Volume 12 Issue 12 June 2016 ` 100
FAST AND ACCURATE MEASUREMENT WHEREVER IT’S NEEDED PORTABLE LASER TRACKERS CONTINUE TO GROW IN POPULARITY AND APPLICATION POTENTIAL, TECHNOLOGY HAS DEVELOPED TO PRODUCE THE MULTIPURPOSE INSPECTION TOOLS THAT ARE DRIVING BETTER PRODUCTIVITY IN INDUSTRY TODAY.
QUALITY MANAGEMENT AN EVENTFUL JOURNEY QUALITY MANAGEMENT PRINCIPLES: AN ISO APPROACH
taining Tra
E-VEHICLES FOR A BILLION HUMAN MOBILITY
M
June 2016
IMPORTANCE OF VISUALIZATION IN THE COMPANY
ain
MANAGING CONFLICTS AT WORK
co Re
rd of Gro
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DATA QUALITY MANAGEMENT FOR BETTER BIG DATA ANALYTICS
VISIT MART AT HALL 12A STALL F 91A www.martupdate.com
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foreword Yoga@ Solutions Hi Readers, “Yoga is equivalent to health assurance. Countries with poor health budgets should invest in yoga for preventive health measures and they can save a lot of money. It has become essential that everyone says ‘yes’ to yoga. We cannot wait any longer. Embrace yoga and make it a part of your life”.
-
Narendra Modi
Second International Yoga Day was celebrated across the world on 21st of this month. The Prime Minister was instrumental in getting International Yoga Day declared by United Nations General Assembly during December 2014, a huge recognition for our ancient ways of living and culture, bringing great benefits globally. Performing yoga along with 30000 participants at Chandigarh, Modi urged everyone to embrace yoga and leave controversies for better opportunities. The Prime Minister announced two new yoga awards — national and international — which will be given away by the Union government next year. On today’s competent business environment practicing yoga and meditation will help each of us bring the best results in our professional and personal life. I had this wonderful opportunity to attend the inauguration of the first Additive Manufacturing Solutions Centre by Renishaw globally at Pune mid of this month, an opportunity to go deep inside the wonderful technology, making manufacturing simple. The Centre was inaugurated by Deputy High Commissioner to Britain in India, Mr. Collins Wells who applauded the investment Renishaw is making in AMSC, boosting Make in India campaign launched by our Prime Minister. Renishaw through its AMSC in UK (yet to open officially) is already providing solutions to precision complex components which were also in exhibit at the centre. The new centre will facilitate existing customers and other manufacturers to explore the solutions from design to finishing of complex manufacturing components. “It is difficult to talk of ‘value’ when you cannot measure the ‘value’ you are delivering” quoted Juzer Haideri country head for Mayr, Germany, in India since 1993 and the CEO of NENCO. In an exclusive interview, he talked in detail of the recent Testing and Measuring industry. India entering into the precision world of manufacturing, the scope of cutting edge testing measuring equipments is growing and this opportunity will help our local manufacturers to upgrade their quality and also to compete with the leading suppliers globally. We included a technical feature from Hexagon on Portable Laser Trackers along with the interviews from Testo India, Fluke Process Instruments and Scientech. In the main feature for this edition our senior advisory board member Mr. Saravjit Singh has given a detailed tale about his experience on Quality Management, an interesting journey we should not miss out. Two more features are included in the main story, on “Applying Lean to New Product Development” by Gorur Sridhar and “Quality Management Principles: An ISO Approach” by our consulting editor Arnab Mondal. We are sure you will find our last edition of this volume quite interesting and we look forward your support and feedbacks to make our efforts more fruitful and interactive. Signing off,
Hari Shanker hari@martinfotech.in June 2016
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22 MAIN STORY
10 INNOVATIONS
22
Quality Management – An Eventful Journey
28 Quality Management Principles: An ISO Approach
34
Applying Lean to New Product Development in Engineering Services
36 Data Quality Management for Better Big Data Analytics
Volume 12 Issue 12 June 2016 Annual Subscription `1200 Member INS Editorial Advisory Board
A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre S M Dangi Sandeep Hingne
Mart Infomedia Private Limited
Digital Edition at
C-507, Wisteria Fortune, Bhumkar Chowk Marunji Road Near New Poona Bakery, Wakad, Pune - 411057 India
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Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Orange Printers Private Limited, Plot No: 53, Vattiyoorkavu, Thiruvanthapuram- 695013. Industrial Business MART is a monthly journal published from Thiruvananthapuram Declaration No: A11/96303/14. Industrial Business MART reserves the right to use the information published here in any manne the Publisher no any of its employees accept any responsibilities for any errors or omissions. Š All RightsJune Reserved 2016
CONTENTS 74
Suresh D CEO, Spark Minda Technical Centre
ON FACE
Columns
78 Managing Conflicts at Work 80 Importance of Visualization in the company 84 e-vehicles for a billion human mobility India, the first country in the world?!
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Understanding Chakra Energy Centers in Human Body
40 SPECIAL FEATURE
52 INDUSTRY FOCUS
90 97
MART UPDATE THE LAST LEAF
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IDA Veli, Titanium Post, Thiruvananthapuram- 695021 and Published from”Tharangam”, TC 37/2029, Kodunganoor Post. m. Views and opinions expressed in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 er whatsoever. While every effort has been made to ensure the accuracy of the information published in this edition, neither June 2016
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Curved linear guides from igus – Safe guidance for variable radii
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Even more freedom in designing, thanks to the adaptable guide carriage
Thanks to the new drylin carriages from igus, customers can now use curved linear guides with different radii. (Source: igus GmbH)
At the 2016 Hannover Messe, the motion plastics specialist igus presented the first carriage for linear guides with different radii. The adaptable carriage can thus go into a curve from a straight line and is therefore suitable for a variety of applications in industry ranging from furniture to stage equipment. Even in the driver cabs of agricultural and commercial vehicles, there are specific requirements in a limited space is often expressed. Based on the proven drylin W linear plain bearings, the
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motion plastics specialist igus presented curved rails for linear guides for the first time a year ago. Thereby igus addressed the users’ demands for more and more customised requirements and perfect space utilisation. Application examples here are in the control cabins of construction and agricultural machinery. The advantages of drylin linear guides are ease of installation and maintenance-free use because the bearings do not have to be lubricated. This year igus goes one step further and offers the first carriage for linear guides
with different radii on a rail. The carriage is adaptive, whereby it is possible, for example, to move from a straight line into a curve. “Entirely new possibilities open up especially in applications such as in office equipment or stage machinery,” explains Stefan Niermann, head of drylin linear and drive technology division at igus. Customised solutions for maximum freedom
abrasion-resistant iglidur plastic is used in the new drylin carriage. Thus, the carriage can move on flat rails as well as on concave or convex curved rails. Just as the carriage for a fixed radius, the new version is also available with manual clamping, whereby the carriage can be fixed at any position. Users can order their custom curved aluminium rails with corresponding carriages from igus.
rail spacing, a pivoting
For more details write to vinayak@igus.in and visit
spherical ball made of
www.igus.in
To compensate for the
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New planning tools for assembly systems
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Modular high-performance assembly
The SCHUNK Kombiboxhas been expanded to allow more than 1,700 new combinations.
SCHUNK’s line of modules for high-performance assembly offers more than 10,000 possible combinations for unique freedom of design and flexibility in the planning of assembly systems. Especially for design engineers and system planners SCHUNK,the competence leader for clamping technology and gripping systems has now issued two updates for the time-proven planning tools “Kombibox” and “Toolbox”, which feature many new options in the selection and design of modules. 1,700 new combinations The Kombibox, which enables the fast and easy determination of which components are optimally compatible, has been expanded to allow more than 1,700 new combinations.
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All new products, such as the SCHUNK MPG-plus and EGP small component grippers, the SCHUNK ELB and HLM stroke modules or the SCHUNK Beta and Delta linear modules are now integrated in the tool. At the press of a button users can determine both the suitable adapter plates and the required centering elements and DIN screws. As soon as the desired combination is defined, the Kombibox determines the required assembly accessories, including all standard parts and calculates the position coordinates of the combined mod-ules. The software modules of the Toolbox series have also been significantly expanded, in order to facilitate the design of the single modules. “Toolbox Pick &
Place”, a new tool for selecting the SCHUNK PPU-P Pick & Place units and the SCHUNK DRL rotary lift units, automatically determines cycle times and maximum cycles, without the necessity of poring over data sheets. Moreover, “Toolbox Rotation” has been expanded to include innovations such as the SCHUNK RST-D rotary indexing table and “Toolbox Translation” now includes new stroke variants of the SCHUNK CLM linear modules. Avoidance of over-dimensioning The software tools make it possible to fully utilize the high performance of the single com-ponents and to avoid the high expense of overdimensioning. Both the payload of the guidances and the shock
absorbers as well as the cycle times can be calculated. Also, the utilization of the hydraulic end position damping for the single linear and rotary modules can be determined on the basis of all parameters occurring during operation. This saves time and increases planning reliability. All calculation tools are based on Excel 2003, intuitive to use and generally require no installation. Queries are possible in six languages (German, English, French, Spanish, Italian, and Hungarian). The calculated module data can be downloaded directly from the internet as ready-to-use CAD models. For more details write to info@in.schunk.com or visit Web: www.in.schunk.com
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When the grade gets tough
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Pramet has launched a new milling grade and also expanded its face milling range for stainless steels. The M6330 grade has been developed specifically to achieve longer cutting edge durability and reliability in a range of difficult-to-machine materials with and without coolant.
Particularly suited
coating. The new grade
steels and soft steels up to
and finishing operations done
to adverse cutting
is the latest of many
depths of 5mm.
separately.
conditions, including
new products recently
interrupted cutting, the
launched by Pramet for
The versatile tool can be
A new range of round inserts,
grade is now available
machining stainless steels.
used for both roughing
REHT 24, for face and copy
and finishing operations,
milling and the XEHT 09 wiper
Meanwhile, Pramet
providing increased
inserts add to the options
has also added to its
tooling economy and
face milling range for
significant savings on
stainless steel with new,
machine time. In a recent
larger diameter cutters
product test, machining
and inserts for greater
a piece of steel (3900mm
It promotes greater
depths of cut and more
x 3200mm) with coolant,
operational reliability
powerful machines.
the OEHT performed the
and tool life, with a
These latest tools include
roughing and finishing
high resistance to
the octagonal OEHT
operation in 52 minutes.
heat-related cracks.
09 inserts, suitable for
A competitor tool
This is due to improved
unstable conditions
performed the same task
abrasion resistance from
and machining fragile
in the same conditions in
For more details visit
a new substrate and PVD
components in stainless
252 minutes with roughing
www.dormerpramet.com
with many of Pramet’s most popular inserts, including the ADMX, HNGX, LNGX, LNMU, OEHT and numerous other ranges.
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available. All can be clamped into the same milling cutter, further increasing versatility and cost efficiency. A wide assortment of new milling cutters, ranging from 80 - 315mm diameter, is also available. Internal coolant delivery is supported by each cutter, including for large diameters.
June 2016
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25,000 published articles in 2014: EMEA: 45% - Asia: 35% - Americas: 20%. Most of the articles are published in the top 1000 media worldwide.
With a proven process set for more than 70 active customers, we can adapt to all specific client needs with the highest reliability. We have developed in house the most advanced PR dedicated ERP, enabling transparency and real-time full online reporting. International media management is then made easy, fast, and efficient for optimal results.
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June 2016
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High-temperature Pyrometers fit for Harsh Environs
Easy operation, superior precision, and longevity combined in one rugged infrared thermometer
Fluke Process Instruments introduces the Endurance series of high-temperature infrared thermometers. Featuring a stainless steel IP65 housing and galvanically insulated I/Os, these units enable continuous process monitoring of the most demanding industrial applications, including primary and secondary metals manufacturing, carbon processing, and silicon production. Providing a measurement resolution of 0.1 °C, they also meet the requirements of the semiconductor industry. Two models cover wide measured temperature ranges of +550 °C
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to +1,800 °C and +1,000 °C to +3,200 °C, respectively. They can be operated in one- or twocolor (ratio pyrometer) mode. An optical resolution of up to 150:1 allows measurements of smaller objects from a distance. The series is designed for comfortable configuration and operation. The sensors feature an intuitive rearpanel user interface and a built-in web server for data archiving, traceability, and process troubleshooting. The PC-based Endurance setup and monitoring software includes time-saving tools such as the new match function which automatically detects the correct emissivity of the
measured surface. What is more, Fluke Process Instruments has further extended the range of sighting options and now offers a high-resolution on-board video camera for remote monitoring of the application and sensor alignment via Industrial Ethernet. In addition to laser sighting, which marks the position or size of the measurement spot, LED sighting projecting the actual spot size on the target is also available now. Endurance series pyrometers provide a robust solution for manufacturers seeking to improve product quality and uniformity, reduce reject rates,
maximize throughput, and minimize energy costs. Periodic lens cleaning checks are unnecessary, since a dirty lens alarm tells users when it is really time to clean. Accessories include an air-purge collar. The rugged sensors operate reliably at ambient temperatures up to +65 °C or up to +315 °C using cooling accessories. The manufacturer provides a bestin-class four-year warranty. The sensors use either Power over Ethernet (PoE) or DC power (18 to 48 VDC, 500 mA). They are available with Industrial Ethernet, RS-485, or Profinet interfaces as required. For more details write to india@ flukeprocessinstruments.com
June 2016
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Renishaw reels out new RTLA scale length options to 21 metres
Renishaw, the global metrology specialist, has more than doubled the maximum length of its RTLA linear stainless steel ribbon scale. It is now available in lengths up to 21 metres and can be used with or without the FASTRACK™ scale carrier system.
The longer RTLA scales, used
100 m/s, smooth velocity
immunity gives outstanding
with Renishaw’s RESOLUTE™
control with interpolation
performance even on the
absolute optical encoders, are
errors (SDE) of ±40 nm and
very long axes typical of
now suitable for applications
excellent positional stability
heavy industrial applications.
with very long axes. These
with jitter (noise) of 10 nm
include large aerospace
RMS.
trimming and drilling systems,
to the substrate using
RESOLUTE is also
either their own self-
compatible with a range
adhesive backing or the
of ‘open’ and ‘proprietary’
FASTRACK scale carrier
serial protocols including
system. Comprising two
Siemens DRIVE CLiQ, BiSS®,
miniature guide rails,
FANUC, Mitsubishi and
FASTRACK securely retains
Renishaw’s RESOLUTE is the
Panasonic for connection
Renishaw’s low-profile
world’s most advanced single-
to a wide range of industry-
stainless steel scales and
track true-absolute optical
standard motor drives and
allows them to expand at
encoder system delivering up
controllers. Furthermore,
their own coefficient of
to 1 nanometre resolution,
combining RESOLUTE’s
thermal expansion. RTLA
superior long-term reliability,
easy installation, thanks
with FASTRACK is ideal for
instant operation after power-
to its generous set-up
environments requiring
up without reference return,
tolerances and integral set-
frequent removal and
high speed performance to
up LED, with its excellent dirt
replacement of damaged
wing structure drilling systems, milling machines for power turbine manufacturing and the manufacturing of outsized components.
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RTLA scales are mounted
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scales even when access is limited, thus reducing machine downtime. Installation of RESOLUTE and RTLA scale on machine axes translates into increased up-time, greater reliability and reduced cost of ownership for the end-user. Renishaw is one of the world’s leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. Since its formation in 1973 it has won numerous awards, including a Queen’s Award for Enterprise 2015 for its RESOLUTE true-absolute encoder system. For more details visit www.renishaw.com
June 2016
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16mm Athlonix DC Miniature Motor Features Energy Efficient Coreless Design
Portescap introduces the next frame size in the DCP range of Athlonix™ high power density brush DC mini motors.
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Athlonix DCP motors offer
both featuring an Alnico
are ideally suited for use
turns limitations that affect
an optimized price-to-
magnet inside. The unique
in applications such as
the magnetic flux density
performance solution ideal
constant force spring design
medical& industrial pumps,
in the magnetic circuit,
for a broad spectrum of
for carbon brush ensures
gas analyzers, security
which further limits power
applications. Available in a
consistent performance.
& access, power tools,
output and endurance of
16 mm diameter, the new
An REE (Restriction of
mesotherapy guns and
the motor,” he says.
16DCP motor features an
Electro Erosion) coil is an
tattoo machines.
energy efficient coreless
available option, which
design with an optimized
ensures extended life of
self-supporting coil and
the motor and provides an
magnetic circuit, which
environment of intrinsic
ensures optimum price-to-
safety especially at high
performance is delivered.
speed conditions.
Athlonix 16DCP motors
Component
“Athlonix motors are
standardization and design
powered by a proprietary
modularity ensures quick
self-supporting coil
customization capability
resulting into maximized
for samples across various
magnetic flux and ampere-
applications. Athlonix
turns for a given diameter”
motors are available with
With maximum continuous
says Sunil Kumar, Brush
encoders and gearheads
are available in 2
torque up to 2.63 mNm
DC Product Line Manager
of various sizes and ratios.
variations, precious
and higher stall torque
at Portescap. “In contrast,
They are manufactured in
metal commutation and
than similar motors,
typical self-supporting coils
an ISO certified facility and
graphite commutation,
Athlonix 16DCP motors
have inherent ampere-
are RoHS compliant.
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June 2016
Witness a true international event with state-of-the-art infrastructure
Venue: The Exhibition Center, Helipad Ground, Gandhinagar, Gujarat, INDIA.
June 2016
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MAIN FEATURE
Quality Management: An Eventful Journey Modern quality management enables design for quality followed by desired variance control during production, delivery and life-time service of products and services. It ensures us high quality, durability and reliability over the product’s lifetime
Saravjit Singh Saravjit@pcshp.com
Quality management has changed the world. Quality practice evolved because of a few remarkable quality gurus. Each one defined quality in his own way: 1. “Meeting of customers’ needs” – W. Edward Deming 2. “Fitness for use” – Joseph M Juran 3. “Conformace to requirements” – Philip B. Crosby My personal definition of quality: “Quality is a moving target, forever in consistent conformance to customer’s current and emerging needs and expectations.” In Zero Defects: A New Dimension in Quality Assurance, Philip B Crosby introduced the concept of zero defects, “Zero Defects is a management tool aimed at the reduction of defects through prevention. It is directed at
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motivating people to prevent mistakes by developing a constant, conscious desire to do their job right the first time.” Kaoru Ishikawa focused on the human aspects of quality. He said that quality is essential to achieve customer satisfaction and it must be defined comprehensively. It is not enough to say the product is of high quality; we must focus attention on the quality of every facet of the organization. The way an organization defines quality must be ever changing since consumer needs and requirements keep changing. Armand V Feigenbaum was the originator of “Total Quality Control (TQC)”, popularly known as “Total Quality Management (TQM).” Feigenbaum defined TQC as “An effective system for integrating quality development, quality maintenance and quality
improvement efforts of the various groups within an organisation, so as to enable production and service at the most economical levels that allow full customer satisfaction”. History of quality management I divide the development of modern quality management into four phases: 1. 1900 to 1920: Quality was limited to inspecting the final product to ensure it met defined specifications. 2. 1920s to 1950: Wide use of Statistical Process Control (SPC) in USA. This methodology was used during World War II to produce reliable war equipment. 3. Early 1950’s: Deming and Juran spread the messages of quality to Japanese industry. Before this, SPC and quality control were not practiced by Japanese industry. This was the
start of quality management in Japan. 4. Late 1950’s to 1960s:Ishikawa and other Japanese gurus developed new quality concepts. Toyota Production System revolutionized manufacturing and quality management. 5. 1970’s onwards: West started adopting the new quality tools developed in Japan. In 1996 James P. Womack and Daniel T. Jones published the landmark book Lean Thinking: Banish Waste and Create Wealth in Your Corporation. This book addressed the revolution represented by the Toyota Production System. They wrote that lean thinking allows companies to “specify value, line up value-creating actions in the best sequence, conduct these activities without interruption whenever someone requests them, and perform them more and more effectively.” There are five
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Plan what is needed
Act to correct problems
Figure 1: Deming’s PDCA Cycle for Continuous Improvement
principles of lean thinking: Value, Value Stream, Flow, Pull and Perfection. Some noteworthy developments In 1924 Dr. Schewart, a statistician, devised statistical methods to control quality in production. This laid the foundation for SPC. Deming was invited to Japan in 1950 to teach SPC to Japanese Industry. He taught a systematic approach to problem solving using the Plan, Do, Check, Act (PDCA) cycle developed by Shewhart. This is shown in Figure 1. Even today, PDCA cycle is a universally used quality improvement methodology. It is used to progressively reduce the gap between the requirements of the customers and the performance of the process. In 1951, Joseph M Juran wrote Quality Control Handbook. Seeing this book, in 1954, the Union of Japanese Scientists and Engineers (JUSE) invited Juran to give two lectures, titled “Lectures on Quality Control”. The theme was “Control is the totality of means by which we establish and
June 2016
achieve standards.” The first lecture, of two days duration, addressed Japanese Industry leaders, mostly CEOs. The second, a 10-day lecture was attended by middle managers. Juran’s lectures had a strong and enduring impact. They gave insight into quality control going beyond the use of the use of SPC.
actively led by the CEO himself and satisfy both internal and external customers. My definition of a customer: A customer is anyone who is seeking our help or whom we are trying to help. This broad definition covers both internal and external customers.
Juran developed the quality trilogy, as shown in Figure 2. This says that good quality management requires quality planning, improvement and control during operations. Each improvement is dealt as a separate project, using tools such as Pareto analysis and root cause analysis. As seen in Figure 3, use of Juran’s trilogy achieves breakthrough to an improved level. Standardization and controls then hold gains.
Lack of allotted space permits me to relate only a few of my experiences:-
Deming and Juran’s work laid the foundation of Japan’s quality control movement. The Japanese refined these concepts. Finally, USA learnt about modern quality management from the Japanese. Today, quality focuses on the total organization. It is now universally accepted that quality management must be
My encounters with quality
1961-62: Before going to college, I worked for a full year as an Industrial Radiographer with a UK based company specializing in quality control of oil pipeline welds (today’s standard for this is API 1104). My assignment was on Oil India’s Naharkatya - Barauni oil pipeline project. We used portable “bombs” to expose gamma ray radiographs to examine and certify the quality of butt welded joints in 16” seamless steel pipes. For critical areas, such as river crossings, there was 100% visual welding inspection followed by confirmation through radiographs. Defective welds were repaired in case of slag inclusions, whereas blow hole defects required total re-welding. All rework was again radiographed. Welders
Do it
Check that it works
working on this project were mostly from West Germany and Italy. Every three months each welder had to undergo recertification. This early exposure gave me a valuable lesson in world-class quality control. My second brush with quality was in 1965 when, as a mechanical engineering student, I visited an engineering R&D. While I was being briefed by the R&D head, an engineer rushed into the room. He carried a broken bracket; an important part of an equipment their company manufactured. The boss calmly asked, “what’s the problem?” The engineer said four such failures had been reported from the field last week and the Managing Director was demanding immediate action. The boss reflected for half a minute and gave his verdict, “Make a new drawing of the bracket using the next higher size of angle iron available and release it to the materials department for arranging immediately supply”. Instant R&D! Today, when such a failure occurs, a structured approach is followed. The service department does a preliminary investigation of the failure
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and submits a report on a standardized form. This is studied by the concerned Section Head in the R&D. Then an Engineering Change Note (ECN) is issued. The failure is studied from various angles –possible product misusage, material, manufacturing, and design weakness. Redesign and testing follow a standardized process. Release of new part against the ECN may take three months to a year or more in some cases. Meanwhile an interim solution may be provided to satisfy existing customer and for manufacturing new equipment. Production does not stop. Interestingly, in Toyota since the 1960 their philosophy is to stop the line and fix the problem – not a single defect must move from one work station to the next. Toyota does not do rework, and after assembly corrections, on new cars. Which other company follows this guideline? In 1968, after getting my degree, I worked as a foreman in a field workshop of an organization that constructed and maintained roads in the border areas. We repairing vehicles and earthmoving equipment of various types
and makes. Here are two experiences I had with vehicles and earthmoving equipment. 1. Our organization owned TMB 312 trucks, manufactured by TELCO in collaboration with Diamler-Benz. These trucks operated in tough mountainous terrain. This caused a seemingly inherent and serious failure – chassis crack at the same location near the front suspension spring on the passenger side of the truck. The only option was to scrap these trucks, since the organization did not allow welding the chassis nor permitted changing the chassis frame. No solution was forthcoming at that time, possibly because TELCO’s Engineering Research Centre (ERC) was new – having been established at Pune only in 1966. Today the situation at Tata Motors is different. ERC now has designers working on 20 different engine platforms and 250 vehicle variants. It has state-of-the-art equipment and facilities for noise, vibration and harshness (NVH) and a crash test lab. Such critical failures are very unlikely in their modern trucks. 2. We used many equipment fitted with different models
Quality Control
of a world renowned diesel engine. These robust engines gave faultless service under adverse, high altitude working conditions. Imported models of these engines were never known to have failed during their rated 5,000 hours working life. Amazing! In 1970, we received four indigenously made wheeled loaders fitted with engines of the same brand made by their Indian subsidiary. Within 1,500 hours of usage, at most, three of these engines developed engine oil seal leakage. These seals were made by a wellknown Indian company. The seals should not have failed. Surely, these seals must have passed endurance and other tests at the engine maker’s centralized R&D in USA, the required practice, I learnt. It fell upon me to “fix it right” – road construction work cannot stop. We replaced all the three leaking seal with a substitute USA make seal which was fortunately available in our stores. The product never came back with the same defect. From 1971 to 1977, I worked in an organization which manufactured material handling equipment. We encountered a large number
of field failures. These were attributed variously to weak design, material and manufacturing defects. Few solutions were forthcoming. Our marketing solution – sell the product only with a full set of recommended spare parts kits – and rush a service engineer to customer site whenever he reported equipment stoppage. At least the customer did not lose productivity. However, we had a difficult time getting repeat orders! This was a classic case of lost opportunity because of lack of proper quality management – a practice missing in most engineering companies those days. In 1981, I visited a dealer of a well-known make of cars. There were many oil marks on the floor, as well as under some of the new cars in their show room. The dealership’s manager said engine and gear box oil seal leakage wan one of the inherent problem with their cars. He then made a surprising comment, “the company says do not complain, just sell cars.” I asked, “What can be done?” He said, the dealership offered a Rs.1,200 package to its customers for new cars. Within
Quality Planning
Holding the Gains
Quality Improvement Done Projectwise
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Figure 2: Juran’s Trilogy shown as a Process
June 2016
June 2016
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this amount, they replaced the engine and gear box oil seals and suspension parts to make the car run trouble free for at least a year. If the dealer could come up with a solution, why not the manufacturer? A captive seller’s market can make anyone complacent. From 1982 to 2001 I worked with a renowned vehicle manufacturer. In early 1980s I encountered a frustrating problem in the field. There was very high vibration of battery bracket in one vehicle model. This resulted in consequential battery failure. Our reputed battery manufacturer refused to accept warranty failure claims from dealers, citing excessive vibration of the battery bracket. Our R&D had erred. Today, this organization’s R&D structure is arguably the best in the country. It uses multiple quality initiatives, including FMEA and Reliability Engineering to ensure that failures are minimal during a vehicle’s designed lifetime. It
Quality Planning
understands that great quality always pays. In early 1980s, customers perceived that good quality came at a high cost. They silently accepted the indifferent quality of Indian cars and paid very high prices for second hand imported cars available only through State Trading Corporation of India. In 1983, everything changed when Maruti Udyog stepped in. Maruti 800 was cheaper, better designed and had higher quality than other Indian cars. Its fuel economy was phenomenal. People realized that good quality can be made available at a low price. One big bonus was the supplier base Maruti created. North India based Indian companies collaborated with Japanese suppliers to make world class components in India. Today these suppliers are sterling examples of zero defect, just in time, engineering quality at its best. As a quality consultant, I had
one memorable encounter. This was during a presentation on Lean Management I was making to a CEO and his senior management team. Here is how this conversation went. One of the HODs present asked, “What really is Lean?” My answer, “Lean is absence of fat.”
In that case you can never become a Lean organization.” I got the go ahead to serve this client – on my terms. India is opening out and changing fast. CEOs in all organizations must lead from the front. An important point: unless a company’s quality
He persisted, “What really is at the core of Lean?”
management programme is
Obviously, he knew the subject.
very difficult to successfully
I replied, “Being Lean means doing everything the customer wants you to do, no matter what it takes.” This is not the regular stereotyped answer you expect.
9001:2015 certification. Quality
All the Senior Managers present looked at each other knowingly.
led by its CEO, it may find it implement and secure ISO is now on centre stage. The author Saravjit Singh is a Quality Consultant and Trainer. He is presently focusing on creating customized blended learning solutions for professionals and engineers.
The CEO then stepped in, “Saravjit, I disagree. We cannot do everything the customer wants us to do.”
This is explained on his website
I humbly replied, “Sorry Sir!
at saravjit.singh@gmail.com
http://saravjitsingh.wix.com/ blended-learning You are welcome to write to him
Quality Control (During Operations)
40
Sporadic Spike
COST OF POOR QUALITY 20
Original zone of quality control Chronic waste ( an opportunity for improvement)
Operations begin
New Zone of Quality control QUALITY IMPROVEMENT
0
TIME LESSONS LEARNED
26
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Figure 3: Juran Trilogy in a Work Operations
June 2016
June 2016
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MAIN FEATURE
Quality Management Principles: An ISO Approach Globalisation, intense competitive environment and customer awareness have driven organizations to offer high product and service quality for sustainable growth. And to retain this sustainable growth, it is necessary for any organization to keep focusing on quality management.
Arnab Mondal arnab@martupdate.com
Quality management is the principle of management that customer requirements are met exactly and every person in the organization is involved fully with the commitment of the top management. The quality management is driven by the constant attainment of customer satisfaction through the continuous improvement of all organizational processes. The quality management involves the continuous improvement in quality, productivity and effectiveness obtained by establishing management responsibility for processes as well as output. The quality management assists business for product differentiation, fulfillment of customer requirement,
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and reduction of costs by preventing waste in costs.
help the organization maintain
International Organisation for Standardisation, a federation of 132 national standardization bodies, plays a key role as the upholder and quality management through ISO 9000, ISO 9001 and related ISO standards management through its quality management systems (QMS) standards.
The seven quality management
The ISO standards apply to the processes that yield product and services. The standards are generic in nature so that they used by manufacturers and service industries globally. ISO has laid down some principles, termed as Quality Management Principles which can used as foundations to guide an organisation’s performance improvement and
quality management practices.
principles are: • Customer focus • Leadership • Engagement of people • Process approach • Improvement • Evidence-based decision making • Relationship management Customer focus The primary focus of quality management is to meet customer requirements and to strive to exceed customer expectations. Sustained success is achieved when an organization attracts and retains the confidence of customers and other interested parties.
Every aspect of customer interaction provides an opportunity to create more value for the customer. Understanding current and future needs of customers and other interested parties contributes to sustained success of the organization. Key Benefits • Increased customer value • Increased customer satisfaction • Improved customer loyalty • Enhanced repeat business • Enhanced reputation of the organization • Expanded customer base • Increased revenue and market share Key steps • Recognizing direct and indirect customers as those who receive value from the
June 2016
The quality management is driven by the constant attainment of customer satisfaction through the continuous improvement of all organizational processes.
organization. • Understanding customers’ current and future needs and expectations. • Linking the organization’s objectives to customer needs and expectations. • Communicating customer needs and expectations throughout the organization. • Planning, designing, developing, producing, delivering and supporting goods and services to meet customer needs and expectations. • Measuring and monitoring customer satisfaction and take appropriate actions. • Determining and taking actions on interested parties’ needs and expectations that can affect customer satisfaction. • Actively managing relationships with customers to achieve sustained success. Leadership Leaders at all levels establish
June 2016
unity of purpose and direction and create conditions in which people are engaged in achieving the organization’s quality objectives. Creation of unity of purpose and direction and engagement of people enable an organization to align its strategies, policies, processes and resources to achieve its objectives. Key Benefits • Increased effectiveness and efficiency in meeting the organization’s quality objectives • Better coordination of the organization’s processes • Improved communication between levels and functions of the organization • Development and improvement of the capability of the organization and its people to deliver desired results Key steps • Communicating the organization’s mission, vision, strategy, policies and processes
throughout the organization. • Creating and sustaining shared values, fairness and ethical models for behaviour at all levels of the organization. • Establishing a culture of trust and integrity. • Encouraging an organizationwide commitment to quality. • Ensuring that leaders at all levels are positive examples to people in the organization. • Providing people with the required resources, training and authority to act with accountability. • Inspiring, encouraging and recognizing people’s contribution.
levels and to respect them as individuals. Recognition, empowerment and enhancement of competence facilitate the engagement of people in achieving the organization’s quality objectives.
Engagement of people
development, initiatives and
Competent, empowered and engaged people at all levels throughout the organization are essential to enhance its capability to create and deliver value. To manage an organization effectively and efficiently, it is important
Key Benefits • Improved understanding of the organization’s quality objectives by people in the organization and increased motivation to achieve them • Enhanced involvement of people in improvement activities • Enhanced personal creativity • Enhanced people satisfaction • Enhanced trust and collaboration throughout the organization • Increased attention to shared values and culture throughout the organization
to involve all people at all
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Key steps • Communicating with people to promote understanding of the importance of their individual contribution. • Promoting collaboration throughout the organization. • Facilitating open discussion and sharing of knowledge and experience. • Empowering people to determine constraints to performance and to take initiatives without fear. • Recognizing and acknowledge people’s contribution, learning and improvement. • Enabling self-evaluation of performance against personal objectives. • Conducting surveys to assess people’s satisfaction, communicating the results, and taking appropriate actions. Process approach Consistent and predictable results are achieved more effectively and efficiently
when activities are understood and managed as interrelated processes that function as a coherent system. The quality management system consists of interrelated processes. Understanding how results are produced by this system enables an organization to optimize the system and its performance. Key Benefits • Enhanced ability to focus effort on key processes and opportunities for improvement • Consistent and predictable outcomes through a system of aligned processes • Optimized performance through effective process management, efficient use of resources, and reduced crossfunctional barriers • Enabling the organization to provide confidence to interested parties as to its consistency, effectiveness and efficiency Key steps • Defining objectives of the system and processes
necessary to achieve them. • Establishing authority, responsibility and accountability for managing processes. • Understanding the organization’s capabilities and determining resource constraints prior to action. • Determining process interdependencies and analysing the effect of modifications to individual processes on the system as a whole. • Managing processes and their interrelations as a system to achieve the organization’s quality objectives effectively and efficiently. • Ensuring the necessary information is available to operate and improving the processes and to monitor, analyse and evaluate the performance of the overall system. • Managing risks that can affect outputs of the processes and overall outcomes of the quality management system.
Improvement Successful organizations have an ongoing focus on improvement. Improvement is essential for an organization to maintain current levels of performance, to react to changes in its internal and external conditions and to create new opportunities. Key Benefits • Improved process performance, organizational capabilities and customer satisfaction • Enhanced focus on root-cause investigation and determination, followed by prevention and corrective actions • Enhanced ability to anticipate and react to internal and external risks and opportunities • Enhanced consideration of both incremental and breakthrough improvement • Improved use of learning for improvement • Enhanced drive for innovation Key steps
Consistent and predictable results are achieved more effectively and efficiently when activities are understood and managed as interrelated processes that function as a coherent system.
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June 2016
EXHIBITION & CONFERENCE – ALUMINIUM DIE CASTING 1 - 3 DECEMBER 2016 | BIEC, BENGALURU, INDIA www.alucast2016.com
For more information & space booking, please contact: NürnbergMesse India Pvt. Ltd.
Aluminium Casters' Association of India
Ms. Rucheeka Chhugani
Ms. Veena Upadhye
Tel +91 11 4716 8828
Tel + 91 20 2729 0014
rucheeka.chhugani@nm-india.com
alucastindia@gmail.com
June 2016
Organizer:
Event Producer:
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• Promoting establishment of improvement objectives at all levels of the organization. • Educating and training people at all levels on how to apply basic tools and methodologies to achieve improvement objectives. • Ensuring people are competent to successfully promote and complete improvement projects. • Developing and deploying processes to implement improvement projects throughout the organization. • Tracking, reviewing and auditing the planning, implementation, completion and results of improvement projects. • Integrating improvement considerations into the
development of new or modified goods, services and processes. • Recognizing and acknowledging improvement. Evidence-based decision making Decisions based on the analysis and evaluation of data and information are more likely to produce desired results. Decision making can be a
consequences. Facts,
• Determining, measuring and
evidence and data analysis
monitoring key indicators to
lead to greater objectivity and
demonstrate the organization’s
confidence in decision making.
performance. • Making all data needed
Key Benefits • Improved decision-making processes • Improved assessment of process performance and ability to achieve objectives • Improved operational
available to the relevant people. • Ensuring that data and information are sufficiently accurate, reliable and secure. • Analysing and evaluate data and information using suitable methods.
complex process, and it always
effectiveness and efficiency
involves some uncertainty. It
• Increased ability to review,
competent to analyse and
often involves multiple types
challenge and change opinions
evaluate data as needed.
and sources of inputs, as
and decisions
• Making decisions and take
well as their interpretation,
• Increased ability to
actions based on evidence,
which can be subjective. It
demonstrate the effectiveness
balanced with experience and
is important to understand
of past decisions
intuition.
Key steps
Relationship management
• Ensuring people are
cause-and-effect relationships and potential unintended
Recognition, empowerment and enhancement of competence facilitate the engagement of people in achieving the organization’s quality objectives.
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June 2016
The quality management assists business for product differentiation, fulfillment of customer requirement, and reduction of costs by preventing waste in costs.
For sustained success, an organization manages its relationships with interested parties, such as suppliers. Interested parties influence the performance of an organization. Sustained success is more likely to be achieved when the organization manages relationships with all of
Key Benefits • Enhanced performance of the organization and its interested parties through responding to the opportunities and constraints related to each interested party • Common understanding of goals and values among interested parties • Increased capability to create
its interested parties to
value for interested parties
optimize their impact
by sharing resources and
on its performance.
competence and managing
Relationship management
quality-related risks
with its supplier and partner
• A well-managed supply chain
networks is of particular
that provides a stable flow of
importance.
goods and services
June 2016
Key steps • Determining relevant interested parties (such as suppliers, partners, customers, investors, employees, and society as a whole) and their relationship with the organization. • Determining and prioritize interested party relationships that need to be managed. • Establishing relationships that balance short-term gains with long-term considerations. • Pooling and sharing information, expertise and resources with relevant interested parties. • Measuring performance and providing performance feedback to interested parties, as appropriate, to enhance improvement initiatives.
• Establishing collaborative development and improvement activities with suppliers, partners and other interested parties. • Encouraging and recognizing improvements and achievements by suppliers and partners. Collectively, these can form a basis for performance improvement and organizational excellence. There are many different ways of applying these quality management principles. The nature of the organization and the specific challenges it faces will determine how to implement them.
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MAIN FEATURE
Applying Lean to New Product Development in Engineering Services Lean can be applied to any industry, not just manufacturing, because any business can benefit from improvements in cycle time, cost savings, productivity, efficiency and more. This case study examines the application of Lean to the engineering services industry in the areas of design, analysis and prototyping of parts to realize improvements in a subprocess of the new product development (NPD) lifecycle.
Gorur Sridhar gnsridhar@gmail.com
Lean Principles There are five general principles in Lean: 1. Identify customers and specify value: From the standpoint of the end customer, specify value by product or service group.
START
2. Identify and map the value stream: Identify all of the steps in the value stream for each product or service, eliminating when possible the steps that do not create value. 3. Create flow by eliminating waste: Make the value-creating
Project input and feasability study
steps occur in tight sequence so that the product or service will flow smoothly toward the customer. 4. Respond to customer pull: As flow is introduced, let customers pull value from the next upstream activity.
5. Pursue perfection: As value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced. Begin the process again and continue cycling through until a state of perfection is reached in which perfect value is created with no
Preparation of schedule Plan and estimation
Subprocess for Lean implementation Finite element analysis and Preliminary design review (PDR)
Generation of 3D models and manufacturing drawings
Project approval and kickoff meeting
Prototype testing and detailed design review (DDR)
Creation of reports and documentation
STOP
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Figure 1: New Product Development Process
June 2016
2x per week
Press Signal Kanban
Manufacturing process
Truck shipment
XYZ Corp
Outside sources
Inventory Box
FIFO
Figure 2: Value Stream Mapping Icons
waste. Simply put, Lean minimizes inputs and maximizes outputs at every process step. Example: New Product Development in Design Department The NPD process in this example of applying Lean to a nonmanufacturing setting is in the design department of an organization. It represents part of the overall project management lifecycle. A macro-
START
level process map of the NPD process is shown in Figure 1. Since NPD activity involves many subprocesses, only one was selected for the pilot project. The subprocess under study was generation of 3D models and manufacturing drawings of the various parts that go into the manufacturing of prototypes. The metrics being monitored were cost of quality (COQ), cycle time and lead time. The data captured to calculate
Assumptions, feasability study of customer’s inputs
Operator
First-in-out sequence flow
Boat shipment
Rework
Delay
Kaizen lightning burst
Quality problem
COQ = (total quality check hours + rework hours) * 100 / total actual hours
The cycle time clock starts when work begins on the request and ends when the item is ready for delivery or the task is completed. Lead time (also referred to as throughput or turnaround time) is the average time it takes for one unit of the product or service to go through the entire process – from start to finish – including time waiting between subprocesses.
Where COQ is expressed as a percentage of the total project cost
Lead time = sum of all subprocess lead times + sum of all wait times between
the COQ were the total hours taken to carry out the quality check of the model and drawing, the total hours taken to carry out the rework identified during the peer review stages, and the actual total hours taken to complete the project.
Estimation and approval of the proposal
Self-review, pear reviews
3D modelling and/or drafting activity
Scheduling, task assingment and planning
Metrics capturing schedule log
Submission to customer and feedback
STOP
June 2016
Electronic Manual Database Information flow information flow
Figure 3: As-is Process Map for Generation of 3D Models and Manufacturing Drawings
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START
Assumptions, feasability study of customer’s inputs
Estimation and approval of the proposal
Self-review, pear reviews
3D modelling and/or drafting activity
Metrics capturing schedule log
Submission to customer and feedback
subprocesses. Once the subprocess for Lean implementation was identified, the five Lean principles were mapped as appropriate. 1. Identify customers and specify value: The customers were identified as internal customers
Scheduling, task assingment and planning
STOP
Figure 4: Process Map for Generation
from departments to whom the CAD (computer-aided design) models and drawings were being delivered. 2. Identify and map the value stream: The value stream was mapped and the as-is process map is shown in Figure 3. (Note: Figure 2 provides a
legend for the symbols used in Figures 3 and 4.) 3. Create flow by eliminating waste: The areas of waste and non-value added (NVA) activities were identified (such as idle time, waiting for submissions, etc.), and appropriate actions were
taken (such as automation, training, database creation, etc.) to minimize and eliminate the waste. Figure 4 shows a revised process map with these improvements incorporated. 4. Respond to customer pull: Delivery target dates were set as internal targets and
Benefits of Lean Implementation Evaluating Factors
Before Lean Implementation
After Lean Implementation
Number of subprocesses
18
11
Number of delay times/waiting periods
9
4
Information flow (automation touch points)
3
8
Database availability/use
1
3
Cycle time (in minutes)
130
90
Lead time (in minutes)
200
130
COQ (percent)
20
11
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the schedule was developed by working backwards to ensure that the waiting time and delays were minimized. This is similar to the pull system in a manufacturing setting with the immediate customer setting the target dates for delivery based on the project’s overall schedule. 5. Pursue perfection: The optimized process map was set as the new baseline to further improve. The metrics collected were continuously monitored to ensure the health of the process. Figure 2: Value Stream Mapping Icons
3. Automation of the drawing checking process (with respect to using spell check and implementing standards) to reduce the cycle time of selfreviews and peer reviews and to avoid defects. 4. Elimination and/or reduction of the NVA intermediate steps (such as rework) using the above automations to avoid delays. 5. Creation of a database helped generate and report the requisite metrics to top management and to the customer. Review steps took advantage of the easy access and speedy retrieval of data.
Value Additions A number of value-add activities were implemented to facilitate the improvements in the 3D modeling process. 1. Automation of the job submission process was introduced to speed up the work assignments and to avoid delays and wait times. This automation enhanced the work scheduling and allocation activity. 2. Automation of the peer review submission process was achieved through product data
management, which avoids the submissions’ being overlooked and helped avoid delays and wait times.
6. Training in some modeling and drafting activities for all stakeholders was implemented to improve team members’ skill sets. This led to enhanced efficiency and productivity by way of fewer defects, improved first pass yield and shorter cycle times. 7. Institutionalized best
COQ (%)
Adopted Six Sigma
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Figure 4: Process Map for Generation of 3D Models and Manufacturing Drawings – After Lean Implementation After implementing Lean, some pockets of delay, rework and quality problems remain. Those pockets will be further optimized during subsequent process improvement cycles. A Taste of the Benefits The table below offers a glimpse into the benefits that were derived out of this particular LSS application. Another way of expressing these improvements is the following: 1. An average of reduction of 40 minutes was realized per 3D model. This amounts to a 30-percent reduction in the cycle time per model. 2. Assuming an average workload of about 300 models per month with a given team
size of six, the total hours saved are about 200 – or 25 working days (8 hours per day) per month. Assuming an average hourly rate of $20 for team members, an additional $4,000 revenue was added to the bottom line each month. The author Gorur N Sridhar is a Mechanical Engineer and a qualified Six Sigma Master Black belt with more than 26 years of experience in Manufacturing, Quality and Design in Aerospace, Automotive, Engineering Services and Medical domains. He has been instrumental for substantial cost savings through Value Engineering, Process Improvements & Failure Analysis. He has mentored more than 100 Six Sigma & Kaizen projects and is a Qualified Internal Auditor for ISO9000, QS 9000 & AS9100 Quality Systems. He is also associated with the Implementation and Sustainance of CMMI L5 activities. He is also equally contributing in EHS and Community development programmes. He is located in Bangalore, India and can be reached at gnsridhar@gmail.com
Adopted LSS
Institutionalized Best Practices and Lessons Learned
Month
38
practices and lessons learned were documented and used to train new team members. Overall, this helped sustain the maturity level of the process.
Figure 5: Lean Implementation Timeline
June 2016
® An ISO 9001:2008 Company
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June 2016
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PRECISION
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RELIABILITY
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MAIN FEATURE
Data Quality Management for Better Big Data Analytics Data quality refers to the level of quality of data. There are many definitions of data quality but data are generally considered high quality if “they are fit for their intended uses in operations, decision making and planning.” Data is deemed of high quality if it correctly represents the real-world construct to which it refers.
Rajesh Angadi rajesh_angadi@hotmail.com
Data quality is a perception or an assessment of data’s fitness to serve its purpose in a given context. For example, few aspects of data quality include: • Degree of excellence exhibited by the data in relation to the portrayal of the actual scenario. • The state of completeness, validity, consistency, timeliness and accuracy that makes data appropriate for a specific use. • The totality of features and characteristics of data that bears on its ability to satisfy a given purpose; the sum of the degrees of excellence for factors related to data. • The processes and technologies involved in ensuring the conformance of data values to business requirements and acceptance criteria.
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• Complete, standards based, consistent, accurate and time stamped. • Accessibility • Reliability • Consistency across data sources • Relevance A considerable amount of data quality research involves investigating and describing various categories of desirable attributes (or dimensions) of data. These lists commonly include accuracy, correctness, currency, completeness and relevance. In practice, data quality is a concern for professionals involved with a wide range of information systems, ranging from data warehousing and business intelligence to customer relationship management and supply chain management.
Within an organization, acceptable data quality is crucial to operational and transactional processes and to the reliability of business analytics (BA) / business intelligence (BI) reporting. Data quality is affected by the way data is entered, stored and managed. Data quality assurance (DQA) is the process of verifying the reliability and effectiveness of data. Data quality management is an administration type that incorporates the role establishment, role deployment, policies, responsibilities and processes with regard to the acquisition, maintenance, disposition and distribution of data. In order for a data quality management initiative to succeed, a strong partnership between technology groups and the business is required. Information technology groups are in charge of building and controlling the entire
environment, that is, architecture, systems, technical establishments and databases. This overall environment acquires, maintains, disseminates and disposes of an organization’s electronic data assets.Effective data quality maintenance requires periodic data monitoring and cleaning. In general, data quality maintenance involves updating/standardizing data and deduplicating records to create a single data view. Key data quality components are as follows: Completeness: Level at which desired data attributes are supplied. Data does not need to be 100 percent complete. Accuracy: Represents data’s real world status. May be calculated by using an automated method with the help of various lists and mapping. Credibility: Extent to which data is considered credible and true. May
June 2016
BIG DATA Big data management is the organization, administration and governance of large volumes of both structured and unstructured data. The goal of big data management is to ensure a high level of data quality and accessibility for business intelligence and big data analytics applications.
differ from by source. Timeliness (age of data): Extent to which data is adequately updated for a current venture. Consistency: Assesses whether various dataset facts match. Integrity: Assesses reference validity and accurate joining of various datasets. Data quality is vital for the following reasons: It provides precise and well timed information to handle accountability and services. It offers prompt information to handle service effectiveness. It helps prioritize and guarantee effective resource utilization. Maintaining data quality requires going through the data periodically and scrubbing it. Typically this involves updating it, standardizing it, and deduplicating records to create a single view of the data, even if it is stored in multiple disparate systems. There are many vendor applications on the market to make this job easier.For businesses that have begun using it, business analytics has become a valuable means of uncovering insights that aid decision making in many areas.
June 2016
For business analytics to produce reliable results, it has to be available in the right volumes (for statistically valid results) and at the right time. It must also be of the right quality.There’s no doubt that most medium and large scale businesses capture and store significant amounts of data that is processed by their core business support systems as well as business intelligence (BI) systems, and maintained by their IT departments. Even so, there may be a hesitation about how to start up an analytics initiative. This may be because of a lack of a clear data quality management system being in place, one that provides confidence that data is owned, managed, controlled, and reliable, and can be made available when required. The whole exercise of setting up and implementing a data quality management system is as followsHow to Define and Implement Data Quality Management System •Governance: what is the governance organization structure, who are the authorities and authorization processes? What are the touchpoints and controls with
vendors? What standards does the data management system follow, and how is data quality assured? •Processes and Technologies: The management of data necessarily comprises a holistic set of standard processes and guidelines that address how data should be sourced, handled, stored and accessed such that any user may be confident that he/she always has the right version that came from a single source. These processes must be defined with reference to associated technologies that are used for these purposes. At the minimum, these processes and technologies should address the following: 1. Sourcing and capture 2. Cleansing and Integration 3. Quality checks 4. Duplicate control 5. Versioning 6. Storage Management 7. Archiving 8. Storage 9. MDM (Master Data
Management) 10. Security and Compliance 11. Development of new systems for handling data There is no shortage of hype regarding the importance of Big Data initiatives in terms of analytics and the business value they can provide the enterprise. The reality of the situation though is that Big Data effectively forsakes both Data Governance and Data Quality in numerous ways, complicating Big Data Governance and Big Data Quality.Big data management is the organization, administration and governance of large volumes of both structured and unstructured data. The goal of big data management is to ensure a high level of data quality and accessibility for business intelligence and big data analytics applications. Corporations, government agencies and other organizations employ big data management strategies to help them contend with fast-growing pools of data, typically involving many terabytes or even petabytes of information saved in a variety of file formats. Effective big data management helps companies locate valuable
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information in large sets of unstructured data and semistructured data from a variety of sources, including call detail records, system logs and social media sites.Important aspect of Big Data and Big Data Governance is the deployment of Cloud-based models and Software Oriented Architecture (SOA). Cloud options are oftentimes desirable for various facets of Big Data initiatives, from the bevy of analytics’ services to Platform as a Service and Infrastructure as a Service offerings. Data Quality as a Service options have advantages over on premise variations of Data Quality solutions in that they utilize reduced infrastructure and are priced more economically. By deploying Big Data at the Cloud we are effectively removing all of the technology requirements. All of
the infrastructure in terms of servers, hardware and software infrastructure, operating systems, middleware—all of that ‘stuff’ that we need to run an enterprise class solution will be offered by Cloud Ecosystem. Quality Big Data Big Data Quality controls can play a substantial role in implementing Big Data Governance and mitigating some of the complications for governance that Big Data inherently has. They can make sense of and effect standardizations for social media and other unconventional data sources, prevent Data Lakes from becoming swamps, and ensure Data Quality over enormous sets of data while adding a critical governance layer to the data integration process. Their ultimate advantage, of course,
Goals of data collecting
Formulating evaluation baseline
is their proclivity for reinforcing governance with a technology that, in many ways, naturally eschews it, while creating greater trust, comfort, and experiences for customers. The orders of magnitude scaling of data volumes for “big data” applications has many different types of data quality practitioners figuratively salivating at the potential opportunities for applying their favorite data quality techniques. First, for some practitioners, there is the perception that in a big data environment, “lots of data” means “lots of errors,” which of course also means “lots of cleansing.” Focus for big data quality means that we have to adjust our approaches to what dimensions of data quality are relevant for big data applications. Because of the limitations on control of
•Temporal consistency, or ensuring that timedependencies are observed; •Completeness, ensuring that the data elements to be used are populated; •Precision consistency, which monitors consistency of the units of measure and the precision of data values that are consumed by analytic applications; •Currency in relation to ensuring that data is as up-todate as possible; •Unique identifiability for entities (such as individuals, organizations and any other domain); •Timeliness in terms of
Determining quality dimensions and elements
Determining indicators
Data cleaning
Data Collecting No
the quality on intake, some of these other dimensions begin to take on a greater level of importance:
Adjustment and feedback
Satisfy baseline ?
Data cleaning
Yes
Output data
Generating data quality report
Data analysis and data mining
No
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Satisfy goals
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Yes
Output results
June 2016
presenting acquired data within a defined agreed-to time frame; and •Semantic consistency, ensuring consistency in the interpretation of identified data concepts in similar contexts. There will still be a need for the practical aspects of data quality that can be automated, especially with the need to scan both structured and unstructured text for reference data validation and entity identification and resolution. The archetypical applications used in support of these activities include: •Data profiling to provide statistical analysis of value frequency and guidance
June 2016
for business rules for data validation; •Data validation using data quality and business rules for verifying consistency and completeness, and to help in disambiguating semantic context; •Identity resolution using advanced techniques for entity recognition and identity resolution from structured and unstructured sources; •Data cleansing, standardization and enhancement that apply parsing and standardization rules within context of enduse business analyses and applications; and
•Inspection, monitoring and remediation to empower data stewards to monitor quality and take proper actions for ensuring big data utility.
been analyzed the challenges faced by big data quality and proposed the establishment and hierarchical structure for data quality framework.
Quality Management for Big Data
The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologies research areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.
The arrival of the big data era makes data in various industries and fields present explosive growth. How to ensure big data quality and how to analyze and mine information and knowledge hidden behind the data become major issues for industry and academia. Poor data quality will lead to low data utilization efficiency and even bring serious decisionmaking mistakes. It has
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SPECIAL FEATURE
Indian Machine Tools Industry: Geared up for AMTEX 2016! The pundits predict India’s manufacturing sector to touch US$ 1 trillion by 2025 accounting for 20-25 per cent of the country’s GDP and creating millions of jobs in the country.
Arnab Mondal arnab@martupdate.com
With the Government’s
special industrial zone, policy
‘Make in India’ mission
help from the government
aimed at upping India
and inflow of foreign
manufacturing production
investments- altogether
to a new level, the target
make it a big time for the
seems en route to success.
Indian manufacturers to
A thrust on various industrial
dream big time. All they
segments, setting up of
need is cohesive approach, a
“Angel India has always been a part of Amtex. We participate in AMTEX not only because it is an International exhibition but everytime we get immense support,responses and business enquiries.Amtex has great scope for anyone to Promote their business” Anil Kumar Director, Angel India Cad Cam
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knowledge building platform and brainstorming sessions for the future. AMTEX Exhibition, an event of international standards, has been a partner in progress so far and in 2016 the event is back again with
promises to make it bigger. AMTEX 2016, in its 11th edition, catering to the machine tool needs of production and consumption hotspot is slated to take place from 8-11 July 2016 at Pragati Maidan, New Delhi.
“The main purpose of participating at Amtex 2016 is to reach out to manufacturing companies in the north of India and talk to them about our advanced manufacturing solutions. Since we are a brand of choice for those who are into complex &multi- axix CNC maching” Vineet Seth Managing Director, India & Middle East, Delcam
June 2016
Maintaining Track Record of Growth 4450+ Exhibitors 430% international participation 4Total floor area is 2,00,000 sqft Cyril Pereira Managing Director, Reed Triune Exhibitions Pvt. Ltd
floor area? How many visitors
AMTEX Exhibition also organizes
are you expecting this edition?
an enlightening conference
We have around 450+ Exhibitors, including 30% international participation from countries like- China,
Congratulations Mr. Cyril
an ideal podium to display
Periera on making AMTEX
the technological progress
Exhibition a brand to reckon
achieved by various machine
with in the machine tools
tools and auto component
industry for automotive,
industries. The show offers
electrical and engineering
a vast covering and full
sectors. How would you
spectrum of existing products
evaluate the journey of
as well as innovative systems
AMTEX Exhibition so far?
and machines.
AMTEX from the start in 2001 has been consistently maintaining a track record of growth in terms of Exhibitors and Visitors, and in a vast country like India one event at say in South or West is not sufficient. Hence, North and AMTEX have become synonymous, and we have our Exhibitions in Delhi and Mumbai in alternative years. What is focus of AMTEX Exhibition 2016? What is the USPs of AMTEX Exhibition in this edition of 2016? The focus of AMTEX is to be
June 2016
parallel with the exhibition. Could delve into the key areas to be highlighted this year in the conference?
Japan, Turkey, Germany,
The conference will bring
Singapore, Taiwan and
together over 25+ speakers
Korea. Our total floor area
and 150 senior level delegates,
is 2,00,000 sqft. And we
featuring sessions on strategy
have participation from the
development, success stories,
following segments-
technology innovations and
o Assembling Systems & Industrial Robots
opportunity to have their opinion heard and discussed.
o CNC Lathes, Machining &
Since manufacturing sector is
Turning Centers, EDM’s
a major proponent of Make in
o Honing, Lapping, Polishing
India campaign, how do you see
and Debarring Machines
AMTEX Exhibition to provide a
o Bar, Section and Tube
fitting platform for knowledge
• Exclusive International
Working Machines
sharing and cooperation
pavilions
o Cutting Tools and
building for the manufacturers?
• Live product demonstrations
Accessories- Drills/Reamers/
• Exclusive Conference
Cutting Tools/Chucks/Holders
Programme, having 25+
o Hydraulics & Pneumatic-
speakers and over 150 senior
Tools & systems, Pumps,
level delegates
o Valves & Compressors
• Business Matchmaking
o Presses- Hydraulic,
programme to arrange assured
Mechanical & Pneumatic
meetings during the exhibition
o Bearings/ Ball Screw/ Linear
between the exhibitor and
Guide Way
visitor
o Drilling, Boring, Sawing and
USP’s of AMTEX 2016:
AMTEX 2016 is not only a platform to showcase the latest technological innovations and products in the machine tool sector, it is also an opportunity to network with industry leaders and experts on an international scale and keep them informed on the trends and expectations
Cutting Machines
of the future. And that is
comprehensive overview of
We are expecting over
will get through the exclusive
the total participation from
30,000+ visitors during this
Conference and Business
various segments and total
edition of AMTEX.
Matchmaking Programme.
Could you give us a
exactly what the participants
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45
“Amtex 2016 is a major show of machine tools in Northern India. Also, our major customer base is in the north. Most of our customers from this region will visit this show thus it gives us an opportunity to be in touch with all these customers to show them our technical prowess in products and also get direct feedback from them” Satish Ranade Senior Vice President, Electronica
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“Golden Laser is a prominent player in the sheet metal industry and considers AMTEX as a perfect platform to display & unveil the latest technology related to sheet metal, fabrication and industrial manufacturing segment”
B M Thakur General Manager, Golden Laser India
The biennial event will
of 417 exhibitors including
Engineering Technology), to
valves, motors, gears,
primarily focus on end user
67 foreign exhibitors
name a few.
compressor and welding.
industries like automotive,
showcased theirs offerings.
power and electrical
The last edition recorded a
Spanning over an area of
The event offers a great
equipment, textile machinery
footfall of over 38,000 trade
20,000sqm with seven halls
business effect, reason why
and consumer goods.
visitors.
across Paragti Maidan, the
the event is endowed with
event consists verticals of
rave reviews from exhibitors
As evident over the years, the
Some of the major
Machine and Machine Tool
and visitor alike. As Mr. Anil
event is a must visit platform
companies participating in
including laser cutting, sheet
Kumar, Director of Angel
for exhibitors, both Indian
the event this year are Ace
metal including hardware,
India Cad Cam puts it, “Angel
and foreign. This edition,
Micromatic (MICROMATIC
Die and Moulds, grinding,
India has always been a part
over 450 exhibitors from
MACHINE TOOLS PVT. LTD.),
cutting, polishing etc. there
of A. We participate in the
India 30 per cent overseas
Jyoti CNC Automation Ltd.,
will also be showcase of
AMTEX not only because it is
from countries like China,
Mitsubishi Electric India Pvt.
automation and material
Germany, Japan, Korea,
Ltd., Renishaw Metrology
handling and display of
Singapore, Taiwan and Turkey
Systems Private Limited,
Instrumentation and
etc. are joining in. In the
Muratec (Murata Machinery
Electricals, and Industrial
last edition of 2014, a total
Ltd.) and Meiban (Meiban
Appliances, such as pumps,
an International exhibition but every time we get immense support, responses and business enquiries. AMTEX has a great scope for anyone
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June 2016
“AMTEX EXHIBITION is an important event for us – for meeting our existing and prospective customers for lining up new business. AMTEX is a permanent fixture in our event calendar and fully meets our expectations”.
to be there in the midst of market and AMTEX is the
software.
most preferred platform”,
Electronica plans to display a bigger size version of its very popular CNC Wirecut EDM model of Sprintcut DLX. Also, at the exhibition the company will launch its CNC Vertical Machining Centres completely manufactured in India.
elaborated Mr. Satish Ranade, senior vice president, Electronica. The exhibition promises a bigger display of new technologies and product
Maulik Patel Managing Director, Sahajanand Laser Technology Ltd
demonstration. UK based Delcam, one of the world’s leading suppliers of CADCAM solutions, and a regular
to promote their business.” Satisfaction is equally echoed by Electronica, Pune based manufacturer of EDMs and WEDMs with over 35 years of experience. “AMTEX 2016 is major show of Mchine Tools in Northern India. Most of our customers from this region
June 2016
a feature based machining
will visit this show thus it gives us an opportunity to be in touch with all these customers to show them our technical
participant in AMTEX is all set
prowess in products and also
machining; PowerSHAPE, a
to get direct feedback from
tribrid modeling software;
them. Also considering the
PowerINSPECT, the hardware
increased level of competition,
independent inspection
it is now very much essential
software and FeatureCAM,
to showcase its 2016 version of PowerMILL CAM software for complex and multi-axis
Parallel to the exhibition, AMTEX will feature a thought provoking conference where 150 senior delegates and 25 speakers of industrial expertise will delve deep into the future of Indian Machine tools industry with an emphasis on future trends, growth strategies, new technologies and innovations, keys to sustainable growth and challenges and expectations of the industry players.
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SPECIAL FEATURE
“Partnering in Knowledge with our Customers” Ainnovative@ Hall 11, Stall C11
Jayesh Patel Marketing Director, AInnovative
Ainnovative International Limited, as its name denotes, is dedicated to providing innovative products like abrasive water jet-cutting machine, CNC plasma and laser cutting machines and robotic water jet cutting machine and water jet pump in India as well as international market. Being a marketing director since 2002 with high technical knowledge for CNC programming and automation, Mr. Jayesh Patel has established and marketed Ainnovative products in India and globally in countries like UK, USA, Africa, UAE, Saudi Arabia, Kuwait, Bahrain, Qatar, Malaysia and Switzerland. He was able to achieve a tremendous success in saving reasonable cost and developing high efficiency machine since last many years. Here are excerpts from an interview of Mr. Jayesh Patel with MART in lead up to AMTEX Exhibition 2016…
What are the main reasons for deciding to exhibit at AMTEX Exhibition 2016? AMTEX is a platform where we can showcase our latest product and technology by which we can increase awareness about strength of our products and company. It also helps in establishing a brand recall for our products and organization. We have been participating in this trade fair for many editions. North India has a huge market potential and we
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look forward to more technical customers to attend the same. This is a great platform to network and connect with industry professionals. We are looking for forward and backward integration with manufacturing and automation companies. How do you value your participation at AMTEX Exhibition 2016? Innovative technology and recent development help the industry to prepare for growing challenges. We are identifying
our potential buyers and competitors in the market and can make nexus with them. What are your target segments at this event?
your company looks to focus on this edition and what are the latest technological innovations your company will showcase this edition?
At this event our target segments are Machining Shops, Fabricators, Machine Manufacturing, Aerospace, Automobile & Auto Components, Defense, Research & Development Organization, Orthopedic Implants manufacturer etc.
The key areas that our company looks to focus on this edition are processing speeds and productivity. Latest technological innovation which we will showcase other than CNC Waterjet Cutting Machine, CNC Laser Cutting Machine and CNC Plasma Cutting Machine is Economic Laser Cutting Machine.
What are the key areas that
What are the USPs of your
June 2016
Economic Laser Cutting Machine - Laser Cut Series The ability to fit in the smallest spaces combined with low investment and operating costs and easy operation are convincing features of the Laser Cut Series
products and services? What kind of partnering in knowledge and after sales service do you provide your customers? From Ainnovative we provide all cutting needs under one proof name it Waterjet, Laser or Plasma. We are the market leader in our segment with more than 250 successful installations, which is the highest in India. We have installations in all segments with pan India presence from Himachal Pradesh to Kerala and Gujarat to West Bengal. We believe in partnering in knowledge with our customers and after sales service is one of the major areas we concentrate on. To make this mission successful we have well experienced technical team, around hundred trained professional to cater different industry needs. Our team can communicate in all Indian languages with 24x7 technical support and with the largest stock of Waterjet spares in India, we are the final answer for industry. Could you also briefly highlight some of your latest
June 2016
innovations on display this edition? After receiving tremendous response for CNC Waterjet Cutting Machine and CNC Laser Cutting Machine, our latest innovations on display is Economic Laser Cutting Machine in which one can reduce investment cost and has high processing speed and productivity. The major features of Economic Laser Cutting Machine: Laser Cutting Machine has processing speeds and productivity. The ability to fit in the smallest spaces combined with low investment and operating costs and easy operation are convincing features of the Laser Cut Series. They are exceedingly fast piercing and remarkably fast cutting motor drive, compact installation, high precision and excellent cutting quality with clean edges. The user-friendliness features are uni-body high strength structure, high rigidity Gantry System, Rigid architecture and easy to access from all sides.
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SPECIAL FEATURE
Tungsten-Carbide Micro End-Mills produced in Italy Pitech Services@ Hall 12A Stall F96
Surendra Kumar Managing Partner, Pitech Services
PI-TECH Services, born in 1992, nearly 25 years ago, are the pioneers of Northern India for the organized Import and Distribution of Die-Elements and Automatic Feeders for Power-Press Automation. This organization is headed by Mr. Surendra Kumar, Graduate in Mechanical Engineering from Rookee (IIT), and Mr. Sumant Kumar, having done Masters in Electrical and Electronic Engineering from USA; both being Partners. Mr. Surendra Kumar is one of the founder members of the Indo Italian Chamber of Commerce and Industry in India and has been in its alternative Chairman for North India. In 2007 he was decorated with Knighthood by the President of Italy for this contribution in bringing together the industries of India and Italy.
What are the main reasons for deciding to exhibit at AMTEX Exhibition 2016? The Indian industry is settled in various industrial clusters all over India. The purpose of an exhibition is to bring closer the seller to the buyer and to expose the industry to recent developments in technology. Each fair draws visitors mainly from the industrial clusters closest to it. We like to participate both in the North and in the South. Having participated already in a fair at Bengaluru this year, we thought it worthwhile to participate now in a fair in Northern India, and for this purpose we chose the AMTEX Exhibition. How do you value your participation at AMTEX Exhibition 2016? We treat it as an important
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opportunity. New Delhi is surrounded with industrial leaders present all around it in the NCR. It is for this reason that we have a lot of expectations from this fair. What are your target segments at this event? We hope to receive visitors from manufacturing industries for Bearings, Gears, SheetMetal or Plastic Parts, Moulds and Dies; and those looking for automation; for consistency in Manufacturing, and for higher Productivity. What are the key areas that your company looks to focus on this edition and what are the latest technological innovations your company will showcase this edition? We would like to highlight our products as real sources
of technology-transfer. Our products have already helped Indian small-scale manufacturers to become exporters; offering quality that could match international competition. In the field of automation, our customers have been able to fine-tune their manufacturing cycle-time, and thus meet the targets of production. What are the USPs of your products and services? What kind of partnering in knowledge and after sales service do you provide your customers? We offer products from WorldLeaders who are much advanced in technology, and whose products can help to improve quality and productivity. In an international arena, the user has the right to buy what he needs, irrespective of the place of origin of the product. He should be given the freedom to choose.
Should a product not be available indigenously, there should be the freedom to buy it from another place. Could you also briefly highlight some of your latest innovations on display this edition? We are displaying a series of special end-mills for the machining of Turbine Blades; as well as providing information on ‘Patented’ Tool-Holders, We shall exhibit for the first time Tungsten-Carbide Micro End-Mills produced in Italy by an organization having over 40 years of expertise in this field. Some of these tools are produced from nano-sized particles, treated specially. These tools can perform excellently with their reach in the most difficult areas, and the acutest of angles. These can help to generate curves earlier considered difficult.
June 2016
Low Cost, New Innovation, Best & Quick Service Support Mehta Cad Cam@ Hall 9, Stall A-24
Shailesh Mehta Managing Director, Mehta Cad Cam Systems Pvt Ltd
Established in the year 1989, Mehta Cad Cam Systems Pvt Ltd is one of the oldest and largest companies engaging in the field of CNC, Laser and digital printing technologies in India. Headquartered at Ahemdabad, they don’t merely manufacture and bring the latest machines or technologies from different parts of the globe but also develop arrays of applications and educate our customers to learn about their values and significance. Mehta Cad Cam Systems provides the newest technologies keep surfacing or trending in the current market from time to time. It’s not just the technologies but also the solutions/concepts which they constantly provide to their customers. Shailesh Mehta, Managing Director, Mehta Cad Cam Systems shares about the latest innovations exhibited at Amtex Delhi.
What are the main reasons for deciding to exhibit at AMTEX Exhibition 2016? We believe that Amtex exhibition is one of the most important exhibition in engineering industries for northern region. We do manufacture revolutionary fiber laser metal cutting machine which is top in demand. We value a lot and expecting many visitors from different parts of North India. What are your target segments at this event? We are targeting all the companies or job workers who are associated with metal sheet processing i.e.
June 2016
the company who require to cut SS and MS sheet for their products. What are the key areas that your company looks to focus on this edition and what are the latest technological innovations your company will showcase this edition? - Targeting all the companies and job worker, - Two latest technology: Fiber Laser Metal Cutting, Fiber Laser Marking Can you brief more about Fiber Laser Metal Cutting? Fiber Laser Technology has many advantages over traditional Co2 Laser Cutting
technology like maintenance free, long life of around 1 lakh hours and give very clean cutting with Nitrogen & Oxygen.
service do you provide your customers?
As we all know Co2 Laser Technology is very famous for SS/ MS metal cutting & give good quality of cutting with Nitrogen & Oxygen gas. Co2 Laser source require maintenance time to time. Before 3 to 4 years Fiber Laser Technology came into the market for thin metal cutting like 1 mm, 2 mm SS or MS.
support in all over India.
What are the USPs of your products and services? What kind of partnering in knowledge and after sales
getting job done outside
- The USP of our product is the low cost, new innovation, and best quick service
What kind of business effect do you expect by participating in AMTEX Exhibition 2016? We expect to create awareness about the availability of low cost Laser machine for SS, MS, Aluminum sheet cutting and the companies who are can start thinking to have inhouse facility, because of its revolutionary low prices.
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INDUSTRY FOCUS
Fast and accurate measurement, wherever it’s needed As portable laser trackers continue to grow in popularity and application potential, Akshay Singh, Product Manager India - Portable CMM at Hexagon Manufacturing Intelligence explains how the technology has developed to produce the multipurpose inspection tools that are driving better productivity in industry today.
Akshay Singh akshay.singh@hexagon.com
With global demand continuing to rise, manufacturers face a continuous challenge to enhance their productivity. The need to maintain high quality standards and carefully manage costs – while still delivering the heavily-customised products the
market demands – accentuates the competitive pressure across already crowded industry sectors. Creating more flexible production environments to increase agility and
responsiveness can help to alleviate these pressures, and the key to this is data. Datadriven manufacturing processes use state-of-the-art metrology equipment to gather data from multiple points within production. This data can be
processed into actionable information to inform decision making, achieving the agility required to move ahead of the competition. As a result, dimensional inspection can no longer be
In the Leica Absolute Tracker AT960 laser tracker system, Hexagon Manufacturing Intelligence has developed a multipurpose portable coordinate measuring machine (CMM) with the potential to improve processes across many aspects of production.
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June 2016
The Leica T-Probe handheld probing device enables the AT960 laser tracker to measure hidden or hard to reach points.
considered an end-of-line quality checking process. New technologies allow manufacturers to meet some of their main challenges head on, changing end-of-line checks into along-the-line or even in-the-line quality inspection. They can actively improve the quality of production processes, for example through machine guidance or robotic assembly systems. Realistically, investment in equipment like this is becoming essential to successful process modernisation. But to make such investment pay off, manufacturers must ensure they select the right tools for the job. In the Leica Absolute Tracker AT960 laser tracker system, Hexagon Manufacturing Intelligence has developed a multipurpose portable coordinate measuring machine (CMM) with the potential to improve processes across many aspects of production. From cutting-edge technology to practical tool Laser trackers have been on the market for around a quarter of
June 2016
a century now. Initially written off as expensive and lacking a clear area of application, the technology has stood the test of time and become an indispensable metrology device for thousands of manufacturing companies. Ideal for measuring medium to large parts and offering a flexible solution for large-scale inspection and assembly applications, laser trackers have found a home in the metrology arsenal for all kinds of industries and sectors. Part of the reason behind the adoption of this technology is the rapid development it has shown since launch. In simple terms, a laser tracker is a portable CMM which uses a laser beam to measure accurately in a spherical volume – in the case of the AT960, a measurement volume of up to 120 m (Ø). Essentially a laser tracker measures two angles and one distance to calculate a precise coordinate. A target is positioned at a point to be measured, and the tracker emits a laser beam towards it.
The target reflects this light back towards the tracker station, enabling the system to reference the location of the target. Since the first laser trackers were launched in the early 1990s, Hexagon’s Leica Absolute Tracker range has introduced a number of innovations to make their systems more practical and easy to use. These include the world’s first absolute interferometer and the PowerLock active vision system. But for complex measurement demands, such as those of the automotive industry, perhaps the most significant development has been six degrees of freedom (6DoF) trackers like the AT960. While the original laser tracker systems were only capable of measuring to reflectors, the development of 6DoF tracker technology opened up the potential for probing, scanning and machine control applications. It is this versatility, alongside their portable nature, that makes laser tracker
systems such a useful tool. The advantages of portability, speed and accuracy Looking at the AT960, it’s clear that the technology inside laser trackers has come a long way since the early models. Retaining all the functionality of the previous-generation Leica Absolute Tracker AT901 but leveraging the latest electronics and optical technologies, the sensor unit is significantly smaller than its predecessor. Where previously a 6DoF laser tracker required several accessories to operate at its maximum potential, the AT960’s all-in-one design incorporates all the equipment required to measure to a reflector, Leica T-Probe, Leica T-Scan 5, Leica Absolute Scanner LAS-20-8or Leica T-Mac in one ultra-portable and robust IP54-certified unit. With a sensor weight of less than 14 kg, the entire system fits into a single flight case for easy relocation. Built-in wireless and battery function options minimise setup times so the
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device can be transported easily, unpacked quickly and powered up in minutes to measure in any location. While for factory-based applications portability may not seem an immediate priority, it is surprising how much of an impact it can have on how a device is used. The great advantage of portable CMMs is that they can be moved to the part, instead of the part needing to be relocated to the quality room. With the AT960’s excellent portability, not only does its small footprint save valuable workspace on the shop-floor, but it also allows a range of flexible mounting options including inclined and inverted functionality. It is easily relocated by a single operator, and the speed of setup between locations means the tracker can be moved from one process function to another – whenever and
wherever it is required. With equipment uptime and productivity both important considerations in assessing return on investment, the AT960’s portability makes it an increasingly attractive proposition. As industry has moved towards data-driven manufacturing, the role of metrology has shifted. Where previously quality inspections were something of a burden which ate up resources with limited returns, the equipment available today turns this process into something more proactive, and the ability to gather data quickly and easily is at the centre of this change. Driven by Hexagon’s patented and proven Leica Absolute Interferometer (AIFM) and PowerLock technologies, the AT960 delivers on this promise with high-speed dynamics and user-friendly operating
functions. The third-generation PowerLock active vision technology provides intelligent automatic target location to instantly re-establish an interrupted beam and continue the measurement with no user intervention required, while the AIFM brings together the accuracy of an absolute distance meter and the speed of an interferometer to measure a moving target with the fastest speed possible. In combination with a true real-time operating system, the AIFM and PowerLock allow the AT960 to continue measuring with a maximum distance uncertainty of just 10 μm after beam interruption and deliver a data rate of 1 000 points per second. With its absolute distancing capabilities, the AIFM is
also the critical component behind the accuracy of the AT960 across several different inspection methods. The built-in variozoom technology provides the 6DoF capability required for the system’s probing, scanning and machine control options as well as traditional reflector measurements. This flexible functionality is not just for show – it is a key aspect of the agility that the AT960 offers. The right way to measure, every time Any good piece of equipment should help to complete a task quickly, not slow down or delay the process. But it has to be the right equipment for that task. Almost any manufacturing process can be disrupted by applying the wrong tools, and the metrology aspect of industrial manufacturing is no different. With their ability to
AT960’s all-in-one design incorporates all the equipment required to measure to a reflector, Leica T-Probe, Leica T-Scan 5, Leica Absolute Scanner LAS-20-8 or Leica T-Mac in one ultra-portable and robust IP54-certified unit.
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acquire data very quickly, the laser trackers of the past were sometimes pushed beyond their intended functionality, opening up the possibility of questionable results. One of the major flaws in the earliest laser trackers was that the only way to gather highdensity point cloud data was to scrub the reflector over a surface. Inaccurate to say the least, this method also risks damaging both the reflector and the object surface. Imagine the potential damage that could be caused in recording the dimensions of bodywork for a high-value sports car with this technique. With the four methods of measurement that the AT960 offers, this simply isn’t an issue.
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In a scenario like this, AT960 operators can simply switch from reflector measurements to the non-contact laser scanning solution to record the surface contours at a rate of over 200 000 points per second, or use a probe for hidden points. With PowerLock to automatically locate the target, switching between inspection methods is easy and efficient. And the 6DoF functionality also enables the tracker to power a range of automated applications from simple inspection programs to complex robotic guidance systems. Laser trackers in the automotive world Of course, industrial robots are a familiar sight in
automotive factories. Vehicle manufacturers were the original adopters of automated production equipment and their use will only increase as robots become more accurate. By their nature, robots are very repeatable, but their absolute accuracy is less strong and they remain susceptible to the influence of external factors like temperature. But by using a device with the accuracy of a laser tracker, it is possible to correct a robot’s positioning, even accounting for external factors. Not only does this largely remove the need for robotic calibration, but it also enables manufacturers to turn precision operations such as assembly into automated processes using standard industrial robots.
The technique has already been used to great effect, particularly in the automotive and aerospace industries where laser trackers like the AT960 are employed for such operations in numerous facilities around the world. While robotic guidance is certainly an exciting prospect, the current applications of laser tracker technology for vehicle manufacturing are extraordinarily varied and begin at a much more basic level. The portable nature of trackers enables them to be brought to the production line to inspect parts, cutting the logistical cost and time spent on inspections. Similarly, trackers can be used to check tooling setups and alignment
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in the line, helping to ensure the accuracy of operations while causing minimal disruption to the process. The data-rich point clouds created by laser scanning solutions enable fast inspection of large surfaces, whether they are regular or freeform geometries. Operated manually for spot inspections or mounted on a robot for faster, more efficient inspections of large areas, this method is ideal for body in white and closure part inspection. Extending this application, some manufacturers utilise the same techniques for their flush and gap checks, or even to run virtual assembly programs. With automotive manufacturers increasingly globalised and parts being produced on different lines, in different plants or by different subcontractors, virtual assembly
can be a real advantage in avoiding costly part-mating issues. Production and assembly is not the only area of automotive development to benefit from laser tracker technology. Quick and accurate measurements are also essential in vehicle development. Part testing and subsequent design modifications rely on understanding the behaviour of components during trials and taking a tracker into testing centres can add an immense amount of information in this area. Some manufacturers have even installed laser tracker mountings within wind tunnels to enable consistent inspection of parts between aerodynamic tests or single-
point monitoring under ‘wind on’ test conditions – a specialised application where the high-speed dynamics of a device like the AT960 really come into their own. Laser tracker technology can also be used to support reverse engineering and rapid prototyping. The equipment of the future The rate of development in laser tracker technology over the last 25 years has been impressive. In the AT960, Hexagon has been able to leverage mature technologies alongside new developments to offer absolute portability, absolute speed and absolute accuracy. But just as importantly, this latest generation of laser tracker offers a balance of practicality and user-
friendliness which will enable automotive manufacturers to request or develop new and ever-more sophisticated ways to utilise and apply these three core traits to their specific needs and build increasingly agile factory environments in years to come. The author Akshay Singh is Product Manager India - Portable CMM with Hexagon Manufacturing Intelligence. Akshay oversees the Portable Business Line in India which includes Portable Measuring Arms, Laser Tracker Systems, White Light / Blue Light Scanner Systems. He joined the company in 2011, bringing with him almost 10 years of experience in the Metrology Industry. He is a qualified Mechanical Engineer from University of Pune and has spent lot of his professional years in understanding and assisting various OEMs, setting up different Metrology Processes to improve the overall quality.
For surface digitisation, the Leica T-Scan provides a fast way to record accurate point cloud data.
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INDUSTRY FOCUS
“Testo is the Preferred Brand when it comes to any Measurement Technology�
Kalidas Bhangare Managing Director, Testo India Pvt Ltd
Testo India Pvt Ltd is a wholly owned subsidiary of Testo AG. Testo AG, headquartered at Lenzkrich, Germany is a world leader in design, development and manufacturing of electronic portable test and measuring instruments. Backed by more than 59 years of measurement engineering experience, Testo as a group, has more than 2300 employees, 32 subsidiaries and more than 80 representatives worldwide. Its state of the art manufacturing facility and an extensive R&D unit is located in Germany. Testo India Pvt Ltd established itself in 2006 with its head office in Pune. Testo India has been successfully catering to a wide array of Indian industries with its huge basket of products. Mr. Kalidas Bhangare, Managing Director, Testo India Pvt Ltd on an exclusive interaction with MART shares the journey of Testo India, its new offerings and the present industry scenario to our readers, excerpts:-
The present scenario of Testing and Measuring industry in India... The industry is turning to smart and user-friendly technology. Gone are the days that required manual intervention, calculations and analysis. We have such technology solutions that reduce manual intervention to bare minimum, make the processes error free and bring in a lot of ease & convenience. Testing and Measuring plays a critical role in Manufacturing. What challenges do you face when it comes to hardcore technology? When we talk about manufacturing, every aspect
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included in the process seeks assistance in terms of testing and parameter measurement. In QA process, during machining of products, warehousing & logistics etc measurement & testing has a vital role to play. Now with growing manufacturing techniques and quality standards the need for precision and accuracy has also increased. The technological advancement has encouraged us to improvise and provide better solutions. Digitization has become the necessity now and to cope up with that our new smart measuring instruments are the ideal solution for almost every application. Also we have to work continuously to provide precise and more reliable
solutions that not only save time but also reduce human involvement. For the last one decade major shift happened in the way we manufacture. Can you please share this transformation in your industry sector? Things are not same as they used to be, awareness has enabled the manufacturers to implement many decisions that have brought a revolution in the manufacturing practices. With more focus on energy conservation and sustainable development the manufacturing industry has experienced uplift. Controlled emissions, reduced wastage, restricted energy usage, energy audits
and inspections are now of prime concern. Govt has also taken several measures to conserve resources and save energy. Since the methods have changed significantly so does the requirements for monitoring and as a result of that we are expected to deliver the best. Our compressed air flow meter are precise to monitor the compressed air flow in the industries and our Flue gas analyzers help to save fuel and promote energy conservation. With the shift in the manufacturing technology, our role has also changed considerably. The advantage Indian manufacturing had by the entry of global auto majors setting up their base locally...
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Testo Smart Probes with Smartphone
The entry of many global players in the automotive industry has boosted the Indian SMEs, ancillary and auto ancillary segments of India. Latest trends in the product development have helped the local companies to adapt the new techniques and implement them in their set up. Product durability and reliability has improved immensely. One such application is the paint booths in automotive industries, which focuses more on their quality and use various equipments to maintain the standards. Testo Dew Point transmitters are of prime importance in these applications. Very obvious
that with major global auto majors setting up in India, the Indian manufacturing standards has seen a new day. What factors can bolster the demand of Testing & Measuring Equipments? The measurement and testing equipment industry is blossoming and expanding as never before. With the rapidly growing and changing demand for Wi-Fi, Bluetooth operated devices, smart instruments, cloud data and driven processes, the Test and Measurement market would certainly witness a boom considering these factors. Furthermore,
the increase in the global and domestic demand for digitization to attain smart processes surely makes us anticipate a bright future of the test and measurement industry in India. Tell us about your inception, growth story and current market position... Testo India Pvt Ltd is a wholly owned subsidiary of Testo AG. Testo AG, headquartered at Lenzkrich, Germany is a world leader in design, development and manufacturing of electronic portable test and measuring instruments. Backed by more than 59 years of measurement
engineering experience, Testo as a group, has more than 2300 employees, 32 subsidiaries and more than 80 representatives worldwide. Its state of the art manufacturing facility and an extensive R&D unit is located in Germany. Testo India Pvt Ltd established itself in 2006 with its head office in Pune. Testo India has been successfully catering to a wide array of Indian industries with its huge basket of products. We have built a good customer base for ourselves in this time. We have spanned across India through our channel partners and representatives. We have home offices
Testo 6440 Compressed Air Flow Meter
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in several cities like Delhi, Bengaluru, Ahmedabad, Baroda, Chandigarh, Chennai, Guwahati, Hyderabad, Raipur, Kolkata, Jaipur and Mumbai. With this network, we plan to move further closer to our customers. We also have a high quality service and calibration laboratory where instruments of any brand/make can be calibrated & serviced locally, calibrations traceable to the international standards of PTB Germany. We are glad to inform that Testo India has successfully completed 10 glorious years of its service in India and today, Testo is a preferred brand when it comes to any measurement technology in the industry. It has established itself as a reliable and high quality assuring measurement technology. What new products are there in offer?
Testo has always believed in offering the latest and the superior quality of data measuring techniques to its customers. With a large product basket, it has become a major supplier for HVAC industries, refrigeration, airflow, and environmental monitoring instruments for markets as diverse as chemical, food and beverages, pharmaceutical and biotech. Continuing the trend we have new sets of smart instruments called as Smart Probes - An extension in the range of digital measurement solutions. These instruments can take the measurements even at inaccessible locations effectively and accurately. These innovative, pocket-sized pro measuring instruments can be intuitively operated by smart phone via a free App. The testo Saveris 2 Wi-Fi data logger system is the simple, flexible and reliable solution
to humidity and temperature monitoring in your storerooms, cold storage area and work rooms, as well as during workflow processes. This innovative monitoring system eliminates staff work of reading out and documenting the individual measurement data, simplifying the assurance of high product quality. With a secure online storage of all readings in Testo Cloud the data can be managed and analyzed online by the user via smart phone, tablet or PC absolutely anywhere and anytime. Testo offers a new light weight and more precise air capture hood, testo 420 for larger air intakes and outlets. With only 2.9 kg and ergonomic handles, frequent or difficult measurements too, can be carried out comfortably, without inducing fatigue. Even at turbulent swirl outlets, the flow hood from Testo significantly reduces the usual
measurement errors. The most recent addition has been the Electrical Instruments by Testo which have various USP’s. They would surely prove out to be of significant use and would complement the available product range of Testo, making it a complete tool set for any HVAC/R contractor. How comparative your products are with those offered by other companies? Quality and efficiency are the major drivers for the industry Testo stands in. All our co players are doing good job in benefitting the industry and Testo too has its own ways. As the industry turns more quality conscious, need for better controlled processes arises. And this is what precisely Testo’s measuring instruments do – be it climate monitoring, production quality monitoring, food production &
Testo 6740 Dew Point Transmitter
Testo thermal imagers
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Testo Product Range
transport monitoring and so on. Our products facilitate several industry operations and maintain quality standards. Testo offers several solutions such as flue gas analyser for optimisation of fuel usage, compressed air flow meter for optimising compressed air consumption and thereby energy consumption. Our smart instruments are the perfect examples to highlight our competitive approach. These instruments integrated via an app are the most accessible and user friendly solutions ever. All that you need is a smart phone and a pocket sized Testo Smart Probe and what you have is higher efficiency and reduced time. After all, quality & efficiency both should lead the industry to be leaner and more profitable. Testo just exactly does that. Your take on the PM’s initiative on ‘Start-up India’ and how can it really help the Indian Manufacturing Industry? Undoubtedly a great initiative led by the government. True, it will generate more business, improve economy, make you self sufficient, enable company
June 2016
growth etc. But the best part is when the manufacturers produce goods here, they become the masters of it, they know every bit and inch of their product. Applications, specifications, usage, advantages, reliability, shortcomings, everything home tested and assured. This enables you to provide better service every time and also paves your way to innovate and improvise and keep delivering better. That is how an enterprise grows and becomes market leader. What better than to have so many market leaders in India alone. The impact “Make In India” had in your business for the last two years... More emphasis on Make in India has motivated the manufacturing facilities to produce more. It has encouraged for research, development and use of better technology. Be it the initial designing stage, operation, research, product development or the final inspection, everywhere there is a need to measure, record and analyse various factors. This in turn has given us more opportunities to deliver our products and with so
many products in our basket we have even been able to serve multiple sectors. This initiative has definitely inspired the related market to seek awareness about our products, understand the utility and applications and opt for better solutions. Comparing to global manufacturing techniques, where India stands in manufacturing techniques? It is a little sad to realise that we have been a bit late in adopting the latest manufacturing techniques, rather promote manufacturing in India at first place. But we are progressing at a great pace. With so many government led initiatives and with growing awareness we, in a very short span of time have secured a very prominent position of global stage. Be it the innovative concepts, execution of the project or the technology implemented, India has done exceptionally well. Increased dependence on smart and automated techniques, advanced
manufacturing set ups and contemporary machinery has enabled Indian manufacturers to achieve higher standards. And with Asia developing as the outsourcing hub of the world, India is soon becoming the preferred manufacturing destination of most investors across the globe which will again be a promising factor for the growth of Indian manufacturing techniques. The future of manufacturing in Indian Manufacturing... Already highlighted, we have great minds and greater opportunities in India. Now with so many initiatives, awareness programmes, strategic growth and above all, when the whole world finds a promising edge in the Indian market you can only expect greater results for the manufacturers & manufacturing in India. For more details login to our website www.testo.in or write back to us on info@testoindia.com
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INDUSTRY FOCUS
“Fluke Process Instruments invests in People Education� Enrico Drews Business Development & Sales Director India Fluke Process Instruments
Enrico Drews joined Raytek GmbH/ Germany as a service technician in 1995. From 2005 to 2010 he was Regional Sales Manager Scandinavia & Eastern Europe and 2011 to 2013 he was EMEA Sales Director there. From 2014 he is Sales Director for India & Business Development at Raytek, which became Fluke Process Instruments in summer 2015. He shares with MART the present condition of Testing & Measuring industry as well as the future plans of Fluke Process Instruments.
The present scenario of
and import duties, so the
lot in people education by
like steel, cement, glass,
Testing and Measuring
customer has to find ways to
offering seminars, roadshows,
plastic or solar, the level of
industry in India?
get the best solution, fitting
training events, webinars,
automation has definitely
exactly to his needs and
newsletters, literature onsite
increased a lot during the last
expectations.
but also online‌. We see that
years in India. Our solutions
the people in India are highly
f.e. help to improve on
interested in discovering
production throughput in
and learning about the latest
terms of quality, productivity
The demand on Test & Measuring Equipment in India is interesting and challenging
Testing and Measuring
at the same time. Still the
plays a critical role in
market is very price driven,
Manufacturing. What
it has an impact on the way
challenges do you face
how to find the best price/
when it comes to hardcore
performance solution to
technology?
meet the customer needs.
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The Indian industry has a
When it comes to technology,
very high trust in Test &
the majority of the industries
Measurement Equipment
we are working with in
which has been developed
India are still different than
and manufactured abroad.
in other regions. Since
T&M equipment coming
Fluke Process Instruments
from abroad have a very
proposes high tech solutions
good reputation but also
for the industrial temperature
higher costs due to customs
measurement, we invest a
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technical trends. So I am always very excited, when I meet customers here about their hunger on information and readiness to use our innovative solutions.
and security. India steel market f.e. has to compete with other steel markets,so the increased level of quality and security there as well as the traceability functions we
For the last one decade major
provide help them to gain
shift happened in the way we
market share.
manufacture. Can you please share this transformation in your industry sector? In the industries we serve
The advantage Indian manufacturing had by the entry of global auto majors setting up their base locally?
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Calibration of infrared pyrometers in Dakks laboratory at Raytek’s building
Lower import and customs duty, local supply chain will support lower cost for Indian customers. The entire service and support capability plays a key role. So I believe that suppliers who don’t follow local manufacturing initiatives may face some difficulties in the future to be competitive and successful in India. What factors can bolster the demand of Testing & Measuring Equipments?
Education: if people get educated on new technologies, new processes, this will bolster the demand on T&M devices. In addition of that, if big companies as well as the government in India continue to invest in Infrastructure, Energy and Environment, the demand of T&M equipment will also increase. Tell us about your inception, growth story and current market position?
We are offering a very broad range of temperature measurement solutions for almost all industry sectors. We have a leading position in the market with a strong team of local people solving customer problems very quickly everywhere. We currently grow very fast and show double digit growth rates in the Indian subcontinent. What new products are there in offer?
Our new infrared pyrometer Endurance Series f.e. which allows continuous non-contact temperature measurement until 3200°C in many industrial processes. We also offer a profiling solution for the solar Industry, infrared imaging solutions for waste burning plants to prevent fire, IR-pyrometers for the asphalt industry and of course,our latest solution for the gypsum and glass Industry. The TIP900 has
IR Sensor in construction
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been developed to detect
the world to promote our
had in your business for the
automatically failures in glass
products and serve our
last two years?
and wallboards process. As I
customers. More over we
said before, we have a very
belong to the worldwide
large offer of temperature
organization Fluke which is
measurement solutions, so
well known for robust and
it’s always worth to contact
reliable products.
us and discuss your industrial process. Temperature is the most frequently measured physical parameter, second only to time actually! How comparative your products are with those
We noticed an increasing demand on our products, so we could hire several people in India to serve our local customers and markets.We
Your take on the PM’s
could invest in education
initiative on ‘Start-up India’
programs explaining to a
and how can it really help
wider audience about the
the Indian Manufacturing
use and the benefit of our
Industry?
technology, which is still
“Start- up India” will help
unique for many people.
offered by other companies?
Indian manufacturers to
Comparing to global
become more competitive
manufacturing techniques,
In terms of technology we are
on the global market. The
where India stands in
a leader in offering industrial
demand on “Made in India”
manufacturing techniques?
temperature measurement
products will increase and
solutions for our customers.
finally it will contribute to
We also focus and consider
improve the lifestyle of the
as we serve a wide range
ourselves as the leader for
people in India. They will
of industries. In some cases
local support worldwide.
benefit of better incomes,
we don’t see big differences
We have currently the
better education…
compared to global
strongest network of agents and representatives around
The impact “Make In India”
This is very difficult to answer
standards, in other cases we see a real potential for the
future. Overall I see India on the right way to meet soon global standards. The future of manufacturing in Indian Manufacturing? As I said earlier, if the government supports the initiative, if foreign companies continue to invest into the Indian market, India is on the right way and the outlook is more than positive. In parallel if the amount of bureaucracy is getting less, if the import/ export regulations get easier, the future is very promising for everybody:for the Indian population, the local manufacturers, as well as for foreign manufacturers like us. For more details write to Fluke Technologies Pvt Ltd, #424, Deodhar Center, Marol Maroshi Road, Andheri – E, Mumbai – 400059 Tel : +9122- 29207690 Email: india@ flukeprocessintruments.com Web: www.flukeprocessinstruments.com
EMEA headquarter of Fluke Process Instruments, Berlin / Germany
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INDUSTRY FOCUS
“It is difficult to talk of ‘value’ when you cannot measure the ‘value’ you are delivering”
Juzer Haideri Country Head, Mayr
Mayr GmbH + CO, KG, founded in 1897, having its headquarters in Mauerstetten, Germany, is a world leader in the field of torque measurement, control and transmission. A highly innovative and research oriented company, Mayr has concentrated mainly in the field of overload protection through torque limiting clutches to protect machines and systems from expensive overload damage. They save costs and increase productivity. Juzer Haideri, is the country head for Mayr, Germany, in India since 1993 and the CEO of NENCO, with more than 30 years of experience in the field of mechanical power transmission. Trained extensively at Mayr Germany, he has been certified by Mayr as an ‘Expert Trainer’. NENCO, with its manufacturing facility at Bhosari, Pune, has offered hundreds of solutions, many on highly critical applications in virtually every segment of industry. NENCO has been nominated as the best global partner in the world by Mayr, Germany. He shares the latest techniques available in the Testing & Measuring industry, excerpts:-
The present scenario of Testing and Measuring industry in India? Testing and Measuring happen to be a core emerging segment in India, incidental to the high growth and development of the manufacturing industry which has seen a rapid progress all over India. This unprecedented growth is driven by a global demand for products and the focus of global world class enterprises to reap the harvest with big investments in India for local production at reduced costs
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and of the same quality they produce in their country of origin resulting into a spurt of demand for high quality testing and measuring equipment. In the meantime, there is also a rise in domestic demand to make the test and measurement market realise opportunities from every sector.
military, civil security, and
With all of the above trends
transportation sectors.
and developments, the test
Additionally, robotics will
and measurement market in
soon enter the realm of
India is all set to boom. There
personal relationships acting
are areas of interest for every
as a slave, companion, and
player in the market.
High levels of automation complimented with robots and robotic technology, combined with artificial intelligence, is employed to assist humans in manufacturing, space,
renewable and nuclear
perhaps even a decision maker in the near future. India’s ambitious plans to meet the domestic power demands by 2020 with energy increasing by 36
Testing and Measuring plays a critical role in Manufacturing. What challenges do you face when it comes to hardcore technology?
percent of the total power
It is difficult to talk of
generation implies big
‘value’ when you cannot
investments also into testing
measure the ‘value’ you
and measuring infrastructure
are delivering. How does a
in the country.
manufacturer scientifically
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ROBAstop-M Brake for Pitch and yaw drives
determine performance of his equipment, even under unforeseen conditions that initially did not exist at all ? It is only via a systematic testing and measurement methodology that simulates in a laboratory, real life like conditions that the equipment is going to be actually subjected to on the field. To mention about a very good example is brakes used on the pitch drives in wind power plants. These brakes have to perform round the clock under very aggressive conditions that may include minus temperatures. Mayr, a world leader in the field of safety brakes invested over 15 years of research and testing into the development of a maintenance free wind power brake, the only safety brake certified by Germanic Lloyd GL to -40 °C. The development process included a cold
June 2016
climate chamber that was actually built just to simulate an aggressive real life like condition with -40 °C to test the brake and its materials. The biggest challenge here, is, how many Indian Companies would put in so many years of research and investment in hard core technology for their product development? It may not be surprising to find in India, manufacturers of equipment indulging into the making of their own sub-components like brakes, without possessing even basic experience to build such a critical safety component. Part of the disconnect stems from most people’s tendency to equate quality with an absence of defect.The second challenge is meeting the technological needs of new assessments. The bottom line is that you cannot improve unless you measure ! For the last one decade major shift happened in the way we manufacture. Can you please
share this transformation in your industry sector? The last decade has seen an outburst of technology in India. Conventional manufacturing got replaced with high technology computer aided numerically controlled systems with mass scale automation. As machines became faster, more intelligent and capital intensive, a need occurred to prevent them against accidents resulting from overloads, and programming errors to prevent expensive downtimes and high costs of repairs. Mayr GmbH + CO, KG, founded in 1897, having its headquarters in Mauerstetten, Germany, is a world leader in the field of torque measurement, control and transmission. A highly innovative and research oriented company, Mayr has concentrated mainly in the field of overload protection through torque limiting
clutches to protect machines and systems from expensive overload damage. They save costs and increase productivity. As a global leader, the company possesses the widest product range, and provides tailored solutions for a variety of application from every industry segment. It is a company founded on solid values, imbibed with unquestioned integrity and consistency, amalgamating the best people into collaborative teams that continuously innovate products to identify itself as a market leader in power transmission technology. Through its Indian partner, NENCO, located in Pune, Mayr has since 1993 offered holistic solutions to a host of Indian customers mainly in the field of CNC machine tools, automation, packaging machinery, printing, test benches, elevators and other allied industries. The advantage Indian manufacturing had by the entry of global auto majors setting up their base locally? The advent of global auto majors
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setting up their manufacturing bases in India, offered a big boost to the way Indian industry carried out its manufacturing operations. The first biggest impact was that it transformed the Indian manufacturers from merely ‘manufacturing’, to highly ‘responsible manufacturing’, with a very strong emphasis on safety, reliability and innovation, the 3 core foundation principles always professed by Mayr. Safety brakes by Mayr power transmission provide reliable protection in Z axis and guarantee the safety of human life under the load. With major global automobile manufacturers setting up their base in India, Mayr was the first choice as supplier of brakes for CNC gantries that offered highest safety under suspended loads, also during an emergency stop or power failure. What factors can bolster the demand of Testing & Measuring Equipments? More than often, you read in
the news everyday about cars being called back, as they failed to live up to the specifications promised by the manufacturers. Whether you’re a hard-core car enthusiast or you think of your vehicle as an appliance, you don’t want automotive problems that demand dealership visits or generate roadside delays. Same is the case with every equipment, whether it is a machine tool, or a packaging machine or a CNC gantry crane. Also the fact that one single failure can ruin the future of a manufacturer makes it imperative for every new entrant, to first invest into testing and measuring equipment, even before investment is envisaged for manufacturing of the core product. Tell us about your inception, growth story and current market position? NENCO, an ISO-9001 certified company, was established in
1985 as a company specialising into the design, manufacture and marketing of mechanical power transmission products. Continuous research documented through patents for improvements in the field of power transmission has been the recipe of success for NENCO. Today, with a customer base of over a thousand industries from every possible segment, NENCO manufactures torsionally flexible elastic couplings, backlash free servo couplings, all metallic disc couplings, miniature couplings for encoders, keyless shaft hub locking devices, and shrink discs for frictional shaft hub connection. Through a strategic tie-up with global leader, Mayr GmbH + CO KG, Germany, in 1993, NENCO introduced a plethora of highly innovative, world class backlash free servo couplings, torque limiting clutches, electromagnetic clutches and safety brakes and also provided hundreds of customized
solutions with local value addition, to offer cost effective solutions. What new products are there in offer? With more than 80 patents to its credit, Mayr focuses on continuous research and further development in the field of power transmission. Highly qualified engineers and technicians work on tomorrow’s innovations using the most up-todate tools. Some of the new products introduced include: ROBA-DSM for on line torque measurement: The torque measuring shaft coupling Roba DSM is based on the tried and tested backlash free patented disc pack coupling. The areas of application for this torque measurement coupling range from test stand construction through use in serial production machines right up to condition monitoring. The system permits uncomplicated condition monitoring of machines and systems. Machines can be
ROBA-DSM for on line torque measurement
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optimally utilised through evaluation of coupling data. The ROBA-DSM receiver establishes contactless connection to the extension sensor and supplies it with energy via the ROBA-DSM Stator. On line torque can be measured easily by simply plugging in ROBA-DSM between the driver and the driven machine. The ROBA-DSM can be integrated with the EAScompact torque limiter to offer protection against overload. Torque can be set on the EAS-compact clutch, and if the preset torque is exceeded, the clutch will instantly disengage
and completely cut off the drive. Thus the ROBA-DSM special design can offer triple functions in a single unit Torque transmission, control, and measurement, a perfect economical solution for modern test benches. ROBA-contitorque – Perfect torque limitation With their innovative and economical solutions, Mayr sets new records in the field of power transmission by introducing a special patented design of hysteresis material in the ROBA-contitorque, a highly reliable and wear-free torque limiter that operates
continuously as a slip clutch and brake. Contrary to friction type clutches, the torque is transmitted contact free via magnetic forces. The unlimited service life makes this clutch a very demanding product in screw driving technology, capping, winding, test stands, and any drive that require a high frequency of repetitive disengagements at precise torque settings. ROBA-guidestop Safety brake and backlash free, highly rigid clamping unit for profiled rail guides. ROBA-guidestop safety brakes
Translift brand cranes exclusively assembled with Demag - BAS series of components. Translift will give you lifting solutions in alliance with Demag ( Terex group ) thus making the crane more affordable.
operate according to the failsafe principle. Pre-tensioned cup springs press the brake shoes on to the ‘waistline’ of the profiled rail. Despite the extremely high holding forces, a relatively low nominal pressure of 70 bar is sufficient for hydraulic release. How comparative your products are with those offered by other companies? Mayr holds numerous groundbreaking patents, and is the global market or technological leader for application –optimized safety brakes, for example passenger elevators, stage technology and gravity loaded axes, torque limiters - to protect against
Single girder EOT Cranes. Double girder EOT Cranes up to 20 Tones. Under slung and Monorail Cranes. Jib Cranes. Solo hoist and drive units.
Plot No. 66, Road No. 4, 1st Phase Jigani Industrial Area, Anekal Taluk Bengaluru, India Contact: 080-42147300, 9845205428 8861205674, 9845134315 Email: translift@rightengineers.com www.rightengineers.com / www.tarnslift.in
June 2016
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expensive overload damage and production losses, and backlash free servo couplings. Your take on the PM’s initiative on ‘Start-up India’ and how can it really help the Indian Manufacturing Industry? It is a delight to know for the first time in the history of Indian industry, that somebody at the helm has thought about the enormous potential a startup venture may have. Going by the way history got created by once a startup venture, the big timers of today – Infosys, Flipcart, or Zomato, just to mention a few names, and the wealth created by these ventures, not to mention about the employment generated, it is a very important initiative from the PM. However it must be complimented with other amendments in the system
to get rid of “license raj” and hindrances like in land permissions, foreign investment and environmental clearances. A proposal to extend the tax holiday to five years from three for startups and self-certification scheme in respect of nine crucial labor and environment laws initiated by various government departments in order to reduce the regulatory burden on startups as per the action plan, is a good initiative in this direction. The impact “Make In India” had in your business for the last two years? We can feel the ripples of the “Make in India” initiative launched by the government, two years ago. But to experience a strong wave for the mission, “Make in India” the government has to make the investment grounds more fertile by acting faster on
converting ordinances into bills, especially pertaining to land acquisition, insurance, coal and mining, and also make the Indian tax system simplified by implementing the much talked about GST regime. Also we should not forget that industries run on electricity and to accommodate and sustain “Make in India”, at a level we are envisaging, we need heavy investment in energy sector. Mayr has always been a global player and being a market leader, having eight subsidiaries, in Germany and sales offices in the USA, France, Great Britain, Italy, Singapore and Switzerland, as well as 36 additional country representatives in all industrially important areas, including India, the decision “Make in India”, has always remained on top of the agenda. However this is purely dependent on the
business model that allows an opportunity to profit not only Mayr, but also the customers. The management policy at Mayr “Never Compromise on Safety”, implies that we do not make compromises where safety is concerned. Whether “Made in Germany” or “Made in India”, if it is a Mayr product, it has to pass through the same grueling quality process established by the company for more than a hundred years. Comparing to global manufacturing techniques, where India stands in manufacturing techniques? India is on the threshold of the fourth industrial revolution, as digitalization now follows after the automation of production. The goals are to increase productivity and efficiency, speed, and quality. This is the only recipe for remaining competitive on the path to the future of industry.
ROBA-contitorque – Perfect torque limitation
ROBA-guidestop
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INDUSTRY FOCUS
“Scientech a Strong Indian Brand”
Ambrish Kela Managing Director & CEO, Scientech Technologies Pvt. Ltd.
Scientech Technologies Pvt. Ltd. is a pioneer serving in the field of Electronic Test & Measurement Instruments, Technology Training Equipments, Simulation/Teaching Software and Online Education with over three decades of experience and dedication to this industry. Speaking to MART, Mr. Ambrish Kela, Managing Director & CEO of Scientech Technologies Pvt. Ltd., shares his views on the testing and manufacturing industry in India and his company’s leadership in the industry. Here are the excerpts from the interview…
Could you highlight the
Manufacturing. What
Growth in the Indian test
entry of global auto majors
present scenario of Testing
challenges do you face
and measurement market
setting up their base locally?
and Measuring industry in
when it comes to hardcore
has been driven by the
India?
technology?
global demand. Test and
The Indian testing and
Frankly speaking, there are
measuring industry is a
very little integrated and
mixed bag with both Indian
customer specific solutions,
and foreign manufacturers
that give exact solutions
active in the market.
a customer seeks. The
However, all foreign
technology has to be reliable,
suppliers are interested in
scalable, and affordable.
Box pushing, while the Indian manufacturers are able to provide more customised solutions to their customers.
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For the last one decade, major shift happened in the way we manufacture. Can you please enlighten us
measurement industry has always been a dynamic and fast-growing industry that
manufacturing expanded in the country which in turn propelled Indian
is also gaining use in various
manufacturers to become
high-tech sectors, enabling
more competitive. The Indian
them to attain a global reach.
manufactures with that
It is heartening that the analysts forecast the global T&M equipment market
experience are now able to offer the advantage of next door support and flexibility.
to grow at a CAGR of 5.21%
What factors can bolster
during the period 2016-2020.
the demand of Testing &
Testing and Measuring
about the transformation in
What benefits had Indian
plays a critical role in
your industry sector?
manufacturing reaped by the
www.martupdate.com
Certainly, the markets and
Measuring Equipments? I think customer education
June 2016
Scientech DesignLab2 is more than just a instrument. A compound approach to address 12 needs through one instrument
and engagement in this
Where would you mention
your business for the last
can catch up in shorter
segment can be a plus point.
as your USP of your products
two years?
time with full dedication
The expansion of Electric
vis-à-vis products offered by
vehicles will spur demand.
your competitors?
Take us through the
I would say dedicated
been a strong Indian
inception, growth story and
approach to innovation and
brand with no imported
How do you see the future of
current market position of
customer focus sets us apart
technology dependence.
Indian Manufacturing sector?
your company?
from the other companies
So, it has not impacted us
present in this industry.
in any different way.
operations in 1983, and is now
What is your take on the
one of the leading companies
Prime Minister’s initiative
Compared to global
in TMI, Training Systems,
on ‘Start-up India’ and how
Lighting, and Solar Solutions.
can it really help the Indian
Its products are in use in over
Manufacturing Industry?
Scientech started its
75 countries across the globe.
Pvt. Ltd. has always
I think for country like India
Could you please mention
which is endowed with such
some new innovative
a good human resource and
products in recent times?
energetic youth generations,
Our company is always dedicated to improve on its product and technologies for customer specific solutions. To mention the latest, High end Smart TMI an IoT
Scientech Technologies
this decision is late rather than timely. But I appreciate the government’s step as a good start to support youth join main stream opportunities.
manufacturing techniques, where does India stand in manufacturing
potential and possibilities it has.
The Indian manufacturing sector is currently going through a tough phase. However, the government’s “Make in India” programme has potential to stage a turn around for the Indian
techniques?
manufacturing and lead it
Certainly, Indian lags
government should also
behind the manufacturing
consider a few steps to
industries globally. Much
facilitate the growth such
of it can be attributed
as the cost of business
to the demand scenario
operations should come
and cohesive approach
down for India to be a
by the government and
leader in the global markets.
manufactures, and not
Government should do away
alone to technological
with multiple taxation and unnecessary regulations to
Solutions for Industries and
What impact has “Make in
innovations. However,
Research are few.
India” programme made in
Indian manufacturing
June 2016
and commitment, given the
to growth. However, the
ease out the process.
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ON FACE
“Need for full-fledged EMI/ EMC Testing & HIL Software Testing for AES/ Sub-Systems”
Suresh D CEO, Spark Minda Technical Centre
Spark Minda, the Ashok Minda Group is a leading Tier -1 Auto Components Supplier to all major OEM’s in India & having an outstanding international presence in R&D, Manufacturing and Marketing. With more than 20 years of rich experience in the field of Engineering, Business Solutions, Research & Development and Product Development Mr. Suresh heads Spark Minda Technical Centre. He was previously associated with Bosch Limited, Bengaluru as a Chief of R&D Gasoline Systems and two wheeler power train solutions. His expertise includes Automotive Embedded Systems, Power Train Systems, Electronic Fuel Injection & Transmission Systems, ECUs, BCMs, Control Units, Various Sensors, Genset Control Systems, Infotainment & Instrument Clusters, Telematics & Fleet management Systems etc. In a detailed discussion with MART, Mr.Suresh shares his views on testing and measuring in the automotive segment, Excerpts:-
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How do you see the automotive trends in India? Government of India aims to make automobiles manufacturing the main driver of ‘Make in India’ initiative, as it expects passenger vehicles market to triple to 9.4 million units by 2026, as highlighted in the Auto Mission Plan (called AMP) 2016-26. Government has formulated a scheme for Faster Adoption and Manufacturing of Electric and Hybrid Vehicles in India (called FAME), under the National Electric Mobility Mission 2020 to encourage the progressive induction of reliable, affordable and efficient electric and hybrid vehicles in the country. In what can be seen as perhaps India’s boldest move to curb air pollution, the government has decided to advance the standard for cleaner cars and leapfrog to Bharat Stage-VI emission (emission level similar to Euro VI) norms countrywide by April 2020. This step shows perhaps the strong initiative of India towards the vehicle emission reduction still ahead of the majority of the developed nations in the world. Last but not least is the safety related, no one could have imagined that this country
will bring the introduction of Antilock Braking System (called ABS) mandatory for two wheelers of engine capacity 125 cc and above so soon.These systems are complex in nature in terms of its hardware and software architecture. What does the complexity mean to automobile OEM’s and buyers? Proliferation of electronic systems in automobiles will increase the technical complexity, however the challenge is not onlyin the compatible design solution, much tougher is the detection of such faults early in development phase to avoid the safety critical risks in the field.Reliabilityof these electronic devices is key for safe driving. General environmental tests are not able to detect the complex problems which are associated with either software or hardware or both. The latest cars have multiple microcontrollers / microprocessors working monolithic mode or with real time operating systems. Hence a reliable hardware testing and a proven software validation is important in achieving the overall reliability of the electronic systems.
What are the basis of electromagnetic interference and its influences? Electromagnetic compatibility (EMC) is the branch of electrical engineering concerned with the unintentional generation, propagation and reception of electromagnetic energy which may cause unwanted effects such as electromagnetic interference (EMI) or even physical damage in operational equipment. The goal of EMC is the correct operation of different equipment in a common electromagnetic environment. EMC pursues two main classes of issue. Emission is the generation of electromagnetic energy, whether deliberate or accidental, by some source and its release into the environment. EMC studies the unwanted emissions and the countermeasures which may be taken in order to reduce unwanted emissions. The second class, susceptibility is the tendency of electrical equipment, referred to as the victim, to malfunction or break down in the presence of unwanted emissions, which are known as Radio frequency interference (RFI). Immunity is the opposite of susceptibility, being the ability of equipment to function correctly
in the presence of RFI, with the discipline of “hardening” equipment being known equally as susceptibility or immunity. A third class studied is coupling, which is the mechanism by which emitted interference reaches the victim. New technologies and communication systems in vehicles demands an extensive testing and evaluation, before electronic modules are used in real-time installations, in order to ensure complete safety and reliability. EMC intended to avoid malfunctioning of the vehicles and their sub-systems due to electromagnetic interference between the different components and sub-systems, within the vehicle and its environment. In view of the criticality of EMC compliance, worldwide full-vehicle EMC tests have become mandatory. Additionally, components and sub-systems are also subjected to regulations and need to be tested separately (Component level testing). Achievement of Electro Magnetic Compatibility (EMC) requirements shall be a time consuming and expensive Endeavour for the organizations. EMC compliance is highly critical for products’ success and also
SMIT Proposed Building in Chaken , Pune
June 2016
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for company’s future. Some of the observations in day to day which might be due to the EMC issues as follows:- Car audio getting interference during switching on of electric horn - Mobile phone interference with television & radios - Interference to electronic equipment’s near transformer/ current carrying lines - Mobile phone interfering with aircraft electronics & communication. - Non-operation of electronic devices when the vehicle battery (charging) is low - Failure of electronic devices during heavy rains/thunder storms Does EMI/ EMC have any harmful effects like safety issues in automotive application? These disturbances are very critical in applications such as Aerospace applications, Military equipment’s, Medical devices,
Automotive etc., where the malfunction of electronic modules have graves of consequences. For example, a serious consequence can occur if a signal interferes with the operation of medical equipment that is being used to monitor a patient in intensive care or if the air bag pops up in a car without any incident due to influence of a radar pulses from airport. While the effects of EMI are most cases minor like momentary interference, rare cases the effect may be more catastrophic even leading to life threat. How to prevent these failures and improve the reliability? New technologies and communication systems in vehicles demands an extensive testing and evaluation to ensure complete safety and reliability. In view of the criticality of EMC compliance, EMC tests have become mandatory in vehicle level and component level. International EMC Standards (CISPR25, ISO11452, ISO16750, ISO7637
and ISO10605) been framed to regulate the same. These tests are executed broadly under the category of conduction and radiation to test the emission levels and Immunity levels. What is embedded software mean to automobiles? Embedded software is computer software, written to control machines or devices that are not typically thought of as computers. It is typically specialized for the particularhardware that it runs on and has time and memory constraints.Manufacturers ‘build in’ embedded software in the electronics in cars, telephones, modems, robots, appliances, toys, security systems, pacemakers, televisions and settop boxes, and digital watches. In modern cars a millions of such software codes runs and makes the complexity degree to a higher level. How does hardware in loop testing helps to improve the safety of systems? Hardware-in-the-loop (HIL)
simulation is now a standard component in the vehicle development process as a method for testing electronic control unit (ECU) software. HIL simulation is used for all aspects of development, naturally including safety-relevant functions and systems. This applies to all test tasks (from function testing to release tests, testing a single ECU or an ECU network, and so on) and also to different vehicle domains. Every electronic systems are equipped with microcontrollers / microprocessors like powertrain, body control, vehicle dynamics, driver assistance systems, interior/comfort systems and infotainment etc. are all tested by HIL simulation. At the same time, modern vehicles comes with more and more safety-related systems such as Adaptive Cruise Control, Electronic Stability Program, Power Assisted Steering, and Integrated Chassis Management. To establish a uniform and commonly accepted approach for developing automotive safety-related electric/electronic
Typical EMC testing of a Car
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systems, the safety standard ISO 26262 (“Road vehicles Functional safety”) has been developed by OEMs, suppliers and service providers and released in late 2011. ISO 26262 explicitly names HIL as a suitable test environment for software unit tests and integration tests, even recommends HIL for the verification of safety requirements at component level, and also names it as a suitable method for testing single ECUs/ components and for testing ECU networks up to an entire virtual vehicle. HIL setup with automated testing feature will improvethe efficiency, productivity and quality of delivered software. Usage of HIL enhances the quality of the testing by increasing the scope of the testing and finally improves the product quality. Ideally, an embedded system would be tested against the real plant, but most of the time the real plant itself imposes limitations in terms of the scope of the testing. For example, testing an engine control unit as a real plant can create the following dangerous conditions for the test engineer. - Testing at or beyond the range of the certain ECU parameters (e.g. Engine parameters etc.) - Testing and verification of the system at failure conditions In the above-mentioned test scenarios, HIL provides the efficient control and safe environment where test or application engineer can focus on the functionality of the controller. Tell about your company involvement in this challenging automotive arena? Spark Minda, the Ashok Minda
June 2016
Group is a leading Tier -1 Auto Components Supplier to all major OEM’s in India & having an outstanding international presence in R&D, Manufacturing and Marketing. Group CEO, Mr. Ashok Minda has a clear vision, clarity of thought and focused approach towards the future, this has resulted as a New R&D facility called Spark Minda Technical Centre (SMIT ). SMIT is expected to do the advanced engineering and research activities in automotive domain to bring the modern technologies to India, have acquired highly talented professionals and located in Chaken, Pune. SMIT is installing the state of art design and development infrastructure havingtest facilities catering to EMI/EMC testing as per CISPR 25,JASO, AIS, SAE,ISO11452, ISO16750, ISO7637 and ISO10605 Standards. A semi anechoic chamber to test the automotive systems components being installed in this facility, expected to be operational by Oct’2016. In order to improve safety, efficiency and sustainability in road transport, driver support systems and fully automated intelligent transport systems are among the most promising developments on the market. Extensive development and testing processes are necessary to ensure that these systems are safe and reliable. Until now the full-scale road tests have been expensive, time-consuming and possibly hazardous. SMIT brings a radical change to this landscape. With its HardwareIn-Loop laboratory, we offer a unique environment for the development and testing of intelligent vehicles and transport systems; safely, cost-effectively and manageably.
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TALENT MANAGEMENT
Managing Conflicts at Work
Conflict exists in every organization and to a certain extent indicates a healthy exchange of ideas and creativity. Effectively managing it is arguably the hardest thing a manager has to do
Pavan Sriram pavan@ittige.com
Conflict is an inevitable part of work. We’ve all seen situations where people with different goals and needs have clashed, and we’ve all witnessed the often intense personal animosity that can result. The fact that conflict exists,
however, is not necessarily a bad thing. When you resolve it effectively, you can also eliminate many of the hidden problems that it brought to the surface. There are other benefits that you might not expect, such as:
Increased understanding: Going through the process of resolving conflict expands people’s awareness, and gives them an insight into how they can achieve their goals without undermining others. Better group cohesion: When you resolve conflict
effectively, team members can develop stronger mutual respect and a renewed faith in their ability to work together. Improved self-knowledge: Conflict pushes individuals to examine their goals and expectations closely, helping them to understand
When you resolve conflict effectively, team members can develop stronger mutual respect and a renewed faith in their ability to work together
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A manager is expected to neutralize or minimize conflict, not allow it to grow and run rampant.
the things that are most important to them, sharpening their focus, and enhancing their effectiveness. However, it can either propel or disrupt the momentum for a manager or a team in no time if left unattended. What they don’t realize is that by avoiding tension all together they are unknowingly creating silos and internal disruption amongst employees. This is where managers must act responsibly to be respected. A manager is expected to neutralize or minimize conflict, not allow it to grow and run rampant. According a recent research by SHRM it shows that management style (across all managerial levels) is the number one cause of stress and it can arise from managing differing perspectives and seemingly incompatible concerns of team-members. An early sign of conflict is that “nagging feeling” or tension, indicating that something is brewing under the surface.
June 2016
These signs can provide managers with important information about the current situation and can help in assessing the next steps. More often than not, these early warning signs are a part of a larger web of dynamics present in the organization and can manifest more directly with opposition and conviction. Looking back now over my own career (as an employee, manager and an entrepreneur) I can recall conflicts with the many people I managed over just about everything: being managed too much, not being managed enough, projects that were too tough, projects that were too boring and once in a while someone who was just for no discernible reason downright insubordinate. In that spirit, following are a few things I learned about it: a) Have clarity in communication - To manage conflict effectively, you must be a skilled communicator. That includes creating an open communication
environment in your unit by encouraging employees to talk about work issues. Listening to employee concerns will foster an open environment. b) Don’t be a conflict- avoider - Difficult interpersonal workplace problems won’t disappear by ignoring them; they’ll only get worse. Chronic conflict-avoiders will end up losing the respect of their employees – and their own management. c) Maintain the moral high ground - You are management. You are the voice of reason. Don’t lose control or pull rank or cede the moral high ground - calm control is a much more advantageous position to manage and negotiate from. d) Don’t think in terms of “winning,” so much as constructively resolving - No point winning the battle but losing the war. Manager’s role is not to “defeat the enemy”, but to elicit optimal performance from the people you are managing. It’s imperative
to get conflicts resolved fairly, expeditiously, and move forward as constructively as you can. e) Partner with HR - always call upon HR when faced with unmanageable or difficult employee conflicts. They were unfailingly an objective third party, a sounding board, and a valuable source of reasonable counsel. My philosophy was always, in delicate situations, get all the help you can. It’s an illusion that any of this is easy. No, it isn’t- But if you can develop a consistent, rational approach to managing conflict, it can make your difficult job as a manager a lot less stressful than it would be without it. I look forward to hear from you at pavan@ittige.com on how you are developing the potential to see conflict early on and seize the opportunity within the conflict before healthy tension turns into overly disruptive chaos. Pavan Sriram is the CEO of ITTIGE Learning, a performance-based training company that works with organisations to improve learning outcomes.www.ittige.com
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MANUFACTURING EXCELLENCE
Importance of Visualization in the company Managing SME in India - Part 42
Visual factory attempts to reduce the time and resources required to communicate the same information verbally or written form. Viewers can understand things better without asking questions. Visualization also include various charts, Progress data, status information, graphs etc. In visual workplace, anyone can know in an area on 5W1H - Who, Why, When, What, Where and How. As a continuation of last articles, we will discuss on few more points to manage SME’s better in India.
P S Satish gotopssatish@gmail.com
53. Importance of Visualization in the company I visited one of the manufacturing companies in Bangalore. I was trying to check how work instructions are passed on to the Operator. This is one of the core issue of
the companies. Lot of efforts are put in to prepare many procedures, work instructions and guidelines. There is a gap in translating those instructions and steps into actions. The gap mainly is the language. In the company I visited, display of instructions on what to do
when there is a disruption of the machine was very neat. It was also written well. When I asked the operator whether he understood what is written in English the answer was negative. Then what is the use of those neatly written instructions? The operator
knew only Hindi. In that company, as typical in many companies now days, there were Operators from different language background. In such of above cases, visualization practices come very handy. Displaying
One of the good visualization I saw was in airport of Tokyo, Japan. Though I had no idea of Japanese language, I could get down in Tokyo Narita Airport easily and could catch local train only by following the signs.
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instructions through signboards, sketches and photos is more effective. Visualization helps any one to understand what is happening in the manufacturing process. Graphs for example will enable dissemination of Data quickly. Visual factory attempts to reduce the time and resources required to communicate the same information verbally or written form. Viewers can understand things better without asking questions. Visualization also include various charts, Progress data, status information, graphs etc. In visual workplace, anyone can know in an area on 5W1H (Who, Why, When, What, Where and How)
progress and area to be focused • Better visibility of disturbances for immediate attention • Helps to set benchmarks • Viewer can understand easily and gets a better overall picture • Improves image of the company • Makes operation standards easier and quicker to understand by all concerned • Motivates everybody to improve key performance targets • Visual workplace is safe and supports quality products Types of visuals
Visualization in normal life:
Visuals can do one of the following functions namely – a) Indicator b) Signal c) Control
In bathroom, hot water tap is
a) Indicator
identified with red and cold water tap with blue. Or simply H & C are marked. To enable parking car easily, parking slots are marked neatly. Traffic signals, sign on not to use cigarrates or alcohol, safety signs, picture of man and woman in toilets etc. All these are nothing but visualization for better communication any lay man or even uneducated one. Benefits of Visualization: • Helps in effective implementation of systems • Brings in cross communication within the company. Shared information builds participation • Enhances Customer confidence • Highlights the gap in
June 2016
An indicator provides only information about the situation or environment. They are passive and people may not notice them or respond to them. Example, markings on the floor, Stop signals, Red alert on the notice board, various sign boards. But these indicators are better than having nothing or taken for granted that people are aware. b) Signals Signals grab our attention with audio or light. People may still ignore them and is better than indicator. E.g. Alarm on the machine when there is a breakdown, Red light alarm huter when parts are not there for assembly in one station, alarm when one of the door of car is not closed while driving,
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smoke signal alarms etc. c) Control Controls limit behavior through physical restrictions. Example, traffic gates restricting vehicles, Machine stopping when oil level has come down to a particular level, andon etc. Control is normally combined with signals and or indicators. General tips for visual management in the company • For display of progress/ status charts, graphs or tables of a cell or section, metaplan board can be used. Movable is better as it will have flexibility. Recommended size 1200 mm(W) and 1500 mm (H) • Clear gangway paths indicating movement of forklifts or people. Typically, yellow colours which gives message of watch & move, are recommended. • Appropriate size posters which gives powerful message through pictures can be displayed in shop floor and other areas. It should be relevant for the section.
Examples of topics could be safety, quality and morale. Take care of proper size and location for better visibility. • Standardized colour for machines • Identification of machine with the name and a unique number • General operating procedures and safety aspects near the machine. Think of more picture and less words. Care for common languages of operators. • Red colour trays for rejections. • Quarantine area with lock to keep rejected parts or parts are suspected for quality • To improve aesthetic, look suitable power pots at the appropriate places • Display boards with specific theme example 5S, quality, KPI and general notice board at prominent places. Each board is identified with a person who will maintain the information in the board. • Proper arrangement of board/pad near the machine to record in process quality and also display of control charts,
process flow of component in operation • A corner in shop floor with all updated information of day like rejections, quality issues, supply bottlenecks, resource issues etc. This corner is also used for daily standing meeting for quick resolution of issues and to set priority for the day. In some companies this corner is called DIR (Do it Right) corner. • Pleasing colour for walls • Start with 5S activities for workplace organization • Quality alert board at prominent place to indicate latest customer issue. I have seen companies with LED displaces at few places with Q-alerts and major changes of the day. • Every area is identified with a board e.g. Inward inspection, Stores etc. • Proper usage of tags to indicate disposition of parts • Sign boards related to safety, assembly in emergency, exit way etc. • Band aid boxes with regular fill of medicines • Every item is identified in the
store. Parts are arranged for easy retrieval. A visual board is displayed indicating stocks of critical items to trigger ordering. 2-bin or 3-bin stores could be used for physical control of inventory • Work instructions to operators more with pictures, sketches of Do’s and Don’ts Visual factory brings up problems and abnormalities easily and better visibility on what is happening to all involved. This definitely pushes up quality system. In the next article, I will focus on boards where monitoring charts or monthly KPI’s are displayed, with details of purpose, contents and method to update. Please send your inputs,remarks,opinionsand suggestions toP.S. Satish,Mentor and Capability Developer, M/s Saraswati Industrial Services, Q-103, Mantri Paradise Apartments, Bannerghatta Road, Bangalore-560076. Email:gotopssatish@gmail. com; www.linkedin.com/pub/ satish-cp-pii/35/153/85b; Mob: 9845043202. Have a nice day.
Visuals can do one of the following functions:-
Indicator
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Signals
Control
Indicator: Provides only information about the situation or environment Signals: Signals grab our attention with audio or light Control: Controls limit behavior through physical restrictions
June 2016
June 2016
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ENVIRONMENT
e-vehicles for a billion human mobility India, the first country in the world?! “Now it’s time for India to think bold, at scale of country and globe, be innovative in approach and push for convergence through policies to support aspirations and ambitions of the country. This convergence will necessitate world-wide and countrywide collaboration and pooling of resources, capabilities and capacities across. India is at inflection point and leaving aside all inhibitions we need to take a leap to the future: be the first in the world!”
Harish Pant harish.pant@hotmail.com
Proposed are a set of Five Policy Initiatives to unleash creative forces to make India first country in the world to be with e vehicles for a billion human mobility.
from Finance, Energy, Road and Transport, Oil, Labour, Environment and Industries.
Policy Initiative - 1
• Pay Travel Allowance and Leave Travel Allowance in equivalent GREENS! and credit the same in individuals salary per month.
a) Creation of Green Currency GREENS! in line of Carbon Credits/ Bitcoins/ Block (Green) Chain tradable through a “GREEN! Exchange”. b) Constitution of a regulatory body with representation
c) Unlocking Green Values
Interest/earning algorithm higher than finance interest rate. • No taxes on allowances converted to GREENS!
• Gas, Petrol and Diesel are to be sold also for GREENS!
• For non salaried people, a standard value of GREENS! can be allocated at a price. For additional requirements Higher users buy GREENS! at steeped price or generate GREENS! by other means (details later).
• Accumulated reserve of GREENS! would follow an
• For Hotel Stay - Saved GREENS! from allowances can be used
for paying hotel bills. A Certified Green hotel (by a third party audit) will be authorized to get payments in GREENS! thus increasing their profitability substantially by not paying taxes for the Green Income. • Similarly, if companies/ Individuals follow green practices and generate GREENS! then the expenses for Hotel, travels etc. can be paid through GREENS! which would be cheaper and preferable by the receivers. • Include other allowances like
GREEN CARD
1 88 88 88 088 088 88 HARISH PANT
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A prestigious Green Card for each Indian citizen to mark commitment and contribution to environment!
June 2016
Medicals etc to simplify and clean Paper Bill mess! Policy Initiative - 2 • No tax for No pollution/Electric Vehicles while other cars are taxed as usual thus bring down the Car Prices. Same applies for imported cars for a limited period to speed up electrical Cars fast adaption in India. • EMI Scheme with zero down payment for Zero Pollution/Electric vehicles. (As proposed by Energy Minister Mr. Piyush Goyal) Policy Initiative - 3 Incentives for Green Manufacturing of Cars; also at the time of disposal If a company makes a Zero emission/electric cars and that along with zero net pollution in manufacturing, then it pays less taxes thus increasing profitability and reducing car prices further. Also, if the product is 100% recyclable then the owner earns GREENS! on disposal. Encourage Manufacturers to buy back their old products. Policy Initiative - 4 Encourage Mobility as Service (24x7) through e - cars to significantly increase asset usage and dramatically decelerate new vehicles purchases. Services to fetch far lower income taxes due to earnings in GREENS! Policy Initiative - 5 Generate and propagate GREENS! • Invite e-vehicle manufacturers to immediately start import followed with manufacturing in India. Encourage others to compete and immediately switch to Electric Vehicles design and manufacturing. • Government provides GREENS! incentives to all the existing Petrol Pumps for installing charging station for Cars throughout the country, and also provide finances for New Charging Stations. • Disposal of Polluting old assets
June 2016
e.g. Cars/Trucks to earn GREENS! through a detailed scheme. Onetime scheme: Oldest and earliest adapters get higher GREENS! incentives. • Generate GREENS! Through Forestry and Agriculture - Develop a detailed scheme. • Plant a tree and earn GREENS! • Green book: to digitize and ensure all offices and agencies are paper free/use less paper. • Encourage all entities to prepare carbon footprint reduction plan and earn GREENS! incentives and pay less taxes as well. • Recognize and reward companies/entities/individuals who connect whole life cycle through GREENS! • Last but not the least – Want to buy an e-vehicle all in Cash! Go ahead no question asked for a limited period of six month! A last chance to convert Black to GREENS! including imported cars! Open your “GREENS! Account” immediately by sharing, reflecting and commenting! Lets reach all of 1.4 Billion! Oh golden bird, thou shall return! Mr. Harish Pant, a Mechanical Engineer with multi-faceted global exposure and experience of 30 years across Steel, Automotive, Aerospace and Engineering sectors, is presently working with Hampson Industries Private Limited as Managing Director. He worked with HAL, Maruti Udyog Ltd, General Motors and Jindal Group. Mr. Pant has been honoured with “Distinguished Alumnus” Award by IEI, Member Advisory Council All India Management Association (AIMA) Bangalore, Lifetime member of Aeronautical Society of India, a Fellow of Institution of Engineers and also the recipient of Immai Operational Excellence Award and Award for Industrial Development. For more details, you can email to harish.pant@ hotmail.com
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ENTREPRENEUR SPIRITUALITY
Understanding Chakra Energy Centers in Human Body Spirituality for SME’s- 7 In this seventh series of articles on Spirituality for SME’s let us discuss about another most interesting and highly useful area called Chakra Energy Centers in human body. We have a physical body and we also have an energy body. In the Yogic tradition, the human body has seven energy centers. When the energy centers are healthy and open, so are we- physically, emotionally and in all our relationships.
A S Shetty sedvik@vsnl.com
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The history of the Chakra System goes back to Yoga Upanishads (circa 6000 B.C) and later, in the Yoga Sutras of Patanjali (circa 200 B.C) and over a period of time developed to the present state with a lot of variations and additional features. Chakra Healing and Chakra Therapy are a thriving business in the West and especially in the USA these days. Let us discuss about the essentials of Chakra Energy System in our present article.
situation not improving. They
People experience often something in their life isn’t working, they get a sense of being off-balance. There is a sense of some parts of their life like their relationships isn’t going well, their living situation, their financial
Centers are to be opened and
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may be extremely emotional but cannot express, they feel stifled how to communicate properly. Their career and their sexuality are not satisfactory. They don’t feel being holistic. There is a sense of some parts of their life not going well. Physically, as per medical terms, one may be healthy. Still, one may not experience a sense of wholeness and oneness. In order to master your present state your Chakra Energy balanced. In most humans chakras are at least partially closed most of the time because of the distractions in the mind like anxiety, fear, worry, stress and negative emotions.
There are seven main chakras and they are located along the spine extending out the front and back of the body. Each chakra is associated with a certain part of the body and a certain organ (endocrine gland) which it provides with energy it needs to function. Through these chakras we absorb cosmic energy from the universe. Cosmic consciousness is the eternal source of individual consciousness. The existence of life on the earth becomes possible because of the optimal transmission of cosmic energy. The human body too has two poles- the extra sensory centers called “Sahasrara” in the inner core of the brain and the “Muladhara” beneath the
lower end of the spinal cord. These play respectively the roles of the “North Pole” and the “South Pole” in maintaining continuous flow of the subliminal currents of cosmic consciousness and the vital energy in the body. These chakras can be opened by doing specific Yoga exercises for a specific Chakra. Matter is energy. Human body is energy- with an “aura”. If you come near a master or leader you feel attracted to him. They radiate energy. You feel comfortable and calm when you stand near him. All this is because of his balanced energy system. Let us discuss one by one the seven different chakras, their functions, how to open them and balance them.
June 2016
1. Root Chakra (Muladhar Chakra): It is at the base of the spine. This chakra vibrates at red colour. Food and sleep are the dominant aspects here. Eating is a basic first chakra survival activity. Fear closes this chakra and this can be opened if you walk barefoot on the grass, hug trees and wear red coloured clothes, eat pomegranate fruit. 2. Sacral Chakra (Svadhistana Chakra): This chakra vibrates at orange colour. This is the center for creating relationships of all kinds. This represents ego and sexuality. This chakra is blocked by guilt feelings. If this chakra is closed we feel dull, lifeless and flat. This chakra can be opened by concentrating on the chakra, chanting the sound “VAM” and by having a clean feeling. By doing pelvic yogic exercises, bouncing orange coloured balls on your body also helps in opening and balancing this chakra. 3. Solar Plexus Chakra (Manipura chakra): This chakra vibrates at yellow colour. This chakra is located slightly above the navel. This is the center of will power and self confidence. This chakra is blocked by feelings of shame. To open this chakra, concentrate on the navel chakra, get a nice sun bath and imagine a beautiful yellow ball bouncing against your body. Jogging, pounding a pillow can help you to loosen up. Also Chant “RAM”. 4. Heart Chakra (Anahata Chakra): It is located at the
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center of one’s chest. This chakra vibrates at green colour. This is the center of real, unconditional affection, spiritual growth, compassion, devotion and love. This chakra is blocked by feelings of grief. You can open this chakra by concentrating on this chakra, chanting “RAM” playing with babies and toddlers, doing yogic exercises and imagining a green ball bouncing against your body. 5. Throat Chakra (Visuddha chakra): It is located at the throat. This chakra vibrates at light blue colour. It deals with the truth and blocked by lies the ones we tell ourselves. This is the center for communication, selfexpression and creativity. This center can be opened by concentrating on the throat chakra, chanting the sound “OM” or “AUM”, imagining a blue ball bouncing against your body. 6. Third Eye Chakra (Ajna Chakra): It is located at the middle of forehead just above the brows. The chakra vibrates at indigo colour. This is the center of will, seat of intuition and direct spiritual vision. This is blocked by feelings of illusions. Once the third eye is open and active the crown chakra is easy to open. The third eye is also important in telepathy and controlling others. It is with the third eye and sixth chakra we are able to see auras and energy. It is related to the act of seeing, both physically and intuitively. As such, it opens our psychic faculties.
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7. Crown Chakra (Sahsrara Chakra): This chakra represents the highest level of consciousness and enlightenment. It deals with pure cosmic energy and is blocked by earthly attachments. This is the crown chakra that relates to consciousness as pure awareness. When developed, this chakra brings us knowledge, wisdom, understanding, spiritual connections and bliss. Meditation, head stand, head massage and fasting open this chakra. Once the crown chakra is opened, you will begin to radiate energy, your inner calmness comes and you will have a new outlook on life. You no longer fear death. OSHO says human is like a rainbow. The rainbow has
seven colours and man has seven centers of being. The lowest is “Muladhar Chakra” and the highest is “Sahasrar Chakra”. Man has to pass through all these chakrasseven steps towards the divine. If you live in the first three only you are no more different than the animals. The first three chakras are concerned with food, money, power, domination, sex. Food is the lowest; sex is the highest in the lowest three chakras. A food obsessed person is in the lowest category of animals. He simply wants to survive. Mr. Amit Goswami, a Canadian Indian nuclear physicist-turned-spiritual master writes- In the psychology of the East, feelings are recognized to be associated with physiological
organs and emotions are clearly seen as effects of feelings on the and the body physiology. Materialists think that we feel emotions in the brain- that emotions are brain epiphenomena and then the emotions come to the body through the nervous system and the so called “molecules of emotion”. But actually it is the other way around. We feel feelings at the chakras first, then the control goes to the mid brain for integration through the nervous systems and the “molecules of emotion” and eventually the neocortex gets involved when the mind gives meanings to the feelings. It is also interesting that the chakra imbalances are often produced because the mind intervenes. For example, the general mental suppression
of heart chakra energy especially for the American male population may be responsible for the malfunction of the immune system causing cancer. This is the subject of Chakra Medicine, according to Mr. Amit Goswami. The author A S Shetty, with vast industrial experience of more than 28 years is a mechanical engineering graduate from IIT BHU and a Post Graduate in Welding Technology from Germany. He is one of the leading experts in Rollforming Technology in India. Apart from steering the growth of his company Sedvik Industries Pvt Ltd, he is also helping companies to promote Rollforming Technology as a consultant. In this new series on SME Entrepreneur Spirituality Article series, he is penning down his experiences and you can reach him at sedvik@vsnl.com
Crown Chakra Third eye Chakra Throat Chakra Heart Chakra Solar Plexus Chakra Sacral Chakra Root Chakra
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Plot No. 347A, 2nd Phase, KIADB Industrial Area, Harohalli, BENGALURU-562112 Kanakapura Taluk. Ph: 080-26396461 / 41632962 / 99456 95322 Manfred Maier Email: fenmet@gmail.com , www.fenfemetallurgicals.com Managing Director & COO, HELLER June 2016
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MART UPDATE
Smart Industry Automation Seminar by Emerson Around 260 participants attended the seminar in Mumbai, Kolkata & Chennai. Customers of different categories like OEM, end users, consultants, contractors, and system integrators joined the seminar. Presenters included Rengan Rajan (Managing Director General Manager – India), A.Bhanuprakash (Deputy General Manager – Technical Project Management), T.R.Sathishkumar Manager (Product & Application)
– Technical Support and Xavier Arouette (Business Development Manager – Asia Pacific). Sessions covered the topics of Control Techniques & Leroy-Somer products like Unidrive M, Mentor MP, Powerdrive MD2, Powerdrive F300, LSMV, LSRPM and LSES CPLS, along with features, applications, software and success stories. Attendees were also able to try out new initiatives like the Energy Savings Adviser smartphone
Emerson Industrial Automation held a customer seminar around the theme of ‘smart industryautomation’ in April.
app, as well as learning how to apply Unidrive M Connect and Machine Control Studio to a fully operational Unidrive M kit with remote communication
through Ethernet. The event was well received by the customer, and provided a valuable opportunity for learning and networking.
LAPP India Launches ÖLFLEX® FIRE Survival Cables Lapp India has launched ÖLFLEX® FIRE Survival Cables for circuit integrity application in the event of fire. These cables are passed through C/W/Z fire resistant test and can provide optimum cabling solutions in fire mishaps by maintaining circuit integrity for temperatures up to 950° C, 650° C and 950° C as per application requirements. The inner and outer sheaths of the cables are specially made of halogen free compound which reduces emission of fumes and acid
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gases in the event of fire. ÖLFLEX® FIRE Survival Cables are designed for major infrastructure installations such as – airports, metro rail, rail terminal, bus terminal etc along with building and construction management. Rapid urbanization has escalated the need for high rise buildings, malls, modern houses and offices, all of which depend on wires and cables. As a result, the need for installing quality wire and cables is growing.
Approximately 80% Cables around us are not visible once they are installed. During a fire accident, these cables can propagate fire in the building through electrical circuits. So the need of the hour is to minimize loss during fire mishap which can be achieved by providing intelligent cabling solutions in terms of fire safety
and fire survivability. The use of the ÖLFLEX® FIRE Survival Cable in building management, fire and security systems ensure that vital systems remain functional in the event of a real life incident which requires an emergency evacuation.
June 2016
Red Lion Repeats for 16th Year as Top Panel Meter Provider in Control Design Awards Flexible Panel Meters Accommodate Wide Range of Applications, Among Most Comprehensive in Industry Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking,today announcedthe company has captured the top panel meter slot for the 16thconsecutive year in the2016 Control Design Readers’ Choice Awards. In addition to naming Red Lion the leading provider of panel meters in the industry, the publication’s readers also placed Red Lion in the top five for the following categories: wired network components; network routers and switches; and network protocol converters, bridges and adapters. “Winners from the 2015 Readers’ Choice Awards were elected to the top spot once
again this year in more than 75 percent of the product categories,” said Mike Bacidore, editor in chief of Control Design. “Our readers have spoken, making it clear that Red Lion is a valuable partner and supplier for a variety of automation technology.” Bacidore added that machine builders are sticking with what works, made clearly evident by Red Lion once again being named the top choice for panel meters. “Such customer reception for our industrial automation and networking products is truly gratifying,” said Mike Granby, President, Red Lion Controls. “As a ‘Customer First’ driven organization with
over forty years of history, we strive to provideperformance and reliability that our end users have come to rely on. This award is a true testament to our achievement of that goal.” Control Design invited more than 22,000 individuals who indicated they have buying authority or influence at their organizations to access the confidential ballot. The voting is unaided, which means no list of suppliers is included for guidance or assistance; it’s a ballot of the machine builders, by the machine builders and for the machine builders. Each participant was asked to indicate the first, second and third preference in more than sixty product categories, which were grouped as Control, Hardware, Motion, Networking, Safety,
Sensing and Software. The votes of suppliers are not knowingly counted in the tabulations. With more than 4.5 million panel meters sold since the company’s inception, Red Lion’s range of digital and analog meters is the most comprehensive in the industry. Red Lion panel meters easily accommodate a wide range of applications through varying models, inputs, sizes and other capabilities. From compact CUB indicators to versatile PAX2 process meters, Red Lion provides flexibility that allows customers to seamlessly add or change capabilities with plug-andplay field installable option cards. For more information, visit www.redlion.net/panelselection to select from Red Lion’s range of panel meters.
Proximity Switches from Jayashree Jayashree make Proximity Switches find wide applications in Machine Tools, Foundries, Rolling Mills, Automobiles, Textiles, Pharmaceuticals, Material Handling and all automation systems in general. Proximity Switches of different type are widely used for different applications in various
applications. JAYASHREE ELECTRON has been manufacturing quality Proximity Switches for over 20 years. As one of the largest manufacturers, we offer over 500 models of INDUCTIVE, CAPACITIVE, OPTICAL, MAGNETIC & ULTRASONIC Proximity Switches.
switches. All these models are
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switches carry CSA, CE & UL mark
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June 2016
For more details write to sales@jayashree.co.in and visit www.jayashree.co.in
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Renishaw AMSC to Facilitate Indian Customers’ Journey into AM Renishaw’s new opened Additive Manufacturing Solution Centre (AMSC) at Pune is all set to offer a low risk way to Indian manufacturers for adoption of the additive manufacturing, recognized widely as a transformational manufacturing technology applicable to wide manufacturing segments from component of aircrafts engines to satellite, to even medical field of dental restoration and surgery for facial reconstruction.
Renishaw’s AMSC is designed to offer full local process facilities from design assistance, part build and optimization to post processing such as machining and polishing guided by additive manufacturing expertise from Renishaw. This will provide the customers with process knowledge and confidence prior to investing in this new technology. At the inauguration of the new solution centre Mr. Collins Wells,
Mr. Rhydian Pountney, Director Indian Sales & Operations, Renishaw along with Mr. Marc Saunders, Director- Global Solution Centres, Renishaw opens the AMSC
Deputy High Commissioner of UK in India Mr. Colin Wells had inaugurated Renishaw AMSC at its Pune facility Dy High Commissioner of Britain, appreciated Renishaw’s long term commitment to Indian market and this incredible investment in the new solution centre, mentioning it as a boost to the Make in India programme. He also highlighted Prime Minister’s Narendra Modi’s efforts during his recent UK visit to create new business and social relations between India and Britain. During a presentation on the additive manufacturing, Mr. Marc Saunders, Director- Global Solution Centres, Renishaw elaborated the present scenario, various activities undertaken by
additive manufacturing team of Renishaw and the prospects of Additive Manufacturing Solution Centre. Inauguration plaque was made on built on Additive machine using a SS sub-straight with IN625, build 1mm high fonts. The Invites for the event were built on Additive machine using IN625 with a build time of 4.25 hour per card and weight/volume of 29.3 grams/10.978 cm3, , which was sent to all the invitees. All the attendees at the event were gifted with a Pen drive swivel, which was made on AM machine, titanium metal.
Infineon launches iMotion™ Modular Application Design Kit At PCIM, Infineon Technologies AG (FSE: IFX / OTCQX) launches its iMotion™ Modular Application Design Kit (MADK). The compact and flexible evaluation system provides a scalable design platform for 3-phase motor drives in the range from 20W to 300W. It includes controller and power boards – sensor-less or optionally with sensors. Using the kit, a full functioning motor system will be running in less than one hour, enabling fast time to market. Designers only need a few steps to run the motor: plug the cards into their PC, motor
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and grid, download, install and parameterize the software. Infineon offers four kits which match different motor designs. Every kit includes a control card with debug interface, complete power stage including rectifier and EMI filter. The motor control software is preloaded or available for download, it features an easy to use GUI software for parameterization and tuning. Via standardized M1 20-pin MADK Platform interface connector, various combinations of control and power boards can be realized to best match
different application requirements. The Field Oriented Control (FOC) software supports sensor-less motor control based on the XMC1302 microcontroller. The hardware is also supporting the use of Hall sensors or innovative 3D magnetic sensors. The XMC1302 control card includes a debugger based on Segger J-Link technology. Additionally, the software support for this tool includes an easy to use μC-Probe based GUI. Further application software development can be implemented via DAVE™, Infineon’s free-ofcharge integrated development
environment (IDE), or with major ARM® IDEs, like Keil, IAR or Atollic. Another control option is available with the IRMCK099M, a motion control ASIC with hardwarebased sensor-less FOC control. It comes with a separated bug interface card. Available kits combine the XMC1302 control card with one of four power boards from theμIPM™IRSM836 series or μIPM-DIP IRSM505 series (500V or 250V).
June 2016
Seco Tools Inaugurates New Office & Factory Celebrates 20 years in India Seco Tools India Private Limited, a wholly owned Subsidiary of Seco Tools AB, Sweden located at Koregaon Bhima on PuneAhmednagar National Highway, has completed 20 years of operation in India on May 27, 2016.
on shared values that extend across cultural and geographical boundaries. Seco strives to be perceived by customers, suppliers and employees in a consistent manner, regardless of where in the world you meet the company.
The company inaugurated its new office and factory building on May 27, 2016 at Koregaon Bhima. Internationally acclaimed industrialist Mr. Baba Kalyani , Mr. Lars Bergstrom, President and CEO of Seco Tools, Mr. Andreas Fritz, Managing Director and Sr. Vice President Asia Pacific along with Seco employees and other distinguished guests were present during the event.
“We have been able to live up to the high standards that we and our customers place on us through our shared values: Passion for our customers, family spirit and personal commitment”, says Lars Bergström President and CEO. “These three common values help us make the right priorities and act in a manner that has become Seco’s hallmark for decades” he adds.
Seco is a global business, based
“At Seco, customer relationships have always been a cornerstone of our operations. By choosing Seco, you get more than just a comprehensive portfolio of advanced metal cutting solutions and expert services. You get a partnership based on trust, respect and communication and a team that is always ready to help you gain the competitive advantage.”
Andreas Fritz Managing Director, Seco Tools India
“The shared values are of great importance for the governance of the global operations. Decisions are based on values and goals, which means that Seco, despite its size, can continue to be fast and flexible.”
Lars Bergström President and CEO, Seco Tools “The information age has had a profound effect on the industry. From the need to compete globally to an ever-increasing pace of technological evolution, today’s manufacturers, we as well as our customers, face constant challenges to reduce cost and increase productivity,” says Andreas Fritz, Managing Director, Seco Tools India. Headquartered in Fagersta,
Sweden and present in more than 50 countries, Seco Tools is a leading global provider of metal cutting solutions for milling, turning, holemaking and toolholding. For more than 80 years, the company has provided the technologies, processes and support that manufacturers depend on for maximum productivity and profitability. For more details visit www.secotools.com
Prodaid supplies Vibratory bowl feeder for feeding Bush Prodaid Engineers, the 40 years old vibratory bowl feeder manufacturer from Bangalore recently completed an order for a SPM manufacturer for supplying a vibratory bowl feeder for feeding of Bushes. The bushes were unique in the since that the diameter and the height were the same and
June 2016
hence, orientation was difficult. However, Prodaid provided a unique reverse track mechanism to ensure that only the correctly oriented Bushes were feed forward. This not only resulted in the wrongly oriented bushes being recirculated in the bowl but
also the speed was improved upon. As against the required speed of 30 parts per minute, a speed of more than 100 bushes per minute was observed. Prodaid also provided for an overflow mechanism so that in case the outlet is stopped, the excess bushes fell back into
the bowl. This eliminated the need for a separate sensor for the customer. The bowl was made in stainless steel and PU painted from inside to ensure a very good finish. Model PA-55 was used with a dia 500 mm bowl for this application. For more details visit www.prodaid.com
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MAPAL relies on the Safe-Lock™ system from HAIMER Within a wide range of markets, such as the aerospace industry, cutting tools from MAPAL have successfully established themselves for high-performance machining operations like trochoidal milling. In order to offer users even greater protection against tools being pulled out of the chuck during machining operations, and to prevent damaging single workpieces or the machine itself,
The Safe-Lock™ system from HAIMER is an integrated pull-out protection system for shank tools that combines frictional clamping and form closure. It increases processreliability, enables high material removal rates and provides results that are far better than those achieved with conventional tool clamping methods.
MAPAL is going to rely on the Safe-Lock™ pull-out protection system from HAIMER. The two companies recently signed a corresponding licensing agreement. HAIMER and MAPAL have reached a partnership and licensing agreement. The toolholding specialist from Igenhausen near Augsburg and the precision cutting tool manufacturer from Aalen are combining their strengths to form a new partnership. In the future, they will work strategically closer together on the progression and further development of technologies and their applications in the manufacturing market. The two companies have signed an agreement that has contractually solidified their partnership. “We are proud and happy to have a strong partner at our side in MAPAL that is one of the world’s leading tool manufacturers,” emphasizes Claudia Haimer, managing partner of HAIMER. And the managing partner of MAPAL, Dr. Dieter Kress, is also looking forward to the future cooperation. “We value the highlevel expertise of HAIMER whose innovative solutions in the field of tool holders represent the perfect complement to our high-
tech tools.” Through the agreement, MAPAL has acquired a license to HAIMER’s Safe-Lock™ technology that is patented worldwide.
Dr. Jochen Kress, member of the senior management of MAPAL, Dr. Dieter Kress, Managing Partner of MAPAL, Claudia Haimer, Managing Partner of HAIMER and Andreas Haimer, Managing Director of HAIMER.
“The SafeLock™ system has proven itself both in the market and during our in-house trials. Consequently we have decided to use this leading system,” Dr. Jochen Kress, Member of the MAPAL Senior Management, says. “It is very frequently used for modern machining strategies. With Safe-Lock™ the productivity and tool life can be significantly increased,” Andreas Haimer, Managing Director and President of the HAIMER Group,explains .When it comes to high-speed cutting, absolute safety is especially crucial. Considering the high value of the single workpiece or an unmanned production, scrap parts and machine downtime have to be avoided in order to guarantee process reliability. Through
special drive keys in the tool holder and grooves in the cutting tool shank, the Safe-Lock™ system from HAIMER ensures high accuracy frictional clamping with the security of a form fit between grooves on the cutting tool and the drive keys in the chuck. This prevents the cutting tool from turning or being pulled out of the chuck during machining. As a first step and starting in October, MAPAL will be offering selected cutting tools for highperformance machining with the Safe-Lock™ shank.As a second step, the MAPAL hydraulic chucks will follow and also be designed for this type of pull-out protection.
Dorner Announces Acquisition of Geppert-Band Dorner Holding Corp., the parent company of Dorner Mfg. Corp., has announced the acquisition of Jülich, Germany-based Geppert-Band a leading European manufacturer of belt and modular belt conveyors. Dorner Mfg Corp is an industry leader in the design, applications, manufacturing and integration of precision industrial and sanitary conveyor systems. The addition of
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Geppert-Band expands Dorner Holding Corp.’s geographic coverage and continues its strategy of international expansion. In late 2015, Dorner opened an office in Burlington, ON, Canada and acquired Penang, Malaysia-based, FlexMove; a manufacturer of flexible chain conveyors. “As we continue to see growth internationally the addition of
Geppert-Band allows us to better serve the European market,” said Terry Schadeberg, president and CEO, Dorner Mfg. Corp. “Its product offering and capabilities complement our existing strategy, and we’re pleased to welcome them to the Dorner family.” “We share a lot of similar core values, including a commitment to providing fast deliveries and
quality customer service,” said Thomas Blesinger, president, Geppert-Band. “Dorner has a strong reputation in the conveyor market and we’re looking forward to providing our customers with an even wider variety of solutions.” For more details write to salesindia@bastiansolutions. com or visit www.bastiansolutions.com
June 2016
SPP Mena Expands to Egypt
Motor Driven UL Listed fire-fighting pump supplied to a resort
UL Listed Diesel Engine Driven firefighting pump set for an industry under testing SPP Pumps MENA LLC has been successful in getting various orders for the valueadded products and services. SPP MENA has received an important order from a private investor in Agriculture sector, “Lehaa Group”, to conduct an “Energy Audit” on the irrigation pumping equipment at their Toshka Farm. It was a challenging task especially on the intake pumping system because of the complexity that existed at site. However, SPP MENA conducted an extensive energy audit of the existing system. The data obtained from the audit was compiled, analyzed and energyefficient pumping solutions were recommended. The detailed presentation, given to the Lehaa management, was appreciated, and the customer was happy to see significant reduction in the energy expenses once the new system, recommended by the company, was implemented.
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Impact of the Project: Value-added services like Energy Audits could support the company’s esteemed customers in understanding the operational efficiency of the existing system and benefits of implementing energy-efficient pumping solutions. The Lehaa Group is inclined to accept and implement KBL’s recommendation. In addition to this achievement, SPP MENA has also received prestigious orders for the supply of large Mixed Flow pump sets for irrigation projects and Process pumps for Salt & Mineral industry. The company has successfully executed assembly, testing and packaging of UL listed fire-fighting pump sets, both engine driven and motor driven pumping units with controllers and allied accessories. SPP MENA supplied horizontal Split casing pumping units for a HVAC project in Egypt.
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THE LAST LEAF Dear Readers, The Indian Space Research Organisation (ISRO) last month, successfully tested India’s first indigenously made Reusable Launch Vehicle (RLV), that is capable of launching satellites into space and then re-enter the Earth’s atmosphere. Launched from Sriharikota in Andhra Pradesh, the winged flight vehicle glided back onto a virtual runway in the Bay of Bengal after a 10-minute mission. (Courtesy: inshorts.com) The world’s first 3D printed building, a single storey office spread across 2700 sq. foot, opened in Dubai a few weeks ago. The arc-shaped office building used a 20-foot tall 3D printer and a special mixture of cement to be built. Located near Dubai International Financial Center, the building was complete in 17 days at a cost of about $140000. The advancements in the wearable technology have established the need for a durable and robust electrical design and have prompted research for the development of self-healing electronics.Self-healing materials are the ones that have the ability to naturally repair themselves with little to no external aid, once they have been subjected to extreme physical deformation like being cut in half. However, the world of electrical engineering is at the brink of an enormous technological change. Qing Wang, Professor of Materials Science and Engineering at Penn State, and his team have successfully created a new electrical material that can automatically heal all of its properties. The material itself comprises of boron nitride nanosheets added atop a base material of plastic polymer. Boron nitride nanosheets are impervious to moisture implying that the wearables fabricated from this material can be used while swimming etc.The most extraordinary feature of the material is that it retains its self-healing properties even after being broken multiple times – in fact, once broken, the material restores all the properties required for use in the wearable as a dielectric like mechanical strength, breakdown strength to protect against surges, electrical resistivity, thermal conductivity and dielectric, or insulating properties. Therefore, the future hints of more durable and sturdy electrical design. (Courtesy: wonderfulengineering.com) The search for more sustainable, green architectural materials has led the scientists to develop a transparent version of the natural wood; “the invisible wood” flaunting superior qualities.This is done by a team led by Dr. Liangbing Hu from the Department of Material Science and Engineering at University of Maryland. The invisible wood comes with enhanced strength and thus, can easily replace the hazardous material for the environment like plastics. Apart from that, this wood has the potential to bring about a paradigm shift in the field of design with its breakthrough characteristics. The manufacturing involves removal of an organic substance named lignin chemically, to strip wood of its entire colour. Next, the wood channels are injected with an exposy to ensure that the makeup of the cellular nanofibers remains intact, thereby making the walls of channels to strengthen them and make them robust. The biodegradable nature of transparent wood makes it more environment-friendly than the plastic, as well as a good replacement for glass that is used in architecture today. As a natural insulator, wood could offer better thermal insulation than glass. The transparent wood offers high optical haze enabling it to be idea for use in solar cells for conversion of solar energy into the electrical energy. (Courtesy: Advanced Materials) Consciously, we are making an attempt to create a positive outlook around us aimed at facilitating to stimulate and energise our industry atmosphere. Your feedback in this regard is welcome, to enable us improvise our channel of information and motivation to our readers for a better tomorrow. Till then, Happy Technology! Manoj Kabre Member, Editorial Advisory Board
June 2016
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KEMPPI INDIA PRIVATE LIMITED
Lakshmi Towers, 2/770, Kazura Garden, !st Street, Neelankarai, Chennai- 600041 Phone: 044-45671200 Email: sales.india@kemppi.com 100
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