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MODERN MACHINE TOOLS - October 2011


AN N I VERSARY

Editorial

Raring to grow elcome to the 8th Anniversary Edition of MODERN MACHINE TOOLS! As we raise a toast to this milestone, it is time to thank our internal and external stakeholders, who have made this journey meaningful! Amid this, it is important to take note of the growing focus on the metalworking sector in India. On one hand, there are several challenges to overcome and on the other, many of these have tremendous potential to unlock a plethora of opportunities in the marketplace.

W

The present time could be an inflection point in the annals of the manufacturing industry and in particular, the metalworking segment. Taking the latest global developments into consideration, the clouds of economic uncertainty are still looking ominous from a short- to medium-term perspective. Europe, USA and some other industrialised economies are yet to fully recover from the grip of the recent economic downturn. In this period of worldwide uncertainty, India, along with its BRICS (Brazil, Russia, India, China and South Africa) allies, seems to be a shade better from the viewpoint of economic growth and foreseeable future prospects. However, the big question before the machine tool builders today is about the way forward. Although there is no simple and straight answer to this, one approach (to hedge against such an unfolding scenario) could be to expand the end-use areas and cater to a multitude of industry verticals, rather than being bound to just a few ones. Of course, the core competency of the organisation need not be compromised in this endeavour.

Editorial Advisory Board M Lokeswara Rao President, IMTMA & MD, Lokesh Machines Ltd

Vikram Sirur Vice President, IMTMA & Executive Vice Chairman, Miven Machine Tools Ltd

N K Dhand Past President, IMTMA & CMD, Micromatic Grinding Technologies Ltd

This unique edition delves deeper into the above and more such promising solutions. Turn to the eight exclusive sections (each focussing on a distinct vertical ranging from aerospace to new raw materials, based on the 8th Anniversary theme) to discern what an array of experts across the globe have to opine, not just on the latest trends and technologies but also on the future prospects and pitfalls. Believe, you will benefit from exploring this focussed mix of latest news, views and analyses as much as we at MODERN MACHINE TOOLS enjoyed putting it together. Have a good read and do let us know your valuable feedback. Cheers!

R Srinivasan Past President, IMTMA & MD, RAS Transformation Technologies

Gautam Doshi Advisor, IMTMA & Consultant, Productivity & Quality Improvement Services

S N Mishra

Manas R Bastia manas@infomedia18.in

Past President, IMTMA & Vice Chairman, Bharat Fritz Werner Ltd

October 2011 - MODERN MACHINE TOOLS

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Contents

Aerospace ...........................47

Automobiles .......................71

Editorial National News World News Events Product Update International Products Product Index Engineering Expo Product Index Advertisers’ List

31 36 38 254 264 284 290 292 299

Industry Update

Consumer Durables ........... 97

Mechanical transmission systems: Providing momentum 226 to the industry ....................

Leaders Speak

Electricals and Electronics......... 117

Harry Ehrenberg, President, VARGUS Ltd................... 230

Facility Visit

Energy..............................137

Haas Automation Inc: Engineering excellence in machine tools

.................... 234

Factory Fundamentals PCBN grades facilitate complete process revamp ........... 246

Curtain Raiser

Infrastructure................... 161

Engineering Expo Ahmedabad 2011: Celebrating a decade of excellence ......................................... 250

Report HIMTEX 2011: Expanding the scope of regional investment ................... 260

Highlights of Next Edition: Medical ............................181

New Raw Materials ..........201

Cover photo illustration: Chaitanya Dinesh Surpur 32

MODERN MACHINE TOOLS - October 2011

Special Focus: Micromachining Insight & Outlook: Electrical Discharge Machining

Looking for a specific product? We will find the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

Details on page 286-289


AN N I VERS ARY

National News IMTMA to organise Regional Productivity Summit Indian Machine Tool Manufacturers’ Association (IMTMA) which has been in the forefront of championing a productivity movement in Indian metalworking industries will conduct the ‘Regional Productivity Summits’ on 10th, 15th and 21st October 2011 at Chennai, Pune and New Delhi respectively. Regional Productivity Summits 2011 will showcase the best productivity improvement projects in metalworking industries which have excelled in achieving superior performance. The summit will offer a unique opportunity to understand and learn from the

CARL BECHEM India conducts technical seminar on cutting fluids The technical seminar aimed at the metal working and allied industry was titled ‘Cutting Fluids for Profitability, Safety and Quality in Machining Process’. The two hour long seminar saw active participation from 76 odd participants representing 30 companies from the departments of maintenance, production and research & development.

Harry Hofmann

Harry Hofmann, Head Forming Technology and Metalworking, CARL BECHEM GmbH elaborated on the types of coolant, importance of lubrication and cooling as characteristics of a coolant and possible scenarios encountered during various machining process. He also discussed the perfect cutting fluid to realise the best result. “The objective of these forums is to empower customers by educating them 36

MODERN MACHINE TOOLS - October 2011

experiences and best practices of other companies. The Summit will address and demonstrate a wide variety of productivity improvement projects in TM

2011

metalworking through live case study presentations and keynote sessions. It will bring together productivity ‘Gurus’, champions and aspiring

on technicalities and characteristics of cutting fluids thereby allowing them to derive more value from a consumable category that is traditionally viewed as a sundry cost,” said Hofmann.

Timken appoints General Sales Manager for India Timken India Ltd has appointed Brian T Strunck as General Sales Manager for process industries in India. Strunck has a bachelor’s degree in mechanical engineering from Lehigh University, and a master’s degree in administration from the University of Brian T Strunck Michigan. He joined Timken in 1996 as a design engineer in automotive customer engineering and has held various positions of increasing responsibility in sales, marketing and engineering, most recently serving as marketing manager for the offhighway and heavy truck segments for North America. In his new role, he will lead both the original equipment and aftermarket businesses for the company’s process industries segment in India. He will also be responsible for managing the services business, as well as marketing and new business development.

leaders on a common platform to share experience, ideas and will be an unmatched forum for networking with decision makers, customers, peers and suppliers of productivity aids, experts, academia & researchers in the field. The must-attend event will witness participation by CEOs, senior executives, practising engineers, R&D specialists, industry experts, technologists and middle management personnel from automotive & auto components, tool rooms, machine tools, aerospace, defence & railway units, consumer durables, general engineering and other metalworking manufacturing industries.

Komet India launches technology newsletter As a means to share KOMET’s innovation with its customers, KOMET India has launched its quarterly news letter ‘KPLUS’. This newsletter brings out latest developments in cutting technology for productivity improvements in the area of hole machining solutions. The newsletter highlights recent machining trends, new cutting solutions from KOMET Group and success stories supported by live cases and illustrative examples that KOMET has achieved for its customers. The newsletter also brings to the readers table drilling, reaming and threading solutions that are in its standard product range. Speaking on the launch of KPLUS, S Ravishankar, Managing Director, KOMET India, said, “The newsletter showcases next generation cutting tool solutions offered by KOMET India. This first edition is dedicated to our core product, the drills’ family which includes solid carbide or indexable drills starting from diameter 3 mm to 155 mm.”


National News Arvind Kapur is new ACMA President Automotive Component Manufacturers Association of India (ACMA), the apex body representing India’s auto component manufacturing industry, at its 51st annual session on September 6, 2011 announced the change in guards with Arvind Kapur, Managing Director, Rico Auto Industries Ltd

(L-R): Arvind Kapur, Vinnie Mehta, Surinder P Kanwar

taking over as the new President and Surinder P Kanwar, Chairman & Managing Director, Bharat Gears Ltd as the Vice President for the term 2011-12. Speaking on ACMA’s work priorities for the coming year Kapur said, “It is a matter of great pride to be the President of ACMA at a juncture when the auto component industry in India is gearing up to take head-on the multiple challenges it faces, owing to the dynamics of the global and domestic markets.” Vinnie Mehta, Executive Director, ACMA said, “We are pleased to have Arvind Kapur on board as the ACMA President, an industry veteran, with vast exposure to the auto industry. We are also delighted to have Surinder P Kanwar as

our Vice President, another respected leader from our industry. Further, the new ACMA Executive Committee comprises some of the prominent leaders from the auto component sector. We look ahead to their active engagement and contribution.”

MTE enters into JV with Escofier MTE Indsutries Pvt Ltd, the country’s leading manufacturer of thread rolling machines and Escofier, the world leader in the manufacture of gear rolling machines, spline rolling machines, thread rolling machines, thread rolling dies, are now starting a Joint Venture (JV) for the manufacture of incremental spline rolling dies and rack rolling dies in Hyderabad. MTE

(L-T): Jayasimha Reddy, CEO & S Reddy, MD, MTE Industries; R V Chandravadan, Director, Rajiv Mission, AP Govt; Eric Michoux, President, Escofier SAS, France

has set up a world class infrastructure required for the manufacturing of these products over 9 acre of land in Dundigal. All the required machinery and inspection equipment installed at the facility is set to take the products to the international market. The name of

this JV is ‘MTE ESCOFIER Forming Technologies Pvt Ltd.’ Presently no manufacturer is manufacturing these products in India. This newly formed JV will contribute to import substitution. There is a lot of potential for these products in India as almost all the automotive companies are now importing these products. The shares are equally distributed between both the companies.

Electrotherm to double steel-casting machine production by 2012 Electrotherm (India) Ltd, which offers customised steel-making machinery

to secondary steel industry, expects to produce 100 units of its newly developed continuous casting machine (CCM) by 2012. Twenty projects based on the machine are already underway, and around 30 more would be completed by the end of the year. The CCM would be suitable to small manufacturers as its cost is relatively lower (` 1.5-2 crore) compared to existing options, which costs around ` 2-4 crore. The company also expects to export 30 per cent of the machines to markets in Africa, West Asia and SAARC countries. The company’s equipment are used in 3,400 installations, accounting for 16 million tonne of steel production capacity.

October 2011 - MODERN MACHINE TOOLS

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World News Summer inauguration for METAV 2012 METAV 2012, the International Trade Fair for Manufacturing Technology and Automation, will open its doors in Düsseldorf, Germany from 28 February to 3 March. The latest innovations and solutions will once again be on show for a broad-based trade public. “The preparations for METAV 2012 have been in full swing for several months now. The METAV team has taken on board many and varied topics in their efforts to make the event a genuine highlight in the 2012 diary for metalworking trade fairs,” said Martin Göbel, Project Manager at METAV. The trade show is organised by VDW (German Machine Tool Builders’ Association). The exhibitors’ showcases will once again be complemented by attractive complementary programme. Together with various partners,

special events will be held on subjects like medical technology, composite machining, sustainability in the production process, and recruitment advertising. Service support has also been improved and now exhibitors for the first time can register online.

Siemens claims top spot in China’s PLM market The company’s PLM Software was recognised as market leader in Computer-aided Design (CAD), digital manufacturing and collaborative product definition management. A business unit of the Siemens Industry Automation Division, the company was awarded second year in a row as the number one PLM solution supplier in China based on 2010 overall market presence, according to leading independent global PLM management consulting and research firm, CIM data Inc. This recognition, based on in-depth data and analysis of the PLM market in China, is detailed in CIM data’s 2011 China PLM Market Analysis Report. 38

MODERN MACHINE TOOLS - October 2011

In addition to being named the overall market presence leader, Siemens PLM Software was also ranked number one in the multi-discipline CAD and digital manufacturing segments.

US manufacturing technology orders increase by 102.9 per cent Technology orders for the country totaled $ 506.97 million according to the American Machine Tool Distributors’ Association (AMTDA), and the Association for Manufacturing Technology (AMT). This total, as reported by companies participating in the United States Manufacturing Technology Orders (USMTO) programme, was up 7.3 per cent from June and up 92.7 per cent when compared with the total of $ 263.14 million reported for July 2010. With a year-to-date total of $ 2,975.10 million, 2011 is up 102.9 per cent compared with that of 2010. “The manufacturing beat goes on! Machine tool sales continue to exceed forecasts for 2011. The stock market’s volatility and the traditional summer slowdowns as budgets are depleted was no match for the ongoing demand to get new machines into production as soon as possible. This pace will slow; but for USMTO 2011 so far, there are no signs of what we hear on the nightly news,” said Peter Borden, President, AMTDA. The report, jointly compiled by the two trade associations representing the production and distribution of

manufacturing technology, provides regional and national the US orders data of domestic and imported machine tools and related equipment. Analysis of manufacturing technology orders provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.

Fendi and Maserati launch the Maserati Grancabrio Fendi at the Frankfurt Motor Show 2011 The Frankfurt Motor Show held from 13th to 25th September 2011 witnessed the collaboration of two of Italy’s iconic luxury houses - Fendi and Maserati, based on common values of craftsmanship and traditions. The JV proudly showcased its first joint creation Maserati GranCabrio Fendi. Crafted at the historical Maserati headquarters at Modena, Italy using materials and colours produced for this project was designed by Silvia Fendi. The car has a three-layered dark grey body colour named Grigio Fiamma Fendi, developed specially for the Maserati GranCabrio and has a gold finish on the surface. Fendi’s famous selleria leather has been used for the gear lever and the profiles of the floor mats. A silver oval plaque with engraving of the Maserati trident, the Fendi logo and the 5 digit series number (five being an

iconic number for Fendi) is located on the dashboard and on both sides of the cloth folding roof. Powered by 4.7L V8 engine with automatic transmission and 20 inch Trident design alloy, the car represents a prefect blend between the art of a handmade craftsmanship and cutting edge technology.


World News Mapal bags its largest contract Germany-headquartered precision machining expert Mapal has been awarded its largest contract till date for a wind power project. The contract covers the tooling required for machining three different components that are used in wind turbine gearboxes, all of the components being manufactured from GJS, a form of cast iron incorporating spheroidal graphite. The tools supplied by the country will be used in USA, where the wind turbine gearboxes are being produced. The scope of supply of this important contract extends from bridge tools for finish boring and fine boring to helix milling cutters and very large facing slide tools that are used in conjunction with Mapal’s tooltronic mechatronic system. “We are very excited about this contract, and about the close relationship we have developed with our customer, a leading manufacturer of gearboxes with specialist

succeeds,” said Seiji Kuraishi, Chief Operating Officer, Honda Motor (China). Honda plans to launch five hybrid models next year: the Insight, the CR-Z, a hybrid version of the Fit, a significantly redesigned hybrid version of the Civic and a hybrid model for Honda’s upper-scale brand Acura. Current green-car technology efforts in world’s largest automobile consumer market are largely focussed on electric cars rather than hybrids, which use both electricity and gasoline.

Rockwell eyes more revenues from outside US markets The US-based Rockwell Automation Inc, an over $ 4.5 billion company dedicated to industrial automation and information, is focussing on further expanding its global footprint in emerging markets and expects 60 per Most hybrid cars in China are too expensive for consumers because they are imported, resulting in hefty duties and taxes. Honda’s current Civic hybrid costs about $ 42,200 compared with $ 24,000 to $ 27,000 in the US. Currently, it sells only about 200 to 300 Civic hybrids a year.

Mitsubishi Motors may expand alliance with Malaysia’s Proton expertise in developing products for the most demanding applications,” said Gregor Baumbusch, Sales Manager, Mapal Germany.

Honda plans massive push for hybrids in China The Japanese automobile manufacturer plans a new push to make and sell hybrid cars in the country as it looks for ways to revitalise its brand as the industry faces tough new fuel-economy requirements. “Honda is likely to start producing electric-gasoline hybrid cars in China in two to three years if its sales push 40

MODERN MACHINE TOOLS - October 2011

in Malaysia as well as exchanging technology on electric vehicles. Proton may also make cars under the MMC brand. Proton, Malaysia’s national carmaker, currently manufactures Proton Inspira four-door sedan models based on Mitsubishi Motors’ Lancer after they formed a partnership in December 2008. A statement released by MMC stated, “We aim to expand our business in the Asean region through these new projects while this will help Proton increase its product line-up and help it better utilise production facilities.”

Japan’s Mitsubishi Motors Corp (MMC) is in talks with Malaysia’s top car maker Proton about expanding their partnership. The two companies are discussing jointly producing engines

cent of its global revenues to flow in from outside of the US by 2013-14. “We are clearly focussed on the biggest emerging markets like India, China and South East Asia. If you look at these markets today, they have very good Gross Domestic Products (GDP). With the entire mass of people continuing to move up to what we call the new middleclass, we see a continued opportunity for growth in these markets in the long run,” said Robert A Ruff, President (Asia-Pacific), Rockwell Automation. The company employs over 20,000 professional globally, with around 600 based out of India including 100 at its R&D centre at Bengaluru, currently derives 22 per cent of its revenues from the Asia-Pacific region. According to Ruff, the industrial automation sector was seeing convergence between various disciplines like controls, automation, information and safety.


MMT Oct-2011 Ad Name:Ceratizit Pg No. 43 MMT Oct-2011 Ad Name:Ceratizit Pg No. 43


MMT Oct-2011 Ad Name: Indian Tool Pg No.44 MMT Oct-2011 Ad Name: Indian Tool Pg No.44


MMT OCT-2011 AD NAME: INDO PG NO. 45 MMT OCT-2011 AD NAME: INDO PG NO. 45


MMT OCT-2011 AD NAME: EMUGE PG NO. 46 MMT OCT-2011 AD NAME: EMUGE

PG NO. 46


AEROSPACE Industry Insights Indian aerospace: On a new high............... 48 Interface Bernhard Eisenschink Project Manager, OPEN MIND Technologies AG................... 50 T K Ramesh Chief Executive Officer, Micromatic Machine Tools Pvt Ltd ............. 54 Market Trends Aerospace machining software: Solutions with uniform user interface ......... 56 Practical Tips Aerospace: What the industry needs to fly high? ......... 60 Future Forecast Next aviation hub: Opening doors for global investment........ 68 October 2011 - MODERN MACHINE TOOLS

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Industry Insights AEROSPACE

INDIAN AEROSPACE

On a new high With aspirations high and potential higher, this is probably the most exciting decade for the Indian aerospace industry as the entire world is looking towards the Indian terrain. Looking at this growth with anticipation that the industry would expand further in the next couple of years, the government is slowly opening its gates for investments to pour in. Debarati Basu

F

rom being the chosen outsourcing destination for low cost manufacturers of precision components to being one of the major aerospace hubs on the world map, India has traversed a long way into this industry. Year 2001 saw the opening up of the Indian aerospace industry to private participation. But today, with more and more foreign companies setting a base in the Indian market, the players are hoping for the gates to open wider for unhindered investments. This is surely the age of the BRIC nations - Brazil, Russia, India and China but after Russia and China, all eyes are on the growth potential that India has to offer. While the automotive industry ruled the roost in the last decade, it has also turned into the launch pad for the Indian aerospace industry to make a bigger flight for manufacturing higher precision and supreme quality products. 48

MODERN MACHINE TOOLS - October 2011

Growing market The Indian aviation industry alone has grown almost three folds over the last five years. While the country’s economy is seeing a stable growth with almost 124 million air passengers recorded last year, the air way is seeing a growth rate of around 12 per cent. Judging the potential, Airbus and Boeing has already made significant forays in to the Indian aerospace sector. More foreign companies are now making their way into the industry as well. Taking a cue, the Indian companies have also begun taking a lead into the sector from being component manufacturers to building aircraft. The country has seen some recent joint ventures and investments in this sector. TATA Group recently tied up with Augusta Westland for assembling helicopters with an investment of $ 30 million aiming at mainly the Indian defence sector and

civil markets. Mahindra and Mahindra (M&M) stepped into aerospace components and aircraft manufacturing by acquiring Australia-based Aerostaff and Gippsland Aeronautics with an investment of ` 1.75 billion. The pace at which the country is growing and the rise in the standard of living, the need for a robust civil aviation has seen a rampant growth. Aviation industry has become as much a necessity as automobile. “People are flying a lot and the demand will only increase in the future. Given that the government focuses on offset programmes, this segment is picking up. But compared to other countries, it is still a very nascent industry. Lot of foreign players are setting up their shops here. Although this industry has taken the first few steps, it’s growing very fast. There will be nothing less than a 1000 civilian aircraft in the next 10 years hovering over the Indian


Industry Insights sky. It is a good time for the industry,” points out Santanoo Medhi, Managing Director, Kennametal India Ltd.

Seeking help Although the Indian government holds the reins of the aerospace industry, the industry is optimistic about easing the norms for companies to flourish. With the new Defence Procurement Procedure-2011 (DPP), the government aims to change the way the Indian aviation industry functions. The players in this industry are hoping for simpler procedures and easy availability of finances. The DPP, this time also intends to widen its vortex by including various verticals of this industry so as to bring them all on the same page. While Hindustan Aeronautics Ltd (HAL) has held the reins of the aerospace industry, it is now opening up to collaborations with various Indian and foreign players. As part of the government’s offset policy, substantial investments are expected in this sector by HAL, uplifting its capacity to supply parts, assemblies and components worth 30 per cent of India’s $ 25 billion defence orders. At the same time, more than 95 per cent of Indian manufacturers in the sector depend on subcontracting to HAL. Recent acquisitions by Indian defence forces have generated $ 5 billion worth opportunities for Indian manufacturers, given the 50 per cent offset obligations on current orders. “With government support, more and more companies with specialised aeronautical services will come up. Earlier, there was lack of avenues but now actual manufacturing of aeronautical parts will grow in this country. While the automotive revolution happened in 20 years, the aerospace revolution will take just 10 years because we have already reached a particular level and we need to take off from there. In the next eight to ten years, we would be a strong tier 1 supplier to the aerospace industry,” reflects T K Ramesh, Chief Executive Officer, Micromatic Machine Tools Pvt Ltd.

Santanoo Medhi, Managing Director, Kennametal India Ltd Although this industry has taken the first few steps, it is growing very fast. There will be nothing less than 1000 civilian aircraft in the next 10 years hovering over the Indian sky. It is a good time for the industry.

T K Ramesh, Chief Executive Officer, Micromatic Machine Tools Pvt Ltd While the automotive revolution happened in 20 years, this time the aerospace revolution will take just 10 years because we have already reached a particular level and we need to take off from there. In the next eight to ten years, we would be a strong Tier 1 supplier to the aerospace industry.

T V Sridhara, Business Development Manager, India operations, Measurement Specialities When companies from Europe and the USA outsource product manufacturing and services to India, the requirements and regulations are laid in advance. This has helped the Indian aerospace industry to evolve. We have become more professional, deliverable and ready to accept zero-tolerance type of challenges now.

Challenges to meet

Moving ahead

With more and more companies taking up machining of aerospace components, technological advancements and skilled manpower to deftly handle high precision machining of hard to machine materials continues to be a major hurdle. After titanium, the industry is now seeing a growing demand for composite materials. “Initially aluminium was the king, now we are moving from titanium to composites. We also need to undertake rapid technological advancements as the technology used in the aerospace industry is changing everyday. Highly sophisticated machines and tools required for machining such materials are not available locally. The Indian industry has to depend on imports. A country cannot grow on imports. We need to build our own capability,” explains Medhi. The industry also needs adequate qualified workforce to handle highly sophisticated machines and materials.

Amidst all the challenges, the fact goes uncontested that India does enjoy an edge over the emerging economies in some quarters. The increasing joint ventures and collaborations with foreign players and those within domestic players are opening the path for technology and knowledge transfer. “When companies from Europe and the USA outsource product manufacturing and services to India, the requirements and regulations are laid in advance. So, the manufacturing happens according their regulations and work instructions. This has helped the Indian aerospace industry to evolve. We have become more professional, deliverable and ready to accept zero-tolerance type of challenges now,” avers T V Sridhara, Business Development Manager, India operations, Measurement Specialities. October 2011 - MODERN MACHINE TOOLS

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Interface AEROSPACE

It is imperative to form a consortium to cater to materials standardisation needs of aerospace sector ‌ feels Bernhard Eisenschink, Project Manager, OPEN MIND Technologies AG, a Germany-based CAD/ CAM solution providing company. On his visit to India, he talks to Debarati Basu about the latest in the CAD/CAM industry which is changing the way aeronautical machining is done. Q India is emerging fast in

the aerospace industry. Elaborate on the reason behind the same. This country has highly educated and qualified people in the market which makes this a good place for this kind of industry to grow. Sound knowledge in this field adds to the potential for this industry to grow and contribute to the world market. Some of the key players are showing their interest 50

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in the Indian market as the country is reciprocating to their interest by giving standard quality products.

Q Tell us about the latest in

the CAD/CAM solutions offered to the defence and aerospace sectors. This market is designing complexities and manufacturing complexities. New inventions are been made in solutions like hyperMILL, which has shape level

machining which is able to rough and finish complex structures like turbine housings or curved structural parts based on a so called drive surface. Many improved functionality are being incorporated in flank milling which is able to mill the walls of structural parts including the vertical edges. With the recent invention in strategies of machining in solutions like hyperMILL, the machining time is also bound to reduce considerably.


Interface Q Where does India stand

in terms of Research & Development and technological innovation? What needs to be done to optimise resources and reach global level of excellence? There is considerable amount of research and inventions happening in India. But we still have a long way to go. Many foreign companies are now coming into India to set up their base in the Indian market and manufacture their products here. Looking at the organisations here, I don’t think there is much difference in the level of research compared to other countries. There are also many Indian engineers working in foreign countries like the USA or Germany. I think effort has to be taken to encourage them to return to India and bring in their gained experience to develop Indian products of high quality and technical standards that meet the demands of international markets.

Q What are some recent

trends in the aerospace industry? The shapes of many parts, especially the turbines are becoming more complex which is bring in more and more challenges in terms of materials, geometry shapes, standardisations etc. However, India is growing in this regard by producing parts for all kinds of planes from Dornier to Sukoi.

Q With the advancement in

the technology worldwide, do you feel India is poised to contribute to the global aerospace industry and give the required standard of quality? I recognise a strong pragmatic attitude in India, which is a good thing to get short time results. India is on its way to reach its goal and 52

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step into the global market. Even small companies are contributing to the global companies, which in itself is a good sign. However, to match the required international standards, the focus has to be directed towards methods like process management, quality management and constant improvement. Japan is a good example to learn from about these topics. Failing is a part of the process but we need to learn from our mistakes and experiences and improve upon it.

Q The global economy just

saw the Greece bailout. The US economy has also seen a downturn recently. In what direction is the global economy heading towards and what precautionary measures are being taken this time? I consider it as a big problem that stock market prices are not related to the real worth of the companies represented there. The currency exchange rates have been affected in a big way and causing major issues in exports. I can only hope that the industry is prepared to face the crunch if we see a repeat in a recession like situation. There are a lot of gamblers that make things even worse. Considering this, there is no safe way to handle with this kind of circumstances. Action has to be taken so that gamblers are not able to make things worse than they are.

Q With all eyes on the BRIC

incorporating process management and quality management to make the products more cost effective.

Q New materials like titanium

and composite materials, are making way into the aerospace industry. What are the latest in the market to machine such difficult to machine materials? Special tools are needed for machining these kinds of materials. Machining strategies and inclination strategies for materials like titanium is also an important aspect. However, hyperMILL includes everything that is necessary to be able to cut this kind of materials.

Q What are the challenges

that you encounter in the Indian market? What are the strategies in place to combat them? India is a support centric market, and the market is very wide in terms geography of this country. Regional operations are important to enhance our role in Indian Market.

Q What kind of support

do you sought from the government? As of now the support from government, for CAD/CAM solutions are friendly in India. But, It is imperative to form a consortium to cater to materials standardisation needs of aerospace sector. Also, while the country is geared up with high end technology, the government should facilitate the companies to grow by providing proper infrastructure.

nations, what kind of competition does India face Q How do you forsee the future of this vertical? from the global market? The competition is the same like every industrial nation face. There are however, some passionate people in this market and this passion can make a big difference in the industry. Everything revolves about the price factor. This brings us to

The business is growing and the industry is prepared to learn. We are also looking forward to more and more research and development programmes coming from India, in the aerospace arena.


AN N I VERS ARY

Interface AEROSPACE

The rise of aerospace industry will give an impetus to the local metal working industry …avers T K Ramesh, Chief Executive Officer, Micromatic Machine Tools Pvt Ltd. As the aerospace sector is on a growth path, many Indian companies are now broadening their horizon. Talking to Debarati Basu, Ramesh discusses the transition and challenges that the Indian manufacturing industry will have to take up as it shifts its focus from being just an automotive giant to being an aerospace major.

Q Tell us about the current

scenario of aerospace industry. It is a fast growing nascent industry. Aerospace is growing today and there is a lot of activity taking place in this sector. Markets drive the boom and companies like Airbus and Boeing are beginning to find that there is a huge market potential in this country. These aerospace companies are able to 54

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see the kind of value that we offer in terms of availability of engineers, the work being done with cost effectiveness with a less turn around time. They have also realised that processes like metal cutting, forming, plating etc can be done here in India in much faster, better and cheaper way. Also, there is a lot of government support. On the other hand, the local market is also expanding. More

and more low cost airlines are coming up. The largest orders for Airbus and Boeing for commercial aircraft are coming from India. The Indian manufacturing industry is growing and there is an availability of good level of engineering talent and white collar productivity in which we are better, superior and cost-effective that other countries like China.


Interface Q How would you define India’s position in the

global aerospace technology? From a technology point of view, a lot of work needs to be done to upgrade our technology, in terms of availability of machines and equipments made locally instead of depending on imports. The rise of aerospace industry will give an impetus to the local metalworking industry to grow as well. In the next eight to ten years, we would be a strong tier 1 supplier to the aerospace industry.

Q India is currently the tenth largest defence

spender in the world but we still import 70 per cent of equipment. How can we minimise this dependence? We still depend on other countries for some of the key components of machine tool industry. But with the aerospace industry growing, there is a hope that we will grow in this area. The dependency might not disappear but it would at least shrink. Just like we grew in the automobile sector, similar changes will be seen again.

Q With advanced and new technologies,

difficult-to-machine materials are finding their way in this sector. How has it brought a change in the machining operations? There has been a dearth in the machining and tooling industry. But, now the demand for such machines are going up, we will be upgrading ourselves in these areas to meet the needs and develop machines which can withstand the force and work at high speed required while machining such difficult-to-machine materials. More emphasis and resources will be poured in this area. This will be the first phase of the transition towards aerospace which will happen in the next five years.

Q India is presently the hot spot, with major

global industries entering this market. Do you think this will lead to stalling of growth for the domestic companies? It will not stall the growth but the question would be whether you are good enough to survive and grow. There will of course be some companies who will be affected, irrespective of whether they are Indian or foreign. It will be a game of the survival of the fittest.

Q What is the most important requirement of

this sector currently that would help fasten its growth? Aerospace is a high tech, high knowledge sector. It is purely a knowledge-based industry. The limitations here are not going to be availability of assets or availability of investments. It will all depend on the management of the available knowledge and putting to use right way with right people.

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Market Trends AEROSPACE

Courtesy: OPEN MIND Technologies AG

AN N I VERS ARY

AEROSPACE MACHINING SOFTWARE

Solutions with uniform user interface Weight, quality, manufacturing time and costs are paramount in the manufacturing of structural parts for aircraft construction. Extremely high quality demands for the manufactured parts and absolutely reliable, reproducible processes are pitted against growing cost pressures. As a result, tried and tested component structures and manufacturing processes are being called into question, despite the high concerns for safety in this sector. Aerospace machining software has emerged as a solution to reduce costs and minimise enviornmental impact.

W

herever possible, designers are looking to reduce the weight of structural parts. This is reflected both in the materials used as well as in the construction itself. After using a great amount of composite materials in recent years, the branch is now looking ever more to special aluminium alloys. Today’s monolithic structural components had previously been welded assemblies of many simpler components. 56

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The spectrum of structural parts ranges from external airframe components to internal structural components and fittings. These parts may have simple surface, such as plates with many holes, grooves and openings, all the way through to complex parts with thin, sometimes high walls, small corner radii and increasingly, undercuts. The rising number of integral components with a complex geometry and undercuts shows that, today, all possibilities are being exploited in order to save in terms of material and weight,

as well as to utilise new and more effective processes.

Changes in manufacturing With structural parts, often an extremely large proportion of the raw material must be cut away. In the past, it was possible to achieve a high volume of roughing jobs under time constraints by using large milling tool diameters. Modern machines can also achieve this with high working feeds and high spindle rotations using smaller tool diameters. The


Market Trends smaller tools allow a more effective, close-contoured roughing, and can thereby create higher quality finished components. Cooling lubricant is a significant cost factor in production. In order to reduce costs and minimise environmental impact, effort is being made to use only a minimal amount of lubricants. Changes to tool technologies are therefore indispensable. With new tools, for example, changes to vibration conditions can be taken into account, in order to make sure that the material properties of the part are not altered by surface pressure or heat build-up, as well as ensuring the safe removal of the chips. In CAM programming, the goal is to account for the multiplicity of modified demands with optimal milling strategies.

can be saved in a database, standard operation sequences can be applied quickly and reliably to comparable geometries. Here, 2D features can either be imported as solids through the direct interfaces of the CAD system or determined from surfaces and curves/lines via definable filters. Freely definable features also allow any characteristic geometry to be defined, to which a standard sequence of 2D, 3D and 5-axis machining tasks can be assigned. In this way, 3D pockets, a variety of which are found in structural parts, can be programmed efficiently. The sophisticated postprocessor technology helps utilise controller functions such as machining cycles, local coordinate systems, subroutines or programme part repetitions to achieve streamlined machining.

Flexible CAM solution

Optimised CAM strategies for thin walls

CAM products that offer 2D, 3D and 5-axis machining strategies within a single user interface are the most flexible solutions. One software application employed in this field is hyperMILL by OPEN MIND Technologies AG. In addition to the well-engineered 5-axis technology, CAM software offers innovative solutions in 2D and 3D areas. And the standardised user interface across the entire spectrum of machining strategies simplifies its use. Once learnt, users can programme milling tasks reliably, even when they only use the strategies in question from time to time. A number of intelligent functions assist the user in order to allow the individual optimisation of machining jobs and ensure that the desired high feed rates are achieved during the milling of structural parts. These include, for example, slopedependent machining, HSC functions and 5x shape level roughing etc.

High, thin walls with thicknesses of 1.5 to 4 mm (0.06~0.16 inch) and heights of 150 to 180 mm (6.0~7.2 inch) are a special challenge for manufacturing and CAM systems. The cycle ‘Roughing any stock’ in hyperMILL, for example, allows users to complete machining of bottom surfaces while leaving material for the finishing of the walls. The basis for this is the automatic plane level detection as well as the option of defining horizontal stock allowances. In this way, bottom planes can simply and easily be machined to completion during roughing. The job list-oriented stock tracking and management reliably detects the remaining material following operations using various tools and carried out from various sides. Remaining material areas can thus be roughed precisely with shorter tool paths and machining times.

Trouble-free programming Time can be saved with efficient CAM programming. It lowers input times by intelligently processing geometry data from CAD. With feature and technology macros, which 58

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Flexible undercuts With the help of undercut geometries, structural parts are optimally adapted to their function and weight is minimised. For production, these

undercuts pose a challenge. Depending on whether three or 5-axis milling is being performed, reliable CAM strategies with reliable collision checking and avoidance as well as the relevant tools are required. Several 3D cycles can also be used for lollipop or woodruff cutters. If, for example, a lollipop cutter is employed for 3D rest material machining, undercut areas can be machined without problems. Often, 5-axis machining proves the more elegant solution, allowing a reduction of machining times.

Five-axis on the rise Today, structural parts are still often milled with three-axis processing. Five-axis machining is used for an increasing number of applications, and likewise new components are designed with 5-axis machining as an intended manufacturing process. The 5-axis machines already in use are employed to reduce fixture costs. The ‘onboard’ capacity for simultaneous machining also offers additional possibilities to optimise milling processes. If a very high-quality surface finish is required, then the practice of milling with various fixed tool positions rapidly reaches its limits. And the surface has to be reworked as well. The continuous machining by means of 5-axis technology is the alternative, which often offers better surfaces in addition to minimised machining times. Examples of this are 5-axis drilling, which mills complex holes including threads with a variety of tool positions in one operation, as well as the 5-axis swarf cutting, which in practice has proven to be more effective than stepwise 3D machining. In comparison to 3D machining, 5-axis top milling can also save a considerable amount of milling time. Five-axis contouring is useful for milling grooves with a fixed orientation to the surface. Components can be trimmed, deburred or chamfered with this machining strategy, during which the automatic collision avoidance automatically corrects the orientation of the tool. Courtesy - OPEN MIND Technologies AG


AN N I VERS ARY

Practical Tips AEROSPACE

AEROSPACE

What the industry needs to fly high? This is the era of aviation. While this industry is expanding at an unimaginable pace, challenges faced by the industry are increasing as well. However, the industry is brimming with the determination to make a mark on the global map. Many hope that the road-blocks would clear helping the Indian aerospace industry to become a credible name in the global arena. However, others believe, that the change needs to come from within. We spoke to some of the connoisseurs of this industry to know what this nascent aerospace market needs to grow beyond recognition. Here are the eight practical tips offered by the experts for the industry to adopt. Debarati Basu

&1

The ‘do-all’ attitude: Dependence on imports in today’s scenario is a big no-no for the Indian industry. The Indian machine tool industry still depends heavily on imports to meets its domestic needs. Accordng to a recent survey, the manufacturing industry falls short to meet almost 60 per cent of the local needs. While exports forms the backbone of the survival of

the industry, the experts of this industry feel that it is time now to turn the tables. “We cannot depend on imports any more. If we need anything, instead of sourcing it from other countries, we should see how we can get it done here itself,” says T V Sridhara, Business Development Manager, India operations, Measurement Specialities.

&2

Jack of all trades, master of one: Long known for being one of the low cost manufacturing bases, the country has been providing an array of solutions to the industry. However, to carve its credibility, the industry needs to create its own niche. This is the age of specialisations, which the Indian industry lacks. Instead of foraying into various verticals, the companies

need to put in more effort to evolve in a specific segment in the market. “Earlier, specialising in a single vertical was apprehensive for the industry due to the risk factor involved. But the situations have changed now. Substantial progress is happening in well-defined sectors. Industries should evolve with concentrated markets,” says Sridhara.

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Practical Tips

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Cumulative growth: Ancillary parts form the backbone of the industry and no industry can grow without the support of the smaller ancillary segments. While the aviation sector is booming with bigger players in the aircraft manufacturing industry setting higher goals, equal amount of support needs to be extended

to various other segments associated with it. India has established itself as a strong outsourcing destination for manufacturing and machining precision components. The domestic market would benefit from this booming phase if enough support is provided to this segment.

Policy support: No industry can grow without the support the government. Right from the inception, the aerospace segment has been under the domain of the government. However, judging the magnitude of growth potential of this industry, the government is slowly opening up, encouraging public and

private partnerships. However, the industry players are looking forward for better policies to aid the growth of this sector. Right from registration, land acquisitions procedures and investments in the Indian market, the industry is hoping for faster, hassle-free process with less paper work.

Answerability quotient: With the amount of investments pouring into this industry, experts feel that there should be a degree of answerability maintained for it to grow. Decisions and policy measures by the government should be faster. With millions

at stake, the industry cannot afford to be stalled at various levels for getting government clearances and decisions. Industry experts feel that the projects taken up under publicprivate partnerships should entail to similar answerability on deliverables from both ends.

Professionalism: There was a time when the Indian industry was known for its slipshod attitude towards its deliverables. While the arrival of global players in India has brought in competition for the domestic players, it has also changed the way the Indian industry functions. Experts agree that the laxity in the attitude of the domestic players in terms of

promptness in delivery and quality standards has seen a paradigm shift over the years. The industry today is aware of the global market needs and has been adaptive to mould its working methods. While meeting cut-throat competition from the global market, the industry needs to take a deeper plunge into being more professional in its approach.

Thinking big: The sky has opened up and it is time for the Indian industry to think big and beyond the conventional lines. As the avenue is getting saturated already, the market needs to imbibe the risk-taking ability to provide futuristic solutions. The industry is still far

behind the technological advancements that is ruling the global market. Even as the market is gearing up to incorporate the advancements on their shop floors, it needs to reach up to the level to provide similar solutions to the market.

Getting the right people: This is possibly the most unanimously agreed point by industry experts. With high-end machines at disposal, the industry requires the right people on the job. A concerted effort from the industry and government is required to tackle effectively dearth of qualified engineers.. “What the industry needs today is people. We need good

machinists to run the high-end machines, we need good engineers to manage and produce consistently good components, people who can sell ‘Brand India’ to the world and people in the government who can put together policies that will encourage investment,” says Santanoo Medhi, Managing Director, Kennametal India Ltd.

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Future Forecast AEROSPACE

AN N I VERS ARY

NEXT AVIATION HUB

Opening doors for global investment With a plethora of aviation companies strengthening their base in India, there is no stopping this industry. Global expectations from the Indian industry and the increasing competition in this segment are surpassing each other. The history of automotive success is sure to be repeated at a much higher scale in the aero sector. Debarati Basu

I

ndia today forms the ninth largest aviation market in the world with over 75 per cent of the domestic aviation market ruled by the private airlines. The Ministry of Civil Aviation predicts that the number of international passengers will touch 50 million by 2015. With the availability of skilled manpower, an encouraging business environment, and rising government support, the country is well positioned as an attractive investment destination. According to a latest report released by the International Air Transport Association (IATA), the country’s aviation market has tripled in the past five years. The domestic airline alone has carried over 24.5 million passengers between January and May 2011, recording a growth of 17.6 per cent. With investments pouring in from all quarters, it clearly gives an insight to 68

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the amount of development that will take place in this segment. Although machining of precision components forms our forte, the domestic industry has to plunge deeper to take up complex projects to prove its mettle in the global competition. The industry has to venture into newer domain and explore other avenues. Maintenance, Repair and Overhaul (MRO) forms the next big thing in the aerospace industry. With an estimate of over 900 commercial aircraft traversing the Indian sky over the next 20 years, MRO services forms the key service requirement for the maintenance of the fleet. “There will be more planes and more airports in the country for sure. The only challenge in this segment is the longer gestation periods. For many years, our planes and engines have been going out for MRO activities. But now the situation is changing with business

coming into the country. The key in this segment is the ability to innovate. MRO is a growing industry in India. There are MRO hubs coming up in Delhi, Mumbai, Bengaluru, Chennai, Kolkata, Hyderabad and Trivandrum. We have huge potential and opportunities in this sector,” points out N Sriramulu, President, ITW Chemin. To establish itself as credible name in the global arena, the Indian industry also has to prove its potential in the sector and deliver high quality meeting global standards. “It is not just about quality, but about maintaining consistency. That is where we lag. However, we are definitely moving towards it as the global market does not make excuses on this front,” clarifies Santanoo Medhi, Managing Director, Kennametal India Ltd. Nevertheless, the Indian aviation sector forms the major economic driver of this decade and the domestic market is charging towards it.


AUTOMOBILES Industry Insights Indian automobile sector: Steering the economic growth .......................................... 72 Interface Amit Mahipal Gupta Director, Autolite (INDIA) Ltd...................... 80 R K Behera Founder and Chairman, RSB Group..................................................... 84 Market Trends Automotive tools: Ensuring quality in manufacturing .............. 86 Practical Tips Automobile market dynamics: Realigning business to stay on top gear ... 92 Future Forecast Automobile insights: On the right track .... 96 October 2011 - MODERN MACHINE TOOLS

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Industry Insights AUTOMOBILES

INDIAN AUTOMOBILE SECTOR

Steering the economic growth Automobile industry is the largest in the world with revenues of about $ 1.8 trillion and at times referred as ‘industry of industries’. The Indian automobile industry has demonstrated phenomenal growth and has become the seventh largest manufacturing market in the world. It can play a major role in enabling India to attain global leadership. Swapnil Pillai

D

uring the initial stages of its development, Indian automobile industry heavily depended on foreign technologies. However, over the years, the manufacturers in India have started using technology that is developed indigenously. Today, the Indian automobile industry offers models to meet all possible expectations. The growth of the Indian middle class with increasing purchasing power along with strong growth of the economy has attracted a number of automobile manufacturers, including some of the reputed global leaders to establish themselves in the country to enhance their profile and prospects. 72

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The automobile sector of India is currently the seventh largest in the world. The year-on-year growth rate in vehicles production achieved by the Indian automobile industry has been outstanding as compared to the growth rate achieved by the global automobile industry. The country manufactures about 2.6 million cars contributing significantly to the world’s annual production. The country is the largest manufacturer of motorcycles and the fifth largest producer of commercial vehicles. The figures published by the Asia Economic Institute indicate that the Indian automobile sector is set to emerge as the global leader in the near future. Over the years India has emerged as the fourth largest exporter

of automobiles following Japan, South Korea and Thailand. Engine parts accounted for the bulk of production in the Indian auto components industry, followed by transmission and steering parts. By the year 2050, India is expected to top the car volumes of all the nations of the world with about 611 million cars on the Indian roads. Indian automobile manufacturers like Maruti , TATA Motors, Mahindra and Mahindra and Hindustan Motors have established themselves firmly in the global automotive industry.

The growth trend Economic reforms and deregulation have transformed the Indian automotive market.


Industry Insights

Challenges The changes in design and adaptation of international technologies have enabled the Indian automotive industry to compete globally. It has also exposed the Indian industry to global challenges. The increasing environmental pollution has become a concern for manufacturers and all associated with the industry. The industry is struggling hard to come up with a holistic and integrated approach to reduce carbon dioxide emission. Car manufacturer like Maruti has already introduced the new concept of using recyclable substance for car production. The company strives to apply the same concept in all its future car models. This growing industry is on the search for more advanced ways and measures to meet stringent environment norms. 74

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Passenger vehicles 16.25 per cent Commercial vehicles 4.36 per cent

Three wheelers 3.39 per cent

Courtesy: SIAM

The country offers competitive advantages in energy, manpower and emerging technology and is rapidly emerging as a preferred manufacturing destination for automobiles. The development and upgradation of infrastructure and the existence of a good number of manufacturing plants are aiding the development of the Indian automobile market. The Indian automobile component industry is emerging as a world-class outsourcing destination for global auto majors. It has continuously improved the manufacturing process to embrace automation, robotics and new management techniques. The Indian automobile industry is currently witnessing another phase of re-engineering. It can seamlessly integrate several small units in engineering, automotive components and consumer electronics. It can thus fully explore the production value chain and achieve higher productivity and deliver greater value to consumers. The Indian automobile industry can deliver compelling value to the world in engineering and component manufacturing with its numerous smallscale units and a vibrant information technology industry.

Three wheelers 76.00 per cent Segment wise market share in 2010-11

The rise in oil prices will also impact the growth of the automotive industry. Unless the use of alternative fuels increases, it is very unlikely that the situation will change for the better. To sustain competitiveness in the automotive industry and to improve productivity, continuous innovation by the companies is required. This would necessitate more investments towards R&D and establishing mechanisms to translate R&D results into products and their efficient manufacturing. Similarly the rise in input cost of vehicles like steel, non-ferrous metals and rubber, have grown over the last few years, which in turn has increased the production cost of vehicles. Such cost escalation in input prices has impacted the growth of the Indian auto industry. Another major challenge is the creation of highly skilled human resource required for the auto industry. Auto industry, like many other industries is facing shortage of skilled technical as well as managerial manpower. Though India has a vast pool of professionals, the country needs initiatives and support to nurture these resources to excel in all areas of the industries. Therefore, the Society of Indian Automotive Manufacturers (SIAM) has introduced new strategies

to optimise the skills and also support proposals to train youth across the country including the rural areas. Ministry of Rural Development, National Skills Development Corporation, Indian government, and the Indian automotive industry, are working in synergy to generate a vast pool of skilled manpower for the Indian auto industry.

The road ahead Indian automotive industry holds significant scope for expansion. Indian companies need to increase their penetration in the domestic and global markets. Similarly, the auto components industry that adopts global quality management procedures should capitalise on the European and US market by increasing the number of outsourcing businesses from these regions. Indian economy, which benefits from strong fundamentals and sound regulatory framework, will help the automotive industry to increase the product offerings and absorption of newer technologies. India’s reasonably priced and technology-oriented workforce, together with strengths gained by the country in IT and electronics, will provide momentum to the Indian automotive industry.


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AN N I VERS ARY

Interface AUTOMOBILES

Indian auto components industry has proven its commitment to quality while competing internationally with low cost manufacturer …says Amit Mahipal Gupta, Director, Autolite (INDIA) Ltd. Established in the year 1982, the company has to its credit various awards from the government and industry bodies for its excellent services and manufacturing expertise. In a conversation with Swapnil Pillai, he illustrates the changing landscape of auto industry in India. Q The automotive machining

has witnessed exponential growth over the years. With growing demands for speed and productivity, tell us about the changes on the shop floor. There have been a number of advancements in automotive manufacturing. Right from the design stage, rapid prototyping, CAD, has helped in perfecting the design. Software’s like moldflow, pro-Engineer, CATIA, Unigraphics, Industrial Graphics (IGS), Speos/Lucid shape, have reduced the design time. CAM has cut down the machine time in mould-making. 80

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Automation tools have ensured that the products manufactured have Conformity Of Products (COP) and human errors have been eliminated. These tools have helped in speedy product development, reduced wastages, increased productivity and reduced inspections stages. These developments have also caused corresponding improvements in shop floor management and the shop floor inventories have come down. Today’s shop floors appear far less cluttered and much cleaner. The ambience is more pleasing.

Q With evolving consumer

preference, brief us on the

upcoming trends in the automotive industry. The increased concern for controlling the environmental pollution has caused the automotive industry to look for higher fuel efficiency, alternative fuels, lower weight of vehicles and environmental-friendly materials. Safety has always been the focus of the automotive industry. In automotive lighting segment, use of Light Emitting Diodes (LED) in stop and signal application is fast replacing incandescent bulbs because of quick response time, long life and better shock resistance. With development of high lumen white LEDs, it is a matter of time when it may find application in head lamps


Interface too, for added advantage of low power consumption. Dynamic bending lights, cornering lights, day time running lights etc will find more and more use.

Q How has Autolite (INDIA) Ltd

been leveraging on the booming Indian automotive sector? Not only is the Indian automotive industry experiencing a boom, the Indian auto component industry has also established itself in the world market with major acquisitions overseas. Indian auto components industry has proven its commitment to quality while competing internationally with low cost manufacturer like China. Indian manufacturers have always strived for perfecting the quality. Autolite (INDIA) Ltd is known for its commitment to customer delight. Our company has been recognised by the Government of India as ‘Star Export House’. It has been the preferred supplier to many OEMs and has been actively fetching the increased business of OEMs. The company is planning substantial investment in capacity expansion, modernisation and quality upgradation to meet higher demands.

Q Elaborate on the challenges

that need to be addressed by the industry. The industry is faced with challenges of increased cost of fuel, lowering weight of the vehicle while increasing safety and upgrading quality aspects of the product. Some of the other countries are also catching up on the quality and cost parameters. The inflation in the country with increased cost of raw materials, transportation, and finance for buyers as well as for companies is also affecting the industry. External factors like global economic meltdown, foreign exchange fluctuations are cause of concern for the industry.

Q How can the regulatory

framework be strengthened to ensure sustainable growth of the industry? 82

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For the sustainable growth of the industry, the biggest challenge is the spurious products available in the market. Industry together with regulatory bodies has to find a solution to this problem. The government should consider reduction in interest rates, which will help the buyers as well as the manufacturers for maintaining healthy domestic demand. Further, attractive export incentives to compete with global players to increase the export business should be considered. It is also pertinent to mention here that government should create an automotive hub having all infrastructure facilities like cheap developed land, availability of power, roads, transportation, water etc to attract investment in automobile sector.

Q What are the R&D and

quality assurance initiatives of the company? The company is having various quality system certifications like the ISO 9001, ISO 14001, TS16949. We have taken initiative to fulfill our mission of total customer delight by making the experience of association with Autolite (INDIA) Ltd an enjoyable one. All the products meet conformity of product requirements and have approvals of the certifying agencies in the country of export like CE mark for European countries, DOT for USA, etc. Company’s R&D is well equipped with latest equipments and highly qualified professionals working for new developments of innovative products.

efficiency of automobiles which would reduce environmental pollution. Autolite (INDIA) Ltd is also developing low power consumption LED-based lighting systems for greener environment.

Q How do you rate the talent

pool available in India with respect to global standards? What are the training initiatives undertaken by the company? Though Indians are quite talented, our education system needs a complete overhaul for developing quality education. The industry also has to conduct inhouse training programme to become up to date with the latest technological developments in the world. The company conducts training for two hours every week for every staff and worker even for senior management. The company also conducts on-thejob training on the shop floor for the senior executives.

Q How can the Indian machine

tool industry cater to this fast evolving sector? It is high time that Indian machine tool industry took note of the fact that most of the capital goods are imported. In the field of tool and mould development, China has created a hub. In case of China, it has been mainly government efforts, but in India, machine tool industry probably has to take lead to develop such industry cluster or hubs.

Q How do you foresee the Indian Q Elaborate on the green

initiatives undertaken by the company. The company is ISO 14000 certified for environmental protection and has OSHAS 18000 certification for occupational safety and health. We regularly monitor energy consumption and conducts energy audits. These environmental-friendly measures have been supplemented by tree plantation drives. The company is also concentrating on weight reduction for better fuel

automotive industry? Elaborate your future plans. Indian automotive industry has a bright future. However, recent high interest rates have dampened the growth. But these are minor hiccups and we are going to have more exciting times. Autolite has plans for major investment for substantial capacity increase, modernisation and quality upgradation. Company plans to increase export business considerably in new markets across the globe.


Interface

Implementation of infrastructure projects would help automobile sector to deliver better ...avers R K Behera, Founder and Chairman, RSB Group. The company presently has 12 manufacturing plants spread over six locations in India and manufactures a diverse range of automotive components and systems. In conversation with Swapnil Pillai, he illustrates the need of the hour for rapidly growing Indian automobile market. Q What are your views on the

current scenario of the Indian automobile sector? Presently, the Indian automobile industry seems to be taking a marginal dip. But, we believe this is a shortterm phenomena because of the high domestic inflation, rising interest cost and weak global demand. However, in our view, the medium and long term scenario is optimistic because India is one of the emerging economies and also has the critical mass to support and sustain recovery and growth. 84

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Q What is the need of the hour

to optimise the quality and efficiency of the product offerings? Globally, India including, the expectations of the customers on quality front have risen significantly and continues to rise. Therefore, embracing quality on product offerings has become vital and absolutely necessary for survival and to stay ahead in global competition. We also believe that when we take care of quality across the breadth of our business in all operations,

wastages get eliminated and efficiency improves. Towards this, we are in the process of institutionalising Total Quality Management (TQM) process in our plants.

Q What are the various R&D

and quality assurance initiatives undertaken by your company? We believe that by integrating design and manufacturing, we can provide our customers with cohesive engineering solutions. Thus, R&D is of immense


Interface importance to us. With this in view, our subsidiary i-Design Engineering Solutions Ltd provides our customers, whenever required, with design and testing functions for some of their products. i-Design provides services, including conceptualisation, design, prototyping, testing and eventually validating products. i-Design offers designing and engineering services internally as well as to third party customers, thereby enabling us to develop stronger relationships with our customers on multiple fronts.

Q Brief us on the initiatives to be

undertaken to meet the requirement of qualified workforce for the industry. There is a great need to increase the number and quality of manufacturing / shop floor manpower. There is huge shortage of workforce which also leads to high attrition. The government in cooperation and collaboration with the private industry players should embark on a programme to have more

industrial technical institutes to churn out well qualified production personnel in different manufacturing disciplines.

Q Are the policies of

government facilitating sustainable development for automobile companies? All-round infrastructure development is the key to achieve sustainable development, particularly in the automobile sector. In this aspect, it is our view that, while the government’s policies on infrastructure development are laudable, the translation of these into implementation is not quick enough to reap the desired benefits. Greater acceleration in implementation of the various infrastructure projects would help the automobile sector to deliver better. The government is certainly working towards controlling and softening the macroeconomic environment of high inflation and high interest regime. Once this is achieved, we hope the industry will bounce back from its temporary slowdown.

Q How can the Indian machine

tool industry cater to this fast evolving sector? Indian machine tool industry is known for producing quality products and has the required knowledge, both technical and managerial, to produce and deliver. The industry needs to align with the emerging global trends in terms of complexity, automation and high level of performance. The machine tool industry needs to absorb the fast changing technology quickly and offer these products in the Indian market almost simultaneously as they are unveiled in the developed countries. It needs to enter into technical collaboration with the leading machine tool companies of the world so that machines of global standards are available in India at lower and competitive price. If this happens, the automotive industry may not have to import such machines with high cost and lead time. Service facility may also become available at lower cost and quicker time.

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Market Trends AUTOMOBILES

AUTOMOTIVE TOOLS

Ensuring quality in manufacturing Competitive necessities are driving manufacturers to become more customerfocused. Without the proper tools the constantly evolving consumer preference and the technically advanced raw materials will be difficult to manage. Besides, this can trigger steady margin erosion and market share loss.

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anufacturing processes play a major role not only in the attainment of high product quality, but also in the reduction of manufacturing and consequently also product costs. By using modern production technologies, significant potential for the reduction of costs can be exploited. The tools used are of major importance in this respect, as it is their job to convert the speeds and spindle outputs provided by the machine into metal cutting performance. 86

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Car body file blades This unique invention is still one of the best tools available today to level a brazed joint in automotive applications. The unique profile of file blades makes it amazingly aggressive yet offering the finest surface finish, which in turn makes the joint ready for painting without further surface preparation. These files are ideal for any type of sheet metal work requiring a particularly smooth and scratchfree finish. Since the file leaves no scratch marks, the filed surface can

be painted immediately, without any prior polishing. The milled car body files provide exceptional stock removal rates and unsurpassed surface quality due to positive rake angle, uniquely convex surface, unsurpassed sharpness of teeth.

Essentials of a good car body files Ideal tooth geometry: The teeth of ideal car body files should be milled from the solid metal, as distinct from the usual cutting process. Each tooth should be designed to ensure that

Courtesy: Pferd India

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Market Trends the chip rolls up before the rounded tooth face and is forced into the large chip space. Convex shape to prevent formation of scratch marks: One key advantage of car body files is their convex cross section. This special feature prevents the edges of the file from coming into contact with the work piece, thus preventing undesired scratches in the product surface. The ergonomic holder permits convenient tensioning of car body file blades to match the surface contour of the work piece. Light weight but rugged die-cast aluminium structure, available in two sizes. The file bending radius can be adjusted via the tensioning system. Tanged car body files: Rectangular, curved longitudinal and transverse (convex) files, tanged, cut on one side, and available in different cuts. These files require no file holder, they can be used with a handle.

HSS antenna cutter The unique antenna cutter is used extensively for enlarging holes in automotive panels with minimum burr and vibration. Conical cutter in special cut with shank dia of 8 mm. High Strength Steel antenna cutter for stepless milling, enlarging bores and holes, for eg mounting holes in car bodies

HSS Antenna cutter

Recommendation for use: Speed range 200-500 rpm to be used for smallest burr diameter, eg sheet edge work max 9.000 rpm.

Fine grinding and polishing tools Latest abrasives like ceramic oxide and compact grain ensures 30 per cent less grinding time, higher tool life, better surface finish and results in minimum 25 per cent lower cost per component. 90

MODERN MACHINE TOOLS - October 2011

Nearly all types of material surfaces can be worked on with coated abrasives. Coated abrasives, depending on the type, can be used for wet or dry grinding. Coated abrasives consist of the following components: backing material, basic bond, covering bond, abrasive grit and abrasive layer.

Ceramics (CER)

Abrasive grit

Compactgrain (COM)

Choosing the correct product strongly influences the surface finish and the economic value of a process.

Additional coating layer (Top size)

Zirconia Alumina (ZA)

Ceramic grit Sintered aluminium oxides are divided into sintered bauxite aluminium oxides and sol-gel aluminium oxides. Sol-gel aluminium oxide is mainly used for coated abrasives. This highly modern abrasive has become increasingly popular through its toughness and its good self-sharpening property. The ceramic abrasive leads to an increase in productivity with simultaneous improvement of surface quality and outstanding stock removal. Due to the continuous self-sharpening the highest level of stock removal, an extra-long service life and hence an economical grinding are realised. At the same time they achieve an improved surface quality. For applications involving the dry machining of stainless and high-temperature steels it is recommend. using top size products. Their additional lubricating layer provides increased stock removal rates and significantly reduced temperature in the grinding zone, which prevents work piece structural changes. The ceramic abrasive is particularly suitable for applications requiring low and medium operating pressure and even for low-power cornering grinders. Wide abrasive surface, constant wear, continuous exposure of new grit, high and even cutting performance. The

fibreglass backing does not damage or foul the surface worked in the case of accidental contact. It provides good strength while maintaining a satisfactory degree of flexibility. The recommended applications are deburring, removing welding seams and spots, removing scale, rust and oxidation of any kind. The ceramics series are ideal for aggressive but cool grinding. The use of these series lead to an increase in productivity with simultaneous improvement of surface quality and outstanding stock removal.

Compact grain products Due to uniform stock removal they achieve a consistent surface finish during their entire service life. Compared to conventional abrasives, compact grain products achieve a more consistent surface with less setup time. The compact grain products are special tools for continuous grinding applications. Due to uniform stock removal, they achieve a consistent surface finish during their entire service life. Courtesy: Pferd India


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Practical Tips AUTOMOBILES

AUTOMOBILE MARKET DYNAMICS

Realigning business to stay on top gear The Indian automotive industry after de-licensing has grown at a spectacular rate of 17 per cent on an average for last few years. The industry has now attained a turnover of ` 165,000 crore and an investment of ` 50,000 crore. This has opened up huge business opportunities for the machine tool industry in India. To make the most of the opportunities presented and to stay on top of the business, the following best practices can be adhered to.

Swapnil Pillai

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Know-how is not enough: Being an expert in the field doesn’t guarantee business success. Efficient marketing and administration play a key role in ensuring the prolong stability of the business. Making relevant machinery to meet the industry requirement is not enough. Targeted customers should be made aware of the features and applicability

of the machine. Marketing for business is very important as it aids the growth and profit objective of the organisation. Marketing plays a crucial role in arousing customers’ needs and expectations to the point of consumption and in creating a loyal stream of satisfied customers who continue to patronise the brand.

Hire the right people: Hiring an employee is one of the most important business decisions. While getting a very suitable candidate can make a huge difference to business success, the cost of hiring a wrong or unsuitable candidate can be very high. Most companies often do not place

much importance to this function and hiring is often done in an unprepared manner without much planning. It is very important that each employee meets the expectation of the business for achieving the long- and short-term objectives of the company.

MODERN MACHINE TOOLS - October 2011


Practical Tips

&3 &4 &5 &6 &7 &8

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Consistency in service delivery: Customers prefer a reliable business partner. Consistency is critical for business success. The clients should be delivered the same quality and services that he expects from the brand. The consumer’s confidence can be gained by ensuring that they

get the same quality every time. Consistency makes it easy for customers to choose the service, and results in repeat orders for the client. A loyal client base and repeat business cannot be created with discrepancies but with dependability and consistency.

Implementing quality control system: Quality control system enables an organisation to achieve the goals and objectives set out in its policy and strategy. A fully documented system will ensure that the customer’s confidence in the ability of the organisation to deliver the desired products and services consistently meeting their needs and expectations. Similarly, the organisational

objectives can be met at an optimum cost with efficient use of the available resources like materials, human, technology and information. These requirements can only be truly met if objective evidence is provided, in the form of information and data, to support the system activities, from the ultimate supplier to the ultimate customer.

Focus on innovation: Firm-level innovation is very low in India. Indian machine tools firms source technology, but very few of them improve upon it. The research spending as a percentage of sales amongst Indian firms is low when compared to the R&D spends of companies in developed nations. Today, business environment has become very dynamic with more demanding customers and intense market competition. To

meet this, firms have to create new products, solutions and services that provide a radically better experience for the consumers. In the everchanging world, innovation is the only key which can sustain long-run growth of the company. Companies have to engage themselves in various innovative activities, ranging from manufacturing processes, product improvement, and brand building initiatives to customer satisfaction.

Resolve issues as quickly as possible: Issues are big problems. The manager should manage open issues diligently to ensure that they are being resolved. If there is no urgency to resolve the issue or if the issue has been active for some time, it may not really be an issue. It may be a potential

problem, or it may be an action item that needs to be resolved at some later point. Real issues, by their nature, must be resolved with a sense of urgency. It can be envisaged as a ‘wedge’ that both holds the gains achieved along the quality journey, and prevents good practices from slipping.

Reuse and recycle waste: It takes a lot of valuable energy and materials to create and manufacture products and the resulting industrial waste can be difficult to manage. Reducing and recycling waste becomes imperative. Capturing and recycling waste during the manufacturing process can save money.

An audit can identify very simple ways to easily capture and reuse waste without extensive capital investment. Through better waste management, companies can even enhance their public image by understanding the impact of their use of the precious resource on the community at large.

Branding: It defines precisely how the customer perceives the brand now, and in future. It must be referred to, when making all decisions large and small, by everyone in the organisation. The exact brand the company desires will, thereby, be communicated to all stakeholders, internal and external. Branding facilitates a company to get an

identity of its own which further allows it to compete in tough marketing conditions and to bond a strong relationship with the customers. In many cases the customer is unaware of the services and quality of products a company is manufacturing. Branding will always help in identifying such companies and to boost their image in the potential market.

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Future Forecast AUTOMOBILES

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AUTOMOBILE INSIGHTS

On the right track

The automotive industry forms the core of India’s manufacturing economy. On account of its huge market potential, low base of car ownership in the country estimated at about 25 per 1,000 people and a rapidly surging economy, the nation is firmly set on its way to become an outsourcing platform for a number of global auto companies. Swapnil Pillai

I

ndia is among the few countries that is showing a growth rate of 30 per cent in demand for passenger cars. This accompanied by the de-licensing of the sector and subsequent opening up of 100 per cent Foreign Direct Investment (FDI) through automatic route have been some of the major reasons for multimillion dollars investment by global auto majors into the country. Cities like Chennai are likely to see about ` 8,000 crore or more of investments flowing into the sector followed by a slew of new automobile projects. The proposed units are likely to raise the city’s total auto output by 5 lakhs in a year. Similarly major investments by auto behemoth like TATA Motors, Ford in Gujarat is a proof of the auto investor-friendly atmosphere in India. India is among the most competitive 96

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manufacturers of auto components in the world. Auto component industry in India has potential to grow at a Compounded Annual Growth Rate (CAGR) of 13 per cent to reach $ 40 billion by 2015. Various tax incentives, as well as a fast-track approval process will enable India to become one of the world’s most attractive automotive markets for both manufacturers and consumers. The announcement of ‘Automotive Mission Plan’ for the period of 2006-2016 is a major step towards this objective. The plan aims to make India the next big destination for design and manufacture of automobiles and auto components, with output reaching a level of $ 145 billion. The long-term potential for growth of the auto industry is very favourable, on account of low vehicle penetration in

the country. As income levels rise and easy finance is available, the industry will continue to see a healthy growth rate. Society of Indian Automobile Manufacturers (SIAM) estimates that the growth of the auto industry in FY12 will be around of 12-15 per cent. According to a recent report by SIAM, the size of the Indian automotive industry by the year 2016 varies between $ 122-159 billion, including $ 35 billion of exports. The resulting benefits to society such as economic growth increased jobs would be significant. According to Amit Mahipal Gupta, Director, Autolite (INDIA) Ltd, “Indian automotive industry has a bright future ahead. However, recent high interest rates have dampened the growth but these are minor hiccups and we are going to have more exciting times ahead.”


CONSUMER DURABLES Industry Insights Consumer durables: Building an ecosystem of growth .................................... 98 Interface T V Sridhara Business Development Manager, Indian operations, Measurement Specialities ..... 100 Market Trends Mapping success: On a path towards sustainable growth...................................... 104 Practical Tips Consumer first: Ensuring quality delivery ... 111 Future Forecast Indian consumer durables industry: Carving a niche ........................................... 114

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Industry Insights CONSUMER DURABLES

CONSUMER DURABLES

Building an ecosystem of growth No longer can consumer durable products be classified as just day to day essentials. Today, with the transition that every product has undergone, luxury and necessity have been amalgamated in the same package. The market is being ruled by a plethora of brands and products, each offering a unique design and feature. However, only time will tell how much market share can be captured by the Indian industry. Debarati Basu

B

roadly classified into the white and brown goods, the industry as a whole is booming in the Indian market. New brands and products are making way into the market every month. The industry has taken a huge leap over the last decade and is still expected to grow at an unimaginable rate. The customer base also is ready to accept innovations. Over the years, the demand for consumer products has seen a huge surge in the growing economies of India, China and Brazil and the market is ready to incorporate the technological advancements which are being introduced by the global market. This has also encouraged the industry 98

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to come up with severalinnovations. The strong competition in this segment has also led to price war among major brands to offer better quality products at lower cost. Even with the constant reduction in prices, the industry has portrayed an impressive growth graph. While China has been ranked as the second largest market in the world for consumer electronics, India too is fast picking up to become one of the major markets for the industry.

Market boom For the global market, India no doubt stands to be one of the largest consumer bases. The transition in the lifestyle of the common man has come in as

an impetus for the Indian populace to accept global brands and technology. The consumer durables market is estimated to be ` 300 billion and is expected to reach ` 500 billion by 2015 with the urban market growing at the rate of 9 to 12 per cent annually. According to reports by the Consumer Electronics and Appliances Manufacturers Association, the industry has grown by 12 to 13 per cent as compared to last year. Products like high-definition televisions have been in vogue while split air-conditioner has seen a growth of 60 to 70 per cent. Similar growth has been recorded in flat panel displays like LCDs and plasma display panels which rose by 45 per cent this year. On the other hand, the


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Industry Insights sale of home appliances has surged by nearly 23 per cent. The market size of refrigerators is projected to grow to 12 million units in 2011 while the market for washing machines is anticipated to be no less than six million units.

Market switch Although India forms one of the major markets for the global players, rural India today is the rising consumer durables market in the country which itself is growing at the rate of 30 per cent. With major brands making their way into the rural segment, market leaders predict a growth rate of 40 to 45 per cent in the next fiscal in the rural segment alone. This is due to the boost in the lifestyle among the rural population. Mobile phones, televisions, music systems, air conditioners and refrigerators are the most sought after products in the present time. However, with the technological advancements which the population has adapted to, the trends is moving towards multi utility products like iPods, tablets etc. As the rural and semi–urban market is witnessing a faster growth than the urban market, the latter is now largely becoming a product replacement market. This has led to stiff price competition between the market players to attract customers. Being among the fastest growing economy in the world, the consumer durable sector contributes around 8 per cent in the Index of Industrial Production (IIP) providing jobs to professionals, skilled, semiskilled and unskilled workers, in rural and semi-urban areas. According to the Associated Chambers of Commerce and Industry of India (ASSOCHAM) that the penetration level of consumer durables in the country is about 5 to 7 per cent as compared to other countries. It foresees further penetration in the rural sector in the coming years.

Indian brands vs global players Even as India forms a huge consumer base, the country is yet to become a manufacturing hub. The industry

is dominated by global players like Whirlpool, LG, Samsung, Sony, Nokia among others. However, there are not many home grown players venturing into the industry. At one point of time, Indian companies like BPL, Godrej, Videocon etc ruled the domestic market. However, with the growing competition and the integration of newer technology in the available products, the homegrown companies are struggling to keep pace with the developments. The major challenge faced by the Indian industry is to keep pace with the rampant upgradation of technology and assimilating high-end quality products at a lower cost to be competitive enough in the market. However, of late, the Indian companies have transformed their product portfolio in terms of product design and sophistication in the features to be at par with the global market. But more needs to be done in this area. While the home-grown brands are yet to grow in the domestic market, the industry is a long way from stepping onto the global stage.

Indian machine tool market With more and more foreign brands coming into the country and the growing market in this segment, the Indian machine tool industry should invariably benefit from the surge. However, that has not been the case. Although the IT industry has proven its mettle in the segment, the machine and tool industry is still trying to bargain a bigger piece of pie in the growth of the market. According to experts, the country still heavily depends on imports, leaving the Indian machine tool industry in a lurch. While most of the foreign-made brands find it convenient to have their own service centres in India, they still hesitate to shift their tool room activities to India. The home-grown companies still largely depend on importing the moulds for their production. However, with the steady growth of the home-grown companies and the change in the attitude among

the manufacturers in this sector, the Indian machine tool industry remains optimistic of making it big in the upcoming years with reduced dependence on imports and increased reliance on Indian machine tool providers.

Beating the odds Adding to the competition from the foreign-made goods, the other major challenge faced by the home-grown industry is the distribution pattern and availability of infrastructure which hinders their growth. The industry still needs a welldeveloped distribution networks so as to build a brand image of their own and penetrate fastest into the growing market. The industry is also seeking better policies from the government which would give an impetus to the growth of the Indian companies. While the mergers with foreign brands is making way for the Indian companies to incorporate advanced technology in their products, the industry today however needs to have an extra edge over the foreign made products to survive and grow in this booming industry. What the Indian industry now needs is a fresh perspective to restart its journey again where the soaring competition from global brands needs to be seen as an opportunity to come up with better product offering to the customers. More and more in depth product research needs to be put in for new items to hit the stalls and beat the global offerings. The brand image which companies like BPL and Godrej had once instilled in every household needs to be created again. With a perfect presence and penetration in the domestic market, there is no stopping the Indian companies to foray into global market. The future remains optimistic for the market as a whole to grow, making ground for the Indian populace to be at par with the latest and advanced technology being used across the globe. October 2011 - MODERN MACHINE TOOLS

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Interface CONSUMER DURABLES

Demand will increase but Indian companies would grow marginally …points out T V Sridhara, Business Development Manager, Indian Operations, Measurement Specialities. Talking to Debarati Basu, he discusses the need for home-grown consumer durables companies to minimise their dependence on imports. Q Tell us about the present

market scenario of the consumer durables industry. India has been growing in the white goods industry and there are a lot of new brands, models and equipments which has come into the market. This was certainly not the scenario a decade back. Today, there are more foreign brands in the market. Indian companies are entering into foreign collaborations. The market is filled with foreign brands and Indian companies are also making their presence felt in 100 MODERN MACHINE TOOLS - October 2011

the manufacturing sector. However, for the manufacturing of Indian equipment, critical components and parts are still being heavily imported in the form of knock-down kits or sub-assemblies. This is preventing component-level selling in India. It would take almost five to ten years to bring in a change in this attitude of Indian manufacturers and bring down the dependence on imports.

Q The increasing demand in the

consumer durable products,

has invariably increased the demand from machine tool industry for high precision machining of the products. Is the machine tool industry able to meet the requirements of the industry in terms of volume and technological advancements? The Indian machine tool industry is equipped for the surging demand but the consumer durables manufacturers have to depend on them and lower the imports. The demand in this industry


Interface is ever growing and if a home-grown brand has to cater to this demand, they have to meet the challenges from the foreign brands and reach their standards.

Q Tell us about the kind of

competition that the market faces currently. There are many brands coming into the market but not many Indian brands are entering this segment. Those already into the market are entering into joint ventures and are tagged with a foreign brand to survive in the market now. Number of home-grown companies has to increase but there also needs to be a change in the attitude of the customer. An India-made product is as good as any other foreign brand but given a chance and the budget, people always tend to lean towards buying foreign brands. The manufactures have to deliver what they promise and people

have to accept it as well. This has to go hand in hand.

Q What are the challenges

faced in this segment? And what all is being done to overcome the hurdles? The major challenge comes in with facing stiff competition from foreign brands. We still lack in delivering what we promised. We have to meet the global parameters, quality sustainability, understand the consumption pattern. Also, the life span of the products needs to be longer. Our products lack the finishing and aesthetics that foreign brands provide and we loose our customers on this ground as our products look less attractive than foreign counterparts. However, with time, we have certainly changed. We are trying to make our products aesthetically appealing so as to be in line with the global trends.

Q In what ways does the

industry need to change to survive in the market? To survive we have to be in line with the global brands. We have to provide similar quality, aesthetics and technology that the foreign brands provide. And all this has to be within the stiff price competition that the market today offers. There is also a need to have faith in our home grown brands so that more investments can be made in this sector. The demand in this market is surging everyday. We only have to create our image in the market which would generate credibility among the consumers.

Q How has been the growth

trajectory of the industry? Given the kind of lifestyle that the India is leading, the demand for white goods will increase but the demand for home grown products might stagnate or grow marginally.

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Market Trends CONSUMER DURABLES

MAPPING SUCCESS

On a path towards sustainable growth Today the consumer durables industry in India is growing at the rate of 20 per cent while the rural market itself is growing rapidly at almost 35 to 40 per cent building a market worth ` 300 billion. We are one of the major markets of the world. However, it is now time for the home-grown industry to take the next step forward and become a name to reckon with globally. S Subbarayan

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hat happened in the automobile industry will also happen in the Indian consumer durables industry. From a sales point of view, this is a big and growing market. However, in terms of basic tool making or 104 MODERN MACHINE TOOLS - October 2011

product development, apart from very few Indian companies, this industry is dominated by the global market leaders like Samsung, Nokia, Sony, LG among others. However, what brings us business from this industry is mould making. The machine tool industry looks

at the machining requirements of high-end products like mobile phones, LCD TVs, digital cameras where the complexity of the parts is higher. Moulds of these products by itself are complex and require high perfection, surface finish and high end technology.


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Market Trends By nature, the product life cycle of this industry is very short. Any new model or product survives in this industry for not more than six months. Therefore, the challenge for this industry is to have a good design house and a good back-end tool room support which can churn out new designs continuously on a steady basis. The Indian tooling industry is yet to catch up with the global level of competency in terms of design and delivering high-end tools. So, while the latest developments in high end technology is still dominated by countries like China and Korea, India still focuses more on die maintenance or repeat die casts. The market for machine tools industry in the consumer durables is very small. We are still largely catering to the automotive industry. Even though there is a huge growth here in terms of end user consumption, we have not yet been able to make a big impact in this industry.

Meeting requirements Bigger brands in consumer durables industry do not have their tool room in India. They still import the dies from countries like China, Taiwan or Korea. The maintenance of the dies or duplication of some proven products is however done in India for saving costs. The home-grown companies work on their own design, but to make the process quicker and to launch the product in the market sooner, they find it easy to import the moulds. This way, 50 per cent of the moulds are still imported. The Indian industry is still slow on investing on advanced technology as it involves a lot of money and talented people. But the future of this industry looks very positive. In the next four to five years a lot of ‘Indianisation’ is likely to take place. Many tool rooms in India are upgrading their technology by adding good design team and adding more facilities like painting technology etc. We are seeing a trend where India and China, 110 MODERN MACHINE TOOLS - October 2011

which has a huge consumer base, are the future markets.

Growing competition The prime mover of this industry is the consumer demand. The consumers are now exposed to the global quality and design level and want the best product at a lowest possible price. So, the rise in the foreign brands is forcing the Indian companies to upgrade their quality so that they can compete with them in terms of product design, product quality and cost. While the Indian companies are upgrading themselves, foreign companies find it viable to set up manufacturing facilities in India to give backend support to their production facilities. The die mould industry has a good potential in India in this segment but is yet to explore its true potential. We are still watching the growth and the trend looks good, but a lot depends on how the die mould industry grows. Automotive industry, over the years, has grown in terms of quality and price. But in consumer durables, there are certain areas which require huge technological upgradation but most of the products require highly sophisticated product design capability which has not yet come to India. Even for China, which is a huge production house, the basic product design comes from Europe or US. India has proved itself in the software know-how, but we are yet to prove our capability in hardware, electronics and electrical product design. The high-end machining capabilities require high investments and skilled manpower. For this, we require a global base to justify the investments. Countries like Korea, Japan, Taiwan are already catering to the global market. For us, it is proving to be a challenge as our products still needs a global branding and proven capability. But since the demand is swelling in India, the market will respond positively.

Beating the odds The material cost is going up and equipment are getting expensive day

by day. But in terms of increasing productivity and capabilities, this is an investment that needs to be done. Making a mould takes a lot of skill, investment and time and in this industry the design of the products change rapidly, thereby raising the need for new moulds. Most companies find it cost effective to import the moulding machines and moulds instead of investing in making new moulds. Just like the automobile industry, the government needs to support this industry in a bigger way for more companies to invest in R&D and advanced technologies.

Areas of opportunities Today, lot of devices are getting merged into multifunctional equipments. The best example is that of a digital camera and mobile phone. The industry is now working towards producing multifunctional devices in refrigerators, mobile phone, televisions etc. The Indian industry also has to think on similar track and come up with intelligently integrated products. We are forced by our end users to improve on quality. They are appreciating our products and are considering buying our machines. But the numbers are still small.

Future growth This industry is certainly going to grow, but how much will the die and mould industry catering to this industry grow depends on various factors. But with the number of joint ventures and newer companies coming into the market, this industry will certainly make it big.

S Subbarayan is the Deputy General Manager of the Die Mold Division of Makino India Pvt Ltd. He garners a huge experience in the die and mold sector. Email:subbarayan@makino.co.in


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Practical Tips

CONSUMER FIRST

Ensuring quality delivery The sleeker-than-the-sleekest mobile phone models and laptops with the latest feature will always be in vogue. The Indian consumer, today, has a good taste of the best in the market. The market cannot pull wool over the Indian populace with goods of conventional quality. With a tough competition from the global brands, the onus is now upon the Indian manufacturers to meet customer expectations. We spoke to some of the market leaders to know what the Indian industry needs today to make their mark. Here are the eight practical tips suggested by them to bring in a change. Debarati Basu

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Deliver what is promised: Gone are the days when glitz and glamour was all it took to sell a product. The consumer today is smarter than ever. They know what they need and also know how to compare and assess the products with global products. The Indian manufacturers

cannot underestimate the knowledge base of the Indian customers. Indian products fall short, in terms of providing the promised features, quality and technology. This only pulls down the brand value of the Indian made products.

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Do not undermine Indian brands: Consumers have shown tendency to overlook the Indian brands when compared to the foreign-made products. The customer base as well as the machine tool industry needs to value the

home-grown products as these products are competitive enough with knowledge and quality consciousness. They should get support from the Indian populace to prove their mettle in the industry.

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Invest in local brands: With the recorded growth, consumer durables industry is one of the driving forces of the economy today. However, there is still a hesitation in the Indian market to pour in investment into the home-grown brands. The

industry and the market should have faith and take lead to invest in Indian companies. Along with government support, the market should also pass on the confidence to this segment with investments for this industry to grow.

Transformation in attitude: The Indian industry still believes that the customer would use what is being offered to them. However, the consumer tendency has changed. Keeping a track of the global trends, they ask for more than what is

available on the platter. The Indian manufacturers have to be ready to face this demand to provide them with innovative solutions and features in the products even before they ask. Consumers today create the demand.

Invest on efficient technology: This is one of the fundamental requirements today for the Indian industry. Most companies try to minimise the cost by cutting upon investing on efficient technology. But the consumers want the best technological product at lower cost. So, while the Indian market is not able

to produce a high quality mobile phone at low price, there are global players who are able to do so. Other countries are able to do it because they invest on high-quality technology. The market needs to understand that efficient technology will ultimately bring down the cost in the long run.

Upgrade knowledge: The solution is not just in buying high-end equipment but the industry also needs to invest in upgrading the knowledge base to use the available technology efficiently. Bridging the knowledge gap is very important

for taking the industry to the next level. This can be done by educating people about the quality systems and the overall manufacturing process or by working with strategic partners who can bridge these gaps.

Study the market need: The reason global brands have an upper hand in the market is because of their thorough research of the industry. Also many foreign brands have failed miserably because of selling the wrong product to the

wrong market at the wrong time. Home-grown companies have an added advantage of knowing the soul of the consumer base. They need to make better use of this and provide solutions as per the demographics of the market.

Perfect the perfection: The home-grown companies are finding ways to survive in the market with mergers and joint ventures. While this is bringing in new technology and advancements in the industry, the Indian companies need to perfect their art. The

Indian companies should not just upgrade the technology but also evolve the products aesthetically so as to be in line with the latest in the market. The industry first needs to create a brand image of its own in the country itself before venturing out into the global terrain.

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AN N I VERS ARY

Future Forecast CONSUMER DURABLES

INDIAN CONSUMER DURABLES INDUSTRY

Carving a niche The growth of the consumer durables industry is unstoppable. It is not just the surge in the number of brands entering the market but the increase in the retail industry which has made highly sophisticated products accessible to the consumers. The Indian consumer has grown not just in terms of numbers but also in terms of product preference and technological understanding, giving a stiffer competition to the industry. Debarati Basu

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healthy competition can yield better results and this is what the consumer durables industry is undergoing today. The Indian consumer today is aware of the technological advancements in this segment. The market is surging with demands for LCD televisions, refrigerators, high-end mobile phone, air conditioners etc. However, global players hold an edge over the Indian counterparts in terms of superior technology and bigger investments which makes them the trends-setters of the market. Now, to grow in the industry, most Indian companies are collaborating with foreign brands. So, while the home-grown brands are incorporating the latest technological developments into their products, the global players are finding it easier to enter the Indian market. 114 MODERN MACHINE TOOLS - October 2011

The Indian consumer durables industry has witnessed a considerable change over the last decade. Changing lifestyle, higher disposable income along with greater affordability and a surge in advertising has been instrumental in bringing about a sea of change in the consumer behaviour pattern. Apart from steady income gains, consumer financing and hire-purchase schemes have become a major driver in the consumer durables industry. The rampant transition in the lifestyle of the rural and the semi rural population has made it the most promising and sought after market for the industry today.

Challenges met With competition comes challenges. Currently, the biggest challenge that the consumer durables industry faces is in terms of availability of raw material, proper distribution pattern and potential government support to boost the home-

grown market. Adding to this is the high preference of the customers for foreign products and devices over Indian-made goods with similar features and quality. Most Indian companies in this segment are yet to create a brand identity of their own to remain ahead of competition. India is on a path to become a manufacturing hub and gets major competition from countries like China, Korea and Japan.

Growth potential The growth of the industry remains robust and unhindered. The surge in the industry is also opening the doors for the machine tools industry to benefit. With the entry of the industry in the rural and semi rural populace, the technical know-how in the segment is also getting an equal leverage. It goes without saying that the industry sees a huge potential in the coming years.


ELECTRICALS AND ELECTRONICS Industry Insights Indian electricals and electronics industry: Powering next phase of growth................ 118 Interface Vimal Mahendru President, Indian Electrical and Electronics Manufacturers’ Association (IEEMA). ....... 120 Market Trends E&E sector: On an upward swing ............. 128 Practical Tips E&E arena: Electrifying business opportunities........... 132 Future Forecast Powering the economy: The future is bright..................................... 134

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AN N I VERS ARY

Industry Insights ELECTRICALS & ELECTRONICS

INDIAN ELECTRICALS AND ELECTRONICS INDUSTRY

Powering next phase of growth The Indian electrical equipment manufacturing industry is witnessing a sustained growth momentum, with the industry registering a double digit growth in the financial year 2010-11, in spite of sustained imports, especially from China and South Korea. Hema Yadav

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he domestic electrical equipment manufacturing industry clocked a 16.6 per cent growth during the first quarter of 20112012, the same as in the previous year, according to industry estimates. The Indian Electrical and Electronics Manufacturers’ Association (IEEMA), an industry association of manufacturers of electrical, industrial electronics and allied equipment, has based these growth figures on the production and sales data collected from its member organisations. The electronics industry in India took off around 1965 with an orientation towards space and defence technologies, which was initiated and controlled by the government. This was followed by developments in consumer electronics mainly with transistor radios, black and white TV, and other audio products. In 1982, the government 118 MODERN MACHINE TOOLS - October 2011

allowed thousands of colour TV sets to be imported into the country to coincide with the broadcast of Asian Games in New Delhi. The year 1985 witnessed the advent of computers and telephone exchanges, which was succeeded by digital exchanges in 1988. The period between 1984 and 1990 was the golden period for electronics during which the industry witnessed continuous and rapid growth. From 1991 onwards, there was first an economic crisis triggered by the Gulf War which was followed by political and economic uncertainties within the country. Pressure on the electronics industry remained though growth and developments have continued with digitalisation in all sectors, and more recently the trend towards convergence of technologies. After the software boom in mid 1990s, India’s focus shifted to software. In recent years, the electronic industry is growing at a brisk

pace. It is currently worth $ 10 billion but according to estimates has the potential to reach $ 40 billion by 2011. The largest segment is the consumer electronics segment, which is also the largest export segment of components.

Sector overview Due to increased focus on power quality and energy efficiency by utilities, Discoms and user industries, demand for capacitors surged by 35 per cent in 2010-11. Rising demand from Power Grid, Independent Power Producer (IPP) and some utilities for High Voltage (HV) and Extra High Voltage (EHV) switchgear including products like Automatic Identification System (AIS), Geographic Information System (GIS) resulted in a 28 per cent growth. Pent up demand of medium voltage breakers for substation projects resulted in huge growth of more than 30 per cent.


Industry Insights A positive high is the increased participation from organised sector visible due to BEE (Bureau of Energy Efficiency- star labelling programme), RAPDRP (Restructured Accelerated Power Development and Reform Programme) and CEA’s (Central Electricity Authority) recent recommendations for utilities to procure minimum three-star rated distribution transformers. Presently, Indian exports of electrical equipment are less than 1 per cent of the global trade. With the electricity sector being a sunrise sector across the entire developing world, there also exists a significant export potential for the domestic industry. Industry experts believe the ideal way forward to sustain the growth momentum would be faster Goods and Services Tax (GST) implementation, creation of level playing field, increased focus on exports and SME development. This will lead to further acceleration in the industry’s growth process and contribute significantly

reducing the power demand-supply gap in the country.

Challenges to growth While the electrical equipment industry was geared with production capacity, procedural delays in releasing tenders and contracts, and runaway cost escalation due to price of commodity inputs are holding back electrification of the country. Coupled with these, the challenges of land acquisition, environment clearances, non-availability of domestic coal and the cost of imported coal are further weakening the sector. Experts believe that land acquisition and availability of fuel are the main reasons for the shortfall, but there are several other problems which also need to be tackled urgently. These include inadequate domestic Engineering, Procurement and Construction (EPC) abilities, which is delaying erection and commissioning of power plants, weak project management and

execution, including civil construction, competencies, inordinate delays in commissioning of Balance of Plant (BOP), shortage of domestic supply of skilled manpower, delays in environmental and other clearances and poor logistics infrastructure, including access roads to projects sites, etc. The small and medium industry could for the first time get credit at lower rates through an interest subvention scheme which the government is considering for the sector. Small and medium enterprises selling both in the domestic and foreign markets would be eligible for the subsidised loans, according to a commerce department proposal. The Department is discussing the proposal with the Finance Ministry and hopes to get a favourable decision on the issue soon. If these issues remain unaddressed, the industry may have to look at captive plants to meet its requirements, which would entail huge investments and hamper its growth.

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AN N I VERS ARY

Interface ELECTRICALS & ELECTRONICS

How can we even begin to think of ourselves as a developed nation if we cannot provide adequate stable electricity to our citizens …ponders Vimal Mahendru, President, Indian Electrical and Electronics Manufacturers’ Association (IEEMA). It is the national representative organisation of manufacturers of electrical, industrial electronics and allied equipment. Discussing India’s potential in the electrical and electronic sector with Hema Yadav, Mahendru is positive about the potential in this field. Q Although India is on a growth

trajectory, what are the challenges that the Indian electrical and electronics sector is facing? First, the infrastructure needs to come up to global standards at the earliest. While we see a lot of investments in infrastructure yet the pace of change and development of infrastructure is far below expectations. India’s infrastructure (road network, sea ports, sanitation, water resources etc) is the 120 MODERN MACHINE TOOLS - October 2011

least developed compared to other BRIC nations. A direct outcome of poor infrastructure is an appalling 14 per cent cost being borne by Indian companies for logistics and supply chain. This may be compared to 2.5 per cent for those countries which have a well developed infrastructure set up. Secondly, availability of right talent is a major concern. We take pride having the largest number of engineers in the country, and that Indian institutions churn out largest number of engineers

every year. However, the quality of knowledge and training these young minds have before they enter the work arena is not of global standards. Our syllabi are woefully outdated and not in sync with the emerging world. There are numerous stories of electrical engineers seeking jobs who have never seen inside of a power plant, a transformer or even a basic switch. There is an urgent need to develop skills and talent in line with the emerging world. For the development


Interface of these skills the way we operate our IITs and engineering colleges needs a relook. Students must be exposed to a system of learning and syllabus which is contemporary and pedagogical. Emphasis needs to be on innovation and application, rather than on rote regurgitation of bookish text. Last but not the least; we have tremendous faith in the Indian SME sector and the Indian entrepreneur. The Indian entrepreneur is as sharp and visionary as the best in the world. However, entrepreneurship, enthusiasm and innovation are compromised in the face of vicissitude in government policy and taxation framework. The Indian entrepreneur does not need protection or sops from the government. We need a consistent and steady policy and tax framework for the entrepreneur to unleash his/her potential.

Q What has been the growth

of the electrical equipment manufacturing industry in the first quarter of 2011 taking into consideration the mandate ‘Electricity for All’ by 2012 and do you believe that this target can be achieved? ‘Electricity for All’ is a huge task and the government is putting all efforts in this direction. To coordinate generation, transmission, distribution along with last mile connectivity will be a huge challenge for our country. India embarked on an ambitious journey of Electricity for All by 2012 when the Government of India triggered the power reforms through the Electricity Act in 2003. Since then, India has come a long way. Our per capita electricity availability has almost doubled from approximately 400 Kilo Watt Hours in 2003 to approximately 734 Kilo Watt Hours today. By any stretch, this can be considered commendable. However, if we look at the consumer demand and expectations, we are way behind global average and are definitely lagging in any comparison 122 MODERN MACHINE TOOLS - October 2011

with developed nations. How can we even begin to think of ourselves as a developed nation if we cannot provide adequate stable electricity to our citizens? Personally, I think it will take at least another 25 years to reach that goal.

Q Recently it was reported that

the government has missed the target of ramping up generation capacity, meeting only 36% of the goal set for quarter ended March 2011. How will this impact the Indian electrical equipment segment? Naturally, IEEMA is concerned that in the absence of adequate new power generation capacity enhancement, there is already a slow down in the off take of equipment. We remain concerned at the lesser number of new contracts being finalised by the various procurement agencies.

Q What according to you are

the reasons for the shortfall? What are the other problems that need dire attention from the government and what has been IEEMA’s role in addressing some of these concerns? The shortfall in power generation capacity enhancement is due to several reasons, including delays in contract finalization, land acquisition, financing as well as procedural delays. Due to this slowdown it is obvious that the summer has been quite a strenous one for the consumers. Power availability has been low when the demand has been at peak in the summer months. All of this has added to the cost of power that a consumer pays because of seeking alternatives to grid electricity.

Q IEEMA has been interacting

with the government on policy issues. As the President of IEEMA, what are your recommendations or

suggestions to the government to improve the country’s power generation capacity? IEEMA has been interacting with the government in the last one year to contribute in meaningful ways and assisting the government in bringing electricity to all. One of the most important projects in which IEEMA is engaged with the government is the development of the electrical equipment industry mission plan – 2012-2022. This is an extremely critical document which will bring together requisite government agencies, regulatory bodies, utilities and industry in having a comprehensive view of the challenges and a joint approach to ensuring success. Further, IEEMA is actively engaged with the government in promoting standardisation of equipment and establishing national standards for various equipments used in the network. It is inevitable that while India is putting a grid in place, we also need to focus on Smart Grid. This shall enable us to manage our precious energy resources better.

Q What is India’s share in

global exports of electrical equipment? Currently, Indian power electrical equipment industry has exported goods of approximately $ 4 billion. Presently, Indian exports of electrical equipment are less than 1 per cent of the global exports which currently stands at approximately $ 425 billion.

Q How do you view the role

of SMEs in the electrical equipment segment? SMEs are the backbone of the electrical equipment industry. Over, 70% of IEEMA members are SMEs. We strongly believe that the SMEs will continue to play a major role in providing ancillary services to the electrical and electronics industry as well as creating niche market for their products. I believe there is a lot of innovation available in our SMEs, which we need to tap.


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AN N I VERS ARY

Market Trends ELECTRICALS & ELECTRONICS

E&E SECTOR

On an upward swing An important feature of the slowdown of 2008-10 was not lost on the machine tool industry. While orders for machine tools declined dramatically from the auto sector, no such decline was seen in demand from the power equipment, infrastructure and other heavy engineering sectors. In fact, machine tool companies primarily dependent on the auto sector saw a steep decline in orders whereas companies serving the other sectors were not so badly affected. Two lessons learnt from this: one, not to depend heavily on any one sector for orders, and two, not to neglect the heavy engineering sector for machine tool orders. P J Mohan Ram

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he heavy engineering sector is mainly composed of the power equipment sector dominated by earthmoving, mining and metals, ship building, process plant equipment and strategic sectors like defence, atomic energy etc. The requirement of these sectors is largely for heavy duty machine 128 MODERN MACHINE TOOLS - October 2011

tools. Most of the companies in these sectors have farmed out the machining of smaller components to other units. Therefore the demand from these users will be only for machines for the larger components. The types of components that are machined by the heavy engineering sector are:

      

Large motor/generator stator housings Turbine casings Gearbox and transmission housings Wind turbine blade housings and gear boxes Motor, generator and turbine shafts Large transformer parts Gears and pinions of large module and diameter


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Pressed and forged components Sheet metal cut and rolled parts Large diameter pipe bending, tubing Process plant components Boilers, heat exchanger components

Typically, the machine tools that are required for these machining applications are:  Milling & boring machines (spindle 160 mm and above)  Floor boring, travelling column machines  Plano-milling machines  Heavy duty turning and grinding machines  Presses typically 2000 T and above  Vertical turning machines typically 2000 mm and above  Press brakes of large size  Heavy duty coordinate drilling/deep hole drilling machines  Heavy duty sheet rolling machines  Pipe bending machines for large diameter  Sheet metal and structural fabrication machines The machine tool requirements of the major companies in these sectors run into thousands of crores. As the Indian machine tool industry is not strong in the manufacture of large and heavy duty machine tools, the requirement of machine tools by these sectors is largely met by imports. Traditionally, Italy, Spain, Germany, Czech Republic, Romania have been strong in the manufacture and supply of these machines worldwide. Machine tool companies in these countries have met the Indian demand. It is also encouraging to see that one Spanish company is setting up manufacturing facilities for heavy duty machines in India. Others may follow soon.

Domestic demand This area represents a large opportunity for Indian machine tool companies to meet domestic demand for such machines. So, indigenous development is to be taken seriously. However, the cost of R&D and product 130 MODERN MACHINE TOOLS - October 2011

development for such machines is very high and no single company can absorb this expenditure. Instead of the conventional route, the R&D for such machines must be supported through risk sharing ‘Development Contracts’ from users to suitable machine tool companies. This can be facilitated by setting apart an amount equal to say 5 per cent of the machine tool budget to award contracts for the development of such sophisticated machines. Over a period of time, this approach will enable the development of these machines indigenously. Suitable policy initiatives like allowing a higher depreciation of say 50 per cent to companies using machines developed through such contracts will help them recoup the expenditure faster. Innovative measures are required to spur R&D in areas where our companies would not otherwise venture.

Technology transfer With the free market era in place there is not much scope for a traditional collaboration/technology transfer from foreign companies to Indian manufacturers. Nevertheless, the association of foreign companies with Indian counterparts through Joint Vanture (JV) or Joint Working Arrangements (JWA) can be of benefit to both, and also to the customers in India. By transferring a part of the manufacture to Indian companies, the price of the machines can be brought down. The Indian partner can provide efficient, quick technical support to the customers both during installation, commissioning and prove out, as well as after sale support. Indian engineering talent can be used to design the fixtures, tooling, process planning and application engineering content of these supplies. Here the cost benefit can be substantial when compared with engaging foreign engineers and technicians. Large buyers of such machines in the government and private sector may be asked to insist on a measure of local

content/participation while ordering such machine tools from foreign suppliers. This will encourage such JV/JWA to come up. It is time for Indian machine tool companies to engage in a serious dialogue with foreign manufacturers of such machine tools to explore JV/ JWA tie-ups for their own and the users’ advantage. During the 1990s when foreign exchange was scarce, such arrangements worked extremely well in executing large orders for the users segments needing heavy duty machine tools. In the present era, although foreign exchange is not a factor, cost/price reduction and availability of qualified local technical support and service are important factors. This must persuade foreign and Indian companies to come together to exploit the relatively large demand for such machine tools in India. This demand is not likely to dry up anytime soon, given the ambitious targets in power generation, transportation, infrastructure and strategic sector over the next decade and beyond. The raising of manufacturing GDP from the present 16 per cent to 25 per cent by 2025 can come about only through the implementation of these projects which in turn require large and heavy duty machine tools and manufacturing equipment. This is an opportunity the Indian machine tool industry must not let slip.

PJ Mohanram is the Director - Technology Division at Indian Machine Tool Manufacturers’ Association (IMTMA). He has been an active member of the machine tool industry in India and has taken on the task of improving the level of technology implementation under the aegis of the association. Email: mohanram@imtma.in


AN N I VERS ARY

Practical Tips ELECTRICALS & ELECTRONICS

E&E ARENA

Electrifying business opportunities The coming decade will witness the emergence of Indian electrical and electronics arena in the global domain. To capture maximum market share and lead the competition, Indian manufacturers need to display business acumen and foresight. A sneak peek at the top eight acumen. Hema Yadav

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Business sophistication: This is conducive to higher efficiency in the production of goods and services. This in turn, leads to increased productivity, while enhancing a company’s competitiveness. Business sophistication concerns the quality of a company’s overall business networks including operations and strategies.

When companies and suppliers are interconnected in geographically proximate groups, efficiency is heightened, opportunities for innovation are created, and barriers to entry for new firms are reduced. Individual firms’ operations and strategies all lead to sophisticated and modern business processes.

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Design and development: An integral part of business operations, a company needs to continuously evolve in its design and development of products. In today’s contemporary market, customers are spoilt for choices and to garner more sales, a company requires a good design and development team backing it. To develop reconfigurable, scalable, cost-effective

manufacturing processes, equipment, and plants, a proper design needs to be in place. To develop custom-tailored products or services rapidly, a company can draw knowledge or capability from outside the company as well. A well-defined design and development strategy can help company to respond to ever changing market trends-locally as well as globally.

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Manufacturing infrastructure: This involves a wide spectrum of services, right from concept to execution of a process. Now-a-days customers are looking for complete solutions under one roof for their needs. Companies are privy to the fact that productivity improvements and lower product and process costs are not enough.

To remain competitive they must provide better value for their customers, increase customer base, and develop new business areas. Companies need to identify and supply each customer’s unique requirements with an integrated set of products and services that fit cost, timeliness, and functional requirements that are flexible.

Marketing goods efficiently: Companies with dynamic marketing strategies are well positioned to produce the right mix of products and services given their supply-and-demand conditions. This ensures that the goods can be effectively traded in the economy. Healthy market competition, both domestic and foreign, is important in driving

market efficiency and business productivity, by ensuring that the most efficient firms, producing goods demanded by the market, are those that thrive. The best possible environment for the exchange of goods requires a minimum of impediments to business activity through government intervention.

More quality less cost: An advantage that the South Asian continent possesses over its Western or European counterparts is availability of cheap labour. Customers expect delivery from the subcontinent to deliver high quality products at less

cost. Companies need to find ways to improve efficiency and lower cost. Although China is the leader in delivering low cost products, India is known for its quality. Indian companies need to leverage this to their advantage.

Quality workforce: For any company to succeed, a well-qualified dedicated workforce is a must. Nothing can replace trained/skilled manpower. Companies need to invest in training programmes and cultivating genial working atmosphere, so that employees feel a sense of belonging towards the company. With attrition rate high in the field, creating job satisfaction for its employees,

should be a priority for any company. Also, to regulate a steady flow of dependable workforce for the future, companies need to partner with institutions and government authorities to develop industry-oriented curriculum. Only high-quality education and training can produce highly motivated individuals and teams that can take a company forward.

R&D investment: This forms the backbone of success. All major companies in every field invest heavily in R&D. Even during the global downturn, companies who contributed this way are reaping its benefits today. A prime example

is Apple-the company released around 12 new products during the time of economic gloom. A complete R&D centre helps prepare a company to prepare for the future and tap potential market segments before its competitors.

Technology upgradation: Technology upgradation is critical for improving productivity, efficiency and competitiveness. Cost advantages are being replaced by technology-related factors like zero-defect product quality and international certification of firms’ quality assurance systems. Technological capabilities can be described in terms of three levels: the basic level involves ability

to operate and maintain a new production plant based on imported technology, the intermediate level consists of the ability to duplicate and adapt the design for an imported plant and technique elsewhere in the country or abroad, while an advanced level involves a capability to undertake new designs and develop new production systems and components. October 2011 - MODERN MACHINE TOOLS 133


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Future Forecast ELECTRICALS & ELECTRONICS

POWERING THE ECONOMY

The future is bright The Indian electrical equipment manufacturing industry registered a growth of 16.6 per cent during Q1 of FY 2011-2012, maintaining almost the same growth as Q1 of 2010-2011 which stood at 16.73 per cent. The electronics market in India is forecast to touch $ 125 billion by 2014 from the present market of $ 45 billion. The industry will be one of the key sectors to look out for in the coming decade. Hema Yadav

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he Indian electronics industry is at a nascent stage but the government mandate-’Electricity for All by 2012’ is acting as a power booster. Although, a significant jump in market demand, rise in production of semi- conductors, liberal government policies, vast pool of industrial expertise, lucrative investments, conducive business environment, and finest manufacturing facilities are also some of the factors behind this industry’s upward graph. India’s semi-conductor market alone is expected to reach $ 7.59 billion in 2011. The consumption of electronic gadgets valued at $ 28.2 billion in 2005, is expected to touch $ 363 billion by 2015. Indigenous production of electronic equipment in India was $ 10.99 billion in 2005, but is touted to be $ 155 billion in 2011. 134 MODERN MACHINE TOOLS - October 2011

Considering, the growth graph, India will soon emerge as the preferred destination for consumer electronics. Presently, China, Japan, North & South Korea, Singapore and India are the top manufacturer of electrical and electronic products.

Contributing to economic growth The contribution of Indian electronics and electrical industry to the country’s GDP has been quite substantial and the industry offers varied opportunities for manufacturing. Electric equipment industry contributes over 2 per cent of GDP which is expected to rise to around 12 per cent in 2015. A study conducted by Frost & Sullivan, reveals that consumption of electrical equipment is estimated to go up from over $ 28 billion now to $ 363 billion in the coming decade. Industry experts believe

that during 2010-2015, the Indian electrical equipment manufacturing will grow at 5.5 times the growth rate of global electronic equipment production. Growth in exports have also assisted the growth of some sectors like transformers, switchgear, cables, capacitors, energy meters, transmission line towers and conductors. In the last year of 11th plan, about 15,000 MW of addition to power generation is expected to be commissioned and most of the transmission and sub-station projects at 400 KV and below are likely to be completed despite the fact that most of the High Voltage Direct Current (HVDC) and 765 KV projects are likely to spill-over to the 12th plan period. All the above indicators signal a prosperous prospect for the electrical & electronic industry in India.


ENERGY Industry Insights Energy industry: Switching on India’s green power ........... 138 Interface Klaus Ludwig Vice President, Hwacheon Machine Tools Co Ltd ............ 142 Market Trends Automated solutions: PLM for the energy and utility industry.... 148 Practical Tips Indian energy sector: Making a ‘power’ful nation........................ 152 Future Forecast Energising the nation: Fuelling sustainable growth....................... 160

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AN N I VERS ARY

Industry Insights ENERGY

ENERGY INDUSTRY

Switching on India’s green power With a steady rise of Indian population, the overall energy consumption is set to grow. Most of the energy requirement is bound to come from the urban sector due to industrial growth and rapidly increasing population. With most countries adopting environment-friendly energy solutions to serve the demand efficiently, the time has come for Indian energy sector to shift from conventional to renewable sources. Nishant Kashyap

T

he Indian government is aiming to achieve an economic growth rate of over 8 per cent in the next two decades in order to meet its development objectives. However, rapid economic growth would also entail the need for structural changes in the economy as well as induce shift in the demand patterns. To meet the needs of the Indian consumer in the most effective manner, it is vital to chart out the energy demand and supply dynamics in the country. Having plans for rapid economic growth, it is 138 MODERN MACHINE TOOLS - October 2011

evident that the country’s requirements for energy and supporting infrastructure would increase rapidly as well.

Current market scenario Being the fifth largest energy consumer in the world, India’s energy sector is increasingly drawing international attention. One of the primary reasons for this is the government’s initiative towards stepping up efforts to convert interest into actual dollars of investment. Surjit Lahiri, Practice Head – Energy, Semiconductor Manufacturing

and Storage Verticals, Mindteck, says, “Today, India has one of the highest potentials for the effective use of renewable energy. India is the world’s fifth largest producer of wind power after Denmark, Germany, Spain, and the US. There is a significant potential in India for generation of power from renewable energy sources such as small hydro, biomass, and solar energy. The country has an estimated small-hydro power potential of about 15,000 MW.” New wind power capacity significantly increased worldwide in recent year, and surprisingly, majority of that new capacity


Industry Insights was in developing countries and emerging economies, driven mainly by the booming wind sectors in China and India. Indian companies are extensively focusing on research and technical development programmes in collaboration with developed European countries and US research entities on emerging technologies such as integrated gasification humid air turbines, integrated gasification, etc.

Surjit Lahiri, Practice Head – Energy, Semiconductor Manufacturing and Storage Verticals, Mindteck There is a need to focus energy R&D on achieving higher levels of efficiency, reducing costs for end-consumers, minimising environmental damage and easing dependence on nonrenewable sources.

rapidly and reaching new horizons despite global recessionary trends. According to Lahiri, “Currently about 16 per cent of global energy Conventional to renewable consumption comes from renewables, As going green has become the motto with 10 per cent coming from globally, Indian energy sector is also traditional biomass, which is mainly encouraging renewable energy and used for heating, and 3.4 per cent from making a shift from conventional to hydroelectricity. Renewable energy renewable sources. Clean power like provides 18 per cent of total electricity wind, solar, bio gas and small hydro generation worldwide. Renewable provides the biggest opportunity to power generators are spread across reduce emission and lower India’s many countries and wind power alone dependencies on coal and petroleum for already provides a significant share of meeting its power needs. Currently, clean electricity in some areas.” Presently 18 technology accounts for huge growth of of the 25 State Electricity Regulatory global venture funding, with solar and Commissions (SERCs) have issued wind energy receiving the maximum feed-in tariffs for wind power. Around investor interest. Of the entire renewable 17 SERCs have also specified stateenergy source, wind energy has emerged wide Renewable Purchase Obligations as the star performer, surpassing the (RPOs). The Ministry of New and nearest competitor solar and hydro, Renewable Energy (MNRE) estimates due to technological advancements that there is a potential of around 90,000 and government’s incentives to attract MW for the country, including 48,561 investments in this sector. Wind power MW of wind power, 14,294 MW of has the potential to be sufficient for small hydro power and 26,367 MW the future energy needs of the country, of biomass. In addition, the potential as companies are concentrating on its for solar energy is estimated for most growth and expansion. Thus, wind parts of the country at around 20 MW power generation sector is changing per square kilometer of open, shadow Energy mix of India free area covered with 657 GW of installed capacity. Many studies and Coal projections about Renewable 41 per cent 27 per cent the future energy Nuclear mix indicate that 1 per cent coal would continue Hydro to be the main 2 per cent source of energy, Oil Natural Gas but renewable energy 24 per cent 5 per cent will also play a pivotal role. “There Source: IEA Energy mix of India (Source: IEA) is a need to focus 140 MODERN MACHINE TOOLS - October 2011

energy R&D on achieving higher levels of efficiency, reducing costs for endconsumers, minimising environmental damage and easing dependence on nonrenewable sources.” avers Lahiri.

Policy framework The power sector ranked sixth among the leading sectors of the Indian economy, attracting huge Foreign Direct Investment (FDI). The Government of India has an ambitious mission of ‘POWER FOR ALL BY 2012’. This mission would require India’s installed generation capacity to be at least 200,000 MW by 2012 from the present level of 114,000 MW. To meet this demand, the government has initiated many investment friendly policies. According to the policy, up to 100 per cent FDI with unlimited amount is allowed for most projects relating to electricity generation, transmission, and distribution, except the nuclear power plants. In the renewableenergy sector too, 100 per cent FDI is permitted and a generation-based incentive scheme has been put in place for wind power projects. In December 2009, the MNRE approved a Generation Based Incentive (GBI) scheme for wind power projects, which stipulated that an incentive tariff of ` 0.50/kWh would be given to eligible projects for a (maximum) period of ten years. This scheme is currently valid for wind farms installed before 31 March 2012. As India continues to develop, it has choices on how to accomplish its twin objective of sustainable development and inclusive growth. Choosing to increase its focus on clean and efficient energy source to meet this objective will be the most appropriate choice.


AN N I VERS ARY

Interface ENERGY

India should set an example of how to use green technologies ...says Klaus Ludwig, Vice President, Hwacheon Machine Tool Co Ltd. In a talk with Nishant Kashyap, he discusses the current scenario of the Indian energy sector and how to use green technologies and other effective energy producing methods to improve efficiency. He also emphasises on recent technology development and opportunities for machine tool builders.

Q What are your views on the

current scenario of the Indian energy sector? The booming economy and industry in India is stretching the supply of uninterrupted power supply to the limits. Most of our customers are facing frequent power cuts, resulting in loss of production time, damages to tools, work pieces and sometimes also to the equipment and expensive 142 MODERN MACHINE TOOLS - October 2011

machines as the electronic units cannot take this frequent breakdowns.. Some bigger companies, of course, are trying to use generators to ensure a smooth power supply. However, this is costly and still requires re-starting of the machines once the power had been shut. India, we all hope, will not just result into building blindly nuclear plants as other big nations doing.

Instead, India should set an example of how to use green technologies and other effective energy producing methods. The technology is available, the know-how is also present in abundance. All that is needed is a leader to give the right direction. This would establish India’s position as a true modern and future orientated industry nation, which is not repeating the wrong done by other nations.


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Interface ENERGY

Q Renewable energy like wind

and solar are fast becoming a necessity as the traditional energy sources and demand become scarce. Elaborate. These are some of the modern and available technologies India should go for to produce more energy. India should not only focus on production on an industrial scale, it has to look at the adoption of these technology in every household too. Germany, I believe, is one of the leading countries where energy saving is being taught to school children already. High cost of electricity and water consumption is a major challenge. In other parts of the world, particularly Asia, these costs have not yet reached the level that would prompt people to start save automatically. India has the chance to play a leading and effective role due to its high population. Each and every little effort will make a difference in the long run.

Q How can the Indian machine

tool industry and automation solution provider cater to its one of the biggest and fastest growing sector significantly? One way is optimising the equipment as best as possible. Another option will be to use modern equipment which uses lesser energy as older once. Educating operators and engineers about how to save energy will also do be very helpful. Automation is fast becoming another sector, where not only labour cost is being saved but equipment and factories is being better utilised. However, if the power supply is not stable and frequently interrupted, the efficiency will remain low.

Q The Indian energy sector is

growing rapidly. How can the machine tool companies optimise this? As mentioned before, new equipment and machines in general are now using lesser energy and utilising energy more 146 MODERN MACHINE TOOLS - October 2011

efficiently. The machine tool industry is also trying to make the machines more efficient in power consumption. Latest drive systems using lesser energy by providing better specification is proving to be a great help. Cutting tools and new cutting methods are also using lesser energy.

Q What techniques can machine

tool sector provide to the energy segment? Instead of the machine tool industry helping the energy sector, it makes more sense if the energy sector pitches in to improve the machine tool sector By providing stable power supply, machines and equipment will operate at a higher and more efficient level. This needs to be addressed urgently. Every power cut costs the manufacturing company additional money, along with loss of production damages and time.

Q In terms of technology, what

are the measures adopted by your company to serve the growing energy sector? The machine tool industry has actually limited means to help on a bigger and wider scale. However, every reduction in energy consumption of course will help. And a large country like India, will be able to save massive amount. At the recently concluded EMO exhibition in Hanover Germany, Hwacheon displayed a number of newly designed machines to the customer and industry. All new machines have been designed based on the demands and requirements from industries operating in the field of renewable or new energies. New materials used, higher tolerances required and more complex and bigger parts setting the specification for new machines. Hwacheon has been key-supplier to companies in the Wind- and Solar panel industry since many years. For example, our VT-series has already proven his capabilities to companies manufacturing parts for windmills or high tech water pumps. The Hi-Tech series has seen many

installations within the oil & gas as well as mining industry. Providing a machine to customers where they can rely on it for many years and achieving highest efficiencies even under extreme conditions. Our multi-axis machining centres are a further part of Hwacheon’s growing presence in the field of high precision equipments.

Q Brief us on the initiatives

undertaken to meet the requirement of qualified workforce for the industry. India has a workforce comprising talented engineers. Apart from their technical knowledge, their dedication and working attitude makes it extremely easy to work with them. The manufacturing industries in Asia and specifically India are relying on this workforce who will prove to be the future of this industry. New technologies, automation and smart ideas on how to produce parts on modern machines will be the key to stay ahead in the competition. Not just reducing prices but working smart and efficient is important and need of the hour. The educational sector will, therefore, play a very important role. The institutes need to upgrade the training doled out to provide a suitable platform for new engineers to step into the manufacturing world well prepared. If institutes lack funds and operate with 30-year-old equipment, what level of knowledge can be passed on to the young engineers? The government will need to increase the spending to ensure institutes and training centres are upto-date so that engineers coming out to the industry have all the knowledge required. This will increase efficiency and manufacturing will be more cost effective and save more energy. Smart machines need smart operators. New technologies in machining will need to be utilised. New materials and designs will require new manufacturing methods.


AN N I VERS ARY

Market Trends ENERGY

ELOP V E D

MA N

PLA

TURE AC

UF

N AUTOMATED SOLUTIONS

PLM for the energy and utility industry Energy and utility companies incur huge capital expenses as they procure the resources and improvements needed by their supply chains. With Product Lifecycle Management (PLM), organisations can digitally manage a product’s complete lifecycle from concept to retirement, gaining a higher business value from the product as a result.

D

emographic change, resource scarcity and an increasing focus on environmental protection by leading nations are three of the largest trends affecting the energy and utilities industry. These opposing dynamics place enormous pressures on companies engaged in this industry. In order to explore, find and leverage this planet’s hydrocarbon, air, wind, geothermal, ocean and solar resources, innovation is required on a scale that has never been attempted before. 148 MODERN MACHINE TOOLS - October 2011

Challenges galore The challenge is to meet the industry’s current business needs without compromising the needs of future generations. A company’s teams are tasked with making complex decisions every day. But the company needs a structured and systematic way to harness the information, knowledge and new ideas that are dispersed across and beyond the enterprise. With this in mind, PLM software provides powerful innovation solutions to help you master these challenges while allowing them to sustain a pattern of predictable business growth.

The industry faces the overarching challenge of meeting today’s never ending global demand for energy while delivering its products in a safe, reliable and cost-effective manner. Innovation is essential for mastering these complexities and enabling the company to grow top line revenue, safely deliver products along their supply chain, connect globally distributed teams and ensures quality and regularity compliance with traceability to internal specifications. To address the needs of today’s targeted global markets, energy and

Courtesy: Siemens PLM Software

RT SUPPO


Market Trends utility companies must be able to efficiently manage the innovations that they initiate. These innovations will almost always require these companies to manage multiple processes, coordinate the participation of disparate disciplines and facilitate collaboration between their own operations and outside vendors. Management must have total visibility into the status of their innovation initiatives to facilitate accurate market alignment, reduce risks and provide on-time product delivery. In addition, managers need to be able to fully understand the impact of rising changes in order to identify potential bottlenecks before they pose insurmountable problems. Optimisation of the innovation process is essential for managing the risks that arise in a globally distributed business. Today’s energy customers demand a greater say over how much and what kind of energy they consume. So it is important for the companies to have a more close loop communication with their customers. Collaboration between the company and an informed customer base has the potential for profoundly impacting the shape of the industry. Therefore, it is increasingly important to understand the customer requirements. Energy and utility companies incur huge capital expenses as they procure the resources and improvements needed by their supply chains. Because many of these innovation projects are offschedule, off-budget or non-compliant with established specifications, profitability carries a risky price tag. A lifecycle collaboration solution is needed to enable the companies to squeeze inefficiencies out of one’s supply chain innovations. This solution should provide total visibility into all supply chain’s operational stages to ensure optimal performance and maximise profitability. A plethora of regulations govern the operations of this industry. In addition, economic and governmental pressures are driving one to find more 150 MODERN MACHINE TOOLS - October 2011

sustainable sources of energy. Changing regulations and compliance standards clearly affect the ability to meet these challenges. To facilitate sustainable business practice, one need a digital solution that comprehensively manages regulatory compliance while enabling one to meet long term sustainability goals.

Innovation lifecycle for energy and utilities PLM Software’s digital platform for the energy and utilities industry delivers a single source of plant, product and process information that can be used to manage the innovation lifecycle across all its stages.

PLM benefits for energy and utilities companies Manage risk Risk management is key to ensure that costs remain low. Bringing innovations rapidly to market enables a company to establish brand leadership and a higher price point ahead of their competitors. Increase profitable growth The key to profitable growth is to keep costs low and accelerating project delivery while meeting project specifications. Cost reduction Concurrent product and production design leads to lower material and operating costs. In addition, rationalising specifications on a global basis reduces complexity and further decreases cost. Extended returns In an industry where the lifecycle of a product or plant can last for 60 years, it is imperative that owners/operators have a platform to ensure the safe operation and maintenance of their long life assets Re-use best practices Companies can leverage PLM’s digital deployment capabilities to and rapidly replicate successful business processes

across their disparate geographies, business units and supply chains.

Deliver the right product and deliver the product right The PLM platform and related solutions address the challenges by providing total visibility into the workflow and decision making process that empowers every stage of the business lifecycle. So PLM provides opportunities for a company to:  Maximise innovation throughout the business  Transform the company’s decision making process  Increase the value of the enterprise business knowledge  Minimise lifecycle cost With the energy and utilities industry at a cross roads, the demand is expected to double in just the next 20 years alone. This will place a tremendous pressure on the industry’s infrastructure and supply chain resources. Innovation on a scale not previously seen in this industry will be required to meet the needs. Successful innovation requires open technologies that enable you to access all your enterprise’s knowledge resources, facilitate seamless collaboration both inside and outside one’s organisational borders and instill discipline across all of one’s operations. A PLM software solutions company like Siemens PLM, can help the industry to master the complexities inherent in their business so that they can safely deliver the right product and deliver the product right. PLM solutions for the energy and utilities industry include a complete set of end-to-end applications that accelerate new product and processes that improve productivity, lower operational risks and facilitate environmental and safety compliance. With these solutions, energy and utility companies can connect people and processes – creating, capturing and sharing knowledge across their globally distributed value chain to power innovation and productivity. Courtesy: Siemens PLM Software


AN N I VERS ARY

Practical Tips ENERGY

INDIAN ENERGY SECTOR

Making a ‘power’ful nation Various modes of energy producers like wind, solar, nuclear, oil & gas are witnessing a huge demand in India and planning to increase their capacity. Looking at the growth of Indian energy sector, companies will be sourcing components from local manufacturers. Now, the time has come for Indian machine tool builders to grab the growing opportunities and the make most of them. Nishant Kashyap

&1

tips

tricks

&2

tips

tricks

Increase R&D investment: Innovation starts from a constant desire to be out front, exploring new territories, striking out in new directions. R&D has become the pillar of success, which has forced companies from all sectors to increase investment in this area. Indian machine tool manufacturer have also realised the importance and are investing on R&D, but

still need to fill the gap. With India is on its way to become a global manufacturing hub, machine tool manufacturer, too, need to invest spend more in R&D to provide best technology to the customers. The investment in this field would determine Indian machine tool manufacturer’s competitiveness as compared to other developed countries.

Work on T&D: Human capital is one of the most vital assets in any organisation for its efficient and effective functioning. As a result, companies are increasingly interested in Training & Developing (T&D) to attain competitive advantage and drive company’s value. Introducing training and

development processes in metalworking industry is significantly and positively associated with immediate operation benefits. This is so because companies have come to understand that the investment in human capital is the key to the success of company’s economic growth.

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Practical Tips

&3 &4 &5 &6 &7 &8

tips

tricks tips tricks tips tricks tips tricks

tips

tricks

tips

tricks

Design and development: In a fast-changing marketplace, developers and designers need access to the latest technologies to remain competitive and win new business. Investing in design and development helps companies effectively develop,

design and test new products and solutions. The product must appeal to its users at different levels such as function, usability, cost, reliability, etc. This is why it is important to study the design problem so carefully.

Extra marketing effort: The marketing plan is used as a tool by organisations to check whether the strategies that have been put into record are being implemented. It also works as a tool to determine or measure the performance of

certain product or service. Since many machine tool manufacturers have setup their base in the country, it becomes very important for companies to put extra effort in marketing and make the presence in the market.

Global collaboration: One of the attributes that makes Indian companies so effective in serving many of the world’s technology needs, is its willingness to collaborate. As the machine tool manufacturer began to take root in India, some global companies explored opportunities of collaboration with Indian company, which not

only helped them gaining foothold in the country, but also was beneficial for their Indian counterpart in terms of technological advancement and global reorganisation. Collaboration with global players will be helpful for Indian machine tool builder in terms of technological advancement and explore the opportunities worldwide.

After sales service: When a customer makes repeat purchase of products or services from a company, it shows his loyalty towards it. This happens only when a product or a service delivers consistent value for the money spent by the customers. After sales service helps in keeping the customers satisfied. Customer service promotes proper

communication of customers needs and wants to the product or service provider. This helps the companies to know what their customers want and expect from them. Thus, they can offer their customers products that will meet their requirements.

Technology upgradation: Technology upgradation is a continuous process in the energy sector, which helps the companies to get recognised in the market. Liberalisation of industrial policies and deregulation of controls have led to greater competition from both the domestic as well as international companies. This has reinforced the need for technology upgradation to attain

international levels of competitiveness and to be able to offer contemporary levels of technology. The demands of the user sectors play an important role in selection of technologies and introduction of new products. In order to meet these objectives, the need to put development effort towards the technology upgradation is the need of the hour.

Networking: In this rapidly growing world of business when customers have become more demanding and competition has increased, one has to be willing to network. Networking can help companies improve their business performance, products and staff skills. It can also help them develop knowledge and skills and update in current industry scenario.

For machine tool builder, it becomes very important to network with the companies from energy sector in exhibitions, conference and seminars. Networking with the respective sector will help them to know about their demands, which also help them to increase their presence in the industry and increase market capitalism.

158 MODERN MACHINE TOOLS - October 2011


AN N I VERS ARY

Future Forecast ENERGY

ENERGISING THE NATION

Fuelling sustainable growth Ever since the process of liberalisation which was initiated by the Government of India in 1991, there has been global interest in India’s energy sector. Being one of the fastest growing economies in the world, India is witnessing growing energy demand that is being fueled by an ever-increasing rate of industrialisation. Nishant Kashyap

I

ndia’s enormous potential for energy production and consumption has enhanced investment prospects in this field. The opening up of this sector to global players have created immense opportunities for investments. Today, the country has lot of promise as far as renewable energy is concerned. There is a significant potential in India for generation of power from renewable energy sources like wind turbine, hydro power, biomass and solar energy. India is the world’s fifth largest producer of wind power after Denmark, Germany, Spain, and the USA. The wind energy sector has great potential to grow in the country along with other renewable source like solar, biomass and hydropower. 160 MODERN MACHINE TOOLS - October 2011

Demand drivers

Government initiatives

The key demand driver for the energy industry is rapid growth in manufacturing sector and robust residential consumption. The recent shift in dependence on renewable energy sources offers economic, social and environmental benefits, will increase the demand for renewable energy in the country. McKinsey&Company’s analysis suggests that if India continues to grow at an average rate of 8 per cent for next ten years, country’s power demand is likely to climb from around 120 GW at present to 315 – 335 GW by 2017, 100 GW higher than the current estimates. To meet this demand, the country will require a five-fold to ten-fold increase in pace of capacity addition.

Government initiatives like concessional import duty on specified wind turbine parts, 80 per cent accelerated depreciation in the first year, excise duty reliefs, etc will further help country’s energy sector and attract global players to setup base here. As on March 2011, 14157 MW wind energy has been installed. The Ministry of New and Renewable Energy (MNRE) is aiming to have additional 6,000 MW of wind power capacity installed by 2012. Moreover, companies as well as individuals will get tax breaks for investing in green energy, especially wind farms. The noticeable fact is that coal, oil & gas will continue to be the predominant form of energy in future. However, renewable source will register an exponential growth in coming decade.


INFRASTRUCTURE Industry Insights Building blocks: A strong backbone of a developing nation....................................... 162 Interface Ramesh Chandak President and Chief Executive Officer, Infrastructure Sector, KEC International... 164 Market Trends Infrastructure insight: Developing a sustainable future ............... 172 Practical Tips Infrastructure development: Cementing future success ......................... 174 Future Forecast Indian infrastructure: Creating an ecosystem of growth............. 178

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AN N I VERS ARY

Industry Insights INFRASTRUCTURE

BUILDING BLOCKS

A strong backbone of a developing nation The fast growth of the economy in recent years has placed increasing stress on infrastructure such as electricity, railways, roads, ports, airports, irrigation, urban & rural water supply and sanitation. High transactions costs arising from inadequate and inefficient infrastructure can prevent the economy from realising its full growth potential, regardless of the progress achieved by other sectors. Swapnil Pillai

I

nfrastructure is an important component for industrial and overall economic development of a nation. It is considered as the yardstick to measure the investment viability of a nation. In India, there is a wide gap between the potential demand for infrastructure and the available supply. To minimise this gap, an investment of around $ 445 billion is required over the next five years. It will also have to grow at a Compounded Annual Growth Rate (CAGR) of 15 per cent over the next five years to support the growing 162 MODERN MACHINE TOOLS - October 2011

requirements of every other sector of the economy.

Current scenario India has a good network of rail, road, coastal shipping, and air transport. It has one of the largest road networks in the world. In terms of rail, the country has a broad network of railroad lines measuring around 63,000 km out of which 13,000 km is electrified. There are major ports in Kolkata, Mumbai, Chennai, Vishakhapatnam, and Goa which handle about 90 per cent of sea-borne trade. When it comes to air

transport, a comprehensive network of air routes connect the major cities and towns of the country. But the present infrastructure setup is insufficient to meet the growing requirements of the country and this has initiated huge investments in brownfield and greenfield infrastructure projects. The country currently has only 12 per cent of the national highways that are four-laned. This is quite dismal considering the fact that roads carry about 70 per cent of the freight and about 85 per cent of passenger traffic. The Indian rail network carries around 14 million passengers and


Industry Insights Infrastructure: Deficit and Eleventh Plan physical targets Sector

Deficit

Eleventh Plan Targets

Roads/Highways

65590 km of NH comprise only 2 per cent of network; carry 40 per cent of traffic; 12 per cent 4-laned; 50 per cent 2-laned; and 38 per cent single-laned

6-lane 6500 km in Golden Quadilateral; 4-lane 6736 km NS-EW; 4-lane 20000 km; 2-lane 20000 km; 1000 km Expressway

Ports

Inadequate berths and rail/road connectivity

New capacity: 485 m MT in major ports; 345 m MT in minor ports

Airports

Inadequate runways, aircraft handling capacity, Modernise 4 metro and 35 non-metro airports; parking space and terminal buildings 3 greenfield in NER; 7 other greenfield airports

Railways

Old technology; saturated routes; slow speeds (freight: 22 kmph; passengers: 50 kmph); low payload to tare ratio (2.5)

8132 km new rail; 7148 km gauge conversion; modernise 22 stations; dedicated freight corridors

Power

13.8 per cent peaking deficit; 9.6 per cent energy shortage; 40 per cent transmission and distribution losses; absence of competition

Add 78577 MW; access to all rural households

Source: Eleventh Five Year Plan, Government of India

1.5 million tonne of freight daily. The countries major airports which account for 65-75 per cent of passenger traffic need urgent expansions to meet the increasing influx of passenger and cargo traffic. Similarly, energy production of the country is far behind the industrial and household needs.

Growth avenues The expansion and maintenance of existing facilities mandates consistent and huge investment into the sector. Public sector plays a dominant role in building infrastructure. However, the total resources to meet the deficit in infrastructure exceed the capacity of the public sector. It is, therefore, necessary to attract private investment through appropriate forms of Public-Private Partnerships (PPP). The twin objectives of accelerating urban infrastructure investments and quickly scaling-up new performance-based management models can be achieved through well conceived, structured and transparentlyexecuted PPP. The encouragement of PPP has created a positive impact on the inflow of foreign capital into the country. According to a World Bank report, India is amongst the top ten

developing countries to receive private participation in infrastructure projects. Major investments like increasing the rural infrastructure development fund corpus to ` 18,000 crore from ` 16,000 crore and setting up a corpus of ` 2,000 crore for creating additional warehousing capacity have been initiated. Similarly, the Foreign Institutional Investment (FII) limit in corporate bonds in infrastructure has been raised. The government will also issue tax free bonds of ` 30,000 crore for infrastructure development. There are targets set for various infrastructure sectors to address the gaps in quantity and quality. These strategies would entail strengthening and consolidating infrastructure-related initiatives, such as Bharat Nirman for building rural infrastructure, and sectoral initiatives such as the Rajiv Gandhi Grameen Vikas Yojayana (RGGVY), Accelerated Power Development and Reform Programme (APDRP), Accelerated Irrigation Benefit Programme (AIBP), National Highway Development Programme (NHDP), National Maritime Development Programme (NMDP) and the Jawaharlal Nehru National Urban Renewal Mission (JNNURM).

Roadblocks The Indian infrastructure suffers from a substantial deficit in terms of capacities as well as efficiencies in the delivery of critical infrastructure services. Supply bottlenecks of the critical infrastructure services can severely hamper growth and development. The absence of strong long-term debt market and corporate bond market is a major drawback. The only sources of funding for the project are the banks that charge very high interest rate. The required investment in infrastructure would be possible only if there is a substantial expansion in internal generation and extra budgetary resources of public sector, in addition to significant rise in private investment. There is a need to create a more attractive business climate for private investment. Liberalising financing guidelines and increased access to international debt markets and development of corporate debt market will help the Indian infrastructure sector. Also, government approval and support in terms of land acquisition, regulatory and environment clearances are the other crucial areas that require urgent attention. October 2011 - MODERN MACHINE TOOLS 163


AN N I VERS ARY

Interface INFRASTRUCTURE

Indian machine tool industry and automation providers have an important role to play in the infrastructure sector ‌.avers Ramesh Chandak, President and Chief Executive Officer, Infrastructure Sector, KEC International. The billion dollar company has presence in power transmission, power systems and cables, railways, telecom and water. The company has powered infrastructure development in 45 countries across South Asia, Middle East, Africa, Central Asia and Americas. In an exclusive interaction with Swapnil Pillai, Chandak outlines the current state of the Indian infrastructure and the need of the hour.

Q What are your views on the

Q Over the years, what have

current state of the Indian infrastructure sector?

been the key trends in the infrastructure space in India?

The Indian infrastructure is traversing through one of its most interesting phases today. While the world over many economies is facing a slowdown in their economy, it is expected that India will continue to have a growth of over 7 per cent on a continuous basis. The infrastructure sector is pivotal for India to achieve its expected growth rate.

Firstly, with the Indian economy expected to maintain its Gross Domestic Product (GDP) growth rate, this will translate into the infrastructure sector also continuing to have consistent growth. Secondly, the government has set ambitious targets for the infrastructure sector. The Planning Commission envisions doubling the

164 MODERN MACHINE TOOLS - October 2011

investment in infrastructure sectors to $ 1 trillion (about ` 45, 00,000 crore) during the 12th Five-Year Plan.

Q What have been the key

growth drivers for the industry? Elaborate. In the Twelfth Five Year Plan, one expects to see one third investment from the private sector. The Public-Private Partnership (PPP) model will be a key growth driver. It will be a vehicle for


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MMT Oct-2011 Ad Name: Prakash Pg No.168

MMT Oct-2011 Ad Name: Prakash Pg No.168


Interface driving the infrastructure industry, be it in power, road, port, airport etc…. Most of the companies in the infrastructure space have indicated a good order book position which indicates strong revenue visibility in the near future. Please comment on issues and challenges facing the Indian infrastructure sector. There are several challenges that could affect growth for the sector, such as execution delays, delay in land acquisition, delays in securing environmental and other regulatory clearances, lack of long-term financing to support PPP projects and poor availability of skilled or trained labour. The power sector is plagued by delay in fuel linkages for generation and right of way issues in transmission. There is need for providing long-term debt for financing infrastructure projects that typically involve long gestation periods. Debt finance for such projects should be of a sufficient tenure that enables cost recovery across the project life. Indian capital markets, however, are deficient in long-term debt instruments.

Q In your views, what steps

should be undertaken by the government to address the issues affecting the infrastructure sector? Many of the challenges outlined are related to requirement of government approval and support in term of land acquisition, regulatory and environment clearances. The Land Acquisition Bill will soon come up in Parliament and should hopefully address the difficulties faced in land acquisition. Rapid clearance of key infrastructure projects needs to be fast-tracked. There is a need to reconcile existing infrastructure financing approaches with the country’s need for better governance and a more attractive business climate for private investment. Liberalising financing guidelines and increased access to international debt markets and development of corporate debt market will help the infrastructure sector. 170 MODERN MACHINE TOOLS - October 2011

Q Do you think that a

sustainable future can be developed while meeting the infrastructure needs of the country? Infrastructure development on a sustainable basis is imperative for India’s economic growth. When we talk of sustainable development in future, it must be environmentally and economically sustainable as well as all inclusive in the Indian context. Today, we are witnessing negative environmental impacts like climate change, resource degradation, pollution etc. To tackle these problems, we need to have cutting-edge, cost-effective and cleaner technologies adopted and investments should be inclusive so that even the poor people can participate in the growth process.

Q How can the Indian machine

tool industry and automation solution providers serve this sector efficiently? The Indian machine tool industry and automation providers have an important role to play in the infrastructure sector. They can develop solutions to achieve better quality with better safety standards. Higher accuracy and better interfaces are the trends that can help India along with intelligence and remote diagnostics that automation processes offers today. This must not be restricted to large manufacturers, but must be made possible by medium & smaller units as well. Today, the availability of skilled manpower is a constraint in the construction segment and if better technologies and automation requiring lesser manpower can be developed, it would be useful.

Q The Indian composite or

material sector is growing rapidly. How can the machine tool companies leverage this to serve the infrastructure sector? The material requirement of cement, structural, reinforced steel, stainless steel etc for the infrastructure sector

will be required in large volumes and these needs to be geared up in terms of capacity and available at competitive prices to cater to the demand of the industry.

Q How did the year 2010 pan

out for KEC International Ltd? What were some of the company’s major milestones? One of the major milestones for KEC was the acquisition of US-based SAE Towers, a leading manufacturer of steel lattice transmission towers in the USA with an annual production capacity of 100,000 metric tonnes. The acquisition of SAE Towers will strengthen KEC’s global leadership position in the large and growing markets of North America and Latin America. We have also acquired Jay Railway Projects which will enable us to undertake turn-key signaling contracts in the railway business. The year 2010 was good in terms of the order booking with the order book crossing the ` 8, 000 crore mark. We were awarded high value orders that we are in the process of executing. We also got a substation order in Kazakhstan worth ` 942 crore, tower supply order worth ` 735 crore from Canada; First 765 Kv order by state utility Rajasthan Rajya Vidyut Prasaran Nigam Ltd worth ` 313 crore.

Q Elaborate on your

future plans for the Indian market. We are executing a number of projects in diversified infrastructure segment of transmission, distribution, railways, telecom & water in India. More than 50 per cent of our order book is from India and this market is very important to us. While we have a leadership position in the power transmission segment, we are now focusing on the power distribution, railway and water infrastructure and want to become significant players in these segments.


AN N I VERS ARY

Market Trends INFRASTRUCTURE

INFRASTRUCTURE INSIGHT

Developing a sustainable future The Indian manufacturing sector is on its way to a promising future. The country is increasingly getting recognised for high value goods requiring a fair amount of engineering precision and quality. The machine tool sector is diversifying due to favourable market conditions, prompting global players to make substantial investment in the country. Parag Alekar

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ndia is aiming to increase the share of manufacturing in the country’s Gross Domestic Product (GDP) to 25 per cent by 2025 from the present 16 per cent. This is considering the present infrastructure requirement in the country. This indicates substantial potential for machine tool companies in 172 MODERN MACHINE TOOLS - October 2011

Infrastructure, to grow and expand business with the current surge in Indian economy. The manufacturing industry serving the infrastructure sector in India is believed to have the potential of improving the economic condition of the country. In an attempt to make India a manufacturing powerhouse, the government is mulling creation of

manufacturing hubs that will offer infrastructure, facilities and incentives to manufacturers.

Government initiatives The Department of Industrial Policy and Promotion (DIPP) has put on fast track the national manufacturing policy, which seeks to create National Manufacturing and Investment Zones


Market Trends Machines for the sector

power sector, construction machinery, etc are doing extremely well. Industries Technologies like special heads have been like BHEL, L&T-MHI, SIEMENS, developed for particular applications. etc are finding it difficult to cope with These heads can be used in combination the orders in hand and are investing on the machines through attachment to increase their capacities. Especially changers. For eg, Railway crossing is railways’ will continue growing if, a component made from manganese ministry starts releasing funds for steel. Heavy spindle power & machine increasing capacities which was planned construction is necessary for two years back. To cater to these demands in infrastructure, companies are The investing in new technology so as to reduce the machining time of the infrastructure deficit components resulting in increase Budget impact in India is so critical that in production. The universal With the Union Budget heads, high rapids, flexible projecting GDP to be it could prevent the country manufacturing solutions help ` 8980,860 crore in 2011-12, from achieving prosperity. in achieving this. the size of India’s economy is Proper knowledge related now poised to touch $ 2 trillion Without smooth transportation to available technology for this in near future. If one assumes network, reliable power and industry needs to be shared. Also the current exchange rate of the exact need of the industry ` 45 per US dollar to hold in water India’s potential for should be analysed, to provide more 2011-12, the size of the Indian growth can not be fully economical solutions to maintain economy would be $ 1,996 billion at quality. Also trained manpower is a dollar rates. But the budget estimate, utilised. must. More flexible & high productivity which assumes a 14 per cent growth in solutions are the need of this market. GDP at market prices, is likely to be an R&D should focus to upgrade the underestimate. available technology to satisfy this If one assumes a 9 per cent GDP requirement. growth, and assume an inflation rate machining of this component. Along with the heavy investment to of around 7 per cent, GDP at market But there are very few customers in the develop infrastructural facilities, the aim prices is more likely to grow at 16 per world who will buy machine only for should also be to improve the utilisation cent, which would ensure that the size machining of crossings. So, heads have rate and operational efficiency of India’s GDP would be ` 91,38,419 been developed which can be utilised of existing resources. The importance crore or $ 2,031 billion in 2011-12. for not only crossings, but also for other of infrastructure sector also follows But really impressive is the pace at components like bogie frames, railway from the fact that foreign investors which the size of the economy has switches, etc. Medium & large size are now looking at infrastructural doubled from $ 1 trillion to $ 2 trillion. machines with more flexibility needs to development as a yardstick for India’s GDP touched the first trillion be manufactured and promoted to this directing their investments. In India, in dollar terms in 2007-08, when the industry, which in turn can lead to low infrastructure sector itself is becoming size of the economy grew from $ 949 manufacturing costs maintaining high an attractive investment area for foreign billion in 2006-07 to $ 1,241 billion in standards of quality. direct investments. 2007-08. And now, in just four years, the economy is projected to touch Challenges ahead $ 2 trillion. The infrastructure deficit in India is so In a recent report, the United Nations critical that it could prevent the country Parag Alekar is CEO Industrial Development Organisation from achieving the prosperity that finally of Nicolas Correa SA India Branch. He is an (UNIDO) has put India among the top seems to be within its grasp. Without engineering graduate, 10 manufacturing nations in the world. smooth transportation network, reliable having experience of more The report, however, pointed out that power and water India’s potential for than 18 years in machine India’s production was far less efficient growth can not be fully utilised. tool industry. than that of other leading manufacturers Presently considering the industrial Email: p.alekar@correaanayak.es such as Japan. growth, industries working for railways, (NMIZs). Spread over 2,000 hectare, or about 8 sq km, these zones will be in line with the model adopted by China to boost its manufacturing sector. The DIPP is seeking sops such as tax incentives, flexible labour laws and easier exit norms for foreign investors and refinance facility for overseas debt for these zones. The government hopes to get around the land issue through state procurement, unlike in case of special economic zones where companies are required to buy land on their own.

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Practical Tips INFRASTRUCTURE

INFRASTRUCTURE DEVELOPMENT

Cementing future success Infrastructure development has a crucial role to play for India to sustain its growth, which must become more inclusive as the country matures. Considering the present state of the Indian infrastructure, the manufacturing industry working for this sector is believed to have immense potential to grow. For this potential to be realised, the machine tool companies need to adopt the best practices available globally to stay on top of the business and serve the industry efficiently. Swapnil Pillai

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Investing in R&D: Research and development (R&D) is a process intended to create improved technology that can provide a competitive advantage at the business or industry level. The process through which R&D promotes economic prosperity is complex and multi-faceted. There are direct benefits to companies from their R&D investments. Also, other companies derive

benefits from R&D of the innovating company. The feedback from R&D improves products, processes, and distribution networks. Investing in R&D provides competitive advantage while meeting customer requirements. It also facilitates entry into new markets and increases the revenue. It enhances brand value and the company gains the reputation of being innovative.

Imparting proper training: Training for a manufacturing job is extremely important, and so is retraining. Being employed in the manufacturing industry can necessitate working in various areas that are going to require special skills and knowledge. If proper training is not

imparted to employees, they will be unable to do the job safely or correctly. Proper Training will make them more valuable to the organisation. It will create more valuable employees who will have the experience and training needed to be promoted from within the company.

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Practical Tips

&3 &4 &5 &6 &7 &8

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Enhancing brand visibility: Isolating the business from competition and restricting it only to the existing customers can be unhealthy. It can deprive the company from valuable industry information that can hinder progress. Participating in industrial trade show and exhibitions will broaden the understanding of fellow competitors, learning

their strengths and weaknesses. With all this newly attained information, companies can stay on top and plan the future strategies accordingly. Also a good portion of the target audience learns about new products to be launched. The second gain is through the direct sales that happen at these trade shows.

Introducing project management: The Indian machine tools industry needs to invest heavily in project management because of quality of out put and the time to the market are two deciding factors for achieving success. Project management is a competency that leaders can use in their organisations to handle increasing complexity with higher success rates and acceptance, and lower uncertainty

and costs. Project management also differs from traditional management in that it brings in cross-functional collaboration, governance, execution-discipline, responsiveness and alignment of organisational elements and procedures with features of end-products of projects. It can help companies to bring in agility in innovation, growth and response to changes in the external environment.

Technology collaboration: The Indian machine tool companies should enter into technical collaboration with the leading machine tool companies of the world so that machines of global standards are available in India at lower and competitive price. Companies can remain in the forefront of supplying leading

technology to the end user by collaborating with industry leaders in the control technology, software development and machine design areas. The collaboration can also include activities that may like production, purchasing and the development of machines, as well as sales and services.

Developing portable machine tools: Portable machine tools which are easy to assemble, set up, and operate, and have the power to remove material quickly are finding wider application in the infrastructure industry. They can also

be utilised to correct problems which occur during the development phase of infrastructure projects. Machine tool manufacturers in the country should focus on developing such portable solutions.

Implementing IT in manufacturing: Information Technology (IT) plays a crucial role in modern day business. It ensures the smooth functioning of all the departments in a company such as the human resource, finance, and the critical manufacturing

department of the company. With the help of information technology, the company can get rid of any sort of errors or mistakes in the proper functioning of the tools used for designing and manufacturing purposes.

Well defined strategies: The machine tool companies should develop its marketing abilities in line with other sectors of the capital goods industry. To be successful, companies should have strategic planning programmes in place and have well chalked out business strategies at all levels. In order to enhance

their market share, companies need to improve quality and service followed by reduction in costs, increase in product range and finally adopt more aggressive marketing strategies. The competitive edge lies in satisfying customers by delivering higher quality products at lower prices.

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AN N I VERS ARY

Future Forecast INFRASTRUCTURE

INDIAN INFRASTRUCTURE

Creating an ecosystem of growth With the advent of India as a major commercial and cultural hub in South East Asia, pressure has been mounting on the government to develop world class infrastructure. Until recently, India had been creating infrastructural facilities at snail’s pace mainly by employing public resources. But an accelerated economic growth can be maintained only when India builds infrastructure at a faster rate. Swapnil Pillai

T

he existence and growth of market, abundant resources and global competitiveness has driven investment opportunities in the country.

Growth Trajectory Water, transport, housing, electricity, health & sanitation and education are some of the areas that have immense potential for improvement. A recent India Infrastructure Report estimates the annual investment need for urban water supply, sanitation and roads to be about $ 6.67 billion in the next ten years. The goods traffic in the country is expected to rise by 15 per cent per annum by the year 2015.

Investment opportunities A well-knit and coordinated system of infrastructure plays an important role in the sustained economic growth of the country. Developing sustainable infrastructure would require huge 178 MODERN MACHINE TOOLS - October 2011

investments and thoughtful planning. To ease the pressure on the existing resources, the government has initiated various programmes to upgrade the existing infrastructure. Under the Rajiv Gandhi Grameen Vidyutikaran Yojna (RGGVY), additional power generation capacity of about 90,000 MW would be added to provide electricity to rural households. Similarly upgrading and developing major road projects like the Golden Quadrilateral, North-South and EastWest Corridors, developing 1000 km of expressways, constructing 1, 65244 km of new rural roads, and renewing and upgrading existing 1,92464 km are in various stages of execution. The rail ministry plans to construct dedicated freight corridors between Mumbai-Delhi and Ludhiana-Kolkata. It also plans to construct 10,300 km of new railway lines, modernise and redevelop 21 railway stations and build metro rails in all the major cities of

the country. All these would further strengthen and widen the reach of one of the world’s largest and most reliable rail networks. To optimise the potential of India’s huge coastline, additional capacity of 485 million Metric Tonne (MT) in major ports and 345 million MT in minor ports have been planned. The Indian airports have witnessed huge passenger traffic in the recent years. Substantial investment is required to make the airport ecosystem strong and reliable. On a priority basis, four metro and 35 non-metro airports have to be modernised and redeveloped. There is need for seven new airports along with training, maintenance repair & overhaul facilities. The creation of world-class infrastructure would require large investments in addressing the deficit in quality and quantity. With well planned and properly monitored investments, India’s infrastructure would equal the best in the world.


MEDICAL Industry Insights Medical machining: Scaling new heights .... 182 Interface Rafiq Somani Area Vice President, PTC India ..................................................... 188 Market Trends Medical marvel: Risk management in medical devices .......................................... 194 Practical Tips Tech edge: Need for micro-precision strategies......... 197 Future Forecast Medical applications: The hen with golden eggs ........................ 200

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Industry Insights MEDICAL

MEDICAL MACHINING

Scaling new heights Medical parts manufacturing is a rapidly growing market. The high demand for medical procedures, including joint replacements, heart catheterisations, abdominal surgery, liposuction, colonoscopies, etc has generated an increased need for precision instrumentation. These have given rise to opportunities for machine tool manufacturers to cater to this emerging sector. Hema Yadav

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achining of medical parts or devices is different and more complicated than any other sector as it requires precision at micro level. Reliability and quality are critical in the medical instruments industry. Therefore, manufactures of these precision instruments are focused on finding quality products that will streamline costs and efficiency without forfeiting quality. Component machining for the ultimate machine, the human body, involves high-grade stainless steels, titanium and chrome alloys and demands 182 MODERN MACHINE TOOLS - October 2011

for qualified application solutions and sound cutting tool engineering. When tapping medical parts, two words are critical: small and challenging. Small is for the tiny size of many medical parts and challenging is for the difficult-tomachine materials from which the parts are often made. Developing strategies for tapping medical parts, involves many factors, including the cutting tool geometry, machine capability, tool-holder, metalworking fluid and the parts themselves. Medical parts that are tapped include implants, such as hip and knee replacements and surgical instruments. The medical device

segments that are expected to have high growth include:  Implantable devices like pacemakers, drug pumps, stents and joint replacements  Diagnostic testing devices, including clinical blood, urine and tissue testing  Home healthcare products and electronic monitoring devices

Computer controlled machining As the population ages, more joints are being replaced. Orthopaedic devices for joint replacements are benefiting from new materials, including metallic


Industry Insights alloys, ceramics and biocompatible plastics. New coating materials and application technologies that improve orthopaedic device performance and longevity are also improving patient outcomes. Manufacturing processes for these devices are now being automated through the use of CAD/CAM systems that communicate with CNC milling and grinding machines as well as 5-axis Electronic Discharge Machines (EDM). These are used for production of medical devices such as orthopedic implants, which are made of conductive metals, like stainless steel and titanium. EDM uses an electric arc to sculpt intricate geometries on conductive materials to a dimensional accuracy to the order of ± 0.0001 inch. Widely viewed as a reliable and precise machining technology, EDM provides burr-free, multi-axis machining of parts that, because of hardness or shape, may be difficult or impossible to machine by other methods. Other manufacturing technologies that are used for micro-sized components used in the medical device industry include:  CNC milling, which uses computercontrolled cutting tools to sculpt materials to tolerances of ± 0.0002 in.  Metal injection moulding, which produces complex shapes, multiple wall thicknesses and surface detailing in a single component to tolerances of ± 0.004 in.  Photochemical etching, which creates 2-D profile geometry on thin, flat parts to tolerances of ± 0.001 in. on materials that may be as thin as 0.002 in.  Precision metal stamping, for producing complex shapes and intricate geometry through a series of stations in a progressive die to tolerances of ± 0.001 in, at speeds of hundreds of parts per minute.  Swiss screw machining, for production of seamless cylindrical components with capability for cross-drilling and slotting. 184 MODERN MACHINE TOOLS - October 2011

Market share commanded by three top verticals



Diagnostic testing device: In 2007 the testing device market was valued at $ 34 billion in sales. It currently represent about 10 per cent of the total worldwide market for medical devices. The fastest growing segment within diagnostic testing is In-Vitro Diagnostics (IVD).



Ophthalmic devices: Representing over $ 17 billion in annual revenues globally, this segment is expected to continue growing because of the increased incidence of eye diseases, such as glaucoma and macular degeneration in an aging population.



Home health and remote patient monitoring: Currently a $ 5.6 billion segment, it is forecast to grow at close to 70 per cent annually for the next several years. Devices for monitoring chronic diseases, such as blood glucose testing for diabetics, as well as screening devices, such as pregnancy and fertility tests, are included in this category.

High growth drivers High-tech medical products addressing health issues in aging population is touted to be a big revenue generator for the future. Manufacturers and suppliers of lower-tech products to hospitals, outpatient centres, and other medical facilities might witness slow growth as these products tend to be vulnerable to flat health insurance reimbursement rates that restrict purchases and profit margins. Device segments that are expected to have high growth include:  Implantable devices, such as pacemakers, drug pumps, stents, and joint replacements as well as devices related to minimally-invasive surgery  Diagnostic testing devices, such as those used for blood, tissue and genetic testing as well as optical devices for glaucoma and macular degeneration screening  Home healthcare products, such as diabetic tests, liver function tests, and electronic monitoring devices

International competition Till now, the US looms big in the field of medical machining. Its close competitors include Germany, Japan, the Netherlands and Italy in high technology products. It is interesting to know that most of these foreign companies manufacture a significant

amount of their products in the USA. However, with the recent economic global downturn and a recent scare in world markets, these high-quality, highpriced nations are being challenged by numerous lower-cost producers in China, Brazil, Korea, Taiwan and India, countries which are building up their domestic industries and also compete globally. Also aiding India in its quest for gaining dominance in this field is medical tourism. The country is a hotspot for cheap but qualitative medical procedures. According to a study by McKinsey and the Confederation of Indian Industry, medical tourism in India could become a $1 billion business by 2012. The report predicts that, “By 2012, if medical tourism were to reach 25 per cent of revenues of private upmarket players, up to ` 10,000 crore will be added to the revenues of these players.” According to government estimates, India’s $ 17-billion-a-year healthcare industry could grow 13 per cent in each of the next six years, boosted by medical tourism, which industry watchers say is growing at 30 per cent annually. Close competition is faced by countries such as Greece, South Africa, Jordan, Malaysia, Philippines and Singapore. Powered by the above, the scope for Indian manufacturers in this field is immense.


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Interface MEDICAL

Photo by: Joshua Navalkar

The technology adoption in medical manufacturing in India has been consistent ...states Rafiq Somani, Area Vice President, PTC India, one of the world’s largest and fastestgrowing software companies. Discussing the potential of Product Lifecycle Management (PLM) solutions in medical device industry with Hema Yadav, Somani highlights the potential in the field and the importance of software solutions in achieving the required levels of precision.

Q How has CAD/CAM/PLM

Q What are the specific

evolved in the use of medical machining?

requirements and needs in medical machining?

With the surge in the demand for innovation, complying with strict environmental and regulatory requirements, shrinking price premiums, and the intense competition which demands faster times-to-market, medical device manufacturers are confronting some extremely tough challenge. The complexity of today’s products and the rise of outsourcing have made design solutions like CAD and PLM solutions systems and the management of data and knowledge critical to medical machining.

To facilitate compliance, medical device manufacturers today need a truly closed-loop, integrated change control and quality management system, which will help ensure proper traceability between quality events and engineering activities such as engineering changes and risk assessments. By substituting disparate, standalone product development applications with a cohesive product development system, manufacturers can ensure that the right version of the product data is available to the right people at the right time.

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This efficient and convenient storage of product information, coupled with the ease of its retrieval, and the ability to better manage changing information, are few of the advantages of an integrated platform for product development and quality.

Q As the field of medical machining

is quite niche, how do you foresee its growth in India? We foresee an optimistic growth of medical machining industry in India. The medical devices market continues to grow, driven by the aging population in India and technological innovations in diagnostic and therapeutic medical devices. The present lifestyle and the


Interface increase in the aging population has made people vulnerable to a number of diseases. To assist the populace to lead a healthy life and to increase the longevity, the medical machining industry is highly depending on the application technologies that has significantly improved the performance of the medical devices. Manufacturing processes for these devices are now being automated through the use of CAD/CAM systems. Computer-based manufacturing and design manufacturing industry facilitate the medical device manufacturers to test, design and produce different devices. These systems also maintain documentation history that the regulatory authorities can refer to. CAD solutions like Creo, that are compatible with the equipment, are one of the most sought after software which helps in improving the over all economic efficiencies through reduced inventory requirements, production errors and also reduce time to market.

Q Where does India stand

compared to its global counterparts in terms of technology adoption ? The technology adoption in medical manufacturing in India has been consistent, but slow, largely due to the dominance of developed countries in this space. Having said that, India definitely is the R&D hub for this sector, and most of technology being adopted globally in this space, is developed in India. The Indian government has put in significant effort in last 50 years to develop the scientific and technical infrastructure of the country. The combination of state-of-the-art infrastructure and highly qualified manpower ensures that India is poised to be the global R&D hub for medical machining. This is increasingly being observed in industry as large MNCs have opened their R&D centres in India – a first outside the United States for most of these companies. For example, Jack Welch Research Centre in

Bengaluru is conducting research for GE Medical Systems. It is the company’s largest research outfit outside the United States.

Q How is the business

outlook for machine tool manufacturers catering to this sector? The last 50 years have seen a consistent growth in medical device technology, making this industry, one of the fastest growing customer groups across the globe. The composition of the industry changed during the 1990s as a result of consolidation and foreign investment in US machine tool companies. With the global economic expansion since 2000, the machine tool industry has enjoyed an increase in exports due to the benefit of a falling US dollar. In spite of being an industry with moderate concentration, the business outlook for machine tool manufacturers catering to medical device industry, is definitely looking good.

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Interface Q What are the challenges in

medical machining and how can manufacturers tackle them? Some of the challenges that manufacturers of medical machinery face are listed below – Penetration of new markets: As medical device manufacturers introduce products into new markets, it’s critical that they receive the marketing support of local doctors and scientists, particularly in the case of personal health care devices. For example, in the area of medical diagnostics such as blood glucose measurement, technology has moved from specialist hospital labs to the hands of the patient. Over time, devices like the blood glucose meter, heart rate monitors, pedometers, etc., have become commodity products in many markets. Often, however, medical device manufacturers who are not from the same geography don’t have access to local doctors, scientists, and patient communities. However, outsourcing

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partners have easy access to these communities and are able to bring them together to influence new buyers, thereby benefiting the manufacturer. Access to these new communities creates a larger pool of influencers and support for the product, providing more marketing mileage. Region and race specific disease isolations: In India and other South Asian countries, disease physiologies related to the heart and diabetes are different from those in the US or Europe. Understanding these intricacies requires knowledge related to local culture, food habits, genetic makeup, etc, which can present a challenge to foreign medical device manufacturers. Collaboration with local researchers and the scientific community can produce demographics and profiling related to local communities. This data can help improve the design of equipment and its diagnostics capabilities. Local partners can help manufacturers participate in conducting clinical trials with new technology.

If the trial is race or region specific, they can participate together in global staging of trials and market launches (also validating the technology). Software as a differentiator in medical devices: Software is becoming one of the key differentiators for medical device manufacturers as software is more adaptable and easily customisable. The ease and speed at which software applications can be changed for different use cases, prototyped, and readied is far superior when compared to hardware. In addition, one of the larger challenges faced by manufacturers these days are the distributed team structures. In the new, global workplace, teams involved in the manufacturing process, work from various parts of the world. It is important for manufacturing organizations to have a seamless solution to ensure that every team that is a part of the process has access to most updated data from various teams. This makes PLM adoption very critical in manufacturing.


AN N I VERS ARY

Market Trends MEDICAL

MEDICAL MARVEL

Risk management in medical devices In the design and development of safe, effective medical devices, reducing risks and ensuring reliability are a manufacturer’s primary responsibilities. Not only are these dimensions of product quality mandated by agencies and organisations such as the Federal Food and Drug Administration (FDA), Centre for Devices and Radiological Health (CDRH), and recommended as best practices by the Global Harmonisation Task Force (GHTF) and International Organisation for Standardisation (ISO), product quality and efficacy are the moral and ethical imperative of all medical device manufacturers.

D

ue to the significant impact that a new medical device technology can have on human lives, every aspect of its development – from design and prototyping through manufacture, distribution, disposal and decommissioning – must adhere to strict quality standards that are documented and traceable to functional and safety requirements. These standards may 194 MODERN MACHINE TOOLS - October 2011

apply not only to manufacturers, but also to vendors, suppliers, contractors, Original Equipment Manufacturers (OEMs), third parties, and others in product development and distribution. According to various regulations, each of these complex dimensions of medical device safety and reliability must be systematically analysed in an accurate, documented fashion. When risks are discovered, they

must be evaluated for their severity and probability of occurrence, and eliminated or mitigated as appropriate. Then, medical devices must be monitored throughout their useful lives to ensure that no new or unexpected risks arise; and, if they do, additional risk analysis and control measures must be implemented. Methods for risk analysis and risk control often vary by company, device type and application,


Market Trends but all methods must address the standards and manufacturers must fully document compliance measures. Finally, because the ramifications of not strictly adhering to these regulations can include serious legal and ethical liabilities, medical device manufacturers must have the tools in place to accurately and efficiently manage the risks associated with their products.

Dimensions of medical device risk Assessing and reducing the risks associated with medical devices also helps to reduce the total impact of wide-ranging product recalls, including financial costs as well as reduced customer satisfaction and a damaged company reputation. Most importantly, companies are morally and ethically obligated to know the impact that a product will have on human safety and wellbeing before the product is released to the public. Several commonly used analysis techniques address the risk management requirements of medical

device systems. These methods are used to identify, analyse, control and monitor medical device safety and risks across the product lifecycle.

Methods to evaluate and mitigate sources of risk When tracing the possible risks inherent in medical device software or systems, Failure Modes and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) are often used.  FMEA: An FMEA is a bottom-up analysis method used to identify each potential failure mode for all of the parts in a system and traces these effects up through the system’s hierarchy to identify negative effects at the subassembly, assembly, and system levels  FTA: An FTA is a top-down analysis method, wherein the undesirable end event is identified first and all contributing factors or events are identified next to determine which component or process failures are most critical

When part failures contribute to system risks To evaluate and mitigate part failures that contribute to risks, reliability prediction analysis and advanced system modeling techniques are often used:  Reliability prediction: During a reliability prediction analysis, the likely failure rate of a system may be predicted in the design phase. Reliability prediction establishes system performance metrics using information about the parts that comprise the system. This part information is gleaned from extensive libraries of electronic and non-electronic components and how they react to various environmental stresses. Reliability prediction can also provide insight into alternative, more reliable system designs through trade-off studies that analyse the effects of alternate part designs on overall system reliability.  Advanced system modeling: When more complex systems are analysed for reliability, advanced system

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Market Trends modeling techniques, including Reliability Block Diagrams (RBDs) and optimisation and simulation analyses are used to model and predict system behaviour. Complex system designs supporting parallel redundancy or part dependency can demonstrate improved reliability, helping to mitigate risks due to system failures.

Using an FMEA process An FMEA is a systematic method for identif ying all of the potential failures throughout a system and developing controls to minimise or prevent their occurrence or effects. An FMEA is a bottom-up approach that identifies each failure mode, beginning with the lowest-level components in the system, and examines the effects of their failures on higher levels of the system. In this way, an FMEA can trace the end effects of part failures through to system-level failure and the risks or hazards it can cause. An FMEA can also include an analysis of

196 MODERN MACHINE TOOLS - October 2011

the criticality of each failure mode; an analysis method often referred to as an Failure Mode, Effects, and Criticality Analysis (FMECA) whereby potential failure modes are classified according to their severity y or risk. FMEA is an extremely flexible analysis tool, as it may apply to the product itself or to the process of using the medical device. Its flexibility makes this method ideal for meeting the standards imposed by medical device regulations.

Using fault tree analysis Using a top-down approach, FTA begins at the system level by identifying the failure or undesired event, and then systematically identifies the lower-level factors or events that contribute to the top-level event. An FTA offers the distinct advantage of an event-oriented methodology for evaluating the likelihood of occurrence of a system or component failure. As an extremely flexible analysis methodology, fault

tree allows for the incorporation of a number of different contributing events, including a combination of software or hardware failures, human errors and environmental influences all within a single fault tree. By using a logic tree to graphically represent the contributing events, Fault Tree Analysis can employ quantitative or qualitative analysis to determine the criticality of each contributing factor, identify the minimum combination of contributing factors that can lead to the failure, and assist in the development of control measures that would prevent or mitigate the circumstances leading to the top-level failure or event. Additional quantitative techniques available in FTA use failure and repair data about lower level components to calculate the likelihood of the top-level event. FTA also incorporates importance measures, which help the analyst determine which contributing factor to improve by identifying the criticality of contributing events. Courtesy: PTC India


AN N I VERS ARY

Practical Tips

TECH EDGE

Need for micro-precision strategies Despite India’s relatively low per capita expenditure on healthcare, India’s market for medical devices is in the world’s top twenty - in 2007 India’s medical equipment market was estimated at about $ 1.56 billion. The market is expected to grow about 8 percent annually and approach $ 2.3 billion by 2012. Although India has a growing domestic medical device manufacturing sector the country still imports more than half of its healthcare equipment, in particular high technology products. There is immense opportunity for Indian Machine Tool Builders (MTBs) to build potential and cater to this booming sector. Hema Yadav

&1

After-sales service: India has both government and private healthcare providers, however most growth in recent years has occurred in the private sector (which currently contributes about 80 per cent to growth in the healthcare delivery market). Medical equipment distribution in India is through regional distributors who have networks of subdistributors, and the use of a local, well-qualified

distributor helps in establishing good relationships influencing buying decisions. Smaller medical electronics manufacturer may find it difficult to compete with the larger, branded medical electronics manufacturers unless the product has niche applications. Regardless of the electronics equipment being imported, a rigorous after-sales servicing is the key to gain more market share.

&2

Contract manufacturing: Contract manufacturing is a process that establishes a working agreement between two companies. As part of the agreement, one company custom produces parts on behalf of their client. In most cases, the manufacturer also handles the ordering and shipment processes for the client. As a result, the client does not have to maintain manufacturing facilities, purchase raw

materials, or hire labour in order to produce the finished goods. The basic model used by contract manufacturers translates into different industries. Since the process is essentially outsourcing production to a partner who privately brands the end product, there are a number of different business ventures that can make use of a contract manufacturing arrangement.

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October 2011 - MODERN MACHINE TOOLS 197


Practical Tips

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Foreign collaboration: Countries like US and Germany are in the forefront of medical machining. Indian companies can gain much by knowledge-sharing with companies from these countries. The field of medical machining requires high-precision manufacturing, and

high level of risk assessment. This requires technology upgradation and advancement on a regular basis. Tie-ups and collaboration with foreign partners will help local manufacturers to take advantage of the experience and technology of sector leaders.

Investing in people: For any business to grow, a solid workforce is the backbone of such success. With increasing gap in demand and supply of skilled labour, hiring efficient people and retaining

existing quality employees is a big challenge for any management. A company needs to invest in its people by providing ample growth opportunities, training and motivational programmes etc.

Medical tourism: This is a growing sector in India and is expected to experience an annual growth rate of 30 per cent, making it a ` 9,500 crore industry by 2015. Estimates of the value of Indian medical tourism is estimated to be around $ 2 billion a year by 2012. An estimated 150,000 of Westerners travel to India for low-priced healthcare procedures every year.

India is fast emerging as a strong contender in medical tourism. With the demand in procedures such as laser, cosmetic surgery, alternative medicine, bone-marrow transplant, cardiac bypass, eye surgery and hip replacement etc increasing, manufacturers have a whole range of avenue to cater to.

R&D: The world of medical machining is a rapidly changing one. Procedures are updated and new technologies replace old ones. Only companies who have access to state-of-the-art R&D facilities and capable of catering to this sudden change in demand can survive in the high-end field of medical machining. The Indian government has put in

significant effort in the last six decades to develop the scientific and technical infrastructure of the country. It has allocated a significant amount of budget for Scientific and Technological (S&T) activity under a R&D fund. Companies need to avail such government initiatives and facilities to develop their capabilities and products.

Technology adoption: Technological innovation has long been central to improvements in healthcare. Whether in the form of new products, procedures and treatments, the optimal adoption of innovative medical technologies, integrated within system and service solutions, offers companies great opportunities to deliver improved healthcare. However, there are certain challenges in

adopting these technologies such as financial matters, time constraints, project leaders and champions; staff training and education, employee resistance, external relationships and infrastructure. The rationale for improving rates of technology adoption has a number of strands. Replacing outdated practices with more effective innovations will help companies deliver ‘world class’ products.

Visionary leadership: Leadership is an important function of management which helps to maximise efficiency and to achieve organisational goals. A dynamic and visionary leader can steer the

company on the path of success. A good eye for opportunities, seizing them, problem-solving capabilities and inspirational individual are some of the qualities of an ideal CEO or MD.

tricks

198 MODERN MACHINE TOOLS - October 2011


AN N I VERS ARY

Future Forecast MEDICAL

MEDICAL APPLICATIONS

The hen with golden eggs The global medical devices market continues to grow, driven by the aging worldwide population and technological innovations in diagnostic and therapeutic medical devices. Estimates place the current global market at $ 336 billion in annual revenues. Hema Yadav

T

he field of medical machining is witnessing an unprecedented growth, which is here to stay. Hectic lifestyles, modern way of living and longer life expectancy are some of the factors that have given birth to complicated health problems, which in turn require sophisticated machines and operating procedures to cure them.

Manufacturing opportunities The following verticals will provide immense opportunities for the Indian manufacturers in terms of growth and business expansion. Orthopaedic implants: The orthopaedics market is experiencing record growth with estimated Compounded Annual Growth Rate (CAGR) projected at 200 MODERN MACHINE TOOLS - October 2011

12 per cent through 2011 by Frost & Sullivan. Ophthalmic devices: The eye-care industry has experienced growth from both treatments for age-related vision disorders such as presbyopia, cataracts, macular degeneration, and glaucoma; and cosmetic surgeries such as laser vision correction and implantation of refractive intraocular lenses. Carl Zeiss Meditec reported that the ophthalmic systems and devices segment of this market was at $ 2.2 billion in 2006 and was growing at approximately 10 per cent year-on-year.

Diagnostic devices Diagnostic instruments are the key tools for ophthalmologists and eye-care professionals. Many diagnostic devices in this category are considered to be

capital equipment due to their selling price and long useful life. Healthcare products: With growing awareness about health, the home healthcare market will command a major share in the coming years. According to a new strategic report published by Insight and Intelligence, a Mary Ann Liebert Company, the home health and remote patient monitoring market is currently close to a $ 5.6 billion and will continue to grow at close to 70 per cent for at least the next three to five years. Electronic Medical Device Connectivity (EMDC): A relatively new information systems technology, this niche field supports remote data collection and analysis as well as workflow improvements through Electronic Health and Electronic Medical Records (EMR) systems.


NEW RAW MATERIALS Industry Insights New age materials: Catalyst for innovation and progress ....... 202 Interface FrĂŠdĂŠrique Mutel President and CEO, JEC Group .................................................. 206 Market Trends Machining of aerospace materials: Opportunities in new avenues ................ 208 Practical Tips Materials sector: Creating strategic business avenues ........ 214 Future Forecast Efficient composites: Charting a new course ............................... 218

October 2011 - MODERN MACHINE TOOLS 201


AN N I VERS ARY

Industry Insights NEW RAW MATERIALS

NEW AGE MATERIALS

Catalyst for innovation and progress The Indian manufacturing industry has recorded remarkable performance in recent years. Understanding the demand from high-end sectors such as aerospace, energy, infrastructure and transportation, the material sector has now realised its potential and is capable of producing high quality materials to stringent international specifications for these applications.

Nishant Kashyap

T

oday, the material industry is on an upswing world over. Indian metal producer and steel making units, both in private and public sectors, remain upbeat about their improved volume of turnover, capacity utilisation, sales and profit margins. A number of Memorandum of Understandings (MOUs) have been signed by major steel producers, both domestic and international, with the mineral rich states signifying possibilities of marked increase in both greenfield and brownfield production capacities. 202 MODERN MACHINE TOOLS - October 2011

India’s economic growth is dependent upon the growth of the steel industry. Consumption of steel is considered to be an indicator of economic development. While steel continues to have a stronghold in traditional sectors such as construction, housing and ground transportation, composites and other new raw materials are increasingly used in engineering industries such as aerospace, power generation, petrochemicals and fertilisers.

Importance of composites The high cost of raw materials, non

availability of many essential metals, import restrictions and the lack of mechanised production methods have affected the production of composites in large volumes. As a result, Indian composite industry could not compete with steel, aluminium or timber. But now the situation has changed and all manufacturing sector have realised the importance of composites, which eventually has forced government to give relief in import. A composite combines two metals with individual characteristics to create something with new and unique


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Industry Insights properties. With a rapid growth in the manufacturing sector and heavy investments in infrastructure, the Indian composite industry is expected to grow at a rate of around 25 per cent in the next 4-5 years. The key drivers of this growth will be automobile, infrastructure, wind energy and oil & gas industries in India. The Indian composite industry has a strong manufacturing base with automated processes combined with robust design and development skills. Global companies have entered in the Indian market and have established a strong base not only for local demand but for export as well. Several companies are investing in newer technologies to improve productivity and quality to meet increasing demands of this growth market. The engineering industry is beginning to experience a higher degree of composite adoption, one of the most important enabling technologies is high speed, proven manufacturing processes to turn raw materials into finished parts more efficiently and cost effectively. This includes all aspects of the value chain from raw materials to finished, inspected and installed structures. The composite industry is at a pivotal point in time. The industry is at the cross roads between an emerging industry benefiting only a few players and a high impact industry benefiting many applications. The challenges associated with this historical shift of composites usage on more applications than in the past can be met by expanding the ability to produce and support development of higher volume applications and advancing the performance, quality and supply stability simultaneously.

Composite machining Machining composite materials gives completely new set of hurdles when compared to conventional machining of metals. In fact, working with one specific composite can often differ significantly from working with another. All this factors have pressurised machine tool manufacturers to produce parts that gives high removal rate, increases

Figures in ‘000 tonne

Overall consumption of composites

S No

Sector

2006

2007

2008

2009

2010

15.79

20.27

25.96

33.20

42.46

1

Wind energy

2

Industrial

26

29.10

32.59

36.51

40.92

3

Railways

8

9.60

11.52

13.82

16.59

4

Automobile

20.69

22.67

24.9

26.3

28.1

5

Oil& Gas

1.5

1.6

1.7

1.8

1.9

6

Building & Construction

35.00

39.50

44.65

48.92

55.40

7

Marine

1

1.4

1.8

2.30

3

107.98

124.14

143.12

162.85

188.37

Total

Source: Technology Information, Forecasting and Assessment Council

accuracy and efficiency and provide longer tool life. When a new composite comes to the production floor, a shop pursuing process optimisation must be willing to seek out the tools that offer the best approach to machining. The composites was identified as a potential material for its application in the Indian Railways in early 80s for many passenger coach components such as window sill & frame, trays for battery boxes, roof ceiling and flooring. Composites behave much differently than metals when they are machined. The ingredients in any composite can present contradictory machining demands, while any attempt to cut them poses the real and costly danger of damaging the part. Machine shops need to have the right equipment and skills in place to machine these parts effectively, and many shops are rapidly developing these capabilities. Machine tool builders are constantly developing new tool geometrics and technologies, various tool geometries are available to address the varied nature of composite materials. Hole quality, tool life, and tool cost all significantly impact overall productivity in composite machining.

Demand drivers As Indian economy accelerates rapidly, the country is witnessing significant

growth, with the manufacturing sector clocking exceptional progress. Many global players have set up manufacturing facilities in the country. Industries such as automotive, energy, engineering and infrastructure are ahead in the race. The reflection of this can also be seen in metal sector. There is a huge potential for use of composite in Indian automobile industry especially for catering to the transportation needs of growing middle class population. India has made tremendous progress in wind power sector wherein composite consumption has exceeded China & Japan. There would be a good market for hoods, cabs, frames, and cargo containers that could be used as part of these locally built vehicles. The Indian material industry has made marginal additions to its capacities in last decade. Looking forward the new green field projects and the massive expansions announced by leading producers may increase the country’s production capacity significantly. Removal of infrastructure bottlenecks in railway and road transportation, speedy upgradation of infrastructure and supply of uninterrupted power with consistent frequency will help the industry grow at a rapid space. October 2011 - MODERN MACHINE TOOLS 205


AN N I VERS ARY

Interface NEW RAW MATERIALS

Indian composites market has picked up quite significantly over the past few years ...says Frédérique Mutel, President and CEO, JEC Group. It is the largest composites industry organisation in the world, with a network of 250,000 professionals. JEC represents, promotes and expands composites markets by providing global and local networking as well as information services. In a conversation with Nishant Kashyap, Mutel discusses about latest technological & market developments and future of composites. Q Elaborate on the latest

technology design trends and market developments impacting the composite segment. What are the growth drivers in the sector? Environmental concerns are increasingly becoming an important issue, not only in composites but in the overall industrial material supply chain. Resins and additives — both key components in composites engineering — are dependent on non-renewable resources and energy to 206 MODERN MACHINE TOOLS - October 2011

produce. Over the last decade, major resin and additive manufacturers have strived to develop a more environmental-friendly range of products that are completely renewable. In the fibre industry, composites engineers and researchers are constantly working at improving the mechanical properties of the material. In terms of market momentum, the composites market is developing rapidly and sustained growth in the global composites sector will continue to be fuelled by industrial developments in

Asia. And while the scale of growth in the Asia Pacific region is significant, new technological developments in Europe and North America, from advanced machines to new material resins, will remain a key driving force for innovation in the composites field, as Asian companies are seeking new composite solutions that provide the same level of performance as traditional materials.

Q Indian composites sector is

growing rapidly. How can


Interface machine tool companies contribute further to support this growth? In India, market penetration for composites used to be very low, more than ten times less that the global average due to several reasons, one of these being import measures. But growth in the Indian composites market has picked up quite significantly over the past few years. Annual composites growth rates are estimated to be between 18-20 per cent over the past three years, and this impressive growth is expected to continue. In 2011, the volume of the composites output is expected to reach around 3 per cent of the worldwide composites volume, which is also equivalent to about 6 per cent of Asian volume. The rapid pace of industrial developments in India is driving up demand for the use of process automation to improve manufacturing processes, especially for high value-added applications. Indian tooling firms have an integral role to play in helping manufacturers to achieve cost optimisation, enhanced productivity

and improved product quality by introducing the latest automated solutions into the market.

environmental-friendly technologies in large volume production.

Q What is the future of Q What

are the physical properties of composites that have been well received by the aerospace industry? Weight reduction and improving fuel efficiency remain the most significant issues for global aviation Original Equipment Manufacturers (OEMs), the ability to develop new fibre reinforced materials that help manufacturers address these concerns would be crucial for future composites penetration in nextgeneration aircraft. Aerospace companies are, therefore, increasingly pressured to utilise more technically advanced manufacturing techniques. From a material perspective, carbon fibre-reinforced composites are strong and yet light weight, making it the choice material for companies such as Boeing and Airbus as well as Asian manufacturers, such as COMAC to adopt advanced,

composites? Driven by strong economic growth and urbanisation across the emerging markets in the Asia Pacific region, the demand for advanced composites materials is expected to continue growing at a rapid rate over the next five years. In 2010, global composites production expanded by nearly 5 per cent to reach 8 million metric tonne with the Asia-Pacific region accounting for 38 per cent of the total production volume, driven mainly by unprecedented market growth in China and India. We see that the market demand for composite materials in the electrical and electronics, automotive, aviation and wind energy industry segments have been growing steadily in Asia. According to the annual survey of the composites market conducted by JEC, Asian production is projected to make up 43 per cent of the global composites manufacturing output by 2015.

October 2011 - MODERN MACHINE TOOLS 207


AN N I VERS ARY

Market Trends NEW RAW MATERIALS

MACHINING OF AEROSPACE MATERIALS

Opportunities in new avenues The push for larger, lighter and more fuel efficient aircraft creates real opportunities for aviation supply-chain manufacturers to do a better job machining titanium, including the new titanium-5553 grades. These trends are causing a logjam in airplane parts manufacturing. This can translate into a viable business opportunity in an ever-evolving economy. Moshe Goldberg

I

n the new 210-330 passenger Dreamliner, the ratio of titanium to steel and aluminium is three times higher than in earlier generation aircraft. High tensile steel in the landing gear has been replaced by titanium. Where once you saw aluminium airframes, you now find composites and titanium. Bogey beams and sliders made from high tensile steel 300 M have given way to Ti 5553 or Ti 10-2-3. And that is not all. Wherever composites or plastics were used, adjoining members in titanium family are being used predominantly, because of their closer match in thermal 208 MODERN MACHINE TOOLS - October 2011

expansion characteristics and better bond strength. These trends are already causing a logjam in airplane parts manufacturing. Even under the best conditions, the more familiar titanium alloys take ten times longer to machine than aluminium and perhaps four times longer than high tensile steel. Usually, it requires more horsepower per unit of metal removed and a machine with higher torque. The new titanium-5553 (5Al, 5V 5Mo, 3Cr) grades, 20-35 per cent is stronger than mainstay Ti 6Al, 4V, but even more difficult to machine by a factor of 4 to 1. As the use of Ti 5553 grows, which

it inevitably will, so will the machining logjam in aircraft production. This can become a viable business opportunity which can translate into revenue in future. Titanium is well known as the ‘go-to’ metal due to its high strength to weight ratio. This means weight savings, which translates directly to higher fuel efficiency at a time of rising concern over fuel costs and supplies and lower greenhouse gas emissions amid worldwide concerns over about global warming. Small wonder that use of titanium is growing faster than any other metal, with no real end in sight. Market demand


Market Trends for titanium machining capacity is definitely on the rise. Moreover, the market and political drivers favouring titanium in aircraft are here to stay. Therefore, if a company masters titanium machining and market it well, the future of the company will be made secure.

Mastering titanium machining Now, how to master titanium machining? First, understand its machining characteristics, both good and bad and then select tooling and machining practices specifically tailored to it. Titanium is more difficult to machine than aluminium or stainless. The reasons for its lower machining rate are many. Its high strength means more power is required to produce the chip. With a relatively low modulus of elasticity, titanium tends to deflect away from the cutting edge more than aluminium or steel, and thus needs a sharper cutting edge to hold tolerance. The metal also tends to crater upon tool entry and exit unless the cutting edge remains sharp. Its low co-efficient of thermal conductivity means more heat build-up in the cutting zone, which leads to smearing, welding and built-up edge, all of which undermine the tool and workpiece. ISCAR has developed a line of milling, turning and hole making tools specifically optimised for titanium work. It’s no exaggeration to say that these tools can improve your material removal rates in all popular titanium alloys by more than 40 per cent on average.

Anatomy of a good titanium tool The common attributes of these advanced tools include very sharp edges with honed flanks to delay built-up edge, helical cutting edges to ‘ease’ the insert into the workpiece; as well as heatresistant coatings, internal coolant directed right at the cutting zone. A choice of substrates enables you to optimise either wear resistance on tight machines and optimal cutting conditions (IC 380), or toughness to withstand impact loads and chatter in less-rigid cutting systems, long overhangs and interrupted cuts (IC 328 or 330). In both cases, the emphasis is on predictably long life, so the tool runs securely over machining cycles measured in days rather than minutes. One aerospace fabricator reports double the edge life on both Titanium and other super alloys by switching to the IC380 grade, with no other changes made to the process. Two of the typical characteristics of cutting edge wear that occur while milling titanium are chipping and cracks on the cutting edge, which reduces the insert life. In order to prevent the cutting edge from chipping, ISCAR’s R&D division developed a very tough reinforced carbide substrate. When it comes to rough and tough milling applications in titanium, the tougher carbide substrate exhibits longer tool life. In some applications, when compared to any other available carbide grade, the tool life is made even three times longer. This is very important for the production of parts demanded by the aerospace industry. October 2011 - MODERN MACHINE TOOLS 209


Market Trends Contributing to that extra reliability is the SUMO TEC coating treatment, introduced by ISCAR in 2007, which improves tool performance by smoothing out the coating and reducing friction in the cutting zone. Most ISCAR milling, turning and hole making inserts for titanium work now feature that treatment. Early users in the airframe fabrication business report 25-40 per cent better tool performance in titanium, due to that coating treatment alone.

Composite materials in aerospace Composite materials have gained popularity (despite their generally high cost) in high-performance products that have a need to be lightweight, yet strong enough to battle harsh conditions. Many new types of aircraft have composite material structures which include the wing and fuselage parts. Composite materials provide distinctive advantages in the

210 MODERN MACHINE TOOLS - October 2011

manufacture of advanced products because of attractive features such as high strength and their being lightweight. They are easily damaged unless machining is performed properly. By their nature, composite materials are non-homogeneous, anisotropic, and reinforced with abrasive components. Because of their structure and component properties of high abrasiveness, composite materials are much more difficult to machine than metal alloys and fall under the category of difficult-to-machine-materials. The composite material workpiece can easily suffer intolerable damage during cutting and the tool wear rate can turn out to be unacceptably high. ISCAR’s ongoing research conveys widespread knowledge to its customers for machining composite materials and on the mechanisms governing the chip formation and tool wear development. Cutting composites may incur more damage to the workpiece (like

de-lamination of bottom layers when drilling) if not done carefully or correctly. ISCAR’s new highly advanced milling and boring tools provide complete solutions for machining composite materials. ISCAR’s PCD (polycrystalline diamond) tools have become the popular choice, as they wear less, in particular when cutting advanced composite materials and thus providing unprecedented productivity solutions.

Moshe Goldberg is Manager Marketing –Training and Engineering support at ISCAR Ltd, Tefen, Israel. He is an active member of various international committees working on metal cutting field. He is a highly acclaimed authority in innovative metal machining technologies. Email: headquarter@iscar.co.il


AN N I VERS ARY

Practical Tips NEW RAW MATERIALS

MATERIALS SECTOR

Creating strategic business avenues It is projected that India will become the largest steel producer by 2013. Sensing the demand from aerospace, automobile and energy sectors, the country’s material industry is anxious to churn out services cost-effectively. This demand has given immense opportunities to machine tool builders too. Now, the time is ripe for the industry to reap benefits from the rapid growth registered by the material sector. Here are some tips that will expedite the growth of this industry. Nishant Kashyap

&1

tips

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Focus on R&D: When it comes to machining titanium, magnesium and other composites, high precision machining methods such as laser cutting, plasma cutting, waterjet, etc, that does not affect the material shape and property, becomes the necessity. This factor has made it imperative for machine tool builders to continue

investments in R&D and fulfill the needs of customers. Any company which will update its technology will see the growth in terms of market share and revenue. Results of R&D investment will help companies to respond to customers demands more efficiently and witness more breakthroughs in the industry.

Customer interaction: Increasing emphasis on business awareness has become the key business strategy to interact with customers. Effective customer communication boosts customer loyalty, ensures brand and regulatory compliance and help companies

to know what customers are demanding. With customer interaction, a company can develop the know-how about the current scenario of the industry and customers demands, which will eventually help them to develop innovative products accordingly.

214 MODERN MACHINE TOOLS - October 2011


Practical Tips

&3 &4 &5 &6 &7 &8

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Environment-friendly solutions: Ever since going green and save environment have become new mantra, the customers are demanding machines which are more environments friendly and reduce waste. Currently, materials and alloy industries are looking out for

machines which are less hazardous and reduce wastes in applications like cutting, bending, punching and casting. Adopting eco-friendly products not only increase the life of machines but also benefits in terms of overall revenue.

Global collaboration: The main aim of collaboration with foreign companies is development of high-end technology. Efficiency and productivity of Indian industries can be increased with use of improved technology through foreign technology collaborations. These collaborations induce the required amount of technological development and promotion

of technologically-advanced industries. The technology tie-ups with foreign companies will not only help Indian manufacturers in advancement of technology but also will open the door to the global market. To improve the efficiency and productivity, foreign technology collaborations will be the need of the hour for Indian industries.

Skill development: The rate of technological advance has accelerated at an unprecedented pace. Accordingly, the development of skills through training should be the strategic response to technological change, globalisation and other forces affecting labour markets. This growing sector is witnessing numerous developments, which is forcing companies to effectively work

on employees training and development to keep them updated with changes happening around the world. Introduction of new technologies has reduced the demand for unskilled labour and raised the value of advanced skills and competencies in the industrialised economies that shows skill development should be viewed as a lifetime endeavour.

Excellent service: In recent time, after sales services has become critical business strategy to retain customers. Most of the companies are focusing more and more on providing excellent service to grab a bigger share of customers and retain the existing ones. The market situations are competitive as every brand and company wants to make profits. An efficient after sales

service not only ensures increased sales returns but also enhances customer maintenance. Putting some extra attention into customer support is critical toweards devloping business. A set of happy customers makes it easier for the company to grow. Many companies are now concentrating on implementing the right strategy and hiring the right customer service team.

Technology advancements: There is need for better technique and sophisticated machines when it comes to machining composites like titanium, magnesium and other alloys. Now aerospace, automobile and energy sectors are demanding new raw materials which are light in weight and hard. This new difficult-to-

machine materials demand for high precision machines, especially for applications like cutting, drilling and milling. Machine tool builders need to provide high precision machining technologies, taking the latest technology into account, to cater to the demands of the materials sector.

Enhance brand visibility: Branding is the most important aspect of any business; beyond product, distribution, pricing, or location. A company’s brand is its definition in the world, which eventually helps it in making a presence in the industry. For metalworking, which is a business to business

industry, a different branding strategy is needed. the strategy must give the company opportunities to directly focus on potential customers and increase brand visibility. To remain competitive in the next decade, the industry must focus on branding strategy to grab the customers’ attention.

216 MODERN MACHINE TOOLS - October 2011


AN N I VERS ARY

Future Forecast NEW RAW MATERIALS

EFFICIENT COMPOSITES

Charting a new course

With various kinds of manufacturing activities being practised in the country, consumption of the material sector has increased. Impressive performance of the manufacturing sector, which has grown significantly in recent years, has largely contributed to this performance.

Nishant Kashyap

T

he Indian material industry, which is dominated by steel producers, seems to be concentrating on new raw materials and ferro alloy production. Alloys are one of the vital inputs required for producing special types of steel and used as additive inputs, especially, in the production of special steels. But despite the increase in steel production, the alloy industry has not got the support it requires from the government to make their prices competitive in the international market.

Machine tool industry’s response In

recent

times,

titanium

218 MODERN MACHINE TOOLS - October 2011

and

magnesium are becoming more popular with sectors like aerospace, marine and medical industries. However, due to their reputation of damaging tools and high prices of machine involved, manufacturers shy away from machining these materials. Today, the key challenge in machining these materials is high metal removal rate and accuracy alongwith a reasonable tool life. Machine tool industry has also responded well to the booming demand with superior technologies like cutting, milling, boring, drilling tools and bending & punching machines, especially for the sheet metal working industry.

Going forward The scope for new raw materials industry is huge and industry estimates indicate that it will continue to grow at a healthy rate in the coming years with increasing demands for new raw materials, alloys and stainless steel in the aerospace, automobile, energy and construction of new airports and metro rail projects. The government is planning massive upgradation of the steel production capacity along with modernisation of the existing steel plants in India. Demand for light weight vehicles and aircraft has ensured that the requirement for new raw materials and alloys are on a steady rise and will continue to do so in the future.


Modern Machine Tools (October-11) Insert 10-Pg221


Modern Machine Tools (October-11) Insert 10-Pg222


Modern Machine Tools (October-11) Insert 11-Pg223


Modern Machine Tools (October-11) Insert 11-Pg224


AN N I VERS ARY

Courtesy: Bevel Gears (India) Pvt Ltd

Industry Update

MECHANICAL TRANSMISSION SYSTEMS

Providing momentum to the industry Machines across all verticals of the industry are undergoing a transition to become smaller, sleeker and smarter. The transmission systems which drive the machines are also undergoing a facelift to achieve this result. New technologies in the mechanical transmission systems are making way for the new age machines to be more productive and efficient. Debarati Basu

A

utomatic is the word that is driving the industry today. And to automate technology, the pulse of the machine needs to beat faster. Mechanical transmissions over the years have been rapidly changing to make the entire process more efficient and expedite production. Gears are becoming more compact with high precision designing to be sustainable, cost-effective and deliver better production potential. 226 MODERN MACHINE TOOLS - October 2011

With newer technology coming in, most shop floors are replacing the older forms of mechanical transmission systems with the newer efficient and more sophisticated gear and gear drives to proliferate production capacity. “Gears and mechanical transmission systems would always be an evergrowing market as they form the core and the prime mover of any mechanical device. The growth of this technology is directly proportional to the growth in

manufacturing of automobile or general engineering. And these are sectors which would never dry up,� points out R Seshagiri, CEO & President, Gear and Gear Drives (India) Pvt Ltd.

Changing times It goes without saying that the major motivator for this industry is the rampantly changing automotive industry. With new automobile models rolling into the market, the functionality of


Industry Update R Seshagiri, CEO & President, Gear and Gear Drives (India) Pvt Ltd The growth of this technology is directly proportional to the manufacturing of automobile or general engineering. And these are sectors which would never dry up.

Avenues of opportunity Gears cannot be eliminated from mechanical device. However, the role of mechanical transmission is becoming more prominent with the rise in automation in other sectors. For the Indian industry, agricultural mechanisation today forms the most promising segments for the industry. Being an agriculture-centric country, the industry is now optimistically looking towards high end mechanised farming to replace the conventional pattern. In the last decade, that the country has seen a slow but gradual shift in the farming sector where farmers are making the transition towards mechanising their fields. Different types of machines, right from land preparation, sowing to harvesting are making way into the market making farm activities faster and better. Although mechanisation in farm lands has not yet reached its peak, farmers today are more open to

adopting and investing in agricultural machinery. And with this, the mechanical transmission system sees a better prospect in this segment as well. “Farming is the biggest area where mechanical transmission systems can play a big role. The day farming becomes mechanised to the level of foreign countries, Indian would be a rich country. The trend is already picking up. Many farmers from the north are now showing interest in mechanising their field operations. This has to be initiated by tractor manufacturers by bringing in latest cost effective mechanised farm attachments and equipment,” points out Jamal. Along with this, the general engineering sector is also seeing a big leap, with the demand for most industries like petroleum, food production, construction, etc experiencing a big boost. The challenge here is to make the production

Courtesy: Bevel Gears (India) Pvt Ltd

gears and gear drives is also undergoing colossal change. From manual transmission to automatic transmission, even though the primary job remains the same, the transmission system uses gears to make more effective use of the engine’s torque and to keep the engine operating at a much higher speed. With the increased speed, there are chances of gears to burn out. However, new age transmission system eliminates this setback. Transmission systems today have the capability to run at hot conditions at high speed and also are durable enough to sustain wear out. Also, automation on the Indian shop floor is changing the way the industry functions. “There are different types of gears for transmission that is entering the market. And over the years they have got more and more sophisticated. The progression of mechanical transmission systems has brought in change where the machine itself plays a more important role than man. Automation on shop floors has brought about change in the role of mechanical transmission systems. Today, business depends on volume and automation is the answer to it. More robotic arms in the process add on to the way power transmission functions,” avers Sulaiman Jamal, Managing Director, Bevel Gears (India) Pvt Ltd and Board Member of American Gear Manufacturers Association (AGMA). With this, the conventional gears are being replaced by servo technology and controllers. The result is simply faster, accurate added with lesser cost and more precision. “Mechanical transmission has always been a part of the system. But it is in the last 25 years that this area has seen the major part of the transition. Manufacturing of high accuracy machines with high cutting speed and a complete shift in design has improved the accuracy of the gears. Today, they are compact in size with the capability to run in hot conditions at high speed with high durability. The progress has been phenomenal,” says Seshagiri.

A 1000 mm diameter gear along with its pinion used in milling operations

October 2011 - MODERN MACHINE TOOLS 227


Industry Update

Sulaiman Jamal, Managing Director, Bevel Gears (India) Pvt Ltd We need to build similar confidence among the customers that we have in Swiss watches and German cars. It needs tremendous commitment on the part of the manufacturers.

process faster and sustainable. Better transmission system provides all these perks were the machine never stops. The segment is now looking towards the emerging avenues with the defence, aerospace, atomic and nuclear and wind energy being the upcoming market. With these in the row, the transmission systems is expected to see a huge transition in way the system functions and take it to a different level all together.

Improvements to incorporate The industry today needs the best in the market. And to provide the best, one need to start right from the first stage ie

228 MODERN MACHINE TOOLS - October 2011

procuring clean raw material. However, the unavailability of pure raw material is increasing the dependence on imports. Most companies are entrusting a lot of effort on assuring that the materials are clean and without any inclusions. The purity and quality of the raw materials used has become a matter of concern to the manufacturers so as to have better precision gears ensuring better and faster performance and leading to lesser quality issues in the process. With newer materials entering the industry, the quality of the material being used has an important role to play. The trend in the industry is towards the use of exotic materials. Conventional

materials are being amalgamated with the exotic and composite materials to make it more durable, wear resistant and increase the strength of the material. In the entire process, heat treatment is one of the most crucial parts of the entire process. However, quality heat treatment is still a growing area in the industry. “Heat treatment process is necessary for giving material strength and is a critical process. But in India, we have only a handful of metallurgists who have the adequate knowledge in this field to provide heat treatment that meets global standards. However, we should be in the global league of quality in the next five years. We need to build similar confidence among the customers that we have in Swiss watches and German cars. It needs tremendous commitment on the part of the manufacturers,� says Jamal.

Handling hurdles The country has a huge market for low cost gears and gear drive products


Industry Update

Courtesy: Bevel Gears (India) Pvt Ltd

which compromises with the quality. Most manufacturers in the gear industry face similar predicament to brining in awareness among the industry manufacturers on the quality of the gear and gear drives which would directly affect the production process. There is still a huge market which needs cheaper products sans quality. The industry is also facing the problem of the low quality gear cutting machines which is ruling the sector. There is a dire need for better machines to manufacture high precision gears for the growing market.

Growth path There is a huge transition that is taking place in this sector. The process of the mechanical transition system is turning up to be more sophisticate in terms of design capability and performance so as to match the transition that most of the other sectors are undergoing. “The scope for growth is tremendous as India has fantastic designers. The industry is driving towards automation

A gear cutting operation in progress

and there is a lot of things that man can do in engineering. This is all the game of reducing cost and deskilling so that machines can take over. These are the two main objectives of technology today,� says Jamal.

With the rapid changes in the market, the industry is not far from achieving the level of automation required and with it mechanical transition system will only see a transition that would match global parameters.

October 2011 - MODERN MACHINE TOOLS 229


AN N I VERS ARY

Leaders Speak

The customer should not have to look for us; we should be ready with customer-centric solutions ‌.opines Harry Ehrenberg, President, VARGUS Ltd. The company has been at the forefront of the tooling industry for more than 50 years and is a world-leading manufacturer of high-quality cutting and deburring tools for the metals and plastics industry. In conversation with Swapnil Pillai, Ehrenberg talks about the fast evolving consumer preference and the buoyant Indian market. Q How lucrative is the

Indian market with the Asian economy witnessing significant double-digit growth? The Indian market is indeed witnessing dramatic growth. At the same time, Indian customers have become increasingly demanding and price 230 MODERN MACHINE TOOLS - October 2011

conscious, therefore to remain lucrative in these circumstances it requires longterm commitment and focus on the unique needs of the Indian market.

Q Brief us on the upcoming

trends in the cutting and deburring tools. We find that both in cutting tools and

in deburring tools, the customer is looking more for service and solutions than for product. Therefore our focus is on adding more technical support and service than ever before – we need customer ready 24/7. In addition to our technical staff, we also have developed our signature software, TT GEN and TM GEN which are state-of- the art


Leaders Speak tool selectors and CNC programme generators. These programmes have been received enthusiastically by our customers and are downloadable from our company website.

Q What are the major end-user

segments that are driving the demand for cutting operations in India? The major segments that are driving demand for threading tools in India, which are our main focus, are the oil and gas industry, valves and fittings, automotive, defence and general engineering.

Q What is the competitive

advantage offered by Vargus to its customers? Our competitive advantage is offering a premium product of high quality and reliability that is guaranteed to increase productivity and efficiency every time. VARDEX provides thousands of thread turning and thread milling tooling solutions, available from stock or tailor-made special tools. In addition, VARDEX tools provide solutions for the machining of small-diameter parts, with a large range of cutting tools for boring, grooving and milling applications. The SHAVIV line of handdeburring tools offer professional solutions for the finishing of metal and plastic components with a full range of ergonomic handles and blades of different shapes and sizes. SHAVIV products are the choice of leading companies in the die & mold, automotive, aviation, plastics, electronics assembly, piping and other industries. VARGUS Ltd is a customer-focused organisation, committed to providing premium products of the highest quality, excellent value, top service and technical support. These key values have helped VARGUS Ltd remain the market leader in threading and deburring solutions and will continue to guide our approach to business in the future. 232 MODERN MACHINE TOOLS - October 2011

Q What are the industry

verticals that you cater to? Brief us about your product offers for the same. The following are some of the unique products which VARGUS offers to the various industry verticals: Oil & Gas: Multi-tooth high performance thread turning inserts Valves: MiTM multi-flute for fast thread milling applications to replace the traditional tapping technology Fittings: High performance thread turning inserts for extended tool life and better productivity Automotive: HTC thriller thread milling tools (combination of drilling, threading and chamfering in one tool), new TMSD gear milling solutions and also the V6 6-cornered inserts economical solutions for mass production Defence: Solid carbide thread milling cutters for hard materials and special profile thread turning inserts for unique threading requirements. General engineering:VARGUS provides a very large offering of Thread Turning, Thread Milling and Grooving tools for all types of general engineering applications, as well as hand deburring tools for high quality surface finishes.

Q Elaborate on the R&D facility

at the company. For over 50 years, since our establishment in 1960, R&D has been at the heart of VARGUS. We are continuously investing in our tech center that develops our proto-types as well as recruiting young engineers that will strengthen the present and build the future of VARGUS. For us, at VARGUS, R&D is not only ‘research & development’ it is also ‘re-think & dream’. We challenge ourselves with re-thinking our product and looking for ‘the next big thing’.

looking to offer new and improved solutions in areas of threading and hand deburring. I am happy to announce that we have decided to breakthrough to other important areas of the cutting tools market. At EMO Hannover September 2011, we plan to launch our new Groovex line which represents a major breakthrough in the area of grooving. In addition, the TMSD range of indexable carbide insert tooling offers manufacturers of gears, splines and racks a range of unrivalled advantages compared with conventional hobbing and other gear production routines. TMSD can slash machining and set-up times by at least 50 per cent while also generating superior quality finished machined components. This is due to the higher cutting speeds than possible with HSS tooling and the elimination of subsequent finish grinding or shaving routines. TMSD is suited to the machining of both straight and helical teeth gears, and gear modules from 1 mm to 6 mm. All materials can be accommodated, from very soft to hardened steels of 60 HRC. Each insert profile in the TMSD portfolio is supplied with the appropriate module shape and with one, two or three cutting corners – special forms can be supplied – and a full profile can be achieved in accordance with Class 7 DIN 3962. Finally, because the tooling focuses on carbide inserts located in ‘standard’ tool bodies for end, shell and disk milling on three-axis CNC milling machines (the cutting edge is subject to relatively low loads), TMSD is an affordable solution for companies of every size across a wide range of industrial segments. VARGUS is branching out and will no longer be considered a single niche player.

Q Tell us about the latest

breakthrough technologies developed in your organisation. VARGUS is in a state of continuously

Q Brief us on the green

initiatives at the company. For many years now, VARGUS has taken extensive measures to expand


Leaders Speak VARGUS has taken extensive measures to expand its use of recyclable materials and to minimise its energy consumption whether in the production processes, corporate offices or company vehicles

its use of recyclable materials and to minimise its energy consumption whether in the production processes, corporate offices or company vehicles. We regularly monitor our ecological impact in an effort to minimise our carbon footprint. We believe that this is an important part of being a good corporate citizen.

Q What are the training & development

activities for your engineers to meet the high quality standards? We typically recruit engineers with outstanding credentials, both in academics and practical experience. Attending professional seminars, tradeshows and visiting customers is how we assure that our engineers remain ‘on top of the game’.

Q What is the quality approach adopted by

the company to enhance efficiency? The name VARGUS is synonymous with quality. As an industry leader we do not compromise on issues of quality. This is something that has been handed down from generation to generation and which every VARGUS employee is well aware and proud of. We are all partners in quality.

Q What are the challenges that the industry

is facing, and how should companies try to address these? We need to be more pro-active and try to preempt the customers’ needs. We must figure out where the customer needs is going and meet him there. This is the big challenge: the customer should not have to look for us, we should be ready with customer-centric solutions.

Q Elaborate on your future plans to tap new

opportunities in India. I am happy to announce the establishment of our newest subsidiary, VARGUS India Plc. We have been active in the Indian market for over 15 years with a close network of very professional and reliable channel partners. We have now decided to upgrade our presence and deployment in India by establishing our own subsidiary which will offer greater support and service to both end-users and channel partners. October 2011 - MODERN MACHINE TOOLS 233


Facility Visit

HAAS AUTOMATION INC

Engineering excellence in machine tools

What all does it take to offer one of the best value propositions in the machine tool industry globally? The answer to this lies in seeing in action the manufacturing facility of a world leader. Haas Automation Inc’s Oxnard facility in California, USA is a class apart in many aspects, be its scale of operation, seamless process flow from design to dispatch or future-readiness. Here’s a walk through this world-class facility. Manas R Bastia

T

he story of America’s leading machine tool builder goes back to 1983, when its founder Gene Haas developed the industry’s first programmable rotary indexer to position parts for machining in his own shop. From the very first product that Haas Automation Inc rolled out to well beyond 1,00,000th CNC machines as of now, the company’s philosophy – Build the best products possible for the broadest market and offer them at competitive 234 MODERN MACHINE TOOLS - October 2011

prices – has paid rich dividends over the years and across geographies. Today, its 1-million sq ft design and manufacturing facility at Oxnard is a testimony to Haas’ continuing commitment to help its customers succeed in their respective domains.

Ground zero: Oxnard The 86-acre facility at Oxnard (about 90 minute drive from Los Angeles International Airport) has state-of-theart CNC machine tool manufacturing

capability with an installed capacity of about 1,500 machines per month. This is not only one of the single largest and highly sophisticated manufacturing facilities for CNC machine tools across the globe, but also boasts of outstanding economy-of-scale and highly developed systems. At the centre of these operations lies an advanced SAP platform, which enables seamless manufacturing and distribution of Haas products (that include high quality, high technology CNC machining centres, turning centres


Facility Visit and rotary products) at affordable prices. In addition to the Oxnard facility, Haas Automation has marketing and service support offices based in Belgium (Europe), Shanghai (China) and Navi Mumbai (India). All its products are distributed and supported through oneof-its-kind Haas Factory Outlet (HFO) network, which executes the sales, services and supply of spares to end-customers via smooth integration with the Oxnard facility by using the SAP system.

Seamless process flow With a product range of around a dozen main machine groups comprising toolroom mills and toolroom lathes (and their diminutive ‘office’ versions), turning centres, and the vertical machining centres & horizontal machining centres, Haas Automation manufactures and assembles over 160 variants that form the total product portfolio. At the centre of this plethora of models is the SAP system, which acts as the backbone of all Haas operations linking vendors and HFOs, right from taking orders to making the final delivery. Once an order is placed for a particular model from anywhere in the world, through the HFO, the same is transmitted to the factory where it is converted into a SolidWorks model with each and every parameter accurately mapped. Once the virtual model, an exact replica of the real thing is ready, it is time for assembly. Based on the virtual model, it is now time for ‘kitting’ – different kits are prepared for each assembly process, with every single part accounted for, down to the last bolt and cable tie. “What we ensure by kitting is that experts in the inventory

State-of-the-art inventory management

Haas’ energy conscious innovations

      

Auto power-off setting turns the machine off after a specified number of idle minutes Power-off at M30 sets the control to start a 30-second timer that turns off all power unless interrupted Sleep mode puts the machine into a low-power mode for a programmed length of time Screen saver setting and LCD backlight off setting blanks the LCD after a specified number of idle minutes Conveyor off setting automatically turns off the chip conveyor after a specified number of idle minutes Servos and hydraulics off setting automatically turns off the servos and hydraulic pump after a specified number of idle minutes Reduced tramp oil coolant contamination with the new minimal lubrication system

are putting parts together, and experts in assembly are building machines,” says Robert Murray, General Manager, and a Haas veteran. The kitting process ensures that the assembly is perfect, with no scope for that assembler’s nightmare – a missing bolt or a loose cable. The tool crib is automated with vending machines as the interface.

Best practices in action Haas Automation has been at the forefront of machine tool manufacturing technology, creating innovating products such as the EC-400PP horizontal machining centre with 6-station pallet pool system and its unique robot ready interface that makes interfacing part loading robots on a Haas machine, simple and cost-effective. Some of the salient features in manufacturing excellence of the Oxnard facility include:  There are 25 robotic cells with high speed robots that move at up to

Multi-purpose robotic cells

    



2 metre per second are used on the shop floors to manufacture major parts of machines. Robotic welders are used for welding coolant tank bases, GR bases and SMTC mounts. All parts, including bed, column, slides etc are machined in a single set up to speed up production and ensure high accuracy. Advanced tools and programming techniques are used for 5-side machining at almost half the cycle time compared to normal machining. Spindle assembly is done in two clean rooms. Spindles are balanced and runin on temperature controlled stands. Electrical assembly is done in a 20-step process with each taking 9 minute. Completed electrical assembly is fully tested, independently on the test stand, before being assembled on the machine. Machine specific kits are assembled in the kitting area and delivered to

A view of the production line

October 2011 - MODERN MACHINE TOOLS 235


Facility Visit Robert Murray General Manager What we ensure by kitting is that experts in the inventory are putting parts together, and experts in assembly are building machines.

William Tandrow Director, Mechanical Engineering Design, safety and simplicity are at the heart of all our R&D initiatives.

the production area just in time. SAP helps in doing the exact kitting and delivering it at the right time. Kitting helps the operator from losing time looking for parts or forgetting to assemble some part.

Quality measures Haas machine tools and rotary products are built as per exact specifications to deliver superior accuracy, repeatability and durability. Before leaving Oxnard facility, the typical Haas CNC machine is subjected to more than 300 quality-assurance tests, including up to 168 (24x7) hour of actual running time while in assembly. In fact, whenever a machine is not physically being worked on, it is running pre-programmed tasks to check operational tolerances and performance parameters. Quality assurance follows each individual part from initial fabrication through subsequent installations. Static and operational testing continue as each component sub-assembly is added to the main assembly, thus providing a paper trail of certification through the entire assembly, testing and shipping process. Haas Automation uses a state-of-the-art ball bar system from Renishaw to check not only linear accuracy, but also machine geometry. This ensures the three-dimensional squareness and accuracy of every machine.

World-class innovation Haas Automation invests a significant part of its turnover, nearly 15 per cent, on research and development (R&D). About 120 engineers, out of a total of 850 Haas employees at the Oxnard facility, are engaged in R&D. “Design, safety and simplicity are at the heart of all our R&D initiatives,” says William Tandrow, Director, Mechanical Engineering, Haas Automation Inc. This year, the focus of all R&D efforts for Haas (it receives just about one service call on an average during the warranty period) is on ‘Reliability’. 236 MODERN MACHINE TOOLS - October 2011


Facility Visit John Roth Director, Customer Service We generally get from an idea to a prototype cutting metal in about a year. Obviously moving to a production version of a prototype takes longer.

The transition from an idea to production with the prototype in between is a matter of time and consideration of internal and external factors. “The time taken from conceptualising a machine to its production depends on the complexity of the product but we generally get from an idea to a prototype cutting metal in about a year. Obviously moving to a production version of a prototype takes longer,” says John Roth, Director, Customer Service, Haas Automation Inc. He further adds, “During this process, ideas come from all sides, customer & dealer inputs, trends we see in the market, and our own experience in making parts. We use several design tools ranging from SolidWorks to Cosmos FEA to SAP”.

Service support Haas Automation through the Oxnard facility and its local HFOs supports about 1,15,000 machines starting from the first machine supplied in 1988. With the goal to ensure better service, spares worth $ 3 million are stocked at the central warehouse in Oxnard and spares worth $ 16 million are stocked in consignment across the world. The Haas global footprint spreads over 100 countries – the entire American continent, and all of Europe and Asia, also Australia and New Zealand. With the exception of large parts of Africa and some areas in the Middle East, Haas Automation has customers all across the world. It is now moving into Kenya and Morocco, with an eye on the future. Today the average waiting period for a Haas machine varies between 8-10 weeks, a number that the company is not very happy about. “We have our production schedules decided in advance for each quarter, and for the next, we are scaling up,” says Murray. The company has the capacity to scale up monthly production to 1,500 machines, which it achieved once in early 2008.

Summing up Having taken an elaborate tour of Haas Automation’s sprawling Oxnard facility, one cannot help but wonder about the few key decision makers here who are taking the machine ‘ideas’ and putting them into a larger global context. Although at present the manufacturing capabilities of this facility are adequate enough considering the existing volumes, it has the wherewithal to cater to the next level of growth by further expansion, if needed. October 2011 - MODERN MACHINE TOOLS 237


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AN N I VERS ARY

Factory Fundamentals It has been our persistent effort to provide incremental value to our readers with ‘cuttingedge’ information. As a part of this endeavour, we have this feature - ‘From Modern Machine Shop’, in an exclusive arrangement with the premier metalworking and machine tool publication in North America. Modern Machine Shop (MMS), published by Gardner Publications, US, offers exceptionally high editorial features and circulation standards that have become a hallmark of its operating philosophy and worldwide reputation. We strongly believe that the information provided in this feature will keep our readers updated about the latest global developments in business strategies & technological innovations, the quintessential ingredients for competitive manufacturing.

PCBN grades facilitate complete process revamp Faced with a difficult thread-machining operation in extremely hard material, this pump manufacturer turned to its cutting tool supplier for help. A new combination of PCBN insert grade and geometry improved part quality, reduced cycle time and eliminated the need for annealing, pre-machining and heat treating.

T

wo videos are available under ‘editor’s picks’ in the upper right corner of this page. One depicts the machining of the internal thread, and the other depicts the interpolated drilling routine with the Jabro end mill. The term ‘supplier’ can seem inadequate to describe the role of equipment manufacturers that have no qualms with leveraging their own resources

to help customers improve efficiency and competitiveness. Such companies’ relationships with customers might be described more aptly as partnerships.

Collaboration to meet challenges

A case in point is the collaboration between pump manufacturer A R Wilfley & Sons and cutting tool supplier Seco Tools to address a bottleneck that represented uncharted territory for both. The challenge: efficiently machining Acme 2 internal threads in material with a hardness rating of 70 Rc. Extensive testing at Seco’s Troy, Michigan tech centre led to the development of a new PCBN grade and geometry that enabled A R Wilfley to reliably cut the threads when Wilfley employs Seco’s PCBN350 grade inserts for finish turning this the material was in white iron component its hardened state, 246 MODERN MACHINE TOOLS - October 2011

eliminating the need for pre-machining and heat treating. Thread quality also improved. This success further led A R Wilfley to explore tooling options on an unrelated application, resulting in the elimination of secondary operations there as well. Based in Denver, Colorado, A R Wilfley & Sons specialises in the manufacture of centrifugal pumps with advanced seal technology for abrasive and corrosive applications. Abrasion resistance is essential to achieving sufficient operating life and reliability for these pumps, so the company commonly works with materials that range in hardness from 60 to 65 Rc. The typical process is to pre-machine these cast materials in a ‘soft’ state with solid carbide tooling. Then, components are sent out for heat-treatment - a process that can take about two weeks - before returning to the shop floor for final machining with ceramic inserts. Although not entirely efficient, this method had been employed effectively for many years. Recently, however, one tough job caused the company to


Factory Fundamentals reevaluate. To meet the required tight tolerances and to reduce costs, the company sought to machine this particular series of pumps in the hardened state, as opposed to casting, annealing, pre-machining and heat-treating followed by final machining to bring the part to spec. However, the design of these pumps depended on the use of chilled white iron that was even harder than the varieties of that material typically machined at A R Wilfley. A particular barrier was the machining of an internal ACME 2 thread in the 70-Rc material. Tools wore out quickly, and the thread’s depth, pitch and stringent surface finish requirements added to the difficulty. “When we found that this area would be a bottleneck in our product development and production, we were determined to find a quicker and more cost-effective operation,” says Link Wilfley, Owner and General Manager. Wilfley’s machine shop supervisor Jeff Haugen contacted local Seco sales representative John Mattos to inquire whether the supplier had experience in this area. Mattos, in turn, contacted Chad Miller, Seco’s product manager of advanced materials. After conducting a productivity-cost analysis, Seco suggested that PCBN tooling would be the best bet for improving the quality and effectiveness of the thread milling operation. Compared to the ceramic and hard carbide tooling A R Wilfley had first considered, a PCBN grade would enable faster, longer machining and reduce part costs. According to Seco, those benefits result primarily from the insert material’s hardness, which improves tool life and enables machining at more aggressive parameters.

A R Wilfley employed Seco’s Jabro end mill to generate tapered holes via helical interpolation at an 0.5-degree ramp angle in this white iron part. That operation is followed by internal threading with Seco’s 1/4x18nPTF16R5 thread mill

Improving quality After conducting a productivity-cost analysis, Seco suggested that PCBN tooling would be the best bet for improving the quality and effectiveness of the thread milling operation. Compared to the ceramic and hard carbide tooling A R Wilfley had first considered, a PCBN grade would enable faster, longer machining and reduce part costs. That’s primarily a factor of the insert material’s hardness, which improves tool life and enables machining at more aggressive parameters. However, with support from Seco’s global product development team, Miller discovered that although the cutting tool supplier had machined Acme threads in white iron, it had never produced an Acme 2 thread this coarse using PCBN. So he arranged for a world-wide conference call with Seco experts, including Troy-based threading and turning Product Managers Don Halas and Don Graham, to discuss how such an application might work. After considering the various ideas and theories, the Seco team in Troy set out to discover the right combination of PCBN grade and geometry as well as the optimum cutting conditions for creating the thread. The team created a number of inserts for testing at its Troy technical centre on an Integrex turn-mill from Mazak (Florence, Kentucky). With no published cutting data to suggest which feeds, speeds and cutting depths would be successful, Seco had to rely on its own knowledge base. Failure analysis study of the inserts and surface analysis of the part helped determine which parameters worked best. In the end, after a half dozen trials and remachining the boring bar toolholder with a deeper pocket to improve stability, the cutting tool manufacturer felt it had developed a successful process. Seco started with PCBN350, a tough grade developed specifically for white cast iron applications, to turn the component’s OD. For the more demanding threading operation, it employed PCBN200 at 330 sfpm and an 0.003 inch cutting depth. According to the company, the advantage of this latter grade lies in its binding material. Whereas most PCBN grades use ceramic as the glue that holds the grit together, PCBN200 features a tougher

The shop’s previous cutters wore out quickly during initial attempts to machine this Acme 2 thread in 70-Rc chilled white iron. The thread’s pitch, depth and surface finish exacerbated the bottleneck. The solution, a new grade of PCBN developed by Seco Tools, not only lasts longer in the cut, but also runs at more aggressive parameters and produces a higher-quality thread

A R Wilfley & Sons manufactures centrifugal pumps with advanced seal technology for abrasive and corrosive applications. The company’s product line includes canned motor pumps, chemical pumps, chemical slurry pumps and others for a variety of industries

October 2011 - MODERN MACHINE TOOLS 247


Factory Fundamentals metal binder that is less susceptible to chipping. Good news became even better after tests performed by A RWilfley’s metallurgist George Calboreanu, Ph D showed that the threads were higher quality than those produced by the old method. “Not only was this a better part, but we reduced our lead time by about two weeks, and we have a more reliable process,” says Wilfley. Seco’s Graham adds that many people tend to get “sticker shock” when they see PCBN insert prices. “However, with PCBN we can run the machine faster and more predictably. From this perspective, it was actually cheaper than ceramic,” he explains.

Measuring efficiency The success of this operation led A R Wilfley to wonder whether it could achieve similar efficiency gains on other products. The company decided to let Seco experiment with one of its most complex parts to see if the supplier could

248 MODERN MACHINE TOOLS - October 2011

develop a process for thread milling holes as small as 0.25 inch in hard iron. If successful, that process would result in significant cost savings. Several trials at the cutting tool manufacturer’s technical center led to a two-stage process involving a Jabro solid carbide end mill and a solid carbide thread mill—both standard, off-the-shelf tools. In the first stage, the Jabro end mill generated a tapered hole via helical interpolation at a 0.5degree ramp angle, 100 sfpm and 24 ipm. In the second stage, the company employed a 1/4x18NPTF-16R5 thread mill, compensating 0.002-inch per side to properly gage the internal threads. The Jabro produced more than 30 holes per tool, while the thread mill lasted through 24 holes. The cutting tool manufacturer notes that an important component in this process was the use of heat-shrink technology, which provides higher rigidity and concentricity than a standard connection. At A R Wilfley, the resulting improvements in tool life,

surface finish and dimensional control has more than justified the additional cost. In fact, since that initial test, the company has used this technique on materials as hard as 70 Rc. Through close collaboration with its cutting tool supplier, A R Wilfley has simplified its manufacturing operations. Rather than the previous five-step process (casting, annealing, pre-machining, heat treating and final machining), many of the company’s most critical parts can now be produced in two (casting and final machining). This has also eliminated some inspection steps, handling and paperwork. However, for this quality-minded company, the fact that finished parts are now higher-quality and more reliable is even more important than cost and cycle time savings. “Seco has gone the extra mile and found a true breakthrough,” says Wilfley. “Thanks to their efforts, we will continue to push the level of the quality and dependability of our product offerings.”


AN N I VERS ARY

Curtain Raiser

Ahmedabad Oct 14-17, 2011 Gujarat University Exhibition Hall

Celebrating a decade of excellence Gujarat has achieved impressive economic growth rates over the last ten years with the quantum of investment increasing manifold. With manufacturing industry booming in the state, there is a need for a forum to provide opportunities for gaining trade benefits and developing a long-term business relationship. Providing an ideal interactive platform is Engineering Expo Ahmedabad, which will be completing its 10th year in the state. To be held from October 1417, 2011, it will enlighten the manufacturing community about a variety of products, which will help enhance the industry’s efficiency and will surely act as a nodal point to generate fruitful business leads. Rakesh Rao and Avani Jain

T

he recent announcement of PSA Peugeot Citroën, France’s largest carmaker and Europe’s secondlargest, to invest ` 4,000 crore to build a factory at Sanand near Ahmedabad is yet another example of how Gujarat – which already houses Tata Motors, Ford and General Motors – is slowly emerging as an automobile hub. As Jayesh Ponda, Managing Director, Vijay Enterprises Pvt Ltd, observes, “We always felt that Maharashtra and North India are doing well, but now with the coming of Tata and other major auto manufacturers, we are positive. The growth rate is good. 250 MODERN MACHINE TOOLS - October 2011

Our customers are mainly from the engineering and automobile industry.” Such big bang investments have attracted many companies to venture into Gujarat. “We are looking towards the ever flourishing machine tool and engineering industry in Gujarat. The state’s machine tools industry, which is technology-oriented, has played an important role in the development of this sector in the country,” says Aniruddha Ketkar, Partner, Precimac Solutions, which offers machine automation solution and represents Siemens for new V60 Servos and Alfred Jaeger GmbH for high performance spindles.

Commemorating success The state’s economy and overall development has gathered momentum over the past few years. Snehal Mehta, Director - Marketing, Energy Mission Machineries (India) Pvt Ltd, observes, “In last ten years, Gujarat has grown as a favourable place for industry. Even before that Gujarat was known for engineering industry skills, but recent developments have provided more growth opportunity for smalland medium-scale manufacturers. I personally believe that the same growth will definitely make the state a hub to serve the world market with better products.”


Curtain Raiser Jagdish Panchal, Managing Director, Jekson Machinery Pvt Ltd, adds, “In the last few years, there has been a strong growth in the industrial sector with number of projects being launched in solar and automobile segments. These days, companies want more productivity and highly productive machinery; so the manufacturer needs to focus more on R&D.” Helping companies tap these emerging opportunities over the last decade, Engineering Expo Ahmedabad is providing a platform to foster business and trade. “Participating in the Engineering Expo has been a good experience. We have been getting good responses and that is why we continue to participate. It has helped us grow, renew our old contacts and get new customers,” opines Ponda, a regular participant at the Expo. Seconding his view, Panchal says, “We have participated in previous Engineering Expos. We got a good response as well as high rate of genuine visitors who helped us convert enquiries into orders. Even this year, there will be an increase in number of genuine visitors, thus providing us the opportunity to grow our business further. We are going to launch a high precision CNC plasma cutting machine at the exhibition.” As Engineering Expo achieves another milestone of continued success in its 10th year in Ahmedabad, an ebullient Sandeep Khosla, CEO - Publishing, Infomedia 18 (the organisers), puts this in perspective, “Engineering Expo taking birth in Ahmedabad in 2002 has come a long way today by becoming one of India’s largest multi-location (other places include Pune, Chennai, Indore, Rudrapur and Aurangabad) SME meeting points. Over the years, it has successfully delivered its goal of a preferred destination for SMEs and manufacturing & engineering companies to connect, transact, and leverage ideas to foster growth of individual organisations as well as that of the industry at large. As we look forward with further value-additions for even

Vital stats of Engineering Expo Ahmedabad

260+Participants 15,000+Expected visitors 15,000+Products & services on display Spread over more than

1,00,000 sq ft Expected business worth more than `

45 crore

better experience and reach to the target audience, we welcome large, medium & small industries in manufacturing & servicing sector to be a part of the Expo in this exciting journey.”

Over the years, Engineering Expo has been providing opportunities for SMEs, which are critical for the growth of emerging markets like India, to display their products as well as witness some of the latest technologies that could help develop their business. The 2011 edition will offer similar growth avenues. Arun Vijay, Marketing Director, Autotech CNC, opines, “We offer state-of-the-art technologies with advanced features to supplement needs of industries such as automobile, heavy engineering, iron & steel, power generation, etc. We are focussing on SMEs, which are increasingly looking at modernising their production facility to meet the growing demand from automobile industry. Our aim is to bring in high-quality, affordable technology to Indian industries in the metal-cutting field.”

The mega show Fostering business ties The Expo has been serving as a platform for companies to exhibit their products and services; interact with potential buyers; get new business leads and forge new partnerships. Ketkar avers, “There is always a requirement of regional level exhibitions to reach the local market. Engineering Expo satisfies this. Apart from being one of the major cities of Gujarat, Ahmedabad has good connection with Vadodara and Rajkot – the engineering hubs of Gujarat. We feel it will give good access to surrounding market destinations.” Known for its strong technologybased industries, the state has large number of SMEs offering a wide range of products & services. Mehta observes, “Ahmedabad is one of the fastest growing mega cities in the country, which has a strategic location benefit also. This city has good infrastructure, connectivity by air and road, availability of manpower resources and space to grow more. This is a right location for small- and medium-scale manufacturing industry’s growth, as many allied industries are also located in the city.”

The Expo will provide good exposure to companies that want to reach out to the original equipment manufacturers (OEMs). Vijay opines, “We are participating for the second time in Engineering Expo Ahmedabad. Our aim is to generate awareness about our products & services among the visitors, which will help the company expand its business in the region. We will be showcasing Autotech CNC’s latest offerings and our main focus will be on Pinnacle vertical machining centre (VMC) and Vision Wide double column VMC at the Expo.” Dinesh Malvi, Director, Yashwant Industries, adds, “Since Gujarat is the manufacturing hub of India, exhibitions like Engineering Expo hold high importance here. Previously, we got good response from the customers, who took our catalogue and approached us later for placing their orders. We expect the same this time also and are looking for more orders than before. This has helped us to grow in the past.” In addition, it will provide exhibitors an opportunity to target their products at the right customers. “We are capital October 2011 - MODERN MACHINE TOOLS 251


Curtain Raiser Brimming with prospects Engineering Expo Ahmedabad is an excellent example of starting humble and achieving an enviable feat over the years. Year-on-year, it has gained the confidence and trust of the Indian manufacturing industry. The 2010 edition witnessed overwhelming response from the industry with over 250 exhibitors (43 per cent more than 2009) and about 13,290 visitors (up by 18 per cent from 2009). It generated a business of around ` 38 crore (an increase of 25 per cent compared to 2009). In 2011, over 260 exhibitors and more than 15,000 business visitors are expected to take part. With opportune times ahead, this edition of Engineering Expo is likely to further boost vendor confidence of this region. equipment manufacturers and our purpose of attending any show is mainly brand-building of product and generating immediate business leads. We have succeeded in our purpose in both aspects. Ahmedabad is a base location for us. We expect more buyers to visit the show, whom we can take for a plant visit and demonstrate our enhanced manufacturing facility. This will generate more confidence and respect for our products,” says Mehta. Being a part of one of the leading media houses in the country also provides an added advantage for the Expo. “Exhibitions like this give us a platform to not only showcase our products but also establish good network with the customers as well as other business houses. Moreover, it will help us to reach the niche and right customers. What makes Engineering Expo strong is the Network 18 brand, which ensures right number of footprints and best onsite facilities,” opines Major (Retd.) Amitava Mittra, Chief Operating Officer, BGI Engitech Pvt Ltd, which provides customised protection against intrusion attempts by installing its anti-ramming bollards, crash resistant barriers and gates.

A platform for innovations Large, medium and small industries from the manufacturing and services sector will be showcasing their latest products & technologies. Falgun Pandya, Managing Director, Saimona Airmech, avers, “For the industrial growth, the industrial exhibitions are vital. We are looking for maximum 252 MODERN MACHINE TOOLS - October 2011

visitors from the industrial sector in Gujarat. We are manufacturers of air compressors and PET bottling high pressure compressors for the industrial use. We will be displaying wide range of compressors at the Expo.” Besides, visitors will get an opportunity to witness the performance of novel technologies live. “We have already launched some new products last year. Now at this Expo, our focus is to make buyers more aware about new products, such as plate bending machines, section bending machines and busbar units. We will have live demonstrations of these machines with upgraded automation solutions,” informs Mehta. The Expo will also showcase some of the latest innovations from across the globe. Ketkar informs, “We are introducing Alfred Jaeger make high performance spindles into Indian market. We are expecting immediate attention towards these products from the technology-oriented manufacturing industry of Gujarat.” Local companies can expect to forge new business tie-ups during the course of the event. As Ponda elaborates, “Ahmedabad is our base, so expectations are always high from this Expo. We expect to meet all the new industry players, who are establishing their plants near Ahmedabad as it will ensure direct one-to-one contact with the new customers. We are going to introduce low bake powder paint in Ahmedabad. Our product will be ready by then.” Ponda’s company Vijay Enterprises manufactures powder paint, which is

widely used in engineering/automobile and allied industries. Similarly, new entrants can use this opportunity to introduce their latest offerings. As Mittra points out, “Being a new company, we want to use this Expo to tell our customers, both government and corporate, that we have arrived in Gujarat and now they do not have to move out to other states for fulfilling their demands for security. We are launching three products at this Expo, which include complete range of industrial security solution; industrial & residential gate automation and parking management solution, which can serve the burgeoning shopping malls of Ahmedabad.”

See you at Ahmedabad Over the years, Engineering Expo Ahmedabad has been playing an important role in the industrial growth of the state by bringing together suppliers and buyers on an interactive platform. Being an all-inclusive engineering show, allied sectors can use this opportunity to reach out to a number of industries. “Engineering Expo provides the platform to meet buyers and industry professionals. This is a good opportunity to build a brand name for capital equipment as well as to generate immediate business leads and their conversion to orders. We are happy with the organisers of Engineering Expo for continuous improvement in show management in terms of better exhibits, more publicity to focussed industrial segment, reach to identified buyers and overall performance of the show. We would like to continue our participation in coming years also,” says an elated Mehta, one of the many regular participants at the Expo. As demonstrated during the last nine editions, Engineering Expo Ahmedabad has all the prerequisites – participants and visitors who mean business, excellent infrastructure, organiser with a repute, vast media coverage, etc – to make it a thumping success even this year.


AN N I VERS ARY

Events - National become the world’s largest confluence of power transmission and distribution community; January 19 – 22, 2012; at Bombay Exhibition Centre, Mumbai RUDRAPUR

AHMEDABAD

PUNE

CHENNAI

INDORE

AURANGABAD

Uttarakhand Sept 23-26, 2011

Gujarat Oct 14-17, 2011

Maharastra Nov 18-21, 2011

Tamil Nadu Dec 8-11, 2011

Madhya Pradesh Jan 6-9, 2012

Maharashtra Feb 17-20, 2012

Gandhi Park

Gujarat University Exhibition Hall

Auto Cluster Exhibition Centre, Pimpri-Chinchwad

Chennai Trade Centre, Nandambakkam

Poddar Plaza, Nr Gandhi Hall

Garware Stadium Chikkalthana

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment. For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Mob: 09819552270 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

Regional Productivity Summits 2011 The summits will offer a unique opportunity to understand and learn from the experiences and best practices of other companies. It will address and demonstrate a wide variety of productivity improvement projects in metalworking through live case study presentations and keynote sessions; October 10, 15 & 21, 2011; at LE Royal Meridien, Chennai; The Westin, Pune and Intercontinental Eros, New Delhi respectively For details contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre (BIEC) 10th Mile, Tumkur Road, Madavara Post Bengaluru Tel: +80 6624 6600, Fax: +80 6624 6658 Email: rohith@imtma.in Web: www.imtma.in

LASERTECH INDIA 2011 Exclusive fair on application of laser systems in manufacturing. It brings manufacturers face-to-face with the concept, benefits and applications of such systems; November 18–20, 2011; Bombay Exhibition Centre, Mumbai For details contact: Focussed Event Management Pvt Ltd Plot No F/11 & F/12, Camlin Fine, WICEL Compound,

254 MODERN MACHINE TOOLS - October 2011

Opp SEEPZ Main Gate, Andheri (East), Mumbai Tel: +91 22 3201 9137, Fax: +91 22 2832 4404 Email: info@focussedevents.com Web: www.focussedevents.com

IA India International trade fair for process & production, automation and industrial building automation; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru For details contact: Hannover Milano Fairs India Pvt Ltd B-303, Dynasty Business Park Andheri- Kurla Road, Chakala Andhrei (E), Mumbai Tel: +91 22 4005 0681, Fax: +91 22 4005 0683 Email: info@hmf-india.com Web: www.ia-india.com

CeMAT India Internation trade fair for material handling and logistics; December 6-9, 2011; Bangalore International Exhibition Centre, Bengaluru For details contact: Hannover Milano Fairs India Pvt Ltd B-303, Andhrei (E), Mumbai Tel: +91 22 4005 0681 Email: info@hmf-india.com Web: www.cemat-india.com

ELECRAMA - 2012 Held biennially since 1990, the event has

For details contact: 501, Kakad Chambers 132, Dr Annie Besant Road Worli, Mumbai Tel: +22 2498 4226, Fax: +22 2497 5140 Email: mumbai@ieema.org Web: www.elecrama.com

IMTEX Forming 2012 & Tooltech 2012 International exhibition focussing on the exhaustive range of forming technologies in engineering applications. The concurrent event – Tooltech 2012 is dedicated to cutting tools, tooling systems, machine tool accessories, metrology and CAD/CAM; January 19-24, 2012; Bangalore International Exhibition Centre (BIEC), Bengaluru For details contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road Madavara Post, Bengaluru Tel: +91 80 6624 6600, Fax: +91 80 6624 6661 Email: info@imtex.in Web: www.imtex.in

Modern Machine Shop The event offers an ultimate platform to demonstrate potential and futuristic technologies in the product segment to a large cross-section of business visitors, from the entire engineering industry; April 5-8, 2012; Auto Cluster Exhibition Centre, Pune For details contact: Indian Machine Tool Manufacturers’ Association Bangalore International Exhibition Centre, 10th Mile, Tumkur Road, Madavara Post, Bengaluru Tel: +91 80 6624 6600 Fax: +91 80 6624 6661 Email: info@imtma.in Web: www.imtma.in


AN N I VERS ARY

Events - International The Advanced Manufacturing & Technology Show (AMTS) An excellent platform to showcase technologies, trends, products and solutions in the metalworking industry. The event offers opportunity to network with industry, buyers, professionals, influencers and potential partners; October 19-20, 2011; at Dayton Airport Expo Center, USA For details contact: Dayton Tooling and Manufacturing Association 240 West Fifth Street, Room 13-125, Dayton, Ohio, USA Tel: +1 937 512 3862 Email: amts@dtma.org Web: www.dtma.org

Machine Tools Vietnam 2011 20th Vietnam International Industrial fair will showcase a variety of machine tools; October 19-23, 2011; at Vietnam Exhibition and Fair Centre, Vietnam For details contact: Vietnam Exhibition Fair Centre (VEFAC) 148 Giangvo Road, Hanoi Vietnam Tel: +844 3834 5655 Fax: +844 3831 1228 Email: lien.hoaly@vefac.vn Web: www.vietnamindustrialfair.com

BLECH Polska 2011 This expo will see numerous exhibitors from different countries presenting an array of latest technologies and innovations related to metal-forming and bending solutions and sheet metal manufacturing process; October 25-27, 2011; Kielce Trade Fairs Conference Centre, Kielce, Poland For details contact: Mack Brooks Exhibitions Ltd Romeland House Romeland Hill St Albans, Herts AL3 4ET United Kingdom

256 MODERN MACHINE TOOLS - October 2011

Tel: +44 01727 814400 Fax: +44 01727 814401 Email: info@blechevents.com Web: www.blechevents.com

60596 Frankfurt am Main, Germany Tel. +49 6927 4003, Fax +49 6927 4040 Email: info@demat.com Web: www.demat.com

MWCS 2011 The leading metalworking show in East China will showcase latest CNC machines, precision machine tool and industrial automation; November 1 - 5, Shanghai New International Expo Centre, China For details contact: Hannover Milano Fairs Shanghai Ltd Rm 301, B&Q Pudong Office Tower 393 Yinxiao Rd, Pudong Shanghai 201204, PRC Tel: +86 21 50456700 222/284 Fax: +86 21 68862355 Email: mwcs@hmf-china.com Web: www.metalworkingchina.com

Machine Tool Indonesia 2011 The 25th international machine tool show will showcase latest technology in metalworking and allied industries; November 30 - 3 December; at Jakarta International Expo, Indonesia For details contact: PT Pamerindo Buana Abadi Deutsche Bank Building 13th Floor Jakarta 10310 Indonesia Tel: +62 021 316 2001 Fax: +62 021 316 1981 E-mail: info@pamerindo.com Web: www.machinetoolindonesia.com

FABTECH North America’s largest metal forming, fabricating, welding and finishing event anticipates 30,000 visitors and over 1,200 exhibiting companies covering more than 410,000 net sq ft of floor space; November 14-17, 2011; at McCormick Place, Chicago, US For details contact: Fabricators & Manufacturers Association, International 833 Featherstone roads Rockford, IL 61107 Tel: 815-399-8775 Fax: 815-484-7701 Email: mhoper@fmafabtech.com Web: www.fabtechexpo.com

MTA VIETNAM 2012 The 10th exhibition will serve as a platform to network with pioneers from machine tools, precision engineering and metalworking technology sector; July 3 – 6 July, 2012; at Saigon exhibition & Convention Centre, Ho Chi Minh City, Vietnam For details contact Singapore Exhibition Services Pte Ltd 1 Jalan Kilang Timor 09-02 Pacific Tech Centre Singapore 159303 Tel: +65 6233 6638, Fax: +65 6233 6633 Email: mta@sesallworld.com Web: www.mtavietnam.com

EuroMold 2011 The 18th EuroMold, World Fair for mold making and tooling, design and application development will showcase 1500 exhibitors from 45 countries and approximately 60,000 trade visitors; November 29 – December 02, 2011; at Frankfurt Exhibition Centre, Germany For details contact: DEMAT GmbH Carl-von-Noorden-Platz 5,

The information published in this section is as per the details furnished by the respective organisers. In any case, it does not represent the views of


AN N I VERS ARY

Report HIMTEX 2011

Expanding the scope of regional investment New avenues are opening up and the Indian machine tool industry is making a foray into different sectors. Creating newer machine tool hubs and experimenting with unexplored avenues for growth, the machine tool industry, today, is at its best. Considering this, Hyderabad is all set to be the next best choice for the manufacturing fraternity for which Hitex International Machine Tool Expo (HIMTEX) is providing the boost that the city requires. Debarati Basu

G

iving leverage to the regional machine tool industry, HIMTEX organised the third edition of its Machine Tool Expo in Hyderabad

in September. The three day event, which began in line with the festive season between September 1 and 3, had over 60 exhibitors from various parts of the country and overseas. The event was inaugurated by Shankar Rao, Minister of Small Scale Industry, Public Enterprises and Textile, Andhra Pradesh. Bringing in a ray of hope to the industry, Rao, at the inaugural said, “We, in Andhra Pradesh are doing everything possible to boost the industry growth in

the state. We have been closely studying the industrial growth pattern of various states and will soon come up with a cumulative policy that will ensure growth and progress and encourage investment in the state. We are also encouraging various companies to come ahead and give us their suggestions on subsidies, land acquisition and various other aids that they need. We will extend our full support to the industries.”

Providing opportunities The Indian machine tool industry has been on a steady growth path over the years with exponential increase in the demand. However, the increasing domestic demand is not being met by the production,

Exhibitors’ Views

C J Badrinath, Director, CNC IndiaTools & Services (P) Ltd This is the first time that we are showcasing and participating in the expo and are expecting that we can target the south Indian market. We are also launching our new product at this event.

Rajdeep Roy, Manager, Training and Development, EWAC Alloys Ltd There is a lot of development that is happening in Hyderabad and we are expecting better business here in future. We feel that this is the right time to create awareness about our product and participate in the event.

260 MODERN MACHINE TOOLS - October 2011

thereby, leading to dependence on imports. A favourable market condition, availability of raw material, manpower and support from the government is expected to increase the investment in this sector. Many players keen in this sector are looking to increase their capacity. With improvement in R&D, design and product development capabilities, India has the potential to improve its global presence and the quantum of growth is expected to grow multi fold over the next decade. The huge domestic demand alone has created an immediate need for capacity enhancement and most of the existing players in this segment are either increasing the capacity of their existing units or are setting up additional production facility. Even the Public Sector Units (PSU) dominated sectors are witnessing a revolution in the form of major private business houses vying with each other to make their presence felt. International collaborations are becoming the norm and latest technology and expertise from across the globe is being ushered into the country in a big way. The various sectors of the industry are spread widely across the length and breadth of the country. However, giving access to this industry for the small and medium manufacturers as well as service providers has become a Herculean task. This is where HIMTEX plays an important


new busIness opportunItIes

InvItatIon

invites you to

AHMEDABAD

14 - 17 Oct 2011 Gujarat University Exhibition Hall 10 am - 7 pm

CUT HERE


Exhibitor Profile

Engineering Expo organised by Infomedia18 is one of the engineering industry’s biggest events in country. The 2010-11 edition of Engineering Expo saw business transactions worth over Rs. 161 crores. Launched in Ahmedabad in the year 2002, the event today boasts of a fabulous visitor turnout. The Expo is a preferred destination for SME’s and manufacturing & engineering companies to transact, network, tie-up and exchange ideas for the growth of the industry.

Brought to you

Compressed Air Partner

Supported By

Online Media Partners

Auto & Auto Components | Light & Medium Engineering | Chemicals & Allied Products | Electrical & Electronics | Hydraulics & Pneumatics | IT Products & Services | Automation & Instrumentation | Material Handling Eqpt | Packaging Machinery | Wires & Cables | Machine Tools & Acc. | Pipes & Fitting | Plastics & Polymers | Safety & Security | Process Machinery & Eqpt | Testing & Measuring Instruments

Rajkot Engineering Association

For Further Details, Call Varsha + 91 98195 52270 Or Email engexpo@infomedia18.in

CUT HERE


Report

Next stop: Hyderabad The machine and tool industry is seeing a gradual shift from its already existing hubs across the country to new terrains Hyderabad, being one of them. With the growing infrastructure and government’s intent to encourage industrial development in this region, Hyderabad is growing to be the next industrial hub in India. The expo got an encouraging response from participants from 18 cities of the countries alongwith several international players from China, Singapore and Germany. The objective of the expo and conference was to provide a platform to the equipment manufacturers, dealers and service providers to showcase their products to the industry and decision makers of the process industry for reliable and alternative suppliers to work with them in their quest to find viable optimum solutions in this

Liu Qiujun, Sales Executive, Jinan Tianchen Machine Group Co Ltd This is the first time that I am visiting India and this is also the first expo that I am attending. My company plans to enter the Indian market and exhibit in future expos. We are basically trying to assess the crowd and the kind of market in India.

Susheel Kumara, Director, Revathi PBR Mills The expo has been able to showcase a wide range of products this time. I feel this expo will help me find the products which can be useful for my company.

competitive scenario. “With the kind of growth and development which is coming in, Hyderabad serves as one of the future destinations for the industry. The city is projected to grow at a better pace than any other city. With the growing infrastructure and an urge to have the best quality products, Hitex International Machine Tools show in Hitex Exhibition

centre will serve as a perfect platform for the machine tool companies to open new ventures in South Indian market,” said Sanjay Kapoor, COO, HITEX. The event provided much-needed impetus to a wide range of players from Southern India to generate the country’s interest in this growing segment of the market.

October 2011 - MODERN MACHINE TOOLS 263

Visitors’ Views

role by providing a platform to the industry leaders and small scale industries to interact and showcase their mettle in their respective segment.


AN N I VERS ARY

Product Update This section gives information about the national and international products available in the market

Cassette tool cabinets

Tool systems

Basic Engineers offers a wide range of tools trolleys for various types of applications. The range includes tool-trolleys for VMCs, HMCs, CNC machines, automobile workshop trolleys, maintenance trolleys, wiring trolley, etc. Also offered are specific tools cabinets to serve as cassette type tool cabinets for safely storing press brake tools. Unique, userfriendly and safe designs set these products apart from others. Salient features include: safety of costly tooling, space economy, durability at par, convenient for process, easy to access punch/die, height adjustment as per tool size, provision of scratchproof movement of devices, cassette movement smooth & quite, tooling arrangement in desired sequence, helping operator saving of valuable downtime & setup time, state-of-the-art/user-friendly/smart & selfappealed tool cabinets, return of money value, cost-effective, front access draw for each tooling, and accident prevention.

Samtec Tools & Accessories offers tool systems from Cogsdill, UK. Modular boring tools are the ultimate solution in terms of productivity, flexibility, and accuracy for machining large parts that require multiple operations. A tool change is normally required to produce different diameters or to machine a different feature (such as a face). These systems can perform a variety of precision machining operations on horizontal boring mill. They can also perform operations, such as boring, facing, contouring, taper boring, deep cavity boring, grooving, back-spot facing, chamfering and bottle-boring. All the dimensions of the operation can be controlled or changed just by changing the CNC program. All these operations can be done with a single tooling setup, which in turn eliminates number of tool changes. The internal actuation mechanism in each tool provides precise response to the cutter movement. The CNC control on the machine precisely determines radial cutter movement.

Basic Engineers Ahmedabad - Gujarat Tel: 079-2583 1575, Mob: 09825344527, Fax: 079-2583 1575 Email: info@basicengineers.in

Portable welders Vulcan manufactures various types of models in various capacities in arc welding transformers, spot welding machines, welding rectifiers, MIG/MAG welding machines, TIG welding machines, electroplating rectifier equipments and step-up transformers offered by Canary Electricals. All these machines are strictly manufactured and conform to International Standards, incorporating latest technological developments and controls with highest order of quality & performance. Salient features include: modern looks, novel design concepts, lightweight & compact; real portability for one person to do welding at odd places, like civil worksites, etc; sturdy belt provided for carrying & hanging; made from high-grade materials; protection against overload by thermal cutout; work even on domestic power line; reliable & durable; epoxy powder-coated body for long life; and coil varnishing by vacuum pressurised impregnating varnishing system.

Samtec Tools & Accessories Pvt Ltd Pune - Maharashtra Tel: 020-2551 1026, Fax: 020-25549752 Email: info@samtectools.com

Force-feed lubricators Zenith Hydromatic manufactures and offers force-feed lubricators in highpressure and low-pressure range up to 24 feed pumps. Each feed pump produces discharge up to 0.30 CC/ stroke, working pressure up to 1000 kg/cm^ with different type gear reduction from 1:2 to 1:400 with ratchet drive, handle drive, etc. The lubricators are ideal for air & gas compressors, reciprocating plunger pumps, rubber & plastic machinery, and are also used in similar other industries. Standard feed unit interchange/replacement parts are available for major brand of compressors in the field. Also manufactured are hydraulic cylinders, hydraulic power-packs, pallet pumps, grease pumps, auto bike lifters, double plunger hydraulic hand pumps, etc. Special-purpose lubricators, hydraulic cylinders, hand pumps & lifting jacks, as per customers’ specifications can also be developed (claims the company).

Canary Electricals Ltd

Zenith Hydromatic

Morbi - Gujarat Tel: 02822-250431, Fax: 02822-250433 Email: info@vulcanwelding.com

Ahmedabad - Gujarat Tel: 079-2281 2945, Fax: 079-2281 2945 Email: response@hydraulicsystemsindia.com

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Product Update Permanent magnetic chucks Champion Industries offers permanent magnetic chucks that are efficient holding devices used for surface grinders. The close pole pitch of 11 mm is ideal for holding the job. Evenly spread magnetic field helps to hold even small jobs in quantity to obtain maximum out put and fast production. There is no gap between the magnetic poles, hence small jobs can be holding throughout the surface. The poles extended till the end of surface provide maximum magnetic area that also increases the output. Low magnetic field on the chuck surface keeps the upper surface of the chuck non-magnetic and helps in removing swart easily with the force of coolant. It can also be used on shaping, milling machines for light accurate machining. The permanent magnetic chucks are available in rectangular as well as round shapes, in sizes ranging from 150 mm diameter, up to 600 mm diameter; and in rectangular shapes ranging from 150 mm x 200 mm up to 750 mm x 250 mm. Dimensions can be modified according to customers’ requirements. Champion Industries Surendranagar - Gujarat Tel: 02752-231741, Mob: 09898166908 Email: parthesh_acharya@yahoo.com

Hydraulic cylindrical grinding machines Universal hydraulic cylindrical grinding machines (model UC-600) manufactured by Devco Industries are available in eight models. Casting are close grained and well ribbed, with minimised vibration and distortion. Wheelhead spindle runs in bush bearings and workhead spindle runs in taper roller bearing. Tailstock, wheelhead and workhead spindles are heat-treated to achieve dimensional stability; and performance roundness <0.005 mm. Optional accessories are: mechanical/hydraulic/self-feeding/internal grinding attachment with two-point steady rest, three-point steady rest, wheel balancing stand, balancing arbour & wheel flange, rapid approach. Also available are mini grinders (smallest grinder) with specifications of model UC-150, such as: distance between centre 160 mm, height of centre 102 mm, swivelling angle Âą9-degrees, traverse speed 140-260-370-700 mm/min, infeed of handwheel 0.01 division, grinding wheel size as 250 mm (D) x 25 mm (W) x 76.2 (B) mm, grinding wheel speed at 2300 RPM, workhead spindle speed 90-210-360 RPM (three range), and spindle in taper MT-3. Devco Industries Wadhwancity - Gujarat Tel: 02752-243997, Fax: 02752-240926 Email: devco1980@yahoo.com

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Product Update Cylindrical grinding machines

Universal grinding machines

CNC cylindrical grinding machines (model SWIFT500) offered by Hi-Life Machine Tools are designed to cater to customer requirements of high accuracy, productivity and reliability of performance. These machines are suitable for production as well as tool room applications. Features include: machines with Siemens 802D CNC system, 2-axis and single spindle controlled; specially designed heavy-duty machine bed made of single-piece close grained graded casting; digital AC servo motors for X-Z axes; linear motion guideways for cross slide & better response; universal work head with CNC controlled constant surface speed of workpiece; separate oil filtration/re-circulation unit for grinding wheel head; straight/angular wheel configuration available; CNC control permits multi-diameter external grinding in plunge or traverse, taper, radius, profile grinding; manual pulse generator provided; menu-driven grinding cycles with screens; colour monitor with graphic simulation; and airconditioning unit for control panel.

Hitesh Engineering Works manufactures and offers hydraulic cylindrical grinding machines (model HEW 450 mm) that are light and heavy-duty for high-precision grinding of gauges dies & punches dies for toolroom application with accuracy on diameter 0.002 micron. The one-piece machine body is made from closed grain casting with maximum grinding length of 450 mm and height centre of 130 mm. Tables are flat on one side and V on the other side. Turcite-B linear materials coated are precision hand-scrapped to match corresponding surfaced of the guideways. The grinding wheel spindle is made from EN-24 bush for smooth running of grinding wheels. Grinding wheels sizes are 350 mm x 38 mm x 127 mm. Grinding wheel heads are swivelled to a 45degree movement through racks and pinions. The workhead spindle has an angular contact bearing match pair having 8-speed extra equipment. Also manufactured are 300 mm, 600 mm, 800 mm, and 1000 mm grinding machines.

Hi-Life Machine Tools (P) Ltd

Hitesh Engineering Works

Ahmedabad - Gujarat Tel: 079-2282 1615, Fax: 079-2282 2800 Email: info@hilifegroup.com

Wadhwancity - Gujarat Tel: 02752-241926, Fax: 02752-241036 Email: info@pitrodagrinder.com

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Product Update Torque sensors Kistler Instruments India offers model 4503A dual torque sensors and digital telemetry. The version with a second measuring range (option) is ideal for applications with a high peak torque but moderate operating torque. The dual range sensors offer the advantage of range switching, which allows highly accurate measurement of both the peak and particularly the operating torque. Power is supplied and the measurement signals transferred between the rotating shaft and the case without contact. Type 4503A torque sensors with built-in speed sensor operate on the strain gauge principle. These are universal in application, being suitable for the development laboratory, production or quality assurance. They are typically used for testing of electric motors, generators, drive performance, measurement of transmission or spindle drive friction, at a manual workstation or in networked, automated production cells. The torque sensors find applications in automotive & vehicle engineering, aeronautical industry, mechanical & process plant engineering, and in electric motor manufacture. Kistler Instruments India Pvt Ltd Faridabad - Haryana Tel: 0129-4113555, Fax: 0129-4113551 Email: sales.in@kistler.com

Hydraulic angle shearing machines Jekshine hydraulic angle shearing machines offered by Jekson Machinery are used for angle cutting works, which demand accuracy, quality and productivity. These angle shearing machines are used for shearing of angles used for various purposes. Capacity of the machines ranges from 100 tons to 250 tons. The machines consist of main drive motor and electric control panel with inch & single cycle auto operation. Stroke adjustment rod is available with limit switch. Punch and die adapter is used for angle shearing. Also manufactured are machineries like CNC/conventional hydraulic press brakes, hydraulic presses, CNC waterjet cutting machines, transmission tower making machines, such as angle shearing, angle punching, angle stamping, angle flange cutting, plate punching, CNC plate punching & horizontal bending presses, etc. Jekson Machinery Pvt Ltd Ahmedabad - Gujarat Tel: 079-2290 1850, Fax: 079-2290 1851

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Product Update Press brakes

Keyless transmission elements

Mechanical and pneumatic press brakes offered by Weldor Engineering are available in the capacity of 20 tons to 350 tons and length ranging from 1525 mm to 4000 mm. These press brakes are widely accepted in industries for continuous production runs and also in areas requiring accuracy and repeatability coupled with high production. Double-geared motorised ram adjustment, motorised reversing mechanism, manual back gauge, manual lubrication, one multi groove, V-block and V-punch are standard features. Frame ram and bed, drive system, ram adjustments, clutch & brake are well constructed accurate and reliable. The mechanical and pneumatic press brakes find their applications in steel furniture industries, door frame & slotted angles, refrigeration, door frame manufacturers, automobile industries and control panel manufacturers. Also offered are mechanical/hydraulic & pneumatic press brakes, guillotine shearing machines, power presses/trimming & blanking presses, double-action deep-drawing hydraulic presses and CNC turret punch presses.

NMTG Mechtrans Techniques offers keyless transmission elements that entirely eliminate shafts/hub keyways. This method is very simple. By expansion of the outer and shrinkage of inner rings of the elements, shaft and hub frictional connections are established. These transmission elements have great absorbing capacity of kinetic energy by elastic radial deformation of tapered rings. They are available in a wide range from 10 mm dia to 400 mm dia and in various models. Features include: no keyway, no extra machining, no notch effort; perfect true running; high fatigue strength under alternating torsional stress; free from wear; overload protection effect; easy adjustability; easy mounting and removal; and maintenance-free. The keyless transmission elements are used for connection of gear wheels, chain sprockets, levers, cam plates, belt pulleys, brake drums, flywheels, couplings and clutches, shaft-mounted gearing, flanges, track wheels, impellers, etc.

Weldor Engineering Pvt Ltd

NMTG Mechtrans Techniques Pvt Ltd

Rajkot - Gujarat Tel: 0281-2360242, Fax: 0281-2360466 Email: weldor@weldor.com

Ahmedabad - Gujarat Tel: 079â&#x20AC;&#x201C;2282 1527, Fax: 079-2282 0214 Email: nmtg@nmtgindia.com

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Product Update Lathe machines Premier Lathe Manufacturing Co offers lathe machine that are rigidly designed and suitable for bulk production. These machines combine all the features, which are expected in heavy-duty production lathes with great efficiency and are ideal for all sliding, surfacing and screw cutting operation. Various special features of the machines include: lathe hardened & ground bedways; raw materials used are selected and grade quality raw materials are used; main spindle is hardened & ground with double grinding; and all screws made from bright steel with gun metal screw nut. Some of the technical specifications are: length of bed available from 1675 mm to 6100 mm, admit between centre 555 mm to 4950 mm, centre height available at 330/380 mm, spindle bore available at 55/80/104/130 mm, etc. The lathe machines also have a variety of attachments, like fully or semi Norton gearbox, taper turning attachment, rear tool post and coolant pumps, etc. Premier Lathe Manufacturing Co Rajkot - Gujarat Tel: 0281-238 7556, Fax: 0281-238 9248 Email: premierenterprise@rediffmail.com

Radial drilling machines All-geared radial drilling machines (model RD-40/1000) offered by Poly Kraft Machines have base in one-piece casting of heavy proportion and rigidly cross-ribbed on the underside to prevent any bowing effects under heavy loads. A reservoir for coolant is cast integrated with the base. The T-slots on the surface is hand-scrapped. Column is of high Brinell hardness number suitable for its purpose. Automatic vertical movement of arm is provided with direct coupled flange motor on the bracket, as the lead screw will not rotate even while automatic movement is in operation. Automatic feed mechanism is provided for vertical traverse of the quill. The toughened spindle made of high grade alloy steel is carried in preloaded taper roller bearings to absorb reverse trust and radial loads produced by drilling and boring. The radial drilling machines are supplied with two electric motors, coolant pumps, pipe fittings, tables, etc. Electricals are suitable for 440 V, 50 cycles, 3-phase AC supply. Poly Kraft Machines Ahmedabad - Gujarat Tel: 079-2274 3639, Fax: 079-2274 3639 Email: pkmdrill@gmail.com

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Product Update Hydraulic cylindrical grinders Pitroda Utility Industries manufactures and offers hydraulic cylindrical grinders (model PUI500) with base made of close-grained and heavily ribbed casting for high rigidity in one-piece body. All guideways are carefully handscraped to ensure high accuracy and V-flat table guideways have continuous lubrication. Longitudinal hand travel of the table is by rack & pinion arrangement and automatic travel is by hydraulic mechanism. The hydraulic system consists of hydraulic pump, valves, levers, piping, etc; and all conveniently housed in the base as well as separate powerpack. Rapid approach can be provided hydraulically with separate slide. The wheel head spindle is made of case hardened nickel-chrome alloy steel ground & microfinished and runs in adjustable phosphorous bronze metal bush bearings to achieve high accuracy adjustable and long life. Drive to the wheel head is transmitted by two V-belts. Workhead spindle is made of special alloy steel and runs in taper roller/angular contact bearings. Pitroda Utility Industries Wadhwancity - Gujarat Tel: 02752-243795, Fax: 02752-243167 Email: response@pitrodautilityindia.com

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Product Update Surface grinding machines Pinnacle Engineering Enterprise offers horizontal surface grinding machines with manual table drive. Model GSM-4520 is available with table size of 450 mm x 200 mm whereas model GSM4525 comes with table size of 450 mm x 250 mm. Model GSM 6030 has table size of 600 mm x 300 mm. These surface grinding machines are designed with new concept having linear guideways for easy table movements with wire rope drives to avoid pitch marks usually observed in racks and pinion drives (chatter) on the job ground. With this arrangement the flatness accuracy and grinding finish are achieved as achieved in hydraulic drive precision surface grinding machines. The horizontal surface grinding machines are tested as per IS test chart. Flatness accuracy of within 10 micron and surface finish of within 0.4 to 0.8 micron RA are standard features. Pinnacle Engineering Enterprise Surendranagar - Gujarat Tel: 02752-231167, Fax: 02752-231913 Email: mail@pinnaclegrinder.com

Hydraulic power units Shashwat Systems specialises in manufacturing of standard as well as customâ&#x20AC;&#x201C;built hydraulic power units. Utmost care is taken to ensure that quality standards are maintained throughout the manufacturing process. The entire ranges of hydraulic power units are painted with polyurethane paints, to avoid corrosion, effectively. This ensures quality performance of the power units under all climatic conditions, even in coastal areas, where the salt content is high in the atmosphere. Only standard accessories, such as suction strainers, filler breathers, pressure gauges, gauge isolaters and return line fillers, etc are used during the manufacturing process and high-quality pumps and valves of world-renowned brands like Atos, Rexroth, Vickers, etc, are used in these hydraulic power units, always ensuring excellent performance. This commitment to maintaining quality standards ensures longevity and reliability of our systems. With such adherence to quality standards, the range of hydraulic power units have already made a name for themselves in this highly competitive field, claims the company. Shashwat Systems Pvt Ltd Ahmedabad - Gujarat Tel: 079-6521 4825, Mob: 09824051536 Email: admin@shashwatsystems.com 272 MODERN MACHINE TOOLS - October 2011


Product Update Power shearing machines Mechanical power shearing m a c h i n e s offered by G o d s o n B e n d i n g Systems are constructed sturdily and designed for accuracy & dependability by employment of the latest technology and experience. Sidewalls are designed from mild steel to take heavy loads. Beds and upper beams are fabricated from mild steel to withstand and absorb heavy loads designed specially to adjust the blade clearance as required. Pressure plates are fabricated from mild spring loaded. Clutches, brakes and drives include revolving key clutch, linked with the main gear that engages every time when the foot pedal is pressed. Back gauges in GSH-1-2-3-4 are screw-driven whereas in GSL1-2-3-4 and GSL1-2-3 they are of rack pinion type designed. Blades are generally four-edged and grade-I with single segment. Lubrication oil cups provided are connected with various pipes rendering supply of oil. The power shearing machines are only used for cutting mild steel. Standard equipments include: back gauge, front gauges, wheel & gear guards, foot pedal and pulley. Godson Bending Systems Pvt Ltd Rajkot - Gujarat Tel: 0281-2361467, Fax: 0281-2361873 Email: godsonindia@hotmail.com

Radial drilling machines Universal radial drilling machines (model SER-I) offered by Sahyog Enterprise have drilling capacity of 38 mm, spindle stroke of 220 mm, with 8 speed and working table of 380 mm x 300 mm x 300 mm size. Salient features include: main spindle made from EN steel with 6 slots in machined by hobber machine and Morse Taper bore provided internally grinded, spindle sleeve properly guided in honed drill head bore on 6 ball and roller bearings for smooth and accurate running. The main asset is rigid quality inspection methods combined with skilled workmanship. The radial drilling machines are very simple to install and operate requiring no skilled labour. They have sturdy built up and are designed for both production and tool room job. Also offered are pillar and radial drilling machines in different models and sizes. Sahyog Enterprise Bhavnagar - Gujarat Tel: 0278-2446848, Fax: 0278-2447316 Email: bhavin@siddhapuradrills.com

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Product Update Euro gearboxes Euro Gears are specialised in production of various reduction gearboxes with the edge of research and development in transmission technology. The ongoing process of R&D has made it possible to introduce advance technology and continuous developments to meet market requirements. Euro Gear aluminum alloy housing gearboxes are totally dustproof and oil-tight with attractive esthetical look. The silver grey paint on the body protects the housing from oxidation. Longer and higher number of cooling fins on all faces provides maximum surface area exposing to atmosphere for more capability of heat dissipation, thus improving efficiency, which makes it ideal for hot ambient temperature conditions. Features like robust & compact construction, easy interchangeability of input flanges with standard fasteners, perpendicularly machined matching surfaces makes these gearboxes suitable in all operating conditions of almost every industry by means of right selection. Case carburised and grounded alloy steel worm shaft ensure a positive oil film. United Transmission Ahmedabad - Gujarat Tel: 079-2546 5715, Mob: 098253 25367 Email: unitedhyd@vsnl.net

Pillar drilling machines Shree Shaktivijay Engineering Works offers 38 mm capacity heavy-duty (model 38TPD) pillar drilling machines. The streamline and robust construction of manual drilling machine gives a trouble-free service up to an entire satisfaction of the user. Different parts of the machines, like spindles, backgears, rams, etc, all are made of mild steel. The tooth of the gears is cut helically to improve the transmission efficiency. High quality bearings are used to increase the life of transmissions. The locking devices are provided at appropriate places to increase the safety factor. Well-finished working table and base plate is provided with T-slots. The working table can be adjusted vertically by rack & pinion system. Stock of each and every part is well maintained (claims the company). Technical specifications include: 38 & 40 mm drilling in steel & CI respectively, 25 mm tapping in steel, spindle travel 175 mm, number of spindle speeds 8 mm, range of spindle speeds 80-2600 mm, etc. Shree Shaktivijay Engineering Works Ahmedabad - Gujarat Tel: 079-2562 0703, Fax: 079-2562 0703 Email: response@drillmachineindia.com

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Product Update Lathe machines Balaji cone pulley mediumduty lathe machines (series VM) offered by Vinit Engimech have different heights of centre ranging from 215 mm to 250 mm, with length of bed ranging from 1370 mm to 1830 mm, and admit between centres ranging from 450 mm to 1000 mm. The main spindle hollow ranges from 40 mm to 50 mm. Main spindle nose is threaded type. Dynamically balanced spindles enable them to run at vibration-free motion at 700 RPM. The Norton gearbox is able to cut any of the metric modules and pitch (DP). Bed is made from graded cast iron and flame hardened up to 400 BHN diametric. The lathe machines are maintenance-free and easy-to-use. Parts of the machines are interchangeable and available in stock at the regional dealerâ&#x20AC;&#x2122;s office. Vinit Engimech Pvt Ltd Rajkot - Gujarat Tel: 0281-2312091, Fax: 0281-2311935 Email: vinit@balajilathe.com

CNC turn mill centres Femco India offers twin spindle double disc turret CNC turn mill centres (model Femco HL-35 DMSY) with Y-axis. The double-disc power turret improves process efficiency and work piece accuracy with its 23 station tools capacity. The turret performs milling, drilling, and tapping for both primary as well as sub-spindle. Femco India Pune - Maharashtra Tel: 020-40147870, Mob: 09822310454 Email: sales@femcoindia.com

Circumference gauges Kristeel Shinwa Industries offers precision measuring stainless steel rulers & engineering gauges. These gauges are made specifically to check the outside diameter and circumference of pipes, wooden blocks, big size tanks, etc, that have least count of 0.1 mm. The rugged gauges, fabricated in imported stainless steel by permanent etching graduations and riveted with buckle/vernier scale are useful in pipe manufacturing industries, cylinders, heavy fabricator, round tanks, woodworking industry, etc. Kristeel Shinwa Industries Ltd Mumbai - Maharashtra Tel: 022-4225 6666, Fax: 022â&#x20AC;&#x201C;4225 6690 Email: sales@kristeel.com

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Product Update Vacuum pumps & compressors Minivac side channel vacuum pumps and compressors (turbine blowers) offered by Shree Siddhivinayak Industries are designed to suck or to compress air, gases, nonexplosive air mixtures, etc. These are absolutely oil free with air flow capacities ranging from 42 m³/hr to 1100 m³/hr, with maximum vacuum up to 500 mbar and maximum pressure up to 550 mbar. Salient features include: lightweight due to aluminium construction and have 100 per cent oil free non-pulsating continuous airflow. The vacuum pumps and blowers require practically zero maintenance and have silencers on both suction as well as discharge ports. These are useful in many applications like pneumatic conveying systems, industrial vacuum cleaners, electroplating industries like hot dip galvanising, oxy-generation in aquariums/fisheries, air feeds to industrial ovens and burners, printing and paper handling, air pollution monitoring equipment, dental suction equipment, etc. Shree Siddhivinayak Industries Dist Thane - Maharashtra Tel: 022-2845 8372, Fax: 022-2845 7073 Email: minivac@rediffmail.com

Hydraulic presses Dowel Engineering Works offers power-operated hydraulic presses ranging from 15 tons to 300 tons capacity in mild steel robust construction. The crown, column and bottom are solid without bend and welded. Table is vertically operated by worm winch gearbox and rests on load pins placed in holes in columns at desired height. There is also an option to operate bed-by-bed lifting attachments that are electrically-operated. Rollers are provided with the bed for easy handling of heavy jobs. The cylinder is made from honed tube. Hardchrome plated ram is made from mild steel, operated by doubleacting cylinder. Good quality seals assure long working life. The ram is provided with replaceable socket to facilitate attachment of dies and tools, on customers’ requests. The hydraulic presses are quipped with high-pressure hydraulic pump, DC valve, pressure relief valve, etc, of Bosch Rexroth make; and electric motor of three-phase 440 V of reputed make, like Kirloskar, Crompton or Siemens. Dowel Engineering Works Rajkot - Gujarat Tel: 0281-2362465, Fax: 0281-2362465 Email: dowel@thedowel.com

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Product Update Pneumatic impact wrenches Chicago Pneumatic offers CP7749 ½-inch pneumatic impact wrench to feature side-to-side (S2S®) forward/ reverse functionality. This wrench is well-balanced, lightweight at only 1.98 kg (4.37 pound), and packs a punch with 980 Nm (725 ft lbs) of torque. This is a tool that reduces the strain on wrist and forearm common with the use of typical impact wrenches when changing direction of rotation. The exclusive S2S technology allows user to effortlessly change between forward and reverse with one hand in any position. The three-position power regulator in forward provides control and helps to prevent overtightening, while full power remains constant in reverse to ensure technicians have maximum power to remove fasteners without changing the setting in the forward position. The CP7749 is also available with a two-inch anvil (CP7749-2) for tyre removal applications when accessibility is an issue or the use of ‘flip’ sockets. In continuation to S2S series, Chicago Pneumatic plans to launch more variants in 3/8”, ½”, ¾” and 1” square drive categories. Chicago Pneumatic Thane (W) - Maharashtra Tel: 022-3998 2731, Fax: 022-3998 2725 Email: ashish.malhotra@cp.com, Website: www.chicagopneumatic.co.in

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Product Update gearbox and hardened gears give very long life to the machine. Auto feed gears are also hardened. All gears in the machines are supported through good quality bearings and not the bushes. The machines are supplied with complete electrical panel boards with five pushbutton switches and one limit switch along with two ISI electrical motors. Rotation and easy sliding of gears in bearings give very high reliability. Steel ram and pinion with 9 DP heavy-duty teeth with 250 mm spindle travel enables greater loading capacity. Prakash Mechanic Works Bhavnagar - Gujarat Tel: 0278-243 8241, Fax: 0278-243 8241 Email: pmw@sancharnet.in

Press brake machines

Tungsten carbide rod blanks Blood tungsten carbide rod blanks manufactured by Robin Precision Products are available in comprehensive range of best quality in ground and unground form. These carbide rod blanks are also available in both metric and inch sizes with diameters ranging from Ø3 to Ø 25 mm (Ø1/8” to Ø 1”), imported from Europe. The blanks are highly precision ground and polished to H6/H7 tolerance. Intermediate sizes are also available as per requirements. The tungsten carbide precisely ground rods are widely used for plug/pin gauges, carbide punches, precision V-blocks, jigs, etc. Cobalt composition in the tungsten carbide material tends to oxidise in the atmospheric air, which results into leeching. This is specially being taken care of in the rods, thereby offering worldclass quality.

Shailesh Machine Tools has introduced both, mechanical and hydraulic versions of press brake machines for sheet metals pressing industries. These machines come with sizes varying from 1500 mm to 4000 mm length and bending thickness ranging from 1.6 mm to 8 mm. The machines offer several standard and optional accessories to enhance their productivity, such as auto lubrication systems, motorised ram adjustment, hydraulic hold-down clamping systems, quick die changing systems, pneumatic or hydraulic clutches, manual or motorised back gauging systems, independent electrical control panels as also PLC CNC based systems to suit customers’ most demanding requirements. Shailesh Machine Tools Pvt Ltd Rajkot - Gujarat Tel: 0281-246 1102/62, Fax: 0281-246 1665 Email: info@shaileshmachines.com

Light-duty drills

Rajkot - Gujarat Tel: 0281-2371722, Fax: 0281-2388431 Email: info@bloodtools.com

Nippon Electrical Industries have further modified and developed the most rugged of its kind of 13 mm lightduty drills (model B6D). These drills are metal bodied meant for years of use with absolutely least maintenance. They are almost similar to other nationwide company make with all the spare parts interchangeable and easily available (claims the company).

Radial drilling machines

Nippon Electrical Industries

All-geared auto feed radial drilling machines (40 mm capacity) from Prakash Mechanic Works have gearbox of 9 speeds with all 9 gears of EN-9 steel hardened up to 50 HRC. Oil bath

Ahmedabad - Gujarat Tel: 079-2282 2750, Fax: 079-2280 0119 Email: marketing@nipponpowertools.com

Robin Precision Products Pvt Ltd

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Product Update Pillar drilling machines Siddhapura Engineering Works manufactures and offers pillar drilling machines (model SEW/P-1) that are used for drilling, tapping and boring applications. These machines have drilling capacity of 25 mm, tapping capacity of 20 mm in mild steel and drilling capacity of 32 mm in cast iron. Quill spacers are made from steel while main spindles are made of EN steel with 6 slots. Spindle nose is of MT-3, spindle travel is 250 mm and spindle speed of 8 gears is made from best quality material and helical teethed for smooth & noiseless running. The pillar drilling machines attain standards of IS:2425. They are very useful for every toolroom and maintenance purpose.

technical specifications of these drilling machines are: distance of spindle nose to the table at 600 mm; distance from table to base at 360 mm; distance from spindle centre to pillar face at 200 mm; table travel 310 mm; taper in spindle MT-2; 8 nos of speed; range of speed 80 PPM to 3300 PPM; table size 265 mm x 265 mm; machined area base size 400 mm x 230 mm; overall base size of 450 mm x 290 mm; spindle travel at 130 mm; pillar length of 915 mm; overall height with pulley guard at 410 mm; V-belt section A-38â&#x20AC;?; weight approximately 100 kgs; and 0.5 HP motor of 1440 RPM, 3-phase, 440 V. P Parmar Machine Tools Bhavnagar - Gujarat Tel: 0278-2447409, Fax: 0278-2446564 Email: info@parmardrill.com

Siddhapura Engineering Works Bhavnagar - Gujarat Tel: 0278-242 8054, Fax: 0278-251 1961 Email: bipin@siddhapuradrills.com

Pillar drilling machines

The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of

P Parmar Machine Tools manufactures and offers pillar drilling machines (model PMT P-1) that have drilling capacity of 19 mm and pillar diameter of 75 mm. The

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AN N I VERS ARY

International Products Tool changer systems Colombo Filippetti Torino manufactures tool changer systems, focusing on collaboration with customers in design and development and constant product innovation. The main characteristics of these products are the high exchange speed that the systems realise, using cams, with precise and silent movements. Low maintenance and reduced costs are added to the efficiency of these mechanisms, making them an economic advantage. CTM is the classic tool magazine suitable for installation on vertical and horizontal work centres. CTM is manufactured in different sizes according to the type of tool holder and it is assembled with magazine having different capacity of 12-20 or 30 tools (standard versions) and 24-40-48 or 60 tools (special versions). The CTM is composed of a cam exchanger, a completely mechanical rapid gripper arm and a ring tool magazine. The exchange time varies from 0.8 to 3 seconds, depending on the tool weight and on the exchange distance. Colombo Filippetti Torino Srl Torino - Italy Tel: +39-11-3972211, Fax: +39-11-3497863 Email: info@cofilto.it

Horizontal machining centres StarragHeckert WMW CWK series machines are globally renowned for longterm accuracy, long-term performance and longterm reliability. These are 4-axis compact horizontal machining centres that have many unique features for high-performance and reliability. The rigidity of the bed and column construction, the hydraulically driven chain magazine, the NC rotary table with special braking, pressurised air curtain around rotary table avoids contamination. Cartridge-type spindle with 2-stage gearbox and inline motor having power of 50 kW with torque of 1210 Nm, this feature is specifically suitable for heavyduty machining of titanium, stainless steels and other exotic difficult to machine materials. Construction of pallet changer is robust and has unique wedge mechanism to lock pallet dovetailed coupling mechanically. LM guides having four side line contacts with cylindrical rollers for high accuracy, rigidity and long term accuracy in heavy-duty machining. Hydraulic counterbalance for Y-axis prevents drop during power failure, improves accuracy in Y stroke/interpolation. Rugged hydraulic motor operated ATC and magazine are designed to carrying high weight capacity up to 35 kg, 600 mm long tools. StarragHeckert AG Rorschacherberg - Switzerland Tel: +41-71-8588111, Fax: +41-71-8588122 Email: sales@starragheckert.com 284 MODERN MACHINE TOOLS - October 2011


International Products Horizontal machining centres

Hydraulic angle lock vices

You Ji Machine Industrial Company offers HMC series horizontal machining centres (HMCs) that are available with high rigidity, high accuracy and high efficiency. These HMCs adopt box in box frame type design for the machine column. This design greatly increases the stability of the machine; parallel X axes ball screw with servo tandem control key feature that has excellent performance when the axes move or feed rapidly. Additionally, the capacity of heavy-duty cutting increases by 15 per cent approximately. The machine structure is analysed through finite elements analysis (FEA) to ensure the best design for achieving of rigidity and capacity of anti-vibration. In contrast with conventional single column design, this feature prevents machine from resonance when cutting, greatly increase surface, contour machining accuracy and life time of tools. The B axis has remarkable positioning performance. Rotary and swing type automatic pallet changer systems (APC) are able to save job loading and unloading time, increase desired machining efficiency.

Jin Year Precision Co offers MC pressure-constant hydraulic angle lock vices (back tension) that are available in various models, like JHV-100, JHV-130, JHV-160, JHV160(A), and JHV-200. The hydraulic system device is the front part that results in force to prevent the workpiece tilt. Down thrust with semi-sphere prevents workpiece lift. Pressure constant and clamping force can be preset by repeating and using the same clamping force. Mechanical and hydraulic are two operating methods. The vice body is made of ductile iron FCD60. Vice bed is hardened to HRC45 and maintain accuracy for long. The vice bed height-size and the guide block side are all made with full control can 2, 3, or 4 vices to perform a job at a time is available. The vices have four ways of clamping for users to choose from.

You Ji Machine Industrial Company Ltd

Jin Year Precision Co, Ltd Taiwan - ROC Tel: +886-4-25232817, Fax: +886-4-25151230 Email: liu0930@ms58.hinet.net

The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of

Kaohsiung Hsien - Taiwan Tel: +886-7-6983068, Fax: +886-7-6983071 Email: youji@ms15.hinet.net

October 2011 - MODERN MACHINE TOOLS 285


Network with Engineering Expo Exhibitors Now you can meet and discuss business with Engineering Expoâ&#x20AC;&#x2122;s exhibitors, much prior to the actual exhibition. Just let us know about the exhibitor that you want to get in touch with and we will fix the meeting for you. Contact us on 09819552270

UPDATE 4 Rudrapur 23-26 September 2011 Gandhi Park

Airflic Corporation Products: Refrigaration air dryers, Auto drain valves, Compressed air filters, Dust filtration units, Heatless air dryers

Airtech Cooling Process Pvt Ltd Products: Refrigeration plants, Cold rooms, Walk-in cold rooms, Chilling plants, Cooling units, Cooling towers, Bulk milk coolers, Ammonia plants W: www.airtechengineers.com

Ahmedabad 14-17 October 2011 Gujarat Univesity Exhibition hall

Allied Power Solution

Pune 18-21 November 2011 Auto Cluster Exhibition Centre

Anand Engineering Pvt Ltd

Chennai 8-11 December 2011 Chennai Trade Centre

Indore 6-9 January 2012 Poddar Plaza, MG Road

Products: Advance lightning protection systems, Surge protection devices, Chemical gel earthing, HT/LT panels, Substations, Transformers, Generators, UPS systems, Servo stabilisers, Isolation transformers, VFDs, PLCs, Automatic transfer switches, Industrial & commercial valves W: www.alliedpowersolutions.com

Products: Greases, Antiseizes, Thread compounds, Silicon compound oils, Conveyor chain oils, Gear oils, Gear oil additives, Hot forging lubricants, Dry soild lubricants, Dry bonding coatings, Rust preventive oils, Cleaners & degreasers, Anti-spatters, Metal forming fluids, Crack detection kits, Aerosols W: www.molygraph.com

Aqua Services Products: Gaseous chlorination plants, Bleaching powder dosers, Chlorine solutions, Chemical dosing pumps, Empty chlorine gas cylinders/toners, Water treatment plant spares W: www.aquaservicesindia.com

Ashok Leyland Products: Gensets, Generators, Diesel engines W: www.ashokleyland.com

Aurangabad 17-20 February 2012 Garware Stadium Asian Publications

Book Your Stall Now

Products: Industrial news magazines W: www.productbureau.in

Astha Heat tech Contact www.engg-expo.com T: 09819552270 E: engexpo@infomedia18.in SMS: EXPO to 51818

Products: Industrial heaters, Tubular & finned air heaters, Mica & ceramic band heaters, Hot runner coil heaters, Casted heaters, Heat tracers, Flexible heating pads W: www.indiamart.com/asthaheattech

Auto Service Equi pment Products: Air compressors, Dryers, Air receivers & filters, Pneumatic tools, Automobile garage equipment


Basant Industries Products: Power presses, Industrial process machines, Lathe machines, Grinding machines, Cutting machines W: www.basantinc.com

Best Quality Fastners Products: Machine screws, Stell screws, Hex bolts, Hex weld nuts, Hex nuts, Nylock nuts W: www.rktrades.com

Bharat Machinery Agencies Products: Power tools, Taparia hand tools, Cutting tools, Grinding wheels, Air tools W: www.in.bosch.com

Brahmadevi Engineering Products Products: Ejector pins, Ejector sleeves, HSS punches, Die buttons, Nitrogen gas springs, Die springs, Parting locks, Taper interlocks, Guide pillars, Guide bushes, Shoulder punches, Jector punches, Oil-less products, Mould counters, Water stoppers, Latches, Spring plungers, Date-marked pin sets, Straight block sets, Taper block sets, Camunits, Balllock punches, stripper bolts W: www.diespares.com

Brasstech Engineering Pvt Ltd Products: Brass electrical parts, Transformer parts, Air-conditioning parts, Pipe fittings, CNC turned/milled & forged parts W: www.beplindia.com

Chicago pneumatics sales Products: High-performance air & gas compressors, Refrigerated & heatless dryers, Filters, Air receivers, Genuine parts, Airnet pipings, Quality & proactive services W: www.cp.com

Coatec India Products: Surface coating techonology, CNC profile cutting solutions, Industrial automation & robotics W: www.coatecindia.com

Cosmos Tapes & Labels Pvt Ltd Products: Self-adhesive tapes: Masking, Fine line, Tissue, Foams, Acrylic foam, Butyl foam, Mono/cross filament tapes, Holding tapes, Electrical polyester, Kapton, Glass cloth, PVC, Aluminum foil tapes, Slicone polyester, Thermally conductive Tapes, etc; Die-cuts: Masking profiles, EPDM, Nitrile, EVA, EPE, PU, XLPE, Polyesters, etc; Lubricants: Paint shop conveyor oils, Heavy load greases, Food grade greases, etc; Paint repairing products: Waterproof emery papers, Tools, Polishes & accessories W: www.cosmostapes.in; www.cosmostapes.com

Delair India Pvt Ltd Products: Refrigeration compressed air dryers, Heatless adsorption compressed air dryers, Engineered adsorption dryers, Air filters, Air receivers, Aftercoolers, Moisture separators, Auto drain valves W: www.delairindia.com

Elind Induction Furnaces Pvt Ltd Products: Induction heating equipment W: www.elindinduction.com


Engineering Hindustan Products: Electromagnetic cluches & brakes, Electromagnetic clutches/brakes & clutch-brake combinations, Electromagnetic clutches, AC-DC brakes, Mechanical & hydraulic cluthches & brakes W: www.engineeringhindustan.com

UPDATE 4 Rudrapur 23-26 September 2011 Gandhi Park

Essae Digitronics Pvt Ltd Products: Electronic weighbridge, Weigh-in-motion, Rapid loading system, Machined components, Rail-in-motion W: www.essae.in

Essae Technologies Pvt Ltd Products: Checkpoint products, Datalogic scanners, Unitech scanners, Unitech terminals, Zebra printers, Zebra ribbons, Labels W: www.essaetec.com

Ahmedabad 14-17 October 2011 Gujarat Univesity Exhibition hall

FARO Business Technologies India Ltd Products: Arms, Laser ScanArms, Gauges, Laser trackers, Laser scanners, CAM2 software W: www.faro.com

Pune 18-21 November 2011 Auto Cluster Exhibition Centre

Chennai 8-11 December 2011 Chennai Trade Centre

Indore 6-9 January 2012 Poddar Plaza, MG Road

Ferreterro India Pvt Ltd Products: Webbing slings, Ratchet buckles, Rubber tarps, Cargo bars, Cargo planks, Chimti buckles, Ratchet assy, D-shackles, Bow shackles, Forgings, Dunnage bags, Steel hooks W: www.ferreterro.com

Forging machinery Products: Belt drop hammers, Power presses, Anvil blocks, Billet shearing machines, Power press H-frames, Power press C-frames, Friction screw presses, Forging hammers, Froging presses, Forged components W: www.nkh.co.in

Global Cooling Tower & Equi pments Products: FRP cooling towers, Chiiling plants, Water treatment chemicals W: www.globalcoolingtowers.com, www.gcte.tradeindia.com

Aurangabad 17-20 February 2012 Garware Stadium

Book Your Stall Now

H P Singh and Machinery Products: Lathes & grinding machines, Hydraulic shearing machines, Centreless grinders, Cylindrical grinding machines, All-geared radial drilling machines, Milling machines, Heavy-duty belt-driven lathes, All-geared lathes, Hydraulic press brakes, Power presses, Shaping machines W: www.hpsmachines.com

Hazel Infotech Ltd Contact www.engg-expo.com T: 09819552270 E: engexpo@infomedia18.in SMS: EXPO to 51818

Products: Softwares W: www.hazelinfotech.com

HI Tech Automation Products: Control panels, Leakage testing machines, Reconditioning of PDC machines, SPMs W: www.indiamart.com/hi-tech automation


I.Q Enterprises (I) Pvt Ltd Products: Q-Manager, Ropes & posts, Barricading posts, Flexible & multi-purpose barrier systems, Security barriers W: www.q-manager.com

Igus India Pvt Ltd Products: Cable drag chains, Flexible cables, Polymer bearings W: www.igus.in

Engineering Hindustan Products: Electromagnetic cluches & brakes, Electromagnetic clutches/brakes & clutch-brake combinations, Electromagnetic clutches, AC-DC brakes, Mechanical & hydraulic cluthches & brakes W: www.engineeringhindustan.com

Ind-Chin Enterprises Products: Velding machine, CNC cutting automation, Welding automation, Shearing machines, Rolling machines, Welding & inverter based press brakes, Power generators, Power tools & abrasive, Drill bits, H-beam welding W: www.indchinenterprises.com

Indian Harvesters Products: Shot blasting machines, Shot peening machines W: www.indianharvesters.com

Indo-air Compressors Pvt Ltd Products: Air compressors, Multi-stage high-presurre rotary screws, Compressors, Vaccum pumps, Screw Compressors, Heavy-duty water-coated vertical compressors W: www.indoair.com

Insel Rectifires (India) Pvt Ltd Products: Semiconductor devices, Selenium rectifiers, Surge supressors, Power diodes, Thyristors, Power modules, Bridge rectifiers & IGBTs W: www.rectifierindia.com

J K Industries Products: Guillotine shearing machines, Power presses, Press brakes, Straightening machines W: www.ferreterro.com

Jekson Machinery Pvt Ltd Products: Hydaulic press brakes, Shearing machines, CNC plasma cutting machines, CNC oxyfuel cutting machines, Transmission tower making machines, Speacial-purpose machines W: www.jeksonmachinery.com

Jindal Rectifiers Products: Automatic voltage controllers, Silicon controlled rectifiers, Special-purpose transformers W: www.jindalrectifiers.com

Kamtron System Pvt Ltd Products: Testing & measuring instruments W: www.kamtrononline.com


AN N I VERS ARY

Product Index - Engineering Expo Sl. No E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23 E24 E25 E26 E27 E28 E29 E30 E31 E32 E33 E34 E35 E36 E37 E38 E39 E40 E41 E42 E43 E44 E45 E46 E47 E48 E49 E50 E51 E52 E53 E54 E55 E56 E57 E58 E59 E60 E61 E62 E63 E64 E65 E66 E67 E68 E69 E70 E71 E72 E73 E74 E75 E76 E77 E78 E79 E80 E81 E82 E83 E84

Product

Pg No

AC-DC brakes............................................288, 289 Acrylic foam .......................................................... 287 Advance lightning protection systems................... 286 Aerosols ................................................................. 286 Aftercoolers............................................................ 287 Air compressors .............................................286, 289 Air filters ............................................................... 287 Air receivers........................................................... 287 Air receivers & filters ............................................ 286 Air tools................................................................. 287 Air-conditioning parts........................................... 287 Airnet pipings........................................................ 287 All-geared lathes.................................................... 288 All-geared radial drilling machines ....................... 288 Aluminum foil tapes.............................................. 287 Ammonia plants .................................................... 286 Antiseizes............................................................... 286 Anti-spatters .......................................................... 286 Anvil blocks ........................................................... 288 Arms ...................................................................... 288 Auto drain valves ...........................................286, 289 Automatic transfer switches .................................. 286 Automatic voltage controllers................................ 289 Automobile garage equipment .............................. 286 Balllock punches................................................. 287 Barricading posts ................................................... 289 Belt drop hammers ................................................ 288 Billet shearing machines........................................ 288 Bleaching powder dosers ....................................... 286 Bow shackles.......................................................... 288 Brakes & clutch-brake combinations ............288, 289 Brass electrical parts .............................................. 287 Bridge rectifiers & IGBTs .................................... 289 Bulk milk coolers................................................... 286 Butyl foam ............................................................. 287 Cable drag chains ............................................... 289 CAM2 software..................................................... 288 Camunits ............................................................... 287 Cargo bars ............................................................. 288 Cargo planks.......................................................... 288 Casted heaters........................................................ 286 Centreless grinders ................................................ 288 Checkpoint products ............................................. 288 Chemical dosing pumps ........................................ 286 Chemical gel earthing ........................................... 286 Chilling plants ...............................................286, 288 Chimti buckles....................................................... 288 Chlorine solutions ................................................. 286 Cleaners & degreasers ........................................... 286 CNC cutting automation ...................................... 289 CNC oxyfuel cutting machines............................. 289 CNC plasma cutting machines ............................. 289 CNC profile cutting solutions............................... 287 CNC turned/milled & forged parts ...................... 287 Cold rooms ............................................................ 286 Compressed air filters............................................ 286 Compressors .......................................................... 289 Control panels ....................................................... 288 Conveyor chain oils ............................................... 286 Cooling towers ...................................................... 286 Cooling units ......................................................... 286 Crack detection kits............................................... 286 Cutting machines .................................................. 287 Cutting tools.......................................................... 287 Cylindrical grinding machines............................... 288 Datalogic scanners.............................................. 288 Date-marked pin sets ............................................ 287 Die buttons............................................................ 287 Die springs............................................................. 287 Die-cuts ................................................................. 287 Diesel engines........................................................ 286 Drill bits ................................................................ 289 Dry bonding coatings ............................................ 286 Dry soild lubricants ............................................... 286 Dryers .................................................................... 286 D-shackles ............................................................. 288 Dunnage bags ........................................................ 288 Dust filtration units............................................... 286 Ejector pins ........................................................ 287 Ejector sleeves........................................................ 287 Electrical polyester................................................. 287 Electromagnetic cluches & brakes ................288, 289 Electronic weighbridge.......................................... 288 Empty chlorine gas cylinders/toners ..................... 286

290 MODERN MACHINE TOOLS - October 2011

Sl. No E85 E86 E87 E88 E89 E90 E91 E92 E93 E94 E95 E96 E97 E98 E99 E100 E101 E102 E103 E104 E105 E106 E107 E108 E109 E110 E111 E112 E113 E114 E115 E116 E117 E118 E119 E120 E121 E122 E123 E124 E125 E126 E127 E128 E129 E130 E131 E132 E133 E134 E135 E136 E137 E138 E139 E140 E141 E142 E143 E144 E145 E146 E147 E148 E149 E150 E151 E152 E153 E154 E155 E156 E157 E158 E159 E160 E161 E162 E163 E164 E165 E166 E167

Product

Pg No

Engineered adsorption dryers................................ 287 Filters................................................................. 287 Fine line................................................................. 287 Flexible & multi-purpose barrier systems ............. 289 Flexible cables........................................................ 289 Flexible heating pads ............................................. 286 Foams .................................................................... 287 Food grade greases ................................................ 287 Forged components ............................................... 288 Forging hammers................................................... 288 Forgings ................................................................. 288 Friction screw presses ............................................ 288 Froging presses ...................................................... 288 FRP cooling towers ............................................... 288 Gaseous chlorination plants................................ 286 Gauges ................................................................... 288 Gear oil additives................................................... 286 Gear oils ................................................................ 286 Generators ............................................................. 286 Gensets .................................................................. 286 Genuine parts ........................................................ 287 Glass cloth ............................................................. 287 Greases................................................................... 286 Grinding machines ................................................ 287 Grinding wheels .................................................... 287 Guide bushes ......................................................... 287 Guide pillars .......................................................... 287 Guillotine shearing machines ................................ 289 H-beam welding................................................. 289 Heat tracers ........................................................... 286 Heatless adsorption compressed air dryers............ 287 Heatless air dryers ................................................. 286 Heavy load greases................................................. 287 Heavy-duty belt-driven lathes ............................... 288 Heavy-duty water-coated vertical compressors ............................................... 289 Hex bolts ............................................................... 287 Hex nuts ................................................................ 287 Hex weld nuts........................................................ 287 High-performance air & gas compressors............. 287 Holding tapes ........................................................ 287 Hot forging lubricants ........................................... 286 Hot runner coil heaters ......................................... 286 HSS punches ......................................................... 287 HT/LT panels ....................................................... 286 Hydaulic press brakes ....................................288, 289 Hydraulic shearing machines................................. 288 Induction heating equipment.............................. 287 Industrial & commercial valves ............................. 286 Industrial automation & robotics .......................... 287 Industrial heaters ................................................... 286 Industrial news magazines..................................... 286 Industrial process machines................................... 287 Isolation transformers ............................................ 286 Jector punches .................................................... 287 Kapton ............................................................... 287 Labels................................................................. 288 Laser ScanArms..................................................... 288 Laser scanners........................................................ 288 Laser trackers......................................................... 288 Latches................................................................... 287 Lathe machines...................................................... 287 Lathes & grinding machines................................. 288 Leakage testing machines...................................... 288 Lubricants .............................................................. 287 Machine screws .................................................. 287 Machined components .......................................... 288 Mechanical & hydraulic cluthches & brakes 288, 289 Metal forming fluids.............................................. 286 Mica & ceramic band heaters ............................... 286 Milling machines................................................... 288 Moisture separators ............................................... 287 Mono/cross filament tapes .................................... 287 Mould counters...................................................... 287 Multi-stage high-presurre rotary screws................ 289 Nitrile ................................................................ 287 Nitrogen gas springs.............................................. 287 Nylock nuts............................................................ 287 Oil-less products ................................................ 287 Paint repairing products ..................................... 287 Parting locks .......................................................... 287 Pipe fittings ........................................................... 287 PLCs...................................................................... 286 Pneumatic tools ..................................................... 286

Sl. No E168 E169 E170 E171 E172 E173 E174 E175 E176 E177 E286 E287 E288 E289 E182 E183 E184 E185 E186 E187 E188 E189 E190 E191 E192 E193 E194 E195 E196 E197 E198 E199 E200 E201 E202 E203 E204 E205 E206 E207 E208 E209 E210 E211 E212 E213 E214 E215 E216 E217 E218 E219 E220 E221 E222 E223 E224 E225 E226 E227 E228 E229 E230 E231 E232 E233 E234 E235 E236 E237 E238 E239 E240 E241 E242 E243 E244 E245 E246 E247 E248 E249 E250

Product

Pg No

Polishes & accessories ........................................... 287 Polyesters ............................................................... 287 Polymer bearings ................................................... 289 Power diodes ......................................................... 289 Power generators ................................................... 289 Power modules ...................................................... 289 Power press C-frames............................................ 288 Power press H-frames ........................................... 288 Power presses.........................................287, 288, 289 Power tools ............................................................ 287 Power tools & abrasive.......................................... 289 Press brakes ........................................................... 289 Q-Manager ........................................................ 289 Quality & proactive services.................................. 287 Rail-in-motion ................................................... 288 Rapid loading system............................................. 288 Ratchet assy ........................................................... 288 Ratchet buckles...................................................... 288 Reconditioning of PDC machines ........................ 288 Refrigaration air dryers.......................................... 286 Refrigerated & heatless dryers............................... 287 Refrigeration compressed air dryers ...................... 287 Refrigeration plants ............................................... 286 Rolling machines ................................................... 289 Ropes & posts ....................................................... 289 Rubber tarps .......................................................... 288 Rust preventive oils ............................................... 286 Screw Compressors ............................................ 289 Security barriers ..................................................... 289 Selenium rectifiers ................................................. 289 Self-adhesive tapes: Masking ................................ 287 Semiconductor devices........................................... 289 Servo stabilisers...................................................... 286 Shaping machines.................................................. 288 Shearing machines................................................. 289 Shot blasting machines.......................................... 289 Shot peening machines.......................................... 289 Shoulder punches .................................................. 287 Silicon compound oils ........................................... 286 Silicon controlled rectifiers.................................... 289 Slicone polyester .................................................... 287 Softwares................................................................ 288 Special-purpose transformers................................. 289 SPMs .............................................................288, 289 Spring plungers...................................................... 287 Steel hooks............................................................. 288 Stell screws ............................................................ 287 Straight block sets ................................................. 287 Straightening machines ......................................... 289 stripper bolts .......................................................... 287 Substations............................................................. 286 Surface coating techonology .................................. 287 Surge protection devices ........................................ 286 Surge supressors..................................................... 289 Taparia hand tools.............................................. 287 Taper block sets..................................................... 287 Taper interlocks..................................................... 287 Testing & measuring instruments......................... 289 Thermally conductive Tapes ................................. 287 Thread compounds................................................ 286 Thyristors............................................................... 289 Tissue..................................................................... 287 Tools...................................................................... 287 Transformer parts .................................................. 287 Transformers.......................................................... 286 Transmission tower making machines .................. 289 Tubular & finned air heaters................................. 286 Unitech scanners ................................................ 288 Unitech terminals .................................................. 288 UPS systems .......................................................... 286 Vaccum pumps................................................... 289 Velding machine.................................................... 289 VFDs ..................................................................... 286 Walk-in cold rooms............................................ 286 Water stoppers....................................................... 287 Water treatment chemicals.................................... 288 Water treatment plant spares ................................ 286 Webbing slings ...................................................... 288 Weigh-in-motion .................................................. 288 Welding & inverter based press brakes................. 289 Welding automation.............................................. 289 Zebra printers..................................................... 288 Zebra ribbons ........................................................ 288


Product Index Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68

Product

Pg No

3D modelling .................................................. 272 3D printing systems.....................................................245 Abrasive pneumatic tools............. 190, 191, 193 Abrasive systems...........................................................291 AC drives ..........................................................................217 Accelerometers................................................................ 73 Accessories ............................................................238, 239 AC-DC drives..................................................................... 21 Adapters ...........................................................................236 Adhesives.........................................................................215 Aerosols .............................................................................. 79 Aerospace materials................................. 190, 191, 193 Air purifiers......................................................................113 Air treatment systems................................................... 88 Air-conditioners............................................................... 18 Air-cooled servo stabilisers ......................................... 18 Airline fluids ...................................................................... 79 All-geared autofeed pillar drilling machines ................................................................168, 210 All-geared autofeed radial drilling machines ....168 All-geared radial drilling machines........................168 Aluminium processing equipment ........................224 Aluminum extrusion equiment ...............................270 AMS integrated..............................................................192 Angle encoders..................................Back inside cover APFC panels ...................................................................... 18 Application/precision component machining..............................................................238, 239 Aqueous cleaners..........................................................278 Assembly & high temperature greases .................. 79 Auto tool presetters....................................................... 34 Auto-diff machine simulation .................................... 67 Auto-feed radial drilling machines.........................210 Automated guided vehicles .....................................213 Automatic back spot facing tools ..........................119 Automatic grinding machines .................................269 Automatic lathes...........................................................123 Automation controllers ..............................................257 Automation ............................................ 21, 69, 166, 219 Automobile workshop trolleys ................................189 Automotive lubricants ................................................220 Back-geared auto-feed radial drills.............. 168 Back-geared fine-feed machines ............................168 Bags bailing presses....................................................... 89 Balancing machines .....................................................211 Balancing systems for grinding.......... Back gatefold Ball bearings ...................................................................241 Ball screws .............................................................141, 271 Band saw blades.............................................................. 66 Bearings ...............................................106, 144, 183, 241 Bellow couplings...........................................................271 Belt grinders....................................................................139 Bench drilling machines.............................................276 Bench grinding machines..........................................139 Billet shearing machines .............................................. 16 Blanking lines .................................................................224 Boring ................................................................................233 Brine chillers....................................................................275 BTA/ejector counter boring machines ................... 24 BTA/ejector drilling machines.................................... 24 Building automation....................................................166 Cable carriers ..........................................144, 271 Cable conduits ................................................................. 17 Cable connectors ..........................................................144 CAD.....................................................................................272 CAD/CAM software ........................................................ 29 CAE .....................................................................................272 Cam followers.................................................................272 Cam grinding..................................................................165 Cam works .......................................................................273

292 MODERN MACHINE TOOLS - October 2011

Sl. No 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137

Product

Pg No

Carbide end mill tools.................................. Back cover Carbide end mills............................................................ 63 Carbide rods...................................................................... 43 Carbide tools............................................... 203, 204, 236 Carbide..............................................................................236 Carrier oils........................................................................278 Cash management .......................................................225 Cassette tool cabinets.................................................264 Cast iron cutting.............................................................. 81 Casting .................................................Front inside cover Center drills ....................................................................... 44 Centerless grinding machines ......................... 27, 274 Centerless.........................................................................165 Centre drills .....................................................................236 Centreless grinding machines .................................271 Ceramics ..............................................190, 191, 193, 303 Cermets.............................................................................303 C-frame power presses................................................. 16 Chain oils............................................................................ 79 Chain pulley blocks ......................................................255 Chain wheels ..................................................................248 Chains................................................................................144 Chillers................................................................................. 28 Chuck jaws.......................................................................219 Chucks...............................................................................236 Circumference gauges................................................275 Clamping solutions ........................................................ 46 Clamping tools................................................ Back cover Clamps...............................................................................275 Cleaners ............................................................................167 Close-frame hydraulic presses ................................... 89 CMMs.................................................................................297 CNC angular cylindrical grinding machines ......... 27 CNC cutting machines ................................................166 CNC double column machining centres.........14, 22 CNC equipment............................................................... 19 CNC grinding machines .............................................269 CNC guillotine shears .................................................... 41 CNC horizontal borers.................................................149 CNC horizontal boring/milling machines.............. 14 CNC horizontal machining centres ............................... ........................................................ Front inside cover, 14 CNC horizontal turning centres................................. 14 CNC hydraulic press brakes ........................................ 41 CNC laser cutting machines................................41,166 CNC lathes ............................ 22, 42,123, 149, 180, 199 CNC machine probing .................................................. 67 CNC machine simulation ............................................. 67 CNC machine tools................................... 107, 238, 239 CNC machines ......................... 8, 9, 15, 59, 61, 93, 306 CNC machining centres..................................15, 22, 59 CNC milling machines....................Front inside cover CNC multi-tasking centres........................................... 14 CNC oxyfuel cutting machines ................................166 CNC plasma cutting machines ................................166 CNC precision lathes...................................................... 53 CNC punch presses ........................................................ 41 CNC rotary tables...................................... 190, 191, 193 CNC tap chucks & tap adapters...............................179 CNC tap holders & pull studs ...................................179 CNC tapping centres ..............................................25, 26 CNC toolings...................................................................236 CNC tools holders & pulley studs ...........................179 CNC tools ........................................................................... 69 CNC turn mill centres ..................................................275 CNC turning centres ...............................................15, 59 CNC turning machines................................................165 CNC turn-mill centres.................................................... 14 CNC turret punch presses..........................................253 CNC vertical machining centres.....................................

Sl. No

Product

Pg No

..........................................Front inside cover, 14, 15, 59 138 CNC vertical turning lathes ......................................... 14 139 CNC/VMC machines.................................................75-78 140 CNCs...........................................................7, 15, 20, 59, 70 141 Coating machines.........................................................166 142 Coating plants................................................................166 143 Coating systems ............................................................166 144 Cold chamber pressure die casting machines .... 22 145 Cold forming machines ..............................................177 146 Collet chucks.............................................................53,236 147 Collets................................................................. 10, 11, 236 148 Complex machining applications............................. 34 149 Composite applications................................................ 67 150 Comprehensive smoothing algorithm ................... 34 151 Compressor oils ............................................................... 79 152 Cone pulley heavy-duty lathe machines ............... 95 153 Cone pulley light-duty lathe machines.................. 95 154 Cone pulley medium-duty lathe machines .......... 95 155 Connection cables........................................................159 156 Connectors .............................................................. 83, 144 157 Control cabinets .............................................................. 83 158 Control panels...........................................................17, 83 159 Control system machines ............................................ 34 160 Control systems............................................................... 83 161 Controlling machine tools.............Back inside cover 162 Conventional precision lathes .................................199 163 Converter planomillers ...............................................119 164 Coolant purifying systems.........................................175 165 Coolant separators .......................................................196 166 Coolants.................................................37, 105, 187, 223 167 Cooling towers................................................................. 88 168 Coromills ....................................................Front gatefold 169 Corothread ................................................Front gatefold 170 Corrosion preventives.................................................167 171 Counters & power supplies......................................... 87 172 Countersinks .......................................................12, 13, 33 173 Crabs ..................................................................................255 174 Cranes................................................................................255 175 Crank pin grinding machines...................................165 176 Crush blades ..................................................................... 65 177 Cutting fluids ..................................................................167 178 Cutting heads.................................................................291 179 Cutting machines..........................................................166 180 Cutting oil .............................................37, 105, 187, 223 181 Cutting speed optimisation........................................ 67 182 Cutting systems.............................................................291 183 Cutting tools carbide metal working tools.........303 184 Cutting tools ....................................... 35, 43, 51, 63, 65, 116, 131, 153, 156, 203, 204, 231, 238, 239, 244, 245, 306 185 CV joint machines.........................................................177 186 Cycle time reduction/programming software...221 187 Cylindrical grinders ......................................................143 188 Cylindrical grinding machines .......................267, 271 189 Cylindrical machines...................................................... 61 190 Cylindrical roller bearings..........................................183 191 Cylindrical/ internal grinding machines...............147 192 Deburring solutions ....................................... 145 193 Deep-hole drilling machines ...............................24, 39 194 Deep-hole drilling sub-contracts .............................. 24 195 Demagnetisers ...............................................................196 196 Design ...............................................................................272 197 Desktop printers............................................................245 198 DFMPRO............................................................................273 199 Diamond lapping/polishing systems Back gatefold 200 Diamond tools ..........................................................12, 13 201 Diamond tools ................................................................. 33 202 Didactic equipment for training ............................... 83 203 Die coaters......................................................................... 65 204 Die/mould machines ...........................Cover-on-cover 205 Differential pressure transmitters...........................171


Product Index Sl. No

Product

Pg No

206 Distribution transformers ............................................ 18 207 DNC system for networking CNC machines.......221 208 Double-column milling machines (5-faces).....................................................Cover-on-cover 209 Drawer cupboards........................................................189 210 Drawing & forming compounds .............................167 211 Drill chuck arbours .......................................................236 212 Drill mills...........................................................................236 213 Drill tap centres ........................ Front inside cover, 22 214 Drill tap machines........................................................... 34 215 Drill tools ........................................................... Back cover 216 Drilling machines ............85, 168, 210, 263, 276, 306 217 Drilling tools................... 12, 13, 33, 51, 203, 204, 245 218 Drilling-cum-milling machines .................................. 85 219 Drilling-cum-tapping machines ..............................276 220 Drilling-cum-vertical milling drill machines .......267 221 Drills ........................................................................... 63, 210 222 Drive technology...............................Back inside cover 223 Drives........................................................ 20, 21, 108, 257 224 Dual column design....................................................... 34 225 Dual sone machining centers .................................... 34 226 Duplex deburring tools ..............................................119 227 Dust collectors ...............................................................139 228 EDM accessories & consumables . 190, 191, 193 229 E-drawings publishers.................................................273 230 Electric motor lamination systems.........................224 231 Electrical & electronics ............................ 190, 191, 193 232 Electro magnets.............................................................270 233 Electrolifting magnets.................................................270 234 Electromagnetic chucks .............................................196 235 Element shrink discs ....................................................272 236 Encoders................................................................... 87, 159 237 End mills ................................................................... 44, 236 238 Energy projects................................................................ 18 239 Engineering services....................................................272 240 Engineering tools..........................................................116 241 EngineeringExpo exhibitions ...... 242, 261, 286-289 242 Engineerâ&#x20AC;&#x2122;s files ................................................................. 44 243 EOT/HOT cranes ............................................................255 244 Euro gearboxes..............................................................274 245 Exhibitions .................................242, 261, 266, 286-289 246 Exposed linear encoders................Back inside cover 247 Extra duty lathe machines.........................................267 248 Extra heavy-duty lathes..............................................267 249 Extra hi-cut lathes.........................................................267 250 Facing & contouring heads ........................... 233 251 Factory automation......................................................166 252 Fast drill reshareung machines ........... 190, 191, 193 253 Ferrous casting...............................................................270 254 Fine & auto feed radials ............................................... 85 255 Fixtures..............................................................................275 256 Flame proof hoists........................................................255 257 Flange flacers..................................................................119 258 Floating holders.............................................................179 259 Force-feed lubricators .................................................264 260 Forged components ....................................................270 261 Forging presses ............................................................... 16 262 Forging rolls....................................................................228 263 Freewheel-oneway-clutches.....................................272 264 Friction drop hammers................................................. 16 265 Friction screw presses ................................................... 16 266 Frictionless slides ..........................................................192 267 Fully automatic ................................................................ 22 268 Gantry & NC boring/milling machines ........... 42 269 Gas springs ............................................................258, 259 270 Gauges ..............................................................................268 271 Gear couplings...............................................................248 272 Gear cutting machines........................Cover-on-cover 273 Gear hobbing machines............................................... 64 274 Gear milling machines ................................................145 275 Gearboxes ............................................................... 248,255 276 Geared radial drilling machines ................................ 85 277 Geared drilling machines............................................. 85 278 Geared-head heavy-duty lathe machines ............. 95

294 MODERN MACHINE TOOLS - October 2011

Sl. No 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349

Product

Pg No

Geared-head medium-duty lathe machines ........ 95 Gears ..................................................................................248 Geomcalipers..................................................................273 Glass ...................................................................................127 Goliath cranes ................................................................255 Goods lifts........................................................................255 Greases & specialities ..................................................220 Greases................................................................................ 79 Grinding machines .............................................................. .......... 27, 61, 115, 127, 139, 165, 180, 269, 271, 284 Grinding tools for hard materials .................115, 127 Grip pliers.........................................................................275 Grooving & parting tools ............................................. 43 Gudgen pins ...................................................................183 Guillotine shear................................................................ 41 Gun drilling machines............................. 12, 13, 24, 33 Gun reaming machines ................................................ 24 Gyratory screens............................................................270 Hammers ........................................................... 16 Handling system modules........................................... 83 Hard cut end mills .......................................................... 63 Heavy job turning/boring machines.....................267 Heavy-duty all-geared head lathe machines ....... 22 Heavy-duty drill machines.........................................263 Heavy-duty lathe machines ......................................284 Heavy-duty lathes.........................................................267 Heavy-duty precision machine vices.....................195 Heavy-duty radial drill machines ............................263 Helical gears....................................................................248 H-frame power presses................................................. 16 Hi-cut lathes....................................................................267 High-precision surface grinding machines.........284 High-precision tool holders ........................................ 23 High-pressure hydraulic clamping systems ........................................................................ Back Gatefold High-pressure pumps..................................................291 High-pressure tubes ....................................................291 High-speed centerless grinding machines ........... 27 High-speed drill tap centres .....................................149 High-speed machining centres (3-/5-axes)........... 15 High-speed machining centres ................................. 59 HMC/VMC machines....................................................103 HMIs .........................................................................217, 257 Holdbacks ........................................................................272 Hole-making tools .......................................................... 65 Hollow bars .....................................................................129 Horizontal boring machines .....................................177 Horizontal boring mill.........................Cover-on-cover Horizontal handle clamps..........................................275 Horizontal hydraulic presses ...................................... 89 Horizontal machining centres......................................... ......................................................15, 25, 26, 59, 149, 177 Horizontal machining centres.............................7, 284 Horizontal milling machines.............Cover-on-cover Horizontal pipe & tube bending machines .......... 91 Horizontal screens ........................................................270 Horizontal turning centres ........................................177 Hot forging lubricants.................................................278 HSK ................................................................................10, 11 Hydraulic & gear oils...................................................... 79 Hydraulic angle lock vices .........................................284 Hydraulic angle shearing machines ......................268 Hydraulic cylindrical grinders...................................271 Hydraulic cylindrical grinding machines .............265 Hydraulic forging hammers......................................228 Hydraulic machine vices ............................................195 Hydraulic power units.................................................272 Hydraulic press brakes.................................................. 41 Hydraulic presses (4-column)..................................... 89 Hydraulic presses .........................................91, 228, 276 Hydraulic shearing machines..................................... 91 Hydraulic surface grinding machines ...................269 Hydroforming machines ............................................224 Hypercad ............................................................................ 29

Sl. No 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423

Product

Pg No

I/O junction boxes .......................................... 171 Imaging & vision systems ..........................................166 Import/export financing.............................................225 Indexable tools ...................................................... 63, 277 Induction motors ..........................................................257 Inductive proximity switches ..................................... 17 Industrial control & sensing devices........................ 87 Industrial coolers............................................................. 88 Industrial cooling systems.........................................275 Industrial lubricants .....................................................220 Industrial robots ............................................................157 Industrial vacuum cleaning solutions...................277 Inner/outer race grinding machines .....................165 INTEC-2012 exhibition ................................................124 Internal grinding machines......................................... 27 Internal thread grinding machines ........................165 Iron & steel parts............................................................. 65 Iron workers ...................................................................... 41 ISO & milling inserts....................................................... 63 ISO turning inserts.......................................................... 63 Isolation transformers ................................................... 18 Jib cranes ........................................................ 255 Jigs......................................................................................275 Junction boxes...............................................................171 Keyless transmission elements.............269, 272 Large size horizontal machining centres..... 306 Large size machining centres ..........Cover-on-cover Laser cutting machines................................................. 41 Laser shaping ........................................................ 115,127 Laser systems..................................................................224 Laser tools........................................................................125 Lathe chucks...................................................................219 Lathe machines............. 7, 22, 95, 267, 270, 275, 284 LEDs...................................................................................... 17 Length gauges rotary encoders..Back inside cover Lens mould........................................................................ 65 Letters of credit .............................................................225 Level controllers .............................................................. 87 Light-duty drills .............................................................278 Light-duty lathe machines ..............................267, 284 Linear guideways ..........................................................192 Liner bearings.................................................................192 Liners .................................................................................192 LM guideways ................................................................271 Load break switches ...................................................... 17 Loans..................................................................................225 Lubes .................................................................................105 Lubrication systems .....................................................106 Machine lamps................................................ 293 Machine measurements.................Back inside cover Machine simulation multi-axis................................... 67 Machine tool accessories....................... 116, 179, 265 Machine tool protection systems...... Back gatefold Machine tools accessories .........................................271 Machine tools......................................69, 116, 159, 180 Machine vices............................................ Back gatefold Machined components.....................................209, 270 Machining & grinding fluids.....................................167 Machining centres (5-axis) ........................................149 Machining centres (5-face)........................................306 Machining centres.......................................................... 64 Magnetic equipment...................................................270 Magnetic grill & housing............................................270 Magnetic head pulleys................................................270 Magnetic modular encoders ........Back inside cover Maintenance trolleys ...................................................189 Masonry drills ................................................................... 44 Material handling solutions ......................................213 Measured value acquisition..........Back inside cover Measurement instruments .......................................... 73 Measurement systems ................................................265 Measuring & monitoring relays................................. 87 Measuring instruments...............................................211 Measuring systems.......................................................192


Product Index Sl. No

Product

Pg No

424 Mechanical shears .......................................................... 41 425 Mechanical/hydraulic press brakes.......................... 91 426 Mechanical/hydro-mechanical section bending machines.......................................................... 91 427 Mechatronics ..................................................................106 428 Metal cutting systems.................................................291 429 Metal cutting technology .....................................10, 11 430 Metal cutting tools ........................................ 10, 11, 185 431 Metal forming technologies .....................................102 432 Metal scrape baling presses ....................................... 89 433 Metal working technologies.....................................102 434 Metrology instruments & solutions .......................297 435 MGM brake motors ........................................................ 57 436 Micron drills ...................................................................... 65 437 Milling centres.....................................................................7 438 Milling cutters ...................................12, 13, 43, 33, 151 439 Milling grades...........................................Front gatefold 440 Milling heads ..................................................................306 441 Milling machines ....................Front inside cover, 306 442 Milling solutions ............................................................126 443 Milling tools ...........................65, 203, 204, Back cover 444 Milling................................... 51, 245, Back inside cover 445 Milling-cum-drilling machines.................................168 446 Mini scales........................................................................192 447 Mobile cylinder hydraulic presses............................ 89 448 Mobile drawer systems...............................................189 449 Mobile robotics..............................................................213 450 Modbus I/O junction boxes ......................................171 451 Model export interfaces ............................................... 67 452 Modmachine simulation multi-axis ......................... 67 453 Modular tooling systems ...............................12, 13, 33 454 Mold components .......................................................... 65 455 Monitoring of grinding systems ........ Back gatefold 456 Monorail trolleys ...........................................................255 457 Motion controls ............................................................... 20 458 Motor protection circuit breakers ............................ 17 459 Motorized chain pulley blocks.................................255 460 Motors ................................................................................. 20 461 Multi-angle right-angle universal milling attachments ....................................................................119 462 Multi-functional tools.................................................... 43 463 Multi-media unions.............................................258-259 464 Multi-spindle drilling heads......................................276 465 Multi-spray aerosols....................................................... 79 466 Needle bearings ............................................. 183 467 Non-ferrous casting .....................................................270 468 Oil coolers ......................................................... 28 469 Oil/coolant coolers .......................................................275 470 Online b2b marketplace.................................... 249,292 471 Optipath ............................................................................. 67 472 Overband magnetic separators...............................270 473 Overdraft facility............................................................225 474 Oversize lathe machines ............................................284 475 Panel air-conditioners.................................... 275 476 Panel coolers..................................................................... 28 477 PCB drills............................................................................. 65 478 PCD & CBN tools............................................................303 479 Peel grinding machines................................................ 61 480 Permanent lifting magnets .......................................270 481 Permanent magnetic chucks..........................196, 265 482 Photoelectric sensors .................................................... 87 483 Pillar drilling machines .......168, 210, 263, 274, 283, 484 Pillar-type hydraulic presses....................................... 89 485 Pilot lights.......................................................................... 17 486 Piston pumps..................................................................285 487 Plaining machines ........................................................274 488 Planetary gear heads...................................................271 489 Planomillers.....................................................................274 490 Plasma cutting machines............................................. 41 491 Plastic machined components ................................209 492 Plates-sheets ...................................................................209 493 PLC operated hydraulic presses................................ 89 494 PLCs....................................................................................217 495 Plugs & sockets ................................................................ 17

296 MODERN MACHINE TOOLS - October 2011

Sl. No 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569

Product

Pg No

Pneumatic & hydraulic accessories........................136 Pneumatic automation...............................................109 Pneumatic impact wrenches....................................277 Polishing machines ......................................................139 Polymat.............................................................................209 Portable turning machines........................................119 Portable welders ...........................................................264 Post processors................................................................ 29 Power conditioners ........................................................ 18 Power presses................................................................... 91 Power savers..................................................................... 18 Power shearing machines .........................................273 Power sources ................................................................169 Power supplies...............................................................159 Preci chucks ....................................................................101 Precision bearings ........................................................274 Precision fabrication works.......................................275 Precision gear cutting tools..............Cover-on-cover Precision grinders .........................................................143 Precision lock nuts........................................................271 Precision measuring instruments...........................268 Precision roll turning lathe machines ...................267 Precision steels.....................................................115, 127 Precision switches........................................................... 17 Press brake machines..................................................278 Press brakes............................................................. 41, 269 Pressure sensors .............................................................. 73 Process automation &control equipment............. 83 Process monitoring sensors......................................125 Process oils ......................................................................220 Product assemblies ......................................................270 Product design...............................................................272 Productivity tracking systems..................................221 Profilers & gantry machines......................................177 Program verification ...................................................... 67 Projects (energy) ............................................................. 18 Propeller hub.................................................................... 45 Proximity sensors............................................................ 87 Pull action clamps.........................................................275 Pull studs..........................................................................236 Pulleys ...............................................................................248 Punch presses.......................................................180, 253 PVC flexible braided hoses........................................136 Quick fit machines.......................................... 195 Quick-change tapping chucks/tap adapters......179 Race pins ......................................................... 183 Radial drill machines................................ 168, 210, 263 Radial drilling machines ......................... 270, 273, 278 Reamers .....................................12, 13, 33, 44, 231, 236 Reaming & tapping machines..................................179 Receivables finance solutions ..................................225 Reverse engineering....................................................272 RH & temperature transmitters ...............................171 Robots ...............................................................................157 Rods-tubes-blocks ........................................................209 Roll forming machines.................................................. 91 Roller bearings .....................................................183, 241 Rolling oils .......................................................................167 Rotary dampers ...................................................258, 259 Rotary feed backs ........................................................... 20 Rotary indexing tables........................... Back gatefold Rotary joints & unions.......................................258, 259 Rotary switches................................................................ 17 Rotary tilting vices..............................................130, 195 Rotary .....................................................................................7 Rotary-cum-dividing/indexing heads ...................195 Rotating unions ...................................................258, 259 Rust preventing .............................................................167 Safety lights ...................................................... 87 Safety protection devices ............................................ 17 Saws ..................................................................................... 66 Screw presses .................................................................228 Sealants & surface treatment ...................................215 Sealed linear encoders....................Back inside cover

Sl. No 570 571 572 573 574 575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643

Product

Pg No

Sealing solutions ...........................................................106 Security systems............................................................113 Self-adhesive tapes ......................................................222 Servo stabilisers............................................................... 18 Servomotors....................................................................257 Shafts .................................................................................271 Sheet metal forming machines ...............................224 Shock absorbers ..................................................258, 259 Shrinkfit machines.................................... 190, 191, 193 Shrinking technology..................................................211 Side lock adapters ........................................................236 Single limit switches ...................................................... 17 Sinking EDMs..................................................................303 Siphon systems....................................................258, 259 Sirius..................................................................................... 21 Slant/flat beds ................................................................149 Sleeves .........................................................................10, 11 Solenoid valves..............................................................285 Solid carbide drills/mills .............................................185 Solid carbide reamers..................................................185 Solid carbide special drills/mills ..............................185 Solid carbide special reamers ..................................185 Solid carbide tools........................................................306 Spare parts.......................................................................291 Special hydraulic expansion technology.............219 Special induction hardening machines................169 Special machines...........................................................177 Special purpose machines.... Front inside cover, 64 Special refrigeration equipment.............................275 Special tools....................................................................236 Spherical bearings ........................................................183 Spindle nose tooling systems .................................... 43 Spindle probes...............................................................125 SPMs....................................... Front inside cover, 24, 64 Spur gears........................................................................248 Standard induction hardening machines............169 Standard mobile drawers ..........................................189 Standard pyramid-type plate bending machines91 Stationary work holding systems ...........................219 Steep-taper machines ............................................10, 11 Stock shapes ...................................................................209 Straightening machines .............................................274 Straight-line action clamps .......................................275 Super power hydraulic vices ....................................195 Surface & profile grinding machines.....................147 Surface grinders...................................................149, 269 Surface grinding machines .............................269, 272 Suspension magnets ...................................................270 Switching relays............................................................... 87 Tagma exhibition ........................................... 266 Tap holders......................................................................121 Taper bearings ...............................................................183 Taps .......................................................12, 13, 33, 44, 135 Telecom equipment....................................................... 18 Temperature controllers............................................... 87 Tensioner nuts ...............................................................272 Thermal imaging cameras.........................................237 Thread gauges ...............................................................101 Thread milling & turning machines.......................145 Thread whirling tools ............................Front gatefold Threading solutions .....................................................145 Threading tools..................................Back inside cover Timers.................................................................................. 87 Timing belts ....................................................................248 Timing pulleys drives ..................................................248 Timing pulleys................................................................248 Toggle action clamps ..................................................275 Toggle presses ...............................................................275 Tool bits.............................................................................. 44 Tool changer systems .................................................284 Tool design......................................................................272 Tool grinding machines .............................................147 Tool holders ..................................................... 10, 11, 211 Tool holding systems ..................................................219


Product Index Sl. No 644 645 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675

Product

Pg No

Tool logistics systems..................................................211 Tool monitoring sensors ............................................125 Tool monitoring systems ...................... Back gatefold Tool path simulators....................................................221 Tool presetting machines...................... 190, 191, 193 Tool setting systems....................................................265 Tool systems ...................................................................264 Tooling systems.............................................. Back cover Tools trolleys...................................................................189 Tools...................................................................................236 Tool-trolleys for VMCs & HMCs................................189 Top drills......................................................................10, 11 Torque sensors....................................................... 73, 268 Touch probes......................................Back inside cover Track rollers .....................................................................272 Trade show organisers.................................................. 55 Transfer trolleys .............................................................255 Transformer oils.............................................................220 Transparent gels.............................................................. 79 Tubing accessories ......................................................... 83 Tungsten carbide rod blanks ...................................278 Turbine blades ................................................................. 45 Turbine shafts................................................................... 45 Turned components ....................................................270 Turning centres..............................................................306 Turning holders ............................................................... 43 Turning tools ............................................ 65, Back cover Turning................................. 51, 245, Back inside cover Turnkey solutions............................................................ 18 Turret punch presses........................................... 41, 253 Twin spin bearing reducers ......................................271 Twin-spindle compound grinding machines....... 27

Sl. No 676 677 678 679 680 681 682 683 684 685 686 687 688 689 690 691 692 693 694 695 696 697 698 699 700 701 702 703

Product

Pg No

Twist drills (parallel & taper shank).......................... 44 Twist drills........................................................................236 Ultra-high pressure apparatus........................ 65 Universal ball vices.......................................................195 Universal cutter grinders..........................190, 191,193 Universal cylindrical grinding machines................ 27 Universal dividing heads............................................195 Universal grinding machines....................................267 Universal quick change chucks/adaptors............179 Universal radial drilling machines .....................85, 95 Universal vices 100.......................................................195 UPS systems ...................................................................... 18 Used CNC turret punch presses ..............................253 Used machine tools .....................................................180 Vacuum cleaners ............................................ 113 Vacuum pumps & compressors...............................276 Value engineering ........................................................272 Valve sensors ..................................................................159 Valve terminals ................................................................ 83 Valves................................................................................... 83 Vane pumps....................................................................285 Velocity & feed controllers ..............................258, 259 Ventilators........................................................................222 Vertical & horizontal machining centres................ 42 Vertical handle clamps................................................275 Vertical machining centres (3-/5-axis) ..................177 Vertical machining centres.................... 7, 25, 26, 186 Vertical machining centres-single/double columns ............................................................................149 704 Vertical turning centres ..............................................177 705 Vertical turning machines ........................................... 64 706 Vertical turnmill centres ............................................... 64

Sl. No 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727

Product

Vertical turret lathes ....................................................295 Vibrating equipment ...................................................270 Vibratory motors ...........................................................270 Vision sensors................................................................... 87 VMCs .................................................................................165 Water chillers.................................................. 275 Water purifiers................................................................113 Waterjet cutting systems ...........................................291 Wear parts.......................................................................... 43 Wear-resistant tools ....................................................... 65 Wire rope hoists ............................................................255 Wirecut EDMs .......................................................186, 303 Wired connection .........................................................171 Wireless receivers..........................................................171 Wireless.............................................................................171 Wiring trolleys ................................................................189 Work holding solutions ......................... Back gatefold Work holding technology..........................................283 Work shop tables ..........................................................189 Worm gears.....................................................................248 Yashawa servodrives ..................................... 217

Looking for a speciďŹ c product? We will ďŹ nd the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

298 MODERN MACHINE TOOLS - October 2011

Pg No


Advertisers’ List Advertiser’s Name & Contact Details

Pg No

Austin Engineering Company Ltd E: sales@aecbearings.com W: www.aec-bearings.com

241

Autotech Machine Tools Sales & Ser T: +91-20-27130091 E: sales@autotechcnc.com W: www.autotechcnc.com

8-9

Basic Engineers T: +91-9825344527 E: info@basicengineers.in W: www.basicengineers.in

189

Bharat Bijlee Ltd 257 T: +91-22-24306237 E: vishwajyoti.vengurlekar@bharatbijlee.com W: www.bharatbijlee.com Bharat Fritz Werner Ltd T: +91-80-28395745 E: bfwmarketing@bfw.co.in W: www.bfwindia.com

FIC

Big Daishowa Seiki Co. Ltd T: +81-729-828277 W: www.big-daishowa.com

23

Bilbao Exhibition Centre T: +34-94-404-0000 E: bec@bec.eu W: www.biemh.com

55

Blaser Swisslube India Pvt. Ltd. T: +91-124-4994000 E: india@blaser.com W: www.blaser.com

105

Blaser Swisslube India Pvt. Ltd. T: +91-124-4994000 E: india@blaser.com W: www.blaser.com

187

Blowtech E: blowtech@hotmail.com W: www.vacuumcleanerindia.com

277

Blum Novotest Gmbh T: +91-80-23185468 E: blumnovotestindia@bsnl.in W: www.blum-novotest.com

265

Bombay Tools Supplying Agency T: +91-22-23426495 E: info@bombaytools.com W: www.bombaytools.com

268

BR Precisions T: +91-80-41492904 E: brvices@rediffmail.com W: www.brhydraulicvices.com

Advertiser’s Name & Contact Details Camu Srl T: +0039-444-660700 E: info@camu.it W: www.camu.it

Pg No 298

Advertiser’s Name & Contact Details

Pg No

E MUG Technologies Pvt. Ltd. T: +91-40-66836983 E: info@emugtech.com W: www.emugtech.com

272

Carl Bechem Lubricants(India) Pvt Ltd 37, 223 T: +91-80-22010800 E: info@bechemindia.com W: www.bechem.com

EFD Induction Limited T: +91-80-7820404 E: sales@efdgroup.net. W: www.efd-induction.com

169

Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com

Electroflux Equipments Pvt. Ltd. 270 T: +91-44-26243317 E: marketing@electrofluxequipmentspvtlt d.com W: www.electrofluxequipmentspvtltd.com

43

CGTECH India Software Solutions (P) Ltd 67 T: +91-9845212147 E: Info.India@cgtech.com W: www.cgtech.com Champion Industries T: +91-2752-231741 E: champion_ind@yahoo.com

196

Chamunda Equipments T: +91-79-27522437 E: clamp@chamundaequip.com W: www.chamundaequip.com

275

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

166

Cosmos Impex (India) Pvt. Ltd. T: +91-265-3927000 E: mediasupport@cosmos.in W: www.cosmos.in

238-239

Danfoss India T: +91-44-66501555 E: danfoss.india@danfoss.com W: www.danfoss.com

108

Devco Engineers T: +91-2752-243997 E: devco1980@yahoo.com W: www.liongrinders.com

271

Electronica Hitech Machines Pvt Ltd 102-103 T: +91-20-30435400 E: marketing@electronicahitech.com W: www.electronicahitech.com Emuge India Pvt Ltd 46, 121, 135, 151 T: +91-20-39310000 E: marketing@emugeindia.com W: www.emugeindia.com Engineering Expo 242, 261, 286-289, 290 T: +91-9819552270 E: engexpo@infomedia18.in W: www.engg-expo.com Ermaksan Machinery T: +91-224-2947500 E: sinan.bilgin@ermaksan.com.tr W: www.ermaksan.com.tr Eureka Forbes Limited T: +91-80-30251500 E: fandb@eurekaforbes.com W: www.eurekaforbes.com

41

113

Fagor Control Systems Pvt Ltd T: +91-80-42682828 E: info@fagorcontrolsystems.es W: www.fagorautomation.com

20

Ferrocare International T: +91-20-26830655 E: info@ferrocare.com W: www. ferrocare.com

285

Dijet Industrial Co Ltd T: +91-22-40121231 E: ravisane@dijet.co.jp W: www.dijet.co.jp

63

Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com

195

Doosan Infracore India Pvt Ltd T: +91-80-42660122 E: sandesh.kumar@doosan.com W: www.doosaninfracore.com

14

Flir Systems India Pvt Ltd T: +91-11-45603555 E: manpreet.kaur@flir.com.hk W: www.flir.com

Cadem Technologies Pvt Ltd T: +91-80-26634767 E: sales@cadem.com W: www.cadem.com

221

Dowel Machinery Pvt Ltd T: +91-281-2362465 E: dowel@thedowel.com W: www.thedowel.com

89

Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhammers.com W: www.nkhhammers.com

16

Camozzi India Pvt Ltd T: +91-120-4055252 E: info@camozzi-india.com W: www.camozzi-india.com

109

Drass Mechatronics & Machinery Pvt Ltd 186 T: +91-80-23478764 E: info@drassautomech.com W: www.drassautomech.com

Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com

28

83

237

SOURCE AUTOMATION & INSTRUMENTATION PRODUCTS @ www.engg-expo.com

October 2011 - MODERN MACHINE TOOLS 299


Advertisers’ List Advertiser’s Name & Contact Details Fullton Machinery Co., Ltd. T: +86-411-82767678 E: fullton@fulltontech.com W: www.fulltontech.com

Pg No

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

295

Henkel Adhesives Technologies India Pvt Ltd215 T: +91-20-30460401 E: wecare.loctite@in.henkel.com W: www.henkel.com

Indo-Nihon Technologies T: +91-44-65611352 E: info@indonihon.co.in W: www.indonihon.co.in

G W Precision Tools India Pvt LtdBooklet, 185 T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

Hi-Tech Robotic Systemz Ltd 213 T: +91-124-4715 100 E: marketing@hitechroboticsystemz.com W: www.hitechroboticssystemz.com

INTEC T: +91-422-2222396 E: intec@codissia.com W: www.intec,codissia.com

124

Hitek Engineers T: +91-44-26545463 E: hitekengineers@yahoo.co.in

277

149

Holani Bearings Pvt Ltd T: +91-2827-293342 E: vishal@holani,in W: www.holani.in

183

ISGEC Heavy Engineering Ltd. T: +91-120-3301 001 E: trading@isgec.com W: www.isgec.com ISMT Limited T: +91-20-41434100 E: sachin.joshi@ismt.co.in W: www.ismt.com

129

Galaxiee Machine Tool Sales & Service T: +91-20-27124328 E: galaxiee@vsnl.net

175

Gallus India T: +91-124-4141434 E: info@gallusindia.in W: www.gallusindia.in

131

Gem Equipments Ltd T: +91-22-3267800 E: sales@geminida.com W: www.gemindia.com Geometric Ltd T: +91-22-67056880 E: inquires@camworks.com W: www.camworks.com

88

273

91

Greenleaf Corp E: info@wexper.com W: www.wexper.com

81

GSK CNC Equipment Co. Ltd T: +91-9886835186 E: gskwang@hotmail.com W: www.gsk.com.cn

19

Guhring India Private Limited T: +91-80-40322500 E: info@guhring.in W: www.guhring.in

33

Haas Automation India Pvt Ltd T: +91-20-32935433 E: sales@haasindia.com W: www.HaasCNC.com

39

HSBC Bank E: pareshgada@hsbc.co.in

225

Hurco India Pvt. Ltd T: +91-44-43108726 E: info@hurco.in W: www.hurco.in

Godson Bending Systems Pvt Ltd T: +91-281-2361467 E: godsonindia@hotmail.com W: www.godson-india.com

H G Shah & Co T: +91-79-25621431 E: hgshah2000@rediffmail.com W: www.timingpulley.in

Hong Ji Precision Machinery Ltd. T: +886-4-2422-1095 E: hongji_jasonlin@hotmail.com W: www.hong-ji.com.tw

248

7

34

15, 59

Karolin Machine Tool Pvt Ltd T: +91-22-28572494 E: info@kmt-waterjet.com W: www.kmt-waterjet.com

291

Katlax Enterprises Pvt Ltd T: +91-9328197614 E: info@katlax.com W: www.katlax.com

171

Hyundai Wia India Pvt. Ltd. T: +91-9940653703 E: mvhari@gmail.com W: www.hyundai-wia.com

107

IFM Electronics India Pvt Ltd T: +91-231-2672770 E: info@ifm-electronic.in W: www.ifm-electronic.com

159

Kennametal India Ltd 10-11 T: +91-80-22198341 E: bangalore.information@kennametal.com W: www.kennametal.com

IGUS India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

144

Kim Union Industrial Co., Ltd. T: +886-4-2533-1131 E: kimunion@kimunion.com W: www.threadrolling.com.tw

IMI Machine Tools Pvt Ltd T: +91-2764-233983 E: imi@imitoolsindia.com W: www.imitoolsindia.com

179

Kistler Instruments India Pvt Ltd T: +91-129-4113555 E: sales.in@kistler.com W: www.kistler.com

IMTMA - Finishing School In Production Engineering 240 T: +91-80-66246514 E: anuj@imtma.in W: www.imtma.in IndiaMART InterMESH Limited T: +1800-200-4444 E: pr@indiamart.com W: www.indiamart.com

249, 292

Haimer India Pvt Ltd T: +91-9890153568 E: haimer@haimer.in W: www.haimer.com

211

Heattrans Equipments Pvt. Ltd. T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com

270

Indian Tool Manufacturers T: +91-22-25852559 E: ltmth@hathway.com W: www.indiantool.com

Heidenhain Optics & Electronics (I) Ltd. T: +91-44-30234000 E: info@heidenhain.in W: www.heidenhain.in

BIC

Indian Tools Manufacturing Corporations 276 T: +91-9815300027 E: itcotech@yahoo.com W: www.itco.co.in

300 MODERN MACHINE TOOLS - October 2011

Jyoti CNC Automation Pvt. Ltd. T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

45

Indian Machine Tool Mfg. Association T: +91-80 -66246600 E: imtma@imtma.in W: www.imtma.in

212

44

271

73

Korber Schleifring Gmbh T: +91-80-41554601 E: sales@schleifring.in W: www.schleifring.in

147

Korloy Inc. T: +82-2-2522-3181 E: export@korloy.com W: www.korloy.com

243

Kuka Robotics (India) Pvt. Ltd. T: +91-124-4635774 E: pradeep@kuka.in W: www.kuka.in

157

Kyrus Tools Pvt. Ltd T: +91-11-45118288 E: info@kyrus.in W: www.kyrus.in L.K.Machinery Corp.(Taiwan) T: +886-4-2566-7656 E: louisa@lkmachinery.com.tw W: www.lkmachinery.com.tw

66

25-26


Advertisers’ List Advertiser’s Name & Contact Details Larsen & Toubro Limited T: +91-22-67051093 E: sm.haridas@larsentoubro.com W: www.larsentoubro.com

Pg No

Advertiser’s Name & Contact Details

Pg No

203-204

Neway CNC Equipment (Suzhou) Co.,Ltd 42 T: +(281)276-7100 E: newaycnc@gmail.com W: www.newaycnc.com

Larsen & Toubro Limited T: +91-22-67525656 E: ss-ccd@lth.lthindia.com W: www.larsentoubro.com

217

Nickunj Eximp Entp P. Ltd 190-191, 193 T: +91-22-22190300 E: darayus@nickunjgroup.com W: www.nickunjgroup.com

Lico Machinery Co., Ltd. T: +886-4-2563-0950 E: sales@licomachinery.com W: www.licomachinery.com

123

Nicolas Correa S.A. T: +91-20-25654891 E: india@correaanayak.es W: www.correaanayak.es

126

M S Engineering T: +91-22-29203637 E: msengg2007@gmail.com

180

Nikon India Pvt Ltd T: +91-124-4688 500 E: nind.Inst@nikonoa.net W: www.nikon-instruments.jp/eng/

297

272

Maco Corporation India Pvt Ltd T: +91-33-24758371 E: rdutta@macocorporation.com W: www.macocorporation.com

258-259

MAG Industrial Automation Systems T: +91-80-40677000 E: sales-India@mag-ias.in W: www.mag-ias.in

177

NMTG Mechtrans Techniques Pvt Ltd. T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

Makson Machines Pvt Ltd T: +91-278-2446437 E: makwana_eng@yahoo.com W: www.makwanaeng.com

210

NN Combined Engineering Agencies Pvt Ltd BGF T: +91-40-27844279 E: mail@nncea.com W: www.nncea.com

Manu Engineering Works E: itcotech@yahoo.com W: manugrind@hotmail.com

276

Marposs India Pvt Ltd T: +91-124-4735752 E: surender.sood@in.marposs.com W: www.marposs.com

125

Omron Automation Pvt. Ltd. T: +91-80-40726400 E: in_enquiry@ap.omron.com W: www.omron-ap.com

Metcut Toolings Private Limited T: +91-836-2333092 E: info@metcutindia.com W: www.metcutindia.com

231

Openmind Cadcam Technologies (I) Pvt Ltd29 T: +91-80-30504647 E: Info.India@openmind-tech.com W: www.openmind-tech.com

MGM- Varvel Power Transmission T: +91-44-64627008 E: ravik@mgmvarvelindia.com W: www.mgmvarvelindia.com Micromatic Grinding Technologies Ltd T: +91-120-2712137 E: info@micromaticgrinding.com W: www.micromaticgrinding.com

57

143

Milltronics CNC Machines 93 T: +91-952-442-1410 E: Dianne Hight dhight@gardnerweb.com W: www.milltronics.net

Objet Ap Ltd T: +852-2174 0111 E: info@objet.com W: www.objet.com

245

87

Oriental Machine Tools Co T: +91-22-23423524 E: omtc@omtc-online.com W: www.omtc-online.com

116

OSG (India) Pvt Ltd T: +91-20-66304407 E: indrajit@osg-india.com W: www.osg-india.com

244

P Parmar Machine Tools T: +91-278-2447409 E: info@parmardrill.com W: www.parmardrill.com

263

27

Advertiser’s Name & Contact Details

Pg No

Pitroda Utility Industries E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com

277

Prakash Engineering T: +91-278-2438241 E: sales@prakashmachines.com W: www.prakashmachines.com

168

Pramet Tools India Pvt Ltd T: +91-124-4703825 E: pramet.info.in@pramet.com W: www.pramet.com

51

Precihole Machine Tools Pvt Ltd T: +91-22-25836780 E: info@precihole.co.in W: www.precihole.co.in

24

Precision Industrial Co. T: +91-22-23436717 E: precisionranjit@hotmail.com

274

Prem Brothers T: +91-11-28117456 E: powermaster59@gmail.com W: www.powermaster-india.com

139

Premier Enterprise T: +91-281-2387556 E: premierenterprise@rediffmail.com W: www.premierlathe.co.in

267

Premier Ltd T: +91-22-61179009 E: ericadesouza@premier.co.in W: www.premier.co.in

64

Quaker Chemical India Ltd T: +91-33-22822181 E: admin@quakerchemindia.com W: www.quakerchem.com

167

Quattro Engineering India Limited T: +91-80-25585439 E: bangalore@quattroengg.com W: www.quattroengg.com

69

Raj Petro Specialities Private Limi T: +91-44-42288900 E: francis@rajgrp.com W: www.rajgrp.com

79

Riat Grinders T: +91-161-2530805 E: msriat@sify.com W: www.riatgrinders.com

274

Rightvision (India) Pvt. Ltd. T: +91-120-4261026 E: lasco@rightvision.biz W: www.rightvision.biz

228

Mitsubishi Heavy Industries India Pvt Ltd COC T: +91-11-41021234 E: mtdsales@mhiindia.com W: www.mhiindia.com

Paragon Machinery Co., Ltd. T: +886-4-2539-5678 E: info@paragoncnc.com W: www.paragoncnc.com

MMC Hardmetal India Pvt Ltd T: +91-80-23516083 E: mmcindia@mmc.co.jp W: www.mitsubishicarbide.com

306

Parishudh Machines Pvt. Ltd. T: +91-120-3205167 E: parishudh@goindigroup.com W: www.goindigroup.com

165

Robin Precision Products Pvt Ltd. T: +91-2827-287631 E: info@bloodtools.com W: www.bloodtools.com

236

MTAR Technologies Pvt Ltd T: +91-40-44529901 E: ballscrews@mtar.in W: www.mtar.in

141

Pinnacle Engineering Enterprise T: +91-2752-230552 E: mail@pinnaclegrinder.com W: www.pinnaclegrinder.com

269

Rollomatic Sa T: +41-32-752-1790 E: amitsharma_1973@yahoo.com W: www.rollomatic.com

61

October 2011 - MODERN MACHINE TOOLS 301


Advertisers’ List Pg No

Roto Linear Systems T: +91-80-23572855 E: rotolinearindia@vsnl.net

271

S&T Engineers T: +91-422-2590810 E: sales@stengineers.com W: www.stengineers.com

70

Sah Petroleums Ltd T: +91-22-66301911 E: ipol@sahpetroleums.com W: www.sahpetroleums.com

220

Sahyog Enterprise T: +91-278-2446848 E: sahyogdrills@dataone.in W: www.sahyogdrills.com

85

Advertiser’s Name & Contact Details

Pg No 106

Tungaloy India Pvt Ltd T: +91-22-61248888 E: info@tungaloyindia.com W: www.tungaloy.co.jp.in

Smwautoblok Workholding Pvt Ltd T: +91-2137-616974 E: info@smwautoblok.in W: www.smwautoblok.in

283

Tussor Machine Tools Ind P Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com

199

Sreelakshmi Traders T: +91-44-24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com

222

Tyrolit India Superabrasive Pvt. Ltd T: +91-80-40953259 E: subrahmanya.kumar@tyrolit.com W: www.tylolit.com

115

Sunil Enterprises T: +91-281-2926239 E: microlathes@rediffmail.com

284

Universal Corporation T: +91-22-23422238 E: samson7@vsnl.com W: www.samson-grp.com

136

Superslides & Bushes Corporation T: +91-22-61567567 E: sales@superslides.in

229

Vargus Ltd T: +91-9899073393 E: prasad@vargusindia.com W: www.vargus.com

145

233

Sandvik Coromant India T: +91-20-27104725 E: rupali.kavi@sandvik.com W: www.sandvik.coromant.com/in

FGF

Supreme CNC Machines Pvt Ltd T: +91-44-26285075 E: info@supremecnc.com W: ww.supremecnc.com

284

Surya Marketing Corporation T: +91-20-25694455 E: smc2@vsnl.com W: www.suryamarketing.com

293

Schliff Maschinen Fabrik T: +91-9426416905 E: schliffmaschinen@gmail.com W: www.schliff.in Schneeberger India Pvt Ltd T: +91-22-22632372 E: a.joshi@schneebergerindia.com W: www.schneeberger.com

192

Taegutec India Ltd T: +91-80-27839111 E: sales@taegutec-india.com W: www.taegutec-india.com

Schuler India Pvt Ltd T: +91-22-66800300 E: info@schulerindia.com W: www.schulergroup.com

224

TAGMA T: +91-22-28526876 E: mumbai@tagmaindia.org W: www.tagmaindia.org

Schunk Intec India Pvt Ltd T: +91-80-41277361 E: info@in.schunk.com W: www.schunk.com

219

Takamatsu Machinery Co Ltd T: +81-76-2741403 E: h.nakagawa@takamaz.co.jp W: www.takamaz.co.jp

Seco Tools India Pvt Ltd T: +91-2137-667300 E: seco.india@secotools.com W: www.secotools.com/in

35, 153-156

Techno Industries T: +91-79-25830742 E: info@technoind.com W: www.technoind.com

See Lube Technologies (P) Ltd T: +91-161-4641296 E: info@seelube.com W: www.oilandlubricant.com

278

Techtronics India Limited T: +91-124-2370555 E: info@techtronics.in W: www.techtronics.in

Servomax India Ltd. T: +91-40-44436666 E: dharmesh@servomax.net W: www.servomax.net

18

Siemens Ltd E: lvsgr-mktg.india@siemens.com

302 MODERN MACHINE TOOLS - October 2011

119

21

Pg No

SKF India Limited T: +91-22-66337777 E: rakhi.p.tyagi@gmail.com W: www.skf.com

Samtec Tools & Accessories Pvt Ltd T: +91-20-32941330 E: info@samtectools.com W: www.samtectools.com

Shenoy Engineering Pvt Ltd T: +91-80-28361767 E: info@shenoyengineering.in W: www.shenoyengineering.in

Advertiser’s Name & Contact Details

Teknic T: +91-22-26592392 E: teknic@vsnl.com W: www.teknic.co.in

22

Vinit Engimech Pvt Ltd T: +91-281-2312091 E: vinit@balajilathe.com W: www.balajilathe.com

65

95

Vinit Performance Polymers T: +91-22-28204120 E: mail@polymatindia.com W: www.polymatindia.com

209

BC

Weldor Engineering Pvt Ltd T: +91-2827-252038 E: mahesh.weldor@rediffmail.com W: www.weldorpunchpress.com

253

266

Wendt India Ltd T: +91-4344-405500 E: vijayvernekar@wendtindia.com W: www.wendtgroup.com

127

Werner Finley Pvt Ltd T: +91-80-23289889 E: info@wernerfinley.com W: www.wernerfinley.com

275

Wexper India Ltd T: +91-124-2210020 E: rajan.vaid@wexper.com W: www.wexper.com

303

53

255

304-305

17

The Jaws Mfg Co T: +91-20-26877842 E: jaws@jawsindia.com W: www.jawsindia.com

101

Trident Tools Pvt Ltd T: +91-22-28847191 E: abhay.jain@magicuttools.com W: www.magicut.net

207

Yamazaki Mazak India Pvt Ltd 75-78 T: +91-2137-668800 E: sudhir_patankar@mazakindia.com W: www.mazak.com YG Cutting Tools Corporation Pvt Ltd 12-13 T: +91-80-43543636 E: admin@yg1india.com W: www.yg1.co.kr

Looking for a specific product? We will find the product for you. Just type MMT (space) Name of the Product and send it to 51818 eg, MMT (space) Lathe and send it to 51818.

Our consistent advertisers

Advertiser’s Name & Contact Details


MODERN MACHINE TOOLS

October 2011


MODERN MACHINE TOOLS

October 2011


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Reg No: MH / MR / WEST / 235 / 2009 â&#x20AC;&#x201C; 2011 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 1ST & 2ND Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

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Reg No: MH / MR / WEST / 235 / 2009 â&#x20AC;&#x201C; 2011 RNI No: MAHENG / 2008 / 24347 Licence to Post at Mumbai Patrika Channel Sorting Office, Mumbai GPO., Mumbai 400 001 Date Of Posting 1ST & 2ND Of Every Month / English & Monthly. Date Of Publication: 28th of Every Month

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Modern Machine Tools - October 2011  

‘MODERN MACHINE TOOLS’, India’s numero uno magazine for the metalworking & allied industries, is brought out in association with Indian Mach...

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