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Volume 13 | Issue 12 | June 2017 | `150

empowering engineering excellence

GREEN

MANUFACTURING Industry Environment Face-off Is Traditional Is Environmentalism Traditional Fading?

Environmentalism Green Fading? Manufacturing A Way towards Sustainability

Proactive Industry Sustainable Industrial Growth Rakesh Kumar

Director, CSIR-National Environmental Engineering Research Institute


3 June 2017

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Industry and environment cannot go hand in hand, or so, at least, do we tend to believe. It is, indeed, when one grows at the cost of other. Immediate and incremental benefits reaped out of the rapid industrial growth have been too strong that overlooking the degradation of environment was too obvious.

siji@martinfotech.in

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Correspondent

Arnab Mondal

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Digital Marketing

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Harish Pant

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Managing Director Hampson Aerospace

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Venkitachalam V

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Only when the environmental degradation reached a precarious stage, we the beneficiaries of industrial growth started noticing it. Soon ‘Sustainability’ and ‘Sustainable Development’ became words of prominence for us. It is with this view that the MART spoke to an eminent exponent of environmental science and technologies, Dr. Rakesh Kumar, Director, CSIR-NEERI. In his enlightening interview, Dr. Kumar opines that environment has always been at the bottom of industry’s priority list as compared to other performance areas, suggests how industry and competent government bodies can work in tandem to curb environmental impact, and how NEERI is making efforts in this direction. The cover story on industry environment face-off cites how environmental rules have been tweaked or violated to maximize economic benefits of industry over the years. The article on traditional environmentalism seeks to delve into the depths of old religious practices and their scientific reasons which were in sync with balance of nature. Today, these have lost their actual meanings and importance or are ‘GREENMANUFACTURING’ simply discarded in face of technological advancements. MANUFACTURING, AS ONE Alternative 2017, a debutante event with a noble aim of creating awareness OF THE MAJOR INDUSTRIES about the depletion of conventional WORLD OVER, HAS A SIZEABLE energy resources and need for alternative energy, has been covered in SHARE IN THE DEGRADATION the event section of our June issue. OF ENVIRONMENT. THE SECTOR Green manufacturing is not just limited to adopting a few technologies for HAS TO REALIZE ITS SHARE OF reducing emission. Rather it requires RESPONSIBILITY TOO. a holistic approach and changes at multiple levels to actually become environment friendly manufacturing business. Venkitachalam V in his article has discussed these as much as he has discussed the notion of Indian companies act from pressures and not voluntarily to follow environmental norms. Green practices for environment protection, are equally important for brand image and long term benefits for a company in the eyes of its employees and customers. In his article, Sanjeev Himachai analyses how employees in an organization can be encouraged to follow environmental rules and regulations and contribute to nature. Besides, the June issue has regular columns on other areas of manufacturing along with a special feature Theory of Constraints by Praddep Kumar. We hope you’ll enjoy and encourage our effort.

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CONTENTS #C OVE RSTO RY 08 Industry Environment Face-off

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12 Is Traditional Environmentalism Fading? 14 Think Nature, Think Alternative! 16 Green Manufacturing A way to Wards Sustainability 20 Environment Training and Green Programmes for Employees in Manufacturing 22 Save Water, Save Lives, Save Future!g

24 #ONFAC E 24 Proactive Industry Sustainable Industrial Growth

#C OLUMN 28

Innovative ways of CSR

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Intelligent Manufacturing

36

Optimize Invetories with right control methods

#SU C C ESSST ORY 44

Welding Wonder

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#p o st ev en t rep ort 48

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The Rosemary Kenned Incident

The Green Era

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#greenmanufacturing

Industry Environment Face-off Arnab Mondal arnab@martinfotech.in

Regimes change but instances of tweaking rules and regulations remain constant. More so, when it comes to one of the persistent issue – environment vs. industry. While role and need of industrialization cannot be denied, growth of it in an unmindful and rapid manner makes it hazardous to environment. Those who should bring in a concerted effort to find solutions prefer to walk their comfort ways. And sustainable industrialization, remains far cry. 8 www.martupdate.com

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n UPA-era crisis wouldn’t be improper to begin with: a Ministry of Environment and Forests (MoEF) committee on the Posco project in Odisha recorded “serious lapses and illegalities” as per the Environment Impact Assessment Notification, 2006 and the majority of members recommended revocation of clearance granted in 2007 for a minor port and steel plant. The Ministry had to subsequently ignore the report and conditionally clear the project. Mr. Jairam Ramesh, then Minister of MoEF planned to strike the right balance between GDP growth and conservation, reduce carbon emissions without sacrificing growth — and vitally, to steer the MoEF away from the path of rubberstamped environmental clearances. But the sheer pressure on the Ministry,

including from other Ministries, proved so hard that it had to show causes why it was implementing fundamental laws such as the Forest (Conservation) Act. Environment and industry take such polar positions that often involve clashes of interests of the presiding ministries. Globally, this clash of interest has often taken proportion of debate over the existence of such a clash at all. Despite scientific evidences showing anthropogenic role on climate change, which includes industrial development among other, industry still casts aside climate change as a hoax. If they admit climate change, they deny role of humans for climate change. Even as the argument is proved wrong, the next of denial comes by playing down the climate as a serious problem at all.

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The developing nations of the world cannot be expected to share the green concerns of the developed nations particularly while these countries have to face dire poverty and are engaged in a battle for survival. Scientists, in the United Nation’s International Panel on Climate Change (IPCC), reported with “extreme confidence,� or 95 per cent certainty, that humans are the dominant cause of global warming. The report projected a global average temperature rise of 0.3 to 4.8 degrees Celsius by the end of the century, and a seal level rise of 10 to 32 inches. Pro Industry Approach Advancement of the society is undeniable with the technological advancements due to industrialization. In this regard, many argue that it is important to take care of the millions of people who are starving instead of spending resources on saving the natural resources. The developing nations of the world cannot be expected to share the green concerns of the developed nations particularly while these countries have to face dire poverty and are engaged in a battle for survival. The emphasis of the industrialized world on green issues holds the developing countries back. The reason is that it is considered as interference in the internal affairs of these countries and at the same time it also increases the divide that exists between the first and third world countries. There are many who believe that the emphasis 9 June 2017

on environment is only an attempt to prevent the possible economic competitors. In this regard, an example is given of the high tariffs imposed by the US and the European Union on the products that are made cheaply in the developing countries and can be sold in Europe or America. By restricting the development of profitable but polluting industries, these countries are forcing developing countries to remain economically undeveloped. In this regard it can also be argued that industrialization economic development is necessary for fulfilling the basic requirements of the increasing population of the developing countries. Another ironical situation of industrialization is that although it appears that the world will become a better place if all the countries of the world follow the strict environmental rules however the reality is that a number of these rules are not in the interests of some of the countries of the world. For example, the iron and steel works in China, which is a major source of pollution, also provides a large scale employment to the people. Therefore the equal application of such strict environmental laws may result in creating barriers in the economic progress of some countries and may also result in causing political instability. Besides, it is not necessary in all cases that rapid industrialization places more pressure on the environment. Due to the latest scientific developments, the industries have become much less polluting and energy efficient as compared to the past. Similarly the developing countries can also learn lessons from the environmental mistakes that have been made by the developed countries of the world after Industrial Revolution as well as the industrial disasters that took place in Russia and China. For example, due to the recent scientific developments, much less water, power and raw material is being used by the new steelworks and as a result, much less pollution is being treated as compared to the traditional industries. Similarly, nuclear power plants can provide much more energy as compared to the thermal power plants and at the same time, the nuclear plants contribute

much less in global warming. In the same way, the alternative sources of energy like solar power, wind and hydropower are also being explored for rapid industrialization. It is not correct for the rich and developed countries to require that the poorer nations of the world should also make the conservation of environment their priority. Now, when these countries have become richer, they have become more concerned regarding the environment as now they can afford to do somethi ng regarding this issue. On the other hand, the conservation of environment can wait till the developing countries also become rich. Balancing Act At the same time, there are many who prefer the protection of the environment as against industrialization. These people believe that huge natural resources have already been destroyed and wasted. These people claim that environmental damage is also related to poverty. The advocates of environmental protection are not against economic development that has the potential to make the life of a lot of people better. However they insist on achieving sustainable development that is able to combine environmental protection with economic growth and social justice. For example, the companies in the developed countries are already paying the higher costs of production as a result of the environment protection rules enforced in these countries. It will be unfair for these companies if they have to complete with the codes that have been produced in developing countries at a lesser cost but by damaging the environment. Due to pollution, countries are losing more than they are gaining as a result of industrialization. A perfect example in this regard can be given of China. Serious air and water pollution has been caused the country after two decades of unrestricted economic development. As a result, health problems have increased and the farmers also have to face losses worth billions of dollars every year. In this way, unrestricted economic development is not only harmful for the environment, it is not economically

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beneficial also. Situation Upfront The question how India is going to strike a balance between industrialization and environment – going by the eagerness of the Narendra Modi government to promote industrialization and ensure high economic growth – is gaining traction. India, being one of the world’s largest greenhouse gas emitter – though beset by a high population growth rate – has one of the lowest per capita rates of greenhouse gas emissions, about roughly 1/20th of the US and Australia. Millions of people in small islands, least-developed countries, landlocked countries as well as vulnerable communities in Brazil, India and China, and all around the world – are suffering from the effects of a problem to which they did not contribute. The argument for industrial development for countries such as Brazil and India are thus compelling. The one-third of the world’s population lives in the most heavily industrialized and developed nations accounting for 85 percent of the global personal income and a like fraction of the annual use of global resources. The people living in the less industrialized or developing nations must apportion the remaining 15 per cent of global income and resource use among two-thirds of

the world’s population. The result is an unconscionable prosperity for the majority of people in the developed countries and crushing poverty for the majority in the developing or third world countries. The prosperity of the developed countries has been built on exploitation of the richest soils, the most accessible fossil fuels, and the most concentrated mineral deposits of the entire earth. As they now struggle to maintain and even expand their massive consumption from a resource base of declining quality, the developing countries, as they try to follow the same path to economic development, they remain laced with barriers as rapid industrialization based on the expensive resources that remain, is probably foredoomed by enormous if not insurmountable economic and environmental obstacles. Therefore, however much developing countries clamour for the natural right to seek industrial development with greater rapacity to catch up with the industrialized west; odds are heavily stacked against the environment. Thus, if all the people in India and China seek to own passenger cars at the rate of the US or own as much air conditioners, that would be an environmental disaster. Is there no middle path between the industrial growth and environmental activism? The answer lies probably in sustainable development of industry

and protection of environment in the process. A whole range of environmental protection legislation including the Environment Protection Act, the Wildlife Protection Act, the Forest Conservation Act, and the Water and Air Pollution Act has come under fire possibly in the plea that they are major irritants in the path of India’s industrial growth. Take the instance how the ruling NDA steered clear of the direction in September 2013 by the UPA’s environment ministry to the Central Pollution Control Board to reassess the Comprehensive Environmental Pollution Index, an important criterion for project clearance, while keeping intact the moratorium on new industries in critically-polluted areas. The ministry has lifted the moratorium in eight critically polluted areas – Ghaziabad, Indore, Jharsuguda, Ludhiana, Panipat, Patancheru-Bollaram, Singrauli and Vapi. The report of the high-powered committee to review six top environmental laws of the country, headed by former cabinet secretary TSR Subramanian, prepared in just three months, justified the hyper-ventilation of the NDA ministry, on the grounds of “doing business easier in the country”. India cannot be denied its right to industrial growth but that should not happen at the cost of our environment in view of the larger and the more entrenched costs it might impose on the economy.

United Nations’ Panel on Climate Change projected a global average temperature rise of 0.3 to 4.8 degrees Celsius by the end of the century, and a seal level rise of 10 to 32 inches. 10 www.martupdate.com

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11 June 2017

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#greenmanufacturing

Is Traditional Environmentalism Fading? Nishanshi Shukla martupdate@gmail.com

A

Do you go away from your culture when you gather more knowledge, or you lose knowledge when you go away from your culture? As complex as it may seem, this question lies at the roots of all the advancements and all the catastrophes that human being has created for himself.

major part of the phenomenon of traditional environmentalism is formed by Traditional Ecological Knowledge (TEK). According to the Secretariat of the Convention on Biological Diversity (CBD Secretariat) Traditional Ecological Knowledge is “Knowledge, innovations and practices of indigenous and local communities around the world.

Environment degradation is one such catastrophe that mankind is continuously facing, and certain environmentalists claim that it can be tackled by following the age old traditional practices given to us by the Indian culture; i.e. by the path of traditional environmentalism. But is it so?

Developed from experience gained over the centuries and adapted to the local culture and environment, traditional knowledge is transmitted orally from generation to generation. It tends to be collectively owned and takes the form of stories, songs, folklore, proverbs, cultural values, beliefs, rituals, community laws, local language, and agricultural practices, including the development

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of plant species and animal breeds. Traditional knowledge is mainly of a practical nature, particularly in such fields as agriculture, fisheries, health, horticulture, and forestry.� Traditional Environmentalism is following and making use of this traditional ecological knowledge with the motive of conservation and preservation of the environment. In Indian culture, they are translated into customs and traditions in some form or another. While most of these started with a scientific concept and a logical reason behind them; in current times they have taken the face of practices which are considered merely orthodox or boring. By taking a closer look into the nuances of a few practices, we can decipher the scientific thought behind them. In Vedic culture nature is considered to be an integral part of 12 June 2017


When the culture has the knowledge, the need is of awakening instead of ignoring. human life. According to Isvarakṛṣṇa’s Sankhya-Karika, an old Hindu philosophy of metaphysical dualism, the world exists because of two elements, namely Purusa (pluralistic person) and Prakriti (singularistic nature); a balance in both is what enables the creation and smooth functioning of this entire world. Probably, in order to imbibe this philosophy and generate a culture inclined towards the preservation of cosmic balance between Purusa and Prakriti, Purusa was said to be the manifestation of Shiva and Prakriti was said to be the manifestation of his wife Shakti (Parvati). But today, while Shiva and Parvati are worshipped, the hidden meaning behind them is overlooked. The same phenomenon is seen in various other natural elements. While the river Ganga is called Ganga mata (mother Ganges) and worshipped by words like Har Har Gange (Hail Ganga); it is polluted, dirtied and ruined, but scarcely preserved. While Peepal tree (Ficus Religiosa) is worshipped by being considered as the abode of Lord Vishnu, the hidden message of importance of oxygen given by trees and thus established necessity of tree plantation and preservation is comfortably ignored.

While Surya Deva (Sun God), Vayu Deva (Air God), Varun Deva (Water God), Bhoo Devi (Earth Goddess) etc. are still devotedly prayed, they are not devotedly preserved. Instead these natural elements are exploited by continuous and incremental pollution. During the festival of Diwali, while the original practice was that of lighting diyas (earthen lamps), and the thought behind it was to purify the air and keep away the mosquitoes and insects roaming in the atmosphere after monsoons; the practice has now taken a toll by excessive bursting of crackers, contaminating air more than purifying it. In the ten day long festival of celebrating Lord Ganesha, the last day is that of Ganesh Visarjan wherein after days of worship, the idol is immersed in water. Originally these idols were made of clay dug out from ponds/lakes, in order to make more place for rain water conservation. These clay idols were then worshipped with natural herbs, which when immersed in river/sea water would help the marine life, as their bearer clay would dissolve easily. Also, this festival symbolized the importance of worshipping natural elements like soil, and giving back to other natural beings. But today, the idols are made from harmful materials like plaster of paris, which not only harm natural water, but also cause damage to the marine life. Similar story is with the practice of havans (holy pyres), where the smoke from the offerings made to the pyre purify the air, and the mantras (hymns) create positive vibes and optimistic atmosphere; the practice is now majorly looked upon as overtly religious, boring, and outdated.

Aforementioned practices, along with innumerable others under traditional environmentalism were developed owing to years of knowledge and research by the Indian sages (scholars); but its face is changing. Major reasons of the traditional environmental practices becoming boring or seemingly uninteresting to humans can be attributed to factors like changes in lifestyles and food habitats owing to modernization, occupational shifts from farming and agriculture to modern hi-tech jobs, hype around the western cultures, non-communication of reasons behind the faith in cultural practices and resulting ignorance towards blind faith, erosion of reading of ancient texts and writing in vernacular languages, migration of young generations away from their roots, forest degradation, and others. It can also be attributed to the modern human psychology of avoiding things which don’t guarantee immediate profit or fun. The need of today is to translate the meanings behind the traditional practices as promotional tool of the custom, instead of the custom itself. This cultural knowledge should also be incorporated in the formal educational system. The solution to the problem of environmental degradation was formulated around 2000 years ago in ancient scriptural text, the Isopanishad, which says, “This universe is the creation of the Supreme Power meant for the benefit of all his creation. Each individual life-form must, therefore, learn to enjoy its benefits by forming a part of the system in close relation with other species. Let not anyone species encroach upon the other’s rights.” Is it wise not to follow it?

Today, the Ganesha idols are made from harmful materials like plaster of paris, which not only harm natural water, but also cause damage to the marine life. 13 June 2017

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#greenmanufacturing

Think Nature, Think Alternative

Arnab Mondal arnab@martinfotech.in

Alternative 2017 was a highly successful environmental event with innovative ways and illuminating ideas, creating awareness among people about their reasonability to save the nature. Along with other awareness programmes, ‘Alternative 2017’ also witnessed a special musical performance by Grammy winner Ricky Kej and sand art by Raghavendra Hegde. On this occasion 400 saplings were distributed among participants.

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lternative energy sources - solar and wind and such – are no longer an option, they have become necessity in the face of depleting conventional natural resources and consequent carbon footprint. It is with a view to create this awareness among the people ‘ALTERNATIVE 2017’ was organized. The one-day event organized on 2 June in at New Horizon Engineering College in Bengaluru by UV Green Energy, green energy start-up, in the lead up to the World Environment Day 2017.

of Bengaluru, and encourage them to choose alternatives. Instead of using natural resources, people need to bring in change in their lifestyle, and should opt for sustainable forms of energy like wind, solar and such,” Vinay Shinde, head of UV Green Energy and organizer of the event said.Luminaries and experts discussed environmental issues and enlightened with innovative ideas in the course of this day-long conference. The event covered various aspects of the environment including tackling garbage disposal, water management, protecting the green cover and more.

The event proved to be a highly successful in its first edition with large participation of citizens, environmentalists, NGOs, CSR teams from corporate houses etc. among its target group. “Through this initiative, we wanted to create more awareness about the environment among the citizens

Among the participants were Rajendra Singh, who is well-known as the ‘Waterman of India’, and Varadaraj Rangarajan, who is called the ‘Plastic Man of India’. Varadaraj, who is also the brains behind roads made of plastic, urged people to ‘use plastic for the roads and not on the road.’ 14 June 2017


Alternative 17 is the stratagem of Mr. Vinay Shindhe, CEO-UV Green Energy. Excerpts from the conversation:

What was the driving motto behind ‘Alternative 17’? UV Green Energy is start-up green initiative firm, primarily focusing on CSR framework and competency development to the corporate world in the field of environmental solar projects and solutions.

Could you share with us some of the innovative and alternative ideas for protection of nature that were discussed or unveiled at the event?

What were the target groups of the event? And how spontaneous was their participation?

As for Green Talk Series the various topics for the discussion were... • ‘River Rejuvenation, Making Drought free Karnataka’ by Dr. Rajendra SinghWater man of India, • ‘Innovative Bio Gas Production’ by Mr. Sanjay Kumar Patel, CEO, SP Ecofuel • ‘Biotech Solution for Global warming’ by Mr. Sampath Kumar, CEO, Nualgi • ‘Plastic Waste Management’ by Dr. R. Vasudevan- Plastic Man of India • ‘Widening the way of Organic Farming’ by Mr. H. R. Jayaram, CEO, The Greenpath • ‘Corporate Responsibility for sustainable development of villages’ by Dr. Ashok Das, CEO, Sunmoksha • ‘Urban Lakes Rejuvenation for water security’ by Dr. T. V. Ramachandra, IISc • ‘Citizen Role to Greener Bengaluru’ by Mr.Clement Jayakumar, Whitefield Rising • ‘Future of Electric Mobility’ by Mr.Kartik Gopal, Head-strategy & Business Planning, Mahindra Electric • ‘Save water Save Bengaluru’ by Mr. A. R. Shivkumar, Principal Scientific officer, IISc

Targeted intended group was corporate employees, CSR & sustainability team, NGOs, institutions & community. The event witnessed good participation from corporate and institutions.

Do you plan to emulate the strategies adopted for Bengaluru in other Indian cities as well which are equally or even more in the perils of environmental degradation?

Did the event focus on the role of industry which is the biggest consumer of conventional energy and contributor to carbon footprint?

After the successful event, we received feedbacks from industrialist & corporate as part of their sustainability program that ALTERNATIVE concept should reach to every major Indian city to connect the people to nature by ways of ALTERNATIVE.

An initiative of ALTERNATIVE 17 is the education program of campaign and awareness to the corporate world, NGOs, institutions by way of environmental music consciousness, green talks from contributors to sustainability, nature art and few niche product exhibitions. We feel every social entrepreneur should have larger objective of social need of the development. This is the 1st initiative of 2 year old start-up firm UV Green Energy, connecting people to the nature by celebrating World Environment Day with own funding and taking the collaborative approach from various partners.

The focus is more with bringing awareness to every citizen of the country to GO WITH ALTERNATIVES to protect the planet and our mother earth with the concept of greener together. Our focus is more towards highlighting alternative options to bring the change in every part of our life cycle including the organic food to water, waste plastic and alternative energy.

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This awareness was largely needed to the corporate world CSR teams, so that corporate social responsibility team should brainstorm and come forward for protecting the nature and alternative source to reach social need way of CSR funding.

“We feel every social entrepreneur should have larger objective of social need of the development.” -Vinay Shindhe CEO-UV Green Energy

Inaugral ALTERNATIVE 17 – Lighting the lamp by WATER MAN OF India ( Jal Purush) –Mr Rajendra Singh & Namma Bengaluro Foundation CEO –Mr Sridhar Pebbishetty & Vinay Shindhe ( CEO –UV Green Energy)

Grammy Winner Ricky Kej & Team Performed ALTERNATIVE 17 on the occasion WED. Vinay Shindhe ( CEO UV Green Energy ) & Mahesh Babu ( Mahendra Electric CEO

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#greenmanufacturing

Green Manufacturing A Way towards Sustainability

Venkitachalam V abijitindia@yahoo.co.in

Green Manufacturing includes a holistic approach towards adopting green initiatives throughout the business from green energy use, green product development and green process chain. It offers benefits in terms of enhanced brand value, customer loyalty, better tax traction etc. while also fulfilling the environmental commitment for a company. In India, companies are still primarily driven by ‘RoI’ and ‘regulations’ while adopting green initiatives.

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G

reen Manufacturing (GM) is also known by different names viz. clean manufacturing, environmentally conscious manufacturing, environmentally benign manufacturing, environmentally responsible manufacturing, and sustainable manufacturing. GM is about the techniques, policies, and procedures a firm uses to create manufactured products, that use process that minimize negative environmental impacts, conserve energy and natural resources, are safe to employees, communities and consumers and are economically sound. GM focuses around minimising environmental impact by reducing toxics, waste, pollution, optimising use of raw material, and energy. The society’s rising concern for Green can be grouped into three broad categories – (a) Rising emissions and associated

climate change, (b) Fast depletion of scarce natural resources and (c) Growing waste generation and pollution. Being a green manufacturer means being efficient with the ways you manufacture, saving energies, recycling, and being environmentally aware of your footprint. When a business makes the decision to become a green, or environmentally friendly, manufacturer, it consciously decides to promote certain values. Ever since Industrialization, manufacturing of various goods exploited our natural resources, depleted them without thinking of future implications and polluted environment in various forms. GM is a manufacturing mode with full consideration of resource consumption and environmental impact which focuses at minimizing the environmental impact 16 June 2017


and maximizing resource utilization during the whole product life cycle design, manufacturing, packaging, use and subsequent disposal or recycling along with making enterprises harmonize the economic benefits with that of environmental benefits. Apart from efficient use of inputs and reducing wastes, GM also creates higher environmental awareness among the customers and at the same time shows the company as a propagator of green initiatives improving its brand image among the customers. Many of us think that green production simply entails instituting pollution controls or recycling programs while manufacturing goods. The reality, however, is that Green production focuses upon three fundamental goals: 1) minimize emissions, effluents, and accidents; 2) minimize the use of virgin materials and non-renewable forms of energy; and 3) minimize the life-cycle cost (cradle to grave) of products or services seek to minimize the impact of the manufacturing process on the environment at every stage. Growing concerns over depletion of forests and other natural resources, and environmental degradation created by mining and fossil fuel production. Reliance on recyclable or renewable materials, new energy and material conservation initiatives,

GM is about the techniques, policies, and procedures a firm uses to create manufactured products. and “replenishment” programs (such as forest replanting programs) have all been touted as effective tools in establishing processes that do not unduly harm the environment focuses on profitability through environmentally friendly operating processes Manufacturing companies can address these concerns by focussing on three areas: 1. Green energy - Green energy involves production and use of cleaner energy. This is the first and most obvious step given the dependence of industry on energy. Green energy includes both deploying renewable energy sources like CNG, wind, solar and biomass, and achieving higher energy efficiency in operations. 2. Green products - Developing greener products is the second step in this transformation. ‘Recycled’, ‘Low carbon

footprint’, ‘Organic’ and ‘Natural’ are becoming popular buzz–words which are associated with Green products. Developing Green products can often mean higher costs. However, by developing Green products that are sought by consumers, and effectively marketing them, companies can derive additional volumes and price premiums, which can offset their cost of development. 3. Green processes in business operations - The third area is implementing Green processes in operations. This entails efficient use of key resources, reducing waste generation through lean operations, bringing down the carbon foot–print and conserving water. Employing Green processes improves operational efficiency and lowers costs. A number of companies have started adopting Green initiatives as an integral part of their operations. These initiatives are driven by five factors (i) Rising energy and input costs. (ii) Growing consumer pull for Green products. (iii) Increasing regulatory pressures as policy makers introduce new and stricter environmental and waste management laws. (iv) Technological advances which open up new attractive business opportunities. (v) The need to enhance competitive differentiation, particularly for first movers or those who are able

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Raytek, Ircon and Datapaq – Together we are Fluke Process Instruments www.martupdate.com 17


Companies that wait in adopting Green manufacturing until they are forced to change often find themselves in an expensive, lastminute scramble to meet the requirements.

to break the compromise between short–term higher costs and numerous benefits (eg: brand premium, new customer segments). Green manufacturing involves transformation of industrial operations in three ways: (1) using Green energy, (2) developing and selling Green products and (3) employing Green processes in business operations. Even in tough market conditions, the business case for Green remains compelling. There is greater recognition of the imperatives of becoming Green and understanding that Green has to address all three areas – Green energy, Green products and Green processes. However, companies face challenges on various fronts, most critically in providing leadership for such an effort. Balancing People, Planet, and Profit is the Challenge of Green Manufacturing. Manufacturing companies that adopt Green practices benefit not only through long–term cost savings, but equally importantly, from brand enhancement

Manufacturing companies that adopt Green practices benefit not only through long–term cost savings, but equally importantly. 18 www.martupdate.com

with customers, better regulatory traction, greater ability to attract talent and higher investor interest. However, these benefits require a long term commitment and making tradeoffs against short term objectives, as the economics of Green manufacturing is still evolving and not well understood as yet. Some of the benefits of embracing sustainability and Green Manufacturing are – (i) Reduce energy-related costs – for eg. use of Solar and wind energy, switching to energy-efficient lighting (ii) Attract new customers and increase sales - Consumers are more conscious of the environment, and making improvements will strengthen your reputation (iii) Tax Incentives from Government (iv) Boost workforce morale and innovations (v) Societal impact by implementing changes, you will have a smaller carbon footprint and reduce the number of toxins released into the atmosphere. Future generations ultimately benefit from improved air and water quality, fewer landfills and more renewable energy sources. 4Rs (reduce, reuse, recycle, remanufacture) is slowly being accepted and adopted as the model of growth and sustainability the world over. Green manufacturing in India is at the take–off stage. While there has been significant policy development and adoption by the manufacturing industry in the area of Green energy, there is substantial scope on both the policy front and its adoption in the areas of Green products and Green processes. Successful transformation into Green manufacturing will bring tremendous benefits, both tangible and intangible, for the nation and the business community.

The manufacturing sector has been one of the largest single contributors to environmental pollution. Over the last decade, there has been an increase in the adoption of green technologies; however, it is still largely driven by ‘return on investment’ and ‘regulatory requirements’ as the key evaluation criteria. India Green Manufacturing Challenge (IGMC) is an awarding platform that is designed to recognize manufacturing firms that have shown consistent progress in improving sustainability factors associated to a manufacturing facility. List of few Indian companies who adopted green manufacturing practices and is deploying sustainability - VE Commercial Vehicle (VECV). Pithampur, Larsen & Toubro Rubber Processing Machinery in Kanchipuram, USV, a pharmaceutical company at Baddi, Himachal Pradesh, Bharat Petroleum Corporation Ltd. (BPCL) Mumbai refinery and JK Tyre Industries Ltd. Chennai tyre plant. Companies that wait in adopting Green manufacturing until they are forced to change often find themselves in an expensive, last-minute scramble to meet the requirements. As a result, they end up throwing more money at the problem for a less effective solution than their more proactive counterparts. Green manufacturing is not an option, but a necessity for our well-being and survival. “When a business makes the decision to become a green, or environmentally friendly, manufacturer, it consciously decides to promote certain values.” “Many of us think that green production simply entails instituting pollution controls or recycling programs while manufacturing goods.”

18 June 2017


19 June 2017

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#greenmanufacturing

Environment Training

and Green Programmes

for Employees in Manufacturing

Sanjeev Himachali sanjeev.himachali@gmail.com

People were blinded by the glitter of development with Industrial Revolution, so much so, that impacts of unbridled industrial growth on environment remained unnoticed, until environment reached a precarious stage. For people in an industrial organisation, creating awareness about environmental laws and regulations, and following some basic rules, guided by HR professionals, can be a good ploy to the ultimate goal of environmental protection. 20 www.martupdate.com

I

n our science textbook of 9th grade (CBSE Syllabus) we had a chapter on Environment Pollution. It was the last chapter of the book. Our teacher told us to do self-study without investing too much time on it as only one question of two marks was expected to come in the exam from that chapter. Now, it’s been close to three decades since then and, guess what? Environment pollution is still the least important chapter in our lives. It is given least weightage. With the dawn of the industrial revolution, a global economy has emerged, and our population has grown exponentially. With coming of the Industrial Revolution, humans could advance further into the 21st century. Technology developed rapidly, advanced science crept in giving wide way to manufacturing. The changing phase brought yet another effect in the form of Industrial Pollution. Factory pollution

is often assumed to be smokestack emissions, but it pollutes water and land as well. Once pollutants enter the atmosphere or the water system, they can spread far and wide beyond the factory. Factories contribute to water and land pollution by acidifying rain, chemical spills and disposal of toxic waste. It is estimated that about 50% of pollution is due to industrial and manufacturing activities. Hence, understanding our external physical, biological and chemical environment, and how it affects individuals and manmade systems, has become an essential part of maintaining a healthy human population. While as an individual, I can contribute in different ways to protect or save the environment, either individually or through groups or NGO’s; as a Human Resource Professional, working for a profit-making organization, my role 20 June 2017


gets restricted to creating awareness, conducting training programs and complying with the relevant law. Let me share with you some of the initiatives I took and what environmentfriendly organizations in manufacturing industry do, to protect the environment 1. Paperless Offices – We maintain employee files digitally. Every communication with an employee, leave approval, issuance of promotion, transfer letter, etc. is done electronically. Communication with Government bodies, wherever possible, such as PF Office, is done electronically. 2. Open space Cubicles v/s Closed Cabins – Recently, I visited a factory and I was a bit surprised to see over 25 cabins of the size of 150x150 sq. ft., each equipped with air-conditioners. Instead, I often recommend having cubicles and use fans or air coolers (a set-up we follow in my organization). 3. Carpooling or Company Transport – In our office, employees are advised not to bring their vehicles to the factory; instead, they use office vehicle. Wherever it is not possible for the company transport to reach, we recommend carpooling. 4. Stick to the schedule (No Overtime) – Working for longer hours also means a use of more electricity and other resources. Hence, we strictly follow office working hours. Staying late is highly discouraged. 5. Rain Harvesting and Sewage Water Recycling/Treatment – We use rainwater harvesting instead of bore well. We also have a sewage water treatment plant. The water is then used for irrigating the garden, and plants maintained in the office premises.

a direct impact on human life.

Environmental protection is a concern as well as responsibility for all and sundry, independent of actions by government or organisations. gift them a plant. We plant a tree on their behalf with a nameplate of their name, either in our factory or in nearest forests through NGO’s we are associated with. 8. Environment Pollution Awareness Training Program – Every quarter we conduct awareness training programs and workshops for villagers living in the vicinity of our factory as well as schools within 10 KMS of the radius of our factory. In total, 3,000 to 5,000 people participate in our programs. Till now, there are about 17 industries which are declared to be most polluting. These include the caustic soda, cement, dis¬tillery, dyes and dye intermediaries, fertilizers, iron and steel, oil refineries, paper and pulp, pesticides and pharmaceuticals, sugar, textiles, thermal power plants, tanneries and so on. Pollution caused by these industries has

As an HR Leader, I ensure that every member of my team and every manager of the organization are well versed with Environment Protect Act, 1986 and standards of ISO 14001(EMS - Environment Management System) and ISO 18001 (OSHA - Occupational Health and Safety Assessment Series). The basic principles of ISO 14001 and ISO 18001 based on PDCA – Plan, Do, Check and Act. Standards of EMS exists to help organizations (a) minimize how their operations (processes, etc.) negatively affect the environment (i.e., cause adverse changes to air, water, or land); (b) comply with applicable laws, regulations, and other environmentally oriented requirements; and (c) continually improve in the above. As far as environment pollution is concerned, we are in a very dangerous situation and it’s a time to take tough decisions and actions. One person might not be able to do everything to save and protect our environment but together we all can do something to give a better environment to our future generation. Let’s not pass on our accountability to Government and Business Houses. Sanjeev Himachali is a Talent Management and Development professional with over a decade and a half years of experience in various facets of Human Resource Management across various industries, cultures, and geographies. He helps start-ups, smallsized and mid-sized organisations in identifying and developing potential and competencies of their employees.

6. Solar Energy – We use solar energy for lighting streets, pathways, and garden in our factory. Not only does this help in resource optimization but also in cost saving. 7. Gift a Plant - Whenever premium guests, foreign delegates, a key client, customer or vendor visit our office, we

We plant a tree on their behalf with a nameplate of their name, either in our factory or in nearest forests through NGO’s we are associated with.

21 June 2017

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#greenmanufacturing

Save Water, Save Lives, Save Future! C N Shukla Training & Development Consultant, Pune Techtrol Pvt. Ltd

The level measurement and control instruments manufactured and supplied by Pune Techtrol Pvt. Ltd. are widely used in the processes of waste water treatment. ‘Techtrol’ is recognized as most reliable & trusted brand, delivering quality products unsurpassed in terms of accuracy, workmanship, performance, safety & ease of installation, providing long uninterrupted service in wide & varied industrial applications.

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F

or the rapidly growing human population, the availability of so called abundant natural resources is shrinking; and the case of water is no different! Pune Techtrol Pvt. Ltd., the leading manufacturer of level measurement and control instruments, has always recognized the importance of preserving the environment and has believed in contributing to this noble cause. Human beings can use and consume only fresh water. While three-fourth of the Earth’s surface is covered in water, only three percent of it is fresh; and seventy percent of this three percent is locked up in the ice caps of Antarctic and Arctic regions. What remains, is to be used by the entire human population of seven billion for their ever increasing needs, and habitual wastage. Also,

around ninety percent of fresh water that is consumed, goes down the drains as waste water. Industries, which are increasing continuously in numbers, create lots of harmful pollutants that get mixed with water. The rate at which human beings are bidding farewell to water in the form of waste is indeed alarming. Thus, arises the dire need of waste water management. Waste water treatment is the process of removing contaminants from waste water and making it reusable for all purposes. Processing of waste water is important with regards to the need of environment preservation in the current times. Waste water, if allowed to flow untreated, can play havoc not only with humans, but also with crops, forests and wild life as well. Hence, the treatment of waste water or effluent is 22 June 2017


increasingly becoming vital for survival of human race and the environment. All waste water treatment processes require level monitoring and control. Level instruments are installed in almost all parts of water treatment and effluent treatment plants. The level measurement and control instruments manufactured and supplied by Pune Techtrol Pvt. Ltd. are widely used in the processes of waste water treatment. A very useful feature of “Techtrol” instruments is that there is wide choice of Material Of Construction (MOC) for all the instruments to suit specific requirements of the medium or liquid whose level is to be measured, detected or monitored.

with alarm switches and transmitter for remote indication and control. • Float and Dial Gauge (FDG) is useful for indication of liquid level in under-ground tanks. It is particularly suitable for applications involving limited head-space above the tank. It can also be improvised with alarm switches and transmitter for remote indication and control. • Float & Board Gauge (FBG) is the simplest but very reliable instrument used for indication of liquid level in large storage tanks of effluent / treated water. It can also be improvised with alarm switches.

These level instruments are mainly classified into level gauges, level switches and level transmitters. These “Techtrol” level instruments are specifically designed for this particular application, and hence increase the efficiency and reliability of the process. The application of each of these level instruments for waste water management is explored further:

Pune Techtrol’s wide range of level switches useful for in the application of waste water management are as follows: • Float Guided Switch (FGS) is single or multipoint level switch used for in clarifier and aeration tank. These switching contacts can be used for alarm indication or pump control. • Displacer Switch (DS) is more suited for application in clear effluent and potable water. Switching points rated for 5A, 250VAC and can be adjusted at site as required. • Cable Suspended Switch (FTS) is a simplest type switch and easy to install. These switching contacts are rated for 5A, 250VAC and can be used for alarm indication or pump control and are ideally suitable for application in settling tanks. • Conductivity Type Switch (CNS) is used only for conductive liquids. It can be used for treated & potable water. More suitable in applications where the depth

Using Level Gauges for Waste Water Management: Pune Techtrol’s wide range of level gauges useful for in the application of waste water management are as follows: • Tubular Level Gauge (TTG) and Reflex Flat Glass Gauge (RFG) are glass gauges used to indicate liquid levels of chemical tanks & other storage /process tanks. • Magnetic Level Gauge (MLG) is used to indicate levels of storage tanks of acid & alkali. It can also be improvised

Level Gauges 23 June 2017

Using Level Switches for Waste Water Management:

Level Switches

of tank is large. • Float Pivoted Switch (FPS) is side mounted, single point switch rated for 5A, 250VAC. It is suitable for over ground tanks. • Miniature Float Switch (MFPS/MFGS) is used for level detection in small / medium tanks. Using Level Transmitter for Waste Water Management: Pune Techtrol’s level transmitter useful for in the application of waste water management is as follows: • The Techtrol Ultrasonic Transmitter (TUS) is a non-contact type level transmitter, generally used for measurement of flow in open channel or level monitoring in tanks. It is compact, non-contact, and easy to install, integral type transmitter for continuous level measurement of non-corrosive liquids and slurries. It is programmable through Keys. Owing to its aforementioned characteristics, it proves highly useful in waste water management plants. It is used for various processes in storage tanks, filter beds, flotation cells, water / waste water/effluent treatment (WTP, ETP), etc. Since its inception, Pune Techtrol Pvt. Ltd. has time and again innovated and added on to the list of level measurement and control instruments which can be used for applications like waste water management. It takes pride in being not only a company of products, but a company of value too! For further information please mail us at ho@punetechtrol.com or visit www.punetechtrol.com

Level Transmitters


#onface

RAKESH KUMAR

Director, CSIR-National Environmental Engineering Research Institute

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24 June 2017


Proactive Industry Sustainable Industrial Growth

Environment has not been given due importance in industries’ priority list and “understaffed” pollution control boards have been too meek at times. No wonder environmental impact of industries has grown unbridled. It is time industries do proactive thinking about the sustainability factor and take measures in compliance with environmental norms and regulations to reduce delays in projects and help environment protection. Pollution control boards jointly with research and academic institutions can provide right directions guidance to industries. Dr. Rakesh Kumar, Director, CSIRNational Environmental Engineering Research Institute (CSIR-NEERI), shares his views on this enigmatic industry-environment relationship while also giving glimpses NEERI’s effort in this.

Scrapping and delay of industrial projects due to environmental norms and clearances is common in India. Though industrial growth is essential for economy, environmental protection is inevitable and priority. Where are the industries in India lagging behind global counterparts in achieving ‘sustainability’? The delays in environmental clearances have been very

25 June 2017

often touted as the main reason of slow industrial development. Some of these can be attributed to lack of preventive environmental planning by the industries. Till date mostly, if not all, the industries have addressed environment and sustainability issues as an external to their normal operation. These are addressed after all the other aspects of industries’ setting up are planned. Proactive thinking about what is needed for the India specific

rules and other norms would prevent delays. Talking about the pollution control boards in India, do you think the bodies should play more active role in monitoring and guiding about the environmental aspects of industry rather than the current inspection and certification method? SPCBs (State Pollution Control Boards) have a big role to play in guiding the

The delays in environmental clearances have been very often touted as the main reason of slow industrial development.

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Dr. Rakesh Kumar is the Director of the CSIR-National Environmental Engineering Research Institute (CSIR-NEERI). Prior to this role, Dr. Kumar was Chief Scientist and Head of Mumbai Zonal Laboratory, CSIR-NEERI. He obtained M. Tech. in Environmental Science and Engineering from IIT-Bombay and Ph.D. in Environmental Engineering from RTM Nagpur University. A visionary for sustainable development, Dr. Kumar has made a notable contribution in developing technologies for recycle and reuse of domestic and industrial wastewater which brought a paradigm shift in the country. He has received 9 awards for his outstanding contributions in Environmental Science & Engineering, among which the notable ones are Commonwealth Commission Award, UK in 1994; “Environmental Leadership Award” by US Asia Environmental Partnership and USAID for the year 2005 for outstanding contribution in improving quality of life for the population of Asia. He has been given an award for largest number of technology transfer for low cost waste water treatmentPHYTORID in the year 2012. He has been given VASVIK award for 2012 for his exemplary work for urban environment improvement and sustainable technology “Phytorid” for sewage treatment for better environment. He has been recently awarded “Hiyoshi Think of Ecology Award” in September 2015 for his work on use of ecology in solving environmental engineering problems. 26 www.martupdate.com

industries in terms of what kind of proactive measures industries can take and advise them in advance. Also since SPCBs are understaffed in most states, the preventive planning and planning can be done through research and academic institutions which will be long lasting and sustainability principles can be ingrained. NEERI has been closely monitoring and guiding projects for several Indian rivers which are severely affected, among many other reasons, by industrial effluents and discharges. Do you consider this situation a lack of awareness, lack of options or lack of intention on the part of industries? Indian rivers are affected due to multiple reasons of which major factors are untreated sewage ingress, industrial pockets discharging effluents and poor summer flows. Industrial discharges by major industries are mainly due to commitment to safeguard environment and river, whereas small scale industries need more awareness and finances to deal with their discharges. Common collection and treatment could be a possibility, however, proper design system and basic well maintained primary system by industries will be major pre-requisite criteria for success. Is there any integrated solution available for the industries to assess environmental impacts of their industrial processes, rectify it and also use generated data for their

Environment Management System in future? Integrated solution for industries is available. Sustainability analysis can provide the inputs to their environment footprint of process and products. This kind of analysis can be used to improve their operation and also anticipate any future requirement. Regular credible monitoring and analysis can be the first step towards analyzing areas of improvement and management system. You have made notable contributions in developing technologies for reuse and recycle of domestic and industrial waste water. Please throw some light on such technologies. NEERI has been working in the field of waste water reuse and recycle for a long time. It has specific treatment packages for all sectors of industries.

It is a challenging time for country in terms of push for more manufacturing and creation of jobs while keeping our environmental infrastructure safe for future generation.

26 June 2017


NEERI has been working in the field of waste water reuse and recycle for a long time. It has specific treatment packages for all sectors of industries. CETP processes for various types of clusters have been developed and designed by CSIR-NEERI for many locations. For sewage treatment, Phytorid Technology has been developed which not only treats sewage better than most of the conventional technologies but also does with a minimal O&M cost as it does not need power and moving machineries. It has been installed at many places

across country and has been accepted well. Similarly, for rural sanitation and urban poor, various designs have been developed and being deployed. Is NEERI working on any environmental technologies currently, especially for addressing industrial pollutions? It is working on pharma, chemical clusters for advance oxidation processes for treatment of effluents. The other sectors are fertilizers and leather sectors where better technologies are being developed. NEERI has taken up the first-of-its kind noise levels mapping project in the country. Please tell us about the project. We have been carrying out noise monitoring at various places such as cities, highways, industrial sources. Recently we have undertaken a major work of noise monitoring for 27

cities in Maharashtra. This is not limited to monitoring but our scientists, engineers will delineate silence zones. In addition, identification of areas where noise barriers are required options of types of noise protection. With all the manufacturing and industrial growth taking place in the country, how do you see environmental impact in future? As the Director of CSIR-NEERI what are your suggestions for Indian manufacturing industry to achieve sustainability? It is a challenging time for country in terms of push for more manufacturing and creation of jobs while keeping our environmental infrastructure safe for future generation. Indian manufacturing industries can start the process of sustainability thinking well in advance and not wait for pollution control board directions or any other governmental pressures. With a view to address this

issue, CSIR-NEERI has set up an Industries Desk which will be on single point of contact for any industries to seek information and guidance. Vidarbha Industrial Association has signed an MoU with CSIRNEERI to seek this advantage on 5th June, 2017, World Environment Day. We would encourage that industries and cities both come and be part of the team in this country which will solve the present problems and anticipate future issues. CSIR-National Environmental Engineering Research Institute (CSIR-NEERI), as a Stockholm Convention Regional Centre (SCRC) on Persistent Organic Pollutants (POPs) for Asia Region, organized a workshop on ‘Stockholm and Rotterdam Conventions and Associated Challenges� at CSIR-NEERI on June 6, 2017 in association with Ministry of Environment, Forest & Climate Change. In his opening remarks, Director, CSIR-NEERI Dr. Rakesh Kumar mentioned the objectives and role of Stockholm and Rotterdam Conventions. CSIR-NEERI, Nagpur is devoted to research and innovations in environmental science and engineering besides solving a range of problems posed by industry, government and public. It is a constituent of Council of Scientific & Industrial Research (CSIR), New Delhi and has a nationwide presence with its five zonal laboratories at Chennai, Delhi, Hyderabad, Kolkata and Mumbai. Dr. Kanchan Kumari, Convener of the workshop highlighted the role of CSIR-NEERI as SCRC and its involvement in capacity building and monitoring of POPs.

27 June 2017

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#CSR

Innovative Ways of CSR

Manoj Kabre manoj.k@indo-mim.com

Corporate houses sometimes tread beyond the trodden ways to participate in CSR in innovative ways. In the following article instances have been given where a multinational automotive company supports training programme for growth of a primary sector of economy, while a famous chain of hotels runs activities to touch lives of underprivileged children and ensure environmental protection through innovative methods.

Corporate social responsibility (CSR) promotes a vision of business accountability to a wide range of stakeholders, besides shareholders and investors. Key areas of concern in this article, are environmental protection and the wellbeing of employees, the community and civil society in general, both now and in the future. Yale and Columbia University in its recently published 2016 Environmental Performance Index (EPI) has ranked India at 144th place among 180 countries with over all score of 53.58. One bright side of 2016 ranking of India is 20% improvement in various parameters in last 10 years specially in sanitation and waste water treatment but the deteriorated air quality due to emission from power plants, industries, fossil fuel burning etc. which has placed India at almost bottom (178th place) is quite deploring and call for urgent and concentrated efforts to improve it. The Corporates need to expand their ongoing endeavors in these directions.

3. Shangri-La Hotel, Bengaluru 4. Piaggio Vehicles Private Limited Manoj Kabre, Vice President of Indo-MIM Pvt Ltd, has directed and headed the sales & marketing function for Asia and parts of Europe, spoke at various forums across the world for propagating the MIM technology. His laudable work includes, Chairing – CSR Committee of RBWC, Founding of CaN Trust (NGO), working for needy children. He is also on advisory committee of ‘Your Philanthropy Story’ (YPS) which captures stories through interviews of heroes and the cause they are associated with.

Following are some of the Environmental benefits that are aimed at being accomplished through various initiatives : • Greater material recyclability; • Better product durability and functionality; • Greater use of renewable resources; • Integration of environmental management tools into business plans, including life-cycle assessment and costing, environmental management standards, and eco-labeling. We have CSR activities from the following organisations in this issue: 1. Bajaj Auto 2. Shangri-La’s - Eros Hotel, New Delhi 28 www.martupdate.com

28 June 2017


Training to Dairy Farmers

by Jankidevi Bajaj Gram Vikas Sanstha Jankidevi Bajaj Gram Vikas Sanstha (JBGVS) - a NGO promoted by Bajaj Group has provided training and demos on animal husbandry to the beneficiaries of hybrid, Gir and Gaolao cows distributed and also to other dairy farmers in Pune, Aurangabad and Wardha districts as a part of its ‘Kamdhenu Gopalan Project.’ The programme focuses on using locally available and homemade inputs like sorghum, pearl millet, wheat and sugarcane, Jaggery , salt and agricultural residue for preparing fodder which is safer and cost effective than chemical-laced inputs available in the market. It has been conducting training on the hydroponic technique, use of azolla (type of aquatic plants) and growing of grass on available land in areas where green fodder is not available. JBGVS has also developed a model fodder matrix based on weight and yield capacity of hybrid, Gir and Gaolao cows. Till now, JBGVS has only reached out to 7,400 farmers through 336 programmes. The impact of the project on productivity is positive and visible, according to JBGVS livestock supervisors. For instance, a beneficiary dairy farmer of Pune district with two hybrid cows two years ago, each yielding 12-15 litres milk daily was provided with another cow and trainings under the project and today his total tally of 23 milch cows yield 400 liters, averaging 17 liter per cow. There are other examples where the average daily milk yield of both hybrid and Gir cows over the past couple of years increased by 5-6 litres. Also, instances of Gaolao cows in Wardha dying in the extreme summers of Vidarbh region due to lack of proper nutrition has reduced substantially in project villages, after JBGVS beneficiaries started following the recommended fodder matrix.

Employment Programme for NDS Students by Shangri-La’s - Eros Hotel, New Delhi

Shangri-La’s - Eros Hotel, New Delhi, has been working with Noida Deaf Society (NDS) by hiring 10 students from every batch trained in the hospitality divisions, such as concierge, laundry, housekeeping and security, before the students commence their internship at the hotel. NDS is committed to reintegrating the hearing impaired into mainstream society through life skills and children’s education. NDS provides vocational training to the students to enhance their employability quotient and enable them to become contributing partners to society. The hotel’s ongoing CSR initiatives include regular contributions, such as Earth Day, which is celebrated 4 times a year, and its continuous participation in the Cancer Support Walk. For the past nine years, our employees have generously donated books and clothes to Goonj. Shangri-La’s - Eros Hotel, New Delhi, strives to preserve and conserve the environment, and has taken measures towards being a green and eco-friendly hotel. The guests have a option to let the staff know if they would want their bed linen not to be changed every day and be a part of the initiative to conserve natural resources. The hotel also encourages using biodegradable plastic bags, use of biodegradable material for packaging bathroom amenities, conservation of electricity. In such an initiative, solar panels to heat water, and a treatment plant have been installed, the latter for recycling wastewater from the kitchen and laundry for gardening and flushing. The lights in the public washrooms automatically turn off upon exiting. The hotel also uses an organic waste converter to convert kitchen waste into manure, which is then used in the gardens. Similarly, eco-friendly fuels are used to generate electricity and water, and CFL and Led lights are used to save electricity.

Jankidevi Bajaj Gram Vikas Sanstha Hybrid cows provided by JBGVS to dairy (JBGVS) - a NGO promoted by Bajaj farmers. Group.

Wall painting done by SLND colleagues Tree plantation activity. at NDS.

Company: Bajaj Group NGO: Jankidevi Bajaj Gram Vikas Sanstha (JBGVS) Contact: Atul Sathe, Communication Officer Email: jbgvs@bajajauto.co.in

Company: Shangri-La’s Eros Hotel, New Delhi Contact : Director of Communications-Marketing & Communications Email: Anjori.Kumar@shangri-la.com

29 June 2017

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Bringing Joy to Underprivileged Children

Conserving Natural Resources for Environmental

by Shangri-La Hotel, Bengaluru

Sustainability by Piaggio Vehicles Pvt Ltd.

Shangri-La Hotel, Bengaluru has been working with Cheshire Homes, India & Angels Orphanage from the time the project was announced and the core-operations team came on-board. At present, two women from Cheshire homes have been hired by the hotel and are working in laundry & housekeeping department. Shangri-La Hotel, Bengaluru also sponsored one year education for two children from Cheshire Homes; Jennifer & Jeevitha. Polio afflicted Jennifer walks with the help of a walker. She aspires to be a doctor. Jeevitha is 14 years old and has pre-lingual deafness. She is now in class five studying in Sheila Kovitha Institute for the deaf. She is brilliant academically and very zealous in all aspects of life. The funds for the children’s education were raised through a charity bazaar where the colleagues were encouraged to bring unused artefacts, clothing, books et al for a sale at the hotel ballroom. During Christmas & New Year, Shangri-La Hotel, Bengaluru also brought tonnes of joy, cheer and hope to the 32 children at Cheshire Homes, Bangalore. Guests were encouraged to sponsor wishes expressed (viz. tiffin boxes, school bags, umbrellas and more) by the orphaned children which were then procured by the hotel and handed to the children. Much in line with its Delhi counterpart, Shangri-La Hotel, Bengaluru too takes initiatives to reduce its carbon footprint and to conserve water, guests are given options to skip washing of bed linen to save water. In an initiative to conserve electricity, the hotel uses solar panels to heat water, and a treatment plant has been installed that allows it to recycle wastewater from the kitchen and laundry for gardening and flushing. An organic waste converter has also been installed to convert kitchen waste into manure. Similarly, eco-friendly fuels are used to generate electricity and water, and CFL and Led lights are used to save electricity.

About 50 % area of Pune district is falling under Rain Shadow zone of Maharashtra state. Long term rain fall data analysis reveals that eastern, southern, south-eastern, central and northcentral part area of district around 9 blocks including Baramati are classified as drought areas. The stage of ground water development has reached up to 96.13% in two talukas of the district namely Baramati and Purandhar and are categorized under “Semi-Critical� category1. Piaggio India, in partnership with Sanjeevani Institute for Empowerment and Development, an NGO having expertise in watershed Project, designed and executed watershed projects for around 3000 hectare of watershed area in 2 villages in the catchment of its Baramati plant which falls under the drought prone areas of Pune district. The CSR activity includes soil and water conservation measures across the slope, as high surface run-off leads to severe soil erosion and degradation of land, which results in water scarcity for personal consumption and agricultural needs. Combined with that, biomass and vegetation development on a catchment basis is focused upon; the natural resources base of the local economy (household needs, agriculture, livestock, livelihoods and income) will be thus enhanced. Around 1400 million liters of water harvesting potential created in two villages under phase - I and 4700 persons were impacted positively. Efforts made in increasing storage capacity ultimately led to better percolation of water. Agriculture productivity enhanced substantially as farmers were able to take two to three crops even under below average rainfall. By mobilizing communities to regenerate and manage the natural resources through soil and water conservation measures together with rising Agro-forestry plantation the CSR aims at reducing dependence of the people on whimsical metrological events and reduce their poverty. Piaggio vehicles private limited (PVPL) is replicating the success in 2 new villages for impacting 10000 people cumulatively by March 2018 for larger social good and environmental sustainability.

Shangri-La Hotel, Bengaluru has been working with Cheshire Homes, India & Angels Orphanage from the time the project was announced and the coreoperations team came on-board.

Piaggio India, in partnership with Sanjeevani Institute for Empowerment and Development, an NGO having expertise in watershed Project, designed and executed watershed projects.

During Christmas & New Year, ShangriLa Hotel, Bengaluru also brought tonnes of joy, cheer and hope to the 32 children at Cheshire Homes, Bangalore.

Company: Shangri-La International Hotel Management Ltd. Contact: Vivek Srinivasan, Director of Human Resources Email: vivek.srinivasan@shangrila.com NGO: Cheshire Homes India, Bangalore Unit 30 www.martupdate.com

The project activities include soil and water Conservation, agro forestry plantation, promoting sustainable agriculture, and water management for environmental sustainability.

Company: Piaggio Vehicles Private Limited Contact : Yogesh Kapse, Manager- CSR Email: Yogesh.kapse@piaggio.co.in NGO: Sanjeevani Institute for Empowerment and Development 30 June 2017


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#AI

Intelligent Manufacturing

Rajesh Angadi rajeshangadi2013@gmail.com

Artificial Intelligence will transform the manufacturing into intelligent manufacturing where AI will not only guide numerically controlled machines and robots, but will play key role in their management system. Though such Computer Integrated Manufacturing System created by AI poses challenge to human workforce, it will in a way eradicate the need for human beings to engage in repetitive and poorly paying tasks.

Artificial Intelligence is the science concerned with the creation of machine intelligence which is able to perform tasks, only performed by people. Much of this machine intelligence is symbolic and heuristic. Artificial intelligence (AI) is intelligence exhibited by machines. In computer science, an ideal “intelligent” machine is a flexible rational agent that perceives its environment and takes actions that maximize its chance of success at some goal. Colloquially, the term “artificial intelligence” is applied when a machine mimics “cognitive” functions that humans associate with other human minds, such as “learning” and “problem solving. AI research is divided into subfields that focus on specific problems or on specific approaches or on the use of a particular tool or towards satisfying particular applications. The central problems (or goals) of AI research include reasoning, knowledge, planning, learning, natural language processing (communication), perception and the ability to move and manipulate objects. Approaches include statistical methods, computational intelligence, soft computing (e.g. machine learning), and traditional symbolic AI. Many tools are used in AI, including versions of search and mathematical optimization, logic, methods based on probability and economics. The AI field draws upon computer science, mathematics, psychology, linguistics, philosophy, neuroscience and artificial psychology. Globalization of the world economy and growth of competition on the market impose increasingly greater demands on modern entrepreneurs. Currently, management and control of production enterprises is impossible without an application of appropriate tools supporting decision making at each stage of a company’s functioning from 32 www.martupdate.com

designing through to product exploitation. CIM (Computer Integrated Manufacturing) Systems are an example of such available tools that enable composite automatization of technological and organizational preparation for manufacture, current supervision, technological process control, organization and management. The development of CIM Systems has, in recent years, been directed at applying the methods of artificialintelligence to support decision processes and production control as well as monitoring, simulation andtechnological process diagnosis. Intelligent Manufacturing is: “A set of methods, procedures and tools (e.g. CAD, CAP, CAM) equipped with artificial intelligence tools and supporting designing, planning and manufacturing.” The following, among others, are the basic constituent elements of Intelligent Manufacturing Systems mentioned as

Artificial intelligence’s ability to function as a safety measure and provide another set of eyes, so to speak, can be extremely beneficial to worker safety in manufacturing. 32 June 2017


follows: • Intelligent machines and tools, i.e. numerically controlled machines and robots, • Intelligent manufacturing systems, and • Intelligent management systems. The concept of intelligent manufacturing combines the ability of decision-making support systems in generative systems to obtain knowledge, to learn and to adapt to a changing environment and to the actual arrangement of system components. The nature of intelligent manufacturing is system’s possibility to learn and its self-development as well as the possibility to generate information necessary to control the integrated productionsystem. Designing Intelligent Manufacturing System Intelligent Manufacturing System of a production enterprise denotes a manufacturing systems integrated with information system which provides necessary information, enables its analysis and use of analytical and simulation - based decision making models in order to assist decision making at each stage of decision process, as well as it is capable of learning and adapting to the dynamically changing environment and the current arrangement of system components. In other words, it is a decision supporting system based on the applied methods and tools of artificial intelligence able to solve complex decision problems, semi structured or nonstructured, requiring the processing of incomplete,unreliable, contradictory, or difficult to formalize knowledge. The demands towards Intelligent Management Systems in a production enterprise are as follows: • A possibility of collecting and processing different types of information from all sources, both internal and external in order to acquire and model knowledge necessary to make decisions at all levels of decision process in an enterprise. At the same time, a possibility of modeling knowledge and processes, based on human thinking, is required.

Input

→ Aggregate Outputs

33 June 2017

Fuzzify Inputs

Artificial intelligence’s ability to function as a safety measure and provide another set of eyes, so to speak, can be extremely beneficial to worker safety in manufacturing. • In a decision process, at decision selecting, the decision maker’s subjective evaluation based on hisexperience and intuition should be taken into account in IMS. • There should be a possibility of preliminary information handling and analysis with analytical methods as well as modern artificial intelligence technologies. • A possibility of detecting emergency and critical situations and of prompt reaction to them. There must be a possibility of situational data analysis in real time, necessary in an emergency inside the production system or in its surroundings. • A possibility to allow for complexity and comprehensiveness of decision-making issues in strategic management support. • Taking into account the lack of stability and change dynamics, both in the surroundings and inside the enterprise, the IMSs under design should have the capability for learning from experience and adapting the experience to intensive alteration of working conditions. In intelligent manufacturing systems, the following selected contemporary methods and techniques of knowledge and decision process modeling should be integrated: • Artificial neural networks – the most fascinating tool of artificial intelligence, capable of modeling extremely complex functions and, to some extent, copying the learning activity in the human brain. • Fuzzy logic – technologies and methods of natural language

Apply Rules

Defuzzify

Ouput

In intelligent manufacturing systems, the following selected contemporary methods and techniques of knowledge and decision process modeling should be integrated. www.martupdate.com 33


Artificial intelligence’s ability to function as a safety measure and provide another set of eyes, so to speak, can be extremely beneficial to worker safety in manufacturing. formalization, linguistic and quality knowledge processing and fuzzification. • Genetic algorithms and methods of evolutionary modeling – learning algorithms based on theoreticalachievements of the theory of evolution, enriching the artificial intelligence techniques. The combination of these tools, in which knowledge is represented symbolically, with the traditional expert system will make it possible to create complex programmatic tools for solving difficult decision-making problems at eachstage of enterprise functioning. Artificial Intelligence and Control Engineering Artificial intelligence (AI) relates to control engineering when embedded software helps with situational awareness. The software algorithm looks at feedback from a situation, then actuates the decision (closed-loop control) without human consultation, or the software recommends a course of action with human consultation (open-loop control). Control engineering or control systems engineering is the engineering discipline that applies control theory to design systems with desired behaviors. The practice uses sensors to measure the output performance of the device being controlled and those measurements can be used to give feedback to the input actuators that can make corrections toward desired performance. Control engineering is the engineering discipline that focuses on the modeling of a diverse range of

dynamic systems (e.g. mechanical systems) and the design of controllers that will cause these systems to behave in the desired manner. Although such controllers need not be electrical many are and hence control engineering is often viewed as a subfield of electrical engineering. There are two major divisions in control theory, namely, classical and modern, which have direct implications over the control engineering applications. The scope of classical control theory is limited to single-input and single-output (SISO) system design, except when analyzing for disturbance rejection using a second input. The system analysis is carried out in the time domain using differential equations, in the complex-s domain with the Laplace transform while modern control theory is carried out in the state space, and can deal with multiple-input and multiple-output (MIMO) systems. This overcomes the limitations of classical control theory in more sophisticated design problems. Control engineering was all about continuous systems. Development of computer control tools posed a requirement of discrete control system engineering because the communications between the computer-based digital controller and the physical system are governed by a computer clock. The equivalent to Laplace transform in the discrete domain is the Z-transform. Today, many of the control systems are computer controlled and they consist of both digital and analog components.Therefore, at the design stage either digital components are mapped into the continuous domain and the design is carried out in the continuous domain, or analog components are mapped into discrete domain and design is carried out there. In manufacturing, a machine running a web-based process may have similar situational awareness. There may be a perfectly good reason to leave the machine running when the last material runs through the rollers and an operator is standing in a certain location. If the machine is unattended at that particular moment, embedded code may begin an orderly shutdown as the best response. Control Engineering relates to the next big thing (TNBT) which is the second generation of smartphones, which have the software capacity to provide situational awareness. TNBT devices will

Replacing human with robot in manufacturing is a trend that we can’t stop or avoid. 34 www.martupdate.com

34 June 2017


Will artificial intelligence (AI) take control of human race for Intelligent Manufacturing?

be able to recognize what is going on inside your area or site and determine when something is out of normal but not yet in alarm. Information for this awareness may come from traditional fixed sensors or even by listening for sound patterns such as hisses, whistles, clangs, and bangs. TNBT devices will become true operator assistants; always watching and always listening for out-of-normal conditions or for events that require manual intervention. Seven Artificial Intelligence (AI) tools have proved to be useful with sensor systems: Knowledge-based systems, fuzzy logic, automatic knowledge acquisition, neural networks, genetic algorithms, case-based reasoning, and ambient-intelligence. Applications of these tools within sensor systems have become more widespread due to the power and affordability of present-day computers. The appropriate deployment of the new AI tools will contribute to the creation of more competitive sensor systems and applications. Artificial Intelligence (AI) helps computing in four ways: 1. Natural language understanding to improve communication. 2. Machine reasoning to provide inference, theorem-proving, cooperation, and relevant solutions. 3. Knowledge representation for perception, path planning, modeling, and problem solving. 4. Knowledge acquisition using sensors to learn automatically for navigation and problem solving. Artificial intelligence’s ability to function as a safety measure and provide another set of eyes, so to speak, can be extremely beneficial to worker safety in manufacturing. It can also enhance our ability to understand what’s happening around us and offer solutions that might not be readily available. As artificial intelligence becomes more prevalent across industries, from defence to aerospace, experts in the field will focus on making AI as safe and useful as possible. Using artificial intelligence in a situation where human lives depend on success could prove catastrophic. Manufacturing is going through a revolution from a labor intensive, bluecollar industry to a white-collar, Silicon Valley industry. This use of AI to assist managers to efficiently run their 35 June 2017

operations is part of the transition from manufacturing being a labor intensive business to being highly automated at the operations management level as well as on the production floor.Artificial intelligence will eventually touch nearly every industry on the planet, but self-driving cars are among the most sought-after developments for this technology. Will artificial intelligence (AI) take control of human race for Intelligent Manufacturing? The answer to this question seems to be positive. Several experts of AI have similar comment as “everything that humans can do machines can do”. Stephen Hawking also warned us during an interview with BBC that “The development of full artificial intelligence could spell the end of the human race.” Ex Machina, a recent enthralling science-fiction film presents the possibility of a robot that has cognitive capability to think, feel and even manipulate human beings. Self-driving cars, Siri on your iPhone, weather forecasts, face recognition on your Facebook photos, etc are all examples. A Japanese company with Deep Knowledge found out an Artificial Intelligence (AI) as one of the directors due to its ability to predict market trend that is “not immediately obvious to humans”. Replacing human with robot in manufacturing is a trend that we can’t stop or avoid. Many experts fear that robots will cause a massive job loss which would result in severe social problems. But it’s not that simple, a country’s implementation of robots has no proven relationship to the percentage of manufacturing jobs lot. Rather they will restructure the labor market, accomplishing poorly-paying tasks and at the same time creating job opportunities which require high qualifications. As technology advances, the low cost, high-accuracy and efficiency of robot is going to benefit the human society as a whole on a broader level. The future holds a generated era in which artificial intelligence comes up with its own designs, its own ideas, its own products instead of all our tools being passive, us telling them what to do and them doing it. In real life, however, artificial intelligence is far more benign, and may provide the most critical catalyst for the future of manufacturing. 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.


#MANUFACTURINGEXCELLENCE

Optimize

Inventories with Right Control Methods

P S Satish gotopssatish@gmail.com

Successful control of inventory takes into account the right method or the combinations of methods. And selection of these methods is based on the type of product, size of inventory, customer service level needed, size of the industry, customer demands, distance between customer and supplier.

In the last issue, we discussed on the inventory control cycle and various methods of classification of inventory for better control. In this article, we will discuss further options for control of Inventory. A. Bin systems Here inventory is monitored and controlled using fixed size of bins. Depending on the number of bins used, it is further classified as one bin, two bins or three bins replenishment system a. One-bin replenishment system: Here single bin is used for the item. The bin is periodically checked. Order quantity will be enough to refill the bin. The size of the bin can be suited to match EOQ (economic order quantity) or MOQ (minimum order quantity) b. Two-bins replenishment system: Here two bins are used. When one bin becomes empty, that would be a trigger point for the reorder. The size of bin is dependent on the lead time of replenishment and consumption during procurement. The advantage is that triggering of reordering is visual and reorder level (ROL) can be seen. Not suited when too many varieties are there in stock. While reordering, fixed quantity is ordered. With bar coding or RFID, the movement and position of the bin can be tracked. c. Three-bins replenishment system: Here it is like two-bin system except that one extra bin is kept as a safety stock to take care of fluctuation of lead time of replenishment and demand during lead time. B. Accurate forecasting 36 www.martupdate.com

Inventory can be controlled by accurate forecasting. But this is not an easy task and a lot of efforts are required. Depending on the type of product, forecast is made from data on the past sales, by judgement of persons in the field, by survey (through mail, phone or physical meeting) and using various forecasting models. C. Accurate stock records Here discipline plays a role. Every issue, receipt and balance is recorded to manage replenishment. Reconciliation of physical stock is done regularly to account for any loss. Typical usage is in super markets. Systems like ERP (Enterprise Resource Planning) helps. Discrepancy between electronic inventory and physical inventory makes it difficult to control inventory. Erratic orders will hamper affecting the inventory level. The error is attributed wrong entries, thefts, lack of discipline, improper storage, no proper system and missing training. To check the error, cycle counting is done where each type of items is checked for accuracy between physical and electronic data in turn in a year. D. Fixed time orders Used for the low value items. Maximum level of stock based on average demand and safety stock is set. Orders are placed at fixed intervals. While ordering the difference between maximum level and current level is considered. E. Post-phoned product customization By delaying customization to later stage of supply chain, level of inventory can be controlled. The Dell computer uses such concept where customization is done in last stage after receipt of order from customer 36 June 2017


F. Standardization By standardizing items in the product at the design and development stage, inventory can be reduced. This could be part of concept of value engineering or design for manufacture. Toyota has used extensively when models are changed. G. Continuous Communication By continuous flow of information among supply chain partners on stock levels, the bull whip effect can be reduced which in turn helps to control inventory. If supply chain partners are connected by a system to get real time data, the control will still be better. Information has direct link with Inventory. H. Vendor Managed Inventory (VMI) As the name suggests, here inventory is managed by the vendor/supplier. The responsibility of the supplier includes setting up inventory levels in agreement with the Customer, monitoring closely the level for re-ordering and replenishing. The vendor may do this by physically being present at the Customer site or remotely. The ownership of inventory should be agreed between customer and vendor. The benefits include better visibility of inventory, better service level to customers, better planning by vendor, reduction of customer ordering errors and reduction of inventory cost and its management. Care should be taken at the setting up of VMI, to ensure proper agreement between customer and vendor with regard to ownership, safety and insurance of inventory, inventory levels, situations when inventory does not move for a long time, payments, of situations of stockouts etc. I. Just in time (JIT) Here the focus is on perfect quality, elimination of waste and low inventory. For this to be successful, high level of discipline is required at all levels. There should be a collaborative approach between customer and supplier with constant exchange of information. The concept is to supply items by supplier in right quantity and quality when customer pulls in shortest time in case of Minimum or no stock at Customer end. This will imply frequent supplies by Supplier in small lot sizes. For JIT to be successful, there should be long term contract with the Transporter, small size carriers,

electronic linkages for information flow, usage of returnable containers, flexibility of production system at supplier end, Total productive maintenance and perfect quality at supplier end, efficient material handling and minimizing wastages in packing. J. Other opportunities to control inventory • Better visibility of the inventory in the store. Example, non-moving items are kept separately and is made visible. It triggers quick action • Imports with higher lead time, adds to inventory and difficult to control. Import substitution helps to control inventory. • By proper housekeeping (5S), redundant items will come to surface and brings in orderliness in store. This helps to some extent on inventory control • By proper codification, accumulation of stocks can be avoided. Chances of duplications especially in spare items, can be reduced. Special items are kept separately from common items. • Close monitoring of usage rate, lead time and safety stock • Reduction of safety stock by reducing lead time and improving supplier reliability • By performing periodic inventory review to check movements • By having inventory visualization board • By regular review of measurement of inventory like ITR (Inventory turnover ratio), number of days of inventory, customer service level, number of stock out situation & loss, inventory carrying cost, ageing of inventory, inventory accuracy and other Data to trigger actions As a conclusion of inventory control methods, we need to understand that no single control method will work for all types of industries. The type of control or combinations to be selected based on type of product, size of inventory, customer service level needed, size of the industry, customer demands, distance between customer and supplier and so on. With this, we will conclude series of articles on inventory management. The author, P S Satish heads Saraswati Industrial Service. He has acquired B.E, M.Tech (IIT) and with 30 years of Industrial experience is serving engineering Industries in the area of capability development (purchase, quality & soft skills), consulting and mentoring. Focus is on overall improvement of company for 3C - Competitiveness, Core-competency and Customer satisfaction.

Depending on the type of product, accurate forecast for inventory is made from data on the past sales, by judgement of persons in the field, by survey (through mail, phone or physical meeting) and using various forecasting models. 37 June 2017


#toc

Immediate

Improvement by Applying

TOC

Pradeep Kumar pradeep.toc@gmail.com

Identifying the constraints and taking measures can help output grow immediately while improvement in any other areas, except in constraint, renders no effect in output. Examples show that often constraint operation adds no value to the production process in terms of timeliness of deliverable.

When output of a system is plateauing to a level it means some thing is holding it there. This ‘some thing’ is called the constraint of the system that is obstructing the output to grow. By definition when the constraint is identified and is opened, output must grow immediately. The constraint could be production capacity, supplier, market, resource, policy, mindset, conflict, measurement or any other thing in the business. It is important to identify it because improvement at any other place would be futile in terms of output. This is one reason of stalling many improvement strategies that suggest improving everywhere to be the right way. Improvement at non-constraint could be wasteful or even counter productive if it starts interfering with the performance of constraint. During my career at P&G where I first learnt of Theory of Constraints in the 90’s, we used to quote an example of a supplier that became constraint in supplying a chemical additive whose demand suddenly rose because of the success of one of our laundry products called ‘Tide with Bleach’. A careful look at the operations of this supplier revealed that their performance measurement system was not built around maximizing the output from department with least capacity in the production process. Suitable changes in policy on measurements resulted in 42% increase in production with in 30 days of the intervention.

38 www.martupdate.com

Another case of fast improvement is at one of my clients in China who are in apparel retailing business. They bought popular clothes from wholesale market and showcased them at their retail outlets. A team of 5 to 6 store employees managed the typical store outlet. The sales had plateaued and preferred way to increase sales was to open new outlets in another area. When we examined their bonus system for paying the store employees we found that the employee responsible for highest sales in a month received highest bonus. This not only placed employees to compete with one

The constraint could be production capacity, supplier, market, resource, policy, mindset, conflict, measurement or any other thing in the business. It is important to identify it because improvement at any other place would be futile in terms of output.

38 June 2017


another, but also distracted them from doing important jobs like cashier, or stock management or calling out for discount etc. because these jobs did not result in sales that could be credited to the employee. The bonus policy was identified as constraint and changed to make it based on team performance on total sales of the outlet. The result was 15% jump in sales because collaboration replaced the competitive efforts amongst the employees.

Measurements are mostly responsible for causing parts of a system to become constraints. TOC way of management seeks to define measurements for global good as prime measurements.

If a production system is unable to deliver in time it shows it has been over loaded. There would be material waiting in queue and if it is not managed correctly the system goes out of control leading to continuous fire fighting with hot priorities. Sensible thing to do in such a case is to identify the constraint operation that has least capacity and feed the system at the rate no more than that can be processed by the least capacity operation. This would reduce the work in process stock and improve the flow. In any case the system cannot produce more than what can be processed through the least capacity operation but the delivery date becomes more predictable immediately.

project lead-time by 30 to 40% as is evident from hundreds of success stories around the world. Measurements are mostly responsible for causing parts of a system to become constraints. TOC way of management seeks to define measurements for global good as prime measurements. Other measurements are subordinated to this prime measurement. This strategy is sufficient to produce results in very short time.

Multi tasking is the biggest drag in project process when resources are expected to be productive for their time. When every one is seeking to stay busy they are taking more than one tasks in their hand and switch amongst them based on the priority call given by the system. This multitasking culture increases the lead-time of each task individually and that is what gets captured in the estimates. This is reflected in the picture below. When task A, B, and C are done without interruption or multitasking with other tasks, the lead time for all of them is 1 day. But when A and B are switched half way the lead-time goes up to 1.5 days. Multitasking over three tasks increases the lead-time to two and one third day.

Pradeep Kumar is Mentor, Coach and Consultant for CEOs and Business owners. He is MD of China Subsidiary of Arete Business Consultants and is a partner with HBC consulting in China. He uses Theory of Constraints (TOC) thinking to enable clients visualize the immense possibilities for themselves and their businesses. Pradeep has been in current role of mentoring and coaching since 2006. Previously he was group COO of Singapore multinational TCL for 4 years. And prior to that his 12-year stint with P&G as Associate Director included experience in Japan for 9 years. Currently Pradeep lives in Shanghai and is an active Rotarian and Golfer. He received the top Rotary recognition of “Service Above Self� from Rotary International President in 2013.

Multitasking culture is a constraint in projects and new product development process. This can be addressed by policy change and managing the project for completing in time as a whole instead of by each task. This can reduce

A = 1 day

C = 1 day

B = 1 day

Multitasking 2 tasks-both tasks lead time is 1 one and half days

1/2 day

>

1/2 day

1/2 day

1/2 day

Multitasking 3 tasks-Task lead time increases to Two and 1/3 days

1/3 day

1/3 day

>

1/3 day

1/3 day

1/3 day

1/3 day

> 1/3 day

> 39 June 2017

1/3 day

1/3 day

Multitasking over N tasks will Increase each Task Time to [(n-1)+1/n] days. It is typical for pepole do multitasking half a dozen tasks. That means the average time in their expirence would take 5 times the necessary time(if there were no mutitasking) Pepole mutitasking to meet the local efficency mesurment for staying productive but this hurts the overall productivity!!! www.martupdate.com 39


#learningcurve

The Rosemary Kennedy Incident

Anthony Aravind anthony88ctyf@gmail.com

Rosemary Kennedy, a lesser known member of famous Kennedy clan of America, regained her rightful life courtesy her brother John F. Kennedy after being discarded from the family for her mental illness by her father Joe Kennedy in the name of unethical and prolonged treatment. John F. Kennedy showed the right attitude and a ‘green’ heart driven by love and care, and unmisted by darkness of pride, prejudice and social influence of his father. Likewise, Green Manufacturing needs Green Engineers with ‘Green’ or healthy mindset who can restore Green Ecosystem.

In memory of Rosemary Kennedy Shriver and an attempt to make the world a safer place for the mentally ill, John F. Kennedy in his presidential years passed several legislative bills on Mental Health awareness, funded conducive researches and vocational training for the disabled. Eunice Kennedy Shriver on the other hand funded several researches from the Kennedy Foundation and founded the ‘Shriver Camp’: A Retreat Centre for disabled children and went on to found the Special Olympics. “Things do not happen. Things are made to happen” – John F. Kennedy What comes to you when I say the colour ‘Green’? Yes, I just began this article with a question, perhaps an all too important one. Did you know that it is possible to define your personality based on your associations with different colours? So, take a few minutes and write down the things you would

40 www.martupdate.com

associate with the colour Green. If you’re wondering why this unorthodox opening, it’s because of the theme for this month, “Green Manufacturing /‘GREEn’gineering”. Green is a synonym of Clean, Nature and Human friendly, Fresh, Serene, Harmless, and Life. Don’t kill yourself if you didn’t get it right, rather ponder upon what came to you instead, because in a way your answer defines you. In this issue you must have read quite a lot about Green Manufacturing, hence my focus is not going to be on GREEngineering, but, on GREEngineers. I’m not sure what you’re expecting to read or learn, and I’m not sure if this article will meet your expectation, but I’m confident that what you are about to read will change your perspective about who you are and what you can be. May be now, may be later. Prelude You don’t have to be an American to

know the Kennedys, especially John F. Kennedy, commonly addressed by his initials JFK. John F. Kennedy hailed from arguably the most famous and influential family in the history of The United States of America. As much as the Kennedys are known for being world leaders and pioneers at various forums, they are also known for their tragic death. In this article I’m going to discuss the life of the less famous (hidden in the shadows) Rosemary Kennedy. The Life of Rosemary Kennedy Rosemary Kennedy was the third child of Joe and Rose Kennedy. She was the immediate younger sibling of JFK. Rosemary Kennedy was destined to see the light of the world during World War II, but the war required all the physicians to be at various war camps tending and reviving the wounded soldiers. The delayed arrival of the physician from the war camp to deliver Rosemary Kenney forced the nurse (who was fully 40 June 2017


capable of delivering a child) to push Rosemary Kennedy back inside the birth canal and hold her there for 2 hours. The insensitive decision of the nurse permanently slowed down Rosemary’s mental ability. Living in an era which considered mental illness and dark skin as untouchables, Mr. Joe Kennedy feared for her daughter, hence raised her in complete isolation. Mr. Joe Kennedy’s pride, prestige and prejudice, was fuelled by his son Joe Kennedy Jr.’s ideology, that people with mental illness are an ignominy to humanity, which was Adolf Hitler’s propaganda during that period. Parallel to his befouled ideology of people with mental illness, Mr. Joe Kennedy was introduced to Prefrontal Lobotomy: An experimental corrective surgery which was developed for people with mental illness, high sexual desires, and criminals, which had no or absolutely minimal success rate. Having understood the risk factors involved in such a newly developed experimental corrective surgery Mr. Joe Kennedy signed-in his daughter Rosemary Kennedy for Prefrontal Lobotomy without any reservations and the consent of the members of his family. Unsurprisingly the surgery was unsuccessful with a tragic outcome. Rosemary Kennedy regressedto the state of a 2-year-old girl. The result of the surgery forced Mr. Joe Kennedy to place Rosemary in

John F. Kennedy and Eunice Kennedy realised the pain of many with mental illness like their sister Rosemary Kennedy. While JFK passed several legislative bills on mental health awareness and funded researches vocational training for the disabled, Eunice Kennedy Shriver funded researches for disabled and founded ‘Shriver Camp’: A Retreat Centre for disabled children and went on to found the Special Olympics from the funded Kennedy Foundation. 41 June 2017

a rehabilitation centre, away from the reach of his family members, friends and known associates. Rosemary Kennedy was hidden in the shadows by her own father. 20 years later, John F. Kennedy, after being elected as the 35th President of The United States of America, used his influence to find his sister Rosemary Kennedy and brought her back home. The Kennedy family couldn’t believe what Mr. Joe Kennedy had done to his own daughter at the cost of his prestige, pride and ego. The most affected siblings were John F. Kennedy and Eunice Kennedy Shriver, as they were her immediate siblings. In memory of Rosemary Kennedy and an attempt to make the world a safer place for the mentally ill, John F. Kennedy in his presidential years passed several legislative bills on Mental Health awareness, funded conducive researchesand vocational training for the disabled. Eunice Kennedy Shriver on the other hand funded several researches from the Kennedy Foundation and founded the ‘Shriver Camp’: A Retreat Centre for disabled children and went on to found the Special Olympics. A classic example of the effects of both Non-Green and Green humanity. Here and Now Can you call Rosemary Kennedy’s life a Green life? Given the context of this month’s issue. No, and neither was her father Joe Kennedy’s life. Rosemary Kennedy’s life was a tragedy because of her father’s foolishness and resistance to let go of his pride and societal influence, which is an emotional and mental instability by itself. Now for the ultimate question – Are you a GREEngineer? You can define greengineer with the help of the synonyms of the colour Green I mentioned at the beginning of this article. The world is toiling for a ‘Greener Ecosystem’, but who polluted it in the first place? It was us the non-green people. Unfortunately no one seem to care for a ‘Greener Human Race’, a human race that is perhaps mentally clean, human and nature friendly, with fresh/open perspective, serene amidst storm, harmless to self and others, and overflowing with the goodness of life. I believe in the motto: ‘A Green Human Race leads to a Green Ecosystem’, which can be translated as ‘A GREEngineer leads to GREEngineering’ and to become

a GREEngineer, your mental health/ wellbeing is most important. So, how do you become a GREEngineer? 1. Pasture: The pasture isn’t green on the other side of the shore, the pasture is green where you water it. If the pasture you are looking at is greener, it simply means the person on the other side of the shore has watered and nurtured it well. Stop looking at other people, looking leads to comparing, comparing leads to competing, and competing leads to destruction, because you’ll never stop at one. Stop looking and start watering and nurturing your pasture which is your potential, gifts, skillset, knowledge, experience, relationships, family and most importantly your emotional and mental wellbeing. Pasture is where you’re at and what you possess, so guard it. 2. Prune: Pruning is more important than you think it is. Ask a gardener, what happens to a plant if it isn’t pruned? The plant will begin to look ugly, blossom shabby flowers and bear bitter fruits, because pruning is the process of snipping away all the unnecessary growth that threatens the very purpose of a plant. Do yourself a favour and become a gardener to yourself and identify the unnecessary emotional fluctuations, wrong attitude, unhealthy behaviour, unstable relationships, social pressure, and demanding lifestyle. If you found them, prune them, because they are harming you. If you haven’t found them, you’re still living a plant, because only a gardener can know what is unnecessary for the plant. 3. Provide: Being Green doesn’t stop at you, if it did there’s no purpose in being Green. What is the purpose of Green Engineering? Green Ecosystem? I’m sure you know the answer, now, apply that answer to yourself, and you would have discovered the purpose of a Green you. Marvellous isn’t it? The author Anthony Aravind A is a Counselling Psychologist and a Content Writer based in Bangalore, and specialized in Organizational Behaviour, Marriage and Family Therapy. He is passionate about people, their thought process and their behaviour. He collaborates and brings in his creativity as a professional Musician, knowledge and discernment as a Counselling Psychologist, and radical world view as a Photographer in all his articles.


#Cuttingedge

The Green Era

Ramya Ramakrishnan editor@martinfotech.in

The rapid increase in use of green technology in many international companies has given an impetuous to scientists and researchers to dive deeper into innovations that support the noble cause of saving our planet. Mart has also decided to contribute it’s part towards this step and enlighten few innovations that matters.

Every rational human being today is well aware that Earth has plunged into deep pits of environmental degradation that has exposed its inhabitants to several hazards. Most of this damage is irreversible and hence today nations

all across the globe have prioritised the need to conserve the gifts of nature.The three incredible projects carried out by talented researchers from across the globe (One being an Indian) focuses on ways to produce renewable energy that

can replace the existing binge use of fossil fuels. We stand at a junction where immediate steps and measures to help such budding ideas need to be fuelled and encouraged for a better and safer future.

Carbon-dioxide to support the production of renewable fuel.

VTT Technical Research Centre of Finland and Lappeenranta University of Technology (LUT) have developed a project that demonstrates the production of 200 liter of fuels and other hydrocarbons using carbon- dioxide.

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The Soletair demo plant that produces renewable fuel is established in Lappeenranta and coupled to LUT’s solar power plant in Lappeenranta. The model gives us an insight of the entire process chain ranging from solar power generation to hydrocarbon production all at the same place. The plant would open up gateways to electrify the chemical industries in future without the use of fossil fuels. The demo plant can be divided for our understanding into four units- a solar power plant; equipment for separating carbon dioxide and water from the air; a

section that uses electrolysis to produce hydrogen; and synthesis equipment for producing a crude-oil substitute from carbon dioxide and hydrogen. The point scale plants are designed to support a distributed small scale production which can be increased by adding extra units if required. The Soletair demo plant will be tested by VTT and LUT after which the synthesis unit will be utilized in number of EU projects in the future, further providing a platform for conducting research with multinational and international companies.

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New batteries to help boost usage of clean energy. The researches claim to have derived the map of the future existence of such batteries by using solar and wind energy. These batteries are based on manganese dioxide (MnO2), an abundant, safe and non-toxic material. The unique features of this battery include scope of achieving both high cycle life and high areal capacity. The high areal capacity is essential to pack huge quantities of battery electrodes into a single battery case at a lower cost of production and is an effective alternative to toxic filled method of manufacturing ion batteries. The simple theory behind this innovation is the use of intercalating copper (Cu) into bismuth-modified δ-MnO2, which is called birnessite, which was initially

discovered by Ford Motor Company in 1980 but could not find the way to utilize it at high areal capacity. This research team was led by Sanjoy Banerjee, Distinguished Professor and director of the Institute. The true essence of this research was to build the real practical battery which could only be achieved by high areal capacity. In the past researchers were able to either manufacture high life cycle battery or a high areal capacity battery, but never have they bought together both the elements. Such batteries can be utilized to power up Solar panels and Wind turbines, thus promoting the use of clean energy.

A paper published in the Nature Communications, written by Researchers at The City College of New York-based CUNY Energy Institute, has shed light on the noble way of producing rechargeable high energy density electrical battery that makes the widespread use of solar and wind power possible in the future.

Waste Glass Bottles soon to be the source of power. The programmers questioned the ability of converting whether silicon dioxide in waste beverage bottles into high purity silicon nanoparticles for lithium-ion batteries. The silicon anodes have the capacity to store upto 10% more energy than the conventional graphite anodes however the instability caused due to expansion and shrinkage of material during discharge of this energy makes it unstable.

Finding alternatives to beat the traditional system of converting solar energy into electricity research team from Kobe University have designed a new solar cell that can raise the efficiency of energy conversion to 50% by simply retaining the spectral components of longer wavelengths that are usually lost during transmission of cell.

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The solution to reduce this obstacle is to downsize silicon to the nanoscale by combining an abundant relatively pure form of silicon dioxide and a low-cost chemical reaction, doing so they have created lithium-ion half-cell batteries that store almost four times more energy than conventional graphite anodes. The anodes have been created by crushing and grinding the glass bottles into fine white powder, transforming

the silicon dioxide into nanostructured silicon using magnesiothermic reduction and finally coating the silicon nanoparticles with carbon to help them improve energy storage capacity and stability. Changling Li, a graduate student and the lead author of the research stated that one glass bottle can provide nanosilicons that will suffice hundreds of coin cell batteries and three to five pouch cell batteries. The coin cell batteries made out of glass bottle based silicon anodes surpassed the performance of traditional batteries in multiple laboratory tests, demonstrating excellent electrochemical performance with a capacity of ~1420 mAh/g at C/2 rate after 400 cycles. Cengiz Ozkan, professor of mechanical engineering, and Mihri Ozkan, professor of electrical engineering, led the project. These batteries can be used to power electrical cars, laptops, cell phones etc.

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#SUCCESSSTORY

WELDING WONDER Kemppi India pvt ltd, the renowned manufacturer and global supplier of welding equipments announced the launch of their integrator for welding robot for Indian market in its robot integrators meet held at JW Marriot, Pune on 9th may 2017. Ulrich hoepfel, business area manager for automation, Kemppi Germany unveiled a detailed presentation of the innovative a7 mig welder 450, which roused interest among participants. In conversation with MART, Mr. Hoepfel throws light on the new a7 mig welder 450.

Can you tell us more about launch of A7 MIG Welder? The program, recently held in Pune, was specifically designed to showcase development of Kempi’s robotic automation acrylic outsource. The main target for this presentation was on introduction of A7 MIG welder for automation and robotic welding. The focus was on usability and functionality of the machines for the operators to make it easier, simpler and faster to set up the whole system on site for the customers. So, user friendly usability is crossing nowadays in the automation world. Offering the customers easier interface to set up the parameters will help them to save lot of time. When was A7 MIG Welder 450 launched globally? We started to launch this product last year autumn, roughly six to nine months ago. We started at the headquarters to make the timing faster and then we went wider and wider. Basically, very first integration was in Finland that has many small facilities on Robot. Then we went to UK and next integration was in Portugal which is is basically our biggest integrator in the world. So, it’s using around 200 sets per year. so this is our core integrators as we started and introduced and starting up our whole system. Could you through some light on the benefits of the new product? The new welder has many benefits for its user which are: 44 www.martupdate.com


Welcome to the World of Machine Tools, Multifarious Opportunities & MagniďŹ cence A

Kawasaki

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Kawasaki Robotics

CNC Machine Tools

Angel India Cad Cam Pvt. Ltd.

Pioneer in Spring Machinery Since 2001

Concord CONCORD UNITED PRODUCTS

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Govt. Of India Ministry of New and Renewable Energy

Government of India Ministry of Heavy Industries & Public Enterprises

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• Quick and easy integration with any robot brand with modern fieldbus hardware modules. • Access to the power source from an external computer via ethernet with a regular web browser. No extra programs needed. It enables radical savings in setup time, as well as quick and easy parameter configuration, system management, and monitoring throughout the equipment’s life cycle. • Increased productivity and a short payback period with its Wise software and a wide range of available functions. Wise processes are fine-tuned and pre-set to optimize productivity with welding speeds typically used in automated welding. The same equipment can be used for a wide variety of welding tasks and applications. • A comprehensive, completely balanced package from one supplier results in significant savings in time and effort when integrating the arc-welding package with the robot application. • Suitable for any industry using robotic welding for thin and thick mild steel, stainless steel, and aluminum components. • Enhanced arc ignition functionality (Touch Sense Ignition) delivers minimum spatter and stabilizes the arc immediately after ignition. • The robust wire feeding casing with integrated wire feeder controller electronics enables faster and more accurate control with better resistance to external interference. • An integrated gas-flow sensor in the wire feeder enables the shielding gas flow to be monitored closer to the arc by default – no need for additional sensors. • Search voltage level for the system can be set up freely from web browser interface What are your plans for Indian market? In India, we started only in Pune. This was the official launch to the integrators in Pune. We have a plan and acceptance from the Kempi management board that they will establish the application centre for automation and robotic in Pune after the summer. Can we use this product- A7 MIG Welder in Robots manufactured by different manufacturers? Every robot manufacturer uses different communication

module with several different protocols available and most probably every robot manufacturer uses their own protocol. Therefore, this machine has to work according to this protocol and then the robots have to be implemented in our software for working and functioning together. This is a demanding and challenging phase that our interface works with the outside world. We have an internal communication and then we have outside communication world. So, any kind of robot or any communication module can control this kind of machine. As with robots, the machine can also work equally efficiently with mechanization units like PLC. How was the response from the manufacturers as well as from the users at the programme? Before we made the first official launch, we contacted certain robot manufacturers for e.g. Fanuc, Kawasaki, ABB and introduced and tested this system. The feedback from all robot manufacturers was very positive. We have had a very clever idea which has responsive interfaces that no one else provide as such at an efficient rate with the user interfaces. There are certain responsive interfaces available but not so deeply developed, and the usability is very easy and very comfortable - that was the feedback we received from the robot manufacturer. We also introduced the Kempi machine to the users and received positive response. What are your expectations from the Indian market? Do you think India is still in very nascent stage, when it comes to the automation? We know the statistics and we know the market but we want to be present. Through our application centre we want to be present from the beginning in India. We are here for last 20 years – with presence in energy industry, boiler industry, railway industry and also we provided our product in various products. This is our beginning and we will definitely increase our range in terms of products. India is not at this moment like China in terms of arc welding products sold but in future it will definitely increase.

We have an internal communication and then we have outside communication world. So, any kind of robot or any communication module can control this kind of machine.

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June 2017


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#Posteventreport

Hypertherm XPR 300

Enthralls Participants at ‘Meet the New Plasma’

Hypertherm introduced XPR 300 Plasma System at an event organized recently in Singapore. XPR 300 is equipped with X-Definition plasma, developed by Hypertherm and the most developed plasma cutting till date for the industry. For its faster cut speed, cut quality, intuitive features, automatic system monitoring and also for lower investment associated, this is the right choice for customers.

High precision mechanized plasma cutting reached a new level with the introduction Hypertherm’s XPR 300. Hypertherm recently launched X-Definition, an entirely new range of plasma and the most advanced till date, at Hanover exhibition. New XPR 300 plasma system is the first product to the industry that comes with this X-Definition plasma. Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, organized ‘Meet the New

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Plasma’ at Hotel Jen Tanglin, Singapore on 16th May 2017 to introduce this integrated cutting system through various programmes. Mr. Phil Parker, Marketing Manager, Hypertherm Mechanized Automated Systems and Mr. Nathan Pascarella, Marketing Manager, Hypertherm Automation Automated Systems analyzed the value propositions of the new product in two sessions XPR 300 – Definitive Value Proposition (DVP) part 1 and XPR 300 – Definitive Value Proposition (DVP) part 2 respectively.

“The combination of faster cut speeds, unparalleled cut quality, intuitive features, and automatic system monitoring make it our most advanced and productive plasma yet. It really opens up a wide range of opportunities for companies by providing cut quality and consistency that may make it suitable for applications which have previously been associated with laser, but with the much lower initial investment costs associated with plasma,” said Mr. Paker during his presentation.

48 June 2017


After the technical presentation, the participants had an opportunity to visit the Hypertherm Cutting Technology Center. A live demonstration was presented with the new XPR 300 Plasma which was followed by though provoking questionanswer session and interaction with Hyperterm management. The most advanced plasma cutting system notwithstanding, Hypertherm XPR 300 is an easy to use system equipped with sensors for better system monitoring information and optimization. It is easy to fit and use system, cutting down the set up time for the customer. Another new design feature is a quick change torch that enables an operator to rapidly change torches with just one hand.

Hypertherm, a U.S. based manufacturer of plasma, laser, and waterjet cutting systems, organized Meet the New Plasma’ at Hotel Jen Tanglin, Singapore on 16th May 2017 to introduce this integrated cutting system through various programmes.

All consoles feature advanced auto gas capability allowing operators to select and implement cutting jobs directly from the CNC, along with Wi-Fi in the power supply to enable system, or even multiple system, monitoring remotely.

Key benefits Superior Performance • Industry leading cut quality for stainless and aluminum • Mild steel cut quality is exceptional over longer duration than the competition• 15% increase in cut speeds

High precision mechanized plasma cutting reached a new level with the introduction Hypertherm’s XPR 300.

Efficiency and Ease of Use • Increased efficiency and easier to use over other plasma systems • Reduced console connections, EtherCAT connectivity, easy connect fitting and mobile device connectivity Innovation and Convenience • Remote system monitoring from any device no matter where you are Reliability and Reduced Costs • Ramp down error protection and automatic torch protection¬ deliver optimal consumable life and prevent catastrophic torch failure • Greatly extended consumable life and torch protection¬ reduces operating costs and downtime

49 June 2017

A live demonstration was presented with the new XPR 300 Plasma.

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#INNOVATIONS

Similar price, double the performance:

New plain bearing all-rounder from igus At Hannover Messe 2017, igus showed the improved version of iglidur G, the world’s most successful material for plastic bearings. igus has improved its best-seller, the all-round bearing material iglidur G, and presented this at Hannover Messe 2017. When it comes to the minimization of friction and wear without the need for any lubrication or maintenance, customers can now choose from a catalogue that contains a wide range of bearings made of 53 Tribo plastics with special material properties. In the igus product range, customers can find plastics especially suited for construction and agricultural machines as well as for use in the food or chemicals industry. The most frequently used iglidur bearing, however, is iglidur G. Presented for the first time in 1983, it can now be supplied worldwide from stock in 650 metric catalogue dimensions with diameters ranging from 1.5 to 195 millimeters. It combines a favorable price with many attractive technical properties: a long service life across the entire load spectrum on a wide variety of rotating or pivoting shafts, even in very different ambient conditions, for example when applications are exposed to dirt, dust or impacts. At Hannover Messe 2017, igus presented an upgraded version of this successful universalist: iglidur G1.

“The new G”: service life doubled The new all-rounder achieves the stated goals for these igus products, namely enhancement of technical performance and reduction of costs, and does so in an exemplary manner. This is because the material of “the new G” has considerably improved properties at almost the same price. The igus developers have reduced the wear rates at low loads (up to to 5 MPa) down to levels up to a quarter of what they were before. The service life under heavy loads has almost been doubled, depending on the application parameters. At the same time, the allrounder can now be used continuously at temperatures up to 180°C (iglidur G: 130°C). In addition, the temperature above which an additional means of axially securing the bearing apart from the press fit is recommended has been increased by half to 120 °C In conjunction with the more than 50 per cent reduction of moisture absorption, this means that the material is suitable for an even wider range of ambient conditions. “The new material is

an improved alternative in moving applications where metal solutions have been used up to now”, says René Achnitz, Head of Business Unit iglidur bearings at igus. “With this new material, customers can reduce costs by around 40 per cent, increase the service life of bearings and, at the same time, profit from the special material properties of iglidur such as the absence of a need for lubrication, lower weight and corrosion resistance. “Initially, iglidur G1 will be made available in 113 standard dimensions in the form of cylindrical bearings and flange bearings. Moreover, the range of dimensions will now be expanded continually in response to customer enquiries. Thanks to extensive tests in the 2,750 squaremeter laboratory, it will soon be possible to calculate and configure iglidur G1 online like all the materials contained in the igus catalogue. For more details write to Santhosh Jacob Product Manager, iglidur®,igubal®,xiros® Cell : +91-9535200466 Email: santhosh@igus.in Web: www.igus.in

The plastic arts: At Hannover Messe, igus will be presenting iglidur G1, the new lubrication and maintenance-free plastic bearing. Compared to iglidur G, the new all-rounder offers double the service life for almost the same price. 50 www.martupdate.com

50 June 2017


4th EDITION INDIA MANUFACTURING SHOW

SUPPORTED BY

Ministries of Commerce & Industry; Coal, Mines Skill Development & Entrepreneurship New and Renewable Energy Defence Production, DRDO, Steel Micro, Small & Medium Enterprises GOVERNMENT OF INDIA

2017

It’s time for ‘Make in India’

(Concurrent with 3 days Conference)

30 October - 1 November, 2017

BIEC, Bengaluru, India

Indian Space Research Organisation

AEROSPACE & DEFENCE ENGINEERING

ENERGY & ENVIRONMENT

AUTO & COMPONENTS

AUTOMATION & ROBOTICS

METALLURGY & MINING

INDUSTRIAL ENGINEERING

Expected Participation

250

400

EXHIBITORS

10000

20

DELEGATES

BUSINESS VISITORS

COUNTRIES

Industry Partners

All India Association of Industries

BRICS Chamber of Commerce & Industry

Bangalore Chamber of Industry and Commerce

Federation of Karnataka Chambers of Commerce and Industry

India China Economic and Cultural Council

Official Media Partner

ORGANISERS

Indian Foundry Organisation

India China Chamber of Commerce & Industry

Federation of Indian Micro and Small & Medium Enterprises

Solar Energy Society of India

Society of Indian Aerospace Technologies and Industries

SME Chamber of India

Media Partners

EXPO ORGANISER

CONTACT For Conference: IMS FOUNDATION Telefax: +91-80-2665 1234 / 4171 6085 Email: info@imsfoundation.in

For Exhibition: TAFCON PROJECTS (INDIA) PVT. LTD. Tel: +91-11-4985 7777 (50 Lines) Email: ims2017@tafcon.com

www.indiamanufacturingshow.com


#INNOVATIONS

Specialists for micro cutting

now in sealed design available TRIBOS Polygonal Clamping Technology developed by Schunk is a major innovation in the field of metal cutting. To add more precision, they are now offering these special micro cutting technologies as a sealed version of direct clamping. For many years, the TRIBOS polygonal clamping technology, developed and patented by SCHUNK, are setting benchmarks in the field of metal cutting. Its high absolute accuracy, dy-namics and excellent rigidity and damping value allow best surface qualities and long tool lives. In order to open up the potentials of modern HSC cutting edges and spindles more comprehensively, the competence leader for gripping systems and clamping technology offers the standard series TRIBOS-RM, TRIBOSMini, and TRIBOS-Mini SVL as a sealed version for direct clamping of micro tools with internal coolant supply, too. In the case of deep bore holes and for milling grooves, the internal coolant supply ensures that chips will be re-moved and taken away from the cutting edge for best cutting actions and that optimum cooling of the cutting edge is possible.

Both in combination, allows longer service life of the high-quality tools and excellent finish results at the workpiece. In addition, the sealed de-sign prevents chips or dust from penetrating into the mounting or spindle. In the first step, SCHUNK offers the dust-proof and coolant-proof version (up to 80 bar) for the precision mountings TRIBOS-RM HSK-E 40 and HSK-E 32 with ø 3 mm, 6 mm, and 12 mm, TRIBOS-Mini HSK-E 40 and HSK-E 32 with ø 3 mm and 6 mm, as well as tool extensions TRIBOS-Mini SVL with ø 3 mm and 6 mm. Mechanically insensitive and highly precise The standard version proves itself with a run-out and repeat accuracy of < 0,003 mm at an unclamped length of 2,5 x D and a balancing grade of G 2.5 at 25.000 rpm or ultra-fine bal-anced

at a balancing grade of G 0.3 at 60.000 rpm. They meet all the standards in terms of size accuracy and surface quality and therefore even demanding requirements can be reached. They are suitable for every tool shank in h6 quality, and depending on the type, they are tested up to 205,000 rpm. Since the tools are operating without moveable parts, they are mechanically insensitive and guarantee low maintenance and wear-free clamping. Even after several thousand clamping cycles no material fatigue occurs. With a hydraulic clamping device tool change is done process reliable within a few seconds. For more details write to Satish Sadasivan, Managing Director, SCHUNK Intec India Pvt Ltd , Tel: 080-40538999 Email: info@in.schunk.com Web: www.in.schunk.com

The SCHUNK TRIBOS-Mini and TRIBOS-RM precision toolholders are very popular in the medical technology, optical industry, mi-cro mold fabrication, aviation industry, and watch and jewelry industry, and achieve high precision results on the first go. 52 www.martupdate.com

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53 June 2017


#announcement

“Kusam-Meco” Temperature Monitor and Controller Model - TMC-3 TMC-4

“KUSAM-MECO” has introduced the all new versatile Temperature Monitor and Controller Models No. TCM - 3 and TCM- 4 for Power Transformers. The special features of these models are that it can display temp from 0°C to 250°C via PT-100 Sensor. It has a three phase coil which measures average and maximum temperature with over-temp alarm facility inbuilt. You can set time for Fan to operate automatically and manually also. It can drive 2 industrial fans directly. It has a Built - in high decibel buzzer facility. These are operated by RS – 485 Modbus - RTU mode. The models are with one more additional analog output of 4 20 mA and one more additional input controlled independently by relay. Visit: www.kusamelectrical.com

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Perfect diversityBacklash free reliable servo couplings

New products for switching and control in hazardous

PushPull connection to PCB saves on assembly time

mayr® power transmission provides a wide spectrum of backlash-free, high performance servo couplings and is permanently expanding its standard modular system. Furthermore, new, modern production processes ensure favorable prices and short delivery times. In addition, the company also stands for diverse, future-orientated solutions for safety brakes and overload clutches. For customers, this means high-quality power transmission from a single source.

For years electrical switching devices for hazardous areas have been a focus for Pepperl+Fuchs. For Hannover Fair the portfolio for electrical explosion protection has been significantly expanded and updated.

HARTING M12 PCB angled D coded with PushPull, a complicated sounding name used for a clever connection. The M12 for direct transmission from the cable to the printed circuit board is now immediately available for the fast M12 PushPull system. The M12 PCB connection is now also equipped with the fast, time-saving PushPull system.

Shaft couplings in servo axes are subjected to completely different requirements depending on the application. For this reason, mayr® power transmission provides an extremely wide and mature product portfolio, featuring various steel bellows, elastomer and disk pack couplings in their product range.

Switches and push buttons for panel mounting: Of particular interest is the comprehensive line of switches, illuminated push buttons and emergency stop buttons. They are all characterized by their low mounting depth. The bayonet catch enables fast and secure installation in any switch panel.

Visit: www.mayr.com

www.pepperl-fuchs.com

Certified switches for panel mounting - many functions selectable: Pepperl+Fuchs delivers a large variety of products with many different types of protection and housing variants for machine control and electrical networks in hazardous areas.

Ethernet is transferred from the cable to the circuit board, this is the goal of the new M12 PushPull PCB connection. The direct connection to the PCB comes in an angled D-coded female variant and thus provides space-saving switches with Fast Ethernet up to 100Mbit/s. The direct M12 PushPull connection to the PCB saves additional wiring, assembly space and thus space as well in a generation of devices that are becoming smaller and smaller. Visit: www.HARTING.com

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#MARTUPDATE

NI Showcases Smart Platforms and Tools for the Indian Aerospace & Defence Industry market. At National Instruments, it is our endeavor to provide the bestin-class testing solutions for enabling this industry rapidly develop and deploy systems. The India Defence and Aerospace Symposium 2017 gives us a platform to showcase the advanced technologies that can help build modern & reliable automated test systems for the aerospace & defence segments.” At the event, NI showcased:

NI (Nasdaq: NATI), the provider of systems that enable engineers and scientists to solve the world’s greatest engineering challenges, hosted the India Defence and Aerospace Symposium 2017 in association with Society of Indian Aerospace Technologies and Industries (SIATI). The symposium which witnessed a footfall of 500, was attended by engineers, scientists, managers and professionals in the aviation, space and defence industries and focused on navigation, RADAR, Electronics Warfare, Military Communications, Satellites as well as test rig construction and HIL. At the event, NI showcased how the design, development and test challenges of the Indian Aerospace & Defence

(A&D) Industry can be integrated by smart platforms & tools powered by ready-made technology. The diverse set of industry experts present, shared their ideas on revolution in simulation and test solutions, challenges of RADAR design & test, advanced techniques for phase aligned RF signal generation & acquisition and data acquisition systems for A&D applications. Commenting on the importance of system design for the Aerospace and Defence industry, Tarun Gupta, Business Development Manager, National Instruments India, said, “India is an established technology hub for engineering services and product development for the global defence

• Smarter approach to system design in Aerospace & Defence • Prototyping & Testing modern Electronic Warfare (EW) Systems and RADARs • Gigahertz Record & Playback Systems & Using Software Defined Radios (SDRs) for prototyping communications systems for A&D industry • Validating and Testing of Avionic Systems & Advanced Techniques for Phase Aligned signal generation and acquisition • Architecting Flexible HIL Test Systems for Embedded Controllers & Data Acquisition Systems for A&D Industry The annual National Instruments Defence & Aerospace event aims to bring together and share domain knowledge and best practices from partners in the Indian Aerospace and Defence industry.

Tata Steel Bags Award for Environment Protection from Jharkhand State Pollution Control Board Tata Steel has won two prizes on World Environment Day for commendable efforts in the area of environment protection, improvement and awareness. The awards were given by Jharkhand State Pollution Control Board (JSPCB) in the presence of Shri Raghubar Das, Chief Minister of Jharkhand, India. The company won the first prize in the ‘Large Industry’ category with respect to environment management and creating environment awareness in the society. In the ‘Mining’ category, Tata Steel West Bokaro colliery won the second prize. 56 www.martupdate.com

Tata Steel has received awards in various categories from JSPCB for the fourth consecutive year. The awards were presented during a function held on the occasion of World Environment Day with the theme ‘Connecting People with Nature’. It was organized by JSPCB and Department of Forest, Environment & Climate Change. Shri Raghubar Das, Chief Minister of Jharkhand, India was the Chief Guest for the function. Shri Raghubar Das presented the award to Mr B K Das, Vice President, Iron Making, Tata Steel for winning the first prize. 56 June 2017


Tata Power Solar Posts Rs. 2262 Crore Revenue in FY17 capacity by 65 per cent to 300MW. The efficiency level of the cells and modules coming out of these lines are among the best in the world.

Tata Power Solar, India’s largest integrated solar company, has ramped up the scale of business substantially by focusing on building state of art technology, engineering and strengthening on customer & employee satisfaction. Tata Power Solar increased its revenue by more than two and a half times in just two years to reach Rs. 2262 crore. The focus on efficiency and quality coupled with leveraging technology and innovation has helped the company to implement several challenging projects.

The company, with a view of longterm objective, significantly increased focus on EPC, where it had built strong competencies Tata Power Solar has also been the biggest rooftop player for 3 years in a row. Tata Power Solar, in its effort to encourage domestic manufacturing, made significant expansion and modernization of its cell and module facility in Bengaluru. The second expansion within 2 years doubled the company’s module capacity to 400MW, and increased its cell manufacturing

Commenting on the achievement, Mr Anil Sardana, CEO & MD, Tata Power said, “We are happy to see our team responding to Government of India’s call of ‘Make in India’. Considering the fact that solar EPC is extremely low margin and the pressures faced by the domestic manufacturing sector, the company has turned profitable within a short span, which is a remarkable achievement. Renewables will continue to be our key focus whether it is generation or manufacturing business. It is encouraging to see all our businesses coming together to achieve the ultimate objective of being the largest integrated player”. “The journey has just begun for India’s solar sector and opportunities as well as challenges are galore. While there are some bottlenecks like decreasing unit cost driven by reverse bidding and influx of cheap and subsided imported panels, solar sector continues to be a key sunrise sector with a potential to make a significant and tangible socio-economic and environmental impact”, says Ashish Khanna, ED & CEO, Tata Power Solar.

ExxonMobil Completes New Grease and Synthetic Lubricants Facilities in Singapore ExxonMobil completed its expansion project in Jurong to increase production of grease and synthetic lubricants, including Mobil 1TM, the company’s flagship synthetic engine oil. The milestone was recognized at an opening ceremony attended by Singapore Economic Development Board managing director Yeoh Keat Chuan. The expansion of the Jurong lubricant plant further strengthens the company’s manufacturing capabilities and its ability to meet the growing demand for grease and synthetic lubricants products in the Asia Pacific region. “These new grease and synthetic lubricants production facilities are

57 June 2017

strategically located close to key Asia Pacific markets, ensuring the reliable supply of these premium products to our customers,” said Teoh Song Ping, Asia Pacific lubricant sales director at ExxonMobil. “Our advanced lubricating oils and greases contribute to society’s broader sustainability objectives by helping to increase equipment operating efficiency and engine fuel economy, which contribute to reduced energy and resource use, as well as lower emissions.” The grease plant started production in January 2017, and the synthetics plant, which was completed in March, started production in April following a successful commissioning. www.martupdate.com 57


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Dürr Ecoclean uses virtual reality on an industrial level - Service training and instruction in virtual space the instructor and the trainee may be located thousands of kilometers apart.

As one of the first manufacturers of industrial part cleaning equipment, Dürr Ecoclean uses Virtual Reality in training its global service staff to carry out maintenance support on its complex manipulators. Virtual Reality (VR) is a term currently associated mainly with computer games. However, the rendering and simultaneous perception of reality – and its physical properties – in a realtime computer generated, interactive virtual environment also offers plenty of opportunities in industry. Dürr

Ecoclean, as a producer of forward looking machinery, systems and services for industrial part cleaning and surface treatment in the automotive manufacturing and supplier industries in addition to a host of other industrial market sectors, relies on virtual space in training its service technicians all around the globe. More specifically, this first VR application was developed by Tema Technology Marketing AG to conduct maintenance training on the Scara manipulator developed by Dürr Ecoclean Monschau for its EcoCFlex 3 flexible cleaning cell. In this scenario,

For a realistic rendering of all maintenance operations and workflows, a VR model of the manipulator was created from CAD data. This model can be moved in all directions of freedom via slider bars. Every bolt can be slackened and re-tightened in this manner, yet the individual jobs are logically structured and interdependent. For instance, in performing an oil change in the virtual system, the transmission cover can only be re-closed after oil has actually been added. This approach ensures that the various steps will be trained in their correct and full sequence, thus becoming “ingrained”. In order to achieve this, each service operative can move freely on a defined surface area in virtual space, e.g., by walking around the manipulator. “This development is an important step in ensuring that our global service technicians will be perfectly familiar with their tasks and can provide excellent support to our customers in minimum time”, comments Michael Förster, Chief Executive Officer at Dürr Ecoclean, in explaining his company’s decision in favour of the use of VR.

SKF India registers sales of INR 28047 million in 2016-17 SKF India Limited, India’s leading technology and solutions provider of bearings, seals, lubrication systems, mechatronics and services, has posted a sales figure of INR 28047.2 million in the fiscal year 2016-17. The company earned a net profit of INR 2438.9 million in the fiscal year. Among major development the Company had changed its accounting year from calendar year to fiscal year in 2015-16. The current accounting period of the Company covered 12 months starting from 1 April 2016 to 31 March 2017 as compared to 15 months period of Jan 2015 to March 2016. Commenting on the company’s performance, Mr. Shishir Joshipura, 58 www.martupdate.com

Managing Director and Country Head, SKF India said, “The prevailing economic environment during the financial year called for a differentiated approach to meet the unique challenges posed. Our results reflect the continued acceptance

of our innovative approach by our customers enabling us to consolidate our leadership position. We expect economic environment to improve further, while overcoming the transition challenges under the new GST regime and other economic reforms underway.” 58 June 2017


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