Volume 13 Issue 4 October 2016 `150
empowering engineering excellence
Industry focus
Forging & casting
EYES IN THE
SKY October 2016
COLUMN
greentech: csr cutting edge
virtual reality innovation
predictive engineering analysis INDUSTRIAL BUSINESS MART
1
2
INDUSTRIAL BUSINESS MART
October 2016
Good Wishes for a Joyous Diwali
&
Happy New Year
October 2016
INDUSTRIAL BUSINESS MART
3
4
INDUSTRIAL BUSINESS MART
October 2016
"Most preferred Steel Plant maker up to 1 Million ton capacity per annum - Globally”
Successful Commissioning
of Overseas Turnkey Projects in 2016
·
Watani Iron And Steel Co., Riyadh, Saudi Arabia: 3 sets of 12 MW – 1.5 MW / 30 Ton Induction Melting cum Sintering Furnaces with Transformers and Automation.
·
Darfala for Iron Melting and Steel Manufacturing, Riyadh, Saudi Arabia: 4 MW / 10 Ton Induction Melting Furnace, Continuous Casting Machine, Electrical and Cooling Systems, Material Handling Equipment, Air Pollution Control System, Laboratory Equipment and all other Auxiliaries for the plant.
·
Electrotherm is proud to announce successful commissioning of following overseas turnkey projects during 2016: ·
Ueno Corporation, Dammam, Saudi Arabia: 5 MW / 12 Ton Induction Melting Furnace, Continuous Casting Machine, Electrical and Cooling Systems, Material Handling Equipment, Air Pollution Control System, Laboratory Equipment and all other Auxiliaries for the plant.
Steefo Industries (CIM Metal, Burkina Faso, Africa): 6 MW / 15 Ton Induction Melting Furnace, 2- Strand Continuous Casting Machine, Air Pollution Control System and Electrical equipment.
Alvand Foolad Arya · Co., Qazwin, Iran: 5 MW / 12 Ton Induction Melting cum Sintering Furnace, Continuous Casting Machine, Electrical and Cooling Systems, Material Handling Equipment, Laboratory Equipment and other Auxiliaries for the plant.
R
N
Ÿ
Saleh Steel Industries Ltd., Chittagong, Bangladesh: 4.5 MW / 10 Ton Induction Melting Furnace, Electrical and Cooling Systems.
RWANDA MALAWI
Creative Carbon Pvt. Ltd. (Endmor Steel, Kenya): 4 MW / 10 Ton and 3.5 MW / 8 Ton Induction Melting Furnaces, Continuous Casting Machine, Electrical and Cooling Systems.
A
C
E
S
India's best; globally admired
October 2016
Chakada Steel & Re-Rolling Mills (Pvt. ) Ltd., Dhaka, Bangladesh: 6 MW / 15 Ton Induction Melting Furnace, Continuous Casting Machine, Electrical & Cooling Systems.
GABON
Tag Electrocasting Technologies Pvt. Ltd. (Pioneer Metal), Johannesburg, South Africa: 750 - 150 KW/2 Ton Induction Melting Furnace, Electrical and Cooling Systems for Copper Melting.
U
Ÿ
BURKINA FASO GUINEA
Founderie Du Congo SA, Brazzaville, Republic of Congo: 4 MW / 12 Ton and 6 MW / 15 Ton, Induction Melting Furnaces, Electrical and Cooling Systems.
F
Kavir Damghan Steel Co., Damghan, Iran: 10 MW / 25 Ton Induction Melting cum Sintering Furnace, 6/11 meter radius 2-Strand Continuous Casting Machine (with provision for 3rd strand), Electrical and Cooling Systems, Material Handling Equipment, Air Pollution Control System, Laboratory Equipment and all other Auxiliaries for the plant.
ELECTROTHERM® (INDIA) LIMITED 72, PALODIA, (VIA THALTEJ) AHMEDABAD, GUJARAT- 382 115, INDIA Phone: + 91 2717- 660 550, Email: mkt@electrotherm.com Website: www.electrothermenp.com
INDUSTRIAL BUSINESS MART
5
6
INDUSTRIAL BUSINESS MART
October 2016
empowering engineering excellence
Volume 13 Issue4 October 2016 Annual Subscription ` 1800 Member INS
Editorial Discover, Connect & Collaborate!
Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre P S Satish
J R Mahajan LD Bhakre S M Dangi Sandeep Hingne
Publisher
Hari Shanker
Associate Editor Executive Director Executive Editor
Hiya Chakrabarti
The success of MART is reflected in the impact factor it has on its readers.
Siji Nair
Now in its 13th year, the magazine has never been in a stronger position. This is due to the combined efforts of a strong Editorial Board with a range of specialist expertise in all areas of manufacturing, a dedicated Editorial team, and strong liaison with industry associations, and last but certainly not least, the army of busy professionals who volunteer their time to submit articles on various topics.
Sujatha Thampan
Correspondent
Arnab Mondal
Editorial Coordinator
Pramod Pillai
Editorial Assistant
Nazia Ali
Lead Creative
Chetan Kumbhar
HR & Admin
Richa Chowdhary
Accounts & Opts
Sophiya Bansode
Sales Team Lead Sales
Bishnu Priya Kundu
Mumbai
Ravindranath Kurup
Chennai
V Subramaniam
Delhi
Vidya Rao Contacts
Editorial
+91 70 3093 2700
pramod@martinfotech.in Circulation
+91 70 3093 2696
sales@martinfotech.in Advertisement
+91 70 3093 2699
advt@martinfotech.in Human Resources
+91 70 3093 2697 richa@martinfotech.in
Mart Infomedia Private Limited
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:
October 2016
I am delighted to be taking over the helm as Executive Editor of what has become known affectionately as MART. Those who have been reading the magazine since 2004 will have seen many changes in the last 12 years. In the past, the Editorial team of MART have always sought out and published the latest technologies and information that poised to change our manufacturing sector, true to the magazine’s adage: Delivering Knowledge, Delivering Value.
The journey so far has been truly enriching and rewarding. MART, with its October edition is turning a new leaf. The endeavour is to be THE platform for the manufacturing fraternity to Discover, Connect & Collaborate. The readers will find new content representations and participations. The sections in the magazine will be in sync with the new positioning of MART – ‘Empowering Engineering Excellence’, as well as the monthly theme of the issue. Sections like ‘Cutting Edge’&‘Innovations’, will actively focus on research and development which has direct impact on the sector. We are also including a segment on ‘Resources’ – a guide on services comprising careers and consultancy. MART will also focus on the social angle – spearheaded by Manoj Kabre will bring forth CSR activities by the organisations in the manufacturing sector. However certain sections will remain constant keeping in mind the popularity among readers. As with all social developments – most importantly - the ease of access to information, we have noticed a slow decline in the number of people wishing to have the print version. MART will strive to meet the changing demands of its readers through its revamped website which will be the virtual interactive forum for the fraternity.MART will continue to serve the common interests of readers to meet the challenges ahead. Hope to bring you more updates on MART’s progress in the next issue. Enjoy the reading, and we look forward for your critical analysis, suggestions and future contributions.
Sujatha Thampan sujatha@martinfotech.in INDUSTRIAL BUSINESS MART
7
CONTENTS www.martupdate.com
Volume 13 Issue 4
54 COLUMN
10 NEWS silent talk Question Suggestion Mirror Talk
14 ANNOUNCEMENTS Self Tape
16 tECHNICAL sTORY
Written Self Talk
Self Talk Partner Talk Self-Conversation
66 Learning Curve
24 INNOVATION
44 CUTTING EDGE
28 Cover Story 8
INDUSTRIAL BUSINESS MART
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
October 2016
Guest eDITOR 80 Dr. H Sundaramurthy
79 | Industry Focus Let’s Talk 74 Made In India....Proudly
Case Study 78 SmartSense® Making Foundry Smarter with Iot
Case Study 82 Munjal Castings Increases OEE by 50%
Industry focus 84 Smart Foundry
Technics 88 Emerging Technologies and Design for Manufacturing
POst Event 92
rESOURCES 96
October 2016
INDUSTRIAL BUSINESS MART
9
NEWS Airlander 10: New Hybrid Aircraft Airlander 10, a hybrid aircraft, having features of blimps and airplanes is capable of cruising at a speed of almost 90 mph. The lofty creation is 302 ft long and 143 ft wide with an advanced dynamic shape. Helium filled Airlander 10, has multilayered skin of a thickness of 1 mm. It is powered by four 325HP turbocharged diesel engines and has two big fins to support landing. Although the aircraft requires a crew of four people to ensure safe landing of the airship, the company envisions its landing without any ground crew members.
ASSOCHAM SMEs Excellence Award ASSOCHAM SMEs Excellence Award is now entering into the fourth edition this year. Since the inception, ASSOCHAM has been committed to promote and encourage the small enterprises which are excelling in their fields. SMEs Excellence Award is a tribute to the efforts and success achieved by the micro, small and medium enterprises. Indian MSMEs have been devising the innovative business models which have transformed the daily life of common citizen in many ways. The contribution of MSMEs especially in Indian economy is exceptionally successful and needs to be recognized.
British Steel back in Profit British Steel has claimed that Tata Steel “lost interest” in the Scunthorpe steelworks, one of only two left in Britain, and that the site is back in profit just three months after it was sold by the Indian company. Tata Steel offloaded the Scunthorpe site earlier this year as it battled to stop mounting losses in its UK business.
10
INDUSTRIAL BUSINESS MART
Argand acquires Sigma Sigma Electric Manufacturing Co (‘Sigma’) announced that Argand Partners, LP (‘Argand’), the New York-based private equity fund, had acquired a 100% shareholding in Sigma from existing shareholder Goldman Sachs Private Equity and other shareholders. Argand plans to work closely with the Sigma management team to support the company through the next phase of its growth. Sigma and Argand will actively pursue an aggressive growth strategy, both organic as well as via acquisitions, which will enhance Sigma’s market strengths across the globe. Argand, a New York-based middle market buyout firm, focuses on industrial manufacturers and service providers, where the team has deep sector experience and can leverage its senior executive advisory network to drive the rapid execution of an investment thesis. Sigma is a global leader in machined cast metal parts & assemblies. Global market segments covered include commercial
electrical, retail electrical, appliances, diversified industrials, power tools, instrumentation and telecommunications. Leading multi-national corporation customers include EmersonAppleton, Eaton-Cooper, Legrand, Hubbell, S&C, Whirlpool, Stanley Black Decker, Siemens, ABB, Lowes and Electrolux. Sigma has nine world class manufacturing facilities located in Pune and Jaipur, India. The company has world-class tool room, engineering and machine building facilities. Sigma continues to modernize its facilities through the addition of an increasing number of automation and robotic equipment. Sigma Global headquarters, technical center and 180,000 sq.ft distribution center are located at Garner, near Raleigh, North Carolina, USA to cater to the large North American customer base. Sigma produces castings in aluminum, aluminum-bronze, zinc, steel, iron, and copper. For more details visit www.sigmaelectric.com
Cisco to launch Manufacturing Operations in India Cisco has announced projects embracing “Digital India” and “Make in India” initiatives by the Government of India. The company indicated that it would start manufacturing operations in India along with other projects that focus on the digital transformation of the country. Cisco teamed up with Government of Maharashtra to announce new local projects aimed at digital transformation which includes turning Nagpur into a Smart City and development of eCommerce hub in Dharavi. Nagpur Smart City development will be a major project for the company as it will work as the demonstration of the digital power of Cisco as a networking company. The project will enable city-wide network connectivity along with Wi-Fi hotspots and surveillance solutions. The services like smart transport, lighting, smart parking and environmental sensors will be clubbed together to Cisco’s “City Digital” platform. Dharavi eCommerce Hub will help students
gain quality education using digital learning tools for academics while connecting, collaborating and creating new content. The company is also setting up to 25 Cisco Networking Academies to train 10,000 students in the state by 2020. This is an extension of the 186 total Networking Academies spread across the world. Cisco CEO, Chuck Robbins added that “Digitization opens unprecedented opportunities for every country, state and the city. High technology manufacturing is the convergence of engineering and science.” The company also announced its plans to move beyond the concept of “Smart Cities” and these are “Smart Villages” where the villagers can get Wi-Fi, Healthcare and education. The company is currently working to digitise Fetri village in Nagpur district, In addition, the company will help state-wide deployment of broadband infrastructure to accelerate the Digital Maharashtra Vision.
October 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
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.
www.dormerpramet.com October 2016
INDUSTRIAL BUSINESS MART
11
ElMeasure Moves to New Plant ElMeasure, a leading Energy Management Services company based in Bangalore has moved to state of the art manufacturing & R&D facility at the Hardware Park near the Bangalore International Airport. The new plant measuring close to 60,000 sft in a 3 acre plot houses the manufacturing
facility along with the new R&D center. ElMeasure’s new facility will enable the company to increase its production capacity and also accommodates future business growth and demand for Energy Management products and solutions in India and globally.
Anybus Wireless Bolt — Connecting Devices Wirelessly HMS Industrial Networks now introduces The Anybus Wireless Bolt — a wireless access point designed to be mounted on a machine or cabinet to give it wireless access via WLAN, Bluetooth or Bluetooth Low Energy. This access makes it possible to do configuration via a regular tablet or smartphone or connect to a cloud service, realizing Industrial IoT. The Anybus Wireless Bolt is mounted onto a machine or cabinet (just like a bolt) to give it a robust and IP67-classed wireless interface. It is typically used for configuration purposes. For example, the Bolt makes it possible to Bring Your Own Device (BYOD) such as a tablet or smartphone to a machine and use it as an HMI. Another typical use case is connecting a machine to a cloud service.
INDUSTRIAL BUSINESS MART
“We have seen a steadily growing interest in wireless connectivity through our Anybus Wireless Bridge,” says Martin Falkman, Product Manager at HMS Industrial Networks. “Therefore, we wanted to offer machine builders a robust, industrial-grade wireless solution for on-machine mounting. The Anybus Wireless Bolt is yet another way that HMS enables customers to realize IIoT with solid and secure wireless solutions, getting them ready for the communication demands of the future.”
Sale of Audi Q5 suspended
Atlas Copco to invest in India
The sale of Audi Q5 SUV has been suspended as the emission level from the model is higher than the stipulated level. The model underwent corrective measures, the company has initiated the Type Approval and is waiting for a positive response.
Atlas Copco, a Swedish giant, intends to support “make in India” initiative by investing 70 crore in its Hyderabad manufacturing unit. The contribution is likely to double the capacity of the manufacturing base in Hyderabad and generate employment for 35 people.
The company has not put a timeline for the return of the Q5 to showroom. However Audi India intends to resell the model during festive season.
12
The Wireless Bolt can communicate wirelessly up to 100 meters via WLAN, Bluetooth or Bluetooth Low Energy. On the wired side, the Anybus Wireless Bolt can communicate with devices on serial (RS232/485), CAN or Ethernet. Regardless of communication method, it has the same connector (2x9p Plug Connector) for both power and communication.
As announced by Ronnie Leten, President and CEO of Atlas Copco, the Hyderabad plant will introduce new items such as rotary products for oil and gas application, products for hard metal mining, and innovative deep hole drilling machine to cater to Indian and African markets.
October 2016
Nano-Satellite from IIT-Madras The satellite being built by the students of IIT- Madras is finally nearing functional mode, with the team behind the 12-kg nanosatellite managing to overcome the software and hardware issues that had cropped up during the testing phase. Now, it will complete the final phase of ground testing of the Qualification Model (QM) before being handed over to ISRO for rigorous testing ahead of launchAll components of IITMSAT have been indigenously developed by IIT-M students. During its one-year mission, the Spacebased Proton and Electron Energy Detector (SPEED) on board the satellite will collect and transmit data about electrons and protons there in Earth’s upper ionosphere. This is an interesting study that tests the hypothesis about a possible correlation of particle bursts prior to an earthquake. The detector measures the count rates of high energy protons and electrons and the data collected by IITMSAT could throw more light into the hypothesis, said a team member. The satellite being built by the students of IIT- Madras is finally nearing functional mode, with the team behind the 12-kg nanosatellite managing to overcome the software and
On the Rs 2.5 crore spent on the project as on date, Rs 1.50 crore was contributed by 1970-batch alumnus Dr Krishna Chivukula, Founder and Chairman of Bangalore based INDO US MIM Tec Pvt Ltd hardware issues that had cropped up during the testing phase. Now, it will complete the final phase of ground testing of the Qualification Model (QM) before being handed over to ISRO for rigorous testing ahead of launchAll components of IITMSAT have been indigenously developed by IIT-M students. During its one-year mission, the Spacebased Proton and Electron Energy Detector (SPEED) on board the satellite will collect and transmit data about electrons and protons there in Earth’s upper ionosphere. This is an interesting study that tests the hypothesis about a possible correlation of particle bursts prior to an earthquake. The detector measures the count rates of high energy protons and electrons and the data collected by IITMSAT could throw more light into the hypothesis, said a team member.
Tesla might set up a base in India
Ssangyong to form JV in China
Nitin Gadkari, Transport minister of India, has offered Tesla to set up a manufacturing base in India. The venture would encourage India’s endeavours to reduce the pollution levels of its cities by promoting battery vehicles.
Mahindra Group’s South Korean arm Ssangyong Motor Co is forming a joint venture with China’s Shaanxi Automobile Group to set up a manufacturing plant in the world’s largest automobile market.
India is willing to provide land near a port of Tesla’s preference for setting up the manufacturing unit. However Tesla will be making the decision on the matter after assessing the performance of Model 3, Tesla’s new launch, in the market. Around 400,000 bookings have been made since the launch of Model 3.
Ssangyong Motor Co, which was acquired by Mahindra & Mahindra in 2011, has signed a letter of intent (LOI) with the China’s Shaanxi Automobile Group for a joint venture that will establish local production plant for CBU vehicles as parts of its efforts to grow in China.
October 2016
INDUSTRIAL BUSINESS MART
13
PRODUCTS / ANNOUNCEMENTS
New SilverPlus Technology
Netbiter under the eWON® Brand
Hypertherm, a U.S. based
Having revolutionised the
Hengstler’s new launch,
With Netbiter as part of eWON
manufacturer of plasma,
industry in the past with the
ACURO® AX73 offers
laser, and waterjet cutting
Remote Solutions, HMS is
Tiger tec® and Tiger tec®
systems, has introduced
Silver coatings, the machining
features of specific benefit in
able to present a complete
a lower-amp SilverPlus®
specialists at Walter AG in
applications such as winches,
offering for remote access,
electrode. This new electrode,
Tübingen are now making
cranes, drills and other oil
data and management of
for its HyPerformance family
another technological advance.
and gas industry equipment,
industrial equipment like,
of plasma cutting systems, is designed for cutting at 80 amps which is proven in Hypertherm laboratory testing to last more than twice as long as a standard copper electrode.
as well as at paint plants,
Remote Access with Cosy, an
Walter is one of the world’s first
petrochemical facilities,
companies to present a new
industrial VPN router which
bottling plants and grain mills.
provides a faster and easier
technology platform: Tiger tec® Gold – with the WKP35G milling
Among the principal
grade.
advantages is the connection
Compared with the CVD
concept of the AX73, which
aluminium oxide-coated
allows the routing of cabling
of SilverPlus makes these
grades currently in use, the
and the final encoder
electrodes a popular and
new Tiger tec® Gold with a
installation to be done in
cost-effective choice and
titanium aluminium nitride
separate steps. This provides
are a perfect example of
(TiAlN) coating once again
significant cost and time
Hypertherm’s commitment to
boasts significantly improved
cost cutting for people who
properties – resulting in longer
savings during installation,
own Hypertherm’s products.
tool life, increased productivity
The proven performance
In addition to the new 80
14
Go for better, ACURO® AX73 go Gold Absolute Rotary Encoders
and greater process reliability.
as cabling can be done in advance. Special patented screws are deployed on the
way to open a remote tunnel to do remote commissioning and programming of PLCs, Remote Data with Flexy, a modular and flexible router which can be customized for remote access and data collection and Remote Management with Netbiter, an out-of-the-box solution for remote management of field equipment.
amp electrode introduced,
They recorded markedly
AX73 to protect against dust,
eWON is a very well-known
Hypertherm also offers
improved properties compared with other coatings:
water and corrosion. Inherent
brand within remote access
130, 200, 260, and 400 amp versions with similar
Considerably higher wear
precision, robust design,
and remote data, and with the
performance. Please contact
resistance on the flank faces,
impressive resistance to
addition of Netbiter Remote
Hypertherm or an authorized
reduced formation of hairline
shock, vibration and external
Management, they have a very
partner to request samples of
cracks and greater resistance to
magnetic fields are some of its
strong and complete remote
SilverPlus electrodes.
plastic deformation.
other qualities.
solutions offering.
For more details visit
For more details visit
For moredetails visit
For moredetails visit
www.hypertherm.com
www.walter-tools.com
www. hengstler.com
www. hms.se
INDUSTRIAL BUSINESS MART
October 2016
Mill 4 indexable Milling Cutters
Kennametal is expanding its game-changing Mill 4 family with a new cutting tool, the Mill 4-11. Designed for smaller machining centers, the Mill 4-11 accommodates 40-taper CAT and BT, HSK50, and similarly-
More Efficiency and Flexibility
Robust LED Floodlights
IO-Link sensor/actuator hub
The new 6125 series (for
The new solution from De
with expansion port IO-Link
zone 1) and 6525 series (for
Dietrich Process System adds
actuator/sensor hubs from
zone 2) floodlights from
an important benefit for
Balluff feature eight ports for
R. STAHL are designed for
drying of powders in process
16 in-/outputs. They allow for
challenging environments
industries, cosmetics and
such as chemical, food and oil
food.
example signals from up to
and gas extraction. Offering a
sized spindles. Due to its free-
16 switching sensors to be
cutting capabilities, it is ideal
collected from a distance of
for successful metal removal
up to 20 m so that they can be
in less-than-rigid setups and
made available to the machine
on light-duty machine tools,
controller via IO-Link and an
multitaskers and live-tool
IO-Link master using a simple
lathes.
3-conductor cable. Brand new
Energy-efficient LED
With an 11 mm (0.433 in.)
in the market are versions with
technology makes R. STAHL’s
service life is of 50,000 hours, they feature high corrosion resistance supported by a robust IP66/67-rated enclosure.
an expansion port.
new generation of flexible
Here Slot 7 can be
areas shine. High-quality TIR
reconfigured as an expansion
lenses minimise scattered light
port by means of a simple
and glare effects and enable
high metal removal rates and
parameter entry. A complete
light distribution focused on
excellent tool life.
valve plug or an additional
angles of 10°, 40° or 120°. The
maximum cut length, it addresses the needs of those job shops and manufacturers producing smaller parts and part features while still offering
The Mill 4-11’s has a complex, double-sided geometry that provides low cutting forces for light duty machine tools and less-than-rigid setups, and one of the lowest tooling
Advantageous Alternative Technology
sensor hub can be connected to it, providing flexibility and efficiency. Now it is possible not only to cost-effectively process additional in- and outputs, but also expand the
floodlights for hazardous
Recently, the Guedu® vertical dryers have been installed by several clients, providing decisive quality and productivity improvements. In vertical dryers, the powder is stirred under vacuum that allows an improvement of the drying time by a factor 2 to 10 compared to tray dryers and a total cycle time reduction by a similar ratio. The mechanical mixing during drying improves product homogeneity.
devices are therefore not only
De Dietrich Process Systems
suitable for spot and wide-
is able to supply its customer
angle lighting, but can even
not only with the appropriate
be installed as pendant lights.
drying technology, but
The lense panel modules are
also to design and supply
equipped with hinges for easy
the peripheral equipment,
installation, maintenance
support structure as well as
and repair of the removable
the automation and control
costs per part in the industry
range to a circle of another
Kennametal.
20 m.
components.
systems.
For moredetails visit
For moredetails visit
For moredetails visit
For moredetails visit
www. kennametal.com
www.balluff.co.in
www.stahl.de
www.dedietrich.co.in
October 2016
INDUSTRIAL BUSINESS MART
15
PRODUCTS / TECHNICAL
“Walter Green”: Enhancing Energy Efficiency
C
limate protection is a complex topic.
At Walter, it ranges from using energy-saving LED lighting and targeted leak detection in compressed air systems, through to recycling raw materials and to manufacturing fully carbon-
16
“Walter Green” not only helps to maintain a healthy climate but is also profitable, as Gerhard Schüßler explains. As the Director of Quality & Risk Management, his responsibilities at Walter AG in Tübingen include the areas
offset milling bodies, to name
of environmental and energy
just a few examples.
management.
The crucial factor is that
Carbon neutrality as standard
INDUSTRIAL BUSINESS MART
Walter AG has drawn up an ambitious programme for the efficient use of energy and raw materials. Walter has been promoting climate protection on the basis of this initiative, known as “Walter Green”, for several years. Walter has now developed a new range of tools – with a completely carbon-offset manufacturing process. Gerhard Schüßler, Director of Quality & Risk Management at Walter AG on energy efficiency and Walter initiatives.
“On the one hand, in order to remain competitive, we as a modern company must be able to present our customers with clear evidence that our products are energy-neutral and carbon-neutral. This is increasingly becoming standard practice, not least in the automotive industry. We began establishing a system for this a number of years ago. On the other hand, the
efficient use of energy and raw materials enables a large number of potential savings to be exploited.” For instance, simply replacing the fluorescent tubes used up until now in offices and production halls with modern LED lighting tubes reduces the company’s electricity bill by several tens of thousands of euros a year. “We were able
October 2016
- one gauge, many applications to agree a five-year warranty covering lighting failure with the manufacturer of the lighting systems. However, we will be able to recoup our investment costs in less than three years.” Gerhard Schüßler also closely examined the compressed air system used by his company. “Compressed air is the most expensive type of energy that we generate. We therefore decided some time ago to start regularly checking the system for leaks and plugging any that we found. This enables us to lower the pressure from 7 bar to 5.6 bar, reducing the energy used and providing five-figure annual savings as a result.” Effective factors: Recycling Raw material recycling is particularly effective in terms of increasing energy efficiency and helping to protect the environment. Walter has been systematically establishing a system of raw material recycling for several years. This provides several advantages at once: The use of recycled raw materials, particularly tungsten oxide powder, tungsten metal powder and tungsten carbide powder, gives the company a greater degree of independence from Chinese suppliers, who dominate the world tungsten market. It also conserves natural resources and reduces costs. This also has benefits for Walter customers. Gerhard
Schüßler explains: “We offer our customers a revenue model in which we purchase their used tools. This is in conjunction with all-round service, whereby Walter handles all aspects of logistics, including shipping costs.” It is no surprise that many customers have already made use of this service. After all, it not only provides customers with financial benefits, but also helps to ensure carbon neutrality and competitiveness. However, the potential of recycling has yet to be fully realised. “We could recycle substantially more tungsten, and the volume is increasing rapidly. We want to achieve a harmonious balance by 2020, whereby the volume of recycled material that we purchase is the same as the volume of finished tools that we sell.” Walter began laying an important part of the
Nothing compares to Equator™, Nothing compares like Equator™
groundwork for promoting
The unique new Equator™ is a versatile alternative to traditional gauging, offering inspection of an unprecedented variety of
this issue early on: Wolfram
manufactured parts. It has been developed and proven on
Bergbau und Hütten AG (WBH) in St. Martin in Austria has been part of the Group since 2009 – one of the “pearls of the Austrian economy”, as the Wirtschaftsblatt – a prominent financial newspaper in Vienna – remarked when reporting on the acquisition. Recycling has
the shop-floor with industry-leading gauging users in multiple industries and applications. Benefits which can be gained by using Equator™ include: • Reduced gauging costs • Robust shop floor measurement process • Reduced production bottlenecks
To see Equator in action visit www.renishaw.com/gaugingapps
been carried out within the Group ever since. WBH is mining the largest
Renishaw India G.K Arcade, 3rd Floor, #125/1-18, T. Mariappa Road, Jayanagar 1st Block, Bangalore 560 011 T +91 80 6623 6000 F +91 80 6623 6060 E india@renishaw.com
www.renishaw.com October 2016
INDUSTRIAL BUSINESS MART
17
tungsten deposit in Europe in Mittersill, near Kitzbühel, and has additionally established a great deal of recycling capacity. “The quality of the recycled material that we receive from Austria is outstanding,” says Gerhard Schüßler.
Gerhard Schüßler
Director of Quality & Risk Management, Walter
M4000 – Carbon-offset manufacturing However, there are a number of other factors that Walter uses to design sustainable production processes. The most recent example is the new M4000 milling cutter family, which is setting new standards in several respects. For instance, the tools in the M4000 milling cutter family are, without exception, manufactured using carbon-neutral manufacturing processes and all bear the “Walter Green” eco-label. To ensure that the production processes are fully carbon-offset, Walter has determined all possible carbon dioxide emissions associated with the production – from the raw material, to the production of the tool and its packaging and the entire logistics chain. “We implemented the whole thing in accordance with ISO 14064 with our partner, FirstClimate.” The second step is to ensure the removal of the same quantity of carbon dioxide as is produced. “To do this, we are investing in a reforestation project in Borneo according to a precise plan.” Economic advantages The new M4000 milling cutter family also provides customers with tangible economic advantages. The coatings developed by Walter and the high positive geometries of the tools offer excellent performance data with low power requirements. This also helps users to achieve energy neutrality. Each system indexable insert has four cutting edges and can be used universally for most common milling operations in nearly all materials. This reduces procurement and
18
INDUSTRIAL BUSINESS MART
What has motivated Walter to become so active in issues of environmental protection and resource conservation? We were motivated by three main factors. The first is that using resources sparingly enables usto save money. The second is that sustainable management is essential for any company that intends to compete on the market in the long term. And the third is that, as a company in an energy-intensive sector, we bear a particularly heavy responsibility for our environment, and we want to take that into account.
What are the most important advantages of “green tools” for your customers? Future viability: In just a few years, it will be standard practice for companies to be able to prove the carbon footprint of their products. Performance: Green
tools such as our new M4000 line contain a great many innovations and represent the pinnacle of development in terms of their key performance indicators as well. These two factors together result in competitiveness.
What do you regard as having the greatest untapped potential for using resources more carefully? In the medium term, we consider recycling to have the greatest potential. We still have a long way to go before we can reach our goal of purchasing the same amount of recycled material as the amount of raw material that we process. In the long term, the challenge will be to use as much green energy as possible. It is well-known that sources of renewable energy are very volatile. The extent to which we will be able to quickly and comprehensively benefit from this potential in actual operation depends heavily on how effectively the power grids, environmentally friendly power sources and storage media are developed.
inventory costs and increases the cost efficiency of the tools.
on further measures to push forward with the internal energy transition at Walter.
The M4000 line was launched in January 2015. Walter is offering additional inserts and tool bodies from the M4000 milling cutter family from 1st September 2015 onwards. More products and product lines with the “Walter Green” seal are expected to follow.
For instance, work has begun on planning a highly effective combined heat and power system and a heat recovery system in conjunction with the new structure under development at the company site in Tübingen. “We will use the electricity and thermal energy generated by these systems ourselves.”
In addition, Schüßler is constantly working
October 2016
October 2016
INDUSTRIAL BUSINESS MART
19
PRODUCTS / TECHNICAL
High-Performance, Highly Rigid ROBA®-Guidestop Profiled Rail Brakes Pneumatic safety brakes with the same power as hydraulics
With the new pneumatic ROBA®-guidestop, mayr® power transmission provides an innovative braking concept which fulfils the high safety requirements and achieves high performance density without the use of hydraulics. Image: mayr® power transmission
A
20
compact safety brake in a small construction space with high forces and all this without using hydraulics – mayr® power transmission has developed a new, high-performance, pneumaticallyreleased version of the ROBA®-guidestop profiled rail brake. With this innovative braking concept, which fulfils the everincreasing safety requirements and achieves a high performance density without the use of hydraulics, the company sets new standards.
version, which provides users with new
high holding forces as the hydraulic design
possibilities thanks to the high holding
of the brake.
mayr® power transmission is extending the tried-and-tested ROBA®-guidestop series with a pneumatically-released
INDUSTRIAL BUSINESS MART
forces. For machines, in which a hydraulic system is already available, users can still use the hydraulically-released ROBA®guidestop safety brakes. However, in
Innovative concept with pressure booster The pneumatic ROBA®-guidestop is opened with compressed air at 20 to 30
applications where a hydraulic system
bar. In order to achieve the necessary
would have to be installed first in order
operating pressure, a compact pressure
to operate a brake with high holding
booster is used in combination with the
forces or in which several brakes would be
brake, which mechanically increases the
necessary to achieve the required forces,
system pressure from 4 to 6 bar as is usual
the pneumatically-released ROBA®-
in pneumatic networks, without the use of
guidestop safety brake is now used. It
external energy. This innovative concept
clamps profiled rails equally accurately and
enables a selective pressure increase
backlash-free while achieving the same
directly prior to the brake, i.e.
October 2016
October 2016
INDUSTRIAL BUSINESS MART
21
In order to achieve the necessary operating pressure, a compact pressure booster is used in combination with the brake, which increases the pressure existing in the system purely mechanically and without external energy. This innovative concept enables a selective pressure increase directly prior to the individual brake. Image: mayr® power transmission
22
directly in the system where the higher pressure is required – as a result, short high-pressure lines suffice. The pneumatic ROBA®-guidestop safety brake is available in five construction sizes – each size in both a standard design and in a compact, short design – covering a range of holding forces from 1 to 34 kN. The brake is designed for the different rail construction sizes of conventional linear guidance manufacturers.
elements between the motor and the moving mass, such as spindles, spindle nuts, shaft couplings or gearboxes, therefore have no influence on the safety – as opposed to the concepts using motor brakes, where all drive elements transmit the braking torque to the carriage. Systems using ROBA®-guidestop safety brakes therefore enable a significantly higher rigidity than solutions featuring rotary brakes integrated into servomotors.
Safety thanks to direct clamping
Reliable and precise
Just like the hydraulic brake design, the pneumatic ROBA®-guidestop safety brake acts with extremely high rigidity directly applied to the linear guidance. This means that it is mounted directly on the masses which should be held. This provides a decisive advantage, especially concerning gravity-loaded axes, where the hazard risk for people should be reduced: Drive
The backlash-free clamping of the ROBA®-guidestop directly onto the profile rail provides yet further advantages: The additional rigidity of the NC axis increases process accuracy, improves machining performance and can provide further technological advantages for heavy machining, for example. The machining produces less vibrations and
INDUSTRIAL BUSINESS MART
therefore the surface quality of the work piece is positively influenced. In case of a stationary axis, for example during machining, the brake can absorb the load. As a result, it is possible to switch off the drive motor in this phase and remove it from the controls. This eliminates control movements and is therefore gentle on the ball screw spindle. The closed brake absorbs the axial forces. The service life and maintenance intervals of the drive components are extended. Like all safety brakes by mayr® power transmission, the brakes of the ROBA®guidestop series operate according to a fail-safe principle, i.e. they are closed in a de-energised condition. They reliably guarantee operational and functional safety in machines and systems around the globe. For more details visit www.mayr.com
October 2016
October 2016
INDUSTRIAL BUSINESS MART
23
innovation
Predictive Engineering Analytics Simcenter, a simulation software from Siemen’s combines simulation and physical testing with intelligent reporting and data analytics to help produce digital twins that more accurately predict product performance throughout all stages of the product development process.
P
redictive engineering analytics is the application of multidisciplinary engineering simulation and test with
intelligent reporting and data analytics, to develop digital twins that can predict the real world behavior of products throughout the product lifecycle. Predictive engineering analytics includes both the tactics and tools that manufacturers can leverage to expand traditional design verification and validation into a predictive role in support of systems-driven product development. The ultimate goal of implementing a predictive engineering analytics strategy is to deliver innovation for complex products faster and with greater confidence. Predictive engineering analytics represents the next evolution of product development processes which currently rely on independent workflows in computer-aided engineering (CAE) and testing. Predictive engineering analytics addresses the complex nature of today’s products and product development
useful life, and accommodate product degradation.
environments, which combine mechanical functions with
Benefits of Predictive Engineering Analytics
electronics, software and controls. It integrates different technologies including 1D simulation, 3D simulation covering computational solid mechanics (CSM) and finite element analysis (FEA), computational fluid dynamics (CFD), and multibody dynamics, controls, physical testing, visualization, multidisciplinary design exploration, and data analytics in a managed context to support the engineering and development
24
these products to adapt to changing usage conditions, extend their
Implementing a predictive engineering analytics strategy helps you: • Deliver multi-fidelity models that are as close to reality as possible for each stage of development • Choose the best concepts and system architectures to carry forward in development
of complex systems.
• Implement faster simulation processes needed to drive design
In a predictive engineering analytics approach, the availability
• Keep models in-sync with the actual product in use so the
of sensor-based data combined with high-fidelity, physics-based
simulations are more realistic
simulations allows manufacturers to build and maintain digital
• Leverage simulation and test approaches in concert to gain
twins of the product and to keep them in-sync with the product
greater confidence in meeting requirements
in use. That is of crucial importance to making more useful and
• Use data analytics combined with physics-based simulations to
realistic predictions of product performance that will enable
gain insights and drive innovation
INDUSTRIAL BUSINESS MART
• Effectively balance multi-disciplinary requirements
October 2016
Simcenter helps drive your product designs faster than before, resulting in better, less expensive and more reliable products.
October 2016
INDUSTRIAL BUSINESS MART
25
Predictive Engineering Analytics Software Simcenteruniquely combines 1D system simulation, 3D CAE, and test with multi-disciplinary design exploration to help you predict performance across all critical attributes earlier and throughout the entire product lifecycle. By combining physics-based simulations with insights gained from data analytics, Simcenter helps you look at information more holistically to engineer the best performance and deliver innovations with greater confidence. The Simcenter portfolio includes the following applications to help you achieve predictive engineering analytics: HEEDSÂŽ MDO automates the simulation process and explores the design space. With revolutionary search strategies available only in HEEDS, you can uncover new design concepts that improve products and significantly reduce development costs.
structural and thermal analyses, and composites. LMS Imagine.Lab is the ideal solution to drive virtual, intelligent system design all along the design cycle. It offers all the
3D CAE with connections to design, 1D simulation, test, and data management. Simcenter 3D speeds the simulation process by combining best-in-class geometry editing, associative simulation modeling and multi-discipline solutions embedded with industry expertise. Fast and accurate solvers power structural, acoustics, flow, thermal, motion, and composites analyses, as well as optimization and multi-physics simulation.
Simcenter provides a platform for multi-domain dynamic system behavior analysis and controls validation.
necessary tools to create, manage, and use models and data, answering various model-based system engineering needs. It effectively deals with the specific challenges associated with mechatronic system simulation. LMS Test.Lab is a complete, integrated solution for test-based engineering, combining high-speed multi-channel data acquisition with a full suite of integrated analysis tools, including many modal parameter estimation methodologies. Designed to make testing more efficient, LMS Test.Lab increases productivity and delivers more reliable results.
High-fidelity simulation technologies with an intuitive, integrated user interface.
STAR-CCM+ is a stand-alone simulation solution for computational fluid dynamics (CFD), computational solid mechanics (CSM), heat transfer, particle dynamics, reacting flow, electrochemistry, electromagnetics, acoustics and rheology. Teamcenter Simulation Process
With Simcenter, you can accurately predict performance of your 3D geometry-based designs.
LMS Virtual.Lab is an integrated suite of finite element and multi-body modeling software which simulates real-life performance of mechatronic systems. Engineers are enabled to quickly build complex models and optimize for structural integrity, acoustics, vibration, system dynamics, and durability, as well as the correlation between simulation and test models. LMS SamtechSamcef is a finite element solver suite to simulate critical performance engineering attributes for mechanical systems. It is tailored to cover precise requirements in areas such as wind turbine development, rotor dynamics,
26
INDUSTRIAL BUSINESS MART
control your simulation data and processes in the context of an overall product lifecycle management system.
Increase test efficiency, productivity, maintain the utmost quality.
NX Nastran is a finite element solver that analyzes stress, vibration, structural failure/ durability, heat transfer, noise/acoustics and flutter/aeroelasticity. Simcenter 3D delivers a unified, scalable, open and extensible environment for
Management solution is a module of Teamcenter that is specifically designed to help organisations get control of their simulation data and processes in the context of an overall product lifecycle management (PLM) system. Source: www.plm.automation.siemens.com
October 2016
WWW.WELD-INDIA.COM
WWW.WELD-INDIA.COM
N
th
11
O ITI
ED
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
October 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
INDUSTRIAL BUSINESS MART
27
Cover Story
EYES I N
Once limited to military use, drones are making big impact in the civil and commercial sectors. With unprecedented flexibility they offer reach, time and cost saving etc. Though government regulations are still in place for security reasons, drone technology holds benefit galore for many sectors of economy. MART Correspondent Arnab Mondal explains indepth the market evolution of drones. Featuring case studies from Vel Tech University (VTU), MaherSoft Technologies Pvt. Ltd, Skylark & Aptonomy. 28
INDUSTRIAL BUSINESS MART
October 2016
THE SKY
October 2016
INDUSTRIAL BUSINESS MART
29
Apart from spraying pesticides, fertilizers and water on crops, drones can also be used for monitoring cattle
D
rones, also known as unmanned aerial vehicles (UAV), are pilotless
and non-crewed aircraft that are capable of flight either by remote control or through the use of on-board computers.
Amazon Prime Air is a revolutionary step toward use of drone in delivery service
(sometimes more than 24 hours) and
The major factors driving this market
with ability to carry precision guided
include the increasing demand for
munitions.
drones for commercial applications and
Some of the most common applications of drones are enumerated below:
The invention of drone is the result of
drones. This growth is mainly attributed to the growing demand for drones and drone-generated data in commercial
extensive military research in the 20th
1. Geographical Mapping
century that precipitated many widely
2. Agricultural Survey
used technological innovations. But
3. Disaster Management
what started as a mere military utility has
4. Search & Rescue
morphed into the next big thing for civil
5. Flood Management
and commercial sectors. These unmanned
6. Border Patrol
aerial vehicles are increasingly taking off
7. Anti -Terror Operations
in commercial and civilian sectors such as
8. Maritime Surveillance
media, photography, cinema, agriculture,
surveying, and inspection, among others.
9. Critical Infrastructure Monitoring
energy, delivery services and even
The rules and regulations are being
10. Intelligence Gathering
modified for the European countries
insurance sector. Global Scenario Segmentation of the Drone Market In terms of market segmentations, the drone or the UAV market can be divided into four categories. They are: 1. Micro UAVs - weigh up to 1Kg and have endurance time of 1 hour 2. Small UAVs – weigh up to 15 Kg and
30
rapid technological advancements in
The global market for commercial applications of drone technology, currently estimated at about $2 billion, will balloon to as much as $127 billion by 2020. A growing ecosystem of drone software and hardware vendors is already catering to a long list of clients in agriculture, land
applications. Also, in some countries, the rules for operating drones in the national airspace have been relaxed. For example, in the U.S., the release of the Part 107 rule by FAA for drones below 55lb has paved the way for multiple opportunities in commercial sectors such as mapping,
too so that they can reap the benefits of drones for driving the growth of the economy. Sensors are being used as payloads in UAVs for many commercial and military applications. CBRN and laser sensors in military drones are used for marking targets, guiding munitions, missile defense, electro-optical countermeasures,
have endurance of a minimum of 2 hours
management, energy, and construction.
and in inertial navigation systems,
3. Medium UAVs – have ability to fly at
Many of the vendors are small private
among others. The sensors deployed in
around 4000 ft of altitude for 5-10 hours
companies and startups - although large
commercial UAVs are used for precision
and with payloads varying from 5- 100 Kg
defense-focused companies and industrial
agriculture, pest detection, forestry,
4. Large UAVs –have unique ability to
conglomerates are beginning to invest in
mammal species tracking search
fly at around 50,000 ft for several hours
drone technology, too.
and rescue, target tracking, volcanic
INDUSTRIAL BUSINESS MART
October 2016
monitoring, pollution monitoring, and micro-climates, among others. The key players in the UAV drones market include Lockheed Martin Corporation (U.S.), Northrop Grumman Corporation (U.S.), Aerovironment, Inc. (U.S.), Elbit systems Ltd. (Israel), Israel Aerospace Industries Ltd. (Israel), BAE Systems Plc (U.K.), Thales SA (France), Leonardo SpA (Italy), and DJI (China), among others. India Case Taking cue from several countries which are looking to regulate the import and use of drones within their borders, the Indian government has decided to revise the Indian Customs Declaration Form to include drones in the list of prohibited and dutiable goods making it compulsory for travelers entering India to declare and pay duty for them from 1 April 2016. Although there is no ban on the import of drones into India, there are restrictions on their use. It is currently illegal for civilians to use drones in India due to security, privacy and safety concerns. Even though there are still major restrictions on the civilian use of drones and justifiably so because of possibility of misuse, the Indian market for drones is now a promising one and there is immense opportunity for Indian companies. Given India’s vast repository of electronic and software companies, it is not difficult for it to become a major hub for manufacturing of drones. While India may still rely on global companies for purchase of large UAVs and Combat drones, there is considerable potential for innovation in the market for small and mini UAVs where Indian companies can play a critical role in both making of drones as well as in data analytics of the data collected by drones. There is also a strong potential of Indian companies availing the opportunities of the ‘Make in India’ programme and setting up joint ventures in India for making large drones.
October 2016
Apart from extensive use in the defence sector, drones of the future might have applications in many commercial and civil areas. Some of the prominent are the following
can expedite their work in significant ways,
Agriculture
UAVs are discrete and can monitor animal
Many in the UAV industry cite agriculture as an enormous area of opportunity for drone technology. Not only can drones save farmers money by helping them identify failing plants early and take inventory of crops, but the machines can also be used to map and study the farmland and its irrigation systems.
This type of monitoring offers important
In addition, drones can be equipped to spray pesticides, fertilizers or water on crops. And for farms with livestock, drones can also be used to monitor the animals and quickly gather and track useful data about animal health and population. Architecture and Construction Architectural firms and construction contractors are also benefitting from the use of drones. Architects can use images and footage of a property to create 3D renderings of the structures they aim to build. By cheaply and quickly creating aerial shots architects can create realworld concepts of their projects. This ability is indispensable to creating accurate designs and understanding how they fit within properties. Delivery While still restricted to a pretty low maximum load-bearing weight (55 pounds including the drone itself), delivery-bydrone is yet another promising application. This is especially true for areas where traveling by road is difficult or treacherous. Engineering Engineering firms are also utilising drones on in-depth projects like oil pipelines, transmission cables and maintenance inspections. When they look at performing surveying work, use of drones and sensors
increasing efficiency. Environmental Monitoring and Conservation
populations without disturbing them. insights into conservation efforts, migration tracking, habitat management and flood assessment, which is particularly useful on the coasts. Drones also provide data on the health of vegetative and animal populations, and offers a unique ability to identify species in hard to reach places. Media Local journalists and small-scale media outlets can easily capture aerial footage for news coverage using drones. In addition, drones can get into tighter areas, lower to the ground than a news helicopter could ever hope to travel. Even simple tasks, like recording a face-toface interview, can easily be made more dynamic and engaging with a cameraequipped drone hovering nearby. Wireless Internet Access Another application for drones, one that received much media attention when Facebook purchased solar-drone company Titan Aerospace, is the use of UAVs for internet connectivity. Facebook CEO Mark Zuckerberg’s proposed plan is to bring internet access to the developing world with the Aquila drone, which just completed a successful test flight. Google and Amazon are examples of other large corporations that have also invested in the drone industry. Undoubtedly, all the sectors discussed constitute a huge portion of the Indian economy and have huge growth potential. And it is only a matter of time before drones enter Indian markets in a vibrant way catering a number of civil and commercial sectors.
INDUSTRIAL BUSINESS MART
31
Cover Story/ CASE STUDY
Drones in Corridor Mapping Drones are the current rage with discussions everywhere. Skylark Drones is one startup that is exploring different possibilities that was started earlier this year by Mughilan Thiru Ramaswamy and Mrinal Pai. Featuring Skylark Drones Corridor Mapping Drone case study.
T
he road network in India is scheduled
In the face of increasing demands,
weight of battery and camera.
to undergo massive changes with the
shortening timelines and the need for
II. The area to be covered
expansion of roads happening at about
increased efficiency, we have conducted a
III. The volume of data necessary for
13km per day. The value of roads and
case study to show that Unmanned Aerial
processing
bridges infrastructure in India is projected
Vehicle (UAV) based Photogrammetry
IV. The possible natural conditions
to grow at a Compound Annual Growth
can achieve results nearly identical to
prevailing at the time.
Rate (CAGR) of 17.4 per cent over FY12–17.
traditional method of Manual Survey,
In addition to this the Government aims
while simultaneously reducing cost and
Taking into account the above conditions
to provide additional incentives for timely
saving time.
and factors the altitude off light was set
completion of projects.
at 130m above ground level to provide an expected Ground Sampling Distance (GSD)
Despite the push from both financial
gathering data and then using it to
and official sources the road
generate an orthomosaic map and a
construction industry still faces delays
Digital Surface Model (DSM)1 and Ground
To mark Ground Control Points (GCP) on
due to ineffective planning that has
Control Points (GCP)2 were used as points
the ground DGPS was used. Totally 8 GCPs
repercussions further down the value
of reference to assess the accuracy of the
were used. Before active data acquisition
chain. Some of which are
UAV based map.
was conducted the following procedure
1. Delay in resource allocation and
The processes involved can be classified as
procurement. 2. Clearance delays for land acquisition. 3. Decrease in levels of accuracy and
1. On Field Operations 2. Off Field Operations
quality of mapping practices.
On Field Operations
Hence it can be seen that accelerating
The Skylark Osprey UAV was configured
the planning process in any possible
taking into account the following factors
way by using technology to replace time
before deployment
consuming manual labour is an attractive part of the solution.
32
The case study was conducted by
INDUSTRIAL BUSINESS MART
I. The payload characteristics such as
3 of 4.2cm.
was followed: 1. Preliminary visual survey of the site 2. Inspection of potentially harmful features 3. Assessment of prevailing weather conditions 4. Implementing safety protocol The data acquisition system we used on this project is an Osprey UAV with a high resolution RGB camera flying at an altitude
October 2016
of 130m (Above Ground Level) AGL. Off Field Operations The operations done of field are primarily
in consistency or irregular results during
surface model. To generate Digital Terrain
processing. Hence such data sets are first
Model field data of a few sample trees and
filtered from the total volume of data.
buildings are used to train the algorithm and classify the existing point cloud.
1. Data cleaning
Usually data-sets which do not under-go
2. Data processing
this process lead to increase in processing
Results
time by about 30 per cent or higher.
The two primary outputs produced are
This process takes about 30 minutes to
1. Orthomosaic
produce a data set to work with.
2. Digital Surface Model (DSM)
such as:
Data Processing
These outputs are further processed to
1. The Geo Referenced location in terms of
The data processing starts by identifying
Latitude and Longitude.
key points in the Geo tagged UAV images.
2. Visual imagery sets that help determine
These key points are then identified
the Z component (along with the X and
on multiple over lapping images and
Y component) of the point which is then
triangulated to generate a point cloud.
Data Cleaning The data obtained from the UAVs are sets of Meta data comprising of components
produce digital terrain models, contours, object identification, invert level of drains, height of structures etc. The Error is compared with standard DGPS set-upon the ground .
ortho-rectified.
At this stage GCP from DGPS or RTKGPS
Observation
are imported into the algorithm. This
1. Average error over the 8 points is found
There are data sets which are acquired
helps in increasing the overall absolute
to within 3 cm in the x-y direction and 4.5
during flight turns and other data sets
accuracy of the output. The point cloud is
cm in the z direction
that comprise of visual imagery that have
further densified, meshed and rendered
2. The errors are non cumulative which
low clarity, these may cause a collation
to produce orthomosaics and digital
means that every point’s error is
October 2016
INDUSTRIAL BUSINESS MART
33
independent of every other point in the
background gives the users the real world
highlight the advantages of a UAV enabled
data set.
picture of the corridor and the structures
corridor mapping survey
Drone vs Classical Surveying The classical surveying using Total station for topographic survey of the corridor of 580 meters took about 4hrs. Total number of points that were surveyed were about 600. Using Skylark Osprey UAV we took a initial setup time of 15 mins and a flight time of 10 mins, a total of 25 mins of operation. The total number of points that were surveyed were about 200,000. The contour map generated using CAD points have lesser accuracy as it’s an interpolation between 600 points. The advantage of using Drone outputs for Contour generation is that the number of points taken for generation is about 200,000. Also the authentic true color map of 4.24cm resolution for the
34
INDUSTRIAL BUSINESS MART
around it.
The advantages can be summarized as
The accuracy of outputs using drone based
follows:
survey is accurate at intersections and
1. UAV based survey has a turnaround time
curves. In normal surveying practices more
of about 1/8thof that of manual survey.
number of points are taken hence more
2. Survey grade accuracy levels with little
time is required.
or no human induced errors 3. About 80 times more data is collected to
This can be visualized that there is in
produce actionable data and models
accuracy at the curves and at the road edges as well. The structures in corridor
Please note that although corridor
that can be mapped are drain, manholes,
mapping in this case study has been
electric poles, electric lines and buildings. Accurate canopy cover width and height of
conducted for roads, the same can be applied for surveying of above the ground
trees in the corridor can be mapped. The
pipelines and power lines.
height of building and depth of the drains
The advantages for UAV corridor mapping
can be found out from the drone outputs. Conclusion The case study was done to primarily
are numerous such that the whole of Indian road and highway system could possibly be digitized and analyzed using 3000 drone hours.
October 2016
CNC Machine Tools
ITL Industries Ltd.
SEC
Hurry ! Book Your Space NOW
SUNITA ENGINEERING CORPORATION
[ Diamond Participants ]
[ Gold Participants ]
CNC Machine Tools
[ Silver Participants ]
October 2016
[ Jointly Organised By ]
INDUSTRIAL BUSINESS MART
35
Cover Story/ LET’S TALK
The Journey from
SAE to Skylark In Conversation with Mughilan Thiru Ramaswamy, Co-Founder, Skylark
What was the motivation behind starting
them. That’s when, we started Skylark
Could you share some your major success
Skylark Drones? What role did NASA
Drones to build drone based applications
projects so far with us?
Systems Award 2013 play into this dream?
for enterprises.
My Cofounder and I were part of
What are the application areas where
of Roadway projects, 250+ Kilometers
a collegiate club participating in
your drones are utilized currently? What,
of Canal mapping projects, and 50+
according to you, are the new application
Kilometers of Railway projects so far.
areas where drones can have a big
We are currently working with Smart
International competitions right from our college years. Every year, we used to recruit our juniors through a formal
We have done 300+ Kilometers mapping
impact?
Villages and cities for them to using drone
improvements in our design and
We are using our drones majorly for
planning.
manufacturing technique to build a better
infrastructure, mining and utilities. We
drone to participate in the competition
build drone based GIS applications for
recruitment process. We made significant
with an intention to win it. Finally,We won the NASA systems award
these sectors. I believe drones – will have a great impact on industries where reach,
technology for better urban and rural
We understand DroneVertising is a service area which Skylark offers, specifically for the advertising industry. Could you throw some light on that?
in 2013, which gave us confidence about
productivity and security will be a great
our ability in building these machines.
challenge. Where real-time geographic
We had previously offered Drone-vertising
However, when we looked out in our
data is required in the shortest possible
as a specific service targeting e-commerce
society, we figured that although drones
time – I believe UAVs will fill
firms and other firms – where we can
have a lot of applications no-one was using
that space well.
launch their banners using a drone. We
MrinalPai and Mughilan TR, founders of the Bengaluru-based drone manufacturers and service providers Skylark Drones, have turned their passion for flying drones into a full-time business. Pai and Mughilan’s journey towards Skylark Drones began in 2008, when they started collaborating on the technology as students. Their big breakthrough came when they won the SAE aero design competition, organised by the American space agency NASA in 2013. The next year, they founded Skylark, which now has five full-time staff and eight interns. Pai graduated from R V College of Engineering (RVCE) in 2014 while Mughilan finished his Masters in Aerospace Systems from Purdue University in 2014 after graduating in Mechanical Engineering from RVCE.
36
INDUSTRIAL BUSINESS MART
October 2016
currently stopped the service line, after some initial success.
through effective use of
entrepreneurs – All problems
How do you plan to create
drones.
are solvable. No-one has all
a drone ecosystem in India?
the answers in the beginning,
What is your growth plan for
No-one is perfect. I think trying
your company?
Awareness for advantages
We understand the demand
of drones vis-à-vis traditional
for drones in India is still not
mapping and surveying
mature due various reasons,
methods is still less. Could
Government regulation on
you briefly highlight
UAV for security concerns
those advantages, citing
being one of them. How do
comparative results?
you see the markets evolving
What is total workforce of
for drones in future?
your company as of now?
up-to 20 kilometers per hour
When there is value, the
We are about 20 passionate
the benefits of using drone in
of mapping, creating a huge
market will definitely open up
engineers in the company
general.
productivity increase for the
eventually. There are definitely
from various engineering
industry. Our drone data is
some challenges regarding
backgrounds – Mechanical,
We want to grow as a global
authentic and is 3 centimeters
regulations surrounding
Electronics, Civil and Computer
company with presence in
accurate! Manual survey
drones. I believe within a year
Science – with a common
various developing nations to
techniques take about 4 days
or two – this industry will really
vision of bringing drones into
help them leap frog into this
to do the same amount of
start exploding.
our society.
new technology.
Our fixed wing drones can do
work with lot of interpolated and inaccurate data!
As early movers in this space,
Government’s development
conducive drone ecosystem
layout for smart cities,
for better growth for all the
railways, roads and highways
stake-holders invested in the
are very much in tune with
market.
to learn from mistakes and taking one step at a time with
We want to build a “Drones
perseverance is the key to
for Good”ecosystem in the
success!
near future, where will have a lot of senior business leaders endorsing the use of drones in their industries and promoting
we are trying to create
your service areas. How drones can play a significant
Skylark Drones is one of
role in these development
the successful tech startups
projects in terms of
in the country. How much
cost effectiveness, time
support did you get from the
consumption and hazards?
government polices and in
Using drones can lead to 10x save in time, 100x more authentic data, for a similar price paid for a manual
terms of mentorship? What are your suggestions for budding entrepreneurs in the country?
survey. The best part is the
We received limited support
government can have a digital
from the Government. The
record for all their projects
policies for drones have not
right from the start of the
been formed pegging the
project to the end.
industry back. We have some
Take a moment, and imagine all our land records, all our infrastructure projects accessible to all the relevant
great mentors in our team – who help us take the right business decisions at the right time.
stakeholders at a click of a
Don’t Quit, is the only
button. This is what is possible
advise I wish to give young
October 2016
INDUSTRIAL BUSINESS MART
37
cover story/case study
UAVs from Budding Engineers In the realm of innovations we have 3 revolutionary creations with desirable performance that have been acknowledged and rewarded globally. Following are the projects done by the students from institutions like, IIT, Vel Tech University, University of Victoria and Tamkang University.
P
38
ower line inspection and maintenance in overhead high
robot. Generally the structures of the
Power Line Inspecting Robot (LPLIR)
mechanisms in the robot developed so
rolls over the transmission power line by
voltage lines when power is on is difficult
far are intricate and they should avoid
means of rubber coated rollers. Several
because humans cannot enter the vicinity
obstacles which complicate the system.
features such as high definition and
of high voltage. Now-a-days online
In order to overcome these difficulties,
thermal imaging cameras to transmit the
inspection of power transmission line
a Hexa rotor equipped with camera
images online and also identifying the
is carried out with the help of a mobile
is proposed in this project. The Live
hot spots on the transmission lines are
INDUSTRIAL BUSINESS MART
October 2016
incorporated into the system. The pan and
Our model received great appreciation
tilt camera are mounted on the prototype
from highly reputed jury’s panel. The
and videos can be transmitted through
uniqueness of the system is, A never
wireless to the ground control station.
before concept of combining Electrosmog
The system is completely insulated to
Meter & Multi Rotor UAV system for real
avoid the electromagnetic interference.
time measurement of Magnetic Field
The proposed system can reach different
Strength, Electric Field Strength, Radiation
altitude levels, avoid obstacles and transmit close and clear view of conductor/ earth wire accessories. 2. Telecom tower Struture Inspection and
Power Density and Radiation pattern with optical analysis of verticality of tower structure. The sole motto of this initiative is to provide a safety monitoring solution
Radiation Measurement
and to safeguard human life.
Won prestigeous Aegis Graham Bell Award
3. Multi Faceted Unmanned System For
for the category of “ Best Innovative Businees Model 2014” organized by Aegis Business School, Deloitte, COAI and TCOE competing with world class telecom sectors. Abstract: Aegis Graham Bell Award was awarded for our innovative project model comprising Unmanned Aerial Vehicle for the inspection of telecom tower. More than 50 leading telecom companies and few technical universities competed for various categories of award. The award ceremony was held on 8th November in Delhi to honor best innovations in the field
Disaster Management Won Internationally 4th position in best innovation with student encouragement of 500 US Dollars organized by CANUS and Lockheed Martin in IISC Banglore under the title “Small Sattellite Transmission for
Indo – Taiwan Research Collaboration Vel Tech University collaborated with Tamkang University, Taiwan under the aegis of Global Innovation and Technology Alliance supported by Designation of Science and Technology to develop Micro Aerial Vehicles. We have manufactured Best-in-class mechanisms of 20 cm wing span flapping Micro Aerial Vehicle with desirable performance features of extra-large flapping stroke and minimal vibration. Our research focused on increasing flapping angle, minimizing size and also to reduce the weight of mechanism. A novel arduino controlled Ornithopter system is developed to facilitate formation control of Ornithopter with image processing framework
Disaster Management (SSTDM)”
Indo – Canada Research Collaboration
Abstract:
Vel Tech University is collaborating
The project describes a method of disaster management using unmanned systems. The unmanned system consists of a hovercraft embedded with a VTOLUAV and an underwater vehicle. The hovercraft acts as the ground control station (GCS). This
with University of Victoria, Canada in a research project funded by Designation of Science and Technology and IC – IMPACTS to inspect railway bridges and heritage structures. The proposed scheme comprises of UAV system integrated with smart sensors and wireless
of telecom sector.
receives the signal from the satellite and
The award function was organized by
disaster locations. When the sensor data
Aegis School of Business and Telecom &
first of its kind in India. The application
exceeds a particular threshold and a
Convergence India, supported by COAI
of UAV for inspection activities would
disaster signature is obtained, the sensors
(Cellular Operators Association of India)
drastically reduce the time requirement
send a request to the hovercraft GCS.
and any inaccessible places can be easily
and Telecom Centers of Excellence (TCOE)
local sensors deployed at the presumed
network systems are exceptionally superior over traditional methods and
covered without supporting structures.
India, University as Powered Partner and
Immediately, the GCS launches the quad
Deloitte. VIMAN INITIATIVE TEAM from
copter to the disaster location using GPS
Vel Tecch University have demonstrated
data. The hovercraft also starts moving
a Multi Rotor UAV system which can
towards that location. A camera and
seamlessly determine the radiation
thermal imaging equipment are mounted
level and radiation pattern of a telecom
on the quad for aerial photography. The
This article is contributed by UAV team
tower at desired altitude with analysis
GCS transmits all the data obtained to
of Vel Tech University headed by Dr. E
of structural soundness for the award
the available satellite, National Disaster
Balasubramaniam. No text matter or images
category of “Best Innovative Business
Rescue Force (NDRF) and National Disaster
should be used without consent from the
Model”.
Management (NDM).
University.
October 2016
The integration of real time image processing equipment and development of appropriate processing algorithms are highlighted features of this project.
INDUSTRIAL BUSINESS MART
39
COVER STORY/ case study
3D Printer to Manufacture Drone Spare Parts
Usage of 3D printing to manufacture spare parts of drone has come along as a boon to DIY enthusiast. MaherSoft collaborated with Drona Aviations and developed 3d printed motor holders and drone accessories. We present to you a glimpse of how they did it.
S
o you’re a big fan of drones. But have you ever thought about how 3D printing can be used to manufacture drone spare parts? It’s not as crazy an idea as it might sound.
40
Here is how we did it…
of each material.
What’s the Best Material?
Here’s a quick summary:
MaherSoft offers 3D Printing services to many engineering and design firms. Our clients approach us not only for prototyping of parts but also to produce end use finished products.
Choosing the right material based on the application was really important, because every gram of weight would cost flight time. The heavier the drone, the faster battery will drain. Again, it would be inappropriate to try to navigate properly with an unstable construction made from weak parts.
One such firm is India’s premier drone manufacturer Drona Aviation. They develop and sell DIY drone kits and provide weekly workshops to students and DIY enthusiasts. MaherSoft partnered with Drona Aviation to develop the 3D printed motor holders and drone accessories which can be used in their drone models not only as a prototype but as a finished product for their production models.
With the progression of the 3D printing industry many “high-grade” 3D printing filaments are now available in the market. The extra-strong and durable alternatives to the widely used PLA and ABS will add extra cash on some enhanced filament spools with carbon fiber. So, what is the right material which is durable, easy to print and cost effective? To simplify this process we jotted down the pros and cons
1. PLA - The wide range of available colours and translucencies and glossy feel often attract those who print for display or small household uses. Many appreciate the plant based origins and prefer the semi-sweet smell over ABS. When properly cooled, PLA seems to have higher maximum printing speeds, lower layer heights, and sharper printed corners. Combining this with low warping on parts makes it a popular plastic for home printers, hobbyists, and schools.
INDUSTRIAL BUSINESS MART
2. ABS - Strength, flexibility, machinability, and higher temperature resistance make it often a preferred plastic for engineers, and professional applications. The hot plastic smell deters some as does the plastics petroleum based origin. It’s also cheap
October 2016
and widely available. However, you need a heated print bed for optimal results, and there are the dreaded toxic fumes to consider.
– it’s entirely possible to 3D print drone parts like the motor holders, landing gear, and propellers. And these are usually the parts that break easily.
which suited our production requirement against part quality.
3. PLA / ABS - Exotic filaments with fiberglass or carbon fiber are stable and rigid, but expensive. Also, they’re too brittle for crashes, and not very lightweight despite the fiber.
We started our iteration with motor holders which fit on the main body and the motor fits right into the centre. We had to develop 6 prototypes of the motor holder before it was approved for production on our Indie Desktop 3D Printer since motor holder has to assemble seamlessly to the main body along With the motor inside the holder.
There are some key factors which must be taken into account while designing for 3D printing.
4. Nylon - Has excellent strength and temperature resistance, and is lightweight, but it’s not easy to print. Nylon is expensive as compared to other 3D printing filaments. 5. PET - Is stable and shockproof, but it is relatively expensive, and quite heavy. Conclusion: Printing in PLA is easy and cost effective, but the part was breaking when the motor was pushed into the holder. On the other hand, ABS shows stable engineering properties, as it is more flexible than PLA and similarly priced. We therefore chose ABS to print production ready parts for Drona Aviation. What Drone Parts Can You 3D Print? While it’s not yet possible to fabricate electrical components like motors, sensors or even electronics – but watch this space
October 2016
Role of Printing Parameters in 3D Printers You must be wondering, why does it take so many iterations to freeze a design for the production? The part strength and accuracy in 3D printing depends on infill percentage, layer thickness, shell thickness, speed, temperature, flow rate etc. Using our experience, we varied parameters like infill percentage in range of 40% to 100% to keep the part weight within the limit, the flow rate had to be varied in between 90-100% and shell thickness from 0.8 to 1.2 mm to keep the dimensional tolerances in check. The printing speed plays a vital role for smaller parts when produced in large quantity. Slow speeds give you better part finish but affect the production rate hence we 3D printed at an optimal speed of 40 mm/s,
Designing for 3D Printing
We had to be sure there were no overhangs to avoid any post processing hence the parts were designed with an angle 45 degree to achieve support free parts. Support free design lead to a reduction in production time eventually reducing the cost per piece of the product. Cost Reduction Cost of any product is one of the driving forces for any product to be sustainable. Hence, MaherSoft worked with Drona Aviation to not only improve the structural integrity of the 3D printed part, but also reduce its cost by using the above design techniques and varying 3D printing parameters. The author Karan Sanga\ni is the Chief Sales Officer at the MaherSoft which is a leading 3D printing company. A mechanical engineer from MIT Pune, Mr. Sangini worked with BOSCH and interned with a leading 3D printing company in UK, prior to joining MaherSoft.
INDUSTRIAL BUSINESS MART
41
cover story/ tECHNOLOGY
Flying Guards for the Prowlers Aptonomy Inc. has developed drones with artificial intelligence and self-navigational systems for detecting & deterring intrusion
S
oon the human guards will be replaced by the guarding drones. A new drone has been designed to regulate the security of factories and warehouses. The Aplonomy is believed to be more effective than cameras and alarms and interestingly, comes as more economic alternative than human guards. The drones are expected to be set for patrolling from next year. The drone is over a meter across and is built by adding custom electronics and sensors to an eight propeller craft marketed for aerial photography. Along with the control system, the drone has blue and red lights, a white light and two loudspeakers. Conventional and night
42
INDUSTRIAL BUSINESS MART
vision cameras are installed to capture the videos. Soon, it will be fitted with a thermal camera, which will enable the drone to spot the intruder from a long distance. The drone is programmed to explore a defined area, spot and approach the interloper. The warning lights are then flashed by the Aptonomy drone, asking the interloper to retreat. Meanwhile, the security guard in the control room is notified. If a person ignores the warning, the drone keeps filming while the controller in the control room calls the police. The creation has been given quite
attractive features and, the company is not very keen on equipping the drone with anything more than the cameras and speaker. The only hurdle faced by the Aptonomy is the US airspace protocols, it doesn’t allow any uncrewed aircraft to fly at night or operate autonomously. However, the Federal Aviation Administration has granted permission to some companies to fly drones at night or beyond direct view of their controller. Mihail Pivtroraiko, the co-founder, believes his company could get a similar waiver as the drones will be operating on a secured, private land. Reference: www.technologyreview.com
October 2016
`1600, you save `200 `4500, you save `900 `6000, you save `3000
“Mart Infomedia Pvt Ltd” Send your subscriptions to: The Circulation Manager
Mart Infomedia Private Limited
-507, Wisteria Fortune, Bhumkar Chowk Marunji Road Near New Poona C Bakery, Wakad, Pune - 411057 India Tel: +91 70 3093 2700/ 3093 2696 Email: mart@martinfotech.in Web: www.martupdate.com
43 www.martupdate.com October 2016
February 2015 INDUSTRIAL BUSINESS MART 2014 November 43
CUTTING EDGE/ ROBOTICS & AUTOMATION
Shock-Absorbing Robots Anyone who’s watched drone videos or an episode of “BattleBots” knows that robots can break -and often it’s because they don’t have the proper padding to protect themselves.
R
esearchers at MIT’s Computer Science and Artificial Intelligence Laboratory (CSAIL) will present a new method for 3-D printing soft materials that make robots safer and more precise in their movements -- and that could be used to improve the durability of drones, phones, shoes, helmets, and more. The team’s “programmable viscoelastic material” (PVM) technique allows users to program every single part of a 3D-printed object to the exact levels of stiffness and elasticity they want, depending on the task they need for it. After 3-D printing a cube robot that moves by bouncing, the researchers outfitted it with shock-absorbing “skins” that use only 1/250 the amount of energy it transfers to the ground.The most common damper materials are “viscoelastics” like rubber and plastic that have both solid and liquid qualities. Viscoelastics are cheap, compact, and easy to find, but are generally only commercially available in specific sizes and at specific damping levels because of
44
INDUSTRIAL BUSINESS MART
how time-consuming it is to customise them. The solution, the team realised, was 3-D printing. By being able to deposit materials with different mechanical properties into a design, 3-D printing allows users to “program” material to their exact needs for every single part of an object. The skins also allow the robot to land nearly four times more precisely, suggesting that similar shock absorbers
could be used to help extend the lifespan of delivery drones like the ones being developed by Amazon and Google. The cube robot includes a rigid body, two motors, a microcontroller, battery, and inertial measurement unit sensors. Four layers of looped metal strip serve as the springs that propel the cube. Source: www.mit.edu
October 2016
Held Alongside
Incorporating
Organised by
October 2016
Endorsed
Worldwide Associate Tel : +65 6233 6638 Fax : +65 6233 6633 Email : mta@sesallworld.com
Supported by
Held in
Tel : +44 207 840 2134 Fax : +44 207 840 2119 Email : mta@oesallworld.com
INDUSTRIAL BUSINESS MART
45
CUTTING EDGE/ ROBOTICS & AUTOMATION
No more Restricted Manoeuvres
Marcel Mayer, who is also the incharge of Automated Driving at Schaeffler, explains that, it would be possible to switch flawlessly between front wheel, rear wheel, and all wheel steering, as required by the situation.
The project Omnisteer by researchers from Schaeffler and Karsluhe Institute of Technology is expected to increase the manoeuvrability of the automobiles and electrification making it easier to park.
Experts from Schaffler, Paravan, Hella and researchers from KIT have collaborated to make Omnisteer a success. The project is being financially supported by Federal Ministry of Education and Research . Out of â‚Ź3.4 million, which is the total budget of the project, â‚Ź1.9 million has been sanctioned by the Ministry. Completion of the project is anticipated in 2018.
P
arallel parking will no more be a tedious job as a quick and easy parking strategy is on our way to rescue from the very trouble. A project has been initiated by a bunch of researchers from Schaeffler and Karsluhe Institute of Technology where they have developed new chassis types that can be steered individually. This would indeed simplify the manoeuvre
46
INDUSTRIAL BUSINESS MART
and hence, increase the efficiency. In the Project, Omnisteer, the use of increasing electrification and automation of vehicles will provide users advanced driving functions. The electric drives are known to be more significant than combustion engines as we can directly integrate electric drives into each wheel. One of the project managers, Dr.
Omnisteering seems to be extremely promising as it is capable of providing practical solutions for the traffic problems in urban areas and restricted parking, ensuring safety, comfort, energy and efficiency at the same time. Reference: www.innovations-report.com
October 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
October 2016
Organizer:
Event Producer:
INDUSTRIAL BUSINESS MART
47
CUTTING EDGE/ design & manufacturing
Indie 3D Printer for Pattern Making Fused Deposition Modeling (FDM) is the most cost effective and accessible solution of all the 3D printing types. Indie 3D Printer, using FDM technology, has significantly contributed to cost reduction time saving and precision in pattern making for many companies.
I
magine a world where whatever you imagined could come to life with a simple click of a button. The evolution of print is astonishing, and recent advancement has made this possible with 3D printing. The right blueprint and three-dimensional printer combined with an idea is literally a print button away. To understand the depth of 3D printing it’s important to know the process of generating a lifelike matter from a printer. ‘Additive manufacturing’ is a commonly coined term in the 3D printing world, which is precisely how this is done. It is the process of creating a three-dimensional object by applying, or adding, material in successive layers through the control of a computer.
The capabilities of a 3D printer are close
effective and accessible
to endless. In the beginning of 3D printing
solution. FDM 3D printing
there were half a dozen substances that
works by extruding molten
could generate a print, whereas today hundreds of materials can be used. A printed object can take all sorts of shapes and sizes, and a more complex blueprint will require a more advanced 3D printer. Anything imaginable can or will be able to be printed. Objects commonly in print now include prosthetic limbs, engineering designs, consumer products, medical instruments, scaled replica of a
48
INDUSTRIAL BUSINESS MART
plastic out of a hot nozzle and laying it down on a flat surface, one layer on top of the next. FDM parts are most similar to injection molded parts. How 3D Printing proves to be cutting edge technology in manufacturing ?
house – the possibilities are endless.
Indie is a desktop 3D printer designed,
There are actually many different types of
developed and manufactured in India
3D printing. Each has unique advantages
and it works on FDM technology. Out of
and disadvantages such as speed,
endless applications one such example
compatible materials, and
is sand casting industry where Indie 3D
part quality, FDM being the most cost
Printer has been really useful.
October 2016
using Indie 3D Printer’s FDM Technology companies are able to eliminate the need to traditionally machine patterns to create cavities in the sand. This is a possible option due to the high strength of FDM parts produced from Indie. The companies used to traditionally
Indie is a desktop 3D printer designed, developed and manufactured in India and it works on FDM technology
outsource machining of aluminum match plates for sand casting, a process that was both costly and time consuming. The adoption of FDM to replace this process leads to a reduction in cost, in addition to decreased lead times for new casting patterns. Also, as skilled pattern makers become harder to find, companies have found new innovative ways to employ 3D printing to achieve quality sand casted parts. FDM allows manufacturers to deliver precise patterns for the production of sand casted components. The author Karan Sangani is the Chief Sales Officer at the MaherSoft which is a leading 3D printing company. A mechanical engineer from MIT Pune, Mr. Sangini worked with BOSCH and interned with a leading 3D printing company in UK, prior to joining MaherSoft.
Sand Casting is a metal casting process, using a mold created by depressing a pattern into sand. The pattern imprints a cavity, which is used to cast an array of metal alloys. Sand casting is widely used across many industries to create everything from small items, such as door handles, as well as large components, like engine blocks. 3D Printing has reinvented
October 2016
the traditional practices used in sand casting to reduce cost and increase throughput. Indie 3D Printer can be used to avoid the process of traditional pattern making, which is typically found to be time consuming, costly, and often the leading
Indie 3D Printer can be used to avoid the process of traditional pattern making, which is typically found to be time consuming, costly, and often the leading cause of bottlenecks in production.
cause of bottlenecks in production. By
INDUSTRIAL BUSINESS MART
49
CUTTING EDGE/ electronic and communication
Virtual Reality Leveraging Technology To Drive Business
DTE Energy is focused on next generation technology to advance how they approach every aspect of their business – including ways to improve safety for their customers
B
usiness transformation and
DTE Energy: Recognising the value of
business – including ways to improve
innovation are key to remaining
Virtual Reality (VR)
safety for their customers and, of course, their employees. According
competitive in the global marketplace. Recent research shows almost half of
DTE Energy is a prime example of
to the BLS National Census of Fatal
all CEOs expect their organisations
a company leveraging disruptive
Occupational Injuries, in 2014, there
will be significantly transformed by
technology to drive transformation and
were 19.2 fatal work injuries per 100,000
2020. That’s why companies wanting to
improve its competitive position. The
electrical power-line technicians, ranking
succeed need to embrace and implement
utilities company wants to provide better
the profession ninth in the top 10 of
both disruptive thinking and disruptive
training for its technicians, improve the
civilian occupations with high fatal work-
technology not only when developing new
customer experience, and strengthen
related injury rates.
products and services, but also when
the company brand.
transforming their business processes.
50
By doing this, they can increase their
DTE Energy is focused on next
agility, as well as drive rapid and cost-
generation technology to advance how
effective innovation and growth.
they approach every aspect of their
INDUSTRIAL BUSINESS MART
Fortunately, recent advancements in virtual reality technology are providing risk-free alternatives to real-world, high-consequence training. Virtual
October 2016
reality, commonly referred to as VR, places the user in an immersive, simulated environment. VR systems typically consist of a head-mounted display (HMD), which is used to block out the user’s surroundings and replace the environment with a virtual one using internal screens within the head unit. Advanced systems also utilise headphones, motion tracking controllers, and sensors to engage all of the user’s senses in the experience. Scientists have long predicted the
Virtual Reality systems typically consist of a head-mounted display (HMD), which is used to block out the user’s surroundings and replace the environment.
value of VR in training. Studies about information retention conducted by the National Training Laboratories show the following statistics:
Vive® platform, technicians experience
results in leaner, faster development cycles
• Traditional, passive learning methods
visual immersion with a 110-degree
and better products. In the automotive
such as reading, listening to lectures,
field of view and 360-degree motion
industry, for example, VR is used to design
and watching instructional videos result
tracking. As the training will blend real
new technologies and subsequently fine-
in information retention of between five
and virtual elements and utilise full-room
tune them by testing them in a variety of
and 20 percent.
sensing, trainees will retain real world
simulated environments.
awareness and be able to move around • Seeing a demonstration of a technique
in the virtual space. In short, they’ll be
increases retention to 30 percent.
able to practice dangerous tasks such
• Active learning—repetitively performing a technique or applying information— can increase retention to 75 percent. • Having the opportunity to practice and make mistakes¬ can increase retention to 90 percent. VR offers a way for companies to train
as making repairs at great heights, performing gas shut-offs, and repairing down lines without compromising their own safety or that of the public. The impact of VR on businesses VR offers a number of significant advantages.
their employees in virtually simulated
When used as a training tool, it increases
work situations. Immersive and
the safety of employees and training
interactive technology allows workers
personnel, which can enhance a
to practice and hone their skills by
company’s employer brand and improve
replicating the consequences of their
the quality of services, which will result
actions in the virtual world—but without
in positive competitive differentiation.
the risk involved in real life situations.
At the same time, VR offers a powerful
Recognising the value of VR for
method to simulate and test prototypes,
life-critical, high consequence training,
as well as create new manufacturing
DTE Energy partnered with Vectorform to leverage VR training for its electrical power line technicians. Using the HTC
October 2016
processes. It also provides an effective way of assessing innovative technologies in regard to regulations and compliance. This
VR is also poised to revolutionise the world of marketing, providing consumers with an accessible, commitment-free way to “try before they buy.” According to E.J. Schultz in the AdAge article “Why Virtual Reality Is Auto Marketing’s Sleeping Giant,” a number of automotive manufacturers are embracing VR as a way to reach tech-savvy Gen Z and Millennial consumers. For example, interactive videos which simulate driving a specific model can be used as a hook to attract these consumers to the dealership for a test drive. The potential of VR is unlimited. What’s more: forward-thinking organisations that leverage VR to quickly and cost-effectively explore their vision to develop solutions are likely to position themselves as leaders in their industries while transforming their business. Source: www.automationalley.com
INDUSTRIAL BUSINESS MART
51
CUTTING EDGE/ energy and power
More Efficient Solar Cells More efficient than existing silicon Solar Cells are now possible, thanks to the research team rom Columbia University. Made of Hybrid Organic Inorganic Perovskites (HOIPs) these solar cells are the future of energy.
I
n a discovery that could have profound
solar.Among the materials being explored
six decades to create silicon cells and bring
implications for future energy policy,
for next generation solar cells, HOIPs
them to their current level, and even now
Columbia scientists have demonstrated
have emerged a superstar. Until now no
silicon cells can convert no more than
it is possible to manufacture solar cells
one has been able to explain why they
about 25 percent of the sun’s energy into
that are far more efficient than existing
work so well, and how much better we
electrical current.
silicon energy cells by using a new kind
might make them. The Columbia team
of material, a development that could
has been investigating HOIPs since 2014.
help reduce fossil fuel consumption.The
Their findings could help boost the use of
team, led by Xiaoyang Zhu, a professor
solar power, a priority in the age of global
of Chemistry at Columbia University, focused its efforts on a new class of solar
52
warming.
The research team was spearheaded by Haiming Zhu and Kiyoshi Miyata, two postdoctoral fellows at Columbia. Other members include graduate students Jue Wang, Prakriti P. Joshi, Kristopher W.
cell ingredients known as Hybrid Organic
Over the last seven years, scientists have
Williams and postdoc Daniel Niesner,
Inorganic Perovskites (HOIPs). Their
managed to increase the efficiency with
all of Columbia; Yongping Fu and Song
results, reported in the journal Science,
which HOIPs can convert solar energy into
Jin, collaborators from the University of
also explain why these new materials are
electricity, to 22 percent from 4 percent.
Wisconsin-Madison; and the team was led
so much more efficient than traditional
By contrast, it took researchers more than
by Columbia Chemistry Prof. Xiaoyang Zhu.
INDUSTRIAL BUSINESS MART
October 2016
Witness a true international event with state-of-the-art infrastructure
Venue: The Exhibition Center, Helipad Ground, Gandhinagar, Gujarat, INDIA.
October 2016
INDUSTRIAL BUSINESS MART
53
COLUMN/ hUman Resources
Effective Delegation Delegation is an effective management tool that helps individuals and organisation grow successfully. Through a case study the Sanjeev Himachali highlights how guided training for delegation to an individual yields unprecedented improvements in performance, efficiency, optimization at both individual and organisational levels.
L
ast year July, my friend Abhinav Chopra shared his leadership dilemma with me.
Abhinav is a Managing Director (India) with a consumer goods organization which is a global player in chocolate manufacturing with an annual turnover of more than 75 billion USD and headquartered in the United Kingdom. According to him, under his leadership for the last 10 years, the company had grown propitiously. However, soon after deciding to pass the baton to an able reportee under him for looking after global assignments himself, he realised that all his direct reportees are excellent performers but are not ripe enough to fill in his shoes. He did seek my guidance in training the reportees for the role. All ten of his direct reportees, including the Vice President - HR, and the Vice President – Finance were considered as probable successors of Abhinav. In the first phase of the evaluation, we conducted a behavioural assessment, competency assessment and evaluation to gauge their engagement level. After the first phase, five of the ten probable were eliminated from the process. In the second step, we asked the remaining five probable to take Extended DISC Assessment and took their 360-degree feedback, involving their reporting manager, team members, direct customers and family members. While Extended DISC gave us a view of their natural and at work profiling; 360-degree feedback gave us an insight
54
INDUSTRIAL BUSINESS MART
into their problematic areas as observed by direct stakeholders. When we began the coaching process, we had to eliminate two more probable as they were not coachable. During the process, I also met Nitin Garg, Vice President – Production who wasn’t among the three Functional Heads to be coached as a successor of Abhinav, there is something worth discussing Nitin. According to feedback from his office he was an inefficient and poor delegator;often seen as a frustrated and irritated manager, often overworking yet missing target deadlines, with strained married life and health. My discussion with him led me to believe that he was carrying lot many myths, misconceptions, and conflicts about delegation. My finding about him revealed that though he was brilliant and had business acumen, he lacked the quality of team work and delegating responsibilities to his juniors. This made him a failure as a leader and led to his losing jobs back-to-back until Abhinav got him in his company. My discussion with Nitin further revealed that he felt he complete the assignment all by himself, else delegation might slow the process compromise the quality of the job.I conveyed his shortcoming in these ideas and asked for his cooperation. During the first two weeks, we discussed his fears related to delegation, what kind of tasks can be delegated, the art of delegation and the step-by-step process of
delegation. I have spoken to several managers working at middle and senior levels, and when it comes to delegation, they all reiterated the following 1. I need to know where the task is. What is happening with it? How much has been completed? I just want to stay in control of it. 2. I don’t want to invest my time and efforts into training them. Eventually, they will leave and apply my learnings elsewhere. 3. I enjoy what I do and don’t want to give it up. It is because of my abilities to do the task efficiently that have fetched me the promotion, why should I give it to someone else. 4. I don’t want to admit my failures or limitation. It will send wrong signs to my team. Also, if the person does a better job than me, I will lose respect in my team. 5. I don’t think I have people in my team who are as efficient as me. Nitin was not different from the description given above. Let’s go back to the basics and understand delegation. Delegation (in an organizational context) occurs when a team manager with authority confers upon another person the power to do a particular task or part of a task. It’s a management tool to effectively manage time, resources and people. Usually, delegation is a one-way street – manager
October 2016
Delegation speeds up decision making as power is shared at all levels. It is not about “dumping their work on others” but can be In fact, what leadership writers like to call “employee empowerment.
delegate authority to subordinates. However, the ultimate responsibility for task completion lies with the manager who delegates the authority to complete it. The outcomes of successful delegation are: 1. Time Management - Delegating duties according to their skills ultimately free up your time to focus on broader strategies and securing resources to carry out your plans. Though you are the manager, they specialize in a particular area for which you hired them. Use them—all of them. 2. Decision Making - Organisation grows and expands by delegation. Delegation speeds up decision making as power is shared at all levels. 3. Building Trust - Delegation involves trusting in employees’ abilities and relying on them. It means you trust your employees with autonomy. It helps build a feeling of mutual understanding and trust. It gives managers the opportunity to understand the employees’ approach towards work. 4. Creativity - To implement new ideas in the organization, one needs to have a certain power and the right amount of freedom. A rigid framework and lack of authority may restrict an individual from thinking differently. If deserving individuals are given the right authorities, they may be able to bring innovation. A delegation of authority may invite out-of-the-box ideas and positive changes in the organization. Delegation is one of the finer arts of good management. Yet, the number of supposedly successful managers who struggle with this premise is staggering. What to Delegate?
October 2016
To grow—both personally and organizationally— one has to increasingly focus on those high payoff activities where one can add the maximum value. One must do the task one is passionate about and has required competence to perform it efficiently and delegate or outsource everything else. If I draw a 2x2 matrix of passion and competence, I will get the following Low Passion/Low Competence – These are your least payoff tasks. They are the ones you dread because you don’t enjoy them, and you aren’t good at them. By hanging on to them, you are holding you and your organization back. The sooner you delegate them, the better. Delegate these tasks to those on your team who are efficient in doing them. Low Passion/Highly Competent–Next in the line are activities you used to enjoy at one point in time, may be earlier in your career but not now, though you have the necessary competence to do these. They drain you and keep you from doing your best work. Train someone in your team and delegate these tasks to them. Ensure they enjoy these tasks. High Passion/Low Competence–You love doing these things; however, you are not efficient in doing. The question is whether or not you could become competent with the right training. Evaluate the urgency of the task. If you have time, then learn and do it or else delegate to those who are skilled and competent. High Passion/Highly Competent- Finally, you are left with tasks you are passionate about, and you are competent in giving
your best. These are your highest payoff activities—both for you and your organization. This is where you experience the most satisfaction and make the greatest contribution. You want to do more of these kinds of activities. In addition to the above listed, you must also not delegate those activities that are marked as “Confidential” (Nitin liked this information). How to Effectively Delegate? Step I - Hiring to delegate- The primary difference between a CEO and a bottom line employee is a fact that a CEO has many pairs of hand working for him and completing his task. That’s the overview of delegation. The delegation has its roots in the recruitment process. In fact, it starts from workforce planning. The workforce is hired to be given work and share responsibility. When you recruit in response to a need rather than as part of a growth strategy, it can be easy to lose definition of roles and responsibilities. Having a bare bones organizational chart, overall titles, and blurred job descriptions is fine for the first few years, but as you grow your business, both investors and your employees will look for structure. Take time early on to create strategy and structure. Understand where your skill set honestly lays, and where you could ask for help. Take a step back and assess how you want your business to grow, or what you hope to succeed, and think about the types of roles and people you need to get you there. Even if you do not recruit them all now, it is best to have a plan and grow strategically.
INDUSTRIAL BUSINESS MART
55
Step II - Defining Success- Classify your
team. There is nothing more frustrating
Information, and Accountability. To
people into these three categories and
for an employee than being given a
delegate accordingly.
feel empowered, people need formal
direction, but not the accountability to do
authority and all the resources (like the
1. Be like parents - New or inexperienced people in your organization don’t want to be thrown to the wolves, and you would probably be uncomfortable letting them go unsupervised on a newly delegated task. For a time, until you are both comfortable, become a partner in the mission, participating in the decisions, checking along the way. Do this in your best participative style, remembering that the purpose of this relationship is to train members of the group to carry the ball on their own. 2. Become their consultants - When you and your team both feel ready, let them go off on their own. Let them feel free to come to you whenever they want help and information. Make the best use of your coaching and consulting techniques, but remain outside the project, only responding when called upon. This gives your people the feeling of being supported without constricting their style. 3. Let them Fly - This is for employees who feel confident in their abilities and whom you trust to do the job right. Delegate the total project and step aside. This is your chance to get back to more creative work. Wait for results. Before delegating a task, take some time
it. By promoting accountability and not micromanaging your employees, you will make them happier and give yourself time to concentrate on the roles you enjoy and need to do to push the business forward.
budget, equipment, time and training) necessary to do something with the new authority. They also need timely, accurate information to make good decisions. And they need a sense of accountability
Step IV - Learn to let it go- Many managers
for the work. Through the efficient and
will need to let go of the “if I want
strategic delegation of essential tasks,
something done right, I have to do it
managers should be able to free up enough
myself” mentality. If you’re the type of business person who still phones the office ten times per day while on a vacation, delegation is going to be a challenge. You’ll need to take a deep breath and just let go. Realize that when you delegate something, it’s now out of your hands. You’ll need to step back to avoid interfering with the process and progress. As hard as it may seem, wait until the final product before
of their time for strategic planning and organization. And with a happy workforce and a clear strategic plan in place, a manager can maximize the chances of commercial and operational success. Not only I trained Nitin for effective delegation, but I also worked with him for three months to ensure that all the learning
judging how the delegation is going. At first
is getting implemented meritoriously. It
sight, delegation can feel like more hassle
was such a pleasant experience. After six
than it’s worth. But effective delegation
months, I am receiving rave reviews not
can instantly increase productivity.
only from Abhinav and Nitin but also from
Some managers see delegation as “dumping their work on others.” But done properly, delegation can be, in
Team and Wife of Nitin. They are happy to see these changes in Nitin. I think training is not only about showing PowerPoint
fact, what leadership writers like to call
Presentation, or giving talks or taking
“employee empowerment. “But true
people for 2-3 days of outbound training.
employee empowerment, says one expert,
It is about imbibing the learnings into
requires four things, Authority, Resources,
participants.
to consider what would make it a success, and how you would measure that success. Then communicate those definitions to the team member. After they have completed the task, sit down with them to review the outcomes objectively. Step III - Promote Accountability-
Sanjeev Himachali sanjeev.himachali@gmail.com
Communication in delegation is a key to its success. Finding out that a deliverable wasn’t completed or wasn’t done satisfactorily after the completion date is the nightmare scenario of delegating. After you have defined the roles and responsibilities, it’s time to empower your
56
INDUSTRIAL BUSINESS MART
Sanjeev is a Talent Management and Development professional with over a decade and a half years of experience in various facets of Human Resource Management across various industries, cultures, and geographies. He helps start-ups, small-sized and midsized organisations in identifying and developing potential and competencies of their employees.
October 2016
...looking forward always!
“BE SURE U R THERE”
“ PA R T I C I PAT E A S D E L E G AT E ”
ANNUAL EVENT
GREAT OPPORTUNITY TO WITNESS & LEARN FROM 12 - 15 PRACTICAL SHOP FLOOR PROJECTS IN ADDITION TO OVER 18 PRESENTATIONS, 11 EXHIBITORS, CASTING DISPLAYS
DON'T MISS TO INTERACT WITH BUYERS OF CASTING
AT GDC TECH 2016 Conferen�e � E�hi�i�on on
Aluminium Casting Industry Theme : PROGRESS THROUGH PARTNERSHIP
20 - 21 October 2016 (Thu-Fri) at Hotel Sun-n-Sand, Pune, India. For contact Details
GDC‐TECH FORUM ‘Guruprasad’, 37/4/A, 6th Lane, Prabhat Road, Pune 411 004, India T: +91 20 2565 1717, 2567 0808 | Mobile: +91 97647 11315 arkeyconference@arkeycell.com, mail@arkeycell.com | www.arkeycell.com
October 2016
INDUSTRIAL BUSINESS MART
57
columN/ MANUFACTURING EXCELLENCE
Improving Levers of Competitiveness Cost, delivery, innovation, safety and morale are equally important as production and quality for companies in today’s challenging markets. Cost reduction, on-time delivery, innovation in process and products, focus on safety in process and keeping the employee morale high are keys to remain competitive.. In this 57th article in the series P S Satish continues writing about Levers of Competitiveness.
I
n the previous article, we focused on two levers of competitiveness namely Productivity and Quality. Let us concentrate on other levers – Cost, Delivery, Innovation, Safety and Morale Cost Traditionally, companies used to add profit to the incurred cost to decide on the Price of their products. This is a message to the Customer that they need to pay for all the inefficiencies of the company, if any. This may work probably in government sector or in a monopolistic company in which there are no competitors. Even here, it works till the first competitor comes in. Question is, ‘Will our today’s Customer be ready to pay this way?’. Clear answer is ‘No’. Even our Customer has price pressure from his Customers and he in turn tries to set a target or guidance price for us. That means, the price for our product is decided by our Customer or the market. We can definitely sell at higher price even in nonmonopolistic situation provided we are able to add some specialty into the product compared to our competitors and which the Customer perceives value & ready to pay higher price for. The profit percentage is decided by the management based on their aspirations,
58
INDUSTRIAL BUSINESS MART
investments, market position and the return on safe investment market would have given. With the above logic, appropriate equation in the current business is, Cost = Price – Profit. With given price and profit, we need to manufacture the product within the target cost. This will enhance the competitiveness of the company. Moreover, most Customers especially in automotive sector are looking for year on year reduction of price. The logic is that Customer expects us to increase our productivity with improvements. We need to cover inflation of the market and have a constraint to offer Customer a reduced price without sacrificing the value. Additionally, expectations of Customer on service are also increasing which may have some bearing on cost. To remain in market, there is no choice for the companies other than finding ways to reduce the costs. Resorting to cost cutting which is done only in case of recession in the market is not sustainable. Cost cutting is a short term measure which is done typically without deeper study of implications. What works best in the long term is cost reduction where focus is given on waste elimination.
Delivery If we look at the current market, we see a trend of too many varieties and each with small volume. Best examples are mobile phones and cars. This is because today’s Customer is very choosy and he looks for specific features. Customization is the order of the day and challenge for the companies is mass customization keeping in mind cost and timely delivery. Meeting this in the supply chain is a real challenge. 100% delivery from suppliers is expected in a short lead time. Also in the delivery, customer takes only what is required in time to avoid unnecessary inventory at his end. When we say delivery it also means right quantity, right quality, right time, right cost, right place and in right condition. To meet many of these requirements, lean management with tools like SMED (Single minute exchange die), pull production is becoming popular. What is the use of a good product when not delivered in time? Innovation Without continuous innovation companies cannot stay for long and it should be like daily breathing. It is one of the key for competitiveness and acts as a differentiator
October 2016
Customization is the order of the day and challenge for the companies is mass customization keeping in mind cost and timely delivery.
Cost cutting is a short term measure which is done typically without deeper study of implications. What works best in the long term is cost reduction where focus is given on waste elimination.
compared to the competitors. Innovation makes a distinction between mediocre and excellent companies. Innovation can be applied to all walks of business including service, process and product. With faster innovation of products, there is an advantage of being first mover in the market than the competitors. Innovation includes continuous upgradation of the existing product to enhance the value and also introduction of new products as per the customer or market needs. With the reduction of life cycle of existing products, there is a need to continuously develop new products. This could be an entirely a new product or a variant with improvements on the existing product. Indian companies are trying to focus more on process innovation than product innovation. Both are required. It is high time that our companies spend good efforts to product innovations. Industries can avail Expertise available at research institutes and educational institutions. Some metrics in Innovation include number of new products introduced, share of business from new products, increase of market share of introduction of new features in the product etc. Continuous focus on Innovation will also keep everyone in the company agile and develop ability to compete. Safety Taking care of safety of Employees is one
October 2016
of social responsibility of the company. So also the Equipment so that supplies to Customer is not affected. Taking care of environment is a part of this. Safety should be a kept parameter for the top management to watch. ISO 14001, TPM and OSHAS-18000 implementation should be followed to ensure full compliance on safety. Zero accidents should be the priority to reduce direct & indirect losses and to be a point in management review meetings. Trainings of employees on safety should be a routine. Good saying on importance of safety, ‘Know safety no pain; No safety know pain’ Morale For company to be competitive, involvement by the employees, taking ownership and they feeling proud is becoming a prime parameter. Employees should be trained properly and adequate
resources to be provided. They should be challenged enough with empowerment. Quality circles, Kaizen and TQM initiatives focus on employee involvement and their contributions. It is seen that happy employees contribute more to the company and they are better customer oriented. Regular survey of employee satisfaction gives some indications on the level to improve parameter of morale. After all, everything in the company is done by people and they have to be taken care of. By focusing on above mentioned keys, companies can aspire to remain competitive in the market. Some variations are required depending on the company type. Are we ready to start thinking in this direction? Please send your inputs, remarks, opinionsand suggestions to gotopssatish@gmail.com
P S Satish gotopssatish@gmail.com Saraswati Industrial Service headed by P S Satish, B.E, M.Tech (IIT) 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.
INDUSTRIAL BUSINESS MART
59
COLUMN|LEADERSHIP
Power of Self-Talk Our actions are inspired by our thoughts. If we can change the way we think, we can begin to change the actions we take, writes Pavan Sriram.
C
onsider what happens after you’ve done something embarrassing. Does your inner voice say “that was stupid”? How about if you haven’t even done anything wrong or stupid at all, but what you say and how you say it to yourself is just as critical?
silent
Question Suggestion
Most of us are in constant mental chatter. Often it is tainted with guilt about our past or anxiety about our future. Psychologists have identified one important type of these inner monologues as “self-talk,” where you provide opinions and evaluations on what you’re doing as you’re doing it. You can think of self-talk as the inner voice equivalent of sports announcers commenting on a player’s successes or failures on the playing field. University of North Carolina Chapel Hill’s Steven Rogelberg and his teaminvestigated the nature of self-talk among effective and ineffective managers. They defined effective managers as those who showed strong leadership skills and creativity. The experimental task involved having participants write letters to themselves about their plans and accomplishments. The data from this study in-fact consisted of written examples of self-talk that could then be rated. Letters rated high in constructive self-talk included statements that fit the criteria of being insightful, thoughtfully constructed, selfreflective, and motivational in nature. The constructive self-talkers, in other words, saw themselves as capable of achieving their desired goals. Whether you are in charge of leading people in a high-pressure managerial job or a fresher at work, here are a few simple take-away messages from the Rogelberg study:a) Create Inner Awareness The first step is to know ourselves. It will be hard to make a change to positive thinking without being acutely intimate with the thoughts that run through your mind. Being self-aware allows you to understand other people, how they perceive you, your attitude and your responses to them in the moment.
60
INDUSTRIAL BUSINESS MART
Self Tape
Se Tal
P
Written Self Talk
Self-Con October 2016
b) Avoid Negative Chatter A little self-criticism is a good thing: It can be a reality check that spurs you to be a better person. However remember to keep a tab on your intention that has to be affirmative (formulate your sentences using “do” instead of “don’t,” etc.), written in the first person, and in the present tense. Keep a daily practice of repeating affirmations that are important for you.
talk
c) Keep it Present What may be helpful is to concentrate on steps you can take in the present. If you find yourself becoming stuck, stop and say, “What can I do right now?” Change your internal talk from a future anxiety ridden one to one that is about the more manageable present. You cannot control what will happen in the future but you can take the necessary steps NOW to
Mirror Talk
elf lk
build a better one. d) Differentiate Thinking vs Doing It is no coincidence that the motivation to think and the motivation to act seem to strike us at different times. Instructional self-talk greatly helps when you tell yourself each step you need to take systematically in order to complete something while in the process that you actually do it, Discipline yourself every day to get some dedicated “thinking’ time to improve performance and function of your brain. Replacing self-talk from a negative to a more positive one is not going to happen overnight. If your mind has ingrained habits of thinking negatively, it will take some work and time, more importantly a habit of doing some of these things every day. I recommend that you read this highly acclaimed book “What to Say When You Talk to Your Self” written by psychologist Dr.ShadHelmstetterwhere he shares life-changing tipson
Partner Talk
motivational self‑talk and positive thinking. I look forward to hear from you at pavan@ittige.com on how you are making positive self‑talk a permanent habit by looking at problems in all its facets and giving your subconscious mind directions to overcome them.
Pavan Sriram
nversation October 2016
pavan@ittige.com Pavan Sriram is the CEO of ITTIGE Learning, a performance-based training company that works with organisations to improve learning outcomes.
INDUSTRIAL BUSINESS MART
61
COLUMN|corporate social responsibility
Education for Success in Life Corporate Social Responsibility has become a legal mandate. Manufacturing companies, on an average, score far better than service companies. This difference is attributable to the fact that these issues are more important for the manufacturing sector. Considering this, MART is partnering with Manoj Kabre Vice-President in Marketing, Indo-US MIM Tec Pvt Ltd in starting a column on CSR initiatives by Indian Manufacturing Sector.
C
SR, or Corporate Social Responsibility,
almost a 10x jump in CSR expenditure of
believe that educational outreach efforts
is an act of kindness that is catching
companies, and they are struggling to
have the capability to make a real and
wider attention and popularity these
effectively deploy this capital. However,
lasting difference for all players involved.
days. It refers to the inclusion of social
there are many organisations, which
and environmental considerations into a
have followed this act since long when
company’s operations, so as to accomplish
there were no constraints/ law forcing
the success of a business. In other words, it
companies to adopt policies of social
means satisfying your customer’s demands
responsibility. This probably has been a
as well as managing the expectations of
culture at such organisations, and the
other people such as employees, suppliers
result of them being socially aware.
and the community around you. In a larger sense, this translates to contributing positively to society. We all can see it playing a vital role in the rapidly changing global manufacturing environment. There is also a customer push to organisations, since customers are willing to purchase from socially responsible companies. Social Innovation is a buzzword, amongst organisations, and each of them are setting up employee initiatives to have a broader focus and connect. It has been clearly seen, that a well-thought CSR strategy has helped organisations to have a higher employee morale, lower manufacturing/ distribution costs and better sales. Focus on CSR could be a result of the government directive in form of The Companies Act, 2013 passed by the Indian Parliament in August, 2013 mandating companies of a particular size to invest 2% of their Net Profit in CSR (Corporate Social Responsibility) activities. As per this Act,
62
There is strong desire to change the current state of education. India has to restructure the education system at all the levels i.e. elementary, secondary and higher education level. This is possible when the corporates also perform their responsibilities towards society. They are
This made us conceive a column focused
also the consumers/users of trained/skilled
on CSR and Sustainability, where we
manpower produced by the universities.
plan to take up a specific area of CSR
In order to reap concrete benefits they
contribution each month, and elaborate
must help these universities /colleges
on it, along with a case study of some
to produce such skilled and trained
organisations who have done excellent
manpower by providing funds for research
contribution in this specific field. This
and development, organizing various
could act as a benchmark for the readers,
workshops, training and development
to enable them take up compelling
programs, cross over exchange programs,
initiatives of ISR (Individual Social
infrastructural support and last but not
Responsibility) that could collectively
least providing facilities for qualitative
translate into CSR.
education that quantitative.
This month, we have selected the subject
The role of CSR in education is thus
of “Education” for our CSR focus. The
mitigating the skills gap with considerable
reason we have selected Education as
experimentation, and learning-by-doing
a prime focus subject, is because this
along the way. In this process, the affected
will then lead to Skilling, which is an
individuals, companies, and society at
even bigger concern to tackle. One of
large are likely to benefit. We present
the reports suggests that India will have
herewith some case studies of projects
shortly a population of 100 million people
done by a few manufacturing companies
join the workforce, but will lack the
to do their role in CSR in education.
requisite knowledge and skillset.
In our maiden column we bring you
more than 22,000 companies will spend
There are majority of corporates who
activities done by Azko Nobel, Sigma
~USD 3 billion annually on CSR activities,
have a specific focus on Education as
Electric Manufacturing Corporation Pvt.
starting 1st April, 2014. This represents
a part of their CSR strategy, since they
Ltd and Actuant India Ltd.
INDUSTRIAL BUSINESS MART
October 2016
DISA PARI UDAAN Organisation: Akzo Nobel
According to DISE 2013-14, a total of 1.70 lakh girls dropped out of schools in Karnataka, mainly in the urban district of Bengaluru. To meet this challenge, Akzo Nobel has initiated a program, DISA PARI UDAAN which aims to ensure enrolment and retention of girl children in higher classes in government schools. The girl children are made well equipped with life skills, sexual health education to address personal issues at various stages of life. The program is active in four schools of Bengaluru. Improving toilet facilities, libraries, laboratories and providing sports amenities, tuitions for Mathematics, Science and English are some of the provisions offered by the program. Along with providing a wholesome academic environment, awareness programs are executed to enlighten people of urban slums about birth registration, girl child education and gender awareness training for parents. A preliminary needs assessment survey is conducted to recognise the facilities required for enhancing the performance and encourage more children to use the benefits of schooling. For more details write to Preetyusha Curtis at Prettysha.Curtis@akzonobel.com
Augmenting the quality of life Organisation: Actuant India & Sparsha Trust
Actuant believes that success is not only measured financially, but also in terms of our impact on people and environment. As part of their commitment to Corporate Social Responsibility (CSR), Actuant India is committed to growing socially and works with local non-profit organisations to enhance the quality of life for the underprivileged community. Outreach programs focus on health, education, human concern and culture. Sparsha Trust is one of the organisations that Actuant India works with very closely. The trust is working for the holistic development of needy and vulnerable children focused on promotion and facilitation of Child Rights. It is committed towards identification, rescue and rehabilitation of children from 6 to 18 years old. Actuant India uses CSR activities to address key education needs of children as well as an effective employee engagement tool. The company encourages children of Sparsha Trust to visit the office so that they can spend time with the employees and get a broader perspective and on-the-job exposure. Employees also contribute wholeheartedly with books and stationeries through the year to motivate the children. Sparsha intends to integrate all the centres and construct one sustainable rehabilitation centre with plinth area of approximately 18000 sq.ft for 200 children, expandable to 500 kids. Sparsha has embarked upon building another centre of 18000 sq.ftof area with all the amenities and space for multidimensional learning. Actuant India aims to provide protection, security, knowledge and good values. The company believes, if children became positive and engaging members of the society it will help to develop not only a stronger and healthier community but a safe one as well. For more details write to Archana Prasad at archana.prasad@actuant.com
October 2016
INDUSTRIAL BUSINESS MART
63
Knowledge is Power Organisation: Sigma Electric Manufacturing Corporation Pvt Ltd & Pratham
Sigma has partnered with Pratham which is one of the largest, education oriented NGO in India. It focuses on high quality, low cost and replicable interventions to address gaps in the education system. Commenced in February 2015, the program in partnership runs in 2 blocks, Khed and Mulshil- Maval in Pune, Maharashtra and another one in Jaipur, Rajasthan. It is a science driven program which facilitates experimental learning by organising scientific fairs and workshops. Science Fairs & Workshops The students participating in the fairs are referred to as “BalvigyanMitras” or BVM and their mentors as “Vigyan Mitras” or VM. BVM are trained and encouraged to put forth their ideas and innovations. The fair is held in the school premises where the students showcase their projects and models. Thereafter, students felicitated for participating in the fair. CV Raman Centres At CV Raman Centre, a science centre in each location, students get the opportunity to engage themselves in different experiments, create models and participate in group activities. Around 32 workshops have been conducted across all three centres. The centres are open for children to visit on weekends, and the Vigyan Mitras are present to demonstrate and explain the models. To further enhance children’s skills, two workshops on making organic, dye-sensitized solar cells were organized in the CV Raman Centres in Khed and Mulshi. Community Workshops and ‘Lakhon Mein Ek’ campaign Community workshops are arranged to create awareness and invoke discussions among the adults. A Mobile Science Van is used to reach village communities where workshops are conducted for the young and old alike, enabling local communities to think scientifically. The workshop comprises sky watching and film screening. Sky watching is a very popular activity, where village residents of all ages first observe the sky through a telescope and then describe/discuss their observations. The films screened are either informative videos on health, cleanliness, sanitation or animated movies for entertainment. It serves as a platform for discussions and creating awareness among adults. Community workshops have reached a total of 3517 children in 119 villages across all 3 locations in 2015-16.
For more details write to Amol Pise at apise@sigmaelectric.com
Manoj Kabre manoj.k@indo-mim.com Manoj Kabre, Vice President of Indo-US MIM Tec Pvt Ltd, has directed and headed the sales & marketing function for Asia and parts of Europe, Spoke at various forums across the world for propagating the MIM technology. His highly admirable work includes, Chairing– CSR Committee of Rotary Bangalore Whitefield Central (RBWC), Founding of a Trust (NGO) CaN Trust, working for needy children.
64
INDUSTRIAL BUSINESS MART
October 2016
ifo.president@gmail.com
October 2016
INDUSTRIAL BUSINESS MART
65
Learning Curve
Shelby Cobra 427 Replicated! S helby cobra 427 is a two-door roadster Anglo – American sports car with a brewed 7.0 litre V8 engine designed in both UK and United States since 1962. MIT College of Transportation Design experience that the courses of study exclusively explore an inborn human need of human mobility. Beginning with the concept of transporting people and
66
INDUSTRIAL BUSINESS MART
commodities using a variety of means, its emphasis moves on creating sustainable systems for Transportation Design. It is not only limited to Automobile Design and car design but to design systems which enhance mobility for humans and commodities.
Kalbhor of MIT College Pune, as a part of
Three transportation design students Vishnu Pratap, Deepak Vijayan and Suyash
Maruti 800 to build the model. Initially the
their final year project chose to work on an innovative project with the help of scraps. They found similar entities in the Maruti 800 which were a perfect replication to build the roadster Shelby Cobra 427. They have utilised the heart, the engine of the project was started by the faculty who
October 2016
MIT Project Team
Vishnu Pratap
Deepak Vijayan
Suyash Kalbhor
“We were always waiting to see the end result for our efforts. The feeling that we had when we actually got to see the end product was something that we cannot put into words. We were thrilled to have been able to work on such a project to a point where all the hard work that we put in was more than justified. To sum it up, we feel this was the project that actually gave us a direction in which to move on with our lives.”
A perfect replica of Shelby Cobra was created by the Students of MIT College of Pune as their project. The whole project was built in-house from chassis to suspension except lights and engine which has been utilised from the Maruti 800.
approached the institute for the support. The faculty thought that such a project would be a good learning experience for the students. The entire project took almost nine months to complete. A sum of INR 5 Lakh was allowed for the project from the college authorities, but that didn’t adequate, and when the strongbox ran dry, faculty members and students pitched in
October 2016
from their own pockets. They collectively ended up spending around INR 3.5 lakh to INR 4 lakh on the entire project, apart from the sum initially assigned.
The whole project was built in-house
The faculty members Donshong Koren, Chatanya Kachare , Rakesh Sharma and Ajaya Patil and students Vishnu Pratap, Suyash kalbor, Deepak Vijayan have been working on the project since August 2015.
were used to built the car. The project
from chassis to suspension except lights and engine which has been utilized from the Maruti 800. Hand Machinery tools was divulged on the eight convocation ceremony of the college. All the members worked especially on the fibre glass body to look exactly like the original legend.
INDUSTRIAL BUSINESS MART
67
68
INDUSTRIAL BUSINESS MART
October 2016
Forging & Casting Policy Initiatives Guest Editor Dr. H. Sundaramurthy Let’s Talk P D Pant
Smart Foundry Rajesh Angadi
SmartSense® Manish Kothari Case Study Altair Renishaw
Powered by
October 2016
INDUSTRIAL BUSINESS MART
69
INDUSTRY FOCUS /Guest Editor
Policy Initiatives Foundry & Metal Manufacturing Industry The Indian Foundry sector is well established and ranks 2nd in the world in terms of production. There are approximately 4500 units out of which 80% can be classified as Small Scale units. Our Guest Editor for this month’s Industry Focus on Casting & Forging, Dr H Sundara Murthy, talks about policy initiatives under taken by the Government of India to confront the challenges faced by the industry.
T
he Indian Foundry Industry is a very
in various professional bodies. The work
observation, is the total absence of and
large group mostly inundated with
undertaken by me in several associations
application of technical commerce in all
enthusiastic entrepreneurs mostly without
has left very strong impressions of these
the activities. The entrepreneur thinks
commercial planning, strategy and support,
interlacing groups on the requirements of
that he is technically strong, very proud
family business promoters with or without
all the areas. The first and the second type
of his product performance and keep on
operators have formed a very large group
assuming that the customer depends on
operating at the whims and fancy of the
him for ever.
deep involvement, and few medium and large scale planned operators. I have deep knowledge of each of these sectors by actively engaging in these segments for over four decades of my involvement
market driven forces without any long range plans, mostly surviving on a day to day or month to month existence.
He fails to realise that there is a dynamic technical activity happening outside his unit, be it at the customers
The beauty of this segment is the thrill and bubbling enthusiasm in what they do every day. There is plethora of technical knowledge, grit, determination, SKILL and INNOVATIVENESS in this segment. The fallacy and the truth is that many close
place or the outside progress in the field. There is continuous change in HR controlling his performance in the customers operation, there is progress in technology and better economic methods of manufacturing.
down due to the absence of long range
More than all these factors he fails to
planning.
understand that other than his area
The bane of this activity is, to my
of expertise, there is a need to adopt technical approach in other areas of
Dr. Sundara Murthy, President of Indian Foundry Organisation , is a M.E and Ph.D. in Mechanical Engineering from Indian Institute of Science, Bangalore. He served as the National President of The Institute of Indian Foundrymen. He was also Chairman of Indian Institute of Metals, Bangalore and Governing Council Member of Aluminium Association of India. After working in leading industries, he started Fenfe Metallurgicals, manufacturing aluminium alloy castings. 70
INDUSTRIAL BUSINESS MART
October 2016
October 2016
INDUSTRIAL BUSINESS MART
71
manufacturing operations like Purchase,
improved. The effort of Indian Foundry
and get the Udyog Aadhar number. This
Marketing and Communication with
Organization in organising this meet is to
will be a unique number which will get
the outside world. One or many such
be appreciated as they have been able to
priority is all the services of MSME. He
issues, sometimes very trivial, makes
bring together several industry associations
urged the industry associations to inform
him desperate and he either closes the
like KASSIA, FKCCI, ALUCAST etc. Please
all the members to register in the MSME
operation or continue to suffer. The
walk into our office and explain your
DATA BANK which will help the industry
management line if you fail to plan, you
problems and what you want us to do.
to get connected to the designation
plan to fail is certain to come to play.
We will help you with all possible schemes
to get all the details of the schemes
and assistance.” This statement shows the
available.
This is the story of a large number of MSME units under this category. I have seen many very good units closing down
keenness of the Government to proactively help the industry but the action from the industry side is still to be improved.
their operation in the span of last 40 years
the recently held Foundry Development Council meeting informed that the
Mr. Ravidranath, CMD, National Small
designation is ready to offer all help
Industries Corporation (NSIC) told - Quote-
to the foundries. They have to inform
“ We have several schemes to help the
what is required by the industries. I am
industry through NSIC and MSME. We
overwhelmed by the encouragement by
have schemes to help you procure Raw
the Government officials at all levels and
Initiatives.
Material at the lowest cost, scheme to
designations.
The Government of India has identified all
schemes to get yourself registered with all
these lapses in the MSME segment and
the PSUs and Government establishments
has ambitious plans to help this sector
for procurement and above all we have
to become a robust sector. There is large
many schemes to market your product
scale failure in popularising the schemes
through participation in exhibitions. Please
available with the Government. This is the
get yourself registered in our website to
duty of industry associations.
automatically get all the benefits”. This
for the failure to plan and adopt modern management tools. The reason I am thinking is the failure of many associations engaging in proactively participating with the Governments in the area of Policy
These days the schemes are available in the website of the concerned ministry
upgrade your technology in manufacturing,
proactive approach to appraise the schemes available with various designations is a great effort which is to be appreciated.
and complete details as to how to apply and utilise the schemes for the growth of his unit. Even large industries, though they dedicated designation to take care of Government Policies, they also fail to utilise
IFO is involved in the preparation of CEFC document for the establishment of a training centre for the high tech Electro Slag Refining and NDT centre being established
the facilities.
in HEC, Ranchi. Mr. Vishwajit Sahai, Joint
Mr. Sanjay Chavre, Senior Officer
directed the team comprising IFO, IIT
of Designation of Heavy Industries,
Kharagpur, HEC and Dastur & Co for the
Government of India in his address at the
document preparation. The document was
Southern SME Meet in Bengaluru said -
ready in two months and submitted to the
Quote- “It is very difficult for us to imagine
GoI for approval. I must confess that this is
your problems and difficulties in running
the first time ever a senior IAS officer was
your industries. You have to inform the
excreting pressure on the participants to
details to us. We are informing all of you
complete the work.
the schemes and assistance available with us through various means like circulars, meeting in several association forums etc. The response is less and needs to be
72
Mr. Ramesh Abhishek, Secretary, DIPP in
INDUSTRIAL BUSINESS MART
Secreatary, Designation of Heavy Industries
The proactive participation of senior bureaucrats and their team is really motivating. The speed with which the Government is working is amazing and in fact they are following with the progress of the work recorded in minutes. It is up to the industries and the CEOs to make use of this highly vibrant atmosphere to realise the dream of our beloved Prime Minister Narendra Modi. I request all the MSME industries to get their Udyog Aadhar and register in MSME Data Bank if they have not done already. Please go through the websites which are user friendly to get the latest information: 1. www.msme.gov.in 2. www.dipp.nic.in 3. www.dhi.nic.in 4. www.eepcindia.org 5. www.nsic.co.in
Mr. A. K. Jalan, Secretary, MSME in his address with industry forums in Delhi, informed that industries should register
October 2016
October 2016
INDUSTRIAL BUSINESS MART
73
INDUSTRY FOCUS / let’s talk
‘‘As a Company, we cater to and make each Bharatiya proud of being a Bharatiya!’’ P D Pant Managing Director Metal Power Analytical (I) Pvt Ltd
74
INDUSTRIAL BUSINESS MART
October 2016
Made in India… Proudly! Metal Power Analytical (I) Pvt. Ltd. is the foremost name in the field of analytical instrumentation and materials testing for metals industry in the country. Inspired by the aim of establishing self-reliance for the country and its institutions when it came to high-end instrumentation, P D Pant, Managing Director, Metal Power Analytical (I) Pvt. Ltd. started Metal Power’s spectrometer division, making the Company the very first to design, develop and manufacture Optical Emission Spectrometers (OES) indigenously without taking any technological or financial support from external sources. Today, Metal Power is the largest manufacturer of spectrometers in the country and boasts of the widest range of OES globally. The Company has also become the country’s and Asia’s first accredited manufacturer of solid metal Certified Reference Materials (CRMs). In an interview with MART, P D Pant, talks about the product range, exports scenario and growth plans of his company.
W
e understand Metal Power Analytical India Pvt. Ltd. offers analytical and metallurgical equipment. Could you tell us about your product range? Our Company manufactures a full range of Arc/Spark type Optical Emission Spectrometers for Rapid and Direct, Automatic Elemental Analysis of Metals and Alloys in weight percentages. The models cover both stationary (bench-to-floor-standing) models as well as mobile units. In addition, we also manufacture Hydrogen analyzers for molten Aluminium and a range of sample preparation machines for spectrometers as well as accessories required for all our equipment. We also manufacture solid metal Certified Reference Materials (CRM) and are the only accredited (certified) solid metal CRM manufacturers in the country as well as in all of Asia. Apart from our products, we also have an NABL-accredited Laboratory for both Chemical Testing as well as Proficiency Testing services that we offer to other Laboratories. What are primarily the sectors your Company caters to? We cater to a wide range of sectors that
October 2016
produce, process or consume metals. Our primary customer sectors include: Metal Producing Industries: Primary producers of metal from ore or from scrap for both ferrous and non-ferrous metals, including integrated plants, mini plants, billet manufacturers, etc. Metal Processing Industries: All varieties of foundries, casting units, rolling mills, battery manufacturers, galvanizing plants, wire manufacturers, machine producers, transmission tower manufacturers, engine manufacturers, machinery manufacturers, component manufacturers, auto ancillary companies etc. Metal Consuming Industries: Auto companies, Construction firms, Railways, Ordnance Factories etc. Testing Laboratories: Commercial testing laboratories, R&D research labs – both industrial and educational, Universities and colleges, Training centers etc. Overall, this spans the entire gamut of both public and private sector enterprise, as reflected also in our customer list which spans all sectors and industries such as Civil, Defence, Space, Automobiles, Railways, Steel, Copper, Aluminium and other metals, Battery manufacturers, Power, Textiles, Chemicals, Oil etc., and
other organisations and establishments in material testing, research and education like R&D Units, Educational Institutes – IITs, NITs, Colleges, Universities, Training Centres etc. What would you reckon as the cutting edge advantages that your products and services offer to your customers? What kind of after sales do you offer? The cutting-edge advantages we offer in our products could be classified in four clear heads: Hardware: Our products are designed using the latest technology and we ourselves have made significant developments that push the boundaries of spectrometer technology. We have numerous design patents to our name, specially in the field of optics, that enable us to offer features on our instruments that outstrip anything offered by competitors. Our machines offer class-leading limits of detection, stability and precision - all while being more compact, user-friendly and economical. Analytical features: Our instruments offer top-of-the-line analytical features including – but not restricted to – time-resolved spectroscopy, soluble-insoluble analysis, flexibility of power, frequency and other parameters for allowing researchers to
INDUSTRIAL BUSINESS MART
75
Metavision-108P
conduct a wide array of experiments suiting their analytical needs. Applications and Software: Through our in-house Applications Lab and Software division we offer a range of generic and customized Applications to enable customers to meet specific and specialized testing needs. Right from hardware solutions (such as wire analysis, thin sheets etc.) to software modules customized for user needs, we offer customers the very latest (and greatest) solutions to any need they may have. Economic advantage: Our machines are designed to consume very little power and Argon, while also being extremely easy to use – so much so that even an unskilled operator can be trained within minutes on how to conduct routine analyses. Additionally, we offer a range of products allowing each user to select a product that optimally fits his analytical and budgetary requirements. Finally, we have the best service network and capability in the industry to ensure complete peace of mind post-purchase! This ensures that our customers are assured of the best initial and lifetime costs when selecting from our range of spectrometers. When it comes to service, we live by the credo that “If a thing is worth doing at all,
76
INDUSTRIAL BUSINESS MART
Certified Reference Materials it is worth doing well”. To this end, we have always been fully committed to having our own Service network. Metal Power has 30+ engineers across the country making ours the largest pool of service engineers of any spectrometer firm in the country. We take great pride in our service – focusing on having rapid response and turnaround times with industry-leading performance on time-to-repair. We repeatedly go above and beyond what is considered “normal” and this is a key reason why our customers continue to trust us, with several placing repeated orders on us as they expand and their needs grow. Our Service network offers the following key advantages: 1. 30+ engineers; all of them fully trained by our in-house R&D teams on all our instruments 2. Regular training sessions for all engineers to ensure that they are always trained on all equipment including the latest launches and upgrades 3. Spread across the country in more than 15 locations 4. Regional Service Managers in each Region who carry deep experience and support and guide engineers as well as
directly handle key clients 5. Dedicated Service Desk at the Head Office (Mumbai) for handling customer calls and issues at a global level 6. Full back-end support by the R&D and Applications teams who have designed the instruments and applications in case of any issues that are not directly resolved by the Service personnel 7. Reasonably priced AMC plans, program additions and reasonably-priced spares etc. to ensure that customers have a far lower lifetime-cost of the instrument as compared to imports 8. 24*7*365, toll-free line for Complaint registration and follow-up 9. Online, telephonic and in-person support modes offered to all our customers 10. A commitment from the MD to the service person to ensure that no stone is ever left unturned in ensuring the satisfaction of each and every one of our customers We also offer service support across multiple modes: 1. Telephonic support 2. Online support
October 2016
3. On-site visits Metal Power has its own in-house Research & Development facilities as well as fully in-house Production facilities. We assure all our clients of ready availability of any and all spares, consumables and / or replacement parts. What is the kind of R&D efforts that your company undertakes? In this regard also mention some of the latest innovative solutions in your segment. Our R&D – Shodha Sadhana Kendra – is engaged in improving the performance of our current range of products and services to the absolute limit of current technology and also work on developing and furthering spectrometer technology. Our R&D is also engaged in extending the range of our products to give our country the much required fillip in establishing itself as a center for cutting-edge research, development, design and production in high-tech industry. We have many patents to our credit and are continually adding to this list. Hitherto, for instance, it has generally been taken for granted that the higher the resolution one needs in a spectrometer, the more will be the number of detectors required. We have busted this belief with two of our most recent patents. These are patented techniques of ours, which we consider as very important contributions by our Company. Using these, we deliver classleading resolution, precision and stability of analytical results while also bringing down the costs – both on power consumption as well as equipment itself! Apart from equipment supply your Company also offers material testing service and proficiency testing service for laboratories. Could you enlighten on this? Is this an on-site service or you offer at your facility? A large part of the country continues to rely on external third-party Laboratories for meeting their testing needs. Now, this has created a thriving commercial
October 2016
laboratory industry, but these laboratories all need to develop and prove their own proficiency as testing service providers. These laboratories, as well as other company-owned labs, enroll for on our Proficiency Testing programs wherein they are assessed for their testing processes & prowess. Needless to say, it is not a simple or easy task to get NABL accreditation even as a testing laboratory and getting the same for Proficiency Testing services is therefore an even tougher proposition. Given our depth of expertise in the field however, we believed it is essential to get such an accreditation and do our bit to assist the numerous labs and companies in our country. A couple of years ago, we got NABL accreditation as Proficiency Testing Providers (PTP) to Laboratories. Our Lab Division now conducts PT Programmes regularly on a monthly basis. We are hopeful that this will help greatly to bring up the quality of analytical services which labs in India provide and thus help their own clientele through better and more efficient services, ultimately bringing greater glory to the industries of our Nation. Could you mention some of your major customers from all the segments that you serve? Some of our major customers are the House of Tatas and their associated entities, Mahindra & Mahindra, Ashok Leyland, Kosei Minda, SAIL, NTPC, IITs, NITs etc. What kind of market share your products enjoy in India? Outside India, where are your products exported? And what is the percentage of exports in your entire offerings?
In the segments that we serve, we have over 50% market share. We export to a number of countries across the Middle East, South East Asia, Africa and now also the Americas. Currently, exports form around 20% of our total production. We are set to increase this substantially in the near future.
Metal industry has been sluggish, for quite some time in terms of production and off-take, particularly steel and foundry. Has that made any impact on your sales and margins? Yes, over the last 2 to 3 years, demand has been sluggish. However, we have been able to keep our production shops busy and have consolidated our R&D and other efforts in the meantime. In terms of overall scenario, while things have been sluggish in some areas, we’ve expanded both our product range as well as market portfolio, which has helped us cope and offset any potential downsides. As the Managing Director of Metal Power Analytical India Pvt. Ltd. what are your outlook for testing equipment industry in India and growth plans for your Company? As a Company, Metal Power Analytical must build a line of instruments and products that would be rugged, reliable, accurate and precise. Additionally, they would also be found very useful by all the sectors and customers that we cater to and make each Bharatiya proud of being a Bharatiya! If by doing so, we can inspire others to tread the same path, this would be fantastic news. For too long we as a country have been content to not make, but only buy; not develop, but only consume and this has led to a mindset that we are not capable of cutting-edge research and the design and manufacturing or high-tech equipment. As a Company we have strived and continue to strive to bust this myth. We hope that our example will bring others to share our belief and join us in such high-tech sectors; to compete with and beat the best in the world. Vandemataram!
INDUSTRIAL BUSINESS MART
77
INDUSTRY FOCUS /CASE STUDY
SmartSense®
Making Foundry Smarter with IoT In spite of being the basic part of manufacturing industry, Foundry sector has always lagged behind other industries in case of adapting modern technologies and leveraging the benefits IT. Rhino Machines has come up with indigenous SmartSense® technology to bring the benefits of IT to foundry doorstep, making foundry process more efficient and more productive.
F
oundry has always been a complex process of producing a casting, sometimes to produce 1 kg of casting we end up handling 100 kgs of materials. The variables are enormous, the challenges unlimited, and even after centuries of experience, still unconquered. Being a mix of art and science, it has always lagged behind other manufacturing industries such as, petrochemical, food, paper, FMCG, electronic goods, plastic and so many other process industries. The industries where the content of science has been more than 70-80% have been able to adapt to the IT developments almost at the same pace as its development.
78
behind in adapting any modern technology and so also in IT. Even though Foundry is the mother industry for all manufacturing and infrastructure for any country, the industry has not got its due share of importance. In addition the volume is not high and these two basic reasons have led to very minimal and in scattered areas of development by IT industry directly. It is not only the casting producer, but the supply chain including machine suppliers, material suppliers, service providers, consultants…all are in the same boat. For modern technology India has been heavily dependent on overseas players, which again makes all the solutions not viable.
If we take health care industry, the pace at which they have embraced the IT, is mind boggling. Not only have they been able to use data acquisition, but the analytics used are growing day by day, empowering the doctors and medical fraternity to leverage their skill and abilities.
Indian suppliers have not been tech-savvy,
Foundry however has always lagged
INDUSTRIAL BUSINESS MART
have lagged behind and not yet been able to comprehend the possibilities.
industry. Even though India is the hub for software there is no localisation of the same in foundry industry - all is in piece meal, not comprehensive at all. All the above reasons have always been at the back of the mind of Manish Kothari – the author. Working in the foundry industry since more than 25 years, and having been fortunate of getting educated at MSU – Baroda, where his professor Late Shri P B Desai gave the platform to learn IT & Electronics in 1990 while studying Mechanical engineering, working with his father R C Kothari who always thought laterally and had tremendous international exposure on technology and lastly Renzo Cappelletto – an Italian born French technologist, a thinker with a vision
The industry has made visits to countries
way beyond my own imagination yet with
like Japan, Germany, Italy, USA - all
very strong ground and field knowledge.
advanced systems with lot of IT use,
Leveraging these opportunities, taking
yet these solutions have not been
the lead, Manish Kothari with a team of
implemented in the struggling Indian
motivated and dedicated team of Rhino
October 2016
Machines have embraced technology by leaps and bounds. Starting from making mould handling automation by themselves, not depending on Siemens, but acquiring the knowledge of PLC and programming them, online printing, online support using internet, the journey has been slow but with a solid foundation. After having reached the GCIP 2015 finals, the transformation at Rhino took a different pace, and converted to a partnership among 2 of the top 6 semifinalists – Rhino Machines & Ecolibrium Energy. After their first meeting on 15th April 2016, when the idea was born to connect IT with the foundry and take the IT right into the core of foundry processes, the implementation followed at the pace of IT. By July 2016 the RTC one of the core product of Rhino was enabled on Ecolibrium’s already established SmartSense® platform. Deadlines were set for holistic implementation. What a multi-
October 2016
national would have charged exorbitantly, was implemented at a sustainable and manageable cost platform.
analytics, reporting and alert under their
So what is SmartSense® and what it can do?
But it is a holistic and comprehensive
Here are few examples on how SmartSense® will enable IT in the foundry production industry.
Insights platform. The solution is not limited to Energy only! approach to collating and relating data from across all the major production centres such as Melting, Moulding, Sand, Core, Fettling, Painting & Despatch.
Energy Meter monitoring has been available from many players, but limited to only localised and time based data collection. These systems were not customised to Foundry needs which are both time based and cyclic in nature. In addition most of the solutions were hardware sales, and not software as service (SAS) model.
Data Management Issues addressed by
Taking this forward Rhino has extended its foundry domain knowledge and coupled with the existing presence and stable platform from Ecolibrium to create a platform which will help foundries right from the smallest to the largest with
• Centralized monitoring– geographically
SmartSense®Platform • Access to real time accurate data for Energy, Materials, Production • Hardware issues – Unreliable local hardware & software for critical data • Analytics of data collected – not in real time, limited information & reports, not integrated distant locations data not on same platform • Breakdown & Prive Maintenance – lack of scheduled alerts on common platform
INDUSTRIAL BUSINESS MART
79
What the foundry decision maker achieves with SmartSense®: Input / Output Analytics: • Consumption Analytics based on • Time Scale • Heat Wise • Component Wise (Part No) • Time Period (Shift, Day, Week, Month, Year..)
80
INDUSTRIAL BUSINESS MART
• BenchMarking Consumptions • Production Capacity Analytics • Machine Utilisation • Production Facility Efficiency • Benchmarking Production Criteria • Final Castings Production • Real Time Production Path • Product Cycle Time • Benchmarking consumptions & costs component wise
Asset Management: • Preventive Maintenance • Real Time Alerts • Collation of Preventive Actions • Adjusting Schedules • Predictive Maintenance • Analysing Efficiency • Energy Consumption monitoring • Asset Health Report • Operating Hours • Life Cycle Analysis
October 2016
So what is SmartSense速 and what it can do? Here are few examples on how SmartSense速 will enable IT in the foundry production industry.
The Technology behind the Solution
upgrades.
SmartSense速 has been built and developed in IIM (A) incubation centre for acquiring the data directly from the machine through a very common RS485 protocol used across various systems. The hardware is including the normal SIM from the Cellular system operators with available mobile networks, and connectivity to any of the measuring devices, PLCs and such data devices.
Working with Rhino & its foundry domain knowledge, a full fledged Foundry UI is being designed with the industry specific needs.
The software platform commonly called as User Interface (UI) has been built to work on any web browser, with widgets and insights which includes analytics, reports and alerts. The system is completely developed in India by software engineers with a continuous update as the IT
October 2016
will probably be the first time such a solution is being implemented in this century of more than a century old, and we are proud to have started a new paradigm and way of looking at technology.
Call to Action Once having built the platform to acquire the data, Rhino shall be putting together years of experience of its own organisation and take the experts from the industry on board, to provide comprehensive solution for data acquisition, analysis and then support with consulting.
Manish Kothari Managing Director, Rhino Machines Pvt. Ltd. Started in 1983 as a consultancy firm, Rhino Machines evolved as a full-fledged manufacturer of conventional green sand, pouring and centrifugal casting products in 1991.
SmartSense速 therefore can turn into not only data acquisition but a tool for foundries to find solutions with the platform of IoT. It
INDUSTRIAL BUSINESS MART
81
INDUSTRY FOCUS/CASE STUDY
Munjal Castings Increases OEE by 50% For any manufacturing company to be a market leader and become more competitive, it is vital to reduce costs, maintain quality, and provide timely delivery. Munjal Castings, based in Ludhiana, India, adopted this philosophy for its growth.through Renishaw TRS2 systems
M
unjal Castings, established in 1980, is part of The Hero Group, and caters primarily to Hero Majestic in the automotive industry. The company currently employs 1,200 people at two plants, where it manufactures quality aluminium die cast components using 20 machine tools. Munjal Castings has emerged as one of the trusted names in the aluminium and zinc die casting industry, supplying 600 tonnes of castings each month, with a turnover of 1.5 billion INR. The company supplies components to Hero MotorCorp Ltd, Suzuki Group, Hyundai, Hero Cycles, Nissan, Tata, GM, and Daimler Chrysler, as well as supplying the export market. Aware of the vast business potential in the international automotive industry, the company has commissioned a third plant which is ISO TS 16949:2000 certified and has a capacity of 100 machines. Business challenge A major challenge to overcome was frequent tool breakage, which caused delays in production and led to high levels of scrap and financial loss in terms of materials and time. The reputation of the company was at stake, as even a single substandard component could negatively
82
INDUSTRIAL BUSINESS MART
affect goodwill towards Munjal Castings in the market. The Solution Renishaw TRS2 systems were installed at Munjal Castings to address this challenge. The TRS2 is an award-winning non contact broken tool detection system for machining centres. It determines whether a tool is present by analysing reflective light patterns and ignores any that are created by coolant and swarf, thereby eliminating false indications of a broken tool. Mr. P. L. Arora (Senior Vice-President of Munjal Castings) said: “The company was incurring huge financial losses due to high rejections. This prompted the management to pursue increased automated solutions and they purchased TRS2 from Renishaw. After installing 16 TRS2 systems, huge savings in costs and time have become a reality.” The company’s vision is to increase exports from 400 million INR to 1,000 million INR in the next three years. To achieve this, it has decided to increase automation with the help of process control solutions. According to Munjal Castings, machines with TRS2 installed have had their overall equipment effectiveness (OEE) increased from 50% to 76%. The target is to increase the OEE to
85%. Previously, 250 finished components were produced daily on each machine. Following installation of the TRS2 systems, production increased to 270 components per day. Faith in Renishaw Mr. Arora concluded: “Maintaining quality, cost and delivery within stringent deadlines is our company’s unique selling point, which has helped us to stand apart from others. Daily, we supply 200,000 castings with 150 different component types to the automobile industry. Renishaw’s products are reliable and are of high quality. With faith in Renishaw’s technology, the management is confident of achieving greater results and reaching its targets.” www.renishaw.com
Samina Khalid Samina.Khalid@renishaw.com Marketing Manager Renishaw India
October 2016
The institute of indian foundrymen 104, Sharmad Residency, S. No. 291, Shilavihar Colony, Behind Hotel Olivia, Karve Road, Pune - 411037 Tel.: +9120-25437374, 2542 2902 E-mail: www.iifncts.org October iifpc@iifncts.org Website: 2016
INDUSTRIAL BUSINESS MART
83
INDUSTRY FOCUS /cover story
SMART FOUNDRY NEXT GEN FORGING COMPANIES
The forging industry constitutes a key link between critical manufacturing segments. Deploying leading-edge technology is crucial for forging companies to gain an advantage over their competitors. Rajesh Angadi talks about the required investments, research and innovation.
T
he Indian foundry industry has a long history. It has been transformed from making artefacts, jewellery, etc to making the most complex components for application in automobiles, railways, aero, space and nuclear power, etc. The industry has tremendously changed since then to align itself with changing requirements of the consumer industry. The industry has logged growth of 10-15 per cent over the past 10 years, except in global recession. But after the opening of global economy, competition has increased and also the cost of raw materials, energy, labour, and environmental costs have tremendously gone up over the years. The availability of some materials like good quality foundry sands, iron ore for making pig iron and steel has become serious issues due to mining problems and environmental pressures. The environmental norms and pressures have also impacted the cost of operations and these pressures will continue to grow as we go forward. Moreover, the expectation of buyers with regard to quality, response time for development of value added and readyto- use components at a reduced costs are going up. At the same time due to poor image of the industry, the sector does not attract the talent as it is not considered a preferred employer. The foundry industry in India is largely in MSME category and due to pressure of margins,
84
INDUSTRIAL BUSINESS MART
lack of awareness, high cost of capital, modern design, manufacturing tools and equipment is not able to invest in modern technology. Therefore, going forward and to sustain the growth in this sector, the stakeholders need to focus on various aspects. Forging has traditionally been regarded as a manufacturing process for shaping metal-based shapes by using localized compressive force. Its industry plays an important role in the European manufacturing industry and consists mainly of small and medium-sized enterprises (SMEs). The industry can be broken down into two significant sub-industries: the castings industry and the forging industry.It is argued that the forging industry needs to become more energy efficient and environmentally friendly. Next generation forging technologies are developed to help companies reduce their energy dependency, improve their environmental footprint, and gain a competitive edge in the forging industry. Such companies particularly face strong competitive pressure in traditional highvolume segments from regions where production is less costly, such as Asia. Next generation forging technologies address a wide range of challenges, including a higher complexity of castings, more stringent requirements regarding
eco-efficiency, affordability, the quality of products and delivery conditions, and a lack of specialization and skills in production facilities. Next generation forging technologies not only address these challenges, but also provide significant benefits for end-users, such as lower material consumption, increased flexibility of production, a reduction in overall production costs, and improved materials and material properties. There are various factors that drive the uptake of the trend of next generation forging, which include environmental regulation, a need for increasingly more efficient and flexible manufacturing, and a strong and established customer base.Companies related to forging industry face challenges in access to materials and energy at competitive prices at the global level. Moreover, the increasingly more complex technology of forging companies requires their employees to provide an increasingly specific set of high-level skills to engineer and to operate forging equipment and machinery. Companies face challenges in attracting this talent, and some overcome this by developing and implementing specialized apprenticeship programmes to train incumbent workers. Successful next-generation forging companies display a strong market-based approach, specifically addressing the
October 2016
complex needs of their customers by actively engaging with them. In order to maintain or gain a competitive edge, these companies also strongly focus on excellence and innovation in their day-today business.
simulation software is used to simulate heat-treatment, machine distortion and design optimization, enabling companies to predict the microstructure and mechanical properties of forged products before they are produced.
Next Gen Forging Companies
The government has to be a facilitator for having policies to support ease of doing business and create supporting infrastructure and strengthen institutional support. The industry associations too need to build capacities to stimulate activities which will help the sector, especially the SMEs.
The forging industry constitutes a key link between critical manufacturing segments, i.e. metal suppliers (both ferrous and nonferrous) and end-user industries. Nowadays, deploying leadingedge technology is crucial for forging companies to gain an advantage over their competitors. This has required continuous investments, research and innovation. Forging company needs to be costeffective, preferred process by which metal components of superior quality, integrity, and performance are produced for critical and demanding applications. This requires the development of more efficient forging technologies in the near future. Forging industry of the future needs to be energy efficient and preserve the
Focus on the following aspects: Promote co-operation and cluster working to harness the strength of collaborative approach and enable cluster members to access modern design/manufacturing tools and common training facilities to the extent possible for better productivity and competitiveness. Strengthen institutional capacities as a support system.
parameters to continuously monitor the processes and upgrade these. Skill development to meet future needs. This can again be done in clusters in-house. Promote hygiene, health & safety in shop floor working & management. This will not only improve the per-man productivity, but also improve the image of the sector to attract the younger generation. Quality management, standardizing of processes and continuous upgradation. Big Data is a great opportunity for organisations. Data turn into a strategic resource, whose smart utilization represents a high value and competitive advantage. Establishing the right infrastructure to be able to keep processing time constant while volumes are increasing is a challenge which should not be underestimated. Big Data is a one stop solution where organisations can get optimized Big Data infrastructure solutions including hardware, software and services – all from a single source. Big Data is about large data volumes in the range of
The foundry industry in India is largely in MSME category and due to pressure of margins, lack of awareness, high cost of capital, modern design, manufacturing tools and equipment is not able to invest in modern technology. environment. Consequently, the need for environmentally acceptable, functionally effective, and affordable technologies that integrate pollution prevention into the entire metal forging processing system design will increase significantly.Next generation forging technology provides a solution for these challenges by drawing on lighter, stronger, and higher-quality alloys, rapid prototyping technology, and advanced computer simulation software. The higher-quality alloys enable forgings to compete on the market with otherwise superior materials. Rapid prototyping technology increases the speed of production and adds flexibility for endusers, which increases the competitive position of companies employing the technology. Moreover, advanced computer
October 2016
Promote lean manufacturing by cutting down wastage, rejections, promoting recycling, energy management, scientific designing by using quality management tools and modern software for improvement in yield. Promote energy management with a target to reduce energy intensity by 10-15 per cent over next 5 years by having energy policy and systematic and periodic energy audit. Every unit must have a defined & stated energy policy like the quality policy and pursue it religiously. Focus selectively on low-cost mechanization, especially for hazardous processes which will to an extent improve productivity and also address partly the manpower issue. By systematic recordkeeping, measurements and control of various
many Terabytes to Petabytes coming from versatile internal and external data sources, such as databases, audio and video files, e-mails, IT logs, web logs, social media and the millions and billions of sensors which are built in everywhere. Especially new sources provide data which rarely is structured, but rather unstructured, semi-structured and poly-structured. Very often this data is continuously generated at a very high velocity, and the same high velocity is also demanded when it comes to analyzing the data in real-time to create value for the organization. By discovering facts and insights about customers and suppliers, market conditions, operations and root causes of costs are revealed, that would otherwise remain hidden. This helps you predict things that
INDUSTRIAL BUSINESS MART
85
are going to happen in future, take the right decisions, and initiate the respective actions. Betting on the right horse, skipping useless activities, and optimizing the allocation of resources will increase performance and productivity, accelerate business processes, minimise risks, improve efficiency, effectiveness and profitability and finally give you the competitive edge that you need in today’s tough business world. The 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, visualization and cloud computing - to name a few. Businesses, government and other organisations looking to big data analytics to gain insights and solve challenges typically do not have the core competencies required to process and analyze giant databases.PARC, a Xerox company, (R&D services), Cisco (IT leader), Hitachi Data Systems (big data storage) and Quantiply (enterprise architecture) have created the Big Data Foundry (BDF) that pools together experts in software and hardware who can help enterprise harness data in a more powerful and efficient manner. 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.
86
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. •Reference architectures, data scientists and tools that reduce technological complexity and deployment costs. •Pre-assembled reference architectures to validate your business solutions on target reference architectures before investing in these complex tools and technologies. •Support development of data driven infrastructure to empower your employees to sense, analyze, interpret and act fast on the data insights. As a part of their Industry 4.0 initiative, the customer wished to improve their products, their business and their overall efficiency using actual production data from their assembly lines. The customer had multiple assembly lines with a diverse set of machines, robots and conveyors. They wished to analyze real-time data as well as store the historical data from their lines to identify issues, improve throughput and predict outcomes. There were several challenges that this vision presented. •The customer had invested in multiple SCADA systems across their lines. Multiple heterogeneous systems meant that it was extremely complex to collect data across these systems and present a unified view of production and efficiency data. There were islands of data that were not unified.
Rapid Experimentation Cloud
•The assembly lines consisted of heterogeneous machines, a majority of which were not connected. Data for these machines were manually compiled resulting in delays and inaccuracies in decision making.
Smart (Big Data) Foundry brings
•Connecting additional machines would
INDUSTRIAL BUSINESS MART
result in a humongous growth of data. The existing SCADA systems would not scale to this data growth which meant that there were limits to the amount of real-time and historical data that these systems could handle. •The shop-floor (Operational Data) was isolated from the rest of the IT network in the organization. The existing complex network topology made it a challenge for systems to talk to each other. •The CEOs and decision makers in the company needed modern Rich Internet Applications that would work from anywhere and on any device. They needed modern and responsive web and mobile applications that would present data to then when they wanted it. Solution Foundry (Forging and casting) machines will be part of Unified platform with Internet of Things so that they could send data at the lowest granularity. Unified Platformwould process this data in realtime or on a scheduled manner to provide insights into production efficiency and Overall Equipment Effectiveness (OEE). Some direct benefits include: •Providing production visibility and machine efficiency across assembly lines allowing decision makers to monitor progress at a plant level and drill down into specific machines whenever needed. •Complete historical data is stored and available for analysis. The customer can go back and analyze historical data going back to several years. •All machines are connected regardless of the fact that they are heterogeneous which was previously not possible. All CNC and PLC machines with diverse controllers are now connected. Other machines that affect productivity like robots and testing machines are also connected. The Unified platform is built on a big-data stack and can easily handle the scale up
October 2016
and the data diversity challenges that these machines present. •Energy consumption metrics are collected at a machine level and that information is used to manage energy requirements for current operations and future scale up. •It will be good to have hosted SaaS platform on the cloud so the customer can scale up as per their need. •There should be complete integration with modern web and mobile applications using a comprehensive set of REST APIs. This meant that the customer could inject production data into their ERP systems as well as build applications that would present this data in the most suitable manner on any device.
October 2016
Metal China is leading the foundry industry. In the ‘Big Data’ era, automation, intelligence and digital have been the trend for foundry industry. Die casting industry is currently the most robust branch in foundry industry. With the growing trend for lightweight automobile, the die casting industry in China will continuously maintain a doubledigit growth in the next 10 years. Metal China and the Die Casting Exhibition have seen the big progress of China’s foundry industry. The technology research and development ability is increasing significantly and foundry companies are more professional than before.
capacity to support the sector for continued and sustainable growth.
Rajesh Angadi rajeshangadi2013@gmail.com 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.
In future there is need for the Indian Foundry (Forging) Industry to have partnership globally with manufacturing leaders to strengthen and build its
INDUSTRIAL BUSINESS MART
87
INDUSTRY FOCUS/ techniQUEs
Emerging Technologies and Design for Manufacturing
Ravi Kunju talks about a holistic approach towards the entire product design lifecycle is important as we push the envelope of design with newer materials and manufacturing processes to meet the challenges.
I
2. Conventional low strength Steels are
lifecycle is then paramount as we push the
predicted to dip down below 20% of total
envelope of design with newer materials
growing share of 3D printing, challenging
usage by year 2030 (dropping from 70% in
and manufacturing processes to meet the
conventional thinking.
the 1970s)
challenges. We need environments that
A few days ago I took a flight out of Flint,
3. Alternative materials like Aluminum and
Michigan which was once the epicenter
Magnesium will be on the rise (along with
of manufacturing, luring those near and
high strength steels)
t is a breath of fresh air for the traditional manufacturing process with a rapidly
far promising automotive riches. Over the years a lot has transpired. I was contemplating how the manufacturing industry has the ability to once again put certain regions back on the map, this time around catering to a generation that prides
being stretched by an ever growing desire to lighten structures first in aerospace, and now in the automotive industry; the importance of upfront manufacturing feasibility has risen to new heights. The
itself on personalisation and low tolerance
emergence of alternative materials such
for high emissions.
as: Magnesium, and Aluminum, along with
Product design is rapidly changing to keep pace with the desires of the younger generation, and just to elaborate, in the recent IKB Deutsche Industrial Bank report on manufacturing, the top three trends that caught my attention were; 1. Light weighting is the #1 priority in the automotive industry today (largest
alloys like ZAMAC as well as the addition of new additive manufacturing techniques to 3D print patterns and dies, have brought new process challenges along with
design, better in performance and at the same time easier to manufacture. Is it even possible? In a series of blogs I will be focusing on different emerging technologies that work in tandem with traditional manufacturing methods and have tremendous potential to breathe new life into this industry. In this first blog of the proposed series, I would like to draw your attention towards the metal Casting process with an attempt to articulate the challenges & opportunities; and the benefits of applying simulation driven process to address them.
immense opportunities to this struggling
Investment Casting: Marriage of Additive
industry. It will be increasingly difficult for
and Traditional Manufacturing
manufacturing suppliers to differentiate and still keep their profit margins, if they do not maximize the potential to use the
An increased number of 3D printings are in rapid rise in traditional manufacturing
latest technologies in simulation tools.
industry and specifically for making casting
especially to meet the new
Under these trends, a holistic approach
on this subject by Mirko Bromberger (3D
emissions standards
towards the entire product design
Printing and Simulation-Driven Design for
consumer of manufactured components),
88
As the boundaries of product design are
make great products that are faster to
INDUSTRIAL BUSINESS MART
patterns. Please refer to an earlier blog
October 2016
High Performance Castings) wherein it was
wherein fast, easy, accurate information
shown how a part can be designed from
can be provided to the design and
the ground up using topology optimization
manufacturing Engineers right at their
for light weighting and then worked on
fingertips to meet the challenges,
streamlining the desired casting process.
through the entire product design
As shown in the graphic below, the entire process is highlighted wherein the best of breed technologies were combined together; topology (free form) optimisation for light weighting, 3D printing for making the pattern and using investment casting for making a traditional
phase irrespective of what stage they are at. I strongly feel that to meet the quality standards minimise catastrophic (cancerous) casting defects and to improve productivity of castings, manufacturing feasibility has to be part of the design process. The pace of product innovation
casting. One essence of this entire
can be severely hampered if designs are
exercise is that to produce innovative
thrown over the fence to foundries, to
products, manufacturing feasibility has
take the entire burden of making quality
to be embedded into the product design
components, while still being able to meet
process upfront.
their margins and be profitable.
Secondly a framework needs to exist
The above problems can be solved in an
October 2016
environment that is easy to use, while being accurate in capturing the physics, and also is affordable (to ramp up and use effectively). Altair’s solidThinking Inspire is already making the industry turn its head on topology optimization, by providing technologies upfront to the designers, hiding all the complexities. In keeping with the same philosophy, our latest release of Click2Cast 4.0, helps address casting problems effortlessly through process driven templates for all the above casting process including investments castings. Our customers love the fact that they can run Click2Cast within their design process right from the beginning, wherein product designers can define any location on the product as in-gates (areas from where metal flows into the product) for castings
INDUSTRIAL BUSINESS MART
89
to drive simulation, without having to wait
I made a very broad assessment of the
for detailed process experts to design them
various casting processes and put it into
for them. They can also visualise areas of
quadrants to identify the best casting
potential porosity, thus guiding the process
methods based on the geometry of the
engineers to appropriately do the detailed
part (smallest sectional thickness) and the
design of the runners and risers and the
volume of production.
gating systems. The process engineers can also easily choose the process being used through guided templates to set their problems and run the entire simulation on their own computers.
based on thickness and on the horizontal axis it is based on production volume. Low thickness and high volume production on low volume production on the top left
to easily perform their entire casting
quadrant. Gravity sand casting caters to
simulation in 5 steps, thus bridging the
high volume production for thicker parts.
communication gap within the entire
Investment casting spans in thickness
product supply chain to make quick
but usually geared to lower production
decisions, while utilizing the best process
volume. This process is gaining traction
and simulation tools for the most
as it well caters to make parts that are
challenging designs.
difficult with traditional methods and
that would greatly supplement the reading for those that are interested in digging a
allows geometric freedom. You can learn
Ravi Kunju www.altair-india.in
Ravi Kunju is the Vice President of Strategy and Business Development for the enterprise business unit of Altair.
more about this process here https://www. youtube.com/watch?v=wMzSS3BnMLs
little deeper.
Cancerous Castings
Brief Primer: Broad Classification of
There are visible and invisible defects in
Castings Production and Process
castings. In my opinion those defects that
INDUSTRIAL BUSINESS MART
It is a lot better to watch the attached videos pertaining to the above defect so you can not only understand what they are but also get an understanding on how those can be identified and rectified using simulation tools like Click2Cast.
the bottom right, and high thickness and
Click2Cast environment allows users
Below you will find a primer on Castings
90
In the vertical axis I have the classification
are invisible can be extremely dangerous as they can rip apart the performance. Let’s walk through three defects that can typically occur in the casting process.
October 2016
Plot No. 347A, 2nd Phase, KIADB Industrial Area, Harohalli, BENGALURU-562112 Kanakapura Taluk. Ph: 080-26396461 / 41632962 / 99456 95322 Manfred Maier Email: fenmet@gmail.com , www.fenfemetallurgicals.com Managing Director & COO, HELLER October 2016
INDUSTRIAL BUSINESS MART
91
POst Event
The Connected Enterprise
CII Smart Manufacturing Conclave Featuring post event coverage of CII Smart Manufacturing Conclave held at Pune. The conclave discussed “what, why and how” of smart manufacturing and its inevitable benefits and simplified processes.
I
n order to remain globally competitive, the Indian manufacturing sector will
have to strategise and plan how to take advantage of ICT to leap frog over the present labour intensive and uncertain manufacturing paradigms to a “smart” set up. Manufacturing companies will have to earmark additonal investments and skills to take this leap and be a part of the “smart” world and be part of national level programmes like “Make in India” and “Smart City.”
The recent conclave on
Smart Manufacturing by CII has identified the following three major challenges in adoption of smart 1. Manufacturing – managerial/ cultural 2. Technological 3. Ability to invest The conclave gave an in-depth analysis of understanding Smart Manufacturing and why the time has come to move from Traditional to Smart.
92
INDUSTRIAL BUSINESS MART
The most compelling reason for firms to move from traditional to Smart Manufacturing is market pressure. The need to “do more using less” stems from several factors. Some significant ones are: intense global competition; low innovations; lack of integration between equipments, people and processes; finding and retaining skilled labors; cost pressures; changing consumers’ needs; reducing cost of inventory and increasing requirements on compliance and statutory reporting.
and agile units. Asset efficiency, flexibility,
Following are the topics which were discussed during the conclave which clearly highlighted the absolute necessity of adopting smart practices if India’s manufacturing sector has to make the quantum jump.
with well-planned IT support ensures
Asset Efficiency and Productivity
Effective Information and Communication
Global competitive pressure has compelled the manufacturing and industrial companies to develop into a more efficient
Manufacturing organisations largely focus
scalability and people skill development are some of the attributes that contribute to productivity. Planning for Smart Manufacturing The trick for efficient manufacturing is, well defined processes coupled with robust IT systems. Well defined processes show traits like visibility in performance, transparency, traceability and consistency and repeatability. Smart Manufacturing that suitable defenses are built into the solution including security procedures such as secure remote access, hardware encryption, firewall, physical building security and network security for data.
on automating their enterprise processes such as sales, order management,
October 2016
inventory, warehouse, procurement, planning, etc. for improving enterprise business through appropriate ERP systems to ensure seamless flow of information from order delivery of finished goods. However shop floors processes are manual and paper-based and even if manufacturing systems such as MES are being used, they tend to work in silos
Real Time Management The real time management enables management to control or modify process parameters to achieve the targeted performance of business. Its insight and reporting enables proactive approach to ensure the implementation of necessary actions to avoid any unwanted down time or performance.
within plants and without integration with enterprise processes, which makes the shop floor completely disconnected from the enterprise business. This impacts overall productivity due to manual follow ups, unplanned down times, changeovers, lack of accurate information etc. A number of emerging technologies and standards such as OPC (Object linking and embedding for process control) standards, emerging M2M communication (short range wireless and long range cellular
The implementation of real time management includes phases such as, assessment of overall manufacturing facilities; Plant-and Enterprise- wide integration; Plant- wide optimization to manufacturing intelligence and Manufacturing knowledge “Smart Manufacturing” as a model and practice will occupy very important space in the mind map of manufacturing companies and service companies associated with the manufacturing sector.
network), emergence of IoT (Internet of
The initiative by CII has clearly highlighted
Things) coupled with customized solutions
the absolute necessity of adopting smart
(that sit on top of data acquisition systems
practices if India’s manufacturing sector
such as DCS/PLC’s/SCADA) has helped to
has to make the quantum jump and be
tackle the issue.
globally recognised and be competitive.
October 2016
Dr Arvind Tilak, Co-Chairman, CII Smart Manufacturing Conclave 2016, Immediate Past Convenor, CII Pune IT & ITeS Panel & Chief Executive Officer, Ascent Intellimation Pvt Ltd; Mr Narendra Barhate, Convenor, CII Pune IT & ITeS Panel & Managing Director & CEO, Seed Infotech Ltd; Mr Ganapathiraman G, Vice President and GM - India and South East, ARC Advisory Group; Ms Sujata Tilak, Chairperson, ISA Pune Chapter and Managing Director, Ascent Intellimation Pvt Ltd; Mr Dilip Sawhney, Member, CII Manufacturing Council & Managing Director – India, Rockwell Automation India Ltd; Mr Shishir Joshipura, Chairman, CII Smart Manufacturing Conclave 2016, Chairman, CII Pune Zonal Council & Managing Director, SKF India Ltd; Mr Parag Satpute, Managing Director & Country Manager, Sandvik Asia Pvt Ltd, Mr Nitin Chalke, ViceChairman, CIIPune Zonal Council & Managing Director-India, Eaton Technologies Pvt Ltd & Mr Prashant A N, Director & Head, CII Pune.
INDUSTRIAL BUSINESS MART
93
POst Event
Manufacturing Myanmar 2016: A ‘Launch Pad’ for Manufacturing Growth Manufacturing Myanmar 2016, the only dedicated manufacturing trade event in Myanmar, ended successfully with visitors and exhibitors lauding the event’s reach and role in Myanmar’s manufacturing industry.
T
he event in its third edition held from 22 to 24 September at the Myanmar
Event Park attracted more than 3500 attendees which included government officials, industry associations, trade professionals from Myanmar’s sector. More than a showcase of quality machines, tools and equipment from around the world, the event presented opportunities for industry visitors to network with international peers and experts, and tap their knowledge of the latest trends and developments impacting the global manufacturing scene. Moving the manufacturing sector up the value chain Myanmar’s GDP growth is expected to be 8.3 per cent in 2017. This bodes well for the country’s manufacturing industry, as international businesses continue to invest in the sector. A timely event for local companies, Manufacturing Myanmar 2016 showcased new and best-seller
94
INDUSTRIAL BUSINESS MART
products to the Myanmar market from key international brands. Attendees had the chance to experience first-hand the many products and solutions that will enable them to enhance their processes and productivity, which will enable the manufacturing sector to create and add value.
as Sumitomo (SHI) Cyclo Drive, Widin, F.lli
Highlighting a wide variety of tools, hardware and equipment from leading international manufacturers and distributors including TRUMPF, Optical Gaging, Nikon, OSG, Asia Masima, Guhring and many others, the show showcased a wide range of products, from basic factory equipment such as hand tools and motors, to sophisticated machinery such as portable measuring devices, welding equipment, machining centres, and punching machines from 14 countries and regions.
TRUMPF, Optical Gaging, Summit Goal,
For new exhibitors, they had the chance to connect with potential local agents and distributors. Many companies, such
Pozzi, Goodway, Mindman, NUI Utensili Europa, Shinwa Rules, Fujiya and others, got to engage with local buyers and gained valuable insights into the local manufacturing landscape and business environment. Returning exhibitors Assurich Industries, Nikon, Tungaloy, Guhring, Tochu, Benign Enterprises, Hito Abrasvies and Jinn Jye Precision Machine Factory were not only able to reconnect with existing business contacts, they also had the opportunity to establish links with brand new trade partners from Myanmar. Strong government and industry support Manufacturing Myanmar garnered strong support from senior government and industry officials. Guest-of-honour at the event’s opening ceremony, U Kan Chun, Managing Director of No. (1) Heavy Industries Enterprise, Ministry of
October 2016
Industry, together with senior officials
“Manufacturing Myanmar 2016 plays
technical knowledge and skills, to meet
from Myanmar Food Processors &
an important role in supporting the
industry needs.”
Exporters Association, Myanmar Industry
evolution of the country’s manufacturing
Association, Myanmar Engineering
industry. For local players seeking growth
“Business networking has always been
Society and Food Science and Technology
ventures with key industry players, and
an essential element for our trade shows
Association of Myanmar visited the
others looking to enhance operations
and through Manufacturing Myanmar, we
exhibition to see and learn more about
and upgrade manufacturing capabilities
have gathered manufacturers, suppliers
the latest manufacturing innovations and
through new technologies to satisfy
and service providers from across the
trends.
domestic and international demands,” he
globe. The exhibition proved to be a viable
added.
business platform for local companies to
Addressing the audience at the opening
engage with international companies. We
ceremony, U Zaw Min Win, Chairman
U Aung Myint, President of the Myanmar
of Myanmar Industry Association and
Engineering Society, in his speech, said,
Myanmar Food Processors & Exporters
“Manufacturing in Myanmar is one of the
Association said that “manufacturing has
main sectors supporting the country’s
made considerable progress towards the
economic growth. It is an exciting
and we look forward to continue to
development of a sustainable industrial
time for the manufacturing sector, as
foster these valued partnerships, to help
base. The key manufacturing sector which
foreign investment and multinational
Myanmar’s manufacturing sector move
includes Garment, Electronic Parts, Food
companies come into the market. As the
up the value chain,” said Mr. William Lim,
and Beverage processing, Construction
manufacturing sector moves up the value
Project Director for Machinery Events of
material have attracted growing investment
chain, it is time for local players to step up
organiser, Singapore Exhibition Services.
and consequently have expanded output”
and be the agents for progress. This can
and he expected “manufacturing and other
be achieved by companies investing in
The fourth edition of Manufacturing
industrial activities to play an increasingly
new technologies and equipment, industry
Myanmar will return from 21 to 23
important role.”
professionals arming themselves with
September 2017.
October 2016
are also honoured to have the continual support of the local government and industry organisations for our event
INDUSTRIAL BUSINESS MART
95
RESOURCES
OPPORTUNITIES Sr. Analyst - GBS Procurement Location: Pune Requirement: B.Tech/B.E. - Electrical Flex is a leading sketch-to-scale solutions company that designs and builds intelligent products for a connected world. The company provides innovative design, engineering, manufacturing, real-time supply chain insight and logistics services to companies of all sizes in various industries. Flextronics Technologies Pvt.ltd HR@Flextronics.com
Manufacturing Engineer III (E3) Job Procurement Location: Bangalore Requirement: Bachelor’s Degree Functional Areas : Software Engineering Fixtures Design MULTIPLE Production Root Manufacturing Engineering Product Development Experience : 1-4 years Applied Materials is the world’s largest supplier of products and services to the global semiconductor industry, is one of the leading information infrastructure providers. Applied Materials HR Direct Help Line at +91 877-612-7547
Sr. Application Engineer - Scada HMI PLC Industrial Automation Location: Pune , Hyderabad / Secunderabad Requirement: B.Tech/B.E. - Computers, Electrical, Electronics/Telecommunication, Instrumentation Experience : 1 - 5 years Maestrotek works with leading Machine/ system manufacturer’s in Infrastructure, Pharmaceutical, Automotive & General machinery verticals, developing technology oriented smart solutions to their automation challenges. Applied Materials Maestrotek Innovations Pvt Ltd www.maestrotek-innovation.com Tel: 91-20-65296369
96
INDUSTRIAL BUSINESS MART
Application Developer Process Integration Location: Pune Requirement: Any Graduate Experience : 3 - 7 Years Magna Infotech has been the largest provider of technology staff augmentation & solutions in the Indian sub-continent. Magna provides customers with a comprehensive talent management solution specific to an industry, geography or business purpose Magna InfoTech Recruiter: Srikanth Dasari srikanth.dasari@magna.in http://careers.magna.in Tel: 080-4689 2100
Asst. Manager – Quality (SQIG) Location: Pune Requirement: Bachelor’s Degree Experience : 7 - 8 years Advik is one of India’s leading & global automotive component manufacturers catering to the eclectic needs of a number of domestic and overseas customers across four continents in the two - wheeler, stationary engine and transmission system segments for the past 14 years. Advik Hi- Tech Pvt Ltd Tel: +91 2135 669500
Styling Specialist Location: Pune Requirement: Any Graduate - Any Specialization PG - Any Postgraduate, Functional Areas: Engineering Design, R&D Experience : 1 - 2 yrs Tata Technologies Ltd (TTL), is the world’s leading independent global professional services company engaged in Engineering & Design Services, Product Lifecycle Management, Enterprise Solutions and Plant Automation. Tata Technologies Ltd Tel. +91 20 6652 9090
Product Design Engineer Location: Pune Requirement: B.Tech/B.E. - Any Specialization, Mechanical Experience: 4 - 8 Years Sohum Autogas Systems Pvt Ltd prominent manufacturer,exporter,trader and importer of varied products such as Gas Safety Device,Industrial Regulator, LPG & Natural gas pressure reducing skids, Gas trains for Burner control system Gas Stoves and LPG Reticulated Systems which are designed and developed as per highest industry standards. Sohum Autogas Systems Pvt. Ltd Recruiter: Anuja Puranik Tel: +91 20 24690254 , +91 7276068927 admin@sohumautogas.com
Electrical / Electronics Sales Engineer Location: Pune Requirement: B.Tech/B.E. - Electrical, Electronics/Telecommunication Experience : 1 - 3 Years Ambik Harmonic Filters Pvt. Ltd was incorporated in 1998, by technocrats, having varied experience in Electrical Power Systems. The company has its office in central Pune. The manufacturing facilities are located in close vicinity of Pune city. The company follows a policy of ‘Complete Customer Satisfaction’ at lowest possible cost, ‘Without Compromising on Quality’. Ambik Harmonic Filters Pvt Ltd Recruiter: Dipti admin@ambikharmonics.com Tel: + 91 20 6529 7817
Attention! 4HR Managers 4Training Centres 4Industry Consultants For including your listing in our Resource setion on manufacturing job openings/ course offerings and industry consultancy services, send your details to: Richa Chowdhary Tel: +91 70 3093 2697 Email: mart@martinfotech.in
October 2016
COURSES Raspberry Pi Introduction to Raspberry Pi Preparing Your Raspberry Pi for First Use Setting Up for a Perfect Pi Experience Introduction to LINUX Environment Getting Familiar with the GPIO Pins of your LIVE Projects like LED running Lights, buttons interfacing, buzzer interfacing, and UART interfacing.
Program for Instrumentation/Electronics
Program for Marine Engineering Students/
and Chemical Engineering Students
Shippers
Duration: 7 Days/15 Days Register at: www.robosapi.com
using ladder / function block programming.
Power Boilers: Design, Fabrication, Inspection and Repair This course provides detailed knowledge of the responsibilities of personnel involved in the design, manufacturing, fabrication and examination of new power boiler plant components and new construction activity as defined by Section I of the ASME Boiler and Pressure Vessel Code (BPVC). The objective of the course is to enhance knowledge and understanding of the requirements for design and construction of power boilers in accordance with Section I of the ASME Boiler and Pressure Vessel Code. Duration: 4 Days Register at: - www.go.asme.org/ indiatraining Instrumentation & Control and Data Acquisition System in Fluid Flow in Process & Petroleum Engineering To enable the participants to update their knowledge in the area of flow measurement and control on Oil, gas, water and also to cover the International Standards in flow measurements and also the standard procedure on maintaining fuel installation according to International Standards, Flow measurement and control in flow meters and its calibration, norms and ethics in calculation of custody transfer in petroleum industry etc. Applied Materials Maestrotek Innovations Pvt. Ltd. Duration: 2 months Register at: www.fcriindia.com
October 2016
This four-week program provides fundamental knowledge of process automation and control systems. Participants will learn PLC functionality and its detailed configuration and will be able to design and implement advanced PLC logic
This five-day course provides fundamentals knowledge of marine automation and control systems. Participants will learn PLC functionality and its configuration and will be able to design and implement PLC logic using ladder / function block programming. Participants will also go through hands on practical training on PLC interface with
Participants will also go through hands
SCADA (HMI).
on practical training on PLC interface with
Duration: 5 Days
SCADA (HMI).
Register at: www.honeywell.com
PLC and SCADA (1 Week) Distributed Control Systems (2 Weeks) Onsite (Week) Duration: 4 Weeks (Three Weeks at Honeywell + One Week plant training at RCF, Mumbai). Register at: www.honeywell.com Program for Mechanical and Electrical Engineering Students This five-day course provides fundamental knowledge of process automation and control systems. Participants will learn PLC functionality and its configuration and will
SCADA SCADA Configuration, Interface of AB- PLC with SCADA FAS Smoke Detectors, Control Panel Program for Building Management System This five-day course provides fundamental knowledge on Fire Alarm System and HVAC Control Systems. The program is concept specific and not limited to any particular product. a. Fire Alarm System (2 Days) b. HVAC Control Systems (3 Days) Duration: 5 Days Register at: www.honeywell.com
be able to design and implement PLC logic
3D Printing
using ladder / function block programming.
Additive technology & its application additive
Participants will also go through hands
manufacturing SLA,SLS, FDM preparing the
on practical training on PLC interface with
model for rapid manufacturing.
SCADA (HMI).
Duration: 3 Weeks
Process Automation
Register at: www.igtr-aur.org
Programmable Logic Controllers Supervisory Control and Data Acquisition
BASIC HYDRAULICS
(SCADA)
Introduction, Fundamental Principles, Energy
Duration: 5 Days
Supply Elements, Directional Control Valves,
Register at: www.honeywell.com
Circuit Design & Application Duration: 1 Week
3D SCANNING
Register at: www.igtr-aur.org
Scanning Technology, Types Of Scanners, Preparing The Object For Scanning,
BASIC PNEUMATICS
Capturing The Cloud Data For Small &
Introduction, Fundamental Principles, Energy
Lagre Object, Synthesizing The Model With
Supply Elements, Directional Control Valves,
Overlap,Design Verification Tools.
Circuit Design & Application
Duration: 3 WEEKS
Duration: 1 Week
Register at: www.igtr-aur.org
Register at: www.igtr-aur.org
INDUSTRIAL BUSINESS MART
97
98
INDUSTRIAL BUSINESS MART
October 2016
October 2016
INDUSTRIAL BUSINESS MART
99
Insight Creates Value
KEMPPI INDIA PVT LTD Lakshmi Towers, 2/770, Kazura Garden, 1st Street,Neelankarai, Chennai – 600 041 Phone: +91 44 45671200 mailto: sales.india@kemppi.com www.kemppi.in 68 www.martupdate.com 100INDUSTRIAL BUSINESS MART
September 2016 October 2016