retro-fitting new pre-terminated low cost terminal modules The connector range is complemented with the Ha-VIS preLink® Extender allowing easy cabling extensions. The Ha-VIS preLink® female cable connectors can be accommodated in 19” Patch Panels of either the “Keystone” module or HARTING’s own “HIFF” design format. Finally they can also be fitted individually to panels by integrating into HARTING’s wide ranging IP20 to IP68 bulkhead housing connector designs. For further details visit www.harting.in
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Red Lion adds New Event Engine to RAM Industrial Cellular RTUs Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced its Sixnet® series RAM® industrial cellular RTUs, now feature a web-based user-configurable event engine that can trigger I/O and relays or send SMS text messages based on real-time operational data. With connectivity options such as I/O, serial, Ethernet, and optional Wi-Fi, RAM RTUseasily integrate with existing equipment to provide a remote monitoring M2M solution that performs reliable local control and alerts personnel of critical events. With an intuitive web-based, menu-driven interface that requires no knowledge of programming languages, the powerful RAM event engine
can quickly be configured to trigger actions when predefined alarm values are met. For example, if a tank level is too high or a pressure level is out of range, the RAM event engine will not only cycle a relay to stop a pump or close a valve, but can also send text message notifications to alert when actionsshould be taken. This functionhelps automation engineers, technicians, production managers and network operators make critical decisions. By providing data visibility, control and real-time notifications on field-deployed equipment and processes, the RAM platform enables vertical markets such as oil and gas, utilities, water/ wastewater and alternative energy to take advantage of the benefits associated with the Industrial
Remote Monitoring M2M Solution Enhances Real-Time Control and Notification inIndustrial Environments
Internet of Things (IIoT). With hardened metal enclosures, a wide operating temperature range and industry certifications to ensure safe operation in hazardous locations, RAM cellular RTUs
securely monitor remote devices via 4GLTE cellular communications to enable reliable operation in critical environments. For more details visit www. redlion.net/RAM
Chancellor Merkel and PM Modi visits HARTING High-profile visitors right at the start of the Hannover Messe 2015: the Harting family of entrepreneurs welcomed Federal Chancellor Angela Merkel and the Indian Prime Minister Narendra Modi to the HARTING exhibition stand.
HARTING connects: Federal Chancellor Angela Merkel (second from the left) and the Indian Prime Minister Narendra Modi (far left) received a personalized Han-Modular® connector which was produced live at the HARTING stand from Philip F. W. Harting, Senior Vice President Connectivity & Networks and President/Partner (second from right), and Dietmar Harting, President/Partner and Chairman of the Board of the HARTING Technology Group (far right).
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India is the partner country this year at the annual Hannover Messe which meant a large Indian delegation accompanied the prominent visitors to the HARTING stand. The Hartings informed the Federal Chancellor and the Indian Prime Minister about the latest HARTING
solutions and products in the field of integrated industry and HARTING’s activities in India. Federal Chancellor Merkel and Prime Minister Modi saw their names engraved on a HanModular® connector which was produced live at the “HAII4YOU Factory” and they received as a present. “India has enormous growth potential for the years ahead as an emerging nation. It is therefore becoming increasingly important to HARTING,” remarked Philip F. W. Harting, Senior Vice President Connectivity & Networks and President/Partner.
May 2015
SWB Schmedthenke Werkzeugbau: Original milling machine in operation
Overhead gantry milling machine: An original overhead gantry milling machine is in use in nearby Gütersloh at SWB Schmedthenke Werkzeugbau GmbH. The family-run business is only one year older than the overhead gantry milling machine series, and its development has followed a similarly positive trend.
“The concept for the overhead gantry milling machine was well received“, reports Ulrich Wiehagen, Head of Sales/ Plant Manager at Dörries Scharmann Technologie GmbH, Droop+Rein in Bielefeld, Germany. “All of the 130 or so machines sold since 1994 are still in operation – and without any drop in quality.“ One original overhead gantry milling machine is in use in nearby Gütersloh at SWB Schmedthenke Werkzeugbau GmbH. The family-run business is only one year older than the overhead gantry milling machine series, and its development has followed a similarly positive trend. The tool shop was taken
over by Dipl.-Ing. Jörg Schmedthenke and his father Horst Schmedthenke in 1993 at a time when it had 13 employees. It is now a prosperous company employing 75 people.
as we did not have the appropriate machines.“
It predominantly manufactures very large tools for car body construction in a highly impressive production hall that houses two presses and numerous machines.
To ensure that no more orders were lost, in 2012 the East Westphaliabased company finally bought a used FOG 2500 – a machine tool designed purely for finishing (pallet: 6000 x 2500 mm, triple pallet changer, changer for 60 tools, fork head with three motor spindles, maximum 24,000 rpm).
“As our tools continued to increase in size, we became more interested in an overhead gantry milling machine, says the Managing Director, who now manages the company with his brother. “We were unable to offer the HSC process for finishing large components
It was equipped with new control and drive technology seven years ago. However, Schmedthenke is already thinking about retrofitting drive and control technology for a second time so that highalloy castings can be machined even more effectively.
Starrag Group is a global technology leader in manufacturing high-precision machine tools for milling, turning, boring and grinding workpieces of metallic, composite and ceramic materials. Principle customers are internationally active companies in the Aerospace & Energy, Transportation & Industrial Components and Precision Engineering sectors. In addition to its portfolio of machine tools, Starrag Group provides integrated technology and maintenance services that significantly enhance customer productivity. For further details visit www.starrag.com
“As our tools continued to increase in size, we became more interested in an overhead gantry milling machine.”
Dipl.-Ing. Jörg Schmedthenke Managing Director, SWB Schmedthenke Werkzeugbau GmbH
May 2015
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FDH-1: From the Very First Click The new FieldConnex fieldbus diagnostic handheld device (FDH-1) from Pepperl+Fuchs makes commissioning and troubleshooting a fieldbus installation easier than ever. The mobile device can check any fieldbus segment quickly and easily with the simple press of a button. To make it even easier to install and use the fieldbus infrastructure, Pepperl+Fuchs has developed the new FieldConnex fieldbus diagnostic handheld device (FDH-1). Is the desired signal quality achieved? Is the bus termination correct? The FDH-1 uses a quick and simple method to display the quality of the fieldbus installation. The handheld has been specifically designed to be easy to operate without the need for expert fieldbus knowledge. Just connect the handheld to any fieldbus segment; no PC required! This connection enables the handheld to show whether or not there are any errors in the physical layer installation prior to commissioning a segment. If there are errors, it will pinpoint what they are, where they are, and how they can be corrected. This saves time and money during installation. The FDH-1 can also be used to check existing cables in to determine whether they are suitable for a fieldbus installation. Taking this approach can lead to considerable savings in terms of cabling costs and the amount of maintenance work required, ensuing reliable operation of the fieldbus.
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In existing installations, the Easier than using a multimeter: FDH-1 can check the shortOne touch of a button starts the circuit protection at the installation test of the Fieldspur connections. This is Connex® fieldbus diagnostics handheld device (FDH-1) especially advisable for fieldbus installations that are many years old and may be beginning to experience problems. The Mobile Expert The new FDH-1 handheld device makes the commissioning process easy and ensures that quality assurance of the fieldbus installation is extremely straightforward. The mobile device is incredibly simple to handle and requires no previous technical knowledge, providing a crucial advantage. The device is just as userfriendly as the trusted multimeter, but can do a great deal more. For example, it features an integrated expert system that interprets the measured values, enabling it to detect errors and determine exactly where they are located. Once the errors are detected, it will also provide a simple corrective action statement. In addition to this expert system, a commissioning wizard with guided dialogs ensures the handheld device is easy to use. The wizard compares the installation to values set from fieldbus standards and specifications, enabling a target/actual comparison. If required, the wizard can create documentation in a storage format that can be downloaded via USB. The test report can also simply be
downloaded again at a later date and used for comparison measurements. The new FieldConnex fieldbus diagnostic handheld device from Pepperl+Fuchs makes the fieldbus installation as easy and straightforward as possible, providing the ideal basis for trouble-free operation and maximum availability of processing equipment. The FDH-1 is approved for use in all hazardous areas and for all types of explosion protection. The data sheet and additional application examples can be found at: www.pepperl-fuchs. com/fdh Pepperl+Fuchs is a leading developer and manufacturer of electronic sensors and components for the global automation market. For more than 60 years, our continuous innovation, high quality products, and steady growth
have guaranteed us continued success. One Company – Two Divisions Pepperl+Fuchs – PROTECTING YOUR PROCESS The Process Automation Division is a market leader in intrinsically safe explosion protection. We offer comprehensive, application-oriented system solutions, including customerspecific control cabinet solutions for the process industry. Pepperl+Fuchs – SENSING YOUR NEEDS With the invention of the inductive proximity sensor in 1958, the company set an important milestone in the development of automation technology. Under the motto “Sensing your needs”, customers benefit from tailormade sensor solutions for factory automation.
May 2015
May 2015
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OSG cutting tools with the HAIMER Safe-Lock™ System Strategic partnership and licensing agreement between two market leaders In April 2015 the OSG Corporation, a world leader in round cutting tools, and Haimer GmbH, market leader in tool holding technology, signed a strategic partnership and licensing agreement. The OSG-Group is bringing their round endmill cutting tools to the global market now with the HAIMER Safe-Lock™-System. The OSG-Group, Japanese market leader for solid carbide endmills, has begun offering their high quality cutting tools with the HAIMER Safe-Lock™
system worldwide. The unique Safe-Lock™ design in cutting tools and toolholders combines a high precision press fit clamping with a positive form locking mechanism. This prevents round cutting tools from being rotated or completely pulled out from its tool holder during heavy machining. The combination of symmetrical pull out protection, highest concentricity and excellent balance of the Safe-Lock™ As a licensed partner, OSG will begin offering their cutting tool shanks with the patented pull out protection system, Safe-Lock™ from Haimer system, results in a vibration free machining process. This leads to a more efficient metal removal rate, that is superior when compared to conventional Milling chucks or Weldon shanked cutting tools and toolholders.
Andreas Haimer President, Haimer Group
“We are very proud and happy to have reached a strong partnership with OSG, one of the largest and leading producers of tools in the world.”
The Safe-Lock™ System from HAIMER is an integrated pull out protection for round cutting tools that uses a friction and form locking system. It increases process security, enables a higher metal removal rate and provides results that are significantly better than conventional tool clamping systems.
OSG has been testing various systems for pull out security over the past several months. Only the technology of the Safe-Lock™ system could convince the high-tech
Japanese company. Jiro Osawa, Technical Managing Director at OSG headquarters and CEO for North America, explains: “Our field testing proved that the combination of our endmills with Safe-Lock™ resulted in higher RPMs and feed rates even with difficult-to-machine materials. This enables our customers to obtain a significant increase in their current metal removal rates, while at the same time having a higher security in their machining processes. Safe-
“In addition to the absolute technical superiority of Safe-Lock™ compared to alternative systems, it is the only system that is actually in high demand globally and also available in various clamping methods.”
Jiro Osawa Managing Director Technology OSG Headquarters
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May 2015
Lock™ also has a very positive effect on tool wear.” For the globally oriented corporation that is represented in 29 countries with 52 subsidiaries, over 5,000 employees and annual sales of approx. one billion US dollars, there was one further crucial factor, as Jiro Osawa argues: “Since we are not only in Japan but also well represented in North America and in Europe, we have decided to sign this license agreement and integrate the SafeLock™ design into our tools worldwide.” OSG is headquartered in Toyokawa, south east from Tokyo, where it has its solid carbide endmill production, coating facilities and production halls with the most modern CNC grinding machines. Due to these manufacturing capabilities, the company is able to insure the highest level of quality and availability of their tools. An additional global production network enables the demands of local markets and customer needs to be met with fast delivery and the highest of service and support. Andreas Haimer, President of the Haimer Group, explains: “We have established Safe-Lock™ as a standard in roughing and heavy machining for which a variety of tools are available worldwide.” Since its launch in 2007, the Safe-Lock™ System has developed very successfully and excited many international customers. Last year alone, the growth was four times higher compared to previous years. For further details write to haimer@haimer.in
May 2015
NORD drives pass series of tests according to EN 50598-2 Top system efficiency under new Ecodesign standard In the most recent Ecodesign standard EN 50598-2, the European Union is establishing efficiency requirements for drive electronics as well as complete drive systems. Ahead of any regulations becoming effective, NORD DRIVESYSTEMS is already performing tests and numerical analyses for components and systems manufactured in-house and can therefore quickly provide detailed information to resolve any customer queries concerning the EN 50598-2 standard. Future requirements can be flexibly fulfilled. The standard defines efficiency classes for frequency inverters and motor starters: IE0 (high losses), IE1 (reference values), and IE2 (losses significantly below reference). Following the same pattern, system efficiency is rated IES0, IES1, and IES2. Current tests with NORD inverters have shown power losses significantly below the reference values in the EN 50598-2 standard both for the inverters themselves and for power drive systems (PDS) combining inverters and energy-efficient motors. Consequentially, NORD is always able to achieve an IES2 system efficiency rating. NORD has always taken a comprehensive approach that considers the entire drive train. All components – gearboxes, motors, power electronics, and functional intelligence are in-house developments manufactured in NORD factories, which makes the company a
Combining frequency inverters and IE2 to IE4 motors, NORD DRIVESYSTEMS achieves an IES2 rating, the top system efficiency according to the EN 50598-2 standard single-source provider of complete drive solutions for over 100 industries. The 50-year-old company has gathered extensive application know-how and a detailed understanding of the interaction of all drive components. System efficiency according to EN 50598-2 is not only rated at full power but at eight designated load points with different torques and speeds. Breaking with a long-established concept, the
standard does not consider energy efficiency percentiles, but incremental power loss in Watts. One consequence of this new approach is that system performance in drive scenarios with the motor at standstill and under load (e.g. elevator stop) can now also be compared. application-specific concepts with energy-saving drives or explosion-protected systems. For further details visit www.nord.com
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New energy supply system for rotary motion up to 7,000 degrees - lightweight and highly flexible Rotary motions in machinery can be tricky when managing cables and hoses. In order to protect and guide them safely, igus has expanded its range of energy chains for rotary motion with a “heavy duty” version of its twisterband. The new twisterband HD is an even stronger, compact, spiral-shaped energy chain for circular motion, with rotations of up to 20 rotations possible. igus has developed the twisterband HD for guiding energy, data and media cables to give operational and functional reliability in rotary motions with high loads. It combines the design features and qualities of the proven twisterchain, a circular energy chain for rotary motion up to a maximum of 360 degrees, with its twisterband, the winner of the Red Dot Design Award. The new twisterband HD combines the strength and stability of the chain with the compactness, flexibility and the rotation angle of the band and therefore fills a gap between the two igus products. To deliver the “Heavy Duty” (HD) in the new “twisterband HD”, the designers at igus have reinforced the band segments significantly and constructed it for more strength and stability. On the other hand, a hinge was developed for the connection of the individual segments, so that the twisterband HD withstands extreme loads with exceptional flexibility and rotational mobility (up to 20 times around its own axis). By using this design
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to connect the elements, the individual parts can be injection-moulded from the standard igus material for e-chains. The twisterband HD is optimised for temperatures below 0°C and therefore suitable for outdoor use. Compact design for cable protection in the smallest installation spaces The twisterband HD guarantees high strength with minimal installation space requirements. The outer diameter of this product is just 300mm, the height starts at 250mm and varies according to the required rotation angle upward. Due to the innovative design, high angles of rotation are possible: horizontally to around 7,000 degrees and vertically to around 3,000 degrees. The design principle also open up the potential for larger versions. But despite this rotational capability, the cables are always well protected. Combined tests with chainflex cables in the igus’ in-house lab arrived at a service life of one million rotary cycles and more. The predefined minimum bending radius contributes towards this, preventing damage to cables. The special hinge design enables a fast filling from the outside. Together with the tribo-
At the Hannover Messe, igus presents the new twisterband HD for rotation in very confined spaces with very high load capacity optimised high-performance plastic of the band, a long service life is ensured even under difficult ambient conditions such as temperatures from -40°C to +80°C. Technically advanced, yet inexpensive, the twisterband HD is the ideal, low wear and low maintenance solution for carrying cables in rotary applications, encased in a compact and tough guiding system. The igus GmbH is a world`s leading manufacturer in the field of energy chain systems
and polymer plain bearings. The family-run company is based in Cologne, represented in 29 countries and contracts 2,200 employees worldwide. In 2012 igus generated a turnover of 399 million Euro. igus operates the largest test laboratories and fabrics in its branch to offer customers innovative and tailormade products and solutions within the shortest time. For more details write to Harish Booshan, Product Manager, E-ChainSystems® & ReadyChains®, igus (India) Pvt Ltd Harish@igus.in, Tel: +91-8049127809 or visit www.igus.in
May 2015
May 2015
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Lapp India launches “Lapp Innovation Award” Announced on the 10th Jubilee of LAPP – PSG College of Technology’s partnership, ‘Lapp Innovation Award’ it recognizes outstanding industries that are using Lapp cables and its associated products for high innovation that has an impact on sales, productivity improvement, energy saving and contribution to the environment through energy saving thereby fostering opportunities for new product development for the Lapp Group. Lapp India and PSG College of Technology signed the extension of 10 years partnership and inaugurated the PSG – Lapp Centre for Excellence in Cable Technology as part of Industry – Academia connect initiative of Lapp India. The centre is equipped with Lapp products demonstration kits, display panels, training kits and various types of tools used
for cutting, crimping, stripping cables and assembling cable accessories. This unique centre serves as a link between industry and institution in offering solutions to the industry related to design, selection and applications of cable, connectors and routing for industries like automation, textile, automotive, machine tools, oil and gas, renewable energy , process industries, as well as in the infrastructure and building sectors. Lapp India is inviting nominations from industries, who have used Lapp Cables and its associated products in creating new innovative products. The industries for the award includes but are not limited to automation, textile, automotive, machine tools, oil and gas, renewable energy , process industries, as
Mr Andreas Lapp - Chairman of the Board LAPP HOLDING AG announcing the Lapp Innovation Award
well as in the infrastructure and building sectors. The competing industries will have to submit a project or business case study that will be judged based on impact on sales, no. of Lapp products used, complexity of application and overall impact on business like contribution to energy
saving or environment. Out of all the submitted projects/ case studies the Top 3 entries will be invited to present their case to a panel of jury at the PSG – Lapp Centre for Excellence in Cable technology at Coimbatore. The application form for nomination can be downloaded from www.psgtech.edu
Grundfos India @ Indian Plumbing Conference 2015 Grundfos Indiaone of the leading pump manufacturers in India, participated at the Indian Plumbing Conference 2015 annual conference organized by Indian Plumbing Association (IPA) and AkarInfoMedia Pvt. Ltd (AIM) during April 17 and 18. Grundfos India showcased its unique Water and Waste Water treatment pumping solutions,Hydro MPC booster systems and SE pump range at the event. The Grundfos Hydro MPC booster system can be used at locations where
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additional pressure is required. Designed to meet specific customer demands for capacity and control, this unique booster system combined with multi pump controller and highly energy efficient motors is a proven solution for meeting variable demands in commercial buildings & industrial applications. The SE range of pumps from Grundfos are designed to handle wastewater, process water and unscreened raw sewage in municipal, utility and industrial applications.
These pumps can be installed in submerged or dry locations without motor cooling. In both the situations, the SE pumps are extremely reliable and very easy to service. The patented S-tube impeller in SE/SL pumps offers hydraulic efficiency upto 84% which is a benchmark for pumps used in sewage applications. Apart from showcasing Hydro MPC booster systems and SE Pumps, Grundfos India also demonstrated its MPC and S Tube range of pumps through demo representations at the event.
May 2015
Roller Burnishing Tools from Bright Burnishing Tools Bright Burnishing Tools Pvt Ltd is an ISO 9001:2008 certified Company manufacturing Roller Burnishing Tools. Burnishing is a cold rolling process on Ferrous and Non Ferrous machined components. Achieving superior surface finish (Four Triangle Finish 0.05 to 0.2 Ra) and close tolerance is easier with less cycle time in single pass. Further there is no rejection / rework in this process hence burnishing cost per component becomes negligible. This process can be carried out directly after boring / reaming in internal diameters and after fine turning in external diameter. Their product range includes
for geometries like Internal Diameter, External Diameter, Internal and External Tapers Angle, Flat Circular Faces, Grooves etc. Besides using our products in conventional machines like Drilling & Lathe, the usage is extended to CNC Machines as well. Their tools are being used in sectors like Automobile, Motors, Hydraulic and
Pneumatic, Farm Equipment, Home Appliances, Aircraft, Defence, Spacecraft, Railways, Textile, Machine Tool, and Pump Industry, etc., and areas where close tolerance and superior surface finish is required. Some of the major advantages of burnishing operations are accurate size, superior finish, quality, hardened
surface, precision, dimensional consistency etc. Also it avoids rejections, saves time and labour costs. For further details write to Bright Burnishing Tools Pvt Ltd, No.42, N.G. Ramaswamy Road, Pappanaicken Palayam, Coimbatore – 641 037 Tel: +91 422 2240122, 4387340 E-Mail: burnish@vsnl.com Web: www. brightburnishingtools.com
Thread milling range offers multiple benefits stainless steel, cast iron, titanium, nickel, copper, aluminium and plastics.
Dormer Pramet has launched a comprehensive thread milling program to provide a reliable and versatile threading option. Available under the Dormer brand, each of the new cutters is recommended for machining most materials, including steel,
May 2015
An Alcrona Pro coating and solid carbide substrate provides a tough and wear resistant structure, offering security and reliability, as well as increased performance and longer tool life. A total of ten versatile milling cutter (J2xx) families have been developed with a mix of
popular thread forms including, M, MF, UNC, UNF, G (BSP) and NPT, with or without internal oil feed. Thread milling offers numerous advantages compared to conventional threading, including increased reliability, smaller chips – supporting continuous machining improved tool life and accurate tolerance adjustment, whilst it is also suitable for dry machining. The same cutter can be used for many materials and diameters, as long as the pitch is the same, while Dormer’s J200 and J205 ranges offer the additional possibility to chamfer, providing better quality and accuracy compared
with conventional taps. Ricky Payling, Dormer Pramet’s application specialist for rotary tools, said: “Thread milling is a relatively slow process with measurable time savings on larger diameters. However, the quality of finish and level of accuracy can greatly compensate for the speed of machining.” The introduction of the thread milling cutters is part of a wider product launch by Dormer Pramet on 1 April 2015 – the first combined unveiling since Dormer and Pramet merged last year. For more information about the thread milling cutters visit www.dormerpramet.com
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Pinch Valves VZQA from FESTO: Reliable shut-off of smooth media flows
Pinch valves VZQA from Festo come into their own in applications requiring smooth media flows and reliable shut-off. In many applications they are an ideal alternative to conventional valves such as diaphragm or ball valves, as they are particularly durable, energy efficient, easy to service and flexible in use thanks to their open architecture. Pneumatic pinch valves are a clean, reliable and technically straightforward solution for controlling and shutting off a wide range of media. Whether dealing with liquid, fibrous,
particulate or granular substances, they bring reliability and durability to all kinds of production processes. The VZQA product series from Festo offers modularity, flexibility, durability, ease of cleaning and straightforward servicing. Reliable flow rate The pinch valve will be launched in two versions: an N/O version for media pressures from 0 to 4 bar and an N/C version for media pressures from 0 to 6 bar. A tubular elastomer pinch valve sleeve opens or shuts off the flow by decreasing or increasing operating pressure as appropriate to the version – all without any additional actuators and with no risk of blockage.
The pinch valves VZQA come with different connection caps, housing materials and sealing components for a variety of configuration options. This makes them extremely useful in optimising pneumatic delivery and metering systems, powder coating systems as well as suction and compressed air control units. At the same time, their compact design saves valuable installation space. Advantages compared with conventional process valves The free passage of the pinch valves VZQA minimises flow resistance, continuously preventing the valve becoming blocked or clogged. Since they are operated with a direct air supply, they also offer impressive value for money. Another plus is their straightforward servicing. The sealing cartridge can be quickly changed in just a few simple steps and without any special tools. The high-performance
pinch valves from Festo can be cleaned quickly and easily by machine thanks to their full passage and design with very little dead space. Performance-packed interior Made from aluminium or stainless steel, the pinch valves prove themselves in even the most challenging environments. The internal parts offer the same durability against external influences. Whether abrasive, corrosive, highly viscous or neutral influences, the VZQA can withstand very high stresses in daily operation thanks to its special sealing cartridge. Energy efficiency The pinch valve VZQA can be actuated with low operating pressures. Depending on the medium and media pressure, an operating pressure of just 0.3-1 bar is sufficient in filling and metering applications to tightly shut off the media flow. For further details visit www.festo.com
Threading Line available for QuadRush
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TaeguTec’s QuadRush line, known for high accuracy and surface quality, is now available for external threading applications.
QuadRush insert’s unique, multi-corner four cutting edges has been expanded to 60 degrees and 55 degrees partial profiles.
With this expansion into threading applications, TaeguTec is providing endusers the highest productivity and economical tools already employed by endusers in grooving, parting, lateral turning and chamfer machining. Furthermore, the
The new line includes the latest GoldRush coating – TT9080 grade – for maximum protection against tool wear and better surface roughness during operations on titanium, high temperature and titanium alloys, stainless, non- and lowalloy steels and cast iron.
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The QuadRush insert’s unique chip former enables machining in multiple applications providing excellent chip control, outstanding performance and repeatability. A further benefit of the new addition to the four corner family of tools is that all QuadRush threading inserts are compatible with QuadRush
standard cartridges and holders. For further details visit www. taegutec.com
May 2015
HaasTec 2015 draws nearly 3300 Visitors to Haas Factory Haas Automation, Inc., reports that its recent HaasTec open house was a complete success, attracting nearly 3300 attendees to the company’s headquarters and manufacturing facility in Oxnard, California. The 4-day event drew visitors from the U.S., Canada, and around the world, with attendees from 48 countries, including China, India, Korea, Latin America, the Middle East, and many European countries. In addition, more than 330 students – from regional high schools, colleges, and universities – attended the event. Held March 17 – 20, HaasTec included machine demonstrations, extensive tours of Haas Automation’s 1-million-square-foot facility, a catered lunch, and 38 exhibitor booths with representatives from major CAD/CAM, tooling, and workholding manufacturers. As an added bonus, the No. 41 Haas Automation Chevrolet that Kurt Busch drove to victory at Martinsville last year was on display, courtesy of Stewart-Haas Racing. Kurt Busch himself made an appearance at HaasTec Thursday – for an autograph session, and a private Q&A meeting with around 100 lucky attendees – before heading to Fontana for the weekend’s race at California Speedway. Visitors to HaasTec often arrived in large
May 2015
groups, accompanied by representatives from their local Haas Factory Outlet (HFO). More than 50 HFOs worldwide arranged trips to the event to personally show customers and potential customers what goes into making a Haas. There were 20 machines on display and running demos at HaasTec, including the new UMC-750SS super-speed universal machining center. Also on hand were the massive ST-55 large-through-bore turning center, the new DM-1 Drill/Mill Center, a wide array of Haas VMCs, and a Haas horizontal with pallet pool system. Attendees also got to see more than 200 Haas machines
in action on the factory floor, making parts for more Haas machines. Of the 298 chipmaking machines in the Haas factory, 70 percent are Haas machines.
also included a display of the company’s very first VMC – machine No. 1, fitted with an early Haas rotary table – alongside its modern-day equivalent.
In addition to the CNC machines, a number of Haas rotary products were also on display, including the new TRT100 high-speed dual-axis rotary table. With a maximum speed of 1000° per second on both axes, the TRT100 provides high-speed, accurate, 3+2 positioning for machining small complex parts. The unit’s compact size and light weight make the TRT100 the perfect dual-axis solution for small machining centers.
Today’s VF-1 still sells for less than the machine’s 1988 introductory price of $49,900, proving that Haas is the industry leader in machine tool value.
Providing visitors with a historical perspective, HaasTec
By all accounts, HaasTec 2015 was an overwhelming success, providing attendees an opportunity to see first hand what goes into making a Haas machine, and why Haas Automation is America’s leading machine tool builder. For more information about Haas Automation and Haas products visit www.HaasCNC.com.
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Web tool creates individual 3D gripper jaws at the press of a button
SCHUNK eGrip is the world’s first fully automatic 3D design tool for additively manufactured gripper fingers. SCHUNK eGrip needs only minimal data for the fully automatic cal-culation of the optimal 3D contour, pricing, and delivery time. The license-free, browserbased web tool from the competence leader for clamping technology and gripping systems, SCHUNK reduces the design and ordering time for cus-tomized gripper fingers to only 15 minutes. With the intelligent software, which is available around the clock and doesn’t require a separate CAD program, the user has to upload the workpiece or component as a STEP or STL file and enter additional specific information, such as the weight, installation position of the gripper and finger length. In a few seconds, the user receives a detailed offer con-taining the 3D
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SCHUNK eGrip reduces the design and ordering time for indi-vidually shaped gripper fingers to only 15 minutes. The software automatically generates the optimal 3D contour of the gripper fingers contour, the delivery time, and the price. SCHUNK eGrip can quickly calculate even complex geometries. Users can either order the top jaws right away or save the offer and retrieve it later. In addition, the outer contour of the generated assemblies, consisting of the gripper, top jaws and workpiece, can be downloaded in STL format for immediate use in the system design. Enormous time and cost advantage The affordable additively manufactured SCHUNK top jaws can be quickly manufactured and are made of lightweight, wearresistant polyamide 12, in either white or black. For use in pharmaceutical and
medical applications, top jaws are also available in FDA-approved polyamide 12. Since polyamide is resistant to chemicals and suitable for use with foods, it can also be reliably used in connection with aggressive media. Due to their low weight, the top jaws are ideal for minimizing cycle times and power con-sumption of systems; they can also be used with smaller robots or handling systems. In combination with the SCHUNK BSWS quick-change jaw system grippers can be re-equipped for a new parts spectrum within seconds. In the first phase, SCHUNK eGrip top jaws are available for SCHUNK universal grippers PGN-plus 40 to 125 and for SCHUNK small component
grippers MPG-plus 20 to 64. Other series are planned. For further details write to Schunk Intec India Pvt Ltd, No 80 B, Yeshwanthpur Industrial Suburbs, Bangalore – 560022 Tel: +91 80-40538999 Email: info@in.schunk.com Web: www.in.schunk.com
May 2015
MillLine: Expansion of Roughing Cutter and NMJ Chipbreake on Tung-Tri for the Square Shoulder Milling Tungaloy Corporation is pleased to announce the expansion of the Tung-Tri Roughing Type cutter and the NMJ chipbreaker for the TungTri family – the square shoulder milling range with indexable inserts. Tung-Tri features the insert with 3 cutting edges, which delivers much more productivity than the conventional 2 cutting edges, and has been enjoying good reputations in the market since its release.
force offer high performance. Up to 2 sub-units (extension units) can be mounted on the cutter body with diameter 80 mm and up, which extends the cutting length and further enhances the efficiency in rough milling.
Tung-Tri Roughing Type is the cutter body with long flute length. The optimized positioning of cutting edges and the inserts with low cutting
The insert is available in grade AH3135, featuring excellent fracture and chipping resistance, for long and stable tool life.
The NMJ chipbreaker has the chip splitter designed to produce small chips and reduce cutting force. Combined with the Tung-Tri Roughing Type cutter, the performance is drastically improved.
Due to this expansion for the Tung-Tri family, the efficiency and productivity in the square shoulder milling are remarkably increased. Tung-Tri is the excellent choice for
high quality, high performance, and the ultimate economical efficiency. For further details visit www. tungaloy.co.jp/in
Porcupine designed to impress Walter BLAXX design provides process reliability and cost efficiency Stability is everything when it comes to porcupine cutters, a characteristic feature of the Walter BLAXX range. Walter is now extending its high-end range: As are its fellow cutters for face milling and shoulder milling, the new Walter BLAXX F5038 porcupine cutter is also characterised by an extremely solid and therefore stable tool body. In conjunction with the tangential, quadruple edge,
system indexable inserts made of Tiger•tec® Silver cutting tool materials, the user thereby achieves top values in process reliability and cost efficiency. In comparison to conventional tool solutions of this type, machining times are reduced by up to 30 percent. What’s more, the accurately arranged, precision indexable inserts produce flawless and step-free shoulders that, to the greatest possible extent, make re-machining superfluous.
Engineering Kompetenz in milling: The new Walter BLAXX F5038 porcupine cutter has an extremely robust tool body and tangential, system indexable inserts made of Tiger•tec® Silver cutting tool materials.
May 2015
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Handle drives or motion profiles for any network with Anybus CompactCom HMS Industrial Networks now presents a new solution for handling profiles - mainly targeting drives and motion applications. The extension to the new Anybus CompactCom 40-series enables drives manufacturers to comply with common profile specifications such as PROFIdrive, EtherCAT DS402, and transparent DS402 on other networks. Trends such as Industry 4.0 and the Industrial Internet of Things (IIoT) mean that more and more industrial devices are getting connected to industrial networks. This is especially true when it comes to drives or inverters which are the most networked devices of all – 3.5 million inverters and 800,000 servo drives are expected to be networked during 2015. But developing and maintaining connectivity to different networks is both time-consuming and resourcedemanding – especially if you want to comply to drive and motion profiles for several networks. Now, by integrating support for Anybus CompactCom into a drive, device manufacturers will be able to offer wide fieldbus and industrial Ethernet connectivity along with integrated profile support to their customers - all through one, single development project. Multi-network connectivity with profiles for drives – How it works Different networks have different standards for how to communicate with a drive
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(for example, to tell the drive to operate at a certain speed). These so called “drive profiles” or “motion profiles” are supported by the Anybus concept through a Profile Driver Package — a software stack which is implemented into the drive during development. The ready-made source code from HMS can be quickly integrated into the processor of any drive. Consequently, the profilespecific data is not actually “translated” inside the Anybus CompactCom. Rather, it passes through the module’s transparent channel unchanged and the conversion is done in the drive utilizing HMS’ Profile Driver Package. The DS402-based Profile Driver can be used to handle any CANbased profile – not just drives and motion profiles – on any network. For example: • EtherNet/IP: Transparent DS402 • EtherCAT: DS402, SEMI, Encoder • PROFINET/PROFIBUS: PROFIdrive The fast track to network connectivity for drives The Anybus CompactCom 40-series enables drives manufacturers to comply with the demands from all major networks, even for demanding high-performance standards such as EtherCAT or PROFINET 2.31. The 40-series is especially designed for demanding applications
requiring low latency and high data throughput. (Process data latency is lower than 15µs and 1500 bytes of process data can be transferred in each direction). The 40-series products are pre-certified for network conformance by all the major network organizations which substantially speeds up testing and compliance. HMS also offers implementation help as a packaged service for drives manufacturers. What is Anybus CompactCom? Anybus CompactCom is a series of communication products which are integrated into an industrial device to offer connectivity to different industrial networks. CompactCom comes in chip, brick or module format, allowing the user to choose level of integration.
HMS Industrial Networks is the leading independent supplier of products for industrial communication including remote management. HMS develops and manufactures solutions for connecting automation devices and systems to industrialnetworks under the Netbiter, Anybus and IXXAT brands. Development and manufacturing take place at the headquarters in Halmstad, Sweden and in Weingarten, Germany. Local sales and support are handled by branch offices in China, Denmark, France, Germany, India, Italy, Japan, UK, and USA. For further details write to HMS Industrial Networks India Pvt 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
May 2015
PM Modi and Chancellor Merkel visits NORD at Hannover
Mrs. Nirmala Sitharaman (Indian Ministry of Commerce and Industry), Mr. PL Muthusekkar ( MD, NORD India), Mr. Ullrich Kuchenmeister (MD, NORD Drivesystems), Mrs. Anjela Merkel (German Chancellor ), Shri Narendra Modi (Prime Minister of India ), Mrs. Jutta Humbert (MD, NORD Drivesystems) At Hannover Messe 2015, the opening walkabout took the Chancellor of Germany, Angela Merkel, and the Prime Minister of the industrial fair’s 2015 partner country India, Narendra Modi, to the stand of NORD DRIVESYSTEMS – who are celebrating their 50th company anniversary this year. The heads of government took note of economical drive units for servo applications. A dynamic racing car simulator, in particular, was of great interest: six intelligently controlled drive axes execute steering commands in real time. The latest generation of distributed frequency inverters enables extremely dynamic, precise control of asynchronous drives. The combination of motor and inverter conforms to the new, highest system efficiency class IES2 according to the
May 2015
European Eco design standard EN 50598-2. The Indian Prime Minister had the particular wish to visit NORD DRIVESYSTEMS. He was aware about the Indian NORD subsidiary – representatives of which Mr. PL Muthusekkar, Managing Director of NORD India along with his sales team are at the industrial fair all week – as a successful technology partner of many industries in the dynamically growing economy. Mrs. Jutta Humbert, Managing director of NORD Drivesystems Group introduced Shi Narendra Modi & Mrs. Merkel about the NORD Group & its journey till date on their arrival at NORD stall during Hannover fair. She also explained how efficiently our hundreds of geared motors are running throughout Rourkela Steel Plant which has been recently inaugurated by Shri Narendra Modi.
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February 2015 November May 2014
THE LAST LEAF Dear Readers, India Ratings expect India’s economy to expand 7.7% this fiscal year, faster than the previous year’s estimated expansion of 7.4%, because of a pick-up in private consumption, which in turn got boosted by a significant moderation in inflation and inflationary expectations. The government’s ‘make in India’ initiative is expected to provide ease of doing Business. As a country, we have felt the need to improve the business eco-system for start-ups by simplifying the capital raising process, boost transparency in valuation and price discovery, and also take into account the interest of retail investors. SEBI has relaxed several rigidities but also suggested some new ones, like at least 500 institutional allotees. The SEBI paper wants post-issue capital lock-period reduced from three years to no more than six months, which is sensible given the rapid uptick possible in the domain of internet. Indian Railways is soon to set up plants to manufacture diesel conforming to Euro-5 specifications in sulphur content, for mechanical traction with technology patented by scientists at the CSIR-Indian Institute of Petroleum (CSIR-IIP) here. The rapid decision to embrace the technology by the world’s largest railway network, Indian Railways, speaks volumes for the Narendra Modi government’s resolve to apply out-of-the-box ideas to reduce India’s carbon footprint. In fact, CSIR-IIP is the first to have the capability to convert 1 tonne of broken buckets, mugs, toothpaste tubes, bottle caps and other Polyolefins products into 850 litres of the cleanest grade of diesel. This is the best news yet for the planet this year because henceforth plastic waste will be viewed more as a resource than a nuisance.Another feather in CSIR-IIP’s cap is the successful project to produce low-carbon jet fuel from the inedible, drought-resistant Jatropha plant. This has already captured the imagination of several governments worldwide. In fact, they also have the knowledge of making jet fuel out of any non-edible oil – even the waste cooking oil from the kitchen. The Union Minister for Science and Technology has appealed to the scientists to constantly strive to develop new technologies and products with zero defect and zero effect which can help to produce a higher GDP per unit of energy consumed, given the fact that Energy and environment are two side of the same coin, in the effort for fighting climate change. (Courtesy: pib. nic.in) Israel is making further strides in the ever-popular and continuously growing 3D printing sector. A new initiative funded by the Office of the Chief Scientist hopes that the first titanium airplane parts will be 3D printed by the end of 2015. Another Israeli company Stratasys will be part of a project aimed at putting the first 3D printed car on the roads within two years. KOR EcoLogic will be in charge of the design end, building every inch of the car using computer aided design software. The design will then be turned into reality using RedEye On Demand and Stratasys printers, using only 40 extremely complex interlocking pieces, made possible by 3D printing. (Courtesy: nocamels.com) Manufacturing is a key sector in Singapore, accounting for about one-fifth of GDP and employing half a million people. With restructuring, it is moving towards high value added engineering production like the adoption of the latest technological advances in automation, robotics and 3D printing. 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
May 2015
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