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Rs 75 October-december 2013

RNI No 71129/98

Event Focus EMO Hannover 2013 A breathtaking display of cutting edge technology report Indian Manufacturing Barometer Taking the Pulse ALSO IN THIS ISSUE: + The Simulation Advantage + Aerospace Industry: The Technological Trendsetter + New Facility Launches

Manufacturing in

Three Dimensions 3D CAD-CAM and simulation software  are heralding a new age of manufacturing


TradeMeet

4 Foreword

In three dimensions

Cover Focus The utility and power of tools and equipment derive as much from their functional aspects as it does from the form it which these are molded. Much of this design earlier was a mechanical work, much laborious, more time consuming and of limited range. Today’s virtual revolution is changing all of this, putting much more power in the hands of designers in the earliest stages of their work.

x o b l i Ma Write in your views to: The Content Editor The Machinist, Netscribes (India) Pvt. Ltd, Podar Center, 85 Parel Post Office Lane, Off Dr Ambedkar Road, Parel (East), Mumbai 400 012, Maharashtra, India. Fax: +91 22 4098 7500 Email: timesb2b@netscribes.com To find us on the web log on to: www.machinist360.com or www.timesb2b.com

l redefine the design of IBM, three things wil According to Paul Brody en source electronics, ducts in coming years: op and manufacture of pro takes small steps nting. As manufacturing pri 3D and cs oti rob t intelligen k around the ongoing ly need to take a loo into the future, we on nting is already being their significance. 3D pri lise rea to nts me op vel de ly to find applications manufacturing, and is like touted as the future of ce travel, bioengineering and bewildering as spa in areas as widespread and home products. D/CAM and simulation, exciting world of 3D CA Closely associated is the elling its various ist is devoted to unrav chin Ma the of e issu s and thi facturers can derive ry explores how manu nuances. The cover sto software early in the adopting 3D design by fits ne be le ltip mu provide helpful the market scenario and at k loo We . ges sta n productio st suited software. tips for selecting the be we bring you the key ely watched event, and EMO at Hannover is a wid is our coverage of three new feature in this issue highlights in pictures. A mmins. India, LMT India and Cu plant launches by Lapp CAD/CAM and other lore the world of 3D Our regular columns exp m PwC-FICCI takes the ing. Finally, a report fro aspects of manufactur facturing space. pulse of the Indian manu ormative. Do write to s issue interesting and inf We hope you will find thi om. timesb2b@netscribes.c us with your feedback at:

Happy reading! Content Editor


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Contents

Volume 8 Issue 4 oct-dec 2013

Printed and Published by Joji Varghese on behalf of owners World Wide Media Pvt. Ltd, The Times of India Building, Dr DN Road, Mumbai 400 001 and printed at Rajhans Enterprises No 134, 4th Main Road, Industrial Town, Rajajinagar, Bengaluru 560 044 and published at Worldwide Media Pvt. Ltd, The Times of India Building, Dr DN Road, Mumbai 400 001

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Editor Jitesh Pillai Worldwide Media Pvt. Ltd, The Times of India Building, Dr DN Road, Mumbai 400 001

Editorial Content & Design Netscribes (India) Private Limited E-mail: amit.sharma@netscribes.com Content Editor: Amit Sharma

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INDIA Times International Marketing The Times of India Building Dr DN Road, Mumbai 400001 Tel: + 91-22-22731116 Fax: + 91-22-22731948 E-mail: int.times@timesgroup.com UK & EUROPE Mr Bharat Vasvani No 54, Sydney Road, West Ealing, London W13 9EY, United Kingdom Tel: +44-208-8403838 Fax: +44-208-8403493 E-mail: timesofindia@btconnect.com USA C Umesh The Times of India 1311 College Avenue Palo Alto CA 94306 Tel: 650 796 6867 E-mail: timesofindia@compuserve.com

All rights reserved. Reproduction without prior permission of the publisher is expressly prohibited. The publisher makes every effort to ensure that the magazine’s contents are correct. However, we accept no responsibility for any errors or omissions and accept no responsibility for any loss or damage caused as an effect thereof. The opinions expressed by experts are their own and in no way reflect those of the publisher.

The Future of Design 16 New technologies in design are capturing the three dimensions of reality as never before. Amit Sharma explores the scenario

New Facilities Lapp India launches Lapp Experience Centre in Bangalore 12 The new centre will provide comprehensive connectivity solutions and pave the way for reliably connecting with customers

LMT India launches global manufacturing facility in Pune 13 The plant is a highly integrated manufacturing facility that is designed to produce world-class hobs for the automotive industry

Cummins Opens Plant for High Horsepower Engines at Phaltan 14 The plant is the seventh factory at the Cummins Megasite, and its largest high horsepower facility in the world

Event Focus EMO Hannover 2013 – Mecca of Metalworking 21 Fairgrounds Hannover in Germany witnessed a breathtaking display of machine tools and manufacturing equipment

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The World of Laser Technology 26 Come November and Mumbai will play host to the second edition of Laser World of Photonics India

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Report Indian Manufacturing Barometer: Taking the pulse 41

Trends 3D CAD Modelling Technology and Digital Manufacturing 28 Vikas Khanvelkar, MD, DesignTech Systems, takes us step by step into the world of 3D CAD modelling

Insight The Simulation Advantage 31

Excerpts from a PwC-FICCI report on the Indian manufacturing scenario

Simulation and virtual environments are allowing manufacturers to reduce product development lifecycle time and derive an array of other benefits

In Retrospect

Aerospace Industry – The Technological Trendsetter 33

Case Study

Satish Godbole, VP of Motion Control Systems – Drive Technologies, Siemens Ltd, explores the aerospace manufacturing techniques

The Journey Towards Success 44 The story of DesignTech’s journey towards success

Smooth under Pressure 55 Autodesk Simulation Moldflow helps Faurecia to better manage auto parts production

White Paper Designs for a Better Product 47

Future of Indian Manufacturing Industry 37 Prasanna Gandhi, Manager – Internal & External Communications, Ma Foi Strategic Consultants, on the four waves of manufacturing in India

Excerpts from a Dassault Systemes whitepaper on the factors that define a better product

Training Grooming tomorrow’s industry leaders 50

Powering Up Discoms 39 Lalit Jalan, CEO, Reliance Infrastructure Limited, analyses the challenges and opportunities for power distribution companies

The Industry professionals can now jump start their careers through the Global Manufacturing Leadership Programme launched by the Aditya Birla Group

Products 52 Events 55 Regulars Making Headlines – National News 8 Making Headlines – Global News 10


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MakingHeadlines National UPS Provider CyberPower expands India footprint CyberPower, the power solutions provider that has recently made a foray into the Indian market, unveiled its full range of products and channel schemes in the capital along with plans to step further in the Indian market while creating a better completed local service network. CyberPower has made its successful entry through the establishment of four regional offices, Mumbai, Kolkata, Bangalore, and New Delhi, for a completed local service supports. CyberPower's products include UPS, inverters, power distribution units as well as mobile and car chargers. After making its debut in India in the under-10 kVA UPS range, CyberPower is now targeting to take the market leader in the Home and SOHO UPS segment before planning to gradually expand its coverage to other segments up to 200 kVA power solutions. “We have confirmed the partnership with Ingram Micro as our global national distributor and are in touch with other tier 1 channel partners for national distribution. We are looking for potential channel partners to further strengthen our distribution structure both nationally and regionally,” said Arun Ghosh, Country Head of CyberPower India.

Duroshox’s R&D facility recognised by Indian Ministry of Science and Technology Engineering and vehicle component manufacturer Duroshox received recognition for its in-house research and development facility from the department of scientific and industrial research (DSIR) under the Ministry of Science and Technology, Government of India. This prestigious recognition is bestowed to organisations which undertake persuasive research and development to come up with new innovations in products and technology that can be used by the organisations to be at par with world-class technology. With this certification, Duroshox joins the 1,500 companies in India to be honoured with this distinct accreditation. Duroshox has concentrated on value engineering and improvements in production efficiency that has led the company to become a key supplier for off highway, engineering, commercial vehicle and agriculture equipment components industry and an

Original Equipment supplier of choice to several major companies. “The recognition of our R&D is a key milestone achieved by Duroshox and we will continue our endeavour to drive our efficiencies in the custom design, research and custom manufacturing space,” said Anshul Goel, Managing Director, Duroshox.

SABIC partners with IITB-Monash SABIC Research & Technology Private Limited (SRTPL) has signed a multi-year strategic partnership agreement with one of the leading research academies, the IndianAustralian IITB-Monash. This partnership will pave the way for close collaboration in multiple

research projects, allowing both organisations to mutually develop advanced technologies into innovative solutions that meet global needs and demands in a number of areas that benefit society. The scope of collaboration will extend to all of SABIC’s Technology & Innovation centres worldwide. This partnership is an expansion of SABIC’s existing relationship with IITB-Monash, and will deliver a much closer relationship that will enable the world-class research teams of both organisations to work together in their respective joint research areas. IITB-Monash is based at the Powai campus of IIT Bombay and operates as an


National independent, autonomous research institution. “SABIC’s global partnerships in technology and innovation are central to the company’s growth plans, and this latest agreement with IITB-Monash represents an important step forward in our global commitment to advancing technologies and responding to the needs of society across a range of technology sectors,” said Ernesto Occhiello, SABIC’s Executive Vice President – Technology & Innovation.

Godrej Consumer expands manufacturing footprint in Africa FMCG giant Godrej Consumer Products is gearing up to expand its manufacturing footprint in the African continent by setting up factories in Tanzania and Uganda. It already has manufacturing facilities

MakingHeadlines

in South Africa, Mozambique, Kenya and Nigeria. GCPL has already made four acquisitions in Africa and is in discussions to take over some local companies there. “We are looking at it (opportunities). Our growth in Africa is through acquisition of local companies. Some discussions are going on,” Godrej said. The FMCG major is optimistic on the African market to drive its international sales as sales from the continent’s operations account for 25 percent of its total international sales. GCPL has already acquired stakes in Darling Group Holdings, Kinky Group, Rapidol and Tula, three of which are involved with hair care. "Our businesses are mainly in hair care. Our companies are leaders in hair colour in 14 countries in Africa," Godrej said.

SAIL and Siemens partner enhance technical skills of workforce Steel Authority of India Ltd (SAIL) has signed a Memorandum of Understanding (MoU) with Siemens Ltd to enhance the technical skills of SAIL’s work force. According to the MoU, SITRAIN, a business unit within the Siemens Industry Sector that imparts industrial training services, will provide training to SAIL personnel involved in projects, maintenance and other technical departments of SAIL’s plants. The MoU is valid for a period of three years and is the third consecutive pact signed with Siemens. Siemens will impart training in the areas of Automation, DC/AC Servo Drives, switchgears and other related technologies.

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MakingHeadlines International US celebrates Manufacturing Day On October 4, 2013 the United States of America celebrated its second annual Manufacturing Day to show Americans that manufacturing was alive in the country and create a positive public perception. The Manufacturing Day was aimed at expanding knowledge about manufacturing careers and its value to the American economy. The event was targeted at students, parents, educators, media, customers, suppliers and the community at large. Factories and steel mills across the country threw open their doors to the public and organised student tours. Last year, at the inaugural Manufacturing Day, roughly 7,000 people attended 240 events in 31 states. “When people tour the factories, they get a better idea of how much is still made right in their backyards. They also see the working conditions are better than they might have imagined,” said Patricia Lee, director of marketing for Rockford, Illinois-based Fabricators and Manufacturers Association, one of the organisers.

Manufacturing gathers pace in September across nations

US manufacturing rose to its highest level since 2011, according to data from the The Institute for Supply Management (ISM). The institute said its index of national factory activity stood at 56.2 in September, up from 55.7 in August. A reading above 50 indicates expansion. Manufacturing activity in the country slowed in the spring

and contracted in May, according to ISM, due to government spending cuts and sluggish global demand. China, the world’s second largest economy, also saw it manufacturing activity increase for the second straight month, suggesting that the recovery was gaining pace. HSBC’s September purchasing managers' index rose slightly to 50.2 from 50.1 in August. Recent export data from the Asian country has also shown an uptick. Although the country has not introduced major stimulus measures, in late July it took steps to bolster growth which included reducing taxes on small companies and encouraging railway development. Data from market Economics showed that despite falling slightly in September, manufacturing activity across the Eurozone continued to rise for the September quarter, coming in at 51.1. The figure in July stood at 51.4. Barring France and

Greece, both of which displayed contractions, all the other nations covered by the survey showed expansion in activity.

Chrysler recalls Jeeps, Ram pick-up trucks Automaker Chrysler will recall 142,800 Jeeps and Ram pick-up trucks to address issues with software that control instrument lighting and, on the Jeeps, the antilock braking system. About 132,000 Jeep Grand Cherokees in the model year 2014 will be recalled, most of which are in the United States. The software issue caused the


International Jeeps to randomly light up the instrument lights or made them go dark. Engineers also found a problem with the vehicles' anti-lock braking system that affects the instrument display. The company recalled 10,800 Ram 1500, 2500 and 3500 pickup trucks to upgrade the software that controls instrument illumination. Most of the vehicles were still at dealerships. Chrysler said it would upgrade the software free of charge.

MakingHeadlines

Daimler announces plans of new Brazil factory

Samsung expects to post record Q3 profit at 10.1 trillion won

South Korean electronics giant Samsung Electronics is expected to post a record operating profit of 10.1 trillion won in the quarter ended September. The official results are expected later in October. This figure is slightly higher than analysts’ estimates and is 6 percent higher than the April-June figure of 9.53 trillion won. In the quarter ended September a year ago, the revised operating profit stood at 8.06 trillion won. According to analysts, rising memory chip and semiconductor prices were likely the main growth driver in the July-September period. They said that the tech major’s presence in the cheaper smartphone market was also a factor. Samsung shipped an estimated 85-89 million smartphones in the

To ditch high import taxes, German auto company, Daimler AG has said it planned to open a new factory in Brazil for its luxury car brand, Mercedes-Benz. The facility near Sao Paulo, pegged at 170-million euro, is expected to begin churning out up to 20,000 Mercedes C class cars and its GLA SUVs each year in 2016. This is the company’s third plant In Brazil and is expected to create 1,000 direct jobs at the site in addition to about 3,000 at the suppliers’ end. "This local production will allow us to manufacture more competitively in Brazil, without the additional 30 percent in taxes," a Daimler spokeswoman said. In a magazine interview separately, Andreas Renschler, the head of production and procurement at Mercedes-Benz said that Daimler may build a new plant in North America if demand for compact cars rises.

third quarter, analysts estimated and held 33.1 percent share of the global smartphone market. Sales in the third quarter were expected to touch 59 trillion won, a rise of 13% from the year ago period.

China to boost solar power manufacturing To boost manufacturing, China plans to offer substantial tax rebates to solar power manufacturers in the country. As per media reports, solar players can expect a 50 percent rebate on value added tax till the year 2015.

China has been actively selling solar panels, but top manufacturers have been facing the heat of declining demand, with rising debts. The latter is expected to be of the tune of $16.3 billion if only the top ten companies are counted. Some of the defaulting companies include Suntech Power Holdings and LDK Solar Company. Chinese products compete the market with low price tags, buoyed by the large demand for alternative energy solutions from the developed countries.

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New facilities

Lapp India Launches Experience Centre The new centre will provide comprehensive connectivity solutions and pave the way for reliably connecting with customers

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app India, a well known player in electrical connectivity solutions, has inaugurated its new experience centre at Bangalore. The exclusive centre will showcase a vast range of products that Lapp India offers to help meet the connectivity requirements across industries. A special focus of the centre is on Lapp solutions that cater to the eight key industry verticals: Machine Tools, Automation, Automotive, Public Sector, Buildings, Projects business, Renewable Energy and Process. The new centre will serve as a one-stop destination for all cabling solutions and will provide customers an opportunity to touch and feel the entire product portfolio. The centre was inaugurated in the presence of Andreas Lapp,

Chairman of The Board, Lapp Holding AG and Honorary Consul of the Republic of India for BadenWürttemberg and RhinelandPalatinate; and Siegbert E Lapp, Director of Lapp Holding AG, along with the senior management team from India. The chief guest of the event was Dr Ingo Karsten, Consul General of the Federal Republic of Germany. At the Lapp Experience Centre, customers can experience firsthand the German quality and engineering that goes into the making of Lapp products. By opening this Centre, the Company aims to better understand customer requirements and efficiently respond to them. Among the expanse of Lapp solutions on display, cable harnessing solutions are also being

showcased at the centre. Additionally, the customers will get an option to place their orders on the spot with the help of an in-store billing option. Lapp India also plans to educate customers and provide them a first-hand experience of its wide range of products under the series, “Lapp Flavor of the Month”. Lapp India is a 100 percent subsidiary of the Lapp Group which manufactures cables, connectors, cable glands, conduits and accessories. Today, its Bangalore manufacturing unit is the third largest manufacturing facility of the Lapp Group. It has recently completed phase 1 of its second manufacturing plant in Pilukedi, Bhopal which will produce 1,000 kms of single core cables daily, catering mainly to the Building Cable Segment (BCS).


New facilities

Cummins Opens Plant for High Horsepower Engines at Phaltan

The plant is the seventh factory at the Cummins Megasite, and its largest high horsepower facility in the world

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ummins inaugurated its new Phaltan High Horsepower Plant in the Special Economic Zone (SEZ) at the Cummins Megasite in Phaltan. This is the seventh factory to open at the Megasite and its largest high horsepower manufacturing site in the world. The plant will build the QSK 23 Tier I and II engines and can produce 3,000 units per year initially. However, if demand grows beyond this, the plant can be expanded to increase production with minimal investment. Production of the QSK 23 series in-house, which up until now was being imported from Komatsu Ltd., Japan, further consolidates Cummins’

manufacturing capabilities for markets across the globe. The plant will also manufacture QSK 23 Tier IV and QSK 60 engines that will comply with the 2015 emission norms, in the near future. This entire range caters to the power generation, mining, industrial, construction, and oil and gas sectors, in the domestic and global markets. “The Megasite was conceived six years ago to house ongoing and future expansions of the Cummins Group in India,” said Anant J Talaulicar, Managing Director of Cummins Group in India during the inauguration. “This new facility positions us well in the export markets as the economies begin to recover. We are optimistic about our

long term growth prospects and we are continuing to invest manufacturing, technology and service capacities to serve our customers well.” The state-of-the-art lean manufacturing facility spans an area of 39.5 acres and includes engine assembly, testing, painting and machining. Adopting green building practices, operations inside the plant have replaced the conventional hydro dynamometer technology with eco-friendly AC dynamometer technology. This technology helps reduce water consumption and prevents energy loss while testing engines. Once fully operational, the plant will employ close to 350 individuals.

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New facilities

LMT India Launches Global Manufacturing Facility The plant is a highly integrated manufacturing facility that is designed to produce world-class hobs for the automotive industry

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MT India launched its second state-of-the-ar t global manufacturing plant in Pune, spread across with three acres of land and with a built up facility of 30,000 square feet. S Venkatasubramanian, MD, LMT India, explained the plant’s objective: “India has always been our key target place as the market is filled with great talent and skilled workforce. Another major reason behind opening our global manufacturing facility in Pune is to establish a closer network with our customers and achieve quick turnaround times on product side.� Precision tools have been playing a key role in industrial production. At the interface between machine and workpiece, precision tools increase the efficiency of manufacturing processes and often these tools make the machining of demanding new materials economically viable in the first place. The markets for tool specialists are also growing with the ongoing globalisation of industrial manufacturing processes, he added. During the last 12 years LMT Tools has established itself in India as a supplier of precision tools. Its main customers are companies working in the car and commercial vehicle sector. LMT India also caters to sectors like windmill and

aerospace industries. The company has specially equipped service centres at sites in Germany, USA, China and India. Some of the niche products from LMT include hobs, line boring

systems, plastic and composite machining, special tools for die and mold, heavy machining tools and tapping and thread rolling and clamping systems.


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Coverstory


Coverstory

The Future of Design New technologies in design are capturing the three dimensions of reality as never before. Amit Sharma explores the scenario

D

esign and manufacturing have always gone hand in hand. The utility and power of tools and equipment derive as much from their functional aspects as it does from the form it which these are molded. Much of this design earlier was a mechanical work, much laborious, more time consuming and of limited range. Today’s virtual revolution is changing all of this, putting much more power in the hands of designers in the earliest stages of their work. The advance is breathtaking. Some years ago Apple filed for a new way of designing product on the screen – just by using hand gestures and head movements! Today’s hand gesture controlled software allows the designer to assemble a product and use a 3D laser printer to bring it to reality, right before our eyes!

More than a Triple Advantages The possibilities of 3D CAD/CAM and virtual design have thrown the design and manufacturing world

open. Search for 3D and search engine results are filled up with the revolutionary technology of 3D printing. Virtual environments now allow prior testing without the need for physical prototyping. The product development lifecycle has been curtailed, and alternative materials can be identified for reliability. What makes 3D technologies a real head turner are the possibilities of changing the design, exploring ‘what if’ scenarios, and avoid the older process where much effort and cost went into physical testing and taking the feedback. Though the cost impact is higher in the initial stages with 3D software, its virtues come to life when last stage processes save on time and money. One of the prominent leaders in the 3D world is Autodesk, known worldwide for its path breaking work in giving the design world AutoCAD. Its products have found uses in areas other than manufacturing. The five nominations for Oscar’s Best Visual Effects category this year have all

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Coverstory

What to look for while selecting the right 3D CAD software • Determine your requirements: Know beforehand the inputs and outputs of the software and whether these can be professionally handled. • Fix your budget: Apart from the actual cost, there may also be future costs associated with design software. Also take into account the training costs, maintenance and upgrade requirements. • Efficiency in design: Can the software accurately create designs with the minimum steps? • Reliability and stability: Bugs and slow systems can pose operational hurdles. Use the test versions to ensure the system works seamlessly. • Add-ins: Depending on the type of products manufactured, look out for add-ins and additional features that can add extra benefits. • Training period: The software should be easy to learn and adopt. • Operating system: Make sure your OS infrastructure is ready for the software. used its design software. The power of design can be judged from the fact that the design of a machinery is now an important factor for its marketing, since it takes into account such factors as energy consumption and utility at work. One technology aids another. So what happens when 3D software meets the web? With cloud computing, designers need to pay only for CPU per hour utilised, which can result in good savings. According to a Tata Technologies spokesperson, “the software revolution is allowing manufacturers to use virtual environment to test

the quality and robustness of their products, avoid physical prototyping, reduce their product development cycle times and identify alternative reliable materials. These virtual models, in turn, allow validating, synchronising and optimising manufacturing processes before they are implemented to reduce manufacturing time and cost. This was the differentiator which forced present manufacturing industries to promote simulation techniques.” The scenario therefore is radically different from the past. We can do away with the laborious and circular process of designing and testing, and do as much testing as you want right at the earliest stages. Combine these with statistical inputs, and you are fast on your way to the right design.

Disruptive for Good Running in parallel with the virtual design movement are other related developments. According to Paul Brody of IBM, three things will redefine the design and manufacture of product in coming years: open source electronics, intelligent robotics and 3D printing. One effect of this, according to Brody, is that consumers will also have a role to play in what products ultimately reach their hands. Open

In History In 1963 Ivan Sutherland developed Sketchpad as part of his MIT PhD Thesis. This is considered to be the first numerical control programming tool. source CAD and 3D printing will allow end users to contribute to how and what products a company manufactures. Brody cites an IBM survey to back this up, which revealed that 80 percent of the respondents expressed willingness to aid manufacturers in product development.

Key Advantages DesignTech lists down the key advantages of using 3D CAD modelling software: • Better visualisation and imagination • Knowledge and data management • Adherence to international standards, codes and norms • Create robust products • Basic animation • Augments innovations • Mobility: Work from home, office or even when you are on the move • Expedite product design and development cycle


Coverstory • Concurrent engineering: Multitasking from remote places “The best part of 3D modelling software is that you can not only play with it and rotate views 3D dimensionally, but also get an inside view of the product/component/ machinery that you are designing. During this stage, even the aesthetic aspects of design are also taken care of. For e.g., surfacing and rendering of the product is carried out to give it a desired look and feel,â€? says Vikas Khanvelkar, MD, DesignTech Systems.

The Market Scenario According to RnR Market Research report (CAD/CAE Computer-aided Design & Engineering Market 2016), the Global CAD market will witness a CAGR of 8.60 percent

between 2012-16. The European market provides the largest share of revenue pie, with APAC and North America taking the second and third position. The TechNavio report (Global CAD Market 2012-2016) projects a revenue of $8,295.41 million in 2016. What would drive the market and what are its challenges? According to the report, enhanced product visualisation is a major factor that allows companies to come up with better product designs with ease. The challenges, the report says, lie in high initial investment and training. Other challenges during this period are expected to come from the open source market and piracy. In the CAE market, whose key markets lie in automotive, electrical/ electronics, industrial machinery,

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aerospace and defence, the report expects a CAGR of 11.18 percent between 2012-16. TechNavio expects the revenue by 2016 to be $3,402.30 million. The factors of growth include need for shorter time-to-market with speedy development and testing. The challenge is again expected from open source solutions.

Better Products for the Future 3D technologies are not just about dazzling displays of innovation. They have evolved to meet the demands of today and the needs of tomorrow. Many companies are looking at shorter time-to-market and cutting down on production costs. Products too need to look different, aesthetic and well designed. This is where the 3D advantage hits home. The cost advantage of using 3D


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Coverstory minimising energy usage and address other related environment concerns. Simulation software today finds application in the talent assessment field too. Recruiters can now test a candidate’s skills in the real world as part of their overall assessment. “In sectors like engineering and manufacturing, it is important to assess one’s skills in a real-time problem environment. Use of simulators to identify the right talent for a particular job and hands-on exercises and assessments using

Benefits of simulation

is plain and clear. Simplified processes, prior testing and choice of alternative materials make production lean and fit. A focus on design also brings in other benefits. A shorter time-to-market is of importance to both production managers as well as the customers, who expect seamlessness in service and delivery. On the production front, high throughput, accuracy and precision, less downtime and

The CAD industry is expected to grow at a rate of 8.6 percent over the next three years. – Tech Navio

Courtesy: Tata Technologies maintenance are achieved through better designs. Prototype development and prior testing can result in tools and equipment that meet production expectations. The aesthetic appeal also plays an important role in product design. Sleek, organic or complex designs can now be easily conceived and produced. Lastly, on the environment front too, new design technologies can play a role in reducing wastage,

simulation is going to be the future of assessments,” says Ketan Kapoor, co-founder and CEO, Mettl.

The Future of Design With 3D design and printing technologies promising a new age of manufacturing, there may be no looking back. It would be interesting to see what new designs emerge from | the wires and surfaces of touch screens and how they re-create the look and feel of the coming decades.


Event Focus

EMO Hannover 2013 – Mecca of Metalworking D

uring September 16-21, 2013, Fairgrounds Hannover in Germany witnessed a breathtaking display of machine tools and manufacturing equipment as 2,100 exhibitors from 43 countries lined up to showcase their latest innovations and offerings. Touted as the leading international trade fair in metalworking, EMO Hannover is a coveted platform for manufacturing and engineering companies around the world to tap new trade opportunities and build lasting relationships. Shedding light on the increasing use of automation in manufacturing process and the growing use of ‘smart’ techniques, the theme of EMO Hannover 2013 was ‘Intelligence in Production’. Exhibitors largely maintained focus on the process chain, the networking of the machine with the company’s overall software, or on upgrading efficiency levels. Keeping with the theme, EMO Hannover 2013 witnessed widespread and enthusiastic participation from global exhibitors whose product line-ups dealt with equipment ranging from new control system user interfaces with intuitive man-machine communication, to programming and machine status diagnostics using smartphones or a tablet PC, to automatic detection and correction of unsafe machinery states. Driving sentiment further was the positive outlook on the

economic recovery in Europe and other parts of the world, which gave an added impetus to the manufacturing community. Recent forecasts and reports have displayed optimism with respect to investments in sectors such as automobile and automotive supply industries, mechanical engineering, metal production, processing and m e t a l wo r k i n g, electrical engineering and electronics, fine mechanics and optics, medical technology as well as the aerospace, railway vehicle and shipbuilding industries – all of which are the main user segments. The event saw footfalls of about 145,000 trade visitors from over 100 countries. From Asia, China represented the highest number of visitors followed by Japan, Taiwan and India. Areas of interest at the event

included finding solutions for boosting energy and resource efficiency, and user-friendly equipment and the intelligent integration of machines. These were the new themes apart from reducing manufacturing costs and increasing flexibility. The success of the event can be measured with the number of orders. According to the figures on the website, visitors with robust investment plans placed 4-5 orders each at the event. On an average one out of five visitors placed an order. What is commendable is the fact that these numbers had surpassed those recorded in the previous EMO in 2011 which had taken place during an economic upswing. The next EMO is scheduled from October 5 to 10, 2015 in Milan, Italy and will focus on the theme “Let's build the future”.

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Event Focus India at EMO Hannover 2013

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ndia requires machine tools worth over 2 billion euros a year and imports most of them. The last five years have seen machine tool consumption rise by nearly 25 percent in the country. These figures are testament to India’s growing importance as a machine tools and equipment consumer. To tap this potential in the Indian market, the German Machine Tool Builders’ Association organised the 'EMO Focus on India' seminar on September 18, 2013 Indian exhibitors were very satisfied with the event and met their target group visitors, who were mostly from Europe.

Listed Indian exhibitors at EMO Hannover 2013 ACE DESIGNERS - Bangalore ACE MANUFACTURING Bangalore AXIS - Parwanoo BIPICO - Mumbai CHENNAI METCO - Chennai CP GRAT-EX - Mumbai ESGI - Patiala FENWICK - Bangalore GAURAV - Aurangabad GEOMETRIC - Mumbai GRIND MASTER - Aurangabad IMEXSU - Mumbai IMTMA - Bangalore JAIN DIAMOND TOOLS Aurangabad

JYOTI - Metoda KTA - Pune MACPOWER - Rajkot MICROMATIC GRINDING Ghaziabad NIMBLE ELECTRIC - Bangalore PRAGATI - Bangalore SHOBHA - New Delhi SPECTRA TOOLS - Ramanagara SPHOORTI MACHINE - Bangalore TRUCUT - Chennai VIKAS GRINDING - Ahmedabad

Jyoti CNC Automation at EMO 2013

We've been exhibitors at the last five EMOs, and are back for the sixth time this year. The quality of visitors here is always extremely high. Parakramsinh G. Jadeja, CEO, Jyoti CNC Automation Ltd


Event Focus Metalworking: New Dimensions

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Event Focus Trendsetters

dramatically reduces or eliminates downtimes and changeover times – the new REMA-shelf magazine.

A stabilising influence The Fraunhofer Institute for Machine Tools and Forming Technology IWU showcased a new mounting element for active machine and system stabilization.

The new milling process InovaTools’ exhibits included the new HPC milling machines Vibmill for steel, and INOX that can deliver vibration-free milling even under the most extreme conditions.

Optimising automation The EMAG Group presented the outstanding opportunities made possible by intelligently interlinked manufacturing systems.

Highest tool packing density Miksch

set

a

world-first

that

The Laser award goes to… Rineck Maschinenbau GmbH, the German manufacturer of cutting tools for the mold and die industry won the award for a new lasersupported cutting tool.

Five axes for three dimensions Reiden's RX14 cutting-edge CNC technology makes it possible to manufacture three-dimensional work pieces, often in just one step.

Water-resistant robots KUKA Roboter GmbH presented the diverse range of applications for the robot-supported automation of machine tools.

Keeping it smooth Oerlikon Balzers showcased its latest brand – BAL.IQ – under the motto "The Smooth Revolution". The products represent a revolutionary generation of wear-resistant coatings.

Precision made easy The innovative tool preparation from EZset was presented to the public for the first time.

More light! Waldmann GmbH showcased putting its new LED machine lamps MACH LED PLUS under the spotlight.

Don't touch! Polytec lasers Polytec GmbH displayed the first machine to be awarded 2004/22/ MID certification to EU standards.


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Event Focus

The World of Laser Technology Come November and Mumbai will play host to the second edition of LASER World of PHOTONICS INDIA, an event that will showcase the cutting edge of laser technologies that hold promise for a range of industries

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o be held at the Bombay Convention and Exhibition Centre, Mumbai, from November 12-14, 2013, LASER World of PHOTONICS INDIA will put on display laser and photonics technologies for various industrial sectors, mainly manufacturing, ele c t roni c s, pro ce s s i n g, communication, medical technology and general lighting. Photonics and laser technologies are rapidly growing in current and different industrial applications as new alternatives to traditional manufacturing processes. Global automakers like Honda, Volkswagen, Suzuki, etc., have major industrial production bases in India and are aware of the advantages of the laser welding process in the automotive sector. This is mainly due to its high productivity and small amount of down-time compared to the other forms of welding systems. Today, India, along with China, offers the most lucrative opportunities for global manufacturing entities from key sectors. With the entry of global players in India, world-class technologies, especially in laser applications, have been introduced, resulting in a boost to local laser technologies and the niche industry in general. The first edition of the event played host to 128 exhibitors and around 2,688 trade visitors. The trade fair also witnessed a parallel seminar on “Laser Basics and Applications” which featured latest trends,

Event at a glance Key exhibitors: TRUMPF India, IPG Photonics, Laser Science, Sahajanand Laser Technology Ltd., Anatech Instruments, Ametek Precitec, etc. Product categories: lasers and optoelectronics, optics, manufacturing technology for optics, sensors, test and measurement, services, photonics applications, laser systems for production engineering, optical measurement systems, optical information and communication, biophotonics and medical engineering, imaging, security. Conferences: Day 1: Symposium on Laser Material Processing. Day 2: Seminar on Laser Applications: Opportunities and Challenges, in association with The Optical Society of America, Optical Society of India and Tata Institute of Fundamental Research. Website: www.world-of-photonics.net/en/laser-india addressed by 13 renowned speakers from the industry and was attended by 155 trade audiences. Recognising the entrepreneurial ability and appetite of small and medium enterprises (SMEs) in India that can fuel the spectacular trajectory of growth for the sector, The National Small Industries Corporation (NSIC) has extended its support to the Indian SMEs to facilitate their participation at the event with subsidised rates with support from NSIC. Tremendous power, flexibility, speed and quality can be obtained by the use of photonics and lasers, which are used in electronics, molds and dies, biomedical applications and auto manufacturing. Photonics and lasers can be used to manufacture more efficient engines and more powerful batteries. In the automotive industry, high power laser welding installations lead to particle-free working, stress-free energy input, highest aesthetic

quality and high flexibility. Unlike other welding techniques that require a vacuum, laser welding transmits a beam through the air. This process can be easily automated using robotic techniques. There is no radiation by the process and it provides higher quality welds. Organised by Messe München International, which has staged the event every two years since 1973, the second edition expects to see over 100 Indian and international exhibitors as on date and is supported by Ministry of Communication and Information Technology, Ministry of Micro, Small and Medium Enterprises Government of India and The National Small Industries Corporation along with industry associations like Indian Laser Association, Optical Society of India, Photonics Society of India, The Optical Society. The event is co-located with other trade fairs like analytical Anacon India 2013 and InterSolar India 2013.


Event Focus Laser and photonics technology is growing rapidly in India: Bhupinder Singh, Deputy CEO, MMI India 1. What has been the response to the first edition of the show in India? The first edition of LASER World of PHOTONICS INDIA 2012 consolidated its position as India’s No 1 platform for laser and photonics community. The visitors came from industry sectors like automotive, telecommunications, medical, aerospace/aviation, diamond as well as research institutes and others. The trade fair was not just a platform to meet the key decision makers and the who’s who of the industry, but also a forum where the laser and photonics industry, associations and scientific experts gathered to exchange their ideas and shared their vision. 2. Given the economic slowdown, how ready are Indian manufacturers to adopting new technologies? New technologies are means to innovate and develop products/ solutions at a much rapid pace. Today many of the industrial verticals require precision and quick turnaround of their process. This process can be accelerated by modern technologies. One of the most efficient ones is the laser and photonics technology, owing to tremendous power, flexibility, speed and quality of execution. Although, there is a slowdown, companies invest this time for their research and developments, so once the economy flourishes, they line up their products and innovations. 3. What would be the approximate market size for laser technologies in India? The Indian laser and photonics industry is still at a nascent stage. The

application of laser and photonics technology is growing rapidly in India in several key industry sectors like automotive, aerospace, defence, solar, diamond cutting and industrial manufacturing. All of these sectors require precision and less down time. The laser industry in India is growing at a rate of 10 to 15 percent every year. 4. What are your expectations from the second edition? Any message for exhibitors and participants?

The second edition is once again receiving overwhelming response from Government, associations and industry players. The event provides laser and photonics technology its own national platform and intends to improve its level of recognition in the Indian industry. For exhibitors and visitors, it will be a unique opportunity to know the photonics and laser industry and to tap the immense global knowledge shared on this platform.

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Indian Manufacturing Barometer:Taking the Pulse While being cautiously optimistic, the sector is using this period of comparatively sluggish activity to realign the business models and prepare for the future, says a report from PwC and FICCI. Excerpts Summary In an environment of sluggish economic growth, and deceleration of the manufacturing sector, it is not surprising that the mood exhibited by companies appears cautious. Companies appear to have battened down their hatches and are preparing for a period of uncertainty. New investments seem to have been put on hold, with half of the companies surveyed indicating that they had no plans for major investments in FY14. Encouragingly, however, it appears that the sector is using this period of comparatively sluggish activity to realign the business models and prepare for the future. Much of the focus of new investments is on new product introduction and on R&D initiatives aimed at improving product portfolio and mix to increase margins. In the light of a challenging economic environment, companies are also re-evaluating customer propositions and relationships while adding value to the core product and focusing on longerterm and profitable relationships with customers. Despite uncertainty related to economic conditions, and continued constraints to growth, companies seem to believe that the market may have ‘bottomed out’, with GDP growth in FY14 expected

to be higher than in the previous year. Further, the companies surveyed appear confident about their own prospects for growth, with more than 50% largely expecting their own revenues to grow at higher than 10% over the next year and profit margins to improve.

Emerging trends

Manufacturers are cautious about new investments but cost control has not stopped job creation. The impor tance of manufacturing in the overall well being of the economy is more than evident and the government has paved a mission for the sector. Notwithstanding the plans of the government, companies are already

taking measures to try and drive growth in their individual businesses.

Restraining expenditure, not value Customer growth targets for companies are also strongly guided by tightly defined investment parameters. Manufacturing companies are careful about adding capacity but are not in a mood to cut manpower.

Expenditure: Tread carefully Faced with rising costs and weak demand, investments could have taken a back seat. Half the companies surveyed are not planning major new investments and 10% are uncertain about it.


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No job cuts yet However, in India, while companies have stalled their plans of capacity additions and investments, they have also been careful not to cut value in the process. For instance, 44% of the respondents were planning to retain their existing staffing levels, while a further 35% expected to increase headcount over the next 12 months.

Looking forward to expand Companies are ready to explore their options beyond national borders and capture an increasing share of the global pie.

Markets without borders The trend is evident in the responses. Only 4% of the total interviewed companies want a reduction of activity in selected markets abroad in the next 12 months. For the balance, resolution to increase their global footprint seems more aggressive for the future, compared to the last six months. Over the next 12 months, a third of companies surveyed expect international sales to comprise over 20% of their revenues, with the median expectation being 14%.

Target business activities While 57% are expecting to expand to new markets abroad, 43% believe that they will start at least one new strategic alliance or joint venture in the next 12 months. Nearly, two among five companies also plan to set up a new manufacturing, production or distribution facility abroad.

Building competitive advantage beyond cost Competitive advantages need to be sustainable for Indian manufacturing to maintain its attractiveness, since they face

competition not only from other domestic players, but also players in other countries.

Strategically allocating limited resources Manufacturers may have started working towards these goals already. We say this since despite the objective of costeffectiveness and capped expenditures, they are strategically planning to allocate their limited expenses in the next 12 months. They have chosen to spend on new product or service introductions, research and development and facilities expansion. R&D aimed at improving product portfolio and mix to increase margins. The focus area of their investment shows that they are resolute about climbing up the value ladder to sustain their advantage and not solely rely on providing low costs.

Sector-specific investments A closer look at the data reveals that sectors such as auto ancillary were actively pursuing all three areas of expenditure. Metal companies were mostly looking forward to expanding facilities and introducing new products and services. A majority in the building and construction materials sector want to spend only on facilities expansion, capitals goods segment on new products and services and chemicals and engineering companies on R&D.

Special focus: Customer expectations In a difficult economic climate, as sales become sluggish, companies begin to focus, apart from their own

Size Specific Optimism When we segregated the companies surveyed on the revenues of their respective divisions or SBUs, we found that the intensity with which they expanded across the border, in the past six months, varied with size. The participating companies with revenues of 5 billion INR or above in FY12 were more inclined to expand than those with revenues below that level. operations, on driving additional value from their suppliers. With most manufacturers, being themselves suppliers to other businesses, we obtained a range of viewpoints from them, on whether and how customer expectations were changing and how they were reacting to them.

Understanding customer needs Companies are not only aware, but are also preparing to tackle changing demands and preferences of customers by fostering long-

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Not just products, but also solutions

term relationships. While customers are becoming more demanding, particularly with respect to price and payment terms, manufacturers appear to be evolving their business models in order to maintain their operating margins.

manufacturing, but such cost savings can come from the elimination of cost inefficiencies . Cost efficiency can ensure cost competitiveness, which enables companies to gain a larger share of the market.

As customers crave for value additions and efficient delivery systems, companies are striving to keep them interested with service additions. Around 42% are adding services to their products in order to respond to frequently shifting and disparate customer preferences. This finding is witness to the trend that manufacturing companies are progressing much beyond factory operations, driven by competition. Some companies now want to link their manufacturing operations with nonmanufacturing functions such as customer service, logistics, business solutions, procurement and planning. The trend could help manufacturing companies integrate seamlessly with multiple business partners.

Cost efficiency Indian manufacturers are seeing a change in customer dynamics in the present market. Of the companies surveyed, 73% believe that customer requirements and expectations have changed due to the global economic environment as well as the domestic slowdown in growth. We found that Indian customers have strong preferences for higher discounts, among other things. Our interviews also revealed that some players wanted to respond to these shifts to build and maintain long-term relationships with customers, both new and existing. So, how are they doing it? Cost efficiency appears to be the primary strategy to respond to changing customer needs. 76% of surveyed companies stated that they are resorting to cost efficiencies to meet customer requirements. There is ample room to reduce average costs in Indian

Courtesy: PricewaterhouseCoopers and FICCI


In Retrospect 31

The Journey towards Success DesignTech Systems made a modest beginning in the year 1998 as a distributor for SDRC's Ideas software in Maharashtra. Ever since then there has been no looking back

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ittle did DesignTech know that its first baby steps would bring it this far to becoming one of the leading CAD/CAM/CAE, PLM; Additive Manufacturing technologies; Engineering services; and CAD/CAE and PLM trainings provider in India. The visionaries of DesignTech and the founders and directors, Mr Vikas Khanvelkar and Sachin Chougule, realised that CAD/CAM/ CAE, PLM and Rapid Prototyping Technologies will revolutionise the way companies have been developing and building products. They envisioned that these technologies will become the backbone of modern R&D

perceived unnecessary and companies relied heavily on their 2D drawings. The new technologies were also believed to be extremely expensive, and considered fit only for the MNCs and not the SMEs. Mr Khanvelkar and Mr Chougule, backed by the strong support of Mr Sanjay Daga and Mr Atul Marwaha, who now hold the positions of Executive Vice President Operations and Vice President – Engineering Services respectively, went on a mission to transcend this mindset and to let companies know that even the SMEs could afford, adopt and take utmost advantage of these technologies. DesignTech played a lion's share

DesignTech played a lion's share in promoting, and popularising the use of CAD/CAM/CAE and RPT technology to create robust and aesthetically appealing products in reduced time and costs departments on which the entire product design and development processes and in-turn the success of the company will rest. They decided that they wanted to bring the same technology to India and help indigenous mechanical engineering industry match the international standards of product development quality, proficiency and aesthetics and give international players a tough competition in the global market and stay competitive. However, this journey wasn't exactly a walk in the park. In the late 1990s these technologies were

in promoting, and popularising the use of CAD/CAM/CAE and RPT technology to create robust and aesthetically appealing products in reduced time and costs in the Indian mechanical and product development industry. They also gave birth to the Engineering Services division within the company. They started providing 3D CAD modelling and CAE services such as FEA, CFD, Kinematic and Multi body dynamics analysis, Thermal analysis, Crash, drop, Durability and Fatigue tests, Moldflow analysis and many more

to the companies who either lacked required infrastructure or were too tight pressed and so had to get these tasks done from outside to save time and costs. They also devised the use of SDRC's ideas software in jewellery design and pioneered Interactive 3D Technical documentation. Besides 3D CAD/ CAE and PLM technologies, DesignTech also popularised the use of Rapid Prototyping machines in the industry. To overcome the big hindrance of lack of trained manpower in using CD/CAM/CAE and PLM technologies to their best, DesignTech began imparting corporate training to designers, and established a training institute called the DesignTech CAD Academy, which is an authorised training partner of Siemens and Altair for their CAD and CAE suite of solutions respectively. With more than 15 years of experience, DesignTech today has a direct presence in 9 cities in India along with subsidiaries in USA and Hong Kong and an associate office in Canada with the support of a 350+ member motivated team. DesignTech is a recipient of many prestigious awards and has consistently received SE1B ratings by CRISIL which stand for highest performance and good financial standing. DesignTech is a customeroriented company, and they actually live their mission and consider all the suppliers and customers as partners in progress and support them in every way they can in their engineering initiatives to enable them derive best possible returns on their investments.


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Insight

Aerospace Industry – The Technological Trendsetter The aerospace industry is the technological pacemaker when it comes to state-of-the-art production techniques, writes Satish Godbole, Vice President of Motion Control Systems – Drive Technologies, Siemens Ltd

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ery few sectors take what is feasible and then implement real products in such a consequential and creative way. Today, the Indian Aerospace industry is witnessing an unprecedented growth. The civil aviation sector, especially, is growing by leaps and bounds, recording an annual growth in double digits for the last two years. However, this industry too faces the challenge of increasing productivity and efficiency and optimising manufacturing costs and weight of carriers. While the industry has witnessed a plethora of innovation and discovery in recent times to respond to ever increasing challenges, designers are still striving to optimise weight in order to achieve fuel efficiency and cut down on carbon footprints. Composite materials are gaining popularity for their role in weight reduction. This is because composites are versatile and are used for both structural applications and components, right from hot air balloon gondolas and gliders, to passenger airliners, fighter planes and the Space Shuttle. Applications range from complete airplanes to wing assemblies, helicopter rotor blades, propellers, seats and instrument enclosures. Aircrafts today are aiming to make 50 percent of their airframe from

• machining and Virtual productivity enhancement

5-Axis Component manufacturing

composites. Higher degree of flexibility and traceability has become the need of the hour for an aircraft manufacturer to achieve a competitive edge. However, this can be achieved by only deploying high-performance automation solutions. Siemens, as a partner to the aircraft builders and machine builders, has developed dedicated control solutions that guarantee the highest degree of quality and productivity. The entire spectrum of aircraft component manufacturing primarily involves the following processes: • 5-axis machining of structural parts and engine components • Laser drilling • Machining of gear • Laser beam and water jet cutting • Tape layering/Fibre placement

In the aircraft industry, production of highly stressed work pieces involves machining away of a high proportion of material. With 5-axis machining of structural components, up to 90 percent of the raw material can be removed during machining. This calls for extremely high metal removal rates, which can only be achieved with highly efficient machines. The emphasis is more on maximum dimensional accuracy and surface quality rather than machining capability. The most efficient way to achieve this is with 5-axis milling, the most advanced metal cutting discipline. In addition to high performance hardware, the control systems used in 5-axis machining centres must incorporate specific programming, motion control and compensation functions for complex machining tasks. These functionalities simplify work for the users and guide them effectively through entire machining process. It is also important to match and optimise motion control to the requirements of a particular machining task. Rigidity and accuracy of the machine have a considerable influence on precision and surface


Insight

quality, and it is also important to improve these with special control and drive functions.

Laser Drilling Drilling is another fast-growing application of laser technology which is increasingly popular in aerospace industry. Laser drilling involves applying sufficient energy to one point on the work piece so as to achieve controlled evaporation of material. Thanks to its great precision and fast machining time, it is rapidly overtaking other technologies such as conventional drilling and spark erosion, as the method of choice for machining very hard materials from which, for example, turbine blades are made. Laser contour drilling, an

A gear that runs quietly has to be produced on a machine which runs quietly because the gear surfaces are memories of vibrations that are present during manufacturing of the gear intelligent combination of laser drilling and laser carving, can provide a highly efficient way of making tapered ventilation holes in turbine blades for even better turbine performance. Like other innovative laserbased machining methods, laser drilling requires optimum adaptation of the control system for this challenging technology.

Machining of Gears A gear that runs quietly has to be produced on a machine which runs quietly because the gear surfaces are memories of vibrations that are present during manufacturing of the gear. A machine which rises to the challenge of precision and high-quality gear production, has to be mechanically and electronically stiff over a wide range of unsteady frequencies due to the tooth count

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Insight

Anyone who wishes to achieve productivity enhancement, must analyse and optimise the entire CAD/CAM/CNC process chain. of the cutter and rotational velocity.

temperature-sensitive light-weight metals.

Laser Beam & Water Jet Cutting Increasingly, materials being employed in aircraft construction are extremely difficult to cut. These can be machined with conventional chip removal or EDM (Electric Discharge Machine) at high cost, which can be used in limited circumstances only. One alternative to conventional manufacturing processes is to use a laser. In contrast to conventional methods, the laser operates without contact, force-free and with no tools. This technology can be utilised with geometric flexibility, highest possible precision and is independent of hardness and conductivity of the material to be machined. Water jet machining, wherein high pressure water is used to cut machines, has also been adopted by a large number of aircraft builders and suppliers. The strength of high pressure is particularly apparent in cutting composite materials and

Tape Layering/Fibre Placement In modern aircraft construction, a large quantity of aluminium components are being replaced by complex parts made of fibrereinforced materials – primarily carbon fibre reinforced plastics (CFRP). Most are structures on fuselage, an aircraft’s main body section, and wings. This reduces weight and greatly simplifies assembly and logistics. While until recently manufacturing was mostly performed manually, the trend is now to automate the processes, two of which are particularly important: • Automatic tape layering for flat and slightly curved components such as wing cladding • Fibre placement for more curved components such as fuselage segments

Virtual Machining & Productivity Enhancement Productivity is money. Therefore, the

goal must be to achieve productivity in all stages of production. With proper approach and suitable measures, existing equipments can be made significantly productive. Anyone who wishes to achieve productivity enhancement, must analyse and optimise the entire CAD/CAM/CNC process chain. CAD/ CAM system, NC programme and CNC itself must be optimised without adversely affecting the ongoing production or risking machine damage. Usually, final stage of NC programming in work planning is the graphic simulation of machining process and verification of work piece with aid of special applications. With manufacturers having global productions facilities, it is key that various components reach the assembly facility at the right time. To achieve this, strong Manufacturing Execution Systems (MES) should be in place that collates data right from shop floor to top floor. This ensures a smooth assembly of the aircraft. All these processes can be carried out with cent percent precision and accuracy based on the choice of technology that is deployed at every level. Hence, it is essential for an aircraft manufacturer to opt for innovative technologies that would give him a competitive edge.


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Insight

The Simulation Advantage Simulation and virtual environments are allowing manufacturers to reduce product development lifecycle time and derive an array of other benefits

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arlier, manufacturers were forced to learn through actual project implementation phase, the outcome of which had commercial impact due to missing the project time line, rework and wastage. In today's global economy, to improve productivity all manufacturing learning should be captured during design phase along with validation of proposed process before actual implementation phase. Manufacturing as a sector has undergone tremendous technological advancements over the period of time. Advanced manufacturing continues to be the main thrust and driving force behind the sector’s growth globally. Manufacturing simulation techniques play an important role to integrate product designs with the controlled manufacturing process. With 3D simulation tools, manufacturing engineers are able to create virtual models of machine tools, processes, robotic assembly, based on the digital definition of the product. The software revolution is allowing manufacturers to use virtual environment to test the quality and robustness of their products, avoid physical prototyping, reduce their product development cycle times and identify alternative reliable materials. These virtual models, in turn, allow validating, synchronising and optimising manufacturing processes before they are

implemented to reduce manufacturing time and cost. This was the differentiator which forced present manufacturing industries to promote simulation techniques.

design, and manufacturing validation occurs before committing to physical prototypes, thereby helping to save on capital expenditure.

Major Benefits

Some major benefits of digital manufacturing are: • Provides a centralised resource for factory flow simulation, process planning, auto line balancing, station validation and logistics planning • Improves production plans for space and resource utilisation • Simulation helps in finding out various cost effective alternative manufacturing solutions • Helps in optimising inputs (raw material, tools, resources, infrastructure, etc.)

Digital Manufacturing practices take place in realistic 3D environments, where manufacturing plans can be prevalidated in a virtual 3D environment. These processes essentially help in eliminating redundant business systems especially in later part of product manufacturing cycle as well as aid in avoiding unexpected problems on the shop floor. One of the major benefits of 3D/simulation software is that concurrent engineering,


Insight •

metal, casting and plastic parts Machining simulation

1. Robotic simulation: In mass production industries like automotive sector, where small savings in cycle time will result considerable savings in production cost. Robotics simulation can confirm the feasibility and help saving actual manufacturing time at different stages by optimising operating cycles. Simulation also helps in optimising robot movement without any collision. • Leverages logistical data from old shop to new shop • Drives time out of the process • Leverages the full force of leading practices for software utilisation • Educates – contributing to the ability to pre-empt future modifications • Promotes client self-learning to encourage self-sufficiency • Helps define future methodologies • Eliminate investment in prototypes, physical testing • 3D simulation helps to reduce tool tryout time, down time and repair costs • By using 3D simulation platforms, manufacturing can work concurrently with design • 3D simulation solutions will provide edge on reducing lead time to market will help organisation to launch number of products in less time

product quality. By leveraging digital m a n u f a c t u r i n g, manufacturers can achieve cost savings, accelerate time to market, and gain competitive advantage as well as manufacturing excellence. Due to pervasiveness of software driven manufacturing, manufacturers can avail comprehensive solutions that streamline their operations and help them optimise shop visibility and control that integrates the supply chain and enables integration between enterprise and plant-floor systems. By incorporating artificial intelligence in 3D simulation software, which will help to reshuffle execution strategies based on real time situations the design/process variations. (i.e., wear & tear of machines, vibrations, etc). Undoubtedly, manufactures who make effective use of simulation tools will lead the future market.

Emerging Possibilities The emerging possibilities in design and manufacturing through use of 3D/simulation software include boost in product innovation cycles while simultaneously reducing costs and maintaining premium

Applications Some of the manufacturing areas where 3D simulation is effectively used in industries are: • Robotic process simulation • Process simulation for sheet

2. Sheet metal stamping simulation: Validates sheet metal forms at different stages of forming, validates the process and optimises blank size and operation stages. This will also guide to use alternate cost effective materials without affecting part quality. Tool tryout time can be drastically reduced. One case study shows a raw material cost saving of up to 25-35 percent with the use of forming simulation tool. 3. Machining simulation: To machine complex parts on 5 axis machines, where work holding device has 6 simultaneous movements (3 angular and 3 axial), which are very complex to analysis manually, 3D simulation plays a key role to confirm the feasibility of programmes to get the required the quality of product along with productivity improvement from 15-30 percent by optimising cutter path. Courtesy: Tata Technologies

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3D CAD Modelling Technology and Digital Manufacturing Vikas Khanvelkar, MD, DesignTech Systems, takes us step by step into the world of 3D CAD modelling, simulation and digital manufacturing.

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AD Modelling technology has come a very long way from the hand sketching/ drafting 2D drawings on a drawing board. Now there are a plethora of options and software available with different core competencies that can enable and help you design world-class products with utmost accuracy and precision, while boosting innovation, invention, imagination, and creativity. The 3D CAD modelling software technology has been around from 1990s. And ever since then, many

man years of research and funds have gone into the evolution of the technology to make it as proficient and cutting edge as it is today. At the core, 3D CAD modelling technology helps designers view and thus design the products three dimensionally, which enables them to pay attention to the minutest of details in designs, leading to acute precision. There are 2D CAD Software as well. However 3D CAD software range includes – concept design software, solid modelling which

involves parametric modelling/ designing, and surface modeling for high-class surfacing and rendering. Let’s explore it step wise.

The process Concept Design software, as the name suggests, is used primarily in the preliminary stages of product design, wherein after having received feedback/inputs/brief or requirements sheet from Marketing and/or Research Departments, designers can explore, discuss, innovate and or just imagine the


Trends new ideas or concepts of product design. These are just concept level designs, which in the olden days people used to hand draw – the rough idea and sketches on the drawing paper. This software basically gives shape to your ideas and helps you visualise more clearly in a coloured 3D perspective. Some of the examples of Concept level 3D design software are – sT Inspire and sT Evolve from Altair. After having discussed these ideas in great details and after having considered all the pros and cons of the ideas, a few ideas are selected and then passed on to the next level for detailed engineering design, which is also known as parametric or geometric CAD Solid Modelling or Computer Aided Geometric design. In this stage, the designs are made keeping in mind the smallest of the engineering details and dimensions. The best part of 3D modelling software is that you can not only play with it and rotate views 3D dimensionally, but also get an inside view of the product/

component/machinery that you are designing. During this stage, even the aesthetic aspects of design are also taken care of. For e.g., surfacing and rendering of the product is carried out to give it a desired look and feel. High-end modelling software enables Class A surfacing which is specially required in Automotive industry. CAD modelling is an integral part of the broader Digital product design and development process which comes under the broader spectrum of Product Lifecycle Management, most commonly referred to as PLM. 3D CAD models are extremely critical for robust product development, as these designs are also used for CAE, i.e., Computer Aided Engineering, in which product designs pass through a number of virtual analysis and simulation tests to determine their durability, strength and the conditions in which the product will and will not function. Product design simulation is also a very important stage in PLM.

In this the parametric designs are virtually tested by applying various boundary conditions like loads, pressures and various drops, falls or crashes to understand the weak and strong areas of the design. FEA (Finite Element Analysis) involves meshing, which means breaking the product geometry into minutest thousands of pieces and testing the design by applying the forces as per boundary conditions to check whether the design will withstand the conditions. Computational fluid dynamics involves studying how any liquid involved in the product design will move or behave in different conditions. For e.g., how petrol in the petrol tank will move on the roughest of the roads. In thermal analysis we can see how temperature, heat, or steam will affect the functioning of the product. Kinematics and Multi Body dynamics look at components attached to each other in a mechanism in such a way that the functioning or working of one part of the component depends on the

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Key benefits of 3D CAD modelling • Better visualisation and imagination • Knowledge and data management • Adherence to international standards, codes and norms • Create robust products • Basic animation • Augments innovations • Mobility: Work from home, office or even when you are on the move • Expedite product design and development cycle • Concurrent engineering: Multi-tasking from remote places smooth functioning of the other part, and help analyse if there is any hindrances or whether they can function smoothly and in correlation with each other. These types of tests can only be conducted on the available CAD data of the product designs. The HyperWorks suite of solutions from Altair is one example of the range of software that can carry out or conduct all the above mentioned tests on the product designs. Based on these test results, if required the products are redesigned to address the identified weak areas of the design. Also, with the help of product design optimisation software such as OptiStruct from Altair, the designs are optimised in such a way that products are made as light as possible without compromising one bit on the strength and robustness of the product. This software actually highlights the areas of the product design from where the raw material could be eliminated without causing any harm or damage to the functionality and/or strength and tenacity of the product. 3D modelling designs are also used to create prototypes. Rapid

Prototyping Machines, for e.g., from Stratasys Inc., help create functional prototypes which can be used for physical and functional validation of the design. These prototypes help identify ergonomic or functioning fallacies or errors which can be corrected through amendments in designs. Some of the world's leading CAD software are: NX CAD series from Siemens and Product Design suite from Autodesk. 3D modelling hence performs and occupies a very important place in helping companies create robust and aesthetically impressive product designs in minimum time and costs, thus helping companies remain competent and resilient in today's fast changing and precarious market conditions.

Digital Manufacturing Once the products are thoroughly tested and passed through virtual simulations and physical validations, the last stage is Manufacturing. Similar to 3D design software technology, there have been massive developments in the digital manufacturing technology space as well. Today's Digital Manufacturing Solutions and technologies, through their offerings like “Design for Manufacturing” and “Design for Servicing”, help the companies configure the optimum work flows during the plant layout stage, which enables the companies in enhancing the productivity and overall output of the company. Digital manufacturing solutions could be used to design and plan the green plant (right from scratch – new plant) or brown plant (to bring out necessary planning and layout changes in the existing plant). Either ways it configures optimum and customised workflows for companies to help them generate highest possible

level of production output, thereby enhancing the production capacity of the plant. Issues concerning to constraints in manufacturing or feasibility of manufacturing, popularly referred to as “manufacturability concerns” or “ergonomic constraints” are very difficult and highly expensive to rectify once the plant, work flows and processes are established. A prior validation would help companies identify such concerns at the earlier stage of planning and would hence save the time and cost of rectification. Because digital manufacturing solutions create and present the plant planning in the virtual 3D environment, it becomes easy for the companies to validate and evaluate their designs to identify such concerns before hand and address them at the planning stage. Apart from virtual validation of plant and processes, these technologies also help the companies to plan and allocate their resources and also make optimum use of their available plant space. The human ergonomic simulation helps companies to identify the ways and means of carrying out a task manually which would cause minimum possible physical stress to the people working on shop floor. This reduces chances of accidents and occupational hazards. It thus helps companies to build plants that are more efficient yet secured, safe, and worker friendly. Examples of a few renowned Digital Manufacturing software solutions are Tecnomatix from Siemens and Factory Design Suite from Autodesk. Thanks to such technologies, the companies today can try out many “what if” scenarios at minimum costs to validate their processes and arrive at the most optimum layouts and solutions.


Insight

Future of Indian Manufacturing Industry Prasanna Gandhi, Manager – Internal & External Communications, Ma Foi Strategic Consultants, explores the four waves of manufacturing and the Indian scenario

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f the ‘first wave’ was about the revolution in producing, storing, and transporting food, the second wave was about producing, storing and transporting energy. This made it easier, faster and cheaper to produce and to consume. This created new wealth, new class and a society based on mass production, mass distribution, mass consumption, mass education, mass media, mass recreation, mass entertainment, and weapons of mass destruction. You combine those things with colonies, world wars, standardisation, centralisation, concentration, and synchronisation. In many ways this change is discontinous from the ealier agrarian wave. It took about thousands of years for the second wave to sweep the world. But the third wave, the information age, was faster and swifter. Countries which were under the colonial rule, before they could catch up with the industrial revolution, are faced with information age. And you have transit nations, where the systems, institutions and cultures are caught between old agrarian values, not fully florished industries and emerging information age. To understand the future of indian industries, we need to understand its context. The real problem of Indian industry is that it was not a natural transition – with

Way forward: A Frame work for growth

conflicting values, non transferable skills, inadequate capital, and hampered industrial understanding. Despite old civilisation, the skills and knowledge of the people couldn’t find place in the new industrial era. So what developed as industries remained disconnected with vast majority of people and is seen with a lot of suspicion even today. Those that were successful were those clusters which blended traditional role with modern opportunities. It is in this context that our industries are operating, trying to compete within itself, with nations, and importantly the new fourth wave, Eco-Globalism. The future of the manufacturing lies in adding value to the first wave’s needs and wants, using the third wave opportunities and reaching the fourth wave idealism.

The narrow purpose of the industry is to grow, and grow profitably. But what is the holy grail for growth? The growth as a vision for the industry needs to be balaced and anchored. The policies should aim at creating sustainable social capital. The test of the real growth should be: a. The value it creates for all the stakeholders b. Cost of the growth, including ecological cost c. Inclusiveness of such growth It has to be translated into actionable items at the individual business – a.) Products, b.) people and their capabilities, c.) process, and d.) profits levels. Products: The priority products which manufacturing should focus are those which would increase the productivity of ordinary citizens and enhance his/her life. Second are the products which are sustainalble and inclusive in nature. Third should be in security and defense, and fourth should be luxury products. People: The agenda for people should be increasing thier capabilities and ensuring a dignified life. Today it is suffering from perception issues; it is loosing out people to the service industry. It

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needs to become an attractive option for the young and talented. In a country like India where society percieves physical labour as a lower form of work, it is important to reinvent workplace and offer opportunities, facilities and dignitiy to its workers. Process: Much of the conflict arises not in what is produced than in how it is produced. People who have opposed industrialisation and growth have done so because of its process. Carelessness, inefficiency, indifference and ‘jugaad’ have chequered the history of manufacturing companies in India. But today, not just for growth, even to start a business, one needs to get the process act well. Profit: Deployment and utilisation of profit ensures equality and new investment. Managing socio-enonomical and political world: The national manufacturing policy, skill development mission, and the Land Acquisition Bill give a sense of direction and the government’s intention. The HSBC India Manufacturing Purchasing Managers' Index (PMI) - a measure of factory production - stood at 48.5 in August 2013. It is estimated that rising domestic demand in India,

along with the multinationals’ desire to enhance their footprint in the sub-continent, could boost the country’s manufacturing sector to grow six-fold by 2025, to US$ 1 trillion, while creating up to 90 million domestic jobs. Critical though for the success would be gaining the confidence of the public for any large projects. This mistrust has to go; the companies need to understand the definition of growth from the people’s angle and gain confidence. Competition: India is likely to emerge as the second most competitive economy in the world after China in terms of manufacturing competitiveness in the next five years. But it would largely depend on how fast and better we could skill our people and develop clusters. Talent-driven innovation will be the most critical driver of a nation's competitiveness, while the second most important driver position is productivity. Customers & Partners: India is largely driven by domestic demand. Customers are partners in innovation. They are not passive buyers, but activite collaborators in creating new products. With such engagement possibility, co-creating products with the customers can

help companies remain lean and also respond to changes faster. Manufacturing has historically invested in their suppliers and looked at them as partners; the partnership should expand and include other critical stakeholders like educational institutions. Over and above government policies and the environment, there is an urgent need to boost productivity. Using IT to increase shop floor productivity, managing suppliers, increasing customer intimacy and product development a robust integrated IT can make a difference in improving productivity. Today we have a second chance to catch up. The progress of manufacturing still sets the tone for the overall business cycle, and the health of this sector is very much at the core of India's socio-economic fabric. The rapid growth of the services sector much before the manufacturing industry attaining maturity is not a healthy sign. A knowledge-based economy cannot be sustained in the long run unless it is adequately supported by a growing manufacturing economy. Moreover, a service economy cannot continue to thrive on a long-term basis in a country where over 80 per cent of the population is education below the middle-school level. The nation has large stakes in manufacturing, not just because of its contribution to the overall economy, but also because this sector employs 30 per cent of the non-agricultural workforce in India. The future will judge it by the value it creates for all the stakeholders, its impact on lives (including non human lives), and the inclusiveness of such growth. The future of manufacturing, we hope, lies not in the distant moon, but here on earth.


Insight

Powering Up Discoms Lalit Jalan, CEO, Reliance Infrastructure Limited, analyses the challenges and opportunities for power distribution companies.

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s the Indian economy gears up for its upturn, its sustainable development will warrant growth from all sectors particularly the power sector, which will play an instrumental part in catalysing India’s growth. Moreover, it can be firmly said that any rationalisation and modernisation of the policy regime in the power sector will set an example for other infrastructure sectors. Last year saw the power sector face a quagmire of issues; from the country’s worst grid collapse to critical issues surrounding fuel availability and pricing, and mega power projects hanging in the lurch. As we leave behind the past, there are lessons to be learnt and amends to be made. The clear lesson from the recent Indian experience is that the most critical challenge faced by the power sector is the dismal health of discoms, which has led to inadequate investments in the sector. This has, in turn, led to serious power shortfall, as well as poor quality of supply, which are both very serious constraining factors on overall economic output. The combined financial losses of all the power distribution companies stand at a staggering Rs 1,200 billion (Rs 120,000 crore or nearly 1.5 percent of the country's GDP). These losses were due to the rising gap between average cost of supply and the average realisation;

going by which, distribution companies lose Rs 2 for every unit of electricity sold by them. Timely tariff hikes in the power sector are perhaps its most politically sensitive issue. Many states have not revised tariffs in the last 5-6 years, and some for over a decade. With average cost of supply growing at over 7 percent CAGR in recent years, the situation has become untenable. Today, distribution entities across the country, whether in public or private sector, urgently require tariff hikes to the tune of 50-60 percent to meet their operating costs and serve the economy with reliable supply of power. An increase of this magnitude will seem staggering to the political leadership and the consumer, but the stark fact is that this hike would still leave unattended the subject of past accumulated losses due to irrationally-low tariffs. It’s important to note some positive signs initiated by government and policy makers in this regard. Calendar year 2012

Any rationalisation and modernisation of the policy regime in the power sector will set an example for other infrastructure sectors witnessed tariff hikes in 30 Indian states & UT’s averaging between 10 percent and 37 percent. This is for the first time that almost all states have issued tariff orders. Of course, rationalisation of power tariffs has to happen on a perennial basis. It’s critical to understand that purchase costs for power typically comprise up to 80 percent of the total cost of the distribution function. Since the 'truing up' process, involving a fix on the gap between power purchase costs and the revenues from sales, can take a few years for reasonable estimation, its important to institute and implement mechanisms that enable immediate pass through of any variation in

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Insight

The most critical challenge faced by the power sector is the dismal health of discoms, which has led to inadequate investments in the sector power costs. This will avoid build up of so-called ‘regulatory assets’. There are other bedeviling issues too. One of these is the need for reduction in cross-subsidies between diverse consumers. One testimony to the twisted deal in such arrangements is provided by the fact that 24 percent of entire electricity supplied flows to the agricultural sector, but yields less than 6 per cent of the total revenues. While it is laudable that the Government is investing huge amounts in electrifying villages under the RGGVY programme, the question is, are financially distressed distribution utilities in a position to supply power to these villages at zero net realisation, that is after accounting for cash expenses? Very often, we find that cash constrained

SEBs prefer selling power outside the state to paying customers rather than supply to non-paying farmers. With the average cost of supply at over Rs 5.0 per unit every 10 percent increase in agricultural supply will add Rs 7,500 crore to the deficit. Decision makers and people in governance fail to realise that, more than subsidy, it is round-theclock and quality power supply that holds the potential and promise to completely transform life in rural India. A beginning has been made in Tamil Nadu, which has increased tariff on electricity supplied to its agricultural consumers by 589 percent, to Rs 1.75 per unit. Investments in capacity building and modernisation are also key requisites for improving the health of the sector. Delhi has proven to be

a shining example in this regard, where only five to six years ago, a typical resident was exasperated by 4 to 5 hours of daily power cut. This has now reduced to a mere 4 to 5 hours of interruptions in the entire year. This dramatic improvement in quality and reliability of supply has been possible due to large investments in network and technology (Rs 6,500 crore) along with streamlining of systems and processes. A true testimony of the fact that reliability levels in Delhi are now comparable to international benchmarks. Yet all the improvements and the entire reform of the Delhi electricity supply market is under risk for want of urgent tariff rationalisation. As serious bottlenecks have emerged, the need of the hour is to identify and implement solution with utmost urgency. The debt restructuring package for state utilities is one of these positive developments, yet only for the short term. Its long-term benefits will actually depend on the discoms’ ability to lower AT&C losses, hike tariffs and limit operational costs. To sum up, reforms at the power utility level are vital for the overhaul of the Indian power sector, and will lead the way for its sustainable growth in 2013. It is a welcome sign that government has recently shown some resolve in this direction. Lalit Jalan is the CEO of Reliance Infrastructure Ltd. He concurrently holds the post of Chairman of BSES Rajdhani & BSES Yamuna Pvt. Ltd. Jalan has served Reliance Infrastructure in many roles, including CEO of Delhi Power Distribution Company, where he reduced power theft from 55 percent, and as CEO of Reliance Infrastructure in Mumbai, managing several large infrastructure projects. Disclaimer: The views expressed are of the author and may not reflect the views of Reliance Infrastructure.


Case Study

Smooth Under Pressure

Autodesk Simulation Moldflow helps Faurecia to better manage temperature and pressure issues during auto parts production Project Summary Faurecia, headquartered in France, is a leading specialist in the engineering and production of automotive solutions. Through a series of acquisitions and mergers, the company has emerged as a global leader in automotive seating, emission control technologies, interior systems, and automotive exteriors. Today, Faurecia operates in 33 countries with 84,000 employees working across 270 production sites and 40 research and development (R&D) centres. Faurecia’s customer portfolio includes every leading automaker from around the world, including manufacturers in emerging economies such as China, India, and Korea. In India, specifically, the company operates manufacturing plants in Bangalore, Chennai, Hingewadi, and Manesar. It also recently opened an R&D centre in Pune.

The Challenge To differentiate themselves from the competition, automakers are always looking for ways to enhance the interior and exterior appearance of their vehicles. In India, while working for one of the world’s leading automakers, engineers with Faurecia’s Interior Systems unit faced a challenging situation in the development of a new door panel model that would include a speaker grill. The objectives were to create a map pocket family mold for the door panel with two differently sized parts assembled together, and to find the weld line positions and

air trap in the speaker grill using talc-filled polypropolyne (TF-PP) material.

The Solution The design team at Faurecia Interior Systems looked to Autodesk Simulation Moldflow plastic injection molding design software to achieve optimal inputs for the model design of the door panel. Using Moldflow’s analysis tool, they

were able to easily generate a mesh model for the speaker grill holes using the shape factor feature. “Autodesk Simulation Moldflow made it possible to balance the pressure distribution in the two differently sized parts of the map pocket family mold for the door panel,” says Mr. Kishor Phadtare, Lead Engineer—Process CAE for Faurecia. “Based on the analysis results in Moldflow, we were able to choose a design with a better nozzle position. Moldflow gives a perfect nozzle opening sequence regardless of the complexity of the part.”

The Result Autodesk

Simulation

Moldflow

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Case Study predictions helped Faurecia Interior Systems ensure that the required pressure and temperature were maintained during the filling of the TF-PP material in the speaker grill holes, and detect trapped air by locating the accurate positions for the air vents. Moldflow also helped Faurecia’s design team to achieve optimum results for the map pocket family mold parts by providing accurate results on the filling pressure required for the different sizes of the parts in the door panel assembly. “Autodesk Simulation Moldflow software is an integral part of every product development project in our company,” says Mr. Kishor Phadtare. “It is a very versatile solution that helps us to serve ever-changing and more challenging product requirements from our clients.”

About Autodesk Simulation Moldflow Autodesk Simulation Moldflow provides simulation tools for injection mould design, plastic part design and the injection moulding design process. Autodesk Simulation Moldflow Adviser and Autodesk Simulation Moldflow Insight software help reduce the need for costly physical prototypes, avoid potential manufacturing defects, and get innovative products to market faster.

Features Heating and cooling of plastic injection moulds Determine temperature variation in an injection mould during a plastic injection moulding cycle. • Multi-CAD import Evaluate a range of potential plastic part designs regardless of where the 3D CAD data comes from. Import Rhino, Alias and NX files directly. •

Fibre orientation in plastic part designs Better predict the orientation of glass fibres, including long fibre breakage. Analyse resulting material properties for accurate mechanical performance. • Design optimisation Simulation Moldflow Insight design of experiments (DOE) abilities are expanded to all mesh types, moulding processes and simulation tools. • Shrinkage and warpage simulation Evaluate plastic part and injection mould designs to help to control shrinkage and warpage based on gradespecific materials and processing parameters. • Thermoset flow simulation Simulate thermoset injection moulding, RIM/SRIM, resin transfer moulding and rubber compound injection moulding. • Geometry modification With Simulation Moldflow, you can use Autodesk® 360 Fusion software to modify or simplify geometry. • Specialised moulding processes Simulate a wide range of plastic injection moulding processes and specialised process •

applications. CAD interoperability tools Use tools for native CAD model translation and optimisation. • Material data Improve simulation accuracy with precise material data on more than 8,700 surface-specific plastics. • CAE data exchange Validate and optimise plastic part designs using tools to exchange data with structural simulation software. • Autodesk Simulation Moldflow Communicator Collaborate with manufacturing, engineers, suppliers and external customers using the free Autodesk Simulation Moldflow Communicator software (US site). •


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Whitepaper

Designs for a Better Product Excerpts from a Dassault Systemes whitepaper on the factors that define a better product What constitutes a better product? Depending on their job functions and industry roles, designers, engineers, managers, and manufacturers will cite differing factors as to what makes a better product. The answers, in short, are rooted in people’s perceptions— which, in turn, are influenced by their life experiences and unique sets of criteria. Although a “better product” has various meanings for different people, six key factors typically define its attributes: 1. Decreases manufacturing costs. Management, in particular, wants to create the product in the most costeffective manner. In trying to improve a product’s manufacturability, they aim to simplify the overall process, reduce operations overhead, and use lower-priced raw materials. 2. Speeds customer delivery, beats competitors to market. Managers have a large stake in making their products available before competitive offerings, as this can create inroads to attaining dominant market share. Likewise, business customers often equate fast delivery with better products— especially when they need to rectify company problems or capitalize on fleeting opportunities. Even design

engineers relate better products to streamlining design and development cycles. 3. Provides more throughput, requires less maintenance, experiences less downtime. For industrial and manufacturing companies, maximized throughput and uptime are the standard measurements of better product performance— from packaging machinery and mold, tool, and die equipment to mater ials-handling machinery and power and process systems. Purchasers of high-precision tooling equipment, milling machinery, and packaging equipment also rely heavily on operational accuracy and repeatability. 4. Fits together correctly the

first time. Manufacturers across all industries—whether they mass-produce consumer products or custom-produce specialized machinery—want to avoid fit-and-function problems that hinder part assembly on the floor or in the field. They need to know that better products will fit together repeatedly, without interference or scraping between parts. Instilling such confidence in your customers can reduce the need for prototype development, achieving significant cost savings for your company. 5. Offers more aesthetic appeal. Whether you are designing a DVD player or an industrial machine, fashion never goes out


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Whitepaper of style. Products that feature organic shapes, complex geometry, and sleek finishes— particularly in the consumer marketplace—are often perceived as better quality. 6. Increases efficiency or environmental responsibility. As corporate citizenship encompasses more communityrelated responsibilities, managers and consumers are demanding greater participation in “green” initiatives, including saving energy, reducing waste, and eliminating the use of suspect materials. For many people, better products result from manufacturing in more efficient and environmentally responsible ways, such as reducing the number of prototypes and employing more energy-friendly processes.

How SolidWorks Premium helps you design better products Lower manufacturing costs Management is always concerned with how to manufacture a product cost-effectively. Because SolidWorks Premium provides robust functionality in a design-formanufacturing (DFM) environment, you always have the ability to design products that save you time and money. SolidWorks software DFMXpress, for instance, is an upfront design validation tool that allows you to identify geometry that would be

difficult, expensive, or impossible to manufacture by conventional machining operations, such as milling, drilling, and turning. With DFMXpress, you can determine where it would be less labor-intensive to break an edge with a chamfer than to use a fillet—or where a specific diameter-to-depth ratio poses drill breakage or wander risks. SolidWorks Premium also provides capabilities for Draft Check, Thickness Check, Undercut Check, Geometry Check, and Part Difference Check—so you can easily identify potential problem areas upfront and reduce the number of costly prototypes. To further manufacturing readiness, the DimXpert functionality automatically generates dimensioning and tolerancing schemes. DimXpert checks geometric dimensions and tolerances (GD&T) for conformance with industry standards, and provides a dimensioning and tolerancing check that graphically indicates when geometry is underor overconstrained. SolidWorks Premium enables you to generate better, more usable output for manufacturing. As a starting point, many manufacturers employ CAM technologies that rely on 3D CAD rather than 2D CAD data. For example, 3- to 5-axis NC machining operations, rapid prototyping, and mold design usually require 3D models that can be referenced to create NC

toolpaths. With SolidWorks Premium, you can avoid the expense and time of re-creating 2D drawings as 3D solid models, since the native environment is already 3D. By using 3D CAD data provided by the customer to make the toolpath, you can significantly lower the risk of errors introduced when a manufacturer needs to re-create a 3D model based on a 2D drawing. Furthermore, SolidWorks Premium allows you to output drawings and images in common 2D formats—including DWG, DXF™, JPEG, and PDF. This is especiallycosteffective in manufacturing operations that require waterjet, laser cutting, or even 2½ D–axis machining.

With SolidWorks software, you can also generate more accurate quotes. The embedded reuse and automation functionality enables you to capture, archive, and view cost-related information from prior projects that utilized the same parts or vendors, allowing you to maintain better profit margins. Since SolidWorks Premium has the simulation capability to produce virtual prototypes—and eliminate the need for costly physical prototypes—you can reduce expenses accordingly.

Accelerate customer delivery, beat competitors to market Collaboration is at the core of any successful business initiative.


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Whitepaper The exchange of ideas stimulates innovation and creativity, thereby accelerating product design and development as well as manufacturing and delivery. To streamline the product development process, SolidWorks Premium offers robust collaboration features and functionality. SolidWorks eDrawings allows you to share product design information with anyone in any location by simply attaching the file to an email. eDrawings files supply accurate, detailed representations of 3D models and 2D drawings. With eDrawings markup capabilities, your design team can capture comments and feedback for fast responses and revisions, thereby helping to expedite the review and decisionmaking processes. The feature recognition capabilities of SolidWorks software also enable you to import and export 2D and 3D geometric data from other CAD systems and re-create it as SolidWorks software native files. You can use the imported part as a single body or automatically break the part into its individual design features. SolidWorks software even allows you to directly edit individual features by merely clicking on the imported geometry. Such functionality not only increases the value of translated files, but also eliminates the time-consuming task of rebuilding models. In order to accelerate customer delivery and time-to-market, however, you must have the tools to speed the product design phase. SolidWorks Premium provides a host of tools to help you shorten design cycles, while simultaneously decreasing design costs and increasing production efficiencies. With the visualization and animation capabilities of SolidWorks

Premium, you can effectively communicate your ideas in 3D, enabling your design team, vendors, and customers to easily “see” the manufactured product via a 3D image, video, or animation. By enhancing the overall understanding as well as the communication process, 3D visualization and animation tools accelerate design feedback, alterations, and corrections. These tools represent the most advanced CAD technology and provide insights into how finished products will look.

Lightweight Mode, Selective Open, and SpeedPak, SolidWorks Premium lets you easily manipulate large assemblies of tens of thousands of parts—as if you are working with only a few assembly parts. Moreover, SolidWorks Premium always produces accurate and current bills of materials (BOMs). When changes are made to parts and assemblies, its automatic update capabilities immediately revise the BOM. With this exhaustive list, you always know what parts and components are needed. So you can prevent anylast-minute delays caused by an incorrect BOM.

Rapid learning curve —easy to use

When you make design changes, SolidWorks Premium automatically updates drawing views—so you no longer need to revisit all the views and manually incorporate changes in each one. If you use other CAD systems to make changes to a part, however, you must ensure those changes are reflected everywhere that part is used—from part drawings through assembly drawings. With SolidWorks Premium, you can rely on the software to implement all your changes, as well as automatically track and identify where the part is used—including which subassembly, higher-level assembly, and drawings.

Large assemblies and drawings SolidWorks Premium can handle even your most complicated assemblies. With specialized functions like Large Assembly

SolidWorks Premium offers incomparable ease of use. By eliminating the complexities of 3D modeling and minimizing the learning curve, you can focus on creative challenges and design development. With Heads-up User Interaction, Instant3D modeling, intuitive display control functions, and customizable shortcut menus, you can keep clicks and mouse travel to a minimum. For instance, you can perform most of your actions directly on the 3D model environment. SolidWorks software provides an intuitive Heads-up User Interface that helps you easily find the functionality you need. Instead of picking and clicking in sidebar menus, Instant3D capabilities allow you to quickly click and drag sketches to make 3D geometry. Instant3D is also valuable when you need to modify models. Simply click, drag, and alter the geometry—such as a fillet radius or a chamfer size—and the model geometry updates instantly. Courtesy: Dassault Systèmes


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Training

Grooming Tomorrow’s Industry Leaders The Industry professionals can now jump start their careers through the Global Manufacturing Leadership Programme (GMLP), launched by the Aditya Birla Group. The programme aims to identify, groom and develop mid-career technical/manufacturing professionals to take on challenging senior level positions in various manufacturing locations within the Group

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he $40 billion turnover Aditya Birla Group has set an ambitious target of achieving $65 billion turnover in the next two to three years. A large part of this growth is expected to come from the Manufacturing sector. Through GMLP industry professionals will get an opportunity to join its vast and diverse manufacturing businesses ranging from Pulp/ Fibre/Textiles/Linen, Cement and Metals to Chemicals. The candidates selected through GMLP undergo an intensive on-boarding, mentoring, transition and development programme before being provided leadership opportunities in line with their skills and experience. This programme is aimed at degree holding

Programme at a glance

professionals in the manufacturing industry with 10 to 20 years of experience in various sectors. Participants at the programme can look forward to enhance their leadership and functional skills, gain exposure to key processes of manufacturing, research, product development, project management and operations, etc., through challenging assignments. Open to manufacturing professionals irrespective of their specialisation, GMLP will let selected candidates decide their career path in manufacturing. The programme offers selected candidates various avenues to enhance their leadership and functional skills, get exposure to key Group processes and

opportunities to work in crossfunctional areas besides their current area of expertise. At the culmination of the programme, successful candidates will join the league of leaders at the Aditya Birla Group in roles across geographies in more than 36 countries. The pilot version of the programme rolled out previously took on-board several candidates who have now moved on to take up leadership roles in the Group. The participants of the regular programme can look forward to receiving interesting assignments across various Birla businesses around the globe through structured and well planned growth opportunities coupled with global exposure.


Training

The selection process Industries: Metals, Cement, Pulp & Fibre, Carbon Black, Chemicals, Mining, Fertilizers, Acrylic Fibre, Textiles, Insulators Stream: Production, Chemical, Mechanical, Metallurgy, Civil, Mining, Textiles, Electrical & Instrumentation

Roles for successful candidates • Leading the entire operation of a small to medium size unit • Leading a department in a large size unit • Leading a function in a medium to large size unit • Leading special projects in a large size manufacturing unit

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Products

Checker 4G: Low Cost Vision Sensors from Cognex T

he Checker 4G series of vision sensors offer unmatched performance and flexibility to solve even the most difficult applications. The Checker 4G series offers the same powerful and easy to use setup. Checker Vision Sensor is known for plus Ethernet networking for remote setup and monitoring, PLC communication through EtherNet/IP and PROFINET and the ability to save images of every inspection to an FTP server.

What Checker Vision Sensor is? The Checker vision sensor is an all-

inspecting up to 6,000 parts per minute—all in an industrial IP67 enclosure small enough to fit into the tightest of spaces.

How Checker Works? Checker detects a part by finding an actual part feature, such as the apple graphic on top of a juice box. This provides extremely reliable part detection, unattainable with photoelectric sensors. The optional SensorView 2 display lets users see exactly what’s being inspected, as well as production statistics, right on the factory floor with no PC

Applications of Vision Sensors: • Date code and MRP print presence/absence • Detecting missing bottles • Detecting missing caps and lot codes • Verifying seal and cap presence absence • Verifying label presence/absence • Liquid Fill level Inspection

Inspects features that other sensors cannot This is because Checker understands what it sees. It can inspect features that other sensors can’t, such as a code printed on a label. Inspects multiple part features simultaneously There’s no limit to the number of part features you can inspect with a single Checker! Overcomes varying part positions Parts on a line typically vary in position, and Checker tracks all of them without requiring precise part handling. Key Features • Presence sensors verify that features are present • Industry standard Ladder Logic editor allows for customisation of results and eliminates PLC programming • EtherNet/IP industrial protocol with RSLogix5000 Add-On-Profile • PROFINET industrial protocol support • Image storage to FTP server • Remote setup and display through your PC • Encoder-based part tracking for variable speed lines • Up to four discrete outputs • Up to 32 job changes for maximum flexibility • Colored lens filters available


Products

IDMS 120 from Schenck Process S

chenck Process, producer of applied measurement and process technologies, has expanded its portfolio of blowthrough rotary valves by adding another model: the new IDMS 120 injection blow-through rotary valve, which provides wearreduction concept and overloadprotection system. The IDMS 120 can be used in areas like rotary kilns in the cement industry or fluidised bed furnaces in the power generation sector. Schenck Process developed the rotary valve specially to meet the pneumatic requirements created by the use of alternative fuels (RDF) – including fibres, wood chippings and shredded plastics – to generate energy. A conveying blower uses air pressure to move fuel through a pipeline into the furnace. The basic requirement is to safely feed the material into the pipeline, which is under high pressure. The IDMS can feed fuel into a pipeline at pressures of up to 350 mbar. “The extension of our IDMS range offered by the IDMS 120 allows us to address the market trend towards ever-increasing feed performance,” explains Harald Faber, who heads the Application Development unit for alternative fuels at Schenck Process. “It is possible to double the feed capacity of an existing plant by equipping it with the new valve – without the need for costly pipeline or furnace upgrades.” The flexibility of pneumatic feeders also allows clients in the furnace technology industry to test the valve in different positions in order to determine the optimum feed point for a furnace

and thereby decide on the best position in their existing systems. The IDMS 120 also features a unique wearreduction concept: “The b l ow - t h ro u g h rotary valve has a modular construction. All the essential h o u s i n g components can be replaced. The wear strips at the edge of the rotary valve can be changed on location using simple tools, without the need for readjustment. Thanks to the hard seal gap between the rotary valve and its casing, the rate of wear is slow and steady. That makes it easier to control and precludes dramatic increases in air pressure loss due to leaks and the accompanying decrease in pneumatic performance,” Faber explains. Thanks to the TorqLoc shaft-hub connection, the new drive system is protected from overloads: if the IDMS is blocked by contaminants or foreign bodies, the drive train will not be permanently damaged.

while offering high power density • High and constant fill levels thanks to large inlet crosssection and enforced emptying • Highly abrasion-resistant wearing parts and long service life • Delivery rate of up to 150m³/hr with high conveyor line back pressure • Reliable pneumatic conveyance thanks to constant leakage air • Robust construction in line with German standard for industry Website: www.schenckprocess.com

Other benefits at a glance: • Compact, space-saving design

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Products

MakerBot Digitizer Desktop 3D Scanner

T

he MakerBot Digitizer Desktop 3D Scanner uses laser line triangulation to scan an object to produce a readyto-print 3D file usually without requiring any post-processing. It creates a digital 3D model of a physical object by taking a rapid sequence of pictures with a built-in camera as the object rotates automatically on a turntable. Two lasers, mounted on the left and right corners, create laser lines that profile the object as the camera takes image sequences. The included MakerWare for Digitizer software combines the images of the laser lines to create a point cloud. When the scan is complete, the software generates a viewable

3D mesh file for sending immediately to a MakerBot or other 3D printer, creating, in effect, a 3D copying machine. The industry-standard stereolithography (STL) files that are created are also compatible with almost any 3D modeling software. Ideal models for scanning are opaque objects larger than 2” cubed but smaller than 8” and weighing less than 6 pounds. Transparent objects or ones that are shiny or reflective, very dark, or fuzzy are more challenging. To produce optimum results, the MakerBot Digitizer’s camera is fitted with a band-pass filter which rejects all wavelengths other than that of the laser, ensuring that the

camera only records the laser lines on the object. As the item is scanned, images are combined to create a detailed point cloud, which is then converted into a continuous mesh. The complete scanning process takes less than fifteen minutes. A calibration test object is also provided to insure that accurate scans are achieved by the software, which is compatible with Windows 7, Mac OSX v10.7, and Ubuntu Linux v12.04 or later versions. The MakerBot Digitizer Desktop 3D Scanner, made by Makerbot Industries, is desktop-sized at 18.7”x16.2”x8.0”, weighing 4.7 lbs. Website: www.saelig.com


Events RoboBusiness Dates: October 23-25, 2013 Venue: Santa Clara Convention Center, Santa Clara, CA Website: www.robobusiness.com RoboBusiness is the leading business development event for the global robotics industry, where executives come together to accelerate the commercial advancement of robotics. Founded in 2004, RoboBusiness has established itself as the premier business development event dedicated to accelerating the commercial advancement of robotics technologies and solutions. RoboBusiness is specifically designed to be the executive-level, thought-sharing forum for connecting growth-oriented decision-makers with like-minded executives in the business of robotics. The event’s programme is designed to provide invaluable information to all levels of the robotics industry supply chain, including: 1. Robot developers and manufacturers 2. Component and service providers to robotics oems and system integrators 3. Early stage robotics companies 4. Technology investor community 5. Users of robotic products and solutions 6. Higher education and research professionals

European Manufacturing Strategies Summit 2013 Dates: October 28-30, 2013 Venue: Swissôtel Düsseldorf, Germany Website: www.ems-summit.com/ The 9th Annual European Manufacturing Strategies Summit is

packed full of real life manufacturing case studies from companies including Coca Cola, Caterpillar, Mercedes, Pfizer, Airbus and many more. These allow you to benchmark your business against the ‘best in class’ and ensure that you have the tools you need to form a coherent and logical strategy. Attend the European Manufacturing Strategies Summit 2013 to: • Hear how cross industry manufacturers are improving flexibility and processes to keep plant operations both viable and competitive • Develop strategies which take lean to the next level of your continuous improvement • Empower and motivate people to foster business transformation • Identify the future of manufacturing and global trends in Europe • Exclusive site visit: MercedesBenz Düsseldorf Plant

opportunity to network with your peers will arm you with the information you need. Some of the event activities include: • Three streams tailored for executives involved in transportation and logistics, supply chain management, and material handling and green supply chain. • Interactive panel discussions. • Real life case studies from experts. • Hands-on workshops: This year’s topics include green transportation, cloud computing, warehouse optimisation best practice, change management, and many more. • Exhibition with over 60 leading suppliers.

Supply Chain and Logistics Summit North America 2013

The Advanced Manufacturing Technology Show (AMTS), produced by Dayton Region Manufacturers Association, is the region’s only show of its kind. Manufacturers serving Ohio, Kentucky and Indiana will showcase the very best tooling and manufacturing solutions the region has to offer. Everyone involved in the manufacturing process is encouraged to attend and exhibit. This two-day event will feature exhibits, seminars, events and in-booth demos about the latest technologies, trends, products and solutions. Join frontline manufacturing movers and shakers for unbeatable networking opportunities.

Dates: December 2-4, 2013 Venue: Hyatt Regency, Dallas, TX Website: www.supplychain.us.com Researched and validated by a senior industry advisory board, the Supply Chain and Logistics Summit North America will focus on strategic planning and performance initiatives as leading supply chain experts share the latest issues influencing: • Supply chain management • Supply chain technology • Transportation and logistics • Material handling A world class program, personalised meetings with solution providers of your choice, and the

Advanced Manufacturing Technology Show Dates: October 23-24, 2013 Venue: Dayton Airport Expo Center, Vandalia, Ohio Website: www.daytonamts.com/

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Events The Economic Times India Manufacturing Excellence Awards (IMEA) Date: December 6, 2013 Website: www.frost.com Indian Manufacturing Excellence Awards (IMEA) acknowledges endeavour of organisations towards becoming agile and lean. The Award assesses companies’ progress across a raft of criteria and assists in their journey towards excellence. India Manufacturing Excellence Awards (IMEA) was conceptualised and instituted by Frost & Sullivan in 2004 to support companies in their journey towards building a competitive and lean organisation. With effect from 2009, Frost & Sullivan and the Economic Times have collaborated to jointly host the India Manufacturing Excellence Awards. With a mission “to recognise the Indian Manufacturing capability and assess its Global Competitiveness”, ET-IMEA has a robust, highly acclaimed and constantly updated assessment process in place derived from the best global manufacturing practices. Being the only one of its kind in India, ET-IMEA has over the years increasingly received the reputation of being an independent, unbiased and credible evaluation of supply chain efficiencies with respect to their leanness and flexibility. The facilities are rated via a proprietary methodology and the top ranking facilities are eligible for prestigious awards. ET-IMEA is considered to be the most successful and long established manufacturing award program in India, and a unique platform that provides detailed benchmarking and assessment process to help improve business.

The Second International Conference on Intelligent Robotics, Automation and Manufacturing (IRAM) 2013 Dates: December 16-18, 2013 Venue: Indian Institute of Technology, Indore Website: www.iram2013.org The second International Conference on Intelligent Robotics, Automation and Manufacturing (IRAM) 2013 will be held between December 16 to 18, 2013, at Indian Institute of Technology Indore. The conference aims to bring together experts from academia and scientific and industrial communities to address new challenges, present their latest research findings, ideas, development and perspectives of the future directions in the fields of Robotics, Automation and Manufacturing. The conference is structured as plenary lectures followed by parallel sessions in three different streams: Intelligent robotics, Automation and Manufacturing.

12th Manufacturing Summit 2013 Dates: November 21-22, 2013 Venue: Hyatt Regency, Mumbai Website: www.cii.in Under the theme “Winning in the New Normal”, CII through the 12th Manufacturing Summit 2013, aims to table discussions that revolve around the changing context and the implications of various changes on companies. In India, demand has slowed down considerably across several sectors – the auto, home appliances, building material industries for example, are even witnessing contraction in major categories. Infrastructural bottlenecks and factor constraints have become

even more acute. In many ways therefore, the very context of running a manufacturing company now is different and a 'new normal' is being created – characterised by slowing demand, continued volatility in input costs, sustained infrastructural bottlenecks and forced local reliance. Yet, even in these situations, many companies have continued to do well. The Summit will also feature best practices from companies that have continued to thrive in this new normal.

Plastivision India 2013 - Plastic Manufacturers Exhibition Dates: December 12-16, 2013 Venue: Bombay Exhibition Centre, Mumbai Website: www.plastivision.org The All India Plastics Manufacturers' Association (AIPMA) organises Plastivision once in every 3 years in India. The event will witness participation from India and more than 45 countries and visitors from over 61 countries. National exhibitors across businesses such as auxillary equipments, machinery, molds and dies, raw materials and semi finished/finished goods are expected to attend the event. The international list includes exhibitors from China, Hong Kong, United Kingdom, Italy, Germany and UAE, among others. Overall, about 1,500 exhibitors and about 100,000 visitors from sectors such as chemical industry, machine manufacturers, packaging industry, automotive / aerospace, electrical / electronic engineering, construction & housing, healthcare & medical technology and agriculture will attend the show.


The Machinist  

October-December 2013 The Machinist is a World Wide Media publication.

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