MART November 2016 by MART INFOMEDIA PRIVATE LIMITED

Volume 13 Issue 5 november 2016 `150

empowering engineering excellence

An Indian’s Journey with

Exoskeletons

industry focus

AUTOMATION REDEFINED

smart factory the future let’s talk

Sameer Gandhi omron india

GUEST EDITOR

Shishir Joshipura

NEW AGE INNOVATION

skf INDIA

innovation Demonetization Renishaw

Impact on Manufacturing November 2016

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November 2016

CX5120: Intel® Atom™ CPU, 1.46 GHz, single-core

November 2016

CX5130: Intel® Atom™ CPU, 1.75 GHz, dual-core

CX5140: Intel® Atom™ CPU, 1.91 GHz, quad-core

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November 2016

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November 2016

empowering engineering excellence

Volume 13 Issue 5 November 2016 Annual Subscription ` 1800 Member INS

Editorial

Editorial Advisory Board

Automation – a second wave A S Shetty Saravjit Singh Manoj Kabre P S Satish

When robots scale up from a proof of concept, it is automation. “One robot is Robotics, ten robots mean automation”, as Raja Chatila, Director of Research at the French National Center of Scientific Research, aptly sums. Will Robotics solve Alan Turing’s fabled challenge, which is about robots exhibiting cognitive ability?

J R Mahajan LD Bhakre S M Dangi Sandeep Hingne

The Industrial Internet of Things brings a fundamental technological shift. It will transform how people work. New interactions between

Publisher

Hari Shanker

Associate Editor Executive Director Executive Editor

Hiya Chakrabarti

factories and infrastructure that define our physical world. The

Siji Nair

manufacturing, energy and transportation sector representing

Sujatha Thampan

Correspondent

Arnab Mondal

Editorial Co-ordinator

Pramod Pillai

Editorial Assistant

Nazia Ali

Lead Creative

Chetan Kumbhar

Bishnu Priya Kundu

Mumbai

Ravindranath Kurup

Chennai

V Subramaniam

Delhi

Vidya Rao Contacts

Editorial

+91 70 3093 2700 +91 70 3093 2696

sales@martinfotech.in Advertisement

+91 70 3093 2699

advt@martinfotech.in Human Resources

changes. In this edition, we bring you defining opinions from the mavens of Industrial Automation in the Indian manufacturing sector, through its industrial focus segment. As our Guest Editor Shishir Joshipura, to change. It’s very likely that by 2020, we’ll have almost 50 billion machines connected to internet, “talking’ to each other”. We are delighted to have Professor R K Ambegaonkar, Ex-Dean, Faculty of Engineering, University of Pune, anchor the ‘Learning Curve’ – a segment dedicated to our next generation of engineers.

pramod@martinfotech.in Circulation

66% of the global GDP, will see unprecedented opportunities and

MD, SKF India Ltd puts it, “The very definition of automation is set

Sales Team Lead Sales

humans and machines will use the Internet to directly control the

+91 70 3093 2697 richa@martinfotech.in

He will introduce and chair the Forum for Engineering Excellence and Innovation (FEEI), a new initiative by MART. FEEI will help engineering students boost their preparedness to join the industry. Manoj Kabre, in the CSR segment presents endeavours by three prominent establishments in the area of road safety – Autoliv India, UL and Toyota Kirloskar Motors. Our regular features on the other hand, will update you on events, courses and training, which you should not miss! Do write back to us at MART with your suggestions and views.

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Happy reading!

C-507, Wisteria Fortune, Bhumkar Chowk Marunji Road Near New Poona Bakery, Wakad, Pune - 411057 India Tel: +91 70 3093 2700 Editorial: +91 70 3093 2696 Email: info@martinfotech.in, mart@martinfotech.in Visit: www.martupdate.com Emag: www.martonline.in

Digital Edition:

November 2016

Sujatha Thampan www.martupdate.com

CONTENTS Volume 13 Issue 5

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The Card vs The Cloud

Smart Factory: The Future

GREEN TECH 16 | Revving Up Sustainable Energy

INDUSTRY FOCUS

LET’S TALK

22 | Guest Editor

CUTTING EDGE

28 | IoT, Cloud and Emerging Technologies 32 | Connectivity & Collaboration 36 | The Digital Transformation

46 | PC-Based Control Technologies

columN

48 | Demonetization: Impact on Manufacturing 50 | Forces on the Company 52 | HR Automation

56 | Education for Road Safety

Learning Curve

60 | Develop Passion for Improvements & Ideas 62 | Gen-II Exoskeleton

63 | 3D Image and User Interface 64 | Serendipitous Waves

66 | Tractor to Lamborghini! 68 | Technovanza 2016

4010

70 | 3 D Printed Organ-on-a-Chip

71 | An Innovative Support to CP Patients

innovation 72 | F it and go

74 | I nnovative Leap in Coating Technology

75 | R enishaw: XM-60 Multi-axis Calibrator

CASE STUDY

76 | R hino Leads Innovation 78 | T he Old Ways

REGULAR 10 | N ews

80 | E vents

86 | P roduct

88 | C ourses

Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manner whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither the Publisher no any of its employees accept any responsibilities for any errors or omissions. © All Rights Reserved

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news | latest update

Global Aerospace Summit 2016 Seco through cooperative partnerships with aerospace manufacturers and entities around the world, monitors trends, identifies challenges and develops solutions that can overcome the industry’s most demanding applications. To partner aerospace customers in their challenges, Seco organised “Global Aerospace summit 2016” on 21st and 22nd September at Bangalore. The event saw display and demonstration of machining of trending materials in Aerospace, Latest machining methods, Component solutions like Engine Component, Landing gear Component and Airframe Components and Engineering Services.

Tesla to buy German Firm Tesla Motors has agreed to buy a German engineering company to help automate its electric car manufacturing. The company is buying Grohmann Engineering, which is a leader in highly automated manufacturing methods. Tesla expects to start building the $35,000 Model 3 electric car next year, and it wants to build 500,000 cars per year in two years. The purchase price wasn’t disclosed.

Perkins to make India hub Gas and diesel engines maker Perkins will make India the manufacturing hub for its 4000 Series engines to cater to domestic as well as Asia Pacific markets. The company has set up a manufacturing facility in the Shendra Industrial Estate in Aurangabad, along the Delhi Mumbai Industrial Corridor (DMIC). The facility has a capacity of manufacturing 3,000 engines per year.

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ABB to support Railway Expansion in India ABB has won an order from Alstom to supply 1600 traction transformers for 800 new electric freight locomotives in India. The new locomotives will expand Indian Railways’ capacity, easing congestion on busy routes for both freight and passenger services. The transformers will be manufactured locally in ABB’s Vadodara facility in the western Indian state of Gujarat, supporting the government’s ‘Make in India’ initiative to encourage

manufacturing in the country. Indian Railways operates the largest rail network in Asia, and is the world’s second-largest rail network operated under single management. The company moves more than 12,500 trains and 23 million passengers daily, equivalent to the population of Australia. ABB will supply 25 kilovolt (kV)/50 hertz (Hz) underframe traction transformers for the

“The scale of this order is a recognition of our ability to deliver technologically-advanced reliable products, locally and to cater to evolving customer needs. Investments planned in the railways will shape the direction of economic growth in India, paving the way for next level innovative technologies to be designed, adapted and manufactured in the country.”

Sanjeev Sharma CEO and Managing Director, ABB India

800 locomotives (2 units per locomotive).The compact transformers are designed for the most demanding conditions, including extreme temperatures and voltage fluctuations. They will support heavy freight loads over long distance haulage under rigorous conditions, including steep inclines. Traction transformers feed power at safe voltages to essential train functions like traction, brakes, lighting, heating and ventilation, as well as passenger information, signaling and communication. Used by rail operators around the globe, ABB traction transformers are manufactured at its plants in Switzerland, India and China, and provide the highest levels of availability and reliability for uninterrupted train service.

Rotary & Industry come together on CSR Ideation Workshop CSR is an emotional act and needs internal creativity and inspiration – it is not something mechanical. The concept of an Ideation Workshop was conceived with an objective of making a first hand assessment of the “pain points” from the experts who are working in the field of CSR by Rotary Club Bangalore White Field Central (RBWC) last year. The event organised last year, was very successful, in generating ideas for implementation of CSR activities, to accomplish synergy and alignment between the actual needs of the society and the ‘act of giving’ from Rotary. The event for this year, was conducted on Saturday 22nd October 2016 at Premier Inn Hotel, Whitefield, wherein collective brainstorming was facilitated between CSR representatives from various corporates and subject matter experts on six diverse subjects

identified for Ideation - Health and Hygiene, Environment & Ecology, Water & Sanitation, Literacy and Numeracy, Skill Development and Inclusivity for Differently Abled. Under the leadership of RBWC President Rtn.Sandeep Mittal, a core committee was formed at the Club which took leadership in organising this event. The organisations which participated in the event included Akzo Nobel, Axis Bank, Billforge, Cisco,

Cognizant, Danskeit, HCL, Oerlikon Balzers, Schneider Electric, TCS, Tesco, Toyota Kirloskar, etc. An action plan was built to initiate various CSR initiatives, which included, cleaning of lakes, killing the source for diabetes and hypertension, handling water woes of Bangalore, training and mentoring trainers and more. For more details visit http:// rotary-bwc.org/rotary-csrideation-workshop-report November 2016

November 2016

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KEPL awarded by Quality Circle Forum of India

Pune-headquartered Kirloskar Ebara Pumps Ltd (KEPL), a joint venture of Kirloskar Brothers Ltd (KBL) in India, won gold and silver trophies at the ‘31st Chapter Convention CCQC-2016’, organised by Quality Circle Forum of India (QCFI), on September 24th 2016 in Pune, India. Three teams from KEPL (Team Anand, Team MSD and Team Utkarsh) participated and presented their Kaizen case studies. The case studies were highly appreciated and awarded with the ‘gold and silver trophies’. The theme for this convention was ‘quality circle and its allied concepts’. Teams have passed through the entry gate for National Convention Quality Control (NCQC) which will be held at Raipur, Chhattisgarh during December 16 – 19, 2016.

This was a forum for interaction and sharing of knowledge and ideas on quality circle and other allied concepts such as TPM,5-S, Six Sigma,Kaizen, Poka-yoke, SMED, JIT, Kanban etc. The programme was categorised in a QC and allied case study, model exhibition, poster, presentation and visual display. KEPL team ‘Anand’ presented their Kaizen case study titled ‘cost reduction through VA/VE project’ and were awarded with silver trophy, team MSD presented their case study on ‘improve the utilisation of cutting tool (broach) by enhancing keyway sizing machine capacity’ and were awarded with gold trophy. The presentation flow started with the introduction of Kirloskar Group and its uniqueness, introduction to the case study, followed by systematic problem solving steps like problem identification, root cause analysis, permanent solution amongst available alternatives, Kaizen theme and Kaizen idea, implementation and benefits, horizontal deployment of Kaizen theme etc. The effective use of problem solving tools and techniques was demonstrated through this case study. The presentation was concluded with an interactive session of questions and answers.

‘HaasTec’ at Ahmedabad & Gurgaon

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The popular HaasTEC shows are returning to India this year with two events arranged for different regions of the nation. Managed by the Haas Factory Outlet (HFO) in India (Phillips Machine Tools India Pvt. Ltd.), the first HaasTEC will take place from 16th-19th November at Ahmedabad in the western state of Gujarat and will be followed closely by HaasTEC Manesar from 07th to 10th December, in the industrial district of Gurgaon near New Delhi.

Show stopper HAAS UMC-750 five-axis vertical machining centre offers a capacity of 762 x 508 x 508 mm in the X, Y and Z-axis respectively. It features a two-axis inbuilt trunnion rotary table and a 40-taper, 22.4 kW, 12000 rpm direct drive spindle.

In line with previous HaasTEC events, a number of innovative, affordable Haas CNC machine tools will be on view. Indeed, two machines will be on show for the first time in India, the Haas ST-15 & Haas DT-2. All of the Haas CNC machine tools on display will be powered and performing demonstrations, cutting metal.

The HaasTEC events will also feature a number of the company’s industrial partners, all able to offer complementary technologies and advice.

Other Haas CNC machine tool models scheduled to appear at both HaasTEC events include the ST-10Y turning center with Y-axis, VMC’s - VF-2 & VF-2SS & Mini Mill.

Demonstrations, tours and a live Q&A counter will be among other event highlights. November 2016

Senior UK Minister visits Renishaw during India-UK TECH Summit Renishaw, the global engineering technologies company, hosted a visit to its Pune, India facility on 9th November 2016. The facility was visited Mr Liam Fox, the Hon’ MP, British Secretary of State for International Trade. During his visit he toured the 80,000 sqft building where he saw a state-of-the-art metal 3D printing facility, a manufacturing unit that services the Renishaw Group, and a large R&D software facility. The Secretary of State was also presented with a unique metal gift produced on a Renishaw additive manufacturing (3D printing) system and planted a commemorative tree.

Mr Pountney co-chaired ‘The Future of Manufacturing’ workshop with Dr Gopichand Katragadda, the Group Chief Technology Officer at Tata Sons. The workshop brought together a wide cross-section of industry, academia and R&D institutions with an interest in Advanced Engineering and Manufacturing collaboration between the UK and India.

The visit coincided with the India-UK TECH Summit, held in New Delhi from 7-9th November, which marked a celebration of India and UK’s partnership across business, technology, science, innovation, education and design.

Renishaw has offices in five Indian cities, plus resident sales engineers in other key areas. It purchased the Pune site in 2005 and has since made significant additional investments, including a large extension to the facility in 2011 which almost trebled available space. In June 2016 it also opened an Additive Manufacturing Solutions Centre which aims to increase the adoption of metal 3D printing technologies by Indian manufacturers.

Hosting the visit was Mr Rhydian Pountney, Renishaw’s Director and General Manager – UK/ROW Sales Division, who is responsible for the company’s sales and marketing activities in India. He is also co-chair of the Advanced Engineering Working Group of the annual India-UK Joint Economic and Trade Committee (JETCO) which met in New Delhi as part of the Summit.

The Pune facility also houses customer demonstration and training facilities, a procurement operation to directly source high quality components from Indian vendors, a large software development team, and a 100% Export Orientated Unit (EOU) which manufactures certain products that were previously procured and where assembly costs are critical to competitiveness.

Mr. Rhydian Pountney, Renishaw’s Director and General Manager – UK/ ROW Sales Division presented an unique ‘Make In India’ metal gift produced on a Renishaw additive manufacturing (3D printing) system to Mr Liam Fox, Hon’ MP, British Secretary of State for International Trade. November 2016

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Red Lion appoints Jack Lee as new President

Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, recently announced the appointment of Jack Lee as President of the company. “Jack has broad experience in industrial markets, including business development in the rapidly-growing Industrial Internet of Things field. His leadership skills and global industrial background make him well-suited to take Red Lion into its next phase,” said Jo Hallas, Business Group Director at Spectris plc. Jack served as Senior Vice President and Managing Director of the Surface Equipment and Automation Business Group for Dover Corporation before joining Red Lion.

Molinari Rail to set up unit in India Swiss major, Molinari Rail will set up a manufacturing and assembly centre for auxiliary power units for diesel locomotives in India by next year. Molinari Rail AG has entered into a strategic pact to design, manufacture and deliver the auxiliary power units (APUs) for 1,000 diesel locomotives to be built in India for Indian Railways. The group will form a Lucknow-based company that will manufacture 100 auxiliary power units per annum, which can be ramped up later. Molinari mentioned that the SwissRail Industry Association is keen to invest in India.

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The Lapp Group buys CEAM and Fender The Stuttgart-based Lapp Group, a leading supplier of integrated solutions and branded cable and connection technology products, has acquired CEAM CaviSpeciali, an innovative and profitable family company. Its turnover in 2015 was €23 million; Fender generated around €3.5 million in revenue this year. CEAM and Fender were formerly part of COFIMA Holding, a business run by founders Franco and Carlo Magon. Lapp has a long-standing partnership with CEAM. Georg Stawowy, Chief Technical Officer at Lapp Holding AG, said: “The takeover will help us to boost our successful branded products – UNITRONIC® and ETHERLINE®. This will help Lapp to become the innovation leader in cable-based data communication systems in the field of

automation.” Franco Magon, one of CEAM and Fender founders, emphasized that the Lapp Group and CEAM fit together well not only in terms of technology and products but also in their values: “Ethics, innovation, performance and service - these values have been guidelines for CEAM, and they have brought our small family business together with the global player Lapp.” And Carlo Magonadds:” Lapp will continue

to run and support the production sites. The Lapp Group wants Monselice to be its competence centre for industry-standard data transfer technology with a research and development team and a test centre. One of the group’s plans is to develop solutions for fast and flexible data transmission for Industry 4.0 here. The acquisition of CEAM strengthens Lapp’s leading role in industry-standard data communication systems.

Grind Master bags CII Innovation Award Grind Master were awarded CII Industrial Innovations Award 2016 in Manufacturing – Medium Scaled Enterprise, presented on 8th November as a part of the Indo-US Tech Summit in New Delhi. Grind Master has developed key breakthrough technologies with its passion and commitment to making innovative products. The CII Innovation Award is a recognition of this track record of 30 years of quality machine building with more than 4000 Installations worldwide, and 60%

exports that account for 25% of Indian Machine Tool Exports.

strategic innovations in grinding and finishing of advanced materials such as Titanium Sameer Kelkar, CEO, Grind Master and Zircaloy which are used in presented specific examples of industries of national importance Innovation to the Grand Jury in such as Defence, Aerospace and Delhi earlier. “Our NANOFINISH Nuclear Energy. The Disruptive range of machines is a Market Technology of Robotic Deflashing Driven Innovation wherein reliable and Fettling is transforming technology in sophisticated Human lives in Foundry industry. microfinishing and superfinishing Automatic complex casting processes in developed to grab cleaning processes leads to opportunities in major automotive better quality, productivity and OEMs to whom we are a trusted elimination of health hazard.” says supplier now. We also have very Sameer.

“We have a dedicated team of 10 enthusiastic Engineers working on research, supported by over 40-50 people in development of new ideas, systems, processes. Having received this award gives a further boost to our dreams and encourages us to go to a higher level of R&D.” Sameer Kelkar CEO, Grindmaster

“This Innovation has received overwhelming response with more than 20 Solutions delivered within 2 years of the development. An underlying culture of innovation at the grassroot level following the core values of the company sustains and spurs advancement in technology at Grind Master.”, he added. November 2016

November 2016

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GREEN TECH

Revving Up Sustainable Energy FluxGen is a Bangalore-based company working in the field of renewable energy sector. A dedicated team at FluxGen comprising of alumni of Indian Institute of Technology, Indian Institute of Management and Indian Institute of Science are developing technological solutions to make energy reach every household in the affordable way as well as setting benchmark in its unprecedented application areas.

Vasantha Natesh vasantha@fluxgentech.com

FluxGen works in the area of developing Sustainable Engineering Solutions to address the problems in Resource Management Sector â&#x20AC;&#x201C; Energy and Water Crisis. Micro-grid FluxGen ventured into constructing micro-grids after viewing the potential pathblocks like fossil fuel shortages, geographical isolation for rural India in connecting with the outside. FluxGen has deployed a reliable, cost-effective, and eco-

friendly electricity supply system where grid penetration is not feasible. This micro-grid, called the Smart Renewable Energy Micro-Grid is currently running in a village called Mendil located in the forest-covered area of Northern Karnataka state, India. A decentralised renewable energy solar PV plant powers sources of light and electricity to conduct household business and provides an inherent advantage of pooling over stand-alone solar electrification. It also powers irrigation systems for agriculture

and entertainment systems for leisure time and keeping up with news outside the village. The system has been designed to achieve higher mean time between failure of the implemented system, remote monitoring of the systemâ&#x20AC;&#x2122;s health and performance, generation of system diagnostics, and assurance of proper safety using sophisticated engineering methods. The solar inverter features maximum power point tracking

(MPPT), which ensures efficient power extraction from panels and stores the power in lead acid batteries. Smart meters are installed at the usersâ&#x20AC;&#x2122; end. These communicate energy consumption information to the control system using industrial standards communication protocols. The solar hybrid inverter enables synchronisation with windmills or diesel generators designed to handle future increases in energy demand. To distribute the stored energy as required by

Smart Energy and Water Manager

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November 2016

all users, the micro-grid uses a predictive power supply capping algorithm. The algorithm predicts the possible power capping for individual houses depending on the amount of energy harvested per day in batteries. Manual control is also provided for this. If a specific user consumes too much power, the controller automatically disconnects that particular userâ&#x20AC;&#x2122;s line. By reducing the userâ&#x20AC;&#x2122;s energy demand, the micro-grid can restore power to the user. The smart energy meters send the individual power consumption data. All users are automatically informed about their weekly usage rates so they can adjust their power consumption and conserve it accordingly. By implementing certain mathematical computations, we record and graph inverter

November 2016

conversion efficiency and the variation of total load power consumed in a day. Batteries are used to store electricity, but when they are mishandled, their operation may become unpredictable. To continuously inspect battery functionality, graphical data on battery power levels and charging/discharging states and maintains a battery service log record. If the device detects a false operation, it immediately disconnects the batteries. This extends battery life. FluxGen for Academics FluxGen with its technology and expertise also aims at aiding the students to get a hands-on experience in working with renewable energy systems. In Having implemented one such kind of Smart Grid at Mendil, we offer Smart Grid and Renewable

Energy (SGRE) Lab, as a suitable platform, for students and researchers to understand and analyse the performance of Smart Grid as on real field, integrated with Solar panel system, Windmill, Conventional Grid, Weather station, Brake-out box, Smart houses, Smart meters etc. It is featured with reliability in fault detection and selfhealing, efficiency by demand side management, sustainability and market enabling by peak hour energy consumption etc. We also worked on developing a research platform for using sustainable solar energy technology for an efficient and effective energy harvest in solar assisted trains in The Indian Railways. Most long-distance trains having Linke Hofmann Busch (LHB) coaches do not have self-generating systems, thus

making power cars mandatory to supply all the internal electricity needs for lights and fans on both AC and non-AC coaches. Contemplating over this fact, studies were carried out in the Divecha Centre for Climate Change (DCCC) at the Indian Institute of Science, Bangalore, involving feasibility analysis of supplementing diesel generator sets with power from solar PV modules installed on coach rooftops. IISc in association with FluxGen was then approached to implement the proof of concept experiment of this scheme.The tested functional prototype system was then transported to the Integral Coach Factory (ICF), Chennai, Tamil Nadu, India. At the ICF, a specific LHB rail coach was modified with mounted solar PV modules on its rooftop which was later attached to the Coimbatore Shatabdi Express

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train for field validation in real world environmental conditions. The Shatabdi Express train travels at higher speeds and has fewer stops and allows validation for higher speed trains. A subsequent pilot study was done on a double-decker train which travels at slower speeds, thereby, validating the prototype for lower speed trains also. Utilising the space available for photovoltaic (PV) panels on trains, the contribution from solar energy can represent a rather significant fraction of the required energy. The study suggests that the implementation of this scheme would result in an annual savings of Rs. 5,900,000 corresponding to 90,800 litres diesel per rake per year and also it would amount to an annual reduction of 239 tonnes of CO2 emissions. The yield of solar power from PV panels on a moving vehicle depends on several factors such as sunshine

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hours, solar insolation, climatic conditions like temperature and humidity, travelling direction, number of halts, speed of the vehicle, quality of the body of the vehicle and the technology of PV panels placed atop it. We built a robust and reliable analysis system with customisable easy-to-use user interface to continuously acquire, monitor, plot graphs and log real time data of the sensors and the energy harnessed. As travelling direction could also impact the harnessing of energy by the system, the scheme was implemented on a train travelling on a South-North route (Chennai-Coimbatore) as well as on a train travelling on an East-West route (ChennaiMysore). The timing of trial runs was chosen to be during the month of June, being the onset of monsoon in India with cloudy and rainy weather conditions. According to the figures obtained using this pilot study in the report generated

by IISc., railway solar panels, if implemented on all 63,511 coaches in the Railways, enables 450 million units of electrical power to be harnessed from solar energy resulting in savings of 11 crore litres of diesel and reduction of carbon dioxide emission by approximately 3 lakh tonnes every year. The logs collected by this system would allow scientists to reuse the data for other similar terrestrial transportation. The power delivered from the solar panels is measured over a course of a day. Plots of voltage, current and power are rendered by the GUI from dawn to dusk. Agro-based Projects: GKVK The Sensor signal acquisition for Poly House is an acquisition and control system designed for sensor data monitoring, analysis and logging. It is an embedded control system which will periodically acquire the data, communicate all the data parameters to a remotely placed computer system which

provides and stores graphical and statistical data required to carry out research and analysis of the parameters obtained. The display system installed in remote control room will allow the user to have real time data monitoring and a comparative study of the parameters depending on the position and altitude of the sensors. The sensors used are Temperature (T) sensor, Relative Humidity (RH) sensor and Soil moisture sensor (SM). Advanced Irrigation Automating some agricultural tasks in a sustainable and scientific way could address the manpower shortage and also lead to decreased water and electricity use and increased crop yields. Developing a system that provides research-quality data on the weather and key soil parameters and can intelligently irrigate a target agricultural field under appropriate conditions, which saves water, electricity, and manpower. The

November 2016

Clean Fuel: Need of the Hour What is India’s energy grid looking like? Where does alternate/ renewable energy figure in this grid? According to Central Electricity Authority (CEA), the country’s per capita electricity consumption has reached 1010 kilowatt-hour (kWh) in 2014-15. Also, according to UN report, nearly 400 million Indians in India have zero access to electricity. This can be best resolved with the use of renewable energy adoption mechanisms like solar, wind and hydro plants. Geographical positioning of India is favourable to harvest solar energy almost all round the year. Therefore shifting the focus towards clean fuel mechanisms is the need of the hour. One more major issue is the transmission loss and energy theft, which makes us more vulnerable in terms of non-availability of the harvested energy from any source. Hence, we should have better infrastructure and metering systems. Today, India is working towards 750kVA and 1200kVA transmission systems from existing 400kVA transmission lines. This increased level of transmission will reduce line losses, thereby increasing the amount of electricity available at the consumer end. Most of the industries are adapting energy savings as part of the organisation objectives but the work to be done is much greater than the work done so far. Your opinion on energy minister Piyush Goyal’s message - “investment thrust will be towards renewable energy”? India is doing its bit to mitigate climate change and its effects, has shifted its focus towards renewable energies. This is very much visible in the target of achieving 100GW of renewable energy by 2022. Feed In Tariff (FIT), Renewable Portfolio Obligation (RPO) for solar and Accelerated Depreciation Allowance (ADA) in case of wind are certain allowances and schemes approved to encourage participation and investment in renewable energy sector. For inclusive participation from all sectors, such schemes will enable the businesses to enter into the arena of renewable energy systems without any apprehensions about market risk and huge initial cost of investment. FluxGen has its aim overlapped with the target of India of achieving 100GW by 2022, is doing its bit to promote and November 2016 2016 November

Ganesh Shankar Managing Director, FluxGen Sustainable Technologies

Ganesh after completing his MS in research from Indian Institute of Science, Bangalore worked with GE for their Aviation Technologies and Energy Technologies Groups. Further he worked with SELCO SOLAR as Principal Engineer where he executed several Solar Installations before starting FluxGen. Ganesh brings in the Solar Electrical Engineering expertise to FluxGen, while he manages it on a day-to-day basis. Talking to MART he explains why scope of developing renewable energy sector is high in India and how FluxGen is poised to offer its solutions to this goal. sustainably use the energy systems in a more effective manner. Globally, new investment in renewable energy has exceeded fossil fuels. Will this happen in India? India is going in a positive direction towards the renewable energy. Cases of new investments have exceeded in the renewable energy sector compared to non-renewable sector globally. India has initiated its step forward by signing the International Solar Alliance (ISA) during the CoP-21 summit. Unless the infrastructure is developed and knowledge management in this area is focused upon, it will be a challenge to meet the expectation and grow at a faster pace. The Government, the bodies like CII, PGCIL, NTPC, and education institutions and entrepreneurs have to focus in this area to achieve success. In such fields, start-up business entities like FluxGen Engineering Technologies, has expanded its forte and built micro-grid in forest covered area (Mendil), sustainable transportation systems like solar on train, comprehensive energy and water audits that are installed with renewable energy systems. An evidence of increase in investment is reflected in India’s increased solar grid capacity to nearly 8.63GW as of September 2016, which is about 2.8GW solar installations till date as compared to more than all of the solar installations in 2015. The future of alternative energy sources depends on 25% reliability, sustainability, and cost-effectiveness. Where do we stand? What will it take to accelerate the transition from

carbon-emitting energy? Alternate energy sources in the current scenario are tagged not only with sustainability which provides a long term benefit in future years, but with cost-effectiveness and reliability that reap short term benefits. Primarily the mind-set of the people has to view a sea-change in its transition from being dependent on systems that leave carbon footprints. Schemes and allowances from the government like the FIT, RPO would encourage the people to transit from carbon emitting energy sources. What are the limits of wind power and solar photovoltaic cells? Wind and solar PV provide the cleanest fuels for energy generation. However, such mode of power generation face some inherent limitations, that predominantly include high initial investment for procuring the solar PV and wind systems. Feed-In Tariff scheme enables to encourage entrepreneurs in the field of solar power generation to enjoy a fixed amount of tariff, subject to the market risk involved. Also, the potential of solar energy is more restricted to lighting than the machineries and other heavy machinery requirements due to the excessive power required. In the case of wind, wind mills are located in remote locations and wheeling the wind energy to the place of consumption is an infrastructure issue being faced in India. As the wind energy is not continuous, the wind harvesting is done mostly in seasons. www.martupdate.com

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development system provides high-quality logs of weather and soil moisture data, as well as automatic irrigation scheduling for the soil and crop chosen. The system captures weather parameters including relative humidity, ambient temperature, solar irradiation, rainfall, wind direction, wind speed, and the soil moisture at various depths and locations in the field. The software also knows the properties of the particular soil type (for example, loam or clay) and crop (for example, wheat or potatoes) in the target field. Based on this, the system determines whether to irrigate the field and, if so, for how long. It also provides high-quality logs of weather and soil data from the field to any authorised user connected to the Internet. Industry Project – TITAN FluxGen provides for a Water Conservation and Management Programme by Comprehensive

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Water Audit using FluxGen’s wireless module. The audit aids to arrive at a realistic water balance and consumption pattern for the entire region and compare it with the actual requirement for the purpose along with the potential to identify the areas of excessive use. Thereby, optimising the water usage pattern and consequently reducing the overall cost of water receipt for industries. Water audits at regular intervals help in efficient management of the water stock and act before the problem escalates to water crisis and threatens closure due to nonavailability of water.

energy and water to everyone. This can be achieved by providing Comprehensive Water and Energy Audit to industries and apartments which aids to arrive at a realistic energy and water balance, by comparing the consumption pattern with the actual requirement along with the potential to identify the areas of excessive use and thereby curtailing it. Thus it can be achieved by optimising the usage pattern, economically reducing the overall cost of energy and water receipt, electronically updating the data measured to the cloud and ecologically providing a sustainable environment.

FluxGen using renewable energy systems measures and monitors the energy and water consumption practices, using the ‘Smart Energy And Water Manager’. FluxGen intends to enhance the ‘Inclusiveness Quotient’ of the cities, by democratising the availability of

The primary objectives to be ventured in the project are to provide: • On-field Remote Energy and Water management – metering and monitoring • Wireless architecture - Remote Graphical user interface.

• Customised Billing software prepaid / post-paid options for customer bill payments. • Remote user programmable and control, power capping and water threshold feature. • Inbuilt theft detection algorithm. • Preventive maintenance: Automated Mobile App / email service on system performance, scheduled maintenance. • Customised low cost solution to Indian markets. • To help in building Green Buildings, by ‘Green Rating for Integrated Habitat Assessment (GRIHA)’, National Rating. In a nutshell, this product would reduce human dependency and ensure reliable performance of energy and water supply. FluxGen Engineering Technologies is a start-up company based in Bangalore that is keen in developing engineering technologies for energy systems. For more details visit www.fluxgentech.com

November 2016

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INDUSTRY FOCUS | Guest Editor

Transforming Automation with Digital Technologies Digital transformation is a paradigm shift. The very definition of automation is set to change in a world where we are likely to see almost 50 billion machines connected to internet and talking to each other by 2020. Shishir Joshipura in his Guest Editorial talks about how we can deliver a better tomorrow by embracing the change.

Shishir Joshipura is a mechanical engineer from BITS, Pilani, and an Advanced Management graduate from Harvard Business School. He joined SKF in 2009 as Managing Director of SKF, leading SKF towards consolidating its position as the leading manufacturer of bearings, seals, mechatronics, lubrication systems and services and aftermarket products. Prior to SKF, Mr. Joshipura was with Thermax for 26 years.

We are witnessing an era of continuous change accompanied by volatile, uncertain and complex environment. Volatile market conditions are demanding an unprecedented flexibility and complexity management. Technology has completely changed the definition of several held beliefs through enablement of completely different business processes and models. The growing prowess of IT in big data form is enabling Automation and Robotics to be the new means for success. Emerging market dynamics are pushing firms to discover new frontiers on quality, consistency and productivity. Improvements in these parameters on sustainable basis demand a complete relook at automation and manning strategy for manufacturing firms.

information, is calling for a new way to lead and manage.

but ‘how’ they will use the automation and technology effectively to achieve their goals.

The very definition of automation is set to change in a world where we are likely to see almost 50 billion machines connected to internet and “talking” to each other by 2020. The improving interface between IT and manufacturing shop floors processes represent a complete shift in paradigm from “manned” shop floors to “automated/ robotised” shop floors. Availability of information in a never before transparent way – as the management matrix walks into smart phones - is changing the manufacturing manager’s span and reach for the operations. The boundaries of shop floor area have acquired a virtual meaning.

Industry 4.0 or the fourth industrial revolution is projecting a completely different future for business entities where the cyber physical systems will hold sway. This era of digital technology with a uniform access to information, connectivity to networks and freedom of expression with multiple channels to receive and pass on the

Organisations will be pushed constantly to find new frontiers on productivity, cost and quality. Increasing automation across the value chain to do away with “losses” and discover higher value will be the norm for organisations wanting to survive and grow in the new emerging economic order. The question in front of organisations is not ‘if’

Will new levels of automation reduce the complexity? Fast, cheap, and consistent output will certainly reduce the uncertainty and complexity while ushering in transparency and reliability. Automation will help the value chains of organisations evolve to create new sources of competitive advantage. Perhaps, the complexity will shift to the algorithms of the software driving the robots. Higher degree of automation will also mean a new level of skilling requirement and a reduction in “Traditional” work force. The socio economic dimension will add to the complexity as jobs get redefined and an ever growing younger population walks into the mainstream job market in India.

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Automation and Robotics will have their space and increasingly more in demand even as we find solution to the challenge posed by emerging complexities. We can deliver a better tomorrow only by embracing change. November 2016

November 2016

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INDUSTRY FOCUS| MAIN FEATURE

Smart Factory: The Future With the advent of IoT, Big Data Analytics, Advanced Robotics, Additive Manufacturing etc. factories will witness a sea change from how they look today. Termed as ‘Smart Factory’, they will in turn transform the manufacturing process into smart manufacturing.

Arnab Mondal arnab@martupdate.com

Manufacturing denotes a process that turns raw materials into physical products, and the factory is the structure where manufacturing happens. Today, drivers such as technology, sustainability, optimisation and customer demands have transformed the manufacturing industry to become adaptive, fully connected and even cognizant of its own power quality. The information technology (IT) revolution has finally come to factory floors around the world and manufacturing is becoming highlyautomated and IT-driven or simply put, “Smart.” Advances in modern manufacturing technologies make factories smarter, safer and also more environmentally sustainable. Futuristic business model therefore calls for strategic investment to transform operations from cost centers into smart manufacturing profit centers that will dramatically drive sales. The term ‘Smart Factory,’ points at a vision of how industrial production will look like in the future. Surely, the ‘Smart Factory’ will be much more intelligent, flexible and dynamic in future. Manufacturing processes will be organised differently, with entire production chains – from suppliers to logistics to the life cycle management of a product – closely connected across corporate boundaries.

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The implementation of factory of the future concepts requires appropriate technologies to support the seamless integration of manufacturing systems in order to enable information exchange and optimisation throughout whole factories, production networks or ecosystems. However, in enabling such implementations, factory of the future will address some preconditions and challenges. Connectivity and Interoperability To achieve increases in efficiency, quality and individualisation, as promoted by the factory of the future, bidirectional digital information flows are to be implemented. These digital information flows require tighter integration and connectivity between various components and participants in manufacturing ecosystems. Seamless Factory of the Future System Integration Besides connectivity and semantic interoperability, successful implementation and achievement of business value from distributed IoT-based systems require more than a framework for connecting and collecting data from devices. It requires the ability to map the business context in which such devices are applied to the management of their environment. This is to be supported by operational visibility of devices, as well as respective information model analytics mechanisms which set device information to

the application-specific context, for example the specific order, product and process. Architecture for Integrating Existing Systems Most manufacturing enterprises aiming at introducing factory of the future concepts in their business already operate automated production systems where some, most, or all devices and machines are connected with control systems via various layers of automation pyramid, such as PLC, MES and ERP systems. In order to introduce and integrate advanced factory of the future technologies, i.e. to migrate production systems stepwise towards distributed and IoT technologies, interoperability and intelligence, it is necessary to establish appropriate (IT) system architectures which support the stepwise implementation and extension of factory of the future systems, i.e. the modular roll-out of respective solutions. Modeling and Simulation Like the flexible and seamless integration of devices, machines and software systems based on IoT technologies, business context integration is also a key to achieving optimisation in the factory of the future. Product and production system development and planning are becoming increasingly complex, as the number of their components, frequency of market demand November 2016

“Smart Factory solutions based on IIoT in conjunction with instrumentation and automation can provide immense value to shop floor operations. These solutions can deliver in many key areas like performance improvement, predictive maintenance, energy management, asset management, traceability and reporting.”

“In India, IoT has large space to contribute in upraising production quality by ensuring individual skills. ‘IoT’ can be human training tools in India.”

Sujata Tilak Managing Director, Ascent Intellimation Pvt. Ltd.

changes and need for related innovation increase. To manage this complexity, product and production planning are executed incrementally with an increasing level of detail, from conceptual ideas to detailed design. In this context, conceptual design determines roughly 80 per cent of the total costs of a product, and detailed design constitutes the critical path in terms of time and resources during product development, since domain experts create precise engineering specifications as part of the development, using domain-specific modelling and simulation tools. Unfortunately, these models cannot be combined easily – due to model, domain, and tool incompatibility or effectively due to performance reasons to perform systemlevel analyses and simulations. Currently, only a few models and the information generated during product development are passed to the production development. The factory of the future will be supported by inter-operable models and tools that provide a harmonised view of the product from multiple viewpoints during product development from domain-specific to system-level, and from concept design sketches to ultra-high-fidelity. Equally important will be the capability of seamlessly propagating these models and information to the production development modeling and simulation methods. Security and Safety System boundaries are extended when implementing factory of the future concepts, and the number of interfaces to remote systems increases. So do access points for potential threats from outside, which November 2016

Tomoyuki YAMATO Director - India & Sri-Lanka, QUNIE Corporation

results in a need for appropriate IT security and safety measures. Moreover, system complexity increases with the increasing number of system components and the connections between them, which might cause unintended back coupling effects or the accidental overlooking of risks. To address these issues, special attention has to be paid to security and safety issues in factory of the future implementations. Enabling Technologies: IoT and M2M Communication IoT is used to link any type of objects in the physical world having a virtual representation or identity in the internet. The use of the term IoT is spreading to the industrial area, where machines and devices are also becoming increasingly intelligent and connected. Things that have a part or all of their functionality represented as a service based on internet technology are also referred to as cyber-physical systems (CPS) or, if particularly used in the production area, cyber-physical production systems (CPPS), both of which will be core building blocks of the factory of the future. Machine-to-machine (M2M) communication or integration refers to the set of technologies and networks that provide connectivity and interoper¬ability between machines in order to allow them to interact. The concept of M2M integration in indus¬trial applications overlaps with IoT to a large extent, so that the terms are often used interchangeably, as both relate to the impact that interconnected devices will have in both the industrial and con¬sumer worlds. IoT and M2M technologies and solutions will affect the operational environment of manufacturers considerably, as both

technologies contribute to the convergence of the classical manufacturing space with internet technologies and the increasing intelligence of devices used to improve manufacturing environments. Cloud-based Application Infrastructure and Middleware Other key components of the IoT include computing capabilities such as cloud and fog computing. Enterprises must make choices about which information and processing can be delegated to the computing infrastructures at the edge, and which should be delegated to the internal or external processing capabilities. Data transfer from the edge of the IoT network to processing centres must take into account the variability of device communication, ranging for example from high frequency pulses to batch uploads. Methods of data transfer from device to cloud must function regardless of whether constant and stable communication channels are available but also with intermittent disruption. Cloud technology paired with mobile devices is providing transparency and visibility of information at every location and time, even among various partners in a network. Data collected from the ever expanding network and number of endpoints must be conveyed to processing systems that provide new business solutions and applications, whether it is through the cloud or through an internal core infrastructure. IoT solutions must have the ability to store and process large volumes of historical and diverse data and must be able to respond immediately to incoming data streams, which makes cloud and fog computing appropriate www.martupdate.com

components of IoT implementations. Accordingly, emerging cloud-based IoT solutions and vendors are providing the capability to integrate not only applications and processes but also things and sensors. Such systems can serve as the IT backbone for factories of the future and for entire supply chains, especially when the systems enable seamless intra- and inter-factory integration and facilitate dynamic scaling of device integration and computing power according to the changing needs of the manufacturer. In addition, cloudbased solutions will allow manufacturing enterprises to reduce the required core computing infrastructure and will enable them to respond flexibly to changing infrastructure needs that in turn are caused by changing requirements in the manufacturing environment. Data Analytics Both IoT and cloud-based technologies increase data generation and availability in manufacturing environments. For the manufacturing domain, this data will allow enterprises to monitor and control processes at a much higher level of sophistication. Previously unknown sources of incidents in shop floor processes will be identified, anticipated and prevented. The ad-hoc availability of such a large amount of data opens new opportunities for novel types of analysis and visual representation. Batch-generated static

reports are no longer state-of-the-art, as it becomes possible for users to view, chart, drill into and explore data flexibly in close to real-time, and as automated reasoning algorithms can now be applied to provide decisions that have in-process impact on manufacturing operation and optimisation. However, not only manufacturing-related data gathered by respective IoT systems is relevant for analysis. In addition to common business management systems, conditions on an inter-company level or from other ecosystems also have to be considered. Smart Robotics The emergence of IT in the manufacturing domain not only introduces new solutions, such as IoT technologies, to this field of application, but also changes existing automation and control systems, especially robotics. Human-robot collaboration, which is enabled by integrating real-time context awareness and safety mechanisms into robotic systems, combines the flexibility of humans with the precision, force and performance of robots. In current production systems, cell or line production is common practice, in which single workers or small teams operate various tasks in a restricted area using wellformed jigs. However, recent market demands for simultaneous application of agility, efficiency

and reliability are not satisfied by such systems, which are operated solely by human ability or on fully automated lines. Robot cells, in which robots support humans in the execution of production tasks, are being developed to overcome this issue. There exist 3 types of human-robot cooperation: synchronized cooperation, simultaneous cooperaÂŹtion and assisted cooperation. However, such collaboration presents safety issues, since failures of the involved active robot might result in fatal injuries. Moreover, currently no industry safety standards and regulations exist covering this type of human-robot collaboration, so both innovation of system integration technology and creation of new safety standards and regulations are required. The integration of sophisticated sensors and the application of artificial intelligence (AI) enable machine vision, context awareness and intelligence. This produces collaborative robots that not only interact with humans without boundaries in a specific working area and for the execution of a well-defined task, but also anticipate required assistance needs. On one hand, this will make it possible to apply robotics to previously impossible use cases, and on the other hand it will lead to higher productivity due to the elimination of non-value adding activities for shop floor workers.

Surely, the â&#x20AC;&#x2DC;Smart Factoryâ&#x20AC;&#x2122; will be much more intelligent, flexible and dynamic in future.

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November 2016

The integration of sophisticated sensors and the application of Artificial Intelligence (AI) enable machine vision, context awareness and intelligence.

This flexibility of collaboration can be implemented not only for human-robot interaction but also for collaboration among robotics systems. Advanced robots can enhance sensory perception, dexterity, mobility and intelligence in real time, using technologies such as M2M communication, machine vision and sensors. This makes such robots capable of communicating or interacting much more easily with one another. The ability to connect flexibly with the surrounding environment and the recognition of the related production context make advanced robots easily adaptable to new or changing production tasks, including those which are to be executed collaboratively. Flexibility of robotic systems will also be increased by open robotic platforms that allow third parties to enrich robots (robot platforms) with application-specific hardware and software. Examples include special purpose grippers and associated control software. Integrated Product-Production Simulation Not only innovations based on technologies on the shop floor, such as IoT technologies, data analytics and smart robotics, will have an impact on the factory of the future. The digital factory, i.e. the representation of production systems in IT systems for planning and optimisation purposes, will also undergo considerable changes. The digital factory concept refers to an integrated approach to enhancing product and production engineering processes and simulation. This vision attempts to November 2016

improve product and production at all levels by using different types of simulation at various stages and levels throughout the value chain. There exist several types of simulation that create virtual models of the product and production, including discrete event simulation, 3D motion simulation, mechatronic system-level simulation, supply chain simulation, robotics simulation and ergonomics simulation, among others. The ultimate objective is to create a fully virtual product and production development, testing and optimisation.

even individual products.

Traditionally, product and production design are separated. Product requirements have to be specified completely before the production planning and engineering phase can begin. This causes a sequential process, in which any changes produce additional costs and delays. An integrated product and production simulation will decrease timeto-market, as concurrent engineering can be performed on digital models. Visualisation technologies will improve communications among geographically dispersed teams in different time zones. This integrated approach also promises a secure access to all relevant information within the company and throughout partner organisations .

products.

Additive Manufacturing/3D Printing

Conclusion

A major aspect of integrating digital and physical worlds is the transfer of product specifications to executable production processes. Moreover, flexible manufacturing resources such as machining equipment or 3D printers help to keep associated configuration efforts low and thereby support the production of small lot sizes or

The factory of the future will be enabled to

The use of AM for the production of parts for final products continues to grow. Within AM for industry, there has been a greater increase in direct part production, as opposed to prototyping (AMâ&#x20AC;&#x2122;s traditional area of dominance). Within direct part production, AM serves a diverse list of products and sectors, including consumer electronics, garments, jewellery, musical instruments, medical and aerospace

3D printing allows manufacturing to work economically with a large variety of shapes and geometries, including for small product quantities. This has the potential to transform some parts of the production industry from mass production to individual production. The â&#x20AC;&#x153;batch size oneâ&#x20AC;? will become more wide-spread. Furthermore, the number of required steps for producing a product will be reduced, which will lead to a more environmentally friendly production and to new

deliver on-demand customized products with superior quality, while still benefiting from economies of scale and offering humancentered jobs, with cyber-physical systems enabling the future of manufacturing. Smart Move, right! www.martupdate.com

industry focus | SMART MANUFACTURING

IoT, Cloud and Emerging Technologies for Smart Manufacturing Data collection is not a new practice in manufacturing. Whatâ&#x20AC;&#x2122;s new is the analysis of those data and making right decisions based on those for overall performance improvement. IoT, Cloud based applications and Big Data Analytics, Artificial Intelligence, Control Engineering etc. are the emerging technologies which are changing manufacturing into smart manufacturing by revolutionising the data analytics, production process and efficiency.

Rajesh Angadi rajeshangadi2013@gmail.com

Manufacturing organisations are able to accumulate large amounts of plant floor production and environmental data due to advances in data collection, communications technology, and use of standards. The challenge has shifted from collecting a sufficient amount of data to analyzing and making decisions based on the huge amount of data available. Data analytics (DA) can help understand and gain insights from the big data and in turn help advance towards the vision of smart manufacturing. Modeling and simulation have been used by manufacturers to analyze their operations and support decision making. Manufacturing has always had Big Data. We have been collecting data with historians, MES (Manufacturing Execution systems) for decades. It is just a new buzz word for the marketers.Manufacturing is an untapped market for Big Data. There is lots of data, lots of different types of data, and hardly any of it is being used for analysis today Smart manufacturing system requires capabilities and technologies for designing and improving the overall system performance through diagnostic and prognostic assessment based on (big) data analytics. The right insight derived from big data could lead to right actions for enhancing sustainability, productivity, flexibility, and

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competitive advantages and enabling sustainable and agile manufacturing. The contributions from different engineering disciplines to bring out common issues and specific challenges that address predictive modeling for Smart Manufacturing Systems. An initial set of topics includes (but is not limited to) manufacturing Key Performance Indicators (KPIs), Methods, Technologies, and IT Infrastructure for Big Data and Data Analytics; Standards and Protocols; and Business Best Practices for Smart Manufacturing Systems. Manufacturers have been collecting and storing data for years, but now big data technologies enable more constructive use of this information, including how to increase throughput, boost yields, improve efficiency, and reduce downtime. Big data is characterized by huge data sets and varied data types (e.g., images, text, and machine log files), which the production line is producing at a much faster rate than ever before. When this data is analyzed using new tools available on the market, manufacturers can gain valuable insights derived from finding patterns, extracting meaning, and ultimately making decisions that lead to greater efficiency. Big data analytics, Cloud and Internet of Things (IoT) technologies are the substantive foundation that enables advanced levels of smart manufacturing performance. Thatâ&#x20AC;&#x2122;s

why companies are working hard to drive a data revolution in smart manufacturing that will yield new productivity and efficiency gains. IoT Solution Blueprint is easier than ever to learn how big data analytics applied to factory equipment and sensors can bring operational efficiencies and cost savings to manufacturing automation processes. However, many machine tools operate in relative silos, so it is a major challenge to collect, analyze, and act on data generated across the factory floor. This is why companies have assembled various Cloud, Internet of Things and big data technologies that provide the connectivity, security, interoperability, and analytics capabilities that enable higher-performance manufacturing automation. Big Data Analytics in manufacturing is about using a common data model to combine structured business system data like inventory transactions and financial transactions with structured operational system data like alarms, process parameters, and quality events, with unstructured internal and external data like customer, supplier, Web, and machine data to uncover new insights through advanced analytical tools.This definition of Big Data Analytics differs from the traditional approach most manufacturers and vendors have taken November 2016

The AI field draws upon computer science, mathematics, psychology, linguistics, philosophy, neuroscience and artificial psychology.

to dealing with manufacturing data. In most cases, manufacturers have invested heavily in data collection and visibility, mainly through legacy MES, EMI (Enterprise Manufacturing Intelligence), and Data Historians. Big Data analytics promise is all about plucking insights, knowledge and trends from deep reservoirs of raw data. But the reality is that massive troves of data are difficult for commercial and institutional computer systems to collect, sort, manage and analyze in a cost effective and speedy way. Curating and “cleaning” data to improve quality requires access to powerful computing power. Data analytics infrastructures entail complex techniques such as machine learning, visualisation and cloud computing - to name a few. The foundry offers a Big Data Rapid Experimentation Platform made up of readily available technology and an “algorithmic toolbox” designed to accelerate experimentation and reduce risk. Our mission is to help organisations develop innovative data driven methods to find answers to business problems and develop models that focus on solutions that can make a difference. Rapid Experimentation Cloud Big Data Foundry brings collective expertise and technologies to help you experiment and scale new ideas with reduced risk and time-to-value. We provide all the tools and technologies you need to connect, explore, experiment, and validate your hypotheses and problems for smart manufacturing. •Reference architectures, data scientists and November 2016

tools that reduce technological complexity and deployment costs. •Support development of data driven infrastructure to empower your employees to sense, analyze, interpret and act fast on the data insights. Data Sciences Innovation Big Data Foundry member companies collaborate to help you engage worldclass data scientists, data engineers, cloud experts, innovators, and ethnographers all in one place to help you find new routes to revenue and profitability in your organization. With Big Data Foundry as a strategic partner, you no longer need to delay exploring and implementing new Big Data technologies. Internet of Things (IoT) which help for real-time visibility and business intelligence is well within the reach. By converging factory-based operational technologies with global IT networks, companies are increasing uptime and improving operational equipment effectiveness intelligence — from the plant floor through the supply chain which means less downtime, higher productivity, greater resiliency, and the agility to respond to rapidly changing customer and market needs. Smart Manufacturing Operations offering, we can: Optimise your equipment for greatest profit - Smart Manufacturing Operations offering enables the operation of plant equipment to its maximum capacity, increasing revenues and profits.

Shift from reactive to predictive maintenance- Using machine-to-machine data, Smart Manufacturing Operations maintains a real-time picture of operating assets versus capacity and service needs. You can operate equipment at full capacity to maximize revenues, while scheduling service for the least production impact. You can shift production work between plants in your portfolio by viewing plant capacity across your company. Operate at peak energy efficiency- Smart Manufacturing Operations enables plant managers to directly track energy efficiency, sustainability and environmental compliance. Upper-limit alerts give managers time to minimize energy costs and avoid environmental, health and safety fines. Business success is widely attributed to the use of advanced analytics. Smart Manufacturing Operations is a powerful business information and analytics solution that uses data from plant and corporate systems and external sources to create operational insights presented through specialized, preconfigured and userconfigurable dashboards and reports, giving plant managers the information they need to Optimise many parameters essential to meeting demand and reducing cost. Smart Manufacturing Operations Strategy Operations Strategy will work with you to develop a clear strategy, architecture and roadmap to guide your transformation. It will specifically address critical manufacturing functions, including: Operating equipment effectiveness www.martupdate.com

Supply chain and inventory Energy utilization and efficiency Health and safety Environmental compliance Financial performance Smart Manufacturing Analytics Implementation To transform your operation, it will: Tailor and extend our predesigned analytics models for your operation Source and prepare your data for the analytics models Upgrade or install and integrate big data and business intelligence tools with plant and corporate data sources such as ERP, plant historians and laboratory systems Tailor and extend preconfigured reports and dashboards, and put them into production Emerging Technology as Artificial Intelligence Artificial Intelligence (AI) is the science concerned with the creation of machine intelligence which is able to perform tasks, only performed by people. Much of this machine intelligence is symbolic and heuristic. Artificial intelligence (AI) is intelligence exhibited by machines. In computer science, an ideal “intelligent” machine is a flexible rational agent that perceives its environment and takes actions that maximize its chance of success at some goal. Colloquially, the term “artificial intelligence” is applied when a machine mimics “cognitive” functions that humans associate with other human minds, such as “learning” and “problem solving.AI research is divided into subfields that focus on specific problems or on specific approaches or on the use of a particular tool or towards satisfying particular applications.The central problems (or goals) of AI research include reasoning,

knowledge, planning, learning, natural language processing (communication), perception and the ability to move and manipulate objects. Approaches include statistical methods, computational intelligence, soft computing (e.g. machine learning), and traditional symbolic AI. Many tools are used in AI, including versions of search and mathematical optimisation, logic, methods based on probability and economics. The AI field draws upon computer science, mathematics, psychology, linguistics, philosophy, neuroscience and artificial psychology.

- A possibility to allow for complexity and comprehensiveness of decision-making issues in strategicmanagement support.

Demands towards Smart Manufacturing Systems in an enterprise are as follows:

- Artificial neural networks – the most fascinating tool of artificial intelligence, capable of modeling extremelycomplex functions and, to some extent, copying the learning activity in the human brain.

- A possibility of collecting and processing different types of information from all sources, both internal andexternal, in order to acquire and model knowledge necessary to make decisions at all levels of decisionprocess in an enterprise. At the same time a possibility of modeling knowledge and processes, based onhuman thinking, is required. - In a decision process, at decision selecting, the decision maker’s subjective evaluation based on hisexperience and intuition should be taken into account in IMS. - There should be a possibility of preliminary information handling and analysis with analytical methods aswell as modern artificial intelligence technologies. - A possibility of detecting emergency and critical situations and of prompt reaction to them. There must bea possibility of situational data analysis in real time, necessary in an emergency inside the productionsystem or in its surroundings.

- Taking into account the lack of stability and change dynamics, both in the surroundings and inside theenterprise, the IMSs under design should have the capability for learning from experience and adaptingthe experience to intensive alteration of working conditions. In intelligent manufacturing systems, the following selected contemporary methods andtechniques of knowledge and decision process modeling should be integrated:

- Fuzzy logic – technologies and methods of natural language formalization, linguistic and qualityknowledge processing and fuzzification. - Genetic algorithms and methods of evolutionary modeling – learning algorithms based on theoreticalachievements of the theory of evolution, enriching the artificial intelligence techniques. The combination of these tools, in which knowledge is represented symbolically, with the traditional expert systemwill make it possible to create complex programmatic tools for solving difficult decision-making problems at eachstage of enterprise functioning. Artificial Intelligence and Control Engineering Artificial intelligence (AI) relates to control

Data analytics infrastructures entail complex techniques such as machine learning, visualisation and cloud computing - to name a few.

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November 2016

Data analytics infrastructures entail complex techniques such as machine learning, visualisation and cloud computing - to name a few.

engineering is when embedded software helps with situational awareness. The software algorithm looks at feedback from a situation, then actuates the decision (closedloop control) without human consultation, or the software recommends a course of action with human consultation (open-loop control).Control engineering or control systems engineering is the engineering discipline that applies control theory to design systems with desired behaviors. The practice uses sensors to measure the output performance of the device being controlled and those measurements can be used to give feedback to the input actuators that can make corrections toward desired performance. Control engineering is the engineering discipline that focuses on the modeling of a diverse range of dynamic systems (e.g. mechanical systems) and the design of controllers that will cause these systems to behave in the desired manner. Although such controllers need not be electrical many are and hence control engineering is often viewed as a subfield of electrical engineering. In manufacturing, a machine running a webbased process may have similar situational awareness. There may be a perfectly good reason to leave the machine running when the last material runs through the rollers and an operator is standing in a certain location. If the machine is unattended at that particular moment, embedded code may begin an orderly shutdown as the best response. Control Engineering relates to the next big thing (TNBT) which is the second generation of smartphones, which have the software capacity to provide situational awareness. TNBT devices will be able to November 2016

recognize what is going on inside your area or site and determine when something is out of normal but not yet in alarm. Information for this awareness may come from traditional fixed sensors or even by listening for sound patterns such as hisses, whistles, clangs, and bangs. TNBT devices will become true operator assistants; always watching and always listening for out-of-normal conditions or for events that require manual intervention. Seven Artificial Intelligence (AI) tools have proved to be useful with sensor systems (part of IoT’s): Knowledge-based systems, fuzzy logic, automatic knowledge acquisition, neural networks, genetic algorithms, casebased reasoning, and ambient-intelligence. Applications of these tools within sensor systems have become more widespread due to the power and affordability of present-day computers. The appropriate deployment of the new AI tools will contribute to the creation of more competitive sensor systems and applications. Artificial Intelligence (AI) helps computing in four ways: 1. Natural language understanding to improve communication. 2. Machine reasoning to provide inference, theorem-proving, cooperation, and relevant solutions. 3. Knowledge representation for perception, path planning, modeling, and problem solving. 4. Knowledge acquisition using sensors to learn automatically for navigation and problem solving. Artificial intelligence’s ability to function

as a safety measure and provide another set of eyes, so to speak, can be extremely beneficial to worker safety in manufacturing. It can also enhance our ability to understand what’s happening around us and offer solutions that might not be readily available. Will Artificial Intelligence (AI) take control of human race during Smart Manufacturing? The answer to this question seems to be positive. Several experts of AI have similar comment as “everything that humans can do machines can do”. Stephen Hawking also warned us during an interview with BBC that “The development of full artificial intelligence could spell the end of the human race.” Ex Machina, a recent enthralling science-fiction film presents the possibility of a robot that has cognitive capability to think, feel and even manipulate human beings.Selfdriving cars, Siri on your iPhone, weather forecasts, face recognition on your Facebook photos, etc are all examples. A Japanese company with Deep Knowledge found out an Artificial Intelligence (AI) as one of the directors due to its ability to predict market trend that is “not immediately obvious to humans” .Replacing human with robot in manufacturing is a trend that we can’t stop or avoid. As technology advances, the low cost, high-accuracy and efficiency of robot is going to benefit the human society as a whole on a broader level. 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. www.martupdate.com

INDUSTRY FOCUS | internet of things

Connectivity & Collaboration across the Business Landscape Industrial Internet of Things is all set to revolutionise industrial production and business scenario. Emerging technologies in the field such as Cloud computing, Big Data and Data Analytics etc have enhanced the performance of the industry as much by improving processes and decision-making with the power of internet as much as it is by giving reliability and assurance of “no unplanned downtime”.

Ganapathiraman G RamanG@arcweb.com

Transformation and innovation are the buzzwords in the manufacturing sector today. The Internet of Things (IoT) is a universal term that can apply to internetconnected devices in numerous markets, including automotive, medical, residential, consumer, and industrial. The Industrial Internet of Things (IIoT) is distinct, however, due to the unique nature and requirements of devices, assets, and applications used in manufacturing and other demanding industrial environments. The Industrial Internet of Things (IIoT) will transform industrial enterprises with collaboration among intelligent equipment and people. The industrial internet revolution is taking place due to the convergence of automated industrial systems with the power of advanced computing, analytics, low-cost sensing and new levels of connectivity permitted by the internet. The deeper interlocking of the digital world with the world of machines holds the potential to transform the global industry. Information-driven companies are moving to a culture and business model where

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Sharada Prahladrao SPrahladrao@arcweb.com

decisions are made based on analysis of plant data and business processes. This occurs across the three major enterprise value chains: PLM, supply chain and operations; benefiting the organization at three levels – optimisation, business process automation and business transformation. Companies employ software to collect, contextualize, visualize, and analyze data to gain new insights. Armed with new insights, organisations can anticipate changes and drive better business results.

Industrial Internet of Things

tools. No substantial technological breakthrough is needed for industrial solutions to utilize IIoT technologies. In the era of collaboration, the automation and management of asset-intensive enterprises will be transformed by the rise of the Internet of Things (IoT), or as some people call it M2M (machine-to-machine), Industrie 4.0, or simply Industrial Internet. Compared with the Internet revolution, many product and asset management solutions have labored under high costs and poor connectivity and performance. This is now changing. New high-performance systems that can support Internet and cloud connectivity as well as predictive asset management are reaching the market. New cloud computing models, analytics, and aggregation technologies enable broader and low cost application of analytics across these much more transparent assets.

The IIoT architecture builds on current and emerging technologies such as intelligent equipment with an IP address, machine-tomachine (M2M) communications, mobility, cloud computing, analytics, and visualisation

The Industrial IoT promises improved performance of manufacturers’ service operations through remote connectivity as well as incremental connectivity-based revenue streams that represent entire new

The Industrial Internet of Things (IIoT) with advanced analytics offers new opportunities to improve the reliability of industrial assets, enabling owner/operators to progress toward no unplanned downtime, which many consider to be the ultimate objective for maintenance and operations.

November 2016

opportunities. Clearly, the value proposition for the IoT opportunity extends beyond simple connectivity into the ability to build new products and services and achieve competitive differentiation. There are four main parts to the Industrial IoT: intelligent assets with sensors, processors, memory, and communications capability; data communications and infrastructure; software and analytics; and people and business entities that use the technologies for better decision making and improved business processes and models. Big Data Industrial Big Datais software that converge the details created from processes and turns that data into knowledge. Big Data plays a vital role in decision making, and transformational technologies such as analytics, mobility and others are incomplete without this. With advanced analytics, users can get Big Data from anywhere and everywhere and can perform massive calculations, complex algorithm, and analysis for faster decision making.

down capabilities. For maintenance workers and production supervisors, using mobile devices allows access to information at the point of need, without requiring the user to return to a desk or central location. In addition, apps to speed machine setup are already available. Cloud The cloud (private, public and hybrid) can not only dramatically increase productivity but also speed learning by offering a cadre of application tools – everything from

re-useable machine control algorithms to previously established troubleshooting and diagnoses, or simulations for production scenarios. Manufacturers could also use it to compare line performance, therefore becoming a repository of best practices. Key cloud computing characteristics can provide significant benefits for users of the technology. These include: • Agility – on demand computing infrastructure, linearly scalable • Reliability and fault tolerance – self-

IIoT Data. Processes. Devices. Locations.

Small Data Within “Big Data,” there exists structured data regarding specific types of equipment. This “Small Data” provides the needed information to monitor the condition of the equipment and make repairs prior to actual failure. Lower unplanned downtime has many benefits including meeting production schedules, higher customer satisfaction, and lower costs. Also, when the manufacturer of the equipment gains access to real operating data, the product development engineers can improve the product’s design compared to competitors and gain market share i.e., “Closed Loop PLM.”

Red Lion has been connecting devices and moving data for years, enabling customers to easily advance to the Industrial Internet of Things (IIoT). Our IIoT-ready industrial automation and networking products: • Connect: Extend equipment lifespan with protocol conversion • Monitor: Improve process visibility with visual management • Control: Push control to the edge with remote monitoring • Network: Expand network reliability with industrial Ethernet

Learn more today at www.redlion.net/moreIIoT

Mobility Today, smartphones and tablets provide workers with the latest information at their finger tips. The information and applications vary depending on the worker’s role. Maintenance workers will have work orders, repair instructions, and spare parts availability and ordering capabilities, and the like. Operators will have real-time plant operating information. Executives will have rollup performance information and drillNovember 2016

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healing, efficient backups • Service level agreement (SLA)-driven – policies on how quickly requests are processed • Multi tenancy – several customers can share infrastructure without compromising privacy and security of other customers’ data • Service oriented – compose applications out of loosely coupled services. One service failure will not disrupt other services • Virtualized – decoupled from underlying hardware. Multiple applications can be run in one computer • Data – distributing, partitioning, security, and synchronization Analytics Increased data capture by companies requires corresponding focus on obtaining value from the information. With more connected sensors, automated machines, and devices generating data, the support infrastructure must also expand. As investments in the networks and systems that collect, manage, deliver and store this data increase, so does the expected computing power to deliver the value of the information through analytics. Speed becomes the essential ingredient with analytics. Information availability to make an operational decision based on a complete picture requires a high performance infrastructure. With the growing adoption of device networking, more assets have the capability to provide data for proactive asset management. The more focused, structured data coming from a particular

machine or class of assets can be combined with advanced analytics to offer new opportunities for improving asset reliability, uptime, and longevity. The device data, combined with algorithms designed for that specific type of equipment, provide ameans to assess condition with higher fidelity (identify specific components and failure modes with longer advanced notice) and reliability (detect a higher portion of pending failures with fewer false alarms). The combination can significantly improve uptime and reduce maintenance costs by recognizing a problem long before it can cascade into a catastrophic failure with a much larger impact on business performance.

Conclusion The Industrial Internet of Things will have a significant impact on industrial companies by providing more sensors, data, automation, and software applications, including powerful new advanced analytics that will help transform the massive amounts of data generated by intelligent, connected assets into timely, in-context information for both planning purposes and real-time decision support. Think about the promise of “no unplanned downtime” on manufacturing operations with IoT and condition monitoring. The time has come for emerging economies in Asia to embrace these new technologies and pole vault into the future.

Automation and Production System Simulation Virtual commissioning involves the creation of a virtual model that represents an accurate and realistic 3D simulation of mechanical, electrical, and control systems to validate the physical functions of a production system prior to actual physical implementation. The inherent complexity of integrating mechanical, electrical, and control systems has necessitated a rather labor-intensive commissioning process typically carried out by a team of engineers and technicians to physically test, validate, and ultimately bring the production system into operation. Virtual commissioning reduces or eliminates rework to design errors found during physical commissioning. It also reduces requirements for engineering resources, shortens time to product launch, and reduces overall costs.

Raman Ganapathiraman is the Country Manager of ARC Advisory Group India and heading ARC’s India operations since 2012. Prior to his tenure with ARC, he was the Executive Director of BHEL. He has many prestigious awards such as ICWA Cost Management Award, CII Business Excellence, and Quality Control (QC) Awards to his credit. Mr. Raman is a senior member in IEEE and ISA also. He is a gold medalist in Electrical Engineering (B.E.) from Madras University. Sharada Prahladrao is the Editor and Public Relations Manager at ARC Advisory Group India. Prior to joining ARC she worked with reputed PR firms and newspapers. She has also been actively involved with education programme for children with disability and rural children. Sharada holds a graduate degree in Psychology, Economics, and English Literature from Bangalore University and a post-graduate diploma in Journalism.

Speed becomes the essential ingredient with analytics.

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Industry Focus | techmatter

The Digital Transformation: Opening Up Great Opportunities The world has never been as networked as it is now. Whether in gas turbines, trains, manufacturing facilities or medical imaging technologies, reality is taking on a digital dimension.

Digital change is sounding the bell for a paradigm change – in business as well as private life. As one of the world’s leading companies in digitalization, Siemens is playing an active part in this development. The company has set a clear focus and identified digitalization as one of the biggest growth drivers towards a successful future. Even today, Siemens’ worldwide workforce includes about 17,500 software engineers, who contribute a wide range of industryspecific IT and software solutions to their work in electrification, automation and urban infrastructures. Together they are making use of the opportunities that digitalization offers – the virtual world – for Siemens specific application areas in the real world. And there Siemens meets not only its customers’ quality requirements, but its own needs as a company, for example when it comes to maximum availability of products. A new platform for Siemens Digital Services Research and innovation play a key role here. Corporate Technology, Siemens’ central research department, supports the company’s businesses by providing new methods and innovative solutions –

for example, helping to develop industry software in much shorter cycles, in close cooperation with customers. Siemens is also devising platforms that very successfully foster and accelerate the development of data-driven services throughout the company. The company has bundled all the technologies needed for its Digital Services in a powerful platform. It supplements Siemens’ previous capabilities in remote maintenance and optimisation with the latest developments in data analysis, connectivity and cyber-security. That’s the way Siemens business units are enabled to offer their customers new services, based on Siemens people’s own specific knowledge of their domain and their analytical skills – all with high levels of data security. Last fiscal year alone, Siemens conventional and digital services generated some EUR 16 billion in revenues. Now it is expected that Digital Services will show average annual market growth of 15 percent. As this process evolves, the company can draw on years of experience. Siemens has been using smart technologies

to network and manage equipment for more than ten years now. Today Siemens remote maintenance platform connects some 300,000 systems – industrial plants, trains, wind farms, medical imaging equipment – and each month these systems deliver 17 terabytes of data that the platform integrates and analyzes. Siemens experts mine this massive volume of data gathered by sensors in machines and systems to derive valuable discoveries. An exciting example comes from Siemens Mobility Division. Predictive servicing has enabled the Velaro E – Spain’s equivalent of Germany’s ICE Intercity Express train – to achieve 99.9 percent availability on the route between Barcelona and Madrid. Suitable data analyses help predict technical malfunctions and thus service the trains preventively for Siemens’ customer RENFE. That means the train operator can promise to refund passengers’ fares if a train is more than 15 minutes late. And that level of customer service also pays off for the operator – because of the reliable availability of its rolling stock. Indeed, RENFE’s trains have become so punctual that today almost half of all travelers on this route take the

Data is the new raw material of business

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November 2016

train rather than a plane. The figure used to be only one in ten. Siemens platform gives its customers the flexibility they need to get data analyses in whatever place fits their individual needs best. That might be in a cloud, or it could also be locally anchored. But in the future, thanks to intelligently networked devices, customers will also be able to get their analyses directly in the field – meaning right where the data are generated. Web of Systems – Siemens version of the IoT Siemens thinking goes a step further: the company has made the concept of the Internet of Things a reality for industrial applications. In Siemens electrification and automation domains – the real world – Siemens and its customers have built up expertise over the decades that it can now link to the virtual world. Factories, traffic networks and power grids are complex structures that involve interlaced

November 2016

real and virtual systems. Most of these infrastructures are critical. This is why Siemens has evolved the Internet of Things further into what we call the Web of Systems. Using web technologies, Siemens makes systems, devices and machines the starting points for digitally networked industry. That doesn’t mean Siemens equipment sends raw data, unfiltered and unprotected, into a cloud where it’s processed and turned into knowledge by some anonymous entity. Rather, devices interact with and understand each other thanks to built-in computing capacity. And the knowledge of what the data means stays within the real and digital systems. Being open to new approaches But technological skills by themselves are not enough. To be successful in the long run, Siemens is systematically turning itself into a digitalization company – adjusting Siemens processes and Siemens corporate

culture to the new digital culture. In training and continuing education, the company is preparing for new working methods in the digital world. With some 10,000 trainees and dual-track university students, Siemens is one of the largest private business trainers, making future employees ready for the digital world in such areas as cloud computing and robotics. It uses new tools to work together across various disciplines and departments. The company has been learning from digital start-ups’ willingness to take entrepreneurial risks when tapping new lines of business, their ability to learn quickly from mistakes and take corrective action. It is exploring new territory in the way it works with external partners. Being open to new approaches is one aspect of Siemens mindset. Being as quick and flexible as a start-up is another. Guenter Gaugler Siemens AG E:guenter.gaugler@siemens.com W: www.siemens.com/ingenuityforlife

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Industry Focus | TechMatter

The Card vs The Cloud The never-ending quest for more storage While cloud is an answer to the increasing high data storage needs today, it also entails a question of data security and fast processing of data through internet. Moreover, given the rise in file sizes with enhanced content, pixels, colour and data quality, data transfer and retrieving cost for users has also gone up. Here comes the local storage options in smart devices which can provide seamless usage of stored data and security assurance. Also, with the growth in IoT and connected devices in all spheres, local storage will be preferred to remote storage for fast data analysis and decision-making.

Dinesh Bahal Dinesh.Bahal@sandisk.com

Card or cloud? That is the question that consumers and businesses will be asking themselves more and more frequently when they think about storing and sharing video, photos and other files – whether to upload the files to the cloud or save them on a local storage device like a microSD™ memory card, SD™ card, high-capacity USB drive or even a solid-state drive. The impulsive reaction might be cloud. Isn’t everything going to the cloud? Plus, companies like Google and Box offer gigabytes of storage for free. The idea of “free” storage sounds like a win-win for consumers, especially in light of today’s advancing video and photo technologies that deliver incredible clarity, depth and color – all of which result in significantly larger file sizes. But it turns out that there’s no such thing as a free gigabyte. A Brief History Cloud storage itself might be free, but the network fees for transferring videos or photos to the cloud can quickly add up to

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substantial amounts each month, especially because many smart devices now are able to take high-resolution photos and videos – large files that eat up data quickly during transfers from connected devices to the cloud. Most of these transfers now take place over 4G networks, which makes the data usage even more invisible because of the rapid speeds at which files are uploaded or downloaded. Nearly one in five wireless customers paid data overage charges in the last half of 2015, according to a January 2016 study from Cowen & Company. That number is even greater among tablet users: 24 percent of owners with 4G paid an overage charge in the same time period, according to the study. There are a number of factors that contribute to this surge in data use and consumer need for reliable expandable storage instead of or alongside the cloud. Everyone’s a Photographer Partially responsible for the boom in

data use is the renewed interest in digital photography, aided by the high-quality camera almost everyone carries around in their pocket in the form of a smartphone. Since 1826, when the first picture was taken, photography has undergone a complete transformation. Globally, we’re now capturing more than 1 trillion images a year, or 114 million per hour, which adds up to an enormous amount of data. The vast majority of these photos are snapped by phones or digital cameras; in fact, IDC estimates that by 2019, 90 percent of all captured images will come from mobile devices. Shooting on mobile devices makes it even easier to upload, post and share, but the steady increase in megapixels, resolution and file size means higher data use, too. However, there are a number of physical storage options that can help consumers alleviate shrinking factory-standard memory and overage fee woes. Many users can take advantage of removable storage, including microSD memory cards, while others can use specially designed dual USB drives for devices that do not offer expandable storage. November 2016

Given the technology in today’s cards, users can easily watch 4K ultra-high-definition footage without stutter or delay.

Globally, we’re now capturing more than 1 trillion images a year, or 114 million per hour, which adds up to an enormous amount of data. The wide variety of available products not only allows users to quickly increase device storage, but also provides an efficient way to back up content without relying on data caps or network strength. In addition, physical storage can help alleviate security concerns. If consumers are wary of uploading personal content to the cloud, storage options like microSD memory cards and SD cards can lessen concerns, assuring consumers that the data is secure and close at hand. Content on Demand There is no denying that smart devices pulling content from the internet have access to a vast repository of music, images and videos that no one individual could possibly match, but being able to find something does not always translate into easy viewing or access. Networks are working ‘round the clock to grow signal strength, but in the meantime, the burgeoning appetite for content never ceases. Building, expanding and upgrading networks requires construction crews, work permits, transcontinental fiber cables and antennas. Companies continue to improve networks, but slowdowns can still flare up, especially during “internet rush hour.” In addition, files being downloaded or streamed from sites continue to increase in size as high-fidelity content becomes more widely available. In these situations, local storage such November 2016

as microSD memory cards and SD cards can provide users with a frustration-free way to access music, images or videos on demand with little to no delay. There is never any need to worry about peak usage hours, Internet speeds or buffering time. In addition, given the technology in today’s cards, users can easily watch 4K ultra-highdefinition footage without stutter or delay – something that would require a premium broadband connection to achieve.

with Game Changers” podcast. She estimates that 40 percent of IoT data will be stored, analyzed and effectively live in consumer devices rather than a centralized data center to minimize latency concerns for end users. The Power in Your Hands

The Smart Home

Consumers rarely give a thought to where their data is physically stored. Their chief concerns are whether it’s safe, available when they need it, easily accessible and reliable. Wireless networks and internet access provide tremendous opportunities to create, save and share, but they are not absolute when it comes to storage.

As the Internet of Things (IoT) continues to extend into the home, local storage will be further favored over the cloud. There will be a tremendous number of objects gathering far more data than we currently collect, and often that data will have to be acted on rapidly.

As long as data caps, wireless network gaps and security concerns continue to exist, there will always be challenges retrieving content over open networks. The ability to store content locally will be necessary as long as the creation and consumption of data continues to grow at its rapid pace.

As the Internet of Things (IoT) continues to extend into the home, local storage will be further favored over the cloud.

Whether users are looking to capture moments, enjoy digital entertainment, or want a home that does all the thinking for them, there are local storage options, such as microSD memory cards, available or already at work. They are a fundamental part of creating a consistent, seamless and enjoyable user experience.

Given the technology in today’s cards, users can easily watch 4K ultra-high-definition footage without stutter or delay

Connected devices are embraced for their instant analytics and adjustments – there is no time to send it to the cloud. While these devices need fast processors, onboard local storage will help ensure data can be accessed quickly and securely stored. We need to be thinking about different architectures,” said Intel’s Bridget Karlin on a recent episode of the “Internet of Things

Dinesh Bahal is Vice President of SanDisk® Product Marketing, Western Digital. This article was first published on SD Association Thought Leadership blog. www.martupdate.com

lET’S tALK

Adding Value to ‘MAKE IN INDIA’ Initiative Mr. Sameer Gandhi, Managing Director, Omron Industrial Automation in conversation with MART talks about how Omron envisions themselves as the enablers to the ‘Make in India’ initiative. Mr. Sameer Gandhi, Managing Director, Omron Industrial Automation in conversation with MART talks about how Omron envisions themselves as the enablers to the ‘Make in India’ initiative.

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November 2016

Color Mark Detection in a World-standard Size (11 × 21 × 32 mm), with High-speed Response (50 μs) and Accuracy in Spite of Sensing Object Movement

India’s manufacturing sector is on a high growth trajectory. And if implemented to its potential, the ‘Make in India’ initiative will further transform the Indian economy for the better, developing India into a strong manufacturing destination in this century. How is Omron Automation Pvt Ltd gearing up to play a proactive role in the automation industry? Make in India initiative certainly has the potential to transform the Indian economy for better. I believe Indian manufacturers can only make the most of ‘Make in India’ by establishing manufacturing facilities which are world class. It is imperative to attain global standards to cater to the domestic and global market effectively. For this, the manufacturers need to invest more in terms of automation and the latest

equipment and technologies. Omron doves tails here. We envision ourselves as the enablers to the ‘Make in India’ mission. As mentioned above, any manufacturing setup in India has to be of world-class and it has to produce global products and that is possible only if the manufacturer has world-class automation. Omron has a strong portfolio of products and solutions - whether it is PLCs, safety equipment, advanced sensors, robots or servos and drives. Coupled with our prowess in ‘Sensing & Control + Think’ technologies, experience and expansive reach, we can provide end-to-end automation solutions to any facility in the discrete manufacturing arena. This is the value we aim to add in terms of ‘Make in India’.

Albeit manufacturing sector’s rapid growth, we remain grossly underinvested in the field of manufacturing automation. What is your opinion? The demand for manufacturing automation is driven by the product consumer as well as the competition. As the consumer starts to demand better quality and the competition starts to drive down the prices, it fuels the demand for quality and productivity improvements by the manufacturers. Since, automation plays a key role in bringing improvements, the adoption of automation goes up. We’ve seen this in several industries. The automotive industry is a good example of this adoption (of automation) trend. F&B is now evolving very rapidly in the same direction. Lack of skilled manpower is another challenge which sometimes hinders

The new Factory Automation devices are built with Omron’s proprietary Push-In Plus wiring technology. November 2016

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1S series provides an innovative solution for improving the machine performance and making it easy from design to installation with Automation software “Sysmac Studio” by connecting through machine automation controller “NX/NJ series” and open network “EtherCAT”.

the adoption of newer technology and solutions. Could you tell us more about the Colour Mark Sensor on IoT platform which enables higher productivity in packaging processes? The new colour mark sensors aim to further enable the food and beverage makers with the right technology for stable detection of colour marks on food packages. They can detect colour marks which are printed on glossy or colourful materials that may have only subtle differences in colours – which are currently very difficult to detect. This leads to a considerable improvement in productivity (by reducing errors) and reduction in the time necessary to start production and maintenance contributing to an overall enhancement in productivity in the entire packaging process. Tell us more about ‘1S Servo technology’ the innovative solution to enhance machine productivity with higher accuracy and integrated safety? Working on Omron’s flagship integrated automation platform – Sysmac - it is an innovative solution to enhance machine productivity, capacity and integrated safety – mainly for the packaging and other SPM manufacturers. It helps machine developers take complete control from a single environment to provide flawless operations and controls of the machine.

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With enriched design to meet the varied machine requirements, ‘1S servo technology’ Optimises the full cycle through seamless installation, commissioning and finally to the maintenance once in production. In addition to the traditional motion solution, it also offers high resolution multi-turn encoder without battery backup, built-in safety network and improved loop control leading to accurate and higher machine productivity. The technology is totally integrated and controls the processes efficiently. It integrates logic, motion, vision, safety, robotics, I/O, networks, and enterprise connectivity all within single software. How do you support manufacturing innovation worldwide with your unique sensing and controlling technologies? Working with the ‘end’ in mind, we work conscientiously towards achieving the ultimate objective of creating perfect harmony between people and machines to create the best value for the manufacturers so as to enable them to move up the value chain to get the best of quality, productivity, efficiency, safety, etc. What are the panel solutions, Omron Automation the global leader in sensing & control + think technology, has added to their portfolio?

The new panel solutions endeavour to increase operational efficiency and address the need of cost saving at manufacturing sites by downsizing facilities or equipment. The solutions are engineered to address the next generation requirements of control panels. It comprises of lighter, slimmer and short-bodied components which aid in reducing the size of facilities, equipment, floor space as well as a decrease in the cost of logistics. The advanced and customised design results into a considerable saving of dead-space (by almost 50%) and also augments the width between wiring ducts further leading to a compact control panel. This provides more flexibility in design changes and component additions, hence, facilitating future expansion plans. Mr. Sameer Gandhi brings with him an experience of over 26 years spanning across multiple disciplines and industries in the manufacturing and automation realms. As Managing Director, Omron Industrial Automation, India, Mr. Gandhi has led the organisation in strengthening its share in creating intelligence for varied manufacturing sectors such as Automotive, Food and Beverage, Pharmaceuticals, FMCG, Packaging to name just a few. Under his leadership, the company has also been able to diversify its prowess in its sensing & control technology portfolio by adding futuristic concepts like - Robotics, Total Automation Solution, IoT, etc. November 2016

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Industry Focus | Case Study

Smart Identity System connects ERP and Shop Floor The development of innovative labeling and marking solutions is one of the main undertakings of C3 Corporation. Based in Appleton, Wisconsin, C3 recognised at an early stage that intelligent track-and-trace is the key to intelligent manufacturing. Equipped with PC-based control technology, the Smart Identity System developed by C3 provides comprehensive remote connectivity, enabling users to access applications via web-capable devices like smartphones and tablets.

Ajey Phatak A.Phatak@beckhoff.com

C3 track-and-trace systems are used in many industries like foam and urethane production, the paper and packaging industry, the food and beverage industry, as well as in the finished metal products industry. “We work very closely with our customers. We want to understand the entire operation from the shop floor to the top management level and everything in-between. This enables us eliminate bottlenecks and make the whole operation more efficient,” explains Joe Van De Hey, the CEO of C3.

labels, C3 has managed to introduce a new development in the field of integration services. “Our system gives customers an accurate overview of their operation’s throughput rates and effectiveness. Via remote access they can use any web-capable device to issue commands, change templates and labels, run diagnostics and access data,” explains C3 application and database engineer, Drew Demerath. “The openness of the PC Control platform also allows us to adapt our labeling and marking solution to the customer’s specific requirements.”

With the company’s Smart Identity System for marking products with data-intensive

PC-based control: Integrated, highlyconnected control platform

The control platform of the Smart Identity System consists of a Beckhoff CX2020 Embedded PC with a 1.4 GHz Intel® Celeron® CPU, TwinCAT 3 automation software, and EtherCAT as the real-time communication system. “The Embedded PC, with its directly connected EtherCAT I/O terminals, allows us to design the system with great flexibility. This is a huge benefit, because all our applications and installations are customerspecific. The PC-based control solution also enables optimal vertical and horizontal integration. For example, linking to an ERP system is just as easy to implement as it is cost-effective,” adds Joe Van De Hey. “The controller’s connectivity allows you to link it

The Smart Identity System uses a CX2020 Embedded PC running TwinCAT 3 automation software as its control platform and Windows 7 as the operating system. Picture credits/Copyright: C3 Corporation, USA

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November 2016

The Smart Identity System from C3 features extensive connectivity. Users can issue commands, run diagnostics, change templates and labels, and access data from any web-capable device. Picture credits/ Copyright: C3 Corporation, USA

PC-based labeling and marking solutions from C3 can be operated from web-capable devices such as smartphones and tablets. Picture credits/ Copyright: C3 Corporation, USA

to the Cloud and access it via mobile devices from anywhere as long as the customer’s network is VPN-capable.” C3 has also begun to implement OPC UA so that users of Smart Identity Systems can see the same data at the same time with built-in security and data encryption. “Based on PC-based control technology we implemented a web server, a comprehensive database and a controller in a single device,” says Drew Demerath. “Conventional systems can’t compete with this solution because they require multiple hardware layers or separate devices. With PC Control we simply add more software layers, combine everything in a single hardware device, and sell the solution as an all-in-one, turnkey package.” Automation technology and IT convergence via TwinCAT 3 TwinCAT 3 plays an important role in the labeling and marking solutions from C3. In addition to the standard programming languages for automation applications, TwinCAT 3 offers a wide range of IT engineering tools. “The development software, the easy installation of web servers and a series of new software tools give us many options to further advance the functionality of our Smart Identity Systems,” explains Joe Van De Hey. “As a result, we can embed many functions at no additional November 2016

cost into the PC-based software platform, which makes the work of our developers considerably easier.” The TwinCAT 3 software libraries make it possible to implement one or more TCP/ IP servers and/or TCP/IP clients within the TwinCAT 3 controller. The controller variables and/or the direct values from the EtherCAT I/O system can be recorded and saved in databases cyclically or in an event-driven manner. “With the TwinCAT 3 Database Server, C3 was able to significantly expand the history tracking and trend analysis functionalities,” says Demerath. “We can see all the labels and the markings throughout a line, and it is rather easy to view what a facility has produced by the day, month or year.” C3 uses a variety of digital EtherCAT I/O terminals to connect sensors, scales, scanners and other field devices. EP66520010 EtherNet/IP slave terminals handle the communication with other industrial Ethernet systems. They provide a direct link to EtherNet/IP devices in C3 applications and return their data via EtherCAT. Power through intellectual property C3 recently installed the new PC-based Smart Identity System for a highly automated national dairy processor client. “This company can now gather data about its recipes and improve their traceability,” says

Drew Demerath. In the previous system, the main PLC sent requests to a computer, which then sent the print commands to the label printer. The issue was time: Since a single computer controlled all the labelers, a boxed product would frequently be missing a label because it was not printed on time. Consequently, the product had to be sent back through the system to be properly labeled. “EtherCAT allowed us to increase the labeling speed significantly,” says Joe Van De Hey. “The real-time communication system makes sure that all labels are correctly printed by the time each package arrives for final processing.” It also gives the company access to its entire production history. Another advantage of the PCbased solution is the system’s source code protection, says the CEO: “This solution allows the customer to protect valuable intellectual property.” The hot-connect capability of EtherCAT also made it much easier to switch out print engines and consumables. “These processes could take four hours or more on the plant floor if you include the IT department’s involvement with the ERP systems. With PC-based control and EtherCAT, it takes one person just about half an hour now,” reports Joe Van De Hey. Links: www.c3ingenuity.com www.beckhoff.com/print www.martupdate.com

Industry Focus | interaction

PC-Based Control Technologies for Smart Factories Products and facilities of the Smart Factory will be networked vertically and horizontally in the value chain where information technology will meet automation solutions. Beckhoff Automation’s PC-based control technologies will facilitate such networking and communication in the factory of the future. Talking to MART, Ajey Pathak, Head Marketing, Beckhoff Automation Pvt. Ltd. explains…

Mr. Ajey Pathak heads the Marketing division of Beckhoff Automation Pvt. Ltd. and was one of the founding members of Beckhoff Automation in India as well. He has 30 years of experience in Electronics, Electrical Power T&D, Motor & Pump protection, Industrial Automation etc.

How does the Smart Factory concept add value to manufacturing? Everyone seems to be talking about the “Internet of Things”, “Smart Factories” and “Industry 4.0” – all of which are terms used to describe the future of manufacturing. The basic goal is to network all production facilities in an enterprise horizontally and vertically, i.e. to network products, production resources and facilities along the global value chain. The Smart Factory concept aims at using energy and other resources more efficiently to make businesses more competitive. What is Beckhoff Automation’s position regarding Industry 4.0? What solutions do you offer to the customers for their transition to the factory of the future? For Beckhoff, Industry 4.0 is much more than a buzzword. Rather, it is the logical continuation of the convergence of information and communication technology (IT) with automation technology (AT), focused primarily on communication and networking.

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Individual machines in a Smart Factory will exchange more and more data between one another. Added to that, the vertical exchange of data with MES and ERP systems and also with the Cloud will occur. The key to this is PC-based control technology from Beckhoff, which provides the efficiency of built-in communication capabilities. In addition to physical networking, you need protocols that serve each of the various levels in a modern production environment. To provide real-time control communication capability on the fieldbus level, Beckhoff introduced EtherCAT to the market in order to provide a consistent standard for use around the world. In addition, when coupled with OPC UA, which includes features such as built-in security and data encryption, you can communicate vertically in the control pyramid. Engineering plays a significant role as well. Software creation with modern programming languages like IEC61131-3 3rd Edition and C/C++ along with other valuable software tools such as MATLAB®/Simulink® lowers engineering costs. To what extent does Industry 4.0 match

your current product developments? With the company’s PC-based control technology, Beckhoff provides the basic foundation necessary to build networked Smart Factories. Early solutions in the areas of measurement technology and condition monitoring are already available. Furthermore, in the “eXtreme Fast Automation” (efa) project, we research the use of many-core technologies in combination with extremely fast control technology. The goal is to supply highperformance control technologies as the platform for flexible, fail-safe, and resourceefficient Smart Factories. Industry 4.0 will have a significant impact on the way we work. Existing value chains will be broken up and replaced by processes that are more flexible and more tightly networked than ever before. This requires all players in the value chain to think in new ways – from management to the employees on the shop floor. It also requires appropriate IT solutions. The people in the factory will most of all see new forms of interaction between man and machine. November 2016

November 2016

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COLUMN| POLICY MATTERS

Demonetization: Impact on Manufacturing The Demonetization drive by the Centre has not only caught the average citizen unawares but has also thrown a spanner in immediate demand for automobiles, consumer durables, electronics industry in the country. This impact would obviously be more in the short term, but over long term India economy will revive stronger than ever.

Abhijit Deshmane deshmane.abhijit@gmail.com

8th November 2016 Prime Minister of India in a 40 minute long speech announced the Demonetization of existing notes of Rs 500 and Rs 1000 during a televised address on Tuesday evening. PM announced that the notes of Rs 500 and Rs 1000 “will not be legal tender from midnight tonight” and these will be “just worthless pieces of paper. It is not exactly a Demonetization exercise— as it does not dispense with the value of a note—but one that simply replaces the existing notes with new ones, thereby addressing the issues of counterfeit currency and black money. In countries where currency notes are demonetized, the denominations simply disappear from the system. But for simplicity I will continue with the word Demonetization in this article. Reasons for Demonetization:1) To eliminate black money in the economy. 2) To reduce the cash circulation in the economy which “is directly proportional to corruption in our country,” according to PM Modi. 3) To eliminate fake currency and dodgy

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funds which have been used by terror groups to fund terrorism in India. 4) The move is estimated to scoop out crores of black money from the economy. Effects of Demonetization on Manufacturing Industry September 2016, the Index of Industrial Production (IIP) growth displayed a positive print after two-consecutive month’s contraction. IIP for September stood at 0.7% versus the (-)0.7% recorded in August 2016. October IIP numbers to be on the strong side, on the back of festival season. However, the situation is expected to turn sour thereafter from November, which would clearly have a negative impact of currency Demonetization. The Demonetization drive by the Centre has not only caught the average citizen unawares but has also thrown a spanner in immediate demand for automobiles, consumer durables, electronics industry in the country. This impact would obviously be more in the short term, however, the sucking out of unaccounted cash from the system is going to have a medium term impact on sales.

Cash crunch is likely to impact demand. People are likely to defer purchases in short term. Around 35% of passenger car sales in India come from the rural markets, and this share is even higher in case of twowheelers, at around 50%. In urban market 80 % cars are financed by banks or financial institution, hence there will be less impact of Demonetization on automobile industry in urban market, whereas impact from rural market will be bigger. Farmers and small traders transact in cash. In the short term the sales will be impacted by 50 % (3 -4 months) impact will eventually reduce in medium term to 20 %. The unorganized manufacturing sector that falls in the category of SMEs and these units work on the basis of cash, with purchases being made through this mode; all do not have access to credit and their creditworthiness could be of a lower grade. These units would find it a challenge to convert their currency—any time-lag in their operation can affect their functioning and hence there is a concern here. Wage payments, mostly made in cash—as labour in this segment is unorganized, and employed November 2016

Changing face of digital payment revolution that represents thousands of petty vendors, next-door grocers, retail traders, cab drivers, autowallahs and even pan-wallahs, who have adopted innovative ways to accept hassle-free payments from their customers and keep their business rolling

on a daily basis—also becomes a consequent problem. The shortage of currency notes and the restrictions on withdrawals have a short-term impact on these units which must strive hard to meet these requirements. The rural market is heavily dependent on cash transaction. Farmers and small traders transact big chunk in cash, rural market is heavily dependent on cash for buying of consumer durables like televisions, refrigerator, washing machine, mobiles etc. Sales of these manufacturing companies will be hit most for next 6 months, in medium term Demonetization effect may vanish completely. Massive deposit for banks to reduce lending interest rates More than 1.5 lac crore rupees have been deposited in the banks so far, there are few positives for the economy from this:-1. Everyone single citizen has become part of economy by their association with banks 2. Lending rates to small and medium scale industry at will decrease 3. This money can be used for infrastructure development of the country. 4. Giving boast to infrastructure is very important for the economy of the country, Infrastructure sector will create lacs of jobs in the country, which in-turn will drive the economy. Pumping of money in November 2016

infrastructure projects is indispensable to bring back the economy on 8 % growth trajectory. Neighbour country had pumped lot of fake currency in Indian system to de-stabilize the Indian economy, elimination of fake currency has put an end to parallel economy being run, cash transaction of 500 rupee had gone by 86 % and for 1000 rupee note had gone up staggering 106 %, because of this move parallel economy has collapsed. Discretionary consumption may see some impact as consumers with a liquidity crunch may become choosy on where they spend. The current quarter may, therefore, show some impact of this decision on sales growth of companies. The Demonetization is a bold step and we should welcome the government’s decision. There will be short term hiccups to the economy but I don’t foresee long-term impact on businesses or the economy, discouraging of cash transactions is good way forward for the economy. There will be a slight short-term impact for manufacturing industry, but over long term India economy will revive stronger than ever. Only 1% of Indian population pays taxes. In India more than 90% of transaction happen in cash, a tea stall vendor, a vada pav stall and small groceries shop transact in cash. Yesterday saw a vegetable vendor using Paytm as a payment portal. They are the

face of a digital payment revolution that represents thousands of petty vendors, next-door grocers, retail traders, cab drivers, autowallahs and even pan-wallahs, who have adopted innovative ways to accept hassle-free payments from their customers and keep their business rolling. The money these people earn are not accounted in the system, Demonetization move has forced few of them to move towards e-money or banking transactions (oxyzen wallet, PAYTM etc.) Many of them don’t understand the tax system or even if they understand they don’t pay taxes. This move will help government to keep track of their accounts money and they will have to pay income tax. I do understand that things cannot be turned right in matter of few days or months but Demonetization is a step towards fixing accountability and making them pay taxes to the government. People who have evaded taxes all these years will have to pay, taxes earned by government can be put to built infrastructure, better education system, better environment and so on. The author Abhijit Deshmane is working as Deputy Manager with Cox and Kings Limited. An MBA in marketing from Mumbai University, Electronics and Telecommunication Engineer he is having more than 7 years of experience in Marketing & Public Relation. www.martupdate.com

COLUMN| MANUFACTURING EXCELLENCE

Forces on the Company

Companies are facing challenging forces in today’s economy from within and outside in the form of global competition, stringent customer demands etc. Identifying these forces and strategising plans to nullify or eliminate them are the way forward to sustainable growth for a company

P S Satish gotopssatish@gmail.com

Today the industries are working in a highly dynamic environment. The rate of change happened in last 10 years is much higher than what happened, may be, in previous 100 years. VUCA (Volatility, Uncertainty, Complexity and Ambiguity) happening in global environment and LPG (Liberalization, Privatization and Globalization) initiatives for last two and half decades by the Indian Government is putting lot of pressure on the industries. These pressures can be identified as forces from inside and outside of the companies. The leader and the team of the company first need to identify the forces being exhorted on them before acting to reduce the impact of forces if elimination is not possible. They need to look at these

forces considering the fact that the customer wants continuously better product at competitive price, in time and with more customisation. Let us look at some of the forces on the industries and possible ways for elimination. • Cost of operation: In a buyer’s market, the customer has many choices to buy. In this situation, there will be a pressure to reduce the cost compared to the competitors’. Efforts should be made to eliminate the wastes, adding value in every operation, continuous evaluation of process for improvements and so on

• Quality: Here the force is on to deliver top quality and that too consistently. Quality is taken for granted by the customer. Quality mindset should be inbuilt in employees of the company. Quality improvements should be extended to product, process and service. The force will increase continuously as the customer expectation on quality will increase over the period. Any slack is a problem. • Time: The customer creates pressure for delivery on time and speed of delivery. Another force here is speed of development of new products • Flexibility: The customer wants the product whenever needed, at the right place, in the right quantity and quality. Flexibility is

Efforts should be made to eliminate the wastes, adding value in every operation, continuous evaluation of process for improvements and so on

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November 2016

Trade barriers between countries are coming down with push from World Trade Organization (WTO)

expected to manage fluctuation of demands, many varieties and with high degree of customization. Among these four forces explained, please observe the trade-off among themselves. If one of them is focused too much, slackness will come up in others. For example, speed of delivery may come down when cost of operation should be very low. Key for success here is to balance these forces to keep the customer satisfied. Apart from these, let us look at other forces on the industries: • Force is on increase because of globalization. With boundaries between countries vanishing, customer has the option to buy globally at the most competitive price. When companies think of competitors, they should not think of only of local ones. We are seeing many companies in India struggling because of global players. For example, local lock industries almost completely vanished because of Chinese players • Pressure from expectations by customers on information technology adoption by the suppliers is high. IT is no more an option but a necessary enabler to be more effective and efficient. • Trade barriers between countries are coming down with push from World Trade Organization (WTO). By eliminating tariff barriers, Free Trade Agreement (FTA) partners get easier market access to another’s market. India has signed Free Trade Agreements (FTA) with many countries like Singapore, Thailand, Malaysia, Japan etc. November 2016

Giving easy access of Indian market to other countries will put force on local industries. • Force from rapid technological developments cannot be underestimated. Technology clock of products are coming down. With this, there is a need for companies to be more innovative bringing in more technology in the products and processes. • Diversity of workforces in the companies is increasing. In India, we are seeing employees from diversified back ground, culture and skills. With this trend, managers of the company must sharpen their management skills. • Service level expectations from Customers are on increase. Having only good products without proper service is a catastrophe. Service includes how companies respond to customer queries, how to enhance relationship, engaging them more constructively with more proactive communication and so on. All the employees in the company must be oriented towards serving customers to enhance service levels. It is no more the job of just marketing persons. Force for maintaining service level is on continuously and to be focused with proper training and resources. Behavioral differentiation compared to competitors can be a winning factor. • Force from compliance issues is a necessary evil. Government is pushing companies to comply with various acts and policies. The latest one is corporate social responsibility. Ensuring compliance of various requirements creates constant force

on companies. • With increased expectation of delivery fulfillment and improved service levels, logistics including right transportation should be cared. • The biggest challenge of the world today is to ensure growth but not sacrificing the environment. So called sustained development should be ensured. Taking care of environmental aspects which is included as a part of Corporate Social Responsibility is important. Balance between environment and costs should be done. • The companies should try to develop and retain core competencies for long term sustenance. Otherwise, customers may replace the companies if they find no differentiation compared to others. To nullify the forces we discussed above, first step is to understand the forces on the specific company and from business environment and then develop strategies with action plan to weaken the forces. Also, recognize and appreciate that few forces against others or aggravate few more. Can we start to identify? The Author, P S Satish heads Saraswati Industrial Service. He has acquired B.E, M.Tech (IIT) and with 30 years of Industrial experience is serving engineering Industries in the area of capability development (purchase, quality & soft skills), consulting and mentoring. Focus is on overall improvement of company for 3C - Competitiveness, Core-competency and Customer satisfaction. www.martupdate.com

COLUMN | Human Resource

HR Automation:

Effectiveness, Efficiency and Engagement Automation in HR Management is integral to company’s growth in unprecedented ways. It saves time and cost of tedious tasks of multifaceted HR Management for HR Professionals in a company.

Sanjeev Himachali sanjeev.himachali@gmail.com

In last few years, I have developed my own

to set-up a new plant in Pune. Till date,

numerous reasons as to why automation is

unique process of networking with leaders

15 employees were managing the Human

a bad idea. One of the reasons was, losing

and professionals across industries and it has

Resource activities through Microsoft Suit,

‘human touch’. Someone voiced a concern,

worked efficiently for our mutual growth. I

primarily MS Excel and low-level software

“We are working in HR Function, therefore,

call it as ‘Service Model of Networking’ as

for managing payroll. My initial conversation

we need to understand feelings, emotions,

opposed to ‘Sales Model of Networking’.

with the CEO indicated that he was not

and difficulties of our employees and resolve

The ‘Service Model of Networking’ doesn’t

happy with the functioning of HR Team. He

it accordingly. With automation, everything

work on the basis of ‘revenue earned from

asked me about my experience and level of

will become mechanical and we will lose a

every professional network’; instead, it

involvement in HR Automation Projects and

works on ‘value addition’ or ‘Unique Selling

if I will be interested in taking up a project

Proposition’ (USP) you bring to the table.

with the organization. After I submitted my

It is much focused and creates win-win

detailed response to him, he called me for

outcomes. Through “Service Model of

a meeting at his office in Gurgaon. As a part

Networking”, I don’t seek business from

of the project, I was asked to evaluate their

people in my network instead, I ask for their

existing processes, suggest a cost-effective

feedback on my work and my ideas that may eventually add value to their organisations. I believe, it is very engaging and at the same time is a non-irritating approach. It has helped me to reach out and develop a

to purchase it from the market and get customised. I was also asked to provide a list of best THREE HRMS available in the market.

there will be high attrition”. Another HR manager said, “These people don’t know how to operate computers. They are too rigid to learn new things. It will increase the workload on HR Designation”. Yet another member of HR Team blamed the leadership of the organisation, “They never discussed it with us. That’s how they treat us. We work so hard, sometimes we work for 12-13 hours a day and yet they don’t involve us in decision making. They should

wonderful relationship with many CEOs and

Challenges in Successful Implementation of

have involved us in this decision as it was

Managing Directors of small and mid-sized

HR Automation

about our designation before appointing

organisations (less than 5,000 employees).

solution to develop software in-house or

chance to interact with them and as a result,

you as a consultant and paying such a huge 1. Process Owners Opposing the Change

amount (I don’t know how they found about

Last year, in the month of March, I was

Like any other change, this change was

my commercial fee). We would have felt

contacted by the CEO of a mid-sized

also furiously opposed by process owners.

motivated had they given that amount to

engineering organisation headquartered in

For them, automating processes implies

us instead of wasting it”. It took me a lot of

Gurgaon. The organisation which currently

learning new skills. If they fail to do so, they

time to convince them and show them an

employs 625+ employees is now considering

might risk losing their jobs. During my initial

opportunity to grow and learn new skills.

few global acquisitions and is also planning

interactions with the HR team, they gave me

I also gave them an insight into how they

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November 2016

The way to move towards HR Process Automation is to completely shut-down the manual process and use the software efficiently and optimally.

can develop their career in HR and be more

for adding details into the system, added

thereby removes the need for extensive

effective. I won’t claim that the entire HR

3,600,000/- INR per annum. As a result, the

filing systems and large storage areas, which

team was convinced with my explanation

new employee received a salary of 300,000/-

in turn saves the organisation’s money on

and argument but 3/4th of the lot were.

INR per month. After four months this error

rent and utilities. It also speeds up the

came into notice but by then the employee

process of document/information transfer

had already left the organization. There

as and when required thus saves postal

was another case of an employee receiving

and courier expense. It also eases up the

full salary for THREE months after leaving

audit processes conducted for various legal

the organization because the person who

compliances or certification issuances such

was responsible for updating the database

as ISO, CMM, PCMM, etc.

2. Running Parallel Systems HR prefers to run parallel systems - manual as well as automated HR processes. Though they continue with the manual process as a backup plan to ensure functional continuity until the automation is completed and employees get enough training to use processes efficiently and effectively. However, the truth is that in many mid-sized organisations, they never really move to automation. I know few organisations where

missed clicking a tick in the system. In order to maintain database confidentiality and determine accountability, it is important that database updating rights are given to few people only.

b. Improves communication with employees across functions and geographies: I remember days when employees would walk down to HR Designation, sometimes they had to wait in a queue to ask for

they manage time-office and payroll in MS

It took me 30 meetings, involving over 50

information (leave balance, letter for address

Excel as well as in Software. The only way

stakeholders, in a span of four months to

proof, interpretation of any policies, etc.),

to move towards HR Process Automation

understand existing processes and gather

is to completely shut-down the manual

information; challenges faced by HR team

process and use the software efficiently and optimally. There might be few challenges in the initial months of implementation, may be 4-6 months, but after that, it will be easy to work. It will not only save the time but will also increase the accuracy. 3. Inaccurate and Incomplete Database – For an automation of HR processes to work flawlessly, two things must be accurate and updated by minute – Process Flow and Database. If Process Flow And Database are inaccurate and incomplete, then no matter which HRMS one uses and how

and leadership team and create a document and process flow diagrams. In the next phase of my project, I had to conduct a feasibility study and make recommendations. I conducted a one day workshop for the entire HR team on a theme ‘Changing Role of HR in an era of Automated Processes and

make a complaint (discrepancy in salaries) or get their queries resolved. With automation of HR Processes, leave records get updated in real time, all policies are made available to employees, complaints can be raised online where they get a ticket number and a turnaround-time (TAT). Failing to respond within TAT automatically escalates the issue to a higher-up in the hierarchy. Process-flow has

Digitalization’.

been set in such a way that an unresolved

The integral message of the workshop was

Director of the organization. Therefore,

to highlight following seven benefits of HR

the automation brings in transparency

Automation and the new role

in the system. Any announcement can

of HR Function.

be made instantly through the intranet.

complaint gets escalated to CEO or Managing

Communication becomes quick, effective

expensive it is, it won’t give the desired

a. Saves Space: I visited one organization

result. Hence, it is a responsibility of HR

that employs 4,000 employees and is into

to audit the database and process flow on

business for last 20 years. They have rented

c. Factual and Quick Decision Making:

regular basis, preferably on weekly basis. I

a warehouse to stock lakhs of files which

Automation of HR Processes enables

remember one case where an employee was

probably they will never use. When we

Process Owners to create any kind of

offered a salary of 360,000/- INR per annum,

automate HR systems, it saves space by

report and analytics thereby helping them

however, a manager who was responsible

eliminating or minimizing paper records and

to make every kind of decision. Through

November 2016

and low-cost.

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automation, any leader can access the

open position at a single place, evaluate

managers to use a prescribed rating scale

information he requires while being at any

them thoroughly, share it with the hiring

that helps in improving the consistency

place in the world without the necessity of

manager, and organize interviews in a timely

of ratings. Thus, employees perceive the

exchanging emails with HR team members.

manner. With an applicant tracking system,

process to be fairer.

HR Automation has helped managers to

the hiring team can write a job description

determine when and who to hire and

and promote it widely on job sites and social

what best methods are for employee

channels with just a few clicks. Qualifying

development. Automation has allowed skill

questions automatically eliminates

and competency matrices readily available

unqualified applicants and help uncover

to decision makers; hence, before looking outside for required skills and competence, organisations look within and hire talent within by ways of transfers, promotions, etc. d. Increases Productivity and Cost Optimisation: As discussed above, with automation HR saves physical space required; communication becomes efficient, quick and low-cost; and quality and speed of decisions improve, thereby, increasing bottom-line profitability. HR Automation also saves the time of those who need to communicate with HR on regular basis.

the best job candidates. It accelerates the recruiting processes and allows the recruiting team to focus on interviews and deliver outstanding candidate experience. Also, by reducing administrative work, the recruitment team will be able to cut costs and add to the bottom line of business. f. Performance Management: Next to recruitment, the most critical HR function is effective performance management. In the dynamic business environment that we are living in, KRAâ&#x20AC;&#x2122;s of employees change

g. Development of Bench Strength and Succession Planning: With automation, it becomes easier to manage available skills and competencies in the organization more efficiently and effectively. Employees become aware of skills and competencies they need to move to the next level. They can apply for any open role within the organization with a fair knowledge of their probable success rate. HR can help the organization create a learning centre to prepare a talent pool of high-potential and high-performing employees to ensure business continuity. With automation of major HR Processes, the role of HR Professionals in an organization has changed dramatically. It is no longer

several times in a year. Employees need

transactional, administration or activity

regular feedback to keep a track of their

based. It has moved more towards Business

performance, coaching and mentoring

Partnership. Those HR Professionals, who

should be given to those who are lagging

are quick learners and adaptors, not only

behind in their performance targets.

managed to survive in this profession but

Discussing performance once in a year

also moved to never before seen levels

e. Effective Hiring: Managing Talent

can be suicidal. Automated employee

of an organizational hierarchy and got

Acquisition in its manual format is one of the

performance management tools make

promoted as CEOs, Managing Directors and

most tedious tasks, particularly when the

it easier for managers to give feedback

Country Business Heads. On the other hand,

organisation wants to use multiple channels

and easily manage performance review.

those who resisted the change and were

of sourcing. In talent acquisition, a missed

Automated performance management

slow learners have either moved to other

or lost resume can be a very costly affair.

system allows HR to provide descriptions of

professions like sales, digital marketing,

It is important to collate all resumes for an

ratings, especially for job skills and forces

customer services, etc. or they are still

Time saved has a direct impact on resource optimisation and increased productivity. organisations are able to achieve more with fewer resources at a low cost. Accomplishing more in less time boosts morale.

With automation of HR Processes all policies are made available to employees.

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November 2016

With many business processes undergoing digital transformation there is an increase in HR automation as well. working in similar roles in lower salary

as behaviour scientists and performance

of dollars per year by streamlining those

bands. To remain relevant and successful in

Coaches, HR can play a significant role in

processes. Having understood their existing

HR, when major tasks are getting automated,

developing a competitive edge among salesperson of organisations.

processes, growth plans and expectations

professionals in this function must develop following competencies

3. Analytical with reasoning and logic –

from HR, it was discovered that there is no single software that can address every requirement of this organization. Therefore,

1. Leadership Development & Business

With process automation in place, HRs are

Continuity – Help the organization in

now sitting on huge data, which can now

I recommended them - Workday or Ceridian

identifying high-potential and high-

be analysed and used effectively in taking

(Dayforce HCM) for addressing their Talent

performing employees; facilitate leadership

decisions. Today many organisations are

Administration needs and Cornerstone On

development programs; coaching leaders

looking for metrics or analytics in HR which

demand or ascentis for their requirement of

and managers to develop competencies

are not just related to people but also on

Talent Management in multiple locations.

required for high impact and high-risk roles, and correcting behaviours or employees that are hindering their growth potential. This role of HR not only requires them to focus on high-potential and high-performing employees but also give attention to lowperforming and low-potential employees. Help low-performing and low-potential employees get aligned with business goals and strategies. If they don’t improve as per the requirement then Talent Managers must recommend Leadership Team to eliminate such employees from the system. By doing so, HR Professionals will help the organization in creating a culture of accountability, performance, and rewards. It will also ensure business continuity. 2. Inculcating Winning Behaviour among salesperson – Till a few years ago, it was assumed that HR cannot play a significant

processes such as recruitment, retention, compensation, succession planning, benefits,

I am a strong believer of a fact that

training & development, performance

automation of HR processes is not a

appraisal and many others.

threat to HR Professionals working in

4. Effective Communication and Employee Engagement – With several of HR processes getting automated, now HR has plenty of time to get innovative with employee engagement and ensure that every employee of an organization is aware of organizational

this profession. Instead, it allows them to free up their time and make a significant contribution in areas where it matters. In coming years, I foresee organisations coming up with more innovative tools and software to address challenges of Talent

mission, vision, goals, products, and services.

Acquisition, Performance Management,

They can also ensure that every employee

and Talent Development. There is a huge

is able to see the significance of his role

scope for further automating HR processes.

in the big picture. HR is now free to play

With automation, the role of HR will evolve

a significant role in preparing an effective

further and it will get closely aligned

communication strategy and plans to

with Business Strategy, Profitability, and

address needs to all stakeholders based on the mode of communication preferences of

Customers.

every social group taking into consideration

The author Sanjeev Himachali is a Talent

cultural barriers.

Management and Development professional with over a decade and a half years of

role is Sales and Marketing. However, now

It took me ten months to complete the

scenarios are changing. As digital and social

project and submit my reports. It was a

media has begun to take a centre stage in

wonderful experience. While studying their

our lives, HR can certainly play an important

existing HR Processes, I also got a chance

role in product or Service Marketing,

to analyse their office administration

Branding, and Positioning. Of course, they

process, and believe me, those were very

organisations in identifying and developing

must have business acumen, and be well

tedious, time-consuming and expensive.

potential and competencies of their

versed with organizational offerings. Also,

The organization could have saved millions

employees.

November 2016

experience in various facets of Human Resource Management across various industries, cultures, and geographies. He helps start-ups, small-sized and mid-sized

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COLUMN | CORPORATE SOCIAL RESPONSIBILITY

Education for Road Safety Road safety is one of the prime concerns in the world. In response to this, many organisations have initiated programs regarding educating masses on Road Safety. In this issue, we present to you case studies of three such organisations: Autoliv, Underwriters Laboratory and Toyota Kirloskar Motors, which are working on education as applied to road safety. Manoj Kabre manoj.k@indo-mim.com We covered the efforts of various corporates

of death or severe injuries. According to the

bad road conditions, influencing policy, and

in the field of Education during the month

World Health Organization (WHO), every

influencing accountable parties to rectify the

of October’16. Education in isolation does

year more than 1 million people are killed

situation. In this context, they partner and

not meet the actual requirement of the

across the globe on roads. In India, more

needy. In a way, it needs to be supported

than 2 lac road fatalities occurred in 2015

team up with various NGO’s like ‘Save Life

with the infrastructure as well as other

owing to which 75000 people died between

education peripherals. We have made an

age group of 15 to 34. The major reasons

Manoj Kabre, Vice President of Indo-US MIM

effort to compile the contributions of various

for vehicular accidents and fatalities on

Tec Pvt Ltd, has directed and headed the

corporates on CSR activities related to such

Indian roads are drunk-and-drive & lack of

sales & marketing function for Asia and parts

elements in this article.

awareness about road safety.

of Europe, spoke at various forums across the

The role of CSR in education is thus

We present herewith some case studies of

mitigating the skills’ gap with considerable

projects done by a few organisations to do

experimentation, and learning-by-doing along the way. In this process, the affected individuals, companies and society at large

their role in CSR in infrastructure related to education and contributions towards education as applied to road safety. The

Foundation’ and ‘The Arundhati Foundation’.

world for propagating the MIM technology. His laudable work includes, Chairing – CSR Committee of RBWC, Founding of CaN Trust (NGO), working for needy children. He is also on advisory committee of ‘Your Philanthropy

are likely to benefit.

aim of corporates is to contribute to road

Story’ (YPS) which captures stories through

safety with particular focus on accident

interviews of heroes and the cause they are

Road accidents are one of the major cause

prevention, including creating awareness of

associated with.

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November 2016

Company: Toyota Kirloskar Motor For more information: Priyanka Bhattacharya E: priyanka_bhattacharya@toyota-kirloskar.co.in

As a safety crusader, Toyota Kirloskar Motor

Government initiatives to create awareness

has been engaged in Road Safety initiative

on traffic safety. The program includes an

since 2005 through various pan India

interactive course on traffic safety, a film,

campaigns. Toyota is addressing traffic

traffic safety games, and other friendly

safety through integration of people, cars,

formats.

and the traffic environment with the aim of completely eliminating traffic casualties.

Toyota Driving School: The aim of ‘Toyota

Toyota Safety Education Program: Under

importance on making every student a

this program, Toyota educates school

responsible and safe driver. The curriculum

children and teachers through one-day

is a comprehensive driver training program

training program and participates in

that will boast of high quality, practical and

Driving School’ is to ensure extreme

futuristic training models like the driver simulator mechanism which is expected to deliver the “Etios Experience”. Driver Training Programs & Health Checkups - TKM has conducted Driver Training Programs at the Bangalore International Airport as part of the road safety awareness month in Jan 2016 with over 1500 drivers participating in the campaign. 306 drivers were diagnosed with vision problems during the health checkup and provided free spectacles by TKM.

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Inspiring innovations worlwide, enabling readers to dream...

log on to

November 2016

Projects, Research Works, Opinions, Opportunities - the interactive platform...

www.martupdate.com & create thought leadership in your niche

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Company: Autoliv India Pvt. Ltd For more information: Jannita Marthel E: jannita.marthel@autoliv.com

Autoliv, Inc. is the worldwide leader in automotive safety systems, and develops and manufactures automotive safety systems for all major automotive manufacturers in the world. With a focus on their vision ‘Saving More Lives’, Autoliv strongly believe in contributing to the wellbeing of the communities in which they operate. Projects are typically initiated by Autoliv employees who are passionate about their community’s need and take part in a wide range of volunteering activities. Below are few Glimpses on CSR initiatives conducted by Autoliv India: 1. Road Safety Awareness Programs at Schools and Colleges The company conducts awareness program at Ryan International, Auden School, BGS School, BMS College and Bangalore

University. This helps in capturing the young minds and prepares them on how to have safe drive while on roads – the message indirectly reaches their parents.

to corporates such as Biocon and young

2. Safe & Defensive Driving Practice Awareness program to drivers On 6th Feb 2015, NRSO in association with Autoliv India Pvt Ltd addressed around 60 drivers and helpers of ISKCON on Road Safety and driving ethics which was organised at Vasanthapura Kitchen. The company reached out to their travel partner Uttam Travels and Sri Sathya Sai Travels and educated them on safe driving. The focus was on wearing seatbelts and no mobiles while driving and the importance of safe driving.

own vehicles.

3. Road Safety Awareness to Corporates Autoliv’s passion for ‘Saving Lives’ took them

Ltd’s CSR initiatives have got good response

engineers at SRIT. The emphasis was on the importance of being sensitive while on roads and every safety related products in their

4. Road Safety Awareness to General Public Autoliv India has been actively participating in various programs related to Road Safety. More than 20,000 children from 42 schools and many senior officers and citizens attended the Road safety week organised to spread awareness on 28th Jan 2015 in Bangalore. Autoliv India initiated another campaign on 25th June 2016 on road safety at Hoskote Toll where the vehicular movements are of an average 1500/hr. Autolive India Pvt and participation.

Company: Underwriters Laboratory (UL), Bangalore NGO: The Arundhati Foundation (TAF), Bangalore For more information: www.ul.com ; http://ulsafetysmart.com/india Anusha, Consultant-- Road Safety Initiatives, E: anushaa.ch@gmail.com

Underwriters Laboratory (UL) is an organisation that works on a mission to improve Public Safety in India and around the world. Through the ‘Safer Roads, Safer India’ campaign, UL aims to reduce road accident deaths in India through focused efforts in improving education, promoting active citizenship and facilitating research. With more than a century of experience in Fire and Electrical Safety, UL plans to build an ecosystem of safety through focused deliberations and conventions.

works to impart Road Safety Education

For long-term impact, and to inculcate this

to bring about a change in the attitude of

discipline from a young age, Road Safety

young citizens. The lessons are tailored to

should be taught as part of the curriculum.

the age group addressing walking, riding and

Children should be sensitized to respect

driving on the roads, or ensuring safety as

safety and security of self and others.

passengers. TAF is running ‘Classrooms with

Traffic police, traffic wardens, NGOs should

a Cause: Safer Roads, Safer India’ - a program

be invited to share the ground realities.

under the aegis of Youth Services America,

Involving children in mini-projects on road

Underwriter Laboratories and Trax Road

safety, or debates, poster-making, skits

Safety. The aim is to engage young students

will reinforce these lessons. Children and

to use collaboration, communication, critical

young adults are our future and hope. As

thinking and creativity to improve road

ambassadors, they can be more powerful in

The Arundhati Foundation (TAF) is one of UL’s grantees this year that has been doing some tremendous work in Bangalore. TAF

safety. Students will do road audits and

awakening the slumbering consciousnesses

surveys. Their analysis and synthesis will lead

of elders to pay attention to safety, and carry

to further events and solutions.

it forward themselves.

www.martupdate.com

November 2016

Source for the latest high-end manufacturing products / solutions from 400 global solution providers Network with 12,500 trade professionals Keep updated with emerging technologies such as additive manufacturing (3D Printing) and robotics solutions Explore new possibilities at the Capabilities Hub, Optics & Photonics Innovation Hub and Semiconductor Innovation Centre Gain knowledge on IoT in aerospace, inventory & supply chain development in MRO and success stories from aerospace manufacturing at SG Aerospace Connect Discover more about Industry 4.0, automation & additive manufacturing at the Smart Manufacturing Asia conference

Pre-register your visit now at www.mta-asia.com Held Alongside

Incorporating

Organised by

Worldwide Associate Tel : +65 6233 6638 Fax : +65 6233 6633 Email : mta@sesallworld.com

November 2016

Endorsed

Supported by

Held in

Tel : +44 207 840 2134 Fax : +44 207 840 2119 Email : mta@oesallworld.com

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Learning Curve | FORUM

Develop Passion for Improvements & Ideas While addressing the gap between the Engineering institutes and the industry, Professor Ambegaonkar reveals a picture of the current status of budding engineers in our country. Through MART, we attempt to bridge this gap by introducing a platform for the students of engineering colleges, to interact with the industry and its people, which will help the students to gain practical knowledge as well as wider perspective on the work culture.

Professor Ambegaonkar feei@gmail.com I hold confidence and great hope in budding engineers. Apart from their mathematical ability and family support, today’s youth is flooded with information at his finger tips and having mobility in the global village. He or she are at great advantage compared to their earlier generation if they develop habit of reading and writing by assimilating contents that are available to them. They need to stretch little bit by interacting with the industries of their interest and make use of their knowledge base to attack problems that are existing in any manufacturing establishments. The laboratories they are working with, during their curricular experiments are to be translated in knowledge by going through industrial operations.

academia are present, one finds only blame game. Standard allegation from Industry is that colleges do not provide us useful engineers, and that they are answered back that it is not their job.

As a result of global competitions, conferences and Industrial Exhibitions have acquired great importance and is a matter of opportunity to budding engineers. This is a direct access to latest art of technologies to storm your brains. Once your brain gets activated and you develop passions for improvements and throwing ideas, sky is limit for your growth.

On one hand supply of Engineers is growing, investments in manufacturing are growing and on the other hand Industries are switching over to Non-technical hands that can be deployed at much less cost. Many depend on contract labour. Thus, industry finding solution to their problem, though short sighted. This action is certainly damaging structure of work force. Our manufauring strength have sustained through right balance of engineers and skilled workers. Engineering mind that can look for innovations and excellence is the nucleus for any growth.

At MART and through our engineering forums, our initiatives are always there to bridge the gap between the industry and academy. Today the gap is wide. On the platform where Industry representative and

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Net result is that there is massive generation of unemployable engineers every year. In Maharashtra alone there is generation of over 80,000 graduate engineers ever year, who do not enter into engineering career and are getting frustrated along with their parents. This is a great national loss in terms of human resources, loss of time, and various social implications. Capacity for educating Graduate Engineers and Diploma Engineers is on the rise. Currently, seats are going vacant for want of students.

The root cause for not getting employable engineers lies in the fact that in our country, cost of learning is provided by parents or Government. Industry is habituated to acquire hands at prevailing price. Net result is that both are complaining against each other without having true introspection. This situation is certainly not comfortable for any country. I look at this situation rather seriously in the wake of our objective “Make in India”. We need to gear up available mechanisms to give right direction and channelize this important human resource. Mart with their continuous interactions with manufacturing industries and involvement in various national and international seminars, exhibitions & conclaves have come forward to support the cause of “ Making of Excelling Engineers”. I am, therefore, extremely happy and honoured to declare launch of “Forum for Engineering Excellence & Innovations”, where both engineering students and experienced engineers will be members. Industries are to support and Mart to provide section under Learning Curve. My dear young friends and their parents, come to us with your ideas, desires and passions. We will show you path and at the same time facilitate your goals with our partnering industries. November 2016

November 2016

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Learning Curve | ROBOTICS

Gen-II Exoskeleton: Concept to Creation in India! A team of Mechanical Engineering students led by Vimal Govind, a final year student of MES College of Engineering have set benchmark by developing GEN-II Exoskeleton through the repetitive research and experiments which can pioneer the economic production of industrial exoskeletons for manufacturing. Vimal Govind in his Generation II Exoskeleton

Exoskeleton is a machine which has been seen in Hollywood movies, the prominent one being the movie ‘Avatar’. It is a special man-machine that makes man a super human with multiple applications and protective gears and support systems. Due to its potential application in real life cases American Defense Research Academy is spending billions on developing this manmachine. It’s an idea unthinkable to be developed in India because of the huge cost associated with its research. However, a team of Mechanical Engineering students of MES College of Engineering, Kuttippuram, achieved it through the repetitive research and experiments under the leadership of Vimal Govind, a final year Degree student of Mechanical Engineering. The first turning point was a project for an inauguration program in college, which provided the team with better understanding of mechanical feedback and its potential application in Exoskeleton. Soon the team conceptualised and made the prototype GEN-1 Exoskeleton.

It was first presented in MESTECH 2015. The GEN-1 bagged two first prizes at two national level competitions. However, the GEN-1 still was heavy and bulky, and the power it produced was almost consumed for its movements of link itself. Because of which there was not much mechanical advantage. Further research went into the modification of GEN-1 for better flexibility and efficiency. The desired result was obtained from the application of hydraulics and pneumatics. With the hydraulic and pneumatic feedback, a computer model was developed which is small with mechanical advantage of almost 1:100, which means it requires 300g force to lift 30kg. After completion of simulation and computerized material section, Vimal Govind wrote a paper on this research. He presented the paper at an international conference on mechatronics and manufacturing in Singapore (ICMM 2016), conducted by American Society for Research. Out of the papers presented from 13 countries, it was selected as the best paper and was published in

“Such interesting work! I wish him success and victory in Robotic Research society”

Jae Hoon Lee Associate Professor Graduate School of Science and Engineering Ehime University, Japan

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the International Journal of Mechanical Engineering and Robotics Research (IJMERR). This exposure helped get the funds for materializing the concept of GEN-II into a reality and advanced GEN-II came up soon. GEN-II is a man-machine system for material handling by using mechanical feedback. Here the mechanical feedback is a simplest technology which doesn’t require electronic feedback and complex programming techniques which are conventionally provided to control the powered exoskeletons. Padmakumar K, Asst.Professor, Mechanical Engineering Dept., MES College of Engineering, Kuttippuram opines, “This technology will reduce the fabrication expenses for powered exoskeletons. This will create an economic advantage for the massive production of industrial exoskeletons in the world. Here we used conventional pneumatic and electronic equipments for the development to reduce the total overhead cost of current industrial exoskeleton manufacturing”

“I appreciate the team work of the students and their scheduling techniques for accomplishing their mission”.

Padmakumar K Asst.Professor, Mechanical Engineering Dept. MES College of Engineering, Kuttippuram November 2016

DESIGN | LEARNING CURVE

3D Image and User Interface IITs have never failed to surprise us by their innovations. Here is a project by a bunch of students from IIT Kanpur who have developed an application that creates a 3D image on a computer or mobile screen with the help of a web camera or a front camera.

Pranav and Lavisha testing the algorithms

Innovation knows no boundaries when it comes to students of IIT. A team of three students initiated a project to ameliorate the online shopping experience by giving it a three dimensional twist. The members of the team, Pranav Kumar, Lavisha Aggarwal and Mayank Pathak, who are now in the final year of the course, were supported by the faculty and were provided with all the assistance they sought. The group came up with an idea of developing an interface that

could enable us to have a handfree web experience. While using e-commerce websites, the group realized that there was a possibility to develop a display that would enable users to have a real life shopping experience even online.

with respect to the camera.

The main feature of the project is that the display uses the front camera of a device to display any object as if it were real 3 dimensional entity, showing its perspective view on the basis of the viewer’s face orientation

The prototype finds applications

November 2016

potential to being extended

The application uses a single camera for its functioning and is purely based on algorithms. The trio have coded the program in C++ and used OpenCV to render products on the display.

in e-commerce and for gamers.

to making 3D displays, 3D keyboard which would amount to an entirely 3 dimensional experience of the user. The group suggests that it can be combined with the Microsoft Kinect packages to improve

It is useful for electronic

the gaming experience of

commerce companies like

professional gamers. The project

Amazon, Flipkart, ebay, etc

was not only appreciated on

where customers can visualize

institutional level but also won

the products they’re buying in

the Ericson Award.

‘‘Working on this project was a wonderfully enriching experience. On one hand we learned a lot of new things and on the other it helped us contribute our minuscule efforts to the greater cause of innovation and development’’.

Pranav Kumar IIT Kanpur

real¬-time. The product has the

‘‘It is the small things that count in making the world a better place. Innovation is the way forward and rather than thinking of innovating something on a huge scale, doing so to better your everyday life will count in the long run’’.

Lavisha Aggarwal IIT Kanpur www.martupdate.com

Learning Curve | ACCIDENTAL DISCOVERY

Serendipitous Waves Life is all about experimenting. It not only pulls you out of dilemma and uncertainty but renders you a practical solution. Now, in the pursuit of solutions we often come across accidents that are nothing less than serendipity. Be it life or a laboratory, they always give you the rush that one seek s to move forward. We welcome you to the world of scientific experiments that turned out to be boon for us and provoke us to meet many such accidents in our journey to inventions.

Nazia Ali nazia@martinfotech.in

There are several examples of fortunate accidents that have taken place in the scientific world. We feel blessed to be actually using the practical version of those accidents; one such accident took place in 1945. When the greatest powers in the world were engaged in war, a great mind was spending time in building magnetrons for radar sets. That mind was none other than that of Percy Spencer, one of the worldâ&#x20AC;&#x2122;s leading experts in radar tube design of his time. While working, he was standing in front of an active radar set. Suddenly he noticed that the candy bar he had in his pocket was

melted. The curious mind sought an answer to the transformation in the state of the candy bar. In the pursuit of an explanation, Percy and some other colleagues began trying to heat other food objects to see if a similar heating effect could be observed. The first thing they decided to heat was popcorn kernels and that is how the world got its first microwaved popcorn. Spencer then created what we might call the first true microwave oven by attaching a high density electromagnetic field generator to an enclosed metal box. The magnetron would then shoot into the metal box, so that the electromagnetic waves would have no

way to escape, which would allow for more controlled and safe experimentation. He then placed various food items in the box and monitored their temperature to observe the effect. The creation was a milestone in the book of inventions. Soon it was commercialised after Percy filed a patent on 8th of October, 1945. This first commercially produced microwave oven was about 6 feet tall and weighed around 750 pounds. The price tag on these units was about $5000 a piece. It wasnâ&#x20AC;&#x2122;t until 1967 that the first microwave oven that was both relatively affordable and reasonably sized became available.

The world first microwave - 6 feet tall and weighing around 750 pounds

Percy Spencer Inventor of Microwave

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November 2016

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Learning Curve | engineering excellence

Tractor to Lamborghini

Often arguments and jibes lead to catastrophic results. But the story of Lamborghini begs to differ. The leading car manufacturer, Lamborghini, holds a dramatic and inspiring history. Here is a glance of an episode.

Turning heads to 180 degrees on sight of a Lamborghini is not uncommon. Why should it be? The fetching, tantalizing beauty of the cars leave you stunned and yearning. Owning a Lamborghini is no less than a life’s mission for car-freaks! But has it ever crossed your mind how the masterpiece came into existence? Here is how the idea spawned! The owner of Lamborghini, Ferruccio Lamborghini ran a very successful business. Lamborghini Trattori S.p.A. produced tractors from surplus military hardware. Ferruccio Lamborghini served the Air Force Mechanic cops and was well versed with the subject.

As a car enthusiast and a successful entrepreneur, Lamborghini owned many sports cars including Ferrari 250 GT. Ferruccio Lamborghini began having problems with the clutch of the Ferrari which frustrated him so much that he decided to meet the owner of Ferrari and get the problem resolved. Now the encounter turned out to be really dramatic. In response to the complaint made by Lamborghini, Enzo Ferrari, owner of Ferrari, jeered and advised Ferruccio to look after his tractors instead. His words, “the problem is not with the car but with driver”, were not something a

mechanical genius and Italian would take. Considering it as an insult, Lamborghini walked away. The heated encounter with Ferrari provoked Lamborghini to build his own car. Investing from his existing business, Lamborghini founded an auto factory in Sant’ Agata. An unacceptable remark from Ferrari resulted in an opulent and powerful Lamborghini 350GT. The car was designed to reach 150 mph on the Autostrada del Sole, the famous Italian motorway which connects Milan with Naples.

Ferruccio Lamborghini with his creations.

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November 2016

GETTING THE JOB DONE. TOGETHER

Dormer and Pramet have joined forces. Together, we oﬀer a comprehensive range of indexable and rotary cutting tools. Our real oﬀer, though, is about much more. Yes, our products are consistently high quality, easily available and come with the advice and guidance you

www.dormerpramet.com November 2016

have the right to expect. But we also believe in taking time to build a clear understanding of your business needs. This not only ensures we give you exactly the support you need, but helps build trust – the foundation for all true partnerships. That’s how we get the job done. Simply Reliable.

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Learning Curve | techfest

Technovanza 2016 If you enjoy deadly, destructive robot combat wars and find the adrenaline rush addictive, Technovanza 2016 is the place to be at. The event organised by the studnts of VJTI, Mumbai, is a perfect blend of Engineering, Innovation, creativity, fun and fear. Following is a synopsis of the event.

Technovanza is the largest Technomanagement festival in Maharashtra organised by the students of VJTI, and has been honoured with the UNESCO patronage last year. It is a 3-days festival held in the last week of December. Technovanza receives participation from more than 170 colleges for over 50 events from all over India. The event’s popularity has grown in leaps and bounds over the years and last year close to 35,000 people from all over the country attended the event, leading to its grand success. Through competitions, exhibitions, lectures, conferences and social initiatives, Technovanza has been an awe-inspiring and enriched learning experience for every visitor and participant and has captured the imagination of many. PROMINENT PAST SPEAKERS• Dr. John C. Mather, Noble Laureate and senior Astrophysicst at NASA • Late Dr. A.P.J. Abdul Kalam, Former President of India

• Ratan Tata, Former Chairman of TATA Group • Dr. Kiran Bedi, first woman IPS Officer • Harsha and Anita Bhogle, Corporate Consultants • Dilip Chhabria, Founder of DC Design • Narayan Murthy, Co-founder of Infosys HIGHLIGHTS OF TECHNOVANZA:Innovation Spotlight- The Innovation Spotlight is VJTI’s Start up and Internship Expo held by Technovanza. It will provide a platform for students from all universities to apply for internships at Mumbai’s top startups. More than 300 internships will be up for grabs. Last year, over 50 start-ups participated in the Innovation Spotlight. RCMO- Rubik’s cube Mumbai open along with World cubic association (WCA) welcomes cubers from all over the country to showcase their speed cubing skills at the largest cubing competition in the country. Technovanza has been listed in the Limca Book of World Records for making a Cube

Art with 7000 cube. Cube arts made of Dr . APJ Abdul Kalam, Steve Jobs, Sachin Tendulkar, Ratan Tata, Taj Mahal, Nelson Mandela, Harsha and Anita Bhogale have found their way into media articles. With a minimum of half a dozen national records breaking each year at the competition RCMO is Technovanza’s flagship event from the last 5 years. Robowars- Robowars is our Mega Event with a prize money of 1.25 lakhs. It had participants from all over the country like Orissa, Chandigarh, Pondicherry, Gujarat, Tamil Nadu, Kerala, Karnataka, etc. Maker’s Square- Maker’s Square is a national event to put up the projects and exhibits ranging from civil, mechanical to robotics, chemical, physics experiments etc. Projects like Hexagon city implemented in Japan and Germany. As part of our social responsibility, we have undertaken several initiatives like:

Organising Committee of Technovanza 2016

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November 2016

Station Beautification drive on Jogeshwari Station as a part of Social Responsibility Initiative.

Picture of Mahatma Gandhi made of 3000 Rubik’s Cube

Pratigya- Pratigya is our social initiative wherein we go to schools, NGOs and orphanages to generate curiosity about technology in young minds of students and leave a scientific imprint on their minds. Teaching them how to give aptitude tests, career counceling guidance is also one of our aims this year. Mission Mumbai-Through Mission Mumbai, we aim to reach out to the people by providing innovative solutions by the future engineers towards the empowerment of Mumbai. We have targeted problems across the spectrum be it women empowerment, deforestation, redevelopment or highlighting the problems of poor work conditions, awareness of e-waste and many more. Associating with NGOs like Helpage India and Make A Difference (MAD) The Startup Fair The VJTI Startup Fair is an initiative by Technovanza to encourage the entrepreneurial spirit in young India. It is an endeavor to connect the budding entrepreneurs to venture capitalists and to provide them with the assistance required for their ventures to achieve success. The Startup Fair provides a platform for innovative start-ups from all over the country to get in touch with thousands of potential customers. The Expo also serves as a

November 2016

platform for Startups to interact with young minds and present to them, an opportunity to hire interns along with extensive publicity. The Startup panel disscussion:The panel disscussion topic is “Indian Startups: The big bang theory” Confirmed panelists are: 1. Amit Singh (Co founder of Headstart) 2. Sunil Mahale (VP India, Nutanix) 3. Sandeep Agrawal (Co founder of Shopclues Guest lecture series23rd December• Balaji Vishwanathan (Indian writer, author, entrepreneur) • Bajarne Stroustrop (Danish Comuter Scientist) • A.S. Pilai (Indian Scientist) 24th December- Jayant Narlikar (Indian Astrohysicist) 25th December• AS Kiran (Indian Sace Scientist) • Medha Patkar (Indian Social activist) • Krushnaa Patil (Indian Mountaineer) Maker’s Square- Maker’s Square is a national event to put up your projects and exhibits ranging from civil, mechanical to robotics, chemical, physics experiments etc. This is

your chance to make a difference to the world and get into the lime-light. 1. Nerosky Mindwave Mobile 2 Puzzlebox orbit- brain controlled helicopter 3. INDRO Humanoid 4. Applications of gesture recognition and Ghost Tying for computer controllers Patronages:1. SkillIndia 2. Digital India 3. Make in India 4. UNESCO In association with “Your Story” This year, our theme is “Transforming India”. Vishwa Kaira: Technovanza is not just a 3-day event, but a journey of 8 months where every single person from our 250-member committee works with rigorous brainstorming and utter dedication, making it bigger and better every year. It has taught us how to dream BIG and manage time amidst academics and internships, and has, by far, been the best experience of my life. For more details, please visit: technovanza.org www.martupdate.com

Cutting Edge | bIO-eNGIEERING

3D Printed Organ-on-a-Chip Recently, microphysiological systems (MPS), also known as organs-on-chips, that recapitulate the structure and function of native tissues in vitro, have emerged as a promising alternative. Researchers at the Harvard John A. Paulson School of Engineering and Applied Sciences have introduced the first entirely 3D printed Organ-on-a-chip.

Device images with beating cantilever Lori K. Sanders (Lewis Lab, Harvard University)

Harvard University researchers have made the first entirely 3D-printed organ-on-a-chip with integrated sensing. Built by a fully automated, digital manufacturing procedure, the 3D-printed heart-on-achip can be quickly fabricated and customised, allowing researchers to easily collect reliable data for short-term and long-term studies. This new approach to manufacturing may one day allow researchers to rapidly design organs-on-chips, also known as microphysiological systems that match the properties of a specific disease or even an individual patient’s cells. The first author of the paper and postdoctoral fellow at the Harvard John A. Paulson School of Engineering and Applied Sciences (SEAS), Johan Ulrik Lind said that the new programmable approach to building organs-on-chips not only allows easily changing and customising the design of the system but also drastically simplifies data acquisition. Kit Parker who is the co-author of

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the study said that the study’s microfabrication approach opens new avenues for in vitro tissue engineering, toxicology and drug screening research. Parker is the Tarr Family Professor of Bioengineering and Applied Physics at SEAS and Core Faculty Member of the Wyss Institute. Organs-on-chips mimic the structure and function of native tissue and have emerged as a promising alternative to traditional animal testing. However, the fabrication and data collection process for organs-on-chips is expensive and laborious. Currently, these devices are built in clean rooms using a complex, multi-step lithographic process and collecting data requires microscopy or high-speed cameras. “Our approach was to address these two challenges simultaneously via digital manufacturing,” said Travis Busbee, co-author of the paper and graduate student in the Lewis Lab. “By developing new printable inks for multi-material 3D printing, we were able to automate the fabrication process

while increasing the complexity of the devices.” The researchers developed six different inks that integrated soft strain sensors within the micro-architecture of the tissue. In a single, continuous procedure, the team 3D printed those materials into a cardiac microphysiological device — a heart on a chip — with integrated sensors. “We are pushing the boundaries of three-dimensional printing by developing and integrating multiple functional materials within printed devices,” said Jennifer Lewis, Hansjorg Wyss Professor of Biologically Inspired Engineering, and coauthor of the study. “This study is a powerful demonstration of how our platform can be used to create fully functional, instrumented chips for drug screening and disease modeling.” The chip contains multiple wells, each with separate tissues and integrated sensors, allowing researchers to study many engineered cardiac tissues at once. To demonstrate the efficacy of the device, the team

performed drug studies and longer-term studies of gradual changes in the contractile stress of engineered cardiac tissues, which can occur over the course of several weeks. “These integrated sensors allow researchers to continuously collect data while tissues mature and improve their contractility. Similarly, they will enable studies of gradual effects of chronic exposure to toxins.” “Translating microphysiological devices into truly valuable platforms for studying human health and disease requires that we address both data acquisition and manufacturing of our devices,” said Parker. “This work offers new potential solutions to both of these central challenges.” This work was supported by the National Science Foundation, the National Center for Advancing Translational Sciences of the National Institutes of Health, the US Army Research Laboratory and the US Army Research, and the Harvard University Materials Research Science and Engineering Center (MRSEC). November 2016

POWER & ENERGY | CUTTING EDGE

An Innovative Support to CP Patients Approximately 17 million people worldwide live with cerebral palsy, a permanent disability that affects movement ranging from a weakness in one hand to an almost complete lack of voluntary movement. Taking a step towards supporting the affected by the disability, a team of students from University of Virginia’s School of Engineering and Applied Science have designed a solar-powered wheelchair with retractable panels.

Solar powered wheelchair by the students of University of Virginia

The team of University of Virginia comprised electrical and computer engineering graduate students Waldron, Duncan McGillivray, Craig Ungaro and Ankit Shah, who works at the National Institute of Aerospace and NASALangley Research Center, and undergraduate mechanical and aerospace engineering students Maria Michael and Kyung Kim. The team was guided by Mr. Mool Gupta who is a Langley Distinguished Professor & Director for NSF I/UCRC Laser Center, Department of Electrical and Computer Engineering, University of Virginia. The team built the device primarily at the National Institute of Aerospace’s Research and Innovation Laboratories November 2016

Facility in Hampton. The project received support from the Engineering School’s Experiential Program, through funding from alumnus Linwood “Chip” Lacy, with Gupta providing additional financial support through his faculty funds and industry support. The wheelchair concept was inspired by the design of retractable roofs on convertible cars. The chair uses lightweight and robust materials and high-efficiency solar cells with custom-fabricated solar panels that encompass over one square meter when deployed without adding significantly to its length, width, height or weight when stored. The wheelchair can operate for more than 4½ hours at a speed of 5 mph

on a fully charged battery, a range increase of more than 40 percent over batteries alone, and can run indefinitely at a speed of 1 mph on solar power alone, without using the battery. The solar panels charge batteries even under cloudy conditions and have the added benefit of providing shade for the wheelchair occupant on sunny days. The single switch operation means that anyone who can use a joystick can operate the chair. The overall design includes standard wheelchair amenities such as a seatbelt, armrests, footrest and adjustable seating. In addition, USB power outlets are provided to charge modern peripherals such as cellphones, GPS navigation, tablet computers and items such

as a fan and a reading light. An invention disclosure has been filed through the University of Virginia Licensing and Ventures Group. The team won the first position in the competition organised by United Cerebral Palsy where they presented their innovation and received $20,000 from a total prize pool of $25,000. The team intends to use its prize money to make final refinements to the chair and to ship it to Alper Sirvan, the individual in Turkey who posted the initial suggestion for a solar-powered wheelchair. The remaining prize money will be returned to United Cerebral Palsy in support of future World CP Day competitions. www.martupdate.com

innovation | MACHINE TOOL

Fit and go: igus simplifies parallel guidance of e-chain and corrugated tube With the new side plates for the E4.1 energy chain, corrugated tube clips can be fastened quickly and without tools. The motion plastics specialist igus has again expanded its modular kit for the E4.1 energy chain series and now offers a solution for the guidance of e-chain and corrugated tube in the same system. Named E4.1 TUB, this system ensures flexibility, ease of assembly and long service life in a low-wear double system. Individual hoses and cables, which have a significantly shorter service life than the other media, are often guided outside the energy supply chain in a corrugated tube. Thus their replacement can be carried out quickly, without having to open the e-chain. To simplify and strengthen the connection of e-chain and corrugated tube, igus has developed new side plates for the universal E4.1 modular kit. The side plates of the outer link of the e-chains are provided with special rails, on which you can simply slide in clips to hold the hoses. You can thus combine the energy chain with the tube in a very short time. Until now, the corrugated tubes had to

be bolted to the chain using clamps. The so-called clip system holders are available in all four E4.1 sizes in combination with 8 different sizes of high-quality corrugated tubes. The side plates can also be easily retrofitted on existing E4.1 energy supply systems as clip system holders. Neither screws nor tools are required for their attachment to the e-chain and the assembly of the corrugated tubes. Both assembly and disassembly are therefore very fast and easy. The e-chain and corrugated tube are joined together in the E4.1 TUBs, so that the whole system works very harmoniously offering a long service life. The entire system was extensively tested at igus in the test lab with a floor area of 2,750 square metres. The E4.1 modular system for the perfect use of installation space and cable protection Like the corrugated tube, the e-chain is characterised by easy and quick attachment to the machine. To this end the E4.1 e-chain

allows the easy fitting of cables or hoses due to the removable crossbars on both sides. Moreover users can benefit from the high strength, robustness and low-noise characteristics of E4.1 even in small installation spaces. The new side plates can also be combined with the enclosed R4.1 version. In this way, the user can combine: side plates, different crossbars, lids and shelves, separators, brackets, straps and now even clip system holders as needed. The external parallel guidance of corrugated tubes in the E4.1 TUB smoothly extends the potential for cable guidance without a costly retrofit or even replacement of existing systems and without a significant increase in installation space. For machine builders, igus delivers a useful system that is already available from stock in interior heights 32-56 mm - even up to 80 millimetres on request. For more details visit www.igus.in

In the E4.1 TUB, the e-chain and corrugated tube can be reliably guided in parallel, saving space. (Source: igus GmbH)

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November 2016

WWW.WELD-INDIA.COM

O ITI

WELD INDIA THE INDIAN INSTITUTE OF WELDING

INTERNATIONAL CUTTING, WELDING & ALLIED TECHNOLOGY EXHIBITION

15 - 17 DECEMBER MILAN MELA COMPLEX, KOLKATA. INDIA

2016

Cutting & Welding Technology, Metallurgy, Materials Testing, Non-Destructive Testing, Robotics, Automation and Allied Industries

Concurrent Programs National Welding Seminar - NWS 2016

“

Challenges and Developments in Welding and Fabrication technology Theme

The Indian Institute of Welding - IIW India Golden Jubilee Celebration

Organised by THE INDIAN INSTITUTE OF WELDING Head Office IIW India House, Plot 318, Geetanjali Park, 200 Kalikapur Main Road P. O. Mukundapur, Kolkata - 700 099, India Tel: +91- 33 - 2416 0826 / 2416 0942 Email: weldindia2016@gmail.com

November 2016

(1966-2016)

Event Managed by INTERNATIONAL TRADE AND EXHIBITIONS INDIA PVT LTD B 309, 3rd Floor,Statesman House Building, 29, Barakhambha Road,New Delhi – 110001, India Tel. +91 9911185378 , 9643311461 Email: Chandra.Shekhar@itei.in, ed@itei.in , Web: www.itei.in

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innovation | MACHINE TOOLS

Innovative Leap in Coating Technology Walter AG, the German cutting tool manufacturer, is responsible for an important technological advance in the manufacturing sector. This machining specialist is one of the first companies in the world to present a new technology platform for coated indexable inserts based on CVD titanium aluminium nitride (TiAlN): Tiger•tec® Gold has significantly improved coating properties and therefore offers a considerably longer service life, increased process reliability, and increased productivity.

For well over two decades, the machining sector has been working with CVD coatings that are based on aluminium oxide (Al2O3). The properties of these coatings were continuously improved throughout the years, but the developers have since reached their limits with this material. The technological options for further optimising aluminium oxide grades have largely been exhausted now.

(TiAlN) with a significantly higher aluminium content of 85% that is considerably above the standard.

Tiger-tec® Gold is a completely new technological platform based on titanium aluminium nitride (TiAlN) to make the new generation of cutting tool material significantly more resistant to wear and, at the same time, process-reliable. The solution lies in a titanium aluminium nitride

Among other things, the coating impresses with its extremely high hardness and residual compressive stress; it is ideal for milling steel and cast iron materials at medium to high cutting speeds.

“The golden colour has the added welcome effect that it is now much easier to detect wear than it was in the past.”

Wolfgang Vötsch Senior Product Manager Milling, Walter AG

“Our TiAlN coating is the first coating to be created in a CVD procedure that is subjected to compressive residual stress. This helps us to significantly minimise the formation of hairline cracks, and the cutting edge remains intact for longer – which is a prerequisite for a long, process-reliable service life.”

To achieve this, a new process was developed: The ULP-CVD technology. In a combination of Ultra Low Pressure (ULP) and Chemical Vapour Deposition (CVD), the developers successfully separated TiAlN – the basis for manufacturing the new grades.

Jörg Drobniewski Head - Cutting Material Development, Walter AG

Service life increased by around 80% The developers at Walter have carried out around 50 extensive test runs with customer applications this year. In doing so, the developers were able to prove that the coating properties had been significantly improved: The indexable inserts that were coated with Tiger-tec® Gold WKP35G stand out with considerably higher wear resistance on flank faces, lower rate of hairline cracks forming and improved resistance to plastic deformation. The practical tests showed that service life had been increased by

around 80%. In addition to TiAlN as the main coating, the new WKP35G grade also uses titanium nitride (TiN). The advantages of Tiger-tec® Gold for the user can be summarised in four points: - Significantly longer service life – 80% longer, on average - Increased process reliability - Increased productivity - Optimum wear detection. For more details visit www.walter-tools.com

New colour, new coating technology, even greater wear resistance: The Tiger•tec® Gold WKP35G grade from Walter with its special TiAlN coating is just the start of a whole new generation of indexable inserts. Image: Walter AG

Tiger•tec® Gold in the Walter BLAXX M3024 heptagon milling cutter. Already suitable for a wide range of applications, in future, the new Walter WKP35G grade will be compatible with more and more tools.

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November 2016

industrial measuring | innovation

Renishaw unveils the new XM-60 Multi-axis Calibrator The XM-60 is capable of measuring all six degrees of freedom from a single set-up, in any orientation for linear axes. It offers significant improvement in simplicity and time saving over conventional laser measurement techniques. As demands on component tolerances increase, manufacturers are now required to consider all error sources from the machines producing parts; angular errors as well as linear and straightness errors. XM-60 captures all these errors in a single set-up. Designed for the machine tool market, the XM-60 multi-axis calibrator complements Renishaw’s calibration product line which includes the XL-80 laser system, XR20-W rotary axis calibrator and QC20-W wireless ballbar. The XM-60 uses the XC-80 environmental compensator to correct for environmental conditions. The XM-60 multi-axis calibrator provides a highly accurate laser system that incorporates unique technology with a patented optical roll measurement and fibre optic launch system. The compact launch unit is remote from the laser unit, reducing heat effects at the point of measurement. It can be mounted directly to the machine on its side, upside down and even on its back, which is particularly beneficial in areas with difficult machine access. Reducing uncertainties of measurement is paramount for any user. The Renishaw XM60 has been designed to measure machine errors directly, reducing the inaccuracies which can result from complex mathematics used in some alternative measurement

techniques. Direct measurement makes comparison before and after machine adjustments, a quick and simple task with users’ existing part programs for XL-80 measurement. The receiver is fully wireless and powered by rechargeable batteries, avoiding trailing cables during machine moves which could cause inaccuracies or break the laser beam during measurement. The performance of each XM-60 multiaxis calibrator is traceable to international standards and every unit is also certified before shipment. This provides users with the confidence that their system will deliver the specified accuracy day-after-day where it counts - in the workplace. To support the release of the XM-60 multiaxis calibrator, a new version of Renishaw’s CARTO software suite will be released to guide users through the workflow of the measurement process. CARTO 2.0 includes Capture and Explore applications which already provide data capture and analysis for the XL-80 laser interferometer system. The CARTO user interface can easily be configured to suit user preferences, with the ability to change themes and customise displays. It is tablet friendly and has expandable menu sections for ease of use on compact screens. Test methods are automatically saved, so for repeat testing users can simply recall an earlier test. Capture 2.0 features an all new part program generator, supporting Fanuc 30, Heidenhain 530, Mazak Matrix and Siemens 840D controllers, with more to follow in later releases. It has advanced features

to automatically set the dwell time in the program, based on the averaging period selected by the user, and ‘matched time’ mode to assist time based capture when using the XL-80 system. In XM-60 mode Capture 2.0 uses the calibrator’s straightness measurement functionality to improve its ease of use. XM-60 provides users with powerful machine diagnostic capability through the measurement of all degrees of freedom from a ‘single shot’. By capturing three linear and three rotational error sources during any measurement, users can discover the source of their errors, rather than the effect which is often seen when only performing linear measurement. Handling all of this data is performed by the Explore 2.0 application which provides a summary view of all the six channels of data, each of which can be displayed against a wide range of international standards. The management of such high volumes of data is also easily handled within Explore 2.0. A user defined tag can be assigned to any test, or group of tests saved in the database, and data can then be filtered by these tags. Renishaw’s XM-60 multi-axis calibrator is supplied in a robust Peli™ system case, with space for accessories and XC-80 compensator kit. The case has been designed to provide safe storage and transportation of the laser system, and in many applications the laser unit can remain in the case during measurement, simplifying the set-up. An optional fixturing kit is available to help with mounting the XM-60 to machines, which is supplied in a carry case for ease of transportation.

The compact launch unit is remote from the laser unit, reducing heat effects at the point of measurement. November 2016

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CASE STUDY | FOUNDRY

Rhino Leads Innovation for Indian Foundries Rhino Machines has been pioneering innovations in energy efficiency for foundry and forging industries. Inspired by and inspiring India’s invention and innovation glory, Rhino Machines has found accolades for its products and solutions at international exhibitions and competitions. Latest to the list is its successful participation at GCIP 2016.

Continuing on its successful participation in the GCIP 2015 and having finished in the top six and then being showcased at the Rashtrapati Bhawan in March 2016 during the Festival of Innovation for its ECOFLEX® Design Sand Handling System, Rhino was once again selected from about 190 participants this year in the GCIP 2016 in Energy Efficiency & Clean Technology. GCIP – Global Cleantech Innovation Program, supported by Ministry of MSME as the principal body and FICCI, organised by UNIDO, funded by GEF, content & delivery by Cleantech USA, entered into a matured 3rd year of supporting and leveraging Indian MSMEs – start ups and existing industries. Rhino Machines has always come out with unique solutions and has adapted to modern technologies of the world. Its founder Mr R C Kothari – IIT Kharagpur Graduate & IIT Mumbai Post Graduate always carried a vision of being “original” and adaptive to the Indian foundry needs. Mr Manish Kothari – MSU Vadodara Graduate joined in 1991 and was exposed to international technology as early as 1994 at GIFA and was part of the partnership with Fondarc, France – one of the principal partners of Rhino in Green Sand Technology – process and machines. Rhino started working on the development of Stand Alone High Pressure Moulding Machine with the technical support of Renzo Cappelletto in 2008, starting from few sketches and building up the machine. The key criteria to build this product line were: • Focus on moulding process – not on automation • Simple machine – without need of lot of auxiliary machines • Affordable for the MSME sector – prices and usage to be comparable to presently available option of JSQ • Lower cost of ownership • Higher safety level • Optimised energy usage. • Machine to be built completely in India

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• Easy maintenance • Process automation to be incorporated • Modular and expandable technology In 2009, Rhino invested in the first machine taking the box size of M/s Uttam Foundries, Ambala with their assurance to pay the cost of the machine alone after successful trials of the moulding technology. With a vision to meet all the criteria above, the team of Rhino’s engineers including Manish Kothari, Rajnikant Patel (now VP in Elecon) along with Renzo Cappelletto put together the first machine design and the first mould was made in Rhino on 16th Sep 2009. The process of moulding was validated and with the support of hydraulic system associates and internal PLC automation expertise of Rhino, the process itself was established. In this period, M/s Sharp Chucks – led by Mr Ajay Sikka, a young and dynamic industrialist- put its faith in Rhino and ordered a machine for a larger box size and thus in 2010 Rhino was ready with the first real production machine and displayed in IFEX 2010 at Ahmedabad. This was Rhino’s first showcase of the new technology. Yet, Rhino decided to establish the machine in production before full fledged launch and marketing of the product. The years 2011 and 2012 witnessed the establishment of 3-4 machines in Northern region and one in Ahmedabad, which became the starting reference point. Till this time, for Rhino it was a survival game and it was developing its technology for building its brand in the High Pressure Moulding Machine vacant space for MSMEs. As time progressed and as the machines kept getting installed with excellent encouragement from some of the first users, the product went through lot of value engineering, plug and play solutions, user friendliness, consistency of production - all would inspire our own and the customers confidence in the product. The year 2015 was a turning point for

Rhino Machines in a lot of respects, and in particular in the Innovation Ecosystem. With the new government in place, and with the leadership of PM Shri Narendra Modi, the “Make in India” campaign led to the govt machinery starting to identify, encourage and empower the MSME innovators. The MSME – Technology Development Centre, Agra were assigned to bring forward innovations and technologies from the foundry and forging industry by the UNIDOMSME program of GCIP. Mr Pravin Joshi – Dy Director MSME-TDC Agra approached Rhino Machines, travelled all the way and filled up the entry of Rhino Machines for Energy Efficiency Category in the 2015 program. Though there was no validation or documented data, they took the calculations provided by Rhino as the base and with their own judgement, proposed our name in the competition. Right after returning from GIFA 2015, Rhino Machines was asked to provide calculations of the energy saving for its Energy Saving Sand Handling Solution ECOFLEX®. The data provided by Rhino Machines was examined by selectors to select Rhino from the 160 participants to the top 20 semi-finalists. This recognition on national level, motivated and encouraged Rhino Machines team, and it directly and indirectly changed the approach to the product, solutions, and strengthened Rhino’s resolve to innovate for the MSMEs. The Business Building training imparted by Cleantech USA with their workshops and webinars changed the way Rhino looked at the market, product and industry. Rhino participated with start ups, novices and was the only mature industry and the only industry from the core manufacturing sector to bring forward a product with such a strong impact. After its successful display at FOINS 2016 @ Rashtrapati Bhawan, Rhino’s team had been trained enough to recognise the unhidden potential in its MULTIFLEX – High Pressure Moulding Machine, which slowly had November 2016

MUTIFLEX FM Series High Pressure Moulding Machine

Handing over of certificate by DC-MSME Tripathi to Manish Kothari, Managing Director, Rhino Machines

already established itself as a proven and commercial product. Rhino started looking at an “unchartered” area i.e. energy saving from Multiflex. Earlier, the product was being projected only on those criteria which made direct tangible commercial sense. The energy saving did not show such a huge cost benefit and therefore was not highlighted. However, taking cue from the learnings of GCIP 2015, Rhino undertook the exercise of validating the power consumption comparison. Actual energy consumed in kWh for a given number of moulds working at its normal efficiency on a working Simultaneous Jolt Squeeze Machine was measured at Krislur Industries, Bhavnagar. Similarly, the actual energy consumed in Multiflex of a similar area of box was checked at Rhino’s facility. The test on Multiflex was also done in M/s Sagar Ferex in Rajkot to re-validate the data on Multiflex. Though it was obvious from engineering that the power transmission efficiency of compressed air in terms of energy or power input to the compressor and the energy delivered at the point of use was on an average only 30%, we did not realise that in spite of delivering a force 5 to 6 times higher than the Obsolete SJS (JSQ) Machines, the FM (Multiflex) consumed 30% lower energy. Against a unitised power consumption of 0.19 kWh/Mould for a box size of 600 x 500 x 150 mm, the SJS compressor consumed 0.3 kWh/mould for a box size of 520 x 520. November 2016

Rhino has now been deploying real time energy monitoring to validate the energy consumption of Multiflex and increase the no of results available from the field. In addition to the direct impact of energy consumption in the moulding machine, the higher force also resulted in better dimensional stability and reduced weight variation of the casting. This impact was validated at some of the installations who were producing the same casting with the same pattern in the same plant on both the processes. Let us look at the implications. Take a clutch housing weighing 150 kgs, and a saving of 3 to 4 kgs in weight due to reduction in swelling. The impact goes beyond to machining. What needed 3 cuts and an additional 4 minutes of CNC machining (which means the power consumption also) could be done in 2 cuts, i.e. 33% reduction in machining time, cost and energy. The presentation attached has slides which speak for themselves, but can be highlighted as below: 1. The market – we have analysed only for the SME foundry segment which constitute more than 50% in no and in tonnage of India’s 10 Million Tonnes casting production. Let us leave alone the micro and the large and very large industries for the moment. This segment on a conservative outlook needs 145 machines in 2016.

2. The tangible impacts from the implementation of 145 machines (about 50% replacement & 50% new) can be listed as below: a. Energy Saving by Machine Operation : 38 Lakh kWh every year b. Energy Saving by saving in melting power for weight saved : 31 Lakh kWh every year c. CO2 Emissions reduced 5,500 MT every year d. Equivalent Trees Planted for 145 machines @ 20 kg/ CO2 absorption per year – 2.75 Lakh trees 3. The intangibles: a. Operator safety ensured; b. Noise level reduced to less than 85 dB, thus complying with industrial noise level norms in moulding area; c. Reduced no of operations persons; d. Reduced skill of operators; e. Better work environment, and compliance to OHSAS and therefore ISO:14000 f. Global competitiveness; g. Increased customer acceptance and OEM acceptance. The takeaways are many, and now with more than 30 machines in operations, it is time the institutions of the Government and the industrial bodies start focusing on technology upgradation, benchmarking the energy consumptions, OHSAS, pollution compliance. For the casting industry to grow, there has to be conscious effort to upgrade with technologies which are now commercially viable, have process capability and are sustainable. For more details visit www.rhinomachines.net www.martupdate.com

CASE STUDY | MACHINE TOOLS

The Old Ways Engineers love new ideas and new ways of doing things. But they love old ones too: those uncelebrated, underappreciated manufacturing techniques, for example, on which the modern world depends. Italian company, Termomacchine Srl, uses the latest Haas CNC machine tools to make turnkey heat induction systems for clients around the world. Heat induction is a technique almost as old as the industrial revolution itself. And yet, it’s used in manufacturing everything from silicon chips to airframes for fighter jets. Some of the most commonly employed manufacturing techniques have been used in industry for decades, sometimes centuries. Take, for example, induction heating. The phenomenon was discovered by French physicist Leon Foucault in the midnineteenth century – “induce” an alternating current in a conductive object, such as a ferrous metal component, and it heats up! The applications, especially in modern manufacturing, are myriad. Termomacchine Srl, based in Piedmont, northern Italy, has been perfecting induction-heating systems for industrial use for more than 40 years. “We try to do as much manufacturing in-house as possible,” says Bruno Gili, founder and president, Termomacchine Srl. “Quality is everything for us – and for our customers, most of whom are very wellknown companies, in Italy and overseas. We have departments for engineering electrical and electronic systems, mechanics, metallurgy, and quality assurance, of course. Our products are shipped to around 95 countries.” Most of the company’s orders are for one-

off, bespoke, turnkey machines and systems. So, there’s little call for large batches of parts or, therefore, three-shift machining. “We need versatile, simple, reliable machine tools,” says Mr. Gili. “Speed is not particularly important. And, we’re not competing with China or low-cost countries; we have a great deal of expertise, which we apply at all stages of a project, from sales to design, through to service and support.” Bruno Gili has worked with machine tools his entire professional life. In that time, he, like many of his peers, has seen the technology change beyond all recognition – from the advent of tape-based control, to primitive NC, to full multi-axis CNC. “We bought a Haas DT-1 Drill/Tap machine,” he says. “It runs 10 to 12 hours a day cutting aluminium, copper, stainless steel, and even plastic. It’s a truly excellent machine: always reliable, always accurate. It’s a real jewel!” The company also has a Haas TL-2 Toolroom Lathe – which it bought for one particular order. Its latest acquisition is a Haas ST-30Y. “That machine has very useful capacity,” he states. “Although I said we try to make

everything in-house, there are some parts we still subcontract. With the ST, we can, hopefully, bring them back so we have more control over quality and delivery.” The ST-30Y is designed to provide heavy cutting ability, extreme rigidity, and high thermal stability. It has a maximum cutting capacity of 457 x 584 mm, with maximum swings of 806 mm over the front apron and 527 mm over the cross slide. The ST-30Y also has high-torque live tooling and a servo-driven C-axis for 4-axis cutting. Mr. Gili repeats that versatility is the key at Termomacchine, where each new order is different to the last: “And, we don’t make spare parts for stock,” he adds. “We’ll make a new part when the need arises. It’s about speed and the part being right the first time. We have 2000 machines already in the field, so keeping a stock of spares would be impossible, very expensive.” Thankfully, Italy is a country with many companies just like Termomacchine: specialist, quality-obsessed, with an eye on the future but, just as importantly, with a trust in “old,” reliable techniques that may be uncelebrated, but never cease to be vital in modern manufacturing.

The Haas DT-1 Drill/Tap machine runs 10 to 12 hours a day cutting aluminium, copper, stainless steel, and even plastic.

Termomacchine Srl, uses the latest Haas CNC machine tools to make turnkey heat induction systems for clients around the world.

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November 2016

EXHIBITION & CONFERENCE – ALUMINIUM DIE CASTING 1 - 3 DECEMBER 2016 | BIEC, BENGALURU, INDIA www.alucast2016.com

For more information & space booking, please contact: NürnbergMesse India Pvt. Ltd.

Aluminium Casters' Association of India

Ms. Rucheeka Chhugani

Ms. Veena Upadhye

Tel +91 11 4716 8828

Tel + 91 20 2729 0014

rucheeka.chhugani@nm-india.com

alucastindia@gmail.com

November 2016

Organizer:

Event Producer:

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EVENTS |show report

GDCTECH 2016

Progress Through Partnership

Under the leadership of Dr. Aniruddha Karve, Organising Committee Chairman, the Conference GDCTECH 2016, was held on 20-21st October 2016 at Hotel Sun-n-Sand, Pune. The conference was a great success and established a new benchmark. P D Pant, Managing Director, Metal Power Analytical (I) Pvt. Ltd., inaugurated the conference and Mr. Subrato Chaudhuri, Head Supplier Quality – CVBU, Strategic GRP was the Keynote Speaker.

Dr. Aniruddha Karve,Organising Committee Chairman, while welcoming Chief Guest and Keynote Speaker, narrated the objective of the conference as ‘To Focus on theImportance of Collaborative Efforts of Buyers and Die Casters for Development

of Indian Die Casting Industry & to Meet the Requirement of The Buyers of Castings’. P D Pant in his inaugural address emphasised the need of innovation at every stage and urged the delegates to take pride in developing Indian Technology and be innovators. He impressed the need to support the ‘Make In India’ policy. During the inauguration, all 10 participating companies in Project Competition were given certificates and 6 projects were given awards. Anand Joshi, Chairman - Project Competition briefed about the objectives of the competition which help in ‘People Development’. In his keynote address Subrato Chaudhuri, Head Supplier Quality – CVBU, Strategic GRP, emphasised on quality without which Industry cannot grow and he appreciated the theme “Progress Through Partnership” which is very much appropriate in today’s world. At this point of time as all OEM’s are looking for strategic partners to develop components, involvement and collaborative efforts begin from the start only. Over 15 technical papers

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presented by experts and 12 project presentations, covering various areas such as Quality Improvement, Productivity Improvement, Energy Consumption Reduction and Innovation, were presented. Everyone appreciated profusely the idea of project competition and presentations. In the concluding session, the Chief Guest Viren Joshi, Chief Executive Officer & President, Sigma Electric Manufacturing Corporation Pvt. Ltd., emphasised on the need to act in the direction beyond technology like QMS, 5 S and Lean Management. He presentedthe Best Casting Award and Certificates of Participation. Pramod Gajare, Chairman - Best Casting Award Competition, announced the participants and winners. R T Kulkarni, Vice Chairman, Organising Committee acknowledged the contribution of all the stakeholders in the Conference in his vote of thanks and requested to block the date 5, 6 and 7 October 2017 for next GDCTECH 2017 Conference and Exhibition. November 2016

November 2016

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EVENTS |curtain raiser

WIN INDIA Awaits Manufacturing Sector with Opportunities Galore WIN INDIA, the flagship event of Hannover Milano Fairs India Pvt. Ltd and an annual fixture in India’s trade fairs calendar, is returning to Mumbai – since inception and after the maiden show at Bangalore, it has travelled to Mumbai and Delhi – for the 10th edition scheduled during December 01-03, 2016 at the MMRDA Grounds, Bandra-Kurla Complex, Mumbai. The organisers, Hannover Milano Fairs India Pvt Ltd, is a subsidiary of the two of the largest trade fair companies from Europe, Deutsche Messe AG, Germany and Fiera Milano S.p.A, Italy. Leveraging the experience of the parent organisation Deutsche Messe, organisers of Hannover Messe, which is the world’s leading trade fair for industrial technology and now in its 70th year, WIN INDIA brings together three leading international events at a single location, presenting infinite opportunities. The three events are:

Industries & Public Enterprise, Government of India, who was present at the inauguration of the 2015 edition of the show in Delhi, is expected to grace the occasion this year also. The event is co-hosted by the Department of Heavy Industry, Ministry of Heavy Industries & Public Enterprises, Government of India. With the union government making a determined effort to raise the share of manufacturing in the country’s GDP through Make in India campaign, the event is create benchmark in special attention from the government, exhibitors and trade visitors.

• MDA INDIA – Motion, Drive and Automation (Hydraulics & Pneumatics, Electro-Mechanical Transmission) • Industrial Automation INDIA – Factory Automation and Process Automation • CeMAT INDIA – Materials Handling/ Intralogistics, Storage Systems, Warehousing and Logistic Services.

The theme of the show is ‘Integrated Industry – Get new technology first’, and the visitors will have a lot to look at, feel and experience, with live demonstrations and machines in action and robots in motion. With the coming of collaborative robots or Cobots, human beings can now mingle with them, and work shoulder to mechanical shoulder, literally.

Shri Anant Geete, Minister of Heavy

The organisers have followed a strategy

of taking the event by rotation to the three major industry hubs of the country located in the north, west and south of the country. This not only makes sense given the vast geographical spread, but also gives the advantage of a home ground for participating companies of the respective regions. As for the decision to host the event in Mumbai this year, the organisers have listed out the reasons: • Mumbai serves as an economic hub of India • Contributes 10% Factory employment, 25% Industrial output, 70% maritime trade • Mumbai has 2 major ports and 53 minor ports • Jawaharlal Nehru Port Trust handles 55–60% of the country’s total containerised cargo • Home to India’s premier scientific & nuclear institutes like BARC, NPCL, IREL, TIFR, AERB, AECI, and the Department of Atomic Energy • Free Trade Warehousing Zones are proposed to be located in Mumbai and Kandla

Opportunities for manufacturing companies to network, engage and do business in the field of factory and process automation, material handling, warehousing and logistics.

Live demonstrations and machines in action and robots in motion.

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November 2016

• Pune is the largest auto hub of India, with over 4,000 manufacturing units just in the Pimpri-Chinchwad region • Industries developed near Mumbai are auto & auto components, pharmaceuticals, electronics, engineering, petrochemicals, oil & gas, textiles, biotechnology, and IT and ITeS • Logistic Hubs to be developed under Delhi Mumbai Industrial Corridor project in Gujarat state • 6 cities have been shortlisted for Logistic Hub, viz., Vapi, Palanpur, Dahej, Hazira, Gandhidham and Ahmedabad • Specialised Food Parks are being set-up by MIDC in Nagpur, Sangli • Textile Parks to be set-up in Ambernath, Nardhana near Dhule, Nagpur, and • MIDC to develop Wine Parks near Nashik and Sangli.

material handling, warehousing and logistics. WIN India is a 3-in-1 show and shall occupy 12,000 sq.m of exhibition space, besides having technical seminars, workshops and conferences. The exhibition shall feature over 150 companies showcasing products/ technologies and expected to be attended by over 10,000 business visitors,” says Guru Prasath K R, Portfolio Director – Industrial Fairs, Hannover Milano Fairs India Pvt Ltd.

With a major chunk of the visitors for a typical trade show coming from the host city and neighbouring industrial clusters, the number of decision makers among the visitors is expected to be significantly higher. “IA, MDA & CeMAT – these three leading industrial trade fairs provide unparalleled opportunities for manufacturing companies to network, engage and do business in the field of factory and process automation,

Maximizing Efficiency’ by Mr. Arif Siddiqui, Founder, Coign Consulting. Besides these programmes, there are conferences planned by supporting organisations:

Special features for WIN INDIA 2016 include:

• MDA FORUM: Organised by VDMA (German Engineering Federation), to discuss relevant topics pertain to technology, energy efficiency, new market, new application, engineering from the field of Motion, Drives & Automation.

Automation Training Zone: In Association with Automation Industry Association, 3 day training programme will be organised to augment the Government of India’s vision of skill development in manufacturing sector and educate the end user sectors with the latest automation technologies.

• CEO Conclave by FPSI: An informal gathering of CEO’s, MD’s, Sr. Managers from Fluid Power Industry, this meeting brings together the Captains of the Fluid Power community under one roof and facilitates networking, free exchange of ideas / opinions.

Intralogistics Conference: Organised by Institute of Supply Chain Management (ISCM), on theme of ‘Intralogistics 4.0 Converging to a New Paradigm’, a 2 day conference program to discuss Strategic impact of Intralogistics 4.0, future of supply chain.

• ‘Meet the Manufacturer’ Session by FPSI: An event that facilitates introduction of a new product, process or services to the material engineers, product designers, application specialist and distributers.

Masterclass for Supply Chain Professionals: Organised by ISCM, Masterclass on ‘Harmonizing Warehouse Ecosystem for

• Vacuum Technology Workshop & Lectures: Organised by Indian Vacuum Society, workshop will help the professionals in the vacuum technology sector to upgrade their knowledge and skills.

Chhattisgarh to Focus on Smart Manufacturing In an attempt to promote and extend ease of doing business opportunity to investors, Chhattisgarh Government is organising Chhattisgarh Manufacturing Conclave 2016 (CSMC 2016) at Raipur on 18-19 November 2016. Powered by good governance, essential infrastructure coupled with a surplus of power, a stable labour environment, talent pool, abundant mineral resources, and a diverse forest produce, Chhattisgarh is a leading business destination. Chhattisgarh has been aggressively promoting the investor friendly environment created by announcing various incentives to potential companies to set up their base within the State. The state has attracted cumulative investments of Rs 7 lakh crore since 2010, which is second only next to Odisha. Investments have been in various areas ranging from steel, cement, to plastic, solar and electronics. Considering the investment being primarily in manufacturing, the next focus is to establish Chhattisgarh as November 2016

a Smart Manufacturing hub. The companies invited will be requested to share their expertise in high precision engineering and industry 4.0 solutions which can be consumed by the local set ups.

been designed to highlight the requirement of Industrial Automation technologies, Smart Factory systems, Smart Warehousing and Supply Chain modules and has extended all companies in the domain to the event.

CSMC 2016 has been designed to engage leading International and national companies in the field of automation technology in manufacturing with the industries within the State. It is also expected that the companies will be invited to set up their facilities with all possible support from the State Government. Under the promotional activities, various industrialists have been invited to visit Chhattisgarh and experience the available infrastructure and development that has been achieved in the past few years. The first edition of CSMC will attempt has

CSMC 2016 will be organised in partnership with Hannover Milano Fairs India, the organisers of the world’s largest Engineering Exhibition – Hannover Messe held in Hannover, Germany. Chhattisgarh has been partnered with Hannover fairs in their Indian edition WIN INDIA as well as participated in Hannover Messe Germany on regular basis. Hence, with this partnership, it is expected to engage larger international brands to converge at Raipur at the Conclave which has been designed to be an annual feature to support the State adoption of technology. www.martupdate.com

EVENTS |ANNOUNCEMENTS Rajkot Machine Tools Show

Bauma Conexpo India 2016

IBRX Conference India

LES4ICE conference

November 23-26, 2016 NSIC Ground, AJI Industrial Area, Rajkot, Gujarat, India

December 12-15, 2016 HUDA Ground, Gurgaon, Delhi, India

January 9-11, 2017 Marriott Hotel, Panjim, Goa, India

30 November and 1 December, 2016.

The fair organized is by KMG Business Technology and Machine Tools MFRS association- Rajkot is to promote Machine tools industry.

Bauma Conexpo India is an international trade fair for construction machinery, building material machines, mining machines and construction vehicles.

www.mtmarajkot.org

www.bcindia.com

The exhibition will bring together the manufacturers of batteries, equipment and component manufacturers, experts environmentally sound technologies for recycling equipment manufacturers.

FEKO Webinar

Weld India 2016

www.bfi.org.in

6th IEDP Conference

December 15-17, 2016 Milan Mela, Kolkata, West Bengal, India

PLASTIVISION INDIA

Nürnberg Convention Center,

November 30, 2016 Webinar will consist of a brief presentation on summary of different optimisation methods, together with workflow demonstrations to set up a design. web2.altairhyperworks.com

WIN 2016

The exhibition is an ideal B2B platform for entrepreneurs, CEOs, Consultants and Trade Delegations to congregate, brainstorm, showcase and forge meaningful business partnerships.

December 1-3, 2016 MMRDA Ground, Mumbai, India

weld-india.com

The event will provide a platform to demonstrate a complete range of products and services from hydraulics and Pneumatics , automation components to process and factory automation system.

January 5-8, 2017 New Agricultural College ground, Pune, Maharashtra, India

www.win-india.com

ALUCAST 2016 December 1-3, 2016 BIEC, Bengaluru, Karnataka, India India’s one of the biggest exhibition for the Aluminium Die Casting Industry. Industries from various countries will showcase their latest products and technologies. www.alucast2016.com

National Expo 2016 December 2-4, 2016 BIT ground, Chhattisgarh, India The largest Steel and Power Expo is a platform for traders of products for equipments and machineries for steel plant, rolling mills, sponge iron plants and power plants. www.tradeshows.tradeindia.com

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MAHATech 2017

The exhibitions would focus on Process Industry Equipments, engineering, Machinery and Machine Tools, Electricals and Electronics, Instrumentation and Automation Equipments. www.maha-tech.com

International e-conference, IIIR January 7-8, 2017

January 19-23, 2017 Bombay Exhibition Centre, Nesco Complex Ground, Mumbai, Maharashtra, India

IFPEN, Malmaison, Paris, France The conference focuses on the recent advances in Large-Eddy Simulation research applied to Internal Combustion Engine Flows. www.rs-les4ice.com

November 30-December 1, 2016 Nuremberg , Germany The conference will focus on the presentation of highly innovative

PLASTIVISION is organised by All India Plastic Manufacturer’s Association (AIPMA), which is working towards welfare of plastic industry.

products from various industries as

www.plastivision.org

CIEIM

ICIMIA 2017 February 24-25, 2017 Dayananda Sagar College of Engineering, Bengaluru, Karnataka, India

well as manufacturing processes and strategies. www.edpc.eu

January 3-5, 2017 Via Principe Amedeo, 3, 00185 Rome, Italy CIEIM is a conferences for presenting novel and fundamental advances in

ICIMIA 2017 intends to provide an international forum for sharing knowledge and results in all fields of engineering and Technology.

the fields of Industrial Engineering

www.confyy.com

Aerodef Manufacturing

IMTEX 2017 January 26- February 1, 2017 BIEC, Bengaluru, Karnataka, India

and Industrial Management. www.cieim.org

March 6-9, 2017 Fort Worth Convention Centre, Fort Worth, Texas The Aerodef Manufacturing

The e-conference aims at exploring new technologies, understand their impacts on institutional and industrial research and estimate the future of the industry.

It is an exhibition showcasing the latest trends as well as technological advancements made in the metal cutting industry. www.imtex.in

aerodefevent.com

www.iiir.co.in

IETF 2017

IRCSME 2017

Wissenaire 2017

February 2-4 2017 Pragati Maidan, New Delhi, India

January, 8-10, 2017 IIT Bhubneshwar, Orissa, India Wissenaire aims to promote Wetware computing and neuromorphic chips.

Organised by CII, IETF 2017 will provide a platform to display next generation products and technologies from engineering and manufacturing industry.

www.wissenaire.org

www.iesshow.in

exhibition is an opportunity to explore innovative advances in the processes and materials.

January 4-5, 2017 Hyatt Place Hotel, Al Riggal, Dubai It is a platform for the academicians, researchers, industrial participants and students to share their research with global experts. www.ircsme.org November 2016

November 2016

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PRODUCTS | ANNOUNCEMENTS

Anybus CompactCom

Anybus CompactCom is a range of embedded communication interfaces which provides automation devices with connectivity to any industrial network – field buses as well as industrial Ethernet. HMS now expands the Anybus CompactCom 40-series to include connectivity to the gigabit CC-Link IE Field network. CompactCom is designed to be embedded into a host automation device to enable fast communication with any industrial network. Designing in the Anybus CompactCom into an automation device is quick thanks to the accompanying example driver code and configuration file (CSP+) provided by HMS.

It is available in two certified form factors, Module format, which enables instant connectivity for existing CompactCom users by simply plugging in the CC-Link IE Field module and Brick format which is ideal for users who have limited space or want to add their own choice of network connectors. www.anybus.com

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WIDIA launches modular end mills

Upgradation to Unidrive M

WIDIA has launched new,

A leading manufacturer

gives cutting performance of

SpA, has upgraded to Control

flexibility, simple and cost-

effective modular end mills and solid carbide. It is the only tool available that can predictably

take full-width slotting cuts in stainless steel and aerospace

alloys at 1xD deep, and 50% cut widths at 1.5xD. It is easily the most robust modular solution on the market today.

The unmatched metal removal rate is due to a double-taper, face-contact mount and

intelligent thread design. This

provides run out accuracy better than 5 µm (.0002 in.), axial

repeatability of 10 µm (.0004 in.) or better, and up to 25% higher torque and chip load

capabilities than others in this market.

When coupled with the wide

array of carbide, coatings, and

geometries from sister company Hanita, WIDIA provides

manufacturers with a modular

alternative to solid carbide end

mills in 80% of their machining operations

www.widia.com

of tissue and paper-based

consumer products, Soffass Techniques Unidrive M variable speed drives. Unidrive M offers full

mechanical compatibility

in terms of dimensions and

weights, and when retrofitting surface mount drives

existing mounting holes

can be reused, negating the

need for additional drilling. Furthermore, Unidrive M

offers the same power and

control wiring philosophy and

the same menu and parameter structure.

Among the principal uses for Unidrive M at Soffass is the

embosser, where paper veils

are matched together to make the final product thicker and

softer. The drives also control the print units, as well as the winder/unwinder, which

delivers materials to further stages of the process. www.Emerson.com.

20DBM Can Stack Linear Actuator

Portescap introduces the next generation of high power density Can Stack Linear Actuators, the 20DBM. These 20 mm linear stepper motors offer an Optimised design ideal for applications demanding high linear force. The new 20DBM features an Optimised magnetic circuit which provides improved performance over existing designs.

The 7.5 deg step angle provides finer incremental movement with a high degree of accuracy and repeatability. With maximum holding force up to 50N, the 20DBM actuators are ideally suited for use in applications such as electronic pipettes, medical and non-medical analyzers, XY stages and valve actuators. Our fully customizable 20DBM actuators are powered by high energy neodymium magnets, Optimised electromagnetic circuit and patent pending bearing preload design which ensures exceptional performance in a small package. www.portescap.com

November 2016

Rugged Graphite Platform by RedLion

Gateway by ELMEASURE

Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced its rugged Graphite® platform has been expanded to include anew Graphite Core Controller and Graphite Crimson® Control Module that combine communication and control capabilities to reduce cost and ease operations. Both hardware offerings leverage an enhanced version of Red Lion’s powerful Crimson 3.0software with added Crimson Control functionality to provide a single programming solution for control, networking and data visualisation.

“Gateway”, the newest networking product launched by ELMEASURE. The compact product significantly simplifies the way non–internet sensors or devices are linked to the internet so that data, configuration and controlling can be made possible online as it is an advanced industrial serial to Ethernet/ GPRS converter with RS485 or Zigbee interfaces, which allows to connect any serial device over a local area network (LAN) to over the internet to any server or cloud. The product finds wide applications in Energy / Building Management System, Data Centers etc.

www.redlion.net/Graphite.

www.elmeasure.com

Crimson Control enables customers to use IEC 61131 programming languages – such as Ladder Logic, Function Block, Structured Text and Instruction List –to solve specific application needs by developing logic control much like a Programmable Logic Controller (PLC) or Remote Telemetry Unit (RTU) without the added expense.

November 2016

The features of Gateway include Web browser for configuration, Configurable Account based Secured access, requires login name and password for login, Configurable Modbus RTU or Modbus TCP/IP option, Completely isolated in both RS485 and RJ45 side, DHCP / Static IP support, Configurable RS485 baud rate, parity and stop bits, Built in RTC, One touch recovery (Factory Reset Configuration), Optional storage of 16GB, built in 8GB, LED indication for easy setup and trouble shooting.

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REsOURCES | courses Robotic Arm using Arduino Workshop

Workshop on Smart Manufacturing

Outcome Based Engineering Education

Delft University Advanced Dynamics

In this course, you will build a Robotic Arm with 3 degrees of freedom which can act as a Pick and Place Robot and is controlled with the help of your hand gestures. By building this project, you will practically learn about Arduino programming, working of the servo motors - which acts as actuators and Accelerometer sensor for the control of Robotic Arm using hand gestures.

With Smart Manufacturing or

To expose the participants to the various theories and practices of Accreditation. To equip the participants with tools and techniques with which they can handle their current tasks better and in an effective manner towards Accreditation. To give the participants a holistic perspective of Outcome Based Education so that they can shoulder greater responsibilities in their present and future career. To get tuned to the latest developments and best practices prevalent in the Engineering Education. To make the participants efficient in preparation for accreditation of engineering programs. To enhance efficient implementation of active learning inside and outside the class rooms.

The Advanced Dynamics course

Duration:- 2 days 26th Nov to 27th Nov. Email: info@roboversity.com

Industry 4.0, or Industrial Internet of Things, manufacturers are moving towards a new level of interconnected and intelligent manufacturing system which incorporates the latest advances in manufacturing science, information science, data science and automation tools. The greater digital interconnectedness between various parts of the supply and production chains, as well as the higher reliance on automation in these smart factories, is going to make

WINTER TRAINING PROGRAM ON 7 ROBOTS manufacturing ultra-efficient, ultraIN 6 DAYS AT SKYFI LABS CENTER, ABIDS, sophisticated, and ultra-productive. GATE FORUM, HYDERABAD The purpose of this course is to help you build your own robotics projects. You will be provided with the kits and our Engineers will give you the knowledge to develop the 7 projects from scratch. The majority of your time in the course will be spent on hands-on activities. In this training program, you will develop this knowledge by building seven popular robotic systems. Here’s what you’ll learn by hands-on sessions: Concepts of various robotic technologies, working of motors, sensors and microcontrollers, how to design mechanical structure of robot and how to program and test robots. Duration:- 6 Days (12 Dec - 17 Dec, 2016) Email: info@roboversity.com

Duration: One day (December 3rd, 2016) www.iiitdm.ac.in

Duration:-2 Days (December 15th & 16th, 2016)

National Expo 2016

www.terna.org

December 2-4, 2016 BIT ground, Raipur The largest Steel and Power Expo is a platform for traders of products for equipments and machineries for steel plant, rolling mills, sponge iron plants and power plants. http://tradeshows.tradeindia.com/ steel-powerexpo-raipur/

National level Workshop on Big Data & IoT The main objective behind this workshop is to introduce the Big Data and its relevance in the Internet

Ic Engine And Automobile Prototyping of Things (IoT) and also to explore This course helps you practically learn automobile engineering. You will be provided with the tools and our Engineers will give you the knowledge to develop your automobile prototype from scratch. You’ll also spend a majority of time in exploring an IC Engine in addition to the hands-on experience in building your RC Car.

various applications in the area of

Duration:- 6 days ( 02 Jan - 07 Jan, 2017) Email: info@skyfilabs.com

November 2016)

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Big Data and IoT. This workshop will provide a very good opportunity for Researchers, Academicians and Industry Professionals to accomplish the growing demand of applications and quest for research in the area of Big Data. Duration: Two Days (25th and 26th

http://sanjivanicoe.org.in

Bio-Robotics This course is designed for the participants from various interdisciplinary areas such as mechanical, electrical, control, software, biomedical engineering & experts from medical and paramedical fields. In this course a truly high-tech human orthotic and prosthetic limb design with an introduction to traditional fields of prosthetics and orthotics will be covered. Prosthetics and orthotics transform physical disabilities into new mobility opportunities for the subjects with movement disability and in the process lead to improvements in the quality of life of amputees. Participants will be introduced to various facets of the field, including clinical application, engineering, design, and new technology in robotics and assistive technology. Professional options within the professions will also be discussed.

taught at the Delft University of Technology begins with concepts that are simple and intuitive and then generalizes these concepts step by step into a broader analysis of the dynamics. The main goal of the course is to help you learn how to apply the fundamentals of Lagrangian mechanics to practical engineering problems. In this way you will learn to resolve intriguing problems in areas of engineering such as mechanical, aerospace, robotics, biomechanical, mechatronics. Duration: 7 Weeks (Admission Deadline: April 10, 2017 Start Date: April 24, 2017) https://online-learning.tudelft.nl/ courses/advanced-dynamics/

Electrical Design Engineering Course SSITEDI offers electrical design course to students from India. Electrical design Course offered by ssitedi delivers practical insights into the principles of Electrical design. The course includes basic of Electrical Engineering like Co-ordination with other Disciplines, Introduction to Sub-Station, Sub-Station Design Development, Sub-Station Design Calculations, Cable Routing, Earthing Protection Design etc. Duration: 45 Days Visit: www.ssitedi.com

Competency in Practical Engineering for Energy Efficiency

Duration: 5 Days (19th to 23rd December)

The Competency in Practical Engineering for Energy Efficiency course from Engineering Institute of Technology gives you the practical tools to identify and implement programs and projects to reduce energy consumption in the most effective and practical ways.

www.mnnit.ac.in/index.php/ workshop

Duration: 3 months www.eit.edu.au November 2016

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