Page 1

Volume 10 Issue 9 March 2014 Pages 52 `100

• Wise tools: Welder’s Companion • First ever TIG Narrow Gap welding handbook • Fire Safety and Industrial Safety are Two Sides of the Coin • Essentials of Value and Quality Driven Product Design and Development • The Art of Leadership Communication

Kemppi propagate

“Ice Breaking Innovations” Rashmi Ranjan Mohapatra National Sales Manager, KEMPPI India Pvt Ltd

March 2014

www.martonline.in

1


2

www.martonline.in

March 2014


March 2014

www.martonline.in

3


4

www.martonline.in

March 2014


It’s almost two weeks now MH 370 Malaysian Airlines Beijing bound flight from Kualalampur gone missing on 8th of this month and as per the latest reports the flight is crashed over southern Indian Ocean, a long distance away from its scheduled flight path. The Boeing 777-200ER aircraft was carrying 12 crew members along with 227 passengers from 15 nations, five from India and the majority from China. Our deep condolences to the grieving family and nothing can fill the gap created by the loss to them. Once retrieving the black box only the world will know what really happened with the aircraft. With technology growing day by day taking human kind to new level, still an individual plays a major role in shaping the destiny, if it’s of building or destroying! Its election time and the world is eagerly watching the outcome of the biggest democratic verdict where more than eighty crore people will decide the fate of our country in the coming two months. Reaching behind United States the most expensive elections held till today, more than 30000 crores of rupees are expected to be spent into the market which one way will rejuvenate the ailing economy. Leading national parties advertisement budget itself is around 400 crores. The market already started reacting positively expecting a stable verdict, NSE and BSE reaching record numbers. Rupee is getting stronger against dollar and is expected to reach below 60 level mark after a long time. We have to wait till 16th May to see the outcome of this election, and whoever comes in power should give a strong government, the willpower the nation require to march ahead.

Foreword

Hi Readers,

In our country one of the major cause of fatal accidents and loss of lives are fire. It’s very important that we take adequate measures to prevent fire not only in our work place but also at home. It’s in the interest of the community we should take proper attention to prevent fire, as the losses generated are paid by the nation itself. R R Nair, Chief Executive of Navi Mumbai based Safety and Health Information Bureau writes in detail in our Feature story on fire safety.

Hari Shanker Managing Editor

Welding is an integral part of manufacturing. Inspite of the global downtrend, Indian welding industry is showing a steady growth and expected to sustain the same in the near future. The premium exhibition for welding in India, Weld India is one of the world’s largest metal forming, fabrications, welding & finishing exhibitions, is organized by The Indian Institute of Welding and is scheduled from 10th April to 12th April at Pragati Maidan, New Delhi. Visitors are expected from diversified sectors like steel, power and oil refining, chemical, and automobile, defense promising a lot in terms of the welding industry in India. MART is the supporting media for Weld India 2014 and this edition also carries some special features on the welding technologies and the latest offerings in the market.

We always believe in Learning! Change is the only stability we can bring to better ourselves and learning is an important tool towards change. From this edition we are starting a column on Talent Management by Pavan Sriram, Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to troubleshoot human-resource and organizational-development challenges. With 13 years of rich experience in management positions at Crestcom International, Dale Carnegie Training, SunGard and MeritTrac-Manipal Education Group and having worked with over 200 clients across industries in India and abroad, Pavan successfully has targeted organizational talent associated with performance management, leadership development, ineffective communication, talent management and measurement. We are sure his experience and expertise will help our readers to excel by learning. Let me take this opportunity to appeal everyone to perform their rights to vote. Looking forward your feedback to make MART, Smart! Signing off.

March 2014

www.martonline.in

5


Cover Feature 8

2014 Weld India, the Show Timer of Welding Industry

10 Wise tools: Welder’s

Companion from Kemppi

14 First ever TIG Narrow

Gap welding handbook

18 HVOF Thermal Spray

Process Technology Adoption by Assomac

19 Increasing the Welder

Productivity and Weld Accuracy

Columns 24

Fire Safety and Industrial Safety are Two Sides of the Coin R R Nair

28 Essentials of Value and Quality Driven Product Design and Development Saravjit Singh

30

Journey Towards Excellence P S Satish

32 The Art of Leadership Communication Pavan Sriram

Strategic Data Management

34

Rajesh Angadi

Volume 10 Issue 9 March 2014 Annual Subscription `1200 Member INS Editorial Advisory Board

A S Shetty Saravjit Singh Manoj Kabre P S Satish J R Mahajan LD Bhakre Mahesh R P Sandeep Hingne

Managing Editor Executive Director

6

www.martonline.in

Hari Shanker hari@martinfotech.in Siji Nair sijicn@gmail.com

Editorial Team Arnab Chaudhuri Debolina Dutta +91 9038005670 Creative Assistant Sayan Chaudhuri martcreative@gmail.com

Edited, Printed, Published and Owned by Hari Shanker A G and Printed by him at Lotus Printers Private Limited, No:32/25, 2n Bangalore – 560 043. Industrial Business Mart is a monthly journal published from Bangalore. Views and opinions expressed March 2014 Industrial Business Mart reserves the right to use the information published here in any manner whatsoever. While every eff employees accept any responsibilities for any errors or omissions. © All Rights Reserved


On Face 20

Rashmi R Mohapatra National Sales Manager, KEMPPI India Pvt Ltd

27

Ascent

36

Success Story

38

Fair Mart

Feature Article 40

A Red Hot Connection

42

CELOS – From the idea to the finished product

Mart Update The Last Leaf

44 49 Advertisement & Circulation

Regional Directors

National Sales Manager Chiranjit Roy +91 9038 002340 chiranjit@martinfotech.in Asst Manager Customer Shrabanti Hui Support +91 9038 003210 Circulation Officer

Benoy Syam Krishna cm@martinfotech.in

Ahmedabad

Narendra Vora +91 8734999636

Bangalore

John Heston +91 98451 42405

Chennai

Subramaniam V +91 93827 48296

MediaMart Infotech 4/155, Paschim Putiary Kolkata - 700 041, India

Tel: +91 33 24886033/ 9038000711 Email: info@martinfotech.in

Visit www.martonline.in

nd Main Road, Sir M V Industrial Town, WOC Road, Bangalore – 560 044 and Published from No: 217, 3B Main, OMBR Layout, d in the journal are not necessarily those of the Publishers. RNI No: KARENG/2004/13614 March ffort has been made2014 to ensure the accuracy of the information published in this edition, neither the Publisher no any of its

www.martonline.in

7


COVER FEATURE

2014 Weld India, the Show Timer of Welding Industry

Debolina Dutta editor@martinfotech.in

Making India the welding power hub Welding is a smart start of a fabrication that joins usually metals or thermoplastic by using coalescence. Its usage is both in the space and in water. But the Internationally acclaimed method welding is facing a period of recession globally as the data sources of approximately 6% growth per year. But the feature is different here in India as the welding industry is expected to dawning of the age of a steady growth in the near future maintaining a liaison with the fabrication industry. Hitting the 8th weld India Exhibition at Pragati Maidan, New Delhi, it will lead the welding industry worldwide. Weld India is an exhibition that goes beyond myriad times, a countless expectations to outset its mark amidst a touchy market. The manipulation is huge, the growth is substantial. As part of the global exhibition in metal and precision tool industry, arc industry, congregated into the term Weld India, IIW (The Indian Institute of Welding) can shoulder up the challenges to display a variety from its kitty bag. With its association with Fabtech, it hits the fair ground from 10th April to 12th April. Organized by the Indian Institute of Welding, Weld India Exhibitions, 2014 (one of the world’s largest metal forming, fabrications, welding & finishing exhibitions in the world) will provide unique opportunities in diversified sectors like steel, power and oil refining, chemical, and automobile, defense promising a lot in terms of the welding industry in India. The Rs. 1,000-crore welding equipment market in India is very much fragmented and dominated by low priced local manufacturers of welding transformers and welding rectifiers. So being a split group it is majorly dominated by the manual welding equipment. With the rising demand of the automated equipment from the several industries the

8

www.martonline.in

scenario is likely to be changed into a fairly good story. The current scenario suggests an annual expenditure of 2 million U.S dollar for brazing, soldering and resistance, 75 million U.S dollar for arc welding equipment and 400 million U.S dollars for welding consumables. And the day is not far ahead when Indian Welding market envisions the dreams of high strength steel and cross country welding consumables, low alloy electrodes with low impurities and high end grades. SMAW of Cr-Mo steels are wholly manufactured in India whereas those of stainless steel, nickel and cobalt base alloy are wholly imported from the countries abroad. Korea, Japan, U.K, Germany, Sweden, Italy and Holland are some of the major suppliers of consumables to India. And it is not lagging behind when it comes to the import of equipments from Japan, U.S, Finland and Austria, France, Germany etc. Like the top corporate houses in the Indian Welding industry, the weld India will foresee a participation from the bulk number of overseas countries like China, Taiwan, Italy, Germany, Japan, Korea in Welding Technology covering arc welding, solid state processes, brazing, soldering,

adhesive bonding, plastic welding, metallurgy, material testing techniques including NDT, health & safety, robotics & automation, beam processes & special processes including nano Joining. It is the large spectrum of user industry ranging from fabrication and construction to metal coating and other allied fields under one roof to provide for a comprehensive insight into technology and markets. Invariably it will be a startling start as more than 250 high profile exhibitors across the globe and over 10,000 key visitors are expected to throng at the exhibition ground. The exhibitor’s profile variably include presence from the sectors like advanced welding processes, aerospace, defense, nuclear, engineering and manufacturing sectors, fabrication tool, gas equipment and accessories, heat treatment, cutting/ grinding, industrial gases, laser welding & cutting , material including steel, stainless steel, aluminum, metal products like precision metal forming conjoining the areas of repair and maintenance equipment, robotics and computer aided, paint and powder coating applications &

equipments, thermal spray technologies, welding electrodes/equipments, welding metallurgy, welding automation with a deeper focus on surface and cladding technologies----under one roof- in other words the whole pack in a small pouch. So the presentation is a golden opportunity for the leaders alias exhibitors as they pave the way for the congregative welding industry and its allied fields to attract the prospective Indian consumers as well as people across the globe and to gain a foothold in the future of the welding industry. Undoubtedly it will be a smash hit. Currently the fourth largest and the 2nd fastest growing economy in the world, India is emerging as a global manufacturing hub. The consumption of welding consumables has witnessed a healthy growth of over 10% per annum since 2007 with its present value estimated at US$ 700 million. Now the low cost automation is on the ascend and adding to the glam the fact is that efficient power sources increases productivity as well as the requirement of welding equipment is the fastest rise. The concurrent event the IIW International Congress March 2014


2014 is a no mean achievement. And it is also being organized by the Indian Institute of Welding which will host about 700 delegates from India and abroad. About 200 high quality technical papers are expected to be presented at IIW IC 2014. Its objectives are wide. It will persistently co-operate to identify the needs of the surrounding countries, co-ordinate with the delegates from the foreign countries as well as encourage the involvement of other international organizations such as the UNIDO, IAEA & EU in the congress. Its pavilion members will focus on the theme ranging from advances on welding fabrication, advances in welding, cutting and surface processes, advances in welding systems and equipments, development in welding consumables for conventional and new materials, testing & characterization of welds, quality management and reliability in welding to productivity and cost reduction techniques. The list is sufficed as one corresponds the other. More than 130 high profile visitors across the globe are participating at Weld India 2014 that truly goes beyond welding as covering the manufacturers of aerospace and automobile, mining and construction equipment, materials on earth moving machinery equipment, railway coaches, thermal wind power, solar power, testing and measuring instrument, iron steel metal products, sheet metal, thermal, wind power, solar power and heavy fabrication in pursuance of an allied industry from adhesive bonding, plastic welding, cutting metallurgy, materials, testing techniques including NDT, health and safety, robotics and automation, beam processes and special processes like nano joining and other allied March 2014

fuels. The global market of welding industry is expected to grow at a considerable rate throughout the estimated period. The arc welding segment of the industry seems to be growing the fastest with recent years showing maximum growth. The growth of the welding industry has been approximately 6% per year. Conventional electric arc welding equipment and filler metals represent over two-thirds of this total. Each segment of the industry and each welding process have its own growth pattern. Therefore, for a successful projection, the past historic growth patterns, its present position in perspective of the future factors truly accounts for reaping the benefit. Weld India Expo an exclusive showcase of the welding and cutting industry and its allied products. The Weld India Expo offers the best platform for exhibitors to showcase their innovative products and ideas to the trade and welding fraternity, the most diverse array of welding products and technology as welding industry is one of the strong forte with many in the industry for the heavy application and safety features. Weld India provides the right platform for the customers scouting for a tool possessing, stronger structural elements safer and reliable. The evolutionary steps are happening every now and then; up gradation and the downslide is the very course of nature. As India havens the ground of a lively market in the earth moving machinery sectors business standard takes a major boom here. And above all the key factors is to make the standardization of the products. Rests are in the lap of future. Let’s gear up for an exhibition pioneering the world.

Hypertherm Showcases New Products at Weld India 2014 Hypertherm designs and manufactures the world’s most advanced plasma cutting systems for use in a variety of industries such as shipbuilding, manufacturing, and automotive repair. Over the years, the company has been actively serving the Indian market, providing excellent local support capabilities to local partners and customers.

The DuramaxTM Hyamp long handheld torch is the first of its kind in the industry

Hypertherm will once again reinforce its commitment to the Indian market at Weld India 2014. During the threeday event, visitors will get to learn more about the thermal cutting solutions provided by Hypertherm, and the benefits that these innovations offer. At the show, Hypertherm will be introducing two new products to the India market - Powermax30 XP® and DuramaxTM Hyamp Torch. Powermax30 XP® The Powermax30 XP® is an all-new handheld plasma cutting system that delivers high performance in a small, portable power source. Compared to its predecessor, the Powermax30®, Powermax30 XP (PMX30 XP) offers a 50% increase in cutting power with more than twofold increase in consumable life, allowing manufacturers to achieve faster cut speeds at lower operating costs. The 30-amp air plasma system is designed for quick and fussfree cutting, and is able to comfortably cut 10mm-thick metals, and to sever metals up to 16mm-thick. DuramaxTM Hyamp Torch In addition to the PMX30 XP, Hypertherm has broken new ground with its latest addition to the DuramaxTM Hyamp torch series - TheDuramaxTM Hyamp long handheld torch. The first of its kind in the

industry, the long torch opens up new possibilities for scrapping, skeleton cutting, and other applications, and comes in two lengths - 4’ (1.2 m) and 2’ (0.6 m). Apart from the Powermax30 XP and Duramax Hyamp long torch, the full range of systems in the Powermax air plasma series, as well as Hypertherm’s wide range of torches and consumables, will also be on display at the show. Interested visitors will also have the opportunity to catch a glimpse of Hypertherm’s superior Built for Business Integrated Cutting Solution in action through live cutting demonstrations with the fully integrated mechanized HPR260XD HyPerformance® plasma, ArcGlide® torch height control, Edge®Pro CNC, and ProNest® CAM nesting solutions software. In conjunction with Hypertherm’s Built for Business automated live demonstration, there will also be a handheld metal cutting demonstration using Powermax125, the most powerful air plasma system in its class that was recently launched early this year. To learn more about Hypertherm’s proprietary technologies and its local expertise and support services, stop by at Hall 10 Stand A01 at Weld India 2014, Pragati Maidan, New Delhi, from 10 to 12 April 2014. www.martonline.in

9


COVER FEATURE

Wise tools: Welder’s Companion from Kemppi Wise is a range of software based welding products for use with Kemppi FastMig and KempArc welding machines. Tailored Wise welding processes and functions are used for root pass work, sheet metal welding, penetration control, and focused arcs, where energy density is concentrated into a narrow area. to as the short circuit and arc period upslope stages (see picture 1). The WiseRoot process is a modified short-arc process and should not be confused with pulse welding. In the first upslope stage, the filler material is transmitted in the short circuit phase to the weld pool, while the power of the arc is suddenly increased during the second upslope stage and sustained at the desired level.

The last few years have seen developments in MIG/MAG welding power sources, creating greater opportunity to increase the multifunctional aspects of the equipment. Both power source and software technologies have made it possible to further develop tailored welding processes and improve function, aiding the welders’ work, quality and productivity. Kemppi’s Wise product family is designed exactly for this purpose.

voltage parameters digitally. The process monitors the short circuit and ensures correct timing of the filler droplet’s transmission from the filler wire into the weld pool. The process monitors and the short circuit ensures the correct timing of the filler droplet’s transmission from the filler wire into the weld pool. This is a modified short-arc welding process and as a MIG/ MAG welding process it is in category 131, 133, 135 or 138 as defined in the EN ISO 4063 standard. The principle by which the WiseRoot process operates is that of two different shapes being formed from the welding current.

The WiseRoot process for root pass welding Tailored root pass MIG/MAG welding process we consider here is WiseRoot. Patented WiseRoot process controls the power source’s current and

Process

v (mm/min)

Wise Thin

800

1 - MIG

800

Before the first upslope stage, there is a short peak in the welding current, during which the filler material wire contacts the weld pool. In

wfr (m/min)

Picture 2: Variation in the root gap with the same welding power. Root gaps from the left 2, 4 and 6 mm.

I (A)

U (V)

P (W) Q (kj/mm)

4

93

16,7

1517

0,019

4

113

18,3

2028

0,012

Q (%) 0 2520

Table 1: WiseThin and synergic MIG heat input comparison

10

www.martonline.in

The control system of the device monitors the droplet detachment moment throughout the arc. Correctly timed rise and fall of current guarantees a spatter-free pass–over from the short circuit to the open arc. The

Picture 1: The current waveform of the WiseRoot process when the filler droplet is transmitted to the weld pool. The cycle is composed of the arc and short circuit periods. The dashed line indicates a normal short arc.

the first upslope stage, the rapid increase of the current

These shapes can be referred

to the desired level generates a so-called pinch force, which allows the droplet to detach from the tip of the filler wire. The detachment is ensured by slowly decreasing the current. Once the droplet has been transmitted to the weld pool, a second stage of increasing current begins and initiates the arc stage.

second upslope stage shapes the weld pool and ensures sufficient penetration in the root pass. After the two upslope stages, one following upon the other, the current is reduced to the desired base level. Use of a specified base current level ensures that the next filler droplet will be transmitted during the next short circuit. Rapid response and correct November February January March 2014 2013


Here is a list of the key benefits of the tailored root pass welding process: • Wider root gap makes it possible to use a smaller groove angle. • Decrease groove volume. • No need to use a backing ring. • It is a highly efficient process: 10 % faster than normal MAG welding, and three times faster than TIG welding.

After that, the current slowly decreases before the arc period ends and the next short circuit begins. In the WiseRoot process, droplet detachment happens at a low current value, which results in soft transmission to the weld pool. After that, in the arc period, the process gives a precisely measured strong boost to the arc and then rapidly cuts the current to the predetermined level before the next short circuit.

The WiseRoot process’s highly controlled arc reduces spatter in the droplet detachment phase • It is suitable for position and decreases the heat input in the arc phase to be comparable welding. with that in a normal short• Easy to learn and use. arc process. The WiseRoot process allows welding with • Less spatter than in normal wider root gaps than usual, short arc. with the same welding power settings (see picture 2). Root gaps can range from 1 mm to timing in power source control 10 mm, but the welding power combine with the correct shape has to be adjusted to match of the current waveform in the the case. When the welding process to allow uninterrupted, position changes, the welding spatter-free droplet detachment power must still be appropriate and transmission into the weld for the circumstances. On the pool. This keeps the arc stable workshop level, the above and the welding process easy to WiseRoot features can be seen as increased welding quality and control. The WiseRoot process decreased need for post-weld differs from normal shortrework. arc welding. Picture 1 shows normal short-arc and WiseRoot The WiseThin process for sheet waveforms. In the normal shortmetal welding arc process, droplet detachment occurs at a high current value, In sheet metal welding, low which depends on voltage heat input is a desirable feature. control. There are various laser welding

applications that have been used for this purpose, but lasers have their limitations. MIG/ MAG welding has developed so that it is now possible to weld with low heat input, especially in the short-arc area. In tailored processes, one can obtain the same heat input as in laser welding. Kemppi’s WiseThin is a tailored MIG/MAG short-arc process that enables achieving 5–25 % less heat input than with a normal short arc, depending on the welding case. In welding of high-strength steels, this is of great benefit, because the trend is to weld steels of ever higher strengths. This is a driver

difference is that the WiseThin is optimised for sheet metal welding. WiseThin is a modified short-arc welding process and as a MIG/MAG welding process it is in category 131, 133, 135 or 138 as defined in the EN ISO 4063 standard. Picture 3 shows typical welding applications for tailored sheet metal welding processes. In sheet metal laser welding applications, the biggest problems arise from the narrow gap tolerances. With MIG/MAG processes the tolerance window is wider, because they are not so sensitive to gap variations. Tailored processes can increase the width of the gap tolerance

LONG NORMAL SHORT

Stick Out Length

30 20 10

Current 240 A

280 A

330 A

Picture 4: Welding current changes with the stick-out length.

March 2014

Low heatinput and optimal weld bead geometry are among the benefits of tailored processes.

toward a weld process with low heat input. Table 1 compares the WiseThin process’s heat input to the heat input of a normal short arc in welding of an overlap joint. The material is structural steel and the plate thickness 1.0 mm. The principle of the WiseThin process is similar to that of the tailored WiseRoot process for root pass welding. The

window, because of the lower heat input. This makes it easier to handle molten metal. The WisePenetration function for guaranteed penetration In MIG/MAG welding, constant voltage (CV) characteristics are most commonly used. The self-adjusting welding arc is the most important argument for the use of constant voltage www.martonline.in

11


control brings all kinds of benefits.’

Picture 5: The upper row of pictures shows normal MAG process without WisePenetration, and lower row shows how WisePenetration affects the weld. Stickout lengths from left: 25mm, 30 mm, and 35 mm.

characteristics. An increase in stickout length will cause welding power to drop, because welding current decreases (P = U x I). Changes in stick-out length have no effect on wire feed speed or arc voltage. Instead, welding current fluctuates according to the changes in stick-out length. As an example, picture 4 shows you how welding current changes with stickout length when welding S235 steel with 1.2 mm wire and using Ar + 18% CO2 shielding gas and the following welding parameters: wire feed speed 8.8 m/min, voltage 29 V, travel speed 58.0 cm/min. Because of using constant voltage characteristics, the welding current Picture 4: Welding current changes with the stickout length. Depends on the stick-out length: the greater stick-out length, the lower welding current. This can cause serious welding defects, such as lack of fusion, incomplete penetration,

unstable weld quality and spatter. In manual MIG/MAG welding, the stick-out length always varies more or less, depending on the welder’s skills, and this has an effect on the weld penetration. Sometimes the welder must increase the stick-out length because of limited visibility or accessibility, position welding, difficult joints or weld design problems. In mechanised and automated welding, dimensional and geometrical deviations of the joints can cause variation of stick-out length. Those deviations can originate from various phases of the joint preparation or fit-up work. Also the welding heat causes distortion, which increases deviations during welding.

When welding with stick-out lengths within the permitted limits, WisePenetration operates like conventional MIG/MAG process and lets welding current fluctuate with the stick-out length. However, if stick-out length increases above the permitted level, WisePenetration takes the control and ensures that the current remains constant. Picture 5 shows how WisePenetration keeps the penetration constant while the standard process loses its penetration when stick-out length rises above normal limits.

Various joint tracking systems can be used to help this, but they are expensive and do not operate reliably in all welding conditions.

In position welding (other than flat or horizontal vertical), the most common problem is how to control the welding arc and the molten weld pool. This issue is emphasised in MIG/ MAG pulse arc and spray arc welding. For example, it is very difficult to find the correct pulse welding parameters when welding aluminium in horizontal overhead position. To meet the needs of all position welding, Kemppi has developed the WiseFusion function, which keeps arc length more constant and prevents the arc from becoming longer as the stickout length changes.

‘Using the adaptive arc length

Picture 7: 960 MPa grade steel weld. Plate thickness is 6 mm. I-groove welded with a single pass from one side. Welding energy is only 0.58 kJ/mm.

12

www.martonline.in

Kemppi offers the unique WisePenetration function for cases where it is difficult to keep a constant stickout length. This function makes it easy to keep the welding parameters (I, U) within the WPS limits. This guarantees the desired penetration and improves the weld quality. WisePenetration offers constant welding current with stick-out length within the limits defined in welding procedure specification (WPS).

The WiseFusion focused arc function offers many benefits

The principle of operation is based on controlled regulation of pulse or spray arc current and voltage waveform. This produces a welding arc that is more focused and has higher energy density than in normal pulse or spray arc welding. Another benefit of WiseFusion is that a focused arc allows greater welding speeds. The greater welding speed and higher energy density mean less heat input compared to standard pulse or spray arc, and low heat input is a critical factor with certain materials. Using the adaptive arc length control brings all kinds of benefits,

Picture 6: On the left you can see a weld made with pulsed MIG and WiseFusion function. The weld on the right is made with pulsed MIG without fine tuning the arc. The wire feed rate is 4.6 m/min.

such as excellent weld pool control in all positions, narrow and energydense arc, and no need to fine tune the arc length. WiseFusion is very easy to use. Welding parameters are always right, so you don’t need to adjust them. You can use faster welding speeds and get deeper penetration and stiffer, more focused arc. Low heat input and narrow grooves make it also a very productive and cost efficient welding function. For further details do visit www.kemppi.com

March 2014


March 2014

www.martonline.in

13


COVER FEATURE

First ever TIG Narrow Gap welding handbook The reference document for the industry The quality and productivity requirements relating to welded joints are inexorably driving industrial companies towards the implementation of automatic processes. These primary objectives are however supplemented by more subtle notions such as heat input, weld seam regularity or even aesthetic criteria for sectors affecting the general public. Several decades of progress in TIG welding have seen it become an essential process that offers not only the widest scope of use but also reasonable operating constraints compared with more recent developments (laser or electron beam welding).

of numerous machines which have boosted recognition of the TIG process as a real alternative for the automated welding of a wide variety of materials.

Fig. 1 : Narrow Gap TIG welding – an essential process

The effectiveness achieved in producing quality weldments using the TIG process, both in terms of productivity and control in all positions, is at the origin of a large number of automatic applications including orbital welding. This technique has now been popularised with the creation

Efforts made in tool design (miniaturisation, robustness, increased duty cycles, etc.) have made it easier to optimise the designs and service performance of the equipment to be built. The whole range of benefits linked to TIG welding have not only encouraged the automation of sequences that were previously only done manually, but have also been the starting point towards applications involving increasingly large workpieces.

Consequently many variants or developments towards high-power welding power sources, or the introduction of additional functions such as the use of hot wire or double wire feed, or the creation of specific tools such as cladding and narrow gap torches have decidedly widened the scope for TIG. Nowadays it isno longer unrealistic to consider using TIG to Fig. 3: Increase in productivity between a conventional weld workpieces groove and a Narrow Gap groove from 0,5 to 300

14

www.martonline.in

mm thick given the numerous relevant advantages. The TIG welding approach on thick workpieces does however require some specific knowledge with regard, on the one hand, to the choice and use of equipment and, on the other, to workpiece preparation and the development of operating techniques. Productivity is

Gap welding outweigh the substantial gains. Several decisive factors come into play when analysing this question and the final choice must take account of the notion of relativity which may exist between the various situations. It can therefore be seen from comparative tests that, for thicknesses ranging from 12 to 15 mm, the increase in productivity between a

Fig. 2 : Turbine rotor welding with thicknesses of up to 300–400 mm

a question that is invariably posed on developing a Narrow Gap operating procedure. However, in order to choose an operating technique, the strengths and weaknesses of that technique must be known beforehand to avoid ending up in an impasse. Productivity gains are considerable and increase in proportion to the thickness to be welded. It is vital nonetheless to assess the thresholds below which the restrictions involved in Narrow

conventional groove (angle of approximately 20°) and a Narrow Gap groove optimised in relation to the materials is not significant. Profitability will then increase, reaching a factor of 3 on sections around 55 to 60 mm thick. At thicknesses of 30 mm and above, apart from the specific case of welding oneoff parts, a Narrow Gap procedure must be used. The difficulties relating to materials or other operating restrictions are to be considered in order to choose

February March 2014


Fig. 4 : Narrow Gap V2/V3 torch module for thicknesses of 0–100 mm

the Narrow Gap technique that is appropriate and compatible

Fig. 7 : Single stringer bead

Fig. 8 : Multiple-pass stringer bead

Fig. 9 : Single oscillation pass

March 2014

Fig. 5 : Narrow Gap NG torch module for thicknesses of up to 300 mm

with the application in question. Today, Polysude has a comprehensive line of Narrow Gap welding torches for all thicknesses from 30 to 300 mm. The ranges and thicknesses to be welded are to be considered on the basis of the line of torches created and constructed according to various technological constraints. Each torch has a scope which enables it to be used from maximum thickness (maximum torch insertion depth into the groove) up to completion of surface capping runs. With conventional torches from 0 to 45 mm, electrode stick-out has to be adjusted every 5 to 10 mm, when filling up the weld groove. So-called conventional torches remain fully versatile torches that are suited to all types of work. A category of intermediate tools called “V2 and V3 nozzles” exists for 0 to 100 mm thick sections. These nozzles have the particular feature of being insulated and channelling the gas to the root better than a conventional torch but without guiding the tungsten via a true electrode lance. From an insertion thickness of approximately 45 mm, these nozzles are combined with removable trailing shield assemblies to complete the weld, oscillated capping run included. For thicknesses of 0 to 150

mm, 0 to 250 mm and finally 0 to 300 mm, a line of torches is also available with trailing shield assemblies (removable if necessary) for all runs from root to cap. All Narrow Gap solutions (i.e. 0 to 100 mm V2 and V3 nozzles, and 0 to 150 mm, 0 to 250 mm and 0 to 300mm NG torches) exist as fixed electrode or oscillating electrode versions. The deliberate reduction in the volume of metal to be deposited, which is the main objective of Narrow Gap applications, highlights several operational difficulties including that relating to the lack of visibility for operators to track the welding.

influence on weldment quality. Consequently, testing methodologies have been developed to verify and validate the predominant functions where failure could impinge on welding results. Two essential factors are to be considered: • The duty cycle (all functions mounted on the torch being globally combined and validated by the lack of deterioration of its initial function over time).

These difficulties are explained by the effect of several combined factors that differ slightly according to the applications, but which include: • Groove width commonly between 10 and 20 mm for depths of 100 to 300 mm. • Welding on flat sheets or large diameter workpieces rendering tangential viewing angles almost impossible. • Preheating which is very often used when welding heavy wall thicknesses. In addition to these technical aspects, it is also natural to seek comfort for the operator stations and to move them away from the arc given that the radiation remains quite strong due to the use of high currents. To remain compatible with the industrial environment and refrain from overburdening the tools, it is possible to integrate the video function by design, as opposed to the use of add-on external cameras which disfigure the industrial nature of the equipment. The torch is not only the most complex tool, but is also the one that has the greatest exposure and the greatest

Fig. 6 : NG torch with integrated front and rear cameras

• Bead shielding quality. Validation is performed for each new torch reference with regard to functions such as video and gas shielding. More comprehensive tests are performed per torch family or as a result of a notable technological development. Once validated, the concepts are reused per family to reduce the development time of variants and to capitalise on lessons learned on each model. It can be considered today that there are no longer any technological issues in using

www.martonline.in

15


positions where shrinkage and preparation are fully controlled • Multiple-pass stringer beads per layer for optimum control over welding energy and difficult bimetallic joints • Single oscillation pass per layer for welding in positions 5GT and 6GT with limited variations in width – a good compromise between productivity and ease of implementation Fig. 10 : Carriage-type head with narrow rail

a Narrow Gap torch to weld sections with a thickness of 30 to 300 mm. As there is no technological barrier, only technical criteria can be considered. Based on this fact, what are the alternatives, the common features, and the strengths and weaknesses associated with each methodology? The first choice to be made in TIG welding concerns the process variant: cold wire TIG or hot wire TIG welding. Hot wire TIG welding machines generally have higher duty cycles with the capacity to use currents approaching 450 A. There are only advantages to be gained in opting for hot wire welding over the cold wire process and the former is increasingly used

to weld sections over 10mm thick. These machines also offer the benefit of versatility and can make use of the two TIG welding variants quite easily. The only benefit of the cold wire TIG process may lie in the portability of the equipment for occasional use with a lower purchase price, as a direct consequence of the difference in power, for a complete installation. The various welding procedures are differentiated by the filling run layering strategy (cf. Comparison of the various NG filling techniques). Four essential approaches and their advantages shall be examined: • Single stringer bead per layer for welding performance and productivity in all

Fig. 11 : Turbine rotor welding module

16

www.martonline.in

• Multiple oscillation passes per layer (rarely chosen) to use Narrow Gap TIGwelding while adapting to existing preparations. Workpiece profiles, thickness ranges and the environment

machines. “Carriage”-type heads offer the advantage of being able to be used on circular or straight rails. The Polycar MP (friction drive) can be implemented on combined sections (curved or elliptical, etc.). Due to the simplicity of the Polycar MP profile, industrial companies can create their own tool. Straight rails are identical to the “seam welder” notion except for the fact that they can be used in all positions and are an easily implemented solution for linear welds. For thicknesses up to 100mm, the torch holders are the same as for conventional torches. Beware however of circular welds in a horizontal plane which, other than the

Fig. 11 : Turbine rotor welding module

are all essential data when it comes to defining welding equipment. Welding machines are generally matched to the welding tool to be used. A few typical examples of equipment configuration according to the thickness of the sections to be welded are provided below. For sections less than 45mm thick, usual mechanised or orbital welding equipment is suitable as long as it is compatible with the required duty cycles. More versatile and modular PC power sources are suited to mechanized applications, or even more complex applications such as welding robot-type holder-based solutions or orbital welding

particularity of being so-called self-restraining welds (high stress concentration), also call for Narrow Gap torches with a curved profile (to be avoided). Beyond 100mm, the tools gradually increase in size forming, in certain cases, modules that weigh several hundred kilograms (turbine rotor applications, for example). For so-called mechanised applications, the solutions are identical but constructed on the basis of more robust components adapted to the context, the geometry and the weight of the subassemblies, in keeping with the thickness of the workpieces. March 2014


For orbital welding, however, the weight of the torches, the engagement strokes and the need to consider use of 15kg spools (justified by the volumes of metal to be deposited) call for larger tools than the POLYCAR 60-3 and MP orbital heads. In this case, choose heads capable of moving heavy loads (80kg) with an offset providing sufficient flexibility to adapt to heavy-duty sheet metal workpieces. Use of a welding robot is also recommended for anything other than circular trajectories or where the industrial company wishes to acquire a more versatile tool. There are no particular considerations for solutions involving torches intended for applications up to 45mm. A retractable nozzle torch offers a multipurpose solution provided that electrode changing can be accepted as a non-automatable operation. For heavy wall thicknesses, torch weights and dimensions must be integrated and robots compatible with wrist loads of 10 to 50kg selected. The notion of trajectory remains linked to the profile of the torches which limits movements and implies studying torch positioning along the usual three axes. The use of a Narrow Gap torch renders the notion of automated preventive maintenance, such as electrode changing, somewhat illusory. The other approaches are specific to robot use and are to be addressed according to workpiece dimensions and the level of automation (gantry, multi-robot station, seam tracking, etc.). Narrow Gap TIG welding is no longer a solution for exceptional circumstances. It is important to consider it whenever the thickness to be welded exceeds 30mm. An

initial analysis is imperative to ascertain the potential benefit, verify the absence of notable contraindications and above all to choose the methodology and equipment best suited to the context. There are a multitude of solutions with a significant level of industrial maturity confirmed by numerous concrete examples. The difficulties involved in implementing the welding procedures vary according to the chosen technique. The temptation to take a simplistic approach and skip a case-bycase assessment must however be avoided as there is no universal solution. Moreover, in terms of tools, the entire 30 to 300mm thickness range is covered with numerous variants and adaptation possibilities for special cases. For the welding process, knowledge and mastery of TIG are highly important and enable the technique to be popularised, with recourse in the event of difficulties. From the point of view of industrial companies, the implementation of a Narrow Gap application calls for a structured approach with marked steps. In parallel, corresponding approaches for machining facilities, tracking and traceability of materials and inspection techniques may need to be undertaken requiring validation steps close to those used in welding. All of these anticipatory measures are justified by the prospect of substantial gains compared with the use of more conventional techniques. The author A B Kulkarni is Head of Representation of Polysoude India. For further information write to him at Plot no. 7, Shri Shanta Durga Niwas, Shivaji Cooperative Housing Society Ltd, Off Senapati Bapat Marg, Pune - 411 016. Tel: +91 20 40035931, Fax: +91 20 40035930 Mobile: +91 9890529923 E-mail: ab.kulkarni@polysoude.in Web: www.polysoude.com

RUBBER EXTRUDED PROFILES

EPDM Rubber Products : EPDM profiles, Tubes, Sleeves, Beadings, weather strips, Door beadings , Sponge beadings , Furnace seals, Strips, Gaskets, etc Also, Extruded Beadings &Profiles from Neoprene, Nitrille, Natural Rubber, Hypalon , Silicone, Vilton, EPDM, TPR, Polyacrylic HNBR

Silicone Rubber Products : Silicone “O” Ring Chords, Silicone extruded profiles, Silicone strips, Gaskets, Silicone sponge beadings, Silicone tubes, Sleeves, Washers, etc.

Vilton Rubber Products : “O” Ring cords, Vilton profiles, Beadings, Seals, Strips, Gaskets, Tubes, etc

Rubber Moulded Products “O” rings, Oil seals, Bushes, Mountings , Diaphragms, U&V seals, Grommets, Pads, Washers, Cup washers Couplings Rubber sheets, Metal to rubber bonded items Rubber Sheets, etc

Enterprising Polymer Products Pvt Ltd Plot No 29, Anna Industrial Estate, Near Porur Gardens Vanagaram Mettukuppam, Chennai 600095, India Tel: 09840090674, 044 65385424 Telefax: 044 24760576 Email: enterpolymer@hotmail.com, enterpolymer@dataone.in

March 2014

www.martonline.in Visit: www.enterpolymer.com | www.enterpolymer.in

17


COVER FEATURE

HVOF Thermal Spray Process Technology Adoption by Assomac

Nirmal Singh nirmalsingh@assomac.in

High Velocity Oxygen Fuel (HVOF) Coating is a Thermal Spray Coating process where oxygen &fuel gas are ignited in particular atmosphere. This process is used to improve or restore a component’s surface properties or dimensions, thus extending equipment’s life by significantly increasing its resistance to wear, corrosion & erosion. chemically /electro-chemically formed coatings. Tungsten Carbide based powders are widely used in the HVOF Spraying System. These are used to produce dense, high hardness and excellent wear resistance coatings generally to combat the erosion and corrosion occurring in hydro power plant and pumps wire industries. In applications where abrasive or corrosive wear resistance is of primary importance. Wc-co (Tungsten Carbide) with and without nickel or chrome is used. HVOF Spraying does not have these Molten or semi-molten materials are sprayed out to the surface by mean of high temperature, high velocity gas stream, producing a dense spray coating which can be ground to a very high surface finish. The utilization of the HVOF Coating technique allows the application of coating materials such as metals, alloys and even ceramics to produce a coating of exceptional hardness & thus giving substantial resistance to corrosion & wear.

processes, HVOF Coating material is heated& accelerated by a gas stream to a component’s surface, to attain better properties. With the HVOF Coating process, the gas stream is produced by mixing & igniting oxygen & fuel (gas or liquid) in a combustion chamber & allowing the high pressure gas to accelerate through a Thermal Spray Process.

Assomac installed this system in-house for its wire drawing drums /cone rings & other components which help giving a very long life to the components besides giving a very smooth surface finish of wire. The plant is purchase from Sulzermetco & ABB (Robot)

The following process instructions are intended for use as a guide, for coating of carbide powders using “HVOF” Thermal Spray Coating.

Process Flow Chart of HVOF As with all Thermal Spray Coating The main advantage of HVOF Coating

•Improves the performance of the component •Enables the components to operate within Harsh Chemical environments. •Reduces the cost of maintenance •Enables the components to operate in higher /lower temperatures •Improved efficiency of machine •Improves life of mating components. •Saves Electrical Energy.

18

www.martonline.in

Thermal Spray Process

The instruction contain the list and description of production techniques and operation needs to accomplish the process of applying Thermal Spray Coating on components as well as the list of main types of coating defect and their remedies. In recent years, high velocity Oxy Fuel (HVOF) Spraying has been considered an asset to the family of Thermal Spray Processes especially for the materials with melting point below 3000oC to 3300oC. It has proven successful since it shows advantages in density and bond strength making it attractive for many wear and corrosion resistance applications. Its high coating quality results from the use of a hot combustion & new high speed gas jet for thermal spraying. These coatings have environmental advantages compared to

Weight & heating of Powder

Precoating Operations of part (i.e. vapour degreasing, Shot blasting & Ultrasonic cleaning)

Loading of power into powder feeder

fixing of component in manipulator

HVOF Thermal Spray Coating with the help of Robot

Quality Control

limitations. HVOF Thermal Spray coating has a mechanical bond. The bond strength can be of high or 12000 psi, which is attained by the high kinetic energy of the particles. Thermal Spray Coating is an attractive technique as it offers a wide choice of materials & processes that have a reduced impact on the environment when compared to conventional plating processes as explained above. For further details write to info@assomac.in or visit www.assomac.in & www.assomacmachines.com February March 2014


COVER FEATURE

Increasing the Welder Productivity and Weld Accuracy Strongwire launches multi-wire copper coating production line for MIG, TIG & SAW welding wires Welding conglomerate Strongwire Industries inaugurated its state-of-the-art multi-wire copper coating line to manufacture the finest copper coated MIG, TIG and SAW welding wires. Strongwire is indulged in manufacturing, trading and supplying an extensive assortment of products catering to the welding industry. These products range from raw materials to finished welding consumables to high end welding wire manufacturing machineries and equipments.

Touted as “India’s first”, the new facility is located in Bhilad, Gujarat and has an annual production capacity of over 5,000 tonnes. The unit is fully equipped with wire rod pre-processing, straight line drawing, multiline copper coating, precision layer winding machines and drum pail-packing machine for both MIG and SAW wire for diameter 0.70mm to 5.50mm in packing of 15, 25, 30, 100, 250 and 350 kgs. The unit has also installed straightening, cutting and embossing machines to manufacture TIG wires in size range 1.20mm to 3.15mm in 500mm and 1000mm length in 5-kg tube packing. Before the initial drawing the wire rod is cleaned carefully in a 5-stage pre-processing line using water, acid, hot water, borax and hot air on the wire rod surface to completely eliminate mill scale from the wire rod surface. After completing the wire

drawing the drawn wire is put through a multi-line copper coating process comprising of a 14-stage cleaning and neutralising process wherein copper coating is done with de-mineralised water. The multi-line copper coating process as against the conventional copper coating process removes all impurities from the wire surface and gives a uniform coating resulting in longer shelf life and complete

“Quality of copper coated welding wire being

elimination of any rusting on the wire surface. Strongwire Industries was set up in 1992 as a mild steel wire drawing facility specially to cater to the needs of welding electrode manufacturers. Today the company is involved in manufacturing, trading and supplying an assortment of products for the welding industry. These products range from raw materials to finished welding consumables and high end welding wire manufacturing machineries and equipment.

manufactured in many regions of India has

The company’s primary business is manufacturing and distributing to poor and improper wire cleaning process. a wide range of modern welding consumables consisting of At Strongwire Industries, we have completely manual metal arc electrodes, eliminated this problem through a multi-stage cleaning and neutralising process thus increasing copper coated MIG/TIG and SAW welding wires, SAW flux, flux the welder productivity and weld accuracy.” cored welding wires (FCAW) and stainless steel and aluminium Umesh Agarwal filler wires. Founder, Strongwire low shelf-life and face rusting problems due

Strongwire Industries has been March 2014

associated with Tata Steel for over 25 years. Tata Steel has one of the best integrated steel plants in India and is a world-class manufacturer of wire rods. Commenting on this association, Mr Agarwal said, “At Strongwire, we not only source our entire wire rod requirement from Tata Steel but also distribute and market their electrode quality wire rods.” Strongwire Industries also offers consultancy services for turnkey projects for setting up complete welding wire manufacturing units. It has collaborated with two big Chinese manufacturers to source quality machineries. Strongwire has serviced machinery requirements of many companies across India through these exclusive tieups. For more information visit www.strongwire.in www.martonline.in

19


ON FACE

Kemppi propagate “Ice Breaking Innovations” Located at Lahiti city Kemppi, a Finnish company founded in 1949 by Martti Kemppi is a world-class manufacturer of welding equipment. The company has subsidiaries in 17 countries, sales offices and retailers in over 90 countries, and its turnover is more than €120 million. They have been by far rewarded for their unique design with noteworthy “Reddot award”. Kemppi has been present in India for the last 40 years. They have set up a manufacturing unit in Chennai since 2011. Rashmi Ranjan Mohapatra, the national sales manager of Kemppi India Pvt Ltd spoke exclusively with Mart about Kemppi India’s journey till today and shared its future plans in the Indian market in the upcoming years.

According to Kemppi’s latest tagline, “we will keep the ‘Arc Under Control’ and always offer its customers more comprehensive solutions than before”. How do you think you would fulfill your promise to the customers? Innovation is the key to our growth and is in our DNA. We provide comprehensive solution to the customer by our equipment, software and industrial services.

• ARCQ system: ArcQ is another step towards the “Welding Quality Management”. This will help the customer maintain their traceability and can monitor the welding online to avoid costly rework.

Kemppi is the first welding company in the world to be certified with ISO 3834:2. This authorizes Kemppi to provide its own WPS to its customers. This goes on to prove that at each step we try to bring in comprehensive solutions for our customers. 2013 has been another “ice breaking innovation” year for Kemppi. We have introduced “Total Welding Quality Management” to the industry.

• Arc info: This is entry level software to help analyze welding data. You get valuable data about voltage, current, wire feed speed, wire feed motor current etc.

The representation above is a clear indicator of our offering to the customer.

• Standard WPS Packages: Our standard WPS packages are in accordance to EN 1090 EXC 3 and EXC 4. This will immensely help lot of our customers in the Indian sub-continent to

• ISO 3834-2 certification: KEMPPI is again the first

20

company in the world to have the ISO 3834-2 certification. This allows us to create our own WPS for the customer, thus saving a lot of customers’ time and money.

www.martonline.in

• Arc Validator: Kemppi Arc Validator validation system helps manufacturers meet the requirements set by their quality management systems. It automatically creates validation certificates.

maintain the standard and also in exports to the EU.

conferred with the “Reddot award” for design.

• Welding Consultancy and training: We undertake consultancy and training for welding for our customers and ensure that their productivity is increased.

Kemppi is the specialist in “ARC WELDING”. It is not only equipment but the “software”; which addressed the challenge of the welders. All our equipments are software based – to bring the best out of the welder. This is quite unique to Kemppi. We have our own “Software” company to support our system. At Kemppi we offer total solutions to the customer. It consists of Product, Industrial Services and Software. It is this combination which helps the customer to experience as a whole and let them exploit all our potential to their advantage.

• Wise software: These softwares have addressed the challenges faced by the welders and have taken the welding to a new level. Can you brief Kemppi India’s journey till today. Being a leading global company how do you maintain the pressure at bay? Kemppi is based at Lahti in Finland. It was established in 1949. Kemppi is a pioneer in “inverter” technology. We are present in more than 90 countries today. Our product design is quite unique. We have been awarded several awards for our product design, the recent one being the “IF Design Award” in Europe for our KEMPACT 253R. The other notable awards are for “Super Snake”, “MinarcMig” and Fitweld” – which have been

In India we have been present for the last 40 years. We have a good and loyal customer base in the country. Keeping this in mind and the future prospect in India; Kemppi has invested in setting up a plant and office at Chennai, India. This is of strategic importance to the Indian and South East Asian customers. Interestingly, this is the first plant of Kemppi March 2014


outside Finland. Our first product from India was the HiArc M 400i in April2011. In the last 2 years we have added 30 products from our Chennai plant. The latest launch from Chennai plant is HiArc S 400 R – an MMA machine of 400 amps for the local market. Our MIG machine (Hi Arc M 400R) has been a trendsetter in the industry and the new MMA machine will also follow suit. The products which made a difference in the Indian market? As elaborated in the points above it is not some specific products but the whole solution offered by KEMPPI has made the difference. We have products for each segment of the market. Hence it helps in market penetration. How Kemppi India is different from others in the market? At Kemppi we work very closely with the customers. The whole endeavour is to bring joy in welding. Our products are designed to

March 2014

address the challenges faced by the welders. The idea is to make the customer use our strength to their advantage and increase their productivity. We develop products exclusively for segments where they get direct benefit from the equipment, for example our Supersnake is an exclusive product for shipping where they can weld up to 45 metres from the power source. We have launched several products in 2013 which had brought tremendous market share for us. Our ArcQ – Welding Management System is the first of its kind software which changes the face of welding. The grimy, mundane job of welding can

be monitored by software and the user can have the data in real time. Fastmig X 450 is another product which is again industry specific. This product is specifically for “Pipe Welding”. With its unique features it has received rave reviews from the users. ‘Ice-breaking innovations’ - that was Kemppi’s title message for the 2013 Essen fair. Could you please brief on this? There are only 10 million people living north of the 60th parallel. Half of these people are Finns. Finns are used to living in the middle of ice and snow, and they have over the years developed unique know-how which is bound to become even more valuable in the years to come. Finnish territorial waters are covered by thick ice for as much as half the year. In the winter, ice normally covers around half of the Baltic Sea, but during severe winters, the entire sea is frozen over. Over 90% of Finland’s exports and imports are transported by sea, and difficult ice conditions brought out the best of Finnish ingenuity and creativity from early on. Finland is a superpower when it comes to icebreakers, with 60% of all the world’s icebreakers having been built in the country. These vessels are masterpieces of Finnish design and workmanship. Sisu, the first sea icebreaker built entirely in Finland, was completed in 1939, just before the Winter War broke out. It was the second diesel electric

icebreaker in the world. When it was commissioned in 1954, Voima was the first icebreaker in the world to be equipped with two bow propellers. Scale model testing was used for the first time in the world when Urho, completed in 1975, was designed. Finland was also the first country in the world to introduce multipurpose icebreakers. These vessels are used for icebreaking in the winter, and in the summer they are chartered for offshore projects. These are just a few examples. Some of the icebreaking innovations made in Finland also continue benefit other branches of shipbuilding. The world’s largest cruise ships the Oasis of the Seas and the Allure of the Seas, both built in Finland and operating in the Caribbean, berth at ports with an accuracy of less than a metre, thanks to azimuth thrusters which can rotate 360 degrees. The innovations which lead to modern azimuth thrusters were first made when new icebreakers were developed in the 1990s. The first such innovation was the Azipod thruster, in which power was transmitted to the propeller by means of the magnetic field of the electric motor instead of a shaft and gearbox. Other noteworthy Finnish innovations include low-friction paint coatings and a stainless steel coating for use in the waterline area. Both innovations significantly reduce the ice resistance of the icebreaker. www.martonline.in

21


train?” As an organization we work very closely with institutes supporting them in imparting proper training to the next generation of welders. We train the trainers who are not aware of the developments in the welding world globally. We also undertake special welding training program at our Training and Demo centre at Chennai. We invite institutes/ ITI/ Training schools to use our strength as a service provider and create a difference to the society. Can you brief more about your manufacturing facilities in Finland and in India?

While the above paragraph creates the theme it also signifies how Kemppi innovations are also in the same line as a Finnish company. Hilarc, ‘Kemppi Pro’-world’s first digital welding machine and ‘MinarcMig Adaptive 180 with this advancement what are the new innovations on the pipeline? We are getting in to Total Welding Quality Management. There have been a lot of softwares to support the Welding world and increase the productivity to unprecedented levels. Our ISO 3834-2 certification is the way forward. Which are the major areas you feel that the government initiative is a mark for upgradation of the welding industry?

22

www.martonline.in

The Indian government and the industry is slowly changing. The recent launch of “Centre of Excellence” in ITI schools is a big benefit for the whole industry. It generates the work force that has been trained with the latest equipment and ready to deliver in the manufacturing world. In a perspective when the industry is suffering with a paucity of welders, what are your initiatives to customize this issue? The latest report reads that Indian needs 22 lakhs welders in the next 5 years. This has manifold implications to the industry and the country as a whole. While we require a skilled person to contribute to the manufacturing and create an impact to the GDP – the basic question comes forward: “how to train and whom to

We had only one plant in Lahti, Finland (since 1949) prior to the Indian plant in Chennai. The plant is Finland has 3 divisions: equipment, electronics and software. We started commercial production in Chennai since april 2011. At Chennai we manufacture products for South East Asia and Latin America. We started with one basic MIG/MAG machine and have expended to 100 different variants for the various markets. Is there any expansion plan for India in the near future on its manufacturing capability? We have been growing rapidly in India after the incorporation of our manufacturing facility. In 2013 we have grown by 82% year on year. We are adding more lines in 2014 and continue in the same speed till 2016. Any innovations which made a global impact from the Indian facility? No. Our RDI is based at Finland and all the designs and innovations emanates from that centre. The manufacturing

facility merely follows the said standards or design aspects. So, principally we don’t credit ourselves for the global impact. What are the new markets Kemppi has developed in the last 2 years both in the domestic and international market? We have developed products to transcend across the segments. This has helped us in market promotions across the globe. However, in terms of market expansion – we have opened up our new subsidiary in Malaysia to cater to South East Asian market. We have expanded our presence also in the latin America. Can you share your future plans for Indian market in the coming five years? We have made our presence felt in the Indian Market very strongly in the last 3 years. We would still like to grow to become the number 1 equipment manufacturing and selling company in India. We will be adding more products to our portfolio to address the segments. We have also lined up 5 new products to be launched in 2014. Idealized with the dream ‘World of welding’ how does the co-operative strength work to make the brand Kemppi famous? Our customer is at the forefront of all the activity we do. It is the customer’s demand which propels us to work closely with them and come out with a solution tailor made for them. This makes us unique in the market place. We believe that business is done by people to people and KEMPPI strives to bring the “Joy” at each level of the relationship with the customer.

March 2014


March 2014

www.martonline.in

23


MART FEATURE

Fire Safety and Industrial Safety are Two Sides of the Coin

R R Nair shib@vsnl.com

By and large, fires start small and if detection is made early and fire fought and put out quickly, major fires can be avoided. Let us avoid fire in our plant and keep the personal and equipment safe. Introduction Fire creates havoc – loss of lives, damage to plant and property, thereby interrupting production – a National Loss. In most countries of the world even with a fully developed industrial and commercial economy, fire is consuming about one quarter to one third of one per cent of the country’s national product.Fire and explosion are serious hazards in industries which handle large volume of combustible / flammable liquids such as oil, petroleum, petrochemical, fertilizers, chemicals, etc. Fire do not happen only in large industries. As a matter of fact fires in small industries and establishments are more dangerous involving personal, equipment and material. Fire is also one of the leading causes of fatalities at home. It is in the interests of the community at large that proper attention be paid to fire loss since it is the community in the end, which has to pay for all the losses. Insurers may be paying for a part of the damage done, but can only do so out of the premiums collected from the insured.

If the losses exceed premiums, then the insured will ultimately have to pay higher premiums.However, the life lost and the miseries suffered by the injured and their families can never be compensated by any amount of compensation received. Fire is one of the major causes of accidental deaths in India.The number of fire cases reported in India for the year 2012 was 24987, which resulted in the deaths of 23281 persons.However, the injured persons for the same period was only 3057. The major causes of fires and the number of cases reported, the number of persons injured and the number of persons died against each causes are given in the Table below:

Control of Fire The control of fire risks is a complex subject; but it can be simplified if a preplanned system is developed. Fire has enormous potential for destruction, of fuel releases heat so that once it has started a fire will grow at an accelerating rate unless remedial measures are taken. Either the unburnt fuel must be separated from the

heat or the supply of air cut off, or the heat removed. The separation of combustible materials will limit the amount of fuel, which can contribute to the growth of fire. For the ultimate extinguishing of fire, the combustible material must be cooled below its ignition temperature. Water, which has a high latent heat of vaporisation, is the most effective coolant. However, for it to be effective it must be applied in sufficient quantity and at such a rate that it will prevent the accelerating growth of the fire. A fire discovered within two or three minutes of its outbreak may be extinguished with less than 1,000 litres of water. If the water is not applied until five to ten minutes later, which is probably the shortest time in which a fire brigade may reach the scene of the fire, the fire will have grown to such proportions that between 50 and 100 times as much water may be needed for extinguishing the fire. If remedial measures are not taken in the very early stages of following the outbreak of a fire, the amount of water required increases exponentially as the increase in

Injuries And Deaths Due To Fire During 2012 (All India)

Sr No

Number of Persons Injured

Number of Cases Reported

Causes

Number of Persons Died Male

Female

Total

1

Fire Works/Crackers

468

175

200

305

505

2

Short – Circuit

1472

176

1170

269

1439

3

Cooking Gas Cylinder/Stove burst

3790

273

846

2900

3746

4

Other Fire Accidents

19257

2433

5617

11974

17591

24987

3057

7833

15448

23281

Total

Source: Accidental deaths and suicides in India, National Crime Records Bureau, Ministry of Home Affairs 2012

24

www.martonline.in

March 2014


the time taken for the fire fighting forces to reach the scene of the fire and start effective firefighting operations. An automatic sprinkler installation will, in a large majority of circumstances, control and extinguish a fire with less of water and a minimum time and may, therefore, be the most economical way of limiting the loss in a fire, particularly in areas of limited water supplies.

The planning of towns and cities and the siting of factories should be carried out with the needs for fire protection in mind and adequate natural water sources in the vicinity is the first consideration. In the absence of natural sources, provision should be made for the bulk storage of water for use of firefighting purposes only. Water supply for the system must provide the designated flow for a minimum of 30 minutes. If reliance has to be taken in the town planning and in the siting of the fire brigade station to ensure that fire fighting vehicles are not impeded by traffic problems in their attempt to reach the scene of the fire.

The effectiveness of the fire brigade depends on its early arrival at the scene of the fire. Means must, therefore be provided in every building of transmitting the fire brigade control point. Manual means of transmitting the call should be supplemented by an automatic fire detector, which when actuated by the fire automatically transmits a call to the control point.

The principal ingredient contributing to the size of the loss by fire is the amount of fuel exposed to any one fire. Control of this can be achieved by the sub-division of buildings into compartments of limited size by means of fire separating walls and floors, providing resistance to the passage of fire so that an outbreak of fire will be confined to the compartment where it starts. Worldwide, there is a growing tendency towards the construction of tall buildings or high risers. It could well be believed that the status of a city is sometimes judged by, the number of skyscrapers. Quite apart from the constructional problems presented by the need to build high, tall buildings present serious difficulties from the point of view of fire safety. Only where the scarcity of land overrides all other considerations should be development of tall buildings is allowed. The safety from fire of staff and workpeople must be ensured. Provision must be made to ensure that in the event of fire, the occupants of buildings can escape to a place of safety without having to go March 2014

Fire at Vizag HPCL refinery ( Picture courtesy : archives.deccanchronicle.com )

through the fire or through smoke. In buildings of more than one storey the escape of the occupants depends on the use of staircases. These, therefore, have to be planned in such a way that fire cannot affect more than one staircase. Thus, if one staircase is involved with fire or smoke, the occupants can move to another one. The design for the safety of occupants requires a thorough understanding of the behaviour of fire.

The materials used in the construction of buildings should as far as possible be such that they are not capable of making a contribution to the growth and development of a fire. Ideally, therefore, non-combustible materials only should be used in the construction of buildings. Noncombustible materials do not necessarily provide fire resistance. wwSteelwork used for structural purposes loses its strength quite early in the development of a fire with the possible result of the collapse of the building.Concrete when subjected to high temperatures, spalls or chips, and the material fall away with a resultant loss of thickness.

Electricity and Gas are the principal sources of energy for power, light and heat in any community, whether it is industrial, commercial or residential. Both of them are major sources of ignition wherever they are used. All electrical equipment, therefore, must be carefully rated according to the work it is expected to do. If it is overloaded, excessive heat will be generated and a fire may ensure. Fires are also caused by defects in electrical equipment and through damage to electric wiring insulation. They are also caused by, allowing combustible materials to come

too close to electrical equipment, which is running hot. A high standard of installation and maintenance, therefore, is necessary to ensure safety from fire, which may be caused by the use of electrical equipment. Safety codes that have been established by the Bureau of Indian Standards (BIS) and similar bodies need to be enforced. Similar practices to those recommended for electrical installations should be applied for gas installations. A safety code should, therefore, be established for the storage of gas and this should embrace all forms of storage from bulk quantity tanks to small unit cylinders serving private dwellings. In buildings where a central air conditioning plant is installed for the transmission of conditioned air from the plant through ducting throughout the building, provision needs to be made to ensure that the ducting does not provide a means by which fire can be spread throughout the building. Often it is the contents of buildings, rather than the structure itself, which burn.Careful attention, therefore, has to be paid to the layout of plant, process and storage, in particular the handling and storage of hazardous material. The materials, which are controlled in this way include explosives, certain chemicals and flammable liquids whose flashpoint is in the region of 23 Degree Celsius or lower. The most commonly used flammable liquid is liquefied petroleum gases. It should be a requirement that wherever they are used or stored in quantities, there should be a licence in force, which establishes the method of storage and handling as well as www.martonline.in

25


the precautions to be taken. Fires are caused almost entirely by people, either through their actions, which may be accidental or deliberate and malicious or through their failure to take appropriate precautions such as, for example, the regular inspection, maintenance and repair of defective equipment. Managements Role A major fire can bring a business to a halt. Restoring the damage done by fire is only part of the cost of a fire. A fire may have serious consequences for the productive capacity of a business and in the extreme; the time taken to restore production may be such that the business is forced to close down altogether. Not only it can interrupt the whole process of manufacture and production, but also the buildings and plant will be in ruins. Before they can be replaced and production restored, much work in clearing up the site will be necessary. It will also be necessary to determine what has been lost and damaged. Even if only a small part of the plant has been involved in fire, staff from other work will need to be diverted to clear up the mess and to plan the rebuilding and restoration of production. The successful prevention of fire loss depends almost entirely on the management of the business. Fire creates total waste. Such waste would not be tolerated by, efficient management, if it resulted from inefficient operation. No management should, therefore, tolerate the creation of waste by fire. To control the loss through fire, the management must survey the total operation of the business to determine where the loss potential lies. Identification of Risk To mitigate the fire, the first step the management should take is to identify the fire risks. This is best done by using a plan of the premises and identifying on that plan all the potential sources of ignition and the materials, which will burn and the ways in which fire can spread. Uncontrolled cutting, welding and grinding operations can be a cause of fire risks. One more possible ignition source is static electricity, which had caused many major fires. Fires do not start only in manufacturing or storage areas. They may start in the offices or the canteens and kitchens. Fires starting in these places can be prevented from

26

www.martonline.in

spreading to the manufacturing and storage areas by means of adequate fire separation.

and a very high percentage of these fires are extinguished with the sprinklers only.

Fires may also start in the open and spread to the buildings and can be prevented from spreading to the buildings by keeping an area around all buildings free from combustible materials such as storage of finished goods, cartons, stacking pallets and waste and of all combustible vegetation such as grass and scrub.

Water is the most effective extinguishing agent for general protection of the premises, but there are certain fire risks such as live electrical equipment and flammable liquids where the use of water may be dangerous. In such risk areas other extinguishing agents have to be used. The equipment has, therefore, to be chosen with the care and suited to the specific risks to be found on the premises.

Fire Precautions One of the principal means of controlling the extent of fire loss is to limit the amount of material, which may be exposed to any one fire. This is achieved by sub-division with the use of fire resisting separating walls and floors. An important element in the prevention of outbreaks of fires and in their control is the training of the workpeople. As has been said earlier, it is people who cause fires and it is, therefore, people who can be instrumental in preventing and controlling them. By training all workpeople in the operations which they perform, most fire hazards can be avoided. This applies particularly to workpeople engaged in operations involving hazardous materials, but it also applies to the everyday operation of plant and equipment and to the day-to-day behaviour of everybody employed in the business. Fire Extinguishments In the last resort, when a fire breaks out there must be the means of controlling and extinguishing it. Water is vital for this and storage must be provided on each plant for firefighting purposes only. Portable fire extinguishers and hose reels need to be provided for the use of the workpeople, who must naturally be trained in the operation of this equipment. It is quite possible that in many situations an automatic sprinkler system, which provides protection for 24 hours of the day, throughout the year may be more economical and help a fire brigade in efficient control and extinguishments of fire. The automatic sprinkler system automatically detects the fire, delivers water to the seat of the fire and sounds an alarm. The experience gained throughout the world with the automatic sprinkler systems is that many fires are controlled and extinguished with insignificant losses

Provision also has to be made for the detection of the fire and for the sounding of the alarm. Automatic detection systems are the best, since they eliminate the human factor. Even where an automatic sprinkler system is installed, it may be desirable to have an automatic detection system as well. Above all, surveillance by all the concerned personnel is of vital significance for Fire Prevention and Fire Protection.

Conclusion Many times a company suddenly realises that they need a fire protection programme after they have had a major fire. But that is a late thinking. Really a fire protection programme has to be started when the factory is planned. While every effort should be made by industries for fire prevention, provision of adequate fire protection facilities is a basic necessity, so that any fire effectively fought and extinguished. To conclude, fire protection is a vast subject and hardly any particular type of system can be regarded as most suitable for one application. The efficiency of the fire protection depends upon the installation of prudent combinations of various types of system and choice of appropriate components with good workmanship, appropriate design, inspection & testing for proper maintenance, training by experienced & knowledgeable fire safety professionals, etc. By and large, fires start small and if detection is made early and fire fought and put out quickly, major fires can be avoided. Let us avoid fire in our plant and keep the personal and equipment safe. The author R R Nair is the Chief Executive of Safety and Health Information Bureau and he can be reached at C-2/9/3-2, Sector – 16, Vashi, Navi Mumbai – 400 703 Tel.: +91 22 27665975, Mobile: +91 9224212544

February March 2014


ASCENT

Haas machines in a class of their own at technology school

Matt Bailey press@mbmc-uk.com

CNC machining technology is advancing year-on-year. To ensure future generations are familiar with such technology when they enter the employment marketplace, education establishments must keep pace. A case in point can be seen at LiS, situated at Leiden, approximately halfway between Amsterdam and Rotterdam.

LiS is a vocational school that trains what it calls instrument-makers for research organisations, with particular links to the space industry. According to LiS, much of the research that is taking place in the Netherlands would be impossible without the technical knowledge, creativity and devices made by instrument-makers. With so much riding on the education of these important youngsters, a recent recommendation from a visitation committee advised LiS to introduce more CNC machining techniques into its curriculum. As a consequence, in November 2013, the LiS Engineering department

installed three new Haas CNC milling machines: two Super Mini Mills and a VF1. Financing the investment proved a challenge, but not one beyond this forwardthinking vocational school. Aside from certain gifted funds from private individuals and foundations, LiS accrued the necessary capital by taking on high precision contract work for organisations such as ESTEC, the European Space Research and Technology Centre, which is located just 5km away at Noordwijk. LiS also undertakes contracts for Leiden-based Dutch Space (an EADS Astrium company), a supplier of sub-systems for the European space industry.

“All of our students learn how to detail ideas in working drawings and how to manufacture the products themselves. In doing so, students develop a working relationship that connects well to higher professional or university education, and the manufacturing industry. Aside from the space industry, students completing courses at LiS find careers in sectors that include life sciences and health.” Dick Harms Principal LIS

March 2014

“These parties, on one hand provide vital financial resources, while on the other hand, they keep in close contact with the training as they also employ students,” says LiS Principal Dick Harms. “In turn, the students get to perform real project work, under expert guidance of course.” As a result of its investment in Haas machine tools, which were supplied by the Haas Factory Outlet operated by Landré, near Utrecht, Netherlands, LiS is now one of the few schools where

students can pursue machining courses at a high level, both conventionally and using CNC, as Mr. Harms confirms: “We are distinguishing ourselves from other training facilities because students learn by actually doing. Our conviction is that students first have to learn the subject manually and then on CNC. As a result, they can put their practical knowledge to use immediately when they start work in the business world.” The choice of Haas, in part, was made based on the machines’ favourable cost/quality ratio and the good experience LiS gained from a previously installed Haas machine.

“Once you have invested in tools and software, it does not make sense to purchase machines on which they no longer fit,” says Mr. Harms. “Moreover, Haas, with the Super Mini Mill, is one of the few that offers an advantageous CNC machine for small assignments with the same features as a large machine. The SK40 main spindle is also perfect for medium and light milling and finishing – students learn basic skills on this.”

Besides the two Super Mini Mills, LiS also now has a Haas VF-1 with travels of 508 x 406 x 508 mm. This is a rugged, small-footprint vertical machining centre that yields reliability and accuracy via its 40-taper cartridge spindle. LiS Engineering students at level four now learn the principles of CNC milling using the VF-1. At present, around 50 students from LiS Engineering graduate every year, with a percentage advancing to university or professional training in dual education. The good news is that registrations are increasing, boding well for graduate numbers moving forward. www.martonline.in

27


QUALITY

Essentials of Value and Quality Driven Product Design and Development

Saravjit Singh saravjit.singh@gmail.com

Every R&D Manager and Designer must keep in mind that his job is to help conceive and develop a new product in such a way that it effectively and efficiently meet end customer requirements. A product that does not deliver customer perceived value is destined to fail in the market place Value is defined by the end customer. Value is the most cost-effective way to reliably accomplish a function that will meet the user’s needs, desires, and expectations. A product, and its associated services, must have the right performance and cost in order to delivers good value to the user. There are three aspects of value: 1. Utility Value: How useful/ functional the product is seen to be by the customer. This is also known as Use Value. 2. Esteem Value: The value that customer sees in product attributes. This does not directly contribute to utility but is related to aesthetic and subjective value that the customer sees in the product. Both esteem value and functionality are important. Neither one of them should be overlooked or compromised when conceiving, designing and developing the product. 3.Market Value: What the customer is prepared to pay for the product. This is also known as Exchange Value. Market value = Utility Value + Esteem Value Benefits to customer= Function + Quality + Performance The customer judges the worth of the product and its associated services on the basis of all the benefits he receives when he decides to purchase the product. When benefits exceed the expended cost and

28

www.martonline.in

Figure 1: How Value can be increased at design stage

time spent in acquiring and maintaining the product, the customer perceives that the product has good value. As shown in Figure 1, during product design and development, R&D can build in good value by improving the benefits sought by the customer (benefits + Quality + Performance) and reducing the cost through Value Engineering and Design for Manufacturing and Assembly (DFMA). Function is the specific work that a design must perform. The basic purpose always is to accomplish a function. Quality is the consistent conformance of product and its associated services to customer expectations. We need to proactively change, so as to keep ahead of the ever increasing expectations of our customer. This is the only way to ensure that the customer says that we supply quality products and services. Performance is measured by how well we achieve the following: • Quality: This covers designed in quality. This covers design for manufacturing, Design for Assembly, Design for Reliability, and, Design for

Maintainability/Service.

• Return on Investment

• Stakeholder requirements: These include meeting the needs and expectations of all key internal and external customers. The primary purpose is to fulfill all requirements that lead to excellence in serving the end customer.

• Life cycle cost: This includes cost of disposal and recycling costs. Recycling cost can be high for products exported to the European Union.

• Safety and environmental impacts: These are becoming a primary concern in today’s world. Discerning customers not only want good products; they want safer products. They are concerned that producers and their offerings are environmentally friendly. Recyclability of products has assumed priority – especially in the European Union and in North America. Products made for export must have designed in recyclability and minimized use of toxic materials. To achieve all this R&D must use a structured approach of excellence in design for safety and the environment. Cost should be viewed as the total life cycle cost of the product. Criteria for evaluating cost are: • Initial purchase cost • Operating cost • Maintenance cost

Basic and Secondary Functions • Basic function is the primary work/ solution provided by a product. For instance, the basic function of a car is to provide transportation for people. • Most products are not sold on the basis of their basic function alone. Few people buy a car only because of its ability to transport people. Nevertheless, not being able to achieve basic function will cause the loss of the market value of the product. • The customer’s attention is directed to those visible secondary support functions, or product features, which determine the worth of the product. • Designers first address the basic function’s performance and stress the achievement of all of the performance attributes. • Once the basic functions are satisfied, the designers then address the secondary March 2014


functions necessary to attract customers. • Secondary functions are incorporated in the product as features to support and enhance the basic function. Focus on value and not on cost. In the past, and for many R&Ds even today, the focus is on cost reduction. If your company is in the mode of “cost cutting”, it is probably degrading the products by using cheaper alternative materials or reducing sheet metal thickness, etc. This often degrades the performance and life of the product. Don’t take chances by using cost-cutting as a policy. Your R&D must say no to senseless cost cutting and take the lead in using structured Value Engineering as the preferred methodology to reduce cost while retaining or even improving product functionality. This will, in fact, enhance product value in the eyes of the customer. Make a move from cost cutting to product value management. See Figure 2. Focusing on product value satisfies customers and increase product profitability. R&D has to create products in ways that enhance brand performance, product performance, functions and required features. Companies that have managed this exceptionally well include Toyota (especially for the Lexus brand), Harley Davidson, Apple, Samsung and LG. Early integration of strategic suppliers in new product development. R&Ds should consciously do this from product concept creation stage itself. Strategic suppliers have superior knowledge about technologies and aggregates they supply. Early consultation, and integration of these suppliers as partners in design and development has many advantages: 1. They can advise on use March 2014

of existing, aggregates. Incorporating these aggregates reduces lead-time because of ready-availability. 2. You get the aggregate at least cost and without having to invest in tooling costs. 3. The available aggregate is already tried and tested. Its reliability and acceptability is easily ascertained. 4. Early involvement of suppliers means reduction in product cost to the minimum at the design stage.This is a big help, considering that up to 80% of a product’s cost is built in at the design stage itself. Customer collaboration in product concept creation and development. Early integration of customers in the new product development process ensures that what we are designing meets the key requirements of our target customers. This is the best way to achieve highest level of product quality (consistent conformace to customer expections – our definition of quality). For our R&D work we should involve loyal customers who have experience in using our products and the benefits we deliver, as well as new benefits they want us to deliver. They give extremely valuable advice, especially at the product concept creation stage. When customers are invited to test finalized prototypes, their unbiased suggestions and comments are priceless. This also helps to iron out any notable deficiencies that are uncovered by experienced users. Four customer integration methods an R&D can use are: 1. Involve loyal target customers in product design and test. 2. Use product clinics and surveys to record customer interviews and observations for existing and proposed new products.

Figure 2: Change from Cost Cutting to Product Value Management

3. Engage with customers to do price sensitivity analysis.

vi. Standardized and modular design

4. Conduct conjoint analysis for desired attributes, features and pricing trade-offs.

vii. CAD and FEA based design

R&D Framework. A company needs a robust framework to create value added products. For this purpose this is what is necessary: 1. Strong top - management support a. Top - management is actively involved in the project b. Top - management closely monitors the progressof the project c. Top - management provides required resources 2. Robust product development process a. Focus on target customers b. Understand customer value c. Choose the right R&D methods and combine them intelligently. These methods include: i. Quality Function Deployment ii. Design Failure Mode and Effects Analysis (DFMEA) iii. Value Engineering iv. Design for Manufacturability and Assembly (DFMA) v. Concurrent Engineering

viii. Collaborative integration of strategic suppliers and customers ix. Rapid prototyping d. Defined process stages with go/no-go decision gates e. Dedicated gatekeepers to review projects at gates f. Activities per stage and corporate functions involved are clearly defined g. Methods for each stage are defined and documented h. Execute in a consistent manner To achieve high productivity in R&D, it is necessary to have a documented product development process. How many Indian R&Ds follow this guideline. Also, to improve productivity one has to reduce product development lead time. For this purpose one should use Value Stream Mapping as applicable to Development. If your R&D is using the above please send me an email to saravjit@10xquality.org Your response will help me write my next article in this magazine. The subject of this proposed article is “Improving productivity through VSM in R&D”. www.martonline.in

29


MANUFACTURING EXCELLENCE

Journey Towards Excellence

P S Satish gotopssatish@gmail.com

Managing a SME in India - Part 15 As a continuation of last article, we will discuss on few more points to manage SME’s better in India 27. Being a professional company I work with a Japanese partner to support Japanese companies to do business in India. One of the Japanese Companies was looking for a Japanese translator in India. I came across a lady in India by name Ramya (name changed) who was qualified well for the job. We gave her a sample of small Japanese article to translate to English to test quality of translation. She promptly sent us translation. Our Japanese friends came to know soon that she has copied from internet where translation was already available. I politely asked her if she was influenced or biasedby the information available in net. I didn’t use the word copying or plagiarism. She admitted that she has seen in the net but was adamant with the argument that she did not copy though documents showed different. Our house maid Roopa (name changed) is an illiterate lady and is very sincere in her work and timings. We have never insisted any discipline from her. If there is any delay on a particular day or not able to come on a day for a specific reason, she calls my wife to inform. Between Ramya and Roopa who is professional? Naturally, all of us vote for Roopa. If Ramya were professional, she would have informed me when she saw that translation was available already in net. It is difficult to explain what professionalism means but clear meaning comes out when we look at the action. We use the word unprofessional

30

www.martonline.in

“It is an unbearable thought to me that someone can prove that my product is inferior and does not withstand all tests.” Robert Bosch

every day when we look at our plumber using wrench as hammer, tailor never bothered about due date, painter not bothered about variation of shades etc. Like we expect professional approach from individuals known to be an expert in a domain, we also expect companies to be professional. When I was heading purchase in a company, one of our colleagues made a visit to a potential supplier and in his report he made a remark, ‘The Company is technically very capable but not professional’. I asked him why he has not elaborated on company being non-professional. His answer was that it is easy to observe professionalism than describing in words. Taking a clue from this, I try here to explain the characteristics or behaviors of companies which will qualify them to be called as professional.

• Being proactive in approach. Asking customer voluntarily on what area services can be enhanced. • Treating Customer with care and respect. • No supervision required by the Customer for the improvement of the Company. Responsibility is assumed. • To admit their limitations and incapabilitywith the Customer. Not taking credit for the efforts of some other Company. To be upfront clear in offers and proposals what is possible. • Allowing employees to work in a relaxed way but not compromising on the target. • Not doing business only for money. Giving back to society and environment where company is located. • Clear guideline in place to deal with employees when integrity is

compromised. • Being transparent in dealings with Customers, Suppliers and Employees. • Customer feedback is taken positively for improvement. • Keeping up commitments and promises given to Customer. • Regular internal and external communications. • Avoiding jolts and surprises to Customer by giving Information in advance. • Ability to manage business in spite of ups and downs of market situation. Continuously evaluate gap with respect to market development. • Not boasting on past success. Understand well current and future challenges. • Networking with the associations and experts in the March 2014


domain. • Awareness of strengths and weaknesses and evaluate regularly. • Having a clear vision for the company and is known to all employees. Setting clearly target or goal of company. • Developing a culture of going to roots to solve problems and to make all employees as problem solvers. • Ready to say ‘No’ wherever needed instead of saying ‘Yes’ and not delivering. • Building efficient systems to do more with less and better. •Continuously benchmark against competitors and best in Industry. Learning from others including suppliers and seeking help wherever required. • Be authentic in all Information given to Customer, Supplier and Public. • Being optimistic about the future of the company. • Learning from mistakes. Developing a culture where mistakes are allowed as a part of learning or improvement. • Maintaining confidentiality of Customer Information. To respect Non-disclosure agreements signed. • Not copying something which will violate Intellectual property. • Building organizational values and management does walk the talk. • Going with preparation while visiting a Customer. • Every learning of Organization is documented. Standards set are continuously updated with improvements. • Training people to respond to Customers properly and not just reacting. • Being empathetic to see the way Customer sees. March 2014

STATEMENT ABOUT OWNERSHIP AND HIS PARTICULARS ABOUT THE NEWSPAPER INDUSTRIAL BUSINESS MART (Form IV – See Rule – 8)

• Should there be an occasion to part with Customer, leaving with grace. With this, there would be a chance to approach them again.

1. Place of Publication

• Following rules of land. Use judgment when there is ambiguity or no rules. Not bending rules for the convenience of own.

3. Printer’s Name Whether Citizen of India Address Bangalore – 560 043

: Hari Shanker A G : Yes : No: 217, 3B Main, OMBR Layout,

4. Publisher’s Name Whether Citizen of India Address Bangalore – 560 043

: Hari Shanker A G : Yes : No: 217, 3B Main, OMBR Layout,

5. Printer’s Name Whether Citizen of India Address Bangalore – 560 043

: Hari Shanker A G : Yes : No: 217, 3B Main, OMBR Layout,

• To be conscious about the brand of the company. • Avoiding nepotism in giving contracts etc. compromising on quality. • To pay in agreed time any amount due to suppliers and service providers.

: Bangalore

2. Periodicity of its Publication : Monthly

• Having a culture where employees do not misuse office for personal use.

6. Names and addresses of individual who own the newspaper & partners or shareholders holding more than one percent of total capital:- Hari Shanker A G, No: 217, 3B Main, OMBR Layout, Bangalore – 560 043

• To be fair to employees and treat them with respect.

I Hari Shanker A G, hereby declare that the particulars given above are true to the best of my Knowledge and belief.

• Not to exploit employees by taking advantage of their helplessness if any.

Dated : 1st March 2014

Sd/- (Publisher)

• Companies need to take care on how public sees the company. In my experience, there is a lot our MSMEs need to do in the direction of being professional. This aspect which is one of implicit expectations of Customer can be a decisive factor for awarding business especially in export. The owner or top management can take initiative to see the current gap with respect to above points and set an action plans to close the gap. Our Industries are capable and they only need to take first step. I will continue the series of article in the next issue. Please send your inputs,remarks,suggestions toP S Satish, Mentor and Capability Developer, M/s Saraswati Industrial Services, Q 103, MantriParadise Apartments,Bannerghatta Road, Bangalore-560076. Do visit www.satishps.com. Have a good day. www.martonline.in

31


TALENT MANAGEMENT

The Art of Leadership Communication

Pavan Sriram pavan@ittige.com

Communication is the lifeblood of leadership. When leaders are adept at communication they do much more than just manage effectively - they drive stronger business results Language is a very essential tool; through language we sell our goods, services, ideas, and also ourselves. Intelligent participation in a discussion not only shows our lively interest in what’s being discussed, but also our knowledge and expertise. However, one cannot be just wordy without substance. Too often we only focus on the “what” and forget the “how.” The “how” determines if what we say will be understood and retained. Without the “how”, our words will disappear from the listener before its desired effect takes place. Communication is an essential leadership skill - looking back at your last message to a client or a team member, how did you do? Did you add a

visual illustration, interactive opportunity or immediate application that required some form of action? Leaders are the founders of the future Globalization is rapidly redefining today’s business environment. Significant strategic shifts are transforming the playing field. Vast opportunities for growth are emerging at the same time that the pool of highperforming talent capable of seizing those opportunities is shrinking. Those who can stay ahead of the rapid pace of change, anticipate talent needs, and take the lead in developing innovative strategies for the future will likely be tomorrow’s winners. It is the leader’s challenge

to create the circumstances that stimulate improved performance and execution from the people within their organization. The key question for business leaders is not “why” high performance but rather “how”? Leaders who do this build a sense of shared purpose by painting a compelling vision of the future. They answer these questions: Where are we going, what does it look like, what are the benefits, what role do I play in the success? The differentiator is consistency. The best leaders know they need to paint this vision over and over. At every opportunity, they share the vision of what’s ahead. Communication is the lifeblood of Leadership

Drivers for Leadership Communication

32

www.martonline.in

An early Harvard Business School study on what it takes to achieve success and be promoted in an organization says that the individual who

gets ahead in business is the person who “is able to communicate, to make sound decisions, and to get things done with and through people” (Bowman, Jones, Peterson, Gronouski, & Mahoney, 1964). By communicating more effectively, managers improve their ability to get things done with and through people As leaders we are called upon to counsel, cast vision, set goals, make plans, and chart the course for the ship we are leading. The bigger the ship the slower it turns. Often, you will have to communicate a little and steps of progress to keep everyone on board and on the same page. If the ship is small, then you need to communicate clearly so you do not lose people overboard if you turn too quickly. A recent LinkedIn poll from 2000+ participants asking them ‘What do you think is the most important factor

March 2014


in Leadership?’ showed that 38% of overall participants interviewed named communication. 24% of them would like to see better character. Very surprisingly, despite the dominant stress on Vision, Drive and Character in the literature on Leadership, the overwhelming choice was ‘Communication’. Does this really mean that Communication is the most important factor in Leadership? Not really – after all, a poll is only telling us the opinion of people – it’s not measuring which factor has the most impact in practice. But it does highlight something I believe is rather important. The results were pretty consistent across gender, and also across the different sizes of companies respondents worked for. With the exception that communication was (understandably) viewed as even more of an important factor in very large enterprises. Leaders communicate, and communicators Lead From CEOs to supervisors and everything in between, most of the leaders have a few common communication habits that any of us can take to persuade, inform and encourage teams to be more successful. I’d like to

share them with you. There are six rules that will help you communicate more effectively, reduce conflict in your organization, and become a better leader. Leaders need to: Rule 1: Organize thoughts Organizing your thoughts systematically is the first step to effective communication. You should be clear about the message that you want to convey, and it is helpful to have a framework for the conversation. Rule 2: Plan the conversation ahead of time. When you think through a subject, try to envision what sort of reaction you will evoke. Plan out different directions that the conversation may take and prepare your ground accordingly. Rule 3: Be aware of nonverbal signals. Did you know much of our communication happens through nonverbal signals? Non-verbal cues such as facial expressions and tone of voice can communicate as much as 65% of what we want to say. Rule 4: Be succinct. As they say, less is more. This holds true for leadership communication as well. Your

goal in communication is to convey a message and create a certain response. Emphasize your key points simply, and respond to questions directly. Rule 5: Demonstrate how the other person will benefit. When you show how the other person will directly benefit from your offer, you are very close to convincing them. To do this, you must highlight the rewards of your offer, and explain how they will improve his or her life. For example, instead of explaining that a new product is more efficient, you might emphasize how much time or money the customer will save. Rule 6: Be a good listener. The importance of listening to clients and team members and understanding their viewpoints is often overlooked. Effective communication is a two-way process for managers; if you adopt a oneway attitude, you will fail to create a rapport. In the end, there’s no magic formula for great communication. But I’ve seen time and again that the leaders who communicate using these methods are more effective than those who don’t. And I’ve seen very effective

March 2014

communicators become great leaders. I look forward to hearing from you on how communication revolves around your leadership strategy, organization and team vision write to me at pavan@ittige.com with your views and comments Pavan Sriram is the Founder and CEO of ITTIGE Learning, a performance-based training company that works with c-level executives to troubleshoot humanresource and organizationaldevelopment challenges. With 13 years of rich experience in management positions at Crestcom International, Dale Carnegie Training, SunGard and MeritTrac-Manipal Education Group and having worked with over 200 clients across industries in India and abroad, Pavan successfully has targeted organizational talent associated with performance management, leadership development, ineffective communication, talent management and measurement. For further details visit www.ittige.com

www.martonline.in

33


INFORMATION TECHNOLOGY

Strategic Data Management

Rajesh angadi rajesh_angadi@hotmail.com

The growing need for companies to manage surging volumes of structured and unstructured data is continuing to propel enterprise use of open-source Apache Hadoop software. But instead of replacing existing technologies, Hadoop appears to be working alongside conventional relational database management systems (RDBMS).

Hadoop is designed to help companies manage and process petabytes of data. The technology’s appeal lies in its ability to break up very large data sets into smaller data blocks that are then distributed across a cluster of commodity hardware for faster processing. Apache Hadoop is an opensource software framework for storage and large scale processing of data-sets on clusters of commodity hardware. Hadoop is an Apache top-level project being built and used by a global community of contributors and users. It is licensed under the Apache License 2.0. Apache Hadoop framework has following modules:

large number of nodes. At a high level, Hadoop leverages parallel processing across many commodity servers to respond to client applications. The key difference is, rather than only looking at parallel computing, it looks at parallelizing the data access.

• Hadoop Common - contains libraries and utilities needed by other Hadoop modules

(Above picture shows Hadoop Ecosystem and cluster details)

• Hadoop Distributed File System (HDFS) - a distributed file-system that stores data on commodity machines, providing very high aggregate bandwidth across the cluster.

This all sounds great, but in reality Hadoop is designed for large files, not large quantities of small files, so if you have millions of 50 Kb documents, that is not Hadoop’s sweet spot.

• Hadoop YARN - a resourcemanagement platform responsible for managing compute resources in clusters and using them for scheduling of users’ applications. • Hadoop MapReduce - a programming model for large scale data processing. Hadoop’s integral part of Hadoop File System and MapReduce, which has been well designed to handle huge volumes of data across a

34

Hadoop Ecosystems

www.martonline.in

What Big Data really is ? While the volumes of data are growing by leaps and bounds from many sources, such as social media, location data, loyalty information, operations and supply chain, the type of information is also an issue. It may be structured, semistructured or unstructured. Making sense of and gaining knowledge from this data to achieve a competitive advantage should be the

driving goal. So if you have Big Data and need to search and sort through the bulk of that data, then Hadoop may serve your purpose. If the majority of the data is structured or even unstructured but you are able to add structured meta-data describing the unstructured portion and you want to run standard reports on the structured portion or retrieve individual unstructured elements then standard databases may suit your needs. If you have structured, semi-structured, or unstructured with structured meta-data, and want to run complex analyses on the data, to predict or ask questions outside of the standard reports, questions which cannot be prepared in advance (i.e. the types of queries most valuable to real Business Intelligence), then you probably need a columnbased data store.”In two-thirds of the cases, companies are using Hadoop for advanced analytics and for types of analysis that they were not doing before”. The technology is much less likely to be used for analyzing conventional structured data

such as transaction data, customer information and call records, where traditional RDBMS tools still appear to have an edge. Despite Hadoop’s early promise, the study said, enterprises that use it still face challenges related to issues such as security, clustering and a shortage of people with Hadoop skills. During rearrange of acronym from EDW to DWE, standing for “data warehouse environment,” meaning multiplatform DW. From the single-platform EDW to the multi-platform DWE. A consequence of the workloadcentric approach is a trend away from the single-platform monolith of the enterprise data warehouse (EDW) toward a physically distributed data warehouse environment (DWE). A modern DWE consists of multiple platform types, ranging from the traditional warehouse (which includes data marts and ODSs) to new platforms like DW appliances, columnar DBMSs, noSQL databases, MapReduce tools, February MarchJ 2014


Window to the industrial world at your desktop “Industrial business MART” popularly know as MART the largely read international engineering manufacturing monthly, now the one year subscription comes `300 less, Grab it today!

Hadoop Cluster

and HDFS. In other words, users’ portfolios of tools for BI/ DW and related disciplines are diversifying aggressively. The multi-platform approach adds more complexity to the DW environment while BI/DW environments have always managed complex technology stacks successfully. The upside is that users love the high performance and solid information outcomes which they get from workload-tuned platforms. As user organizations dive deeper into big data analytics, many users dependsheavily on SQLbased ad hoc queries as their primary method for data exploration and discovery analytics (sometimes called investigative analytics). At the same time, the same organizations are adopting or considering Hadoop as their primary storage platform for big data. SQL-based analytics and Hadoop are good choices in isolation, but bringing them together has a catch where Hadoop’s support for queries is minimal at the moment. An emerging best practice, among Data Warehouse professionals with Hadoop experience is to manage diverse big data in HDFS, but process it and moves the results (via ETL or other data integration media) to RDBMSs (elsewhere in the Data Warehouse architecture) that March 2014

are more conducive to SQLbased analytics. HDFS serves as a massive data staging area. A similar best practice is to use an RDBMS as a front-end to HDFS data; this way, data is moved via queries (whether ad hoc or standardized), not via ETL jobs. HDFS serves as a large, diverse operational data store. A straightforward solution is to use a specialized analytic database management system (ADBMS) to query big data in Hadoop and elsewhere. This way, you get the rich features and query optimization capabilities of a mature ADBMS, along with the massive data store of Hadoop. Also compared to Hadoop, an ADBMS is far more conducive to the iterative approach to query development that most business analysts and data scientists demand for true investigative analytics. The author Rajesh Angadi completed his BE, MBA, PMP and is Hadoop Certified. With 22 years of Information Technology experience he worked on projects for Unisys, Intel, Satyam, Microsoft, Ford, Hartford, Compaq, and Princeton. He is always fascinated by the latest technology coming up in the IT sector and striving to keep pace with it. Interests in Information Technologiesresearch areas like Hadoop Ecosystem, Predictive Analysis, Telematics, Clinical research with Analysis.

With the last nine years of networking and publishing of MART, we have succesfully made place in the Indian Manufacturing Industry. Our growth was always triggered by the changes undertaken as per the needs of the industry. The contents of MART is unique, with regular columns by industry experts in the diversified feilds of engineering manufacturing, technical features, news updates, interviews, case studies, trade fair informations etc. The guidance and support of the experienced industry professionals through our Editorial Advisory Board have helped us to understand the need of the indian Manufacturer better and produce a journal which is used by the industry as an utility.

Yes, we are interested to subscribe “Industrial Business MART” as per selected option : One Year (12 issues) at ` 900/- You save `300/Three Year (36 issues) at ` 2500/- You save `1100/-

Name : .......................................................................................... Designation : ................................................................................ Company : .................................................................................... Adresss : ........................................................................................ ........................................................................................................ City : ........................................................ Pin : .......................... Tel : .......................................... Mob: .......................................... Send payment favouring “MEDIAMART INFOTECH” to:The Circulation Manager MediaMart Infotech, 4/155, Paschim Putiary Kolkata - 700 041 Email: info@martinfotech.in

Tel: +91 33 24886033/ 9038003210 www.martonline.in

35


SUCCESS STORY

TRTC: The changing face of Manufacturing Kerala The growing need for companies to manage surging volumes of structured and unstructured data is continuing to propel enterprise use of open-source Apache Hadoop software. But instead of replacing existing technologies, Hadoop appears to be working alongside conventional relational database management systems (RDBMS). The journey was a tireless long way back from its inception since the year 1975 amalgamating erstwhile Kerala Small Industries Corporation and Kerala Employment Promotion Corporation. At the outset the industrial development was a premature one without the definite objectives and was very much prone to sick industry. This industrial sickness was among the small and medium industries owing to the lack of efficient manpower, powercuts and the lack of initiatives on the part of the Government. As the proverb goes that Rome was not built in a day, the tagline closely pursues the fact that it is evolving and is reaching fast to its potential growth. Even the top brass of the

industry thinks that in these days manufacturing and production arena are donning the new age in the industry. As to Mr. Dileep Raj, Tool room Head TRTC, Kerala, SIDCO is one of the most trusted institute to shape up the prospects of the tool room industry with advanced features—‘’Conceiving the importance of the industrial development in the state and role of capital goods industry in the process, Kerala Government has trusted the parental organization Kerala SIDCO to set up a tool room with advanced features. Most of the industries are depending small industrial tool rooms at Coimbatore, Bangalore, Delhi etc and it is a time taking process to fulfill their needs through such tool rooms with impedingly higher cost. So as

“A regular supply of quality mould dyes and precision components is one of the main needs of the general engineering industry. In order to complement the Industries Department’s efforts to promote Kerala as a prime investment destination and lure entrepreneurs, SIDCO launched the project with 100 per cent government equity. This will be a model institute for training small and medium entrepreneurs and also prospective investors within and outside the State on tool manufacturing, designing, generating a workforce of skilled workers like supervisors, engineers and designers,” Saji Basheer Managing director, SIDCO

36

www.martonline.in

a support to the local industries in Kerala, Government of Kerala decided to start an advanced tool room with all advanced machineries with a long vision for the growth of industries in Kerala.’’ Thiruvananthapuram, is the key business point that lies on the significant domain to meet up the standardization in the area of the IT, Small and handloom sectors. Being the home of many high and small sized industries Kerala can demand the city of high potential growth in the fields of skilled workforce, quality-driven light engineering work. Now the state is witnessing the growth of heavy industries allied with the medium and small sized level best industries. For its geographical features Kerala is ideally enjoying its position that makes a channel between the Europe and the Far East. Its passes run straight all along the beaches and ports for 600km covering a furry of 9 to 14 districts with an addition of 44 rivers that fulfils the water paucity. Now the demanding status to start TRTC was from the all

levels small sized industries. Earlier there was a shortage of an advanced tool room in Kerala. Traditionally Kerala havens many small industries like footwear industry, food processing industry, machinery parts industry etc. Almost all of these industries required various machine parts as well as moulds & Dies for their business. Kerala also houses LPSC, VSSC, Brahmos, Kamco etc in govt. sector; these strategic organizations required the support of an advanced tool room. Previously the dependence was on the small conventional tool room in Tamil Nadu and Karnataka. And to fulfillment of the dream was hard to idealize. It is only after perceiving the good opportunity in tooling sector Kerala SIDCO pivoted to set up the tool room at the behest of Government of Kerala. After the opening of the tool room and training centre TRTC at Olavanna in Kozhikode by the Kerala Small Industries Development Corporation (SIDCO) there is a major March 2014


significance of growth in the industrial belt in Kerala. Ever since its inception its objectives are closely related to catering to the demand for precision tools and components not only for the aerospace and defense sectors but also for the small and medium industrial units. Moreover there was a persistent cry for the trained manpower. Its infrastructure is such a big that setting up at a cost of Rs.12.5 crore, the tool room is basically equipped to offer broad and integrated services to enhance the growth in tool engineering in the small and medium industries in the State and is committed to uphold the industry from the rudimentary structure. The current market growth is huge as well as pulls the ascending profit from the market. The mission is to lend a new facet to the arena of machine tool industry. Saji Basheer, M.D, Sidco proudly proclaims of TRTC’s becoming an ultimate solution provider for design and manufacturing of industrial and allied equipments. “We have advanced machineries with skilled workers. We are giving more important for quality.

March 2014

So we are in the making the best Tool Room in India in near term. Profit, in various disguise, is the mantra of modern business; but we are a cut above as we submit ourselves for the growth and prosperity of the industries rather than corporate profit making”. On being asked what are the quality measures applied at TRTC? Basheer made a solemn declaration to us saying its mantras are the unbridled improvement and perfection and unique design. The eyes on the quality control as an overall corporate policy. Sidco’s separate quality wing with CMM and other advanced measuring units work for ensuring the quality of the products. With the latest arrival of 3D soft ware DELCAM, the design undertaken by the experts at Sidco adheres highest quality par with international standard. The design engineers are able to extend services right from initial concept, prototype development to commercial production. As its signatory work Sidco has signed a rate contract agreement with VSSC-ISRO on a

couple of days back. The orders from BrahMos are flowing in bulk. So from the next financial year onwards VSSC may be Sidco’s main client. The current production facilities available in TTRC are expanding and it is not far off when one will overflow the other. To name them --5 Axis machining Centre, 4 Axis Machining Centre, 3 Axis machining Centre CNC Lathe machine Wire cut machine EDM machines and all kinds of conventional machines and last of all CMM etc. Now the Government initiative to create a signatory project came to line when an Industrial Estate is set aside for industrial development. The concept of setting up of Industrial Park is getting popularized in the dedicated infrastructure in a delimited area to reduce the per-business expense of that infrastructure. Undoubtedly it is a benefit to keep up the Industrial health in Kerala in one location. The TRTC works for the resurgence of new generation to spread the knowledge and expertise among the youth to set their career path and make them achieve best in the field, imparting the most modern system of education in the course. Its nine tool rooms are functioning in different States. While major industries have captive tool room facility, this will equally contribute to the growth of micro, small and medium enterprises. Recently a survey has pointed that the acute shortage of trained manpower, especially for design, and manufacture moulds, dyes, press tools, jigs

and fixtures is a sensational disclosures in the industry. The training programme provides rich experience coupled with infallible guidance. The Post Diploma in Computer Aided Design and Manufacture 2nd batch is on the go. It’s an advanced software course of 1 year for Diploma/Engineering graduate holders. Machinist course for 10th pass outs is on the anvil. While its objectives is to uphold it as a pioneer training centre in the field of high end technical training in South India, its designing and manufacturing unit are tirelessly striving to achieve the fastest result in the engineering industry. Now SIDCO is not the one way industry to pave the way for industrial structure. Their manifold facet in the industry has the capacitive power to base the very structure to sum up, the growth of the engineering field. So the establishment of the TRTC is a landmark growth and can prove to be beneficial to shape up the future of any industry. To sum up it is an ultimate destination for design and manufacturing of precision moulds, a stimulus for varying needs of industrial development. So truly it says that Kerala is God’s own country lapping up SIDCO nicely to a healthy growth. For knowing more about the manufacturing and training facilities at Kerala SIDCO Tool Toom cum Training Centre do write to Head Production, Kerala SIDCO, Thiruvananthapuram, Kerala. Tel: +91 471 2330612 www.martonline.in

37


FAIR MART

AMTEX:

A Gateway to the manufacturing world

The 9th Amtex 2014 is the glittering event of the year where the convergence of exciting business opportunities, world-class technologies and enthusiastic participants from across the globe is transpiring on a single platform. Commencing from 25th to 28th July 2014 at Pragati Maidan, it will undoubtedly be a gateway to the world of opportunities, a show of runtime for the seasoned houses and a prospect for the new entries. The requisition is persisting; the pressure is to buck up. Standing at this doorstep will it be able to meet the sustainability on the trade issue? The Exhibition is an attempt to create a rostrum for all the relevant sectors and technologies to interact with industry like aerospace, automobiles, defence, electrical and electronics instrument, material handling etc. The opportunity for the exhibitors is enormous to present brand new technologies to enhance

productivity. As in the words of Mr. Suresh Patil - “We came to AMTEX with high expectations. The market is picking up; our sales have increased by 62%. For us as a Company, AMTEX is a key trade fair, a real highlight. We see people from every. All the machines on display at our stand have prospective buyers and will be shipped

“Since its inception in 2001, AMTEX has grown phenomenally to become one of the largest shows in Machine Tools, Machineries and Manufacturing Technologies in India. In the wake of the successful prelude in 2008 and 2010 at New Delhi, AMTEX-2012 witnessed over 1400 stalls sprawled across the Exhibition. It was a grand spectacle of the latest advances in Machine Tools & manufacturing solutions and provided a superlative stage for lively interaction between manufacturers, suppliers and users of the growing Indian market. Cyril Pereira Managing Director, Triune Exhibitors Pvt Ltd

38

www.martonline.in

to our customers immediately after the show.” Mr Patil is a representative of the Accurate Engineering Company Pvt. Ltd. And Mr. Nilesh Patil of Darshana Industries Pvt Ltd asserts - “My objective in coming to AMTEX Exhibition was to find out about new process technology which has been achieved primarily because everything here is well organized and laid out very clearly.” The stage is gearing up for the most hyped event in the coming month as the largest show of machine tools, machineries and manufacturing technologies in the Asian Continent. So can we think this opportunity will undoubtedly be the gateway to the world of opportunities to base the country’s dream to a nurtured state! The fair will be held from 25th to 28th July and the 4days long glamorous machine tool show is seemingly going to be the bellwether event of India’s machine tool manufacturing companies. The charismatic exhibition is being supported by NSIC (National Small Industries Corporation) a PSU established by the Government of March 2014


India in 1955 who are providing subsidy to the MSME sectors to participate in the Exhibition. Enlightening and dazzling news hit us that besides participation from the giants in the Industry in the Machine Tool & Engineering like Segments from the Country, separate pavilions from Taiwan, China and Korea have added glamour to the Exhibition. There is also a sizeable participation from countries like Germany, Turkey, Singapore, Japan etc. Indian Machine Tool IndustryIndia stands 13th in production and 6th in the consumption of machine tools in the world as per the latest survey. The country is all set and about to become a key player in the global machine tools industry and is likely to see substantial high-end machine tool manufacturing. Industry experts say that the phenomenon is linked to the spurt in manufacturing, for which the machine tools sector serves as the mother industry. Every machine tool manufacturing industry has put continuous efforts for in the current volatile economy. Indian Machine tool Industry has around 1000 units in the production of machine tools, accessories/attachments, subsystems and parts. Of these, around 20 in the large scale sector account for 70% of the turnover and the rest are in the SME sector of the industry. Approximately, 75% of the Indian machine tool producers are ISO certified. While the large organized players cater to India’s heavy and medium industries, the small-scale sector meets the demand of ancillary and other units. Many machine tool manufacturers have also obtained CE Marking certification, in keeping with the requirements of the European markets. The Indian machine tools sector offers several opportunities for investment. Given the current gap between demand and supply, there is a clear need for adding capacities in this sector. The industry is moving towards increasingly sophisticated CNC machines, driven by demand from key user segments, such as, automobiles and consumer durables. Machine tool manufacturers need to develop capabilities

“AMTEX exhibition is an important event for us – for meeting our existing and prospective customers for lining up new business. AMTEX is a permanent fixture in our event calendar and fully meets our expectations” Maulik Patel Sahajanand Laser Technology Ltd

to cater to this demand and investments in this area could yield long term benefits. Indian machine tool manufacturing industries are now ready and all set to expand their reach to the international market and Amtex-2014 is going to provide the space to showcase them not only to the domestic market but also to the international market as similar to the previous event that is Amtex 2012 that was witnessed the representation of 14 countries such as exclusive pavilion from China, Taiwan and Korea, participation from USA, Spain, Turkey, Japan, Slovenia, Italy, Israel, Singapore, etc. Spreading over 149 acres of prime land in the heart of New Delhi with an attachment of 71,290 sq.mtrs of covered exhibition space in 18 air-conditioned halls is waiting for the footfalls from the far off countries to pursuing is expected to touch up to lakhs as said sources. Now its 10, 000 sq.mtrs. showcased area is the most craved zone for the exhibitors, visitors for the month of July. Adding edge to the advantage, the potential prospects is northwards. The awaiting event is undulating with a grasp of hope to make a substantial gain and the Asian giants are eagerly waiting to showcase the product into the recent trade development on the machine tool industry. However, the past IMTEX India has skillfully merged the technique to the advanced machine tool trend with quality based corporate tools to meet the global pull. And the development was not in a day. Starting from the year 1994 AMTEX has

“AMTEX is the place where you’ll find the highest-level of innovation. This is where we can show our developments to prospective customers from the length and breadth of the Country. The mood in the industry remains upbeat – especially among the Exhibitors.” Satish Godbole Siemens Limited.

March 2014

constantly gained its position as one of the largest show of machine tools industry which has observed a growth of 300 percent in this period. AMTEX with well over 1200 stalls will do a justice to a grand spectacle of the latest advances in Machine Tools and Manufacturing solutions and is expected to provide a superlative stage for interaction between Manufacturers, Suppliers and Users of the growing Indian Market and thus broaden up the horizon of machine tool industry. AMTEX exhibition holds tremendous significance for all levels in manufacturing organizations – be it CEO’s & entrepreneurs, senior executives, corporate planners & strategists, manufacturing managers and executives, shop-floor, engineers and technicians, agents and dealers spanning industries. Now Why Amtex in Delhi? It is not so because Delhi became a prime spot of industrial business but due to its prospects as it bridges the construction for global investment. Adding edge to the advantage, the potential that DELHI and NCR regions presents is sure to take the prospects of the region northwards. National Capital Region’s (NCR) largest market, significant resources and conducive investment policies make northern states a preferred investment location. At a time when the global industry is in a mode of complete expansion, NCR is proactive in showcasing its capabilities. Regions like Gurgaon and Noida have attracted MNCs who have in turn made way for R&D activities in this region. The region needs to build a stronger base to attract investments and make way for development. It is not only for the reason that the capital metro is the second largest metropolitan city in India-Industrial hub, the seat of the central government & one of the fastest growing cities of the world. The city possesses the infrastructure in India, in terms of travel, conveyance & stay with ample boarding facilities, excellent rail and road connectivity & metro rail system. www.martonline.in

39


MACHINE TOOLS

A Red Hot Connection The composite camshaft is still gaining ground in the marketplace. The main reason for this is the considerable weight reduction it brings, compared to its one-piece rival. The composite version is by now also widely used in the HGV sector. However, a quite considerable disadvantage of many assembly processes are the high joining forces applied, which create unacceptable tolerances in positioning and alignment of the cams. By contrast, the patented heat shrink assembly process from EMAG offers a decisive advantage, as it ensures that „ready-to-fit“ camshafts, gear shafts and other precision composite units can be produced without problem.

The advantages of the composite camshaft are well known: less expense, less weight, the possibility to use different materials for the various constituent components, greater flexibility in production and the ability to implement new cam geometries, such as negative radii, with ease. The necessary reductions in petrol consumption – and with it those of CO2 emissions – are easier to achieve with an increasing use of composite camshafts. Alternative processes for the joining of cam and shaft have one serious disadvantage: the two components cannot be joined with the necessary accuracy to avoid a subsequent finish grinding process. In many

cases, the joining of cam to tube is carried out using a formfit process like press-fitting, knurling and/or spline/serrated gearing. The joining forces required for these processes can deform the components and result in unacceptable tolerances in cam position and orientation. The heat shrink assembly process from EMAG means precision joining Thermal joining, i.e. the heat shrinking of cam onto tube, ensures that the required tolerances are achieved with a reaction force-free process. The know-how to tightly control the process parameters “temperature” and “time” – and the mechanical design of the joining equipment – are of

VA 700 T – Joining machine for the manufacture of composite camshafts. Whilst one cam is heat shrunk, the next one is preheated. Equipping the heat shrinking machine with a number of preheating units allows for the optimal application of this technology to suit the task in hand.

the utmost importance in this.

Finished assembly of a motor cycle camshaft. An optimal combination of robot and special-concept gripping technology allows to join with a fusion gap of < 15 µm.

40

www.martonline.in

An optimal combination of robot and special-concept gripping technology allows for fusion gaps of < 15 µm to be achieved safely. The concept’s great flexibility allows camshaft designers much freedom in their designs and ensures that the process can also be used for medium batch sizes, where frequent component type changes are the order of the day. The high degree of precision of the composite camshaft drastically reduces the need to subsequently grind the cams

or – where precision cams are used – does away with the requirement completely. A further advantage of this process lies in the possibility to use different materials for the composite shaft. This includes forged cams, for instance in 100Cr6, or finish-ground cams, even dimensionally accurate sintered cams that do not require a downstream finishgrinding operation. Secondary components, such as bungs and endpieces, can – just like the actual shaft itself – be made of more advantageous materials. February March 2014


All this allows for the camshaft to be made to suit the requirements of the engine and to optimise it in terms of load bearing capacity and manufacturing costs. And now one step further: Where the camshaft needs to be ground after heat shrink assembly, the joining machine can be linked up to a grinder. This is particularly easy when using an EMAG grinding centre of the VTC DS series. With this, the joining machine robot transfers the assembled camshaft directly to the loading position on the grinding centre. The advantages of this process from EMAG also apply to the machining of other components. When machining gear shafts, ground gears can be joined tightly on the shaft, without having to take account of the grinding wheel overrun at the design stage. It also minimises the length of the shaft and makes the whole unit more compact. Maximum flexibility The EMAG process is characterised by only a very few machining components being in direct contact with the workpiece. It allows for the machines to be reset in the shortest possible time (less than 15 minutes). Joining in seconds and achieving the highest possible

quality The heat shrink assembly process offered by EMAG combines flexibility with productivity, whilst freedom of design and choice of production technologies ensure a short cycle time. Whilst one cam is heat shrunk, the next one is already being preheated. Equipping the heat shrinking machine with a number of preheating units allows for the optimal application of this technology to the task in hand. It is these advantages that may well be the reason why so many firmly established manufacturers of camshafts and other precision assemblies are showing such a great interest in the new process, are asking for machining tests, or are already applying the process under production conditions. In the ideal case, the customer will take advantage of the synergy provided by the EMAG Group and ask for a complete concept to be prepared that covers everything from premachining to heat shrinking and endmachining.

Allows the use of a combination of different materials• Freely selectable component sequence • Freely selectable angular and axial position• Fast resetting in case of product changes The advantages of the composite camshaft: • Less expensive • Less weight • Cams can be made of different materials

Ready-to-fit, complete, heat shrunk assembled camshaft. The high degree of precision of the composite camshaft drastically reduces the need to subsequently grind the cams or – where precision cams are used – does away with the requirement altogether

• Greater flexibility in production • New cam geometries – such as negative radii – can be implemented easily For Further details contact :

EMAG India Pvt. Ltd. Technology Centre 17/G/46-3, Industrial Suburb, 2 nd Stage, Yeshwantpur, Bangalore - 560 022.Karnataka, India. visit www.emag.com

The advantages of the heat shrink process: • Great accuracy, requires no downstream processing after heat shrinking, • Saves on material and offers weight reduction ,• No deformation after heat shrinking •

Also used for gear shafts, heat shrinking of the constituent components ensures a compact design and high functional density, as the gears are in direct contact with the shoulders.

February March 2014 2014

www.martonline.in

41


MACHINE TOOLS

CELOS – From the idea to the finished product CELOS from DMG  MORI marks the beginning of a new era. At the Open House Event in Pfronten, DMG  MORI will be presenting 18 of the 66 exhibits in the new uniform design with CELOS. with CELOS will be available for delivery from the second quarter of 2014. At first glance, CELOS provides the user with a uniform operator interface with multi-touch functionality. But CELOS is much more than this and can do much more. Of crucial additional benefit to the customer are various CELOS APPs such as Job Manager or Job Assistant

CELOS – A notional projection comes true

CELOS is as easy and intuitive to use as a smartphone. CELOS simplifies and accelerates the process from the idea to the finished product and also forms the basis of paperless manufacturing. In addition, CELOS APPS provide the user with integrated and digitised management, documentation and visualisation of order, process and machine data. As well as the above, CELOS is also compatible with PPS and ERP systems and can be linked to CAD / CAM applications and is designed to work with other forward-looking CELOS APPs. CELOS will be provided on all new high-tech machines from DMG  MORI. The first 20 machines from DMG  MORI

42

www.martonline.in

The status manager is the starting point for the interaction between the operator and the machine. Here, CELOS displays upto-date monitoring of the machine and and process. It supplies important key performance indicators for the current order as well as for the order progress. Moreover, it notifies the operator with special icons as well as text messages of any errors, problems or upcoming required maintenance work. Job Manager and Job Assistant support the machine operator with regard to network-integrated planning, preparation, optimisation and systematic processing of new machining jobs. First of all, all productionrelated data for the NC program, workpiece, tools, clamping devices etc. can be combined to form a machining job and instantly visualised with the Job Manager. All documents, data and information required for an order can also be managed in a structured way. For example, the data can be quickly accessed during later processing or obtained from a repeat order.

With Job Assistant the digitally prepared orders can be systematically processed at a later stage. In this process, first of all the availability of all NC programs and equipment (tooling, fixtures, etc.) required for machining is checked. The operator is then guided through the setup process and preparation of the machining job by a dialog. Appropriate queries and necessary confirmations ensure that the machine operator makes no mistakes. Only then is the go-ahead given to start machining. This ensures highly reliable manufacturing, even for more complex orders or more complicated components. Apart from the advantages for the user, the integrated interaction of Job Manager and Job Assistant also demonstrates the excellent scalability of CELOS for very different company sizes. Small companies with a high level of personal operator responsibility particularly benefit from the option of paperless production. On the other hand, already widely networked large companies can optimally organise and use the different competencies of their employees by means of these two CELOS production applications. This is because a skilled worker can first singlehandedly prepare all orders in the Job Manager. The machine operator is then instructed and guided in detail by the Job Assistant. The respective access rights can be organised via the customisable status Each employee must

CELOS – From the visionary notion to the finished product UNIFORM Uniform interface for all new high-tech machines from DMG and MORI CONSISTENT Consistent management, documentation and visualisation of order, process and machine data COMPATIBLE Compatible with PPS and ERP systems, networkable with CAD/CAM products, designed to work with other forward-looking CELOS APPs

login at the 21.5’’ ERGOline® with a SMARTkey®. In all, 12 different CELOS APPs are currently available and can be started centrally via the APP SELECTOR. These also include the CONTROL APP. With this CELOS APP, DMG  MORI provides its customers with the option to switch to the usual control environment of the CNC concerned by tapping once on the appropriate icon on the multi-touch screen of the 21.5” ERGOline®. The CONTROL APP is initially available with controls from SIEMENS (with OPERATE 4.5 on Sinumerik 840D solutionline) and MITSUBISHI (with MAPPS V).

March 2014


March 2014

www.martonline.in

43


MART UPDATE

Bright Ideas for Measuring IO-Link Provides Measurement Output Data in Millimeters The days of complex single-beam evaluations for standard tasks and cumbersome configuration are over. The new LGM Series measuring light grid is the latest member in the Pepperl+Fuchs family of automation light grids. “What makes this product stand head and shoulders above other measuring light grids on the market are the 16 predefined measuring options that are integrated into the unit,” says Carsten Roth, Product Manager. “Users can select the optimum mode for their application from the evaluation methods and receive direct measured values in millimeters, such as the object height, lowest or highest object position, sum, average, etc.” The values are digitally transmitted at extremely fast cycle times, even with beam crossover activated, using IO-Link, which enables convenient commissioning and

maintenance from the control level. Parameterization and configuration are completed via a PC—no external programmer, no additional software. The LGM light grids The new LGM Series measuring light grids provide the measured values have an ultra-low directly in millimeters profile to fit into tight spaces. Innovative, tool-free mounting accessories make Unlike complex products with singleinstallation, alignment, and replacement beam output that evaluate each beam,” fast and easy. The IP67 aluminum housing says Roth, “these measuring light grids withstands harsh environmental conditions provide measured values in millimeters even at cold-storage temperatures. without time-consuming calculations and set new standards with their compact The LGM is available with various design, functionality, and unique price/ resolutions and field heights up to 3200 performance ratio.” mm, permitting large measuring ranges.”

FARO launches new X Series Laser Scanner The FARO® Laser Scanner Focus3D X 130 FARO Technologies, Inc. (NASDAQ: FARO), the world’s most trusted source for 3D measurement, imaging and realization technology, announced the release of the new FARO Laser Scanner Focus3D X 130 this month. Focus3D X 130, the newest member of FARO Laser Scanner Focus3D X Series range of laser scanners delivers tremendous power, compact design, and the flexibility to perform laser scanning in both indoor and outdoor. With a scanning range of 130 meters, this laser scanner is ideal for mid-range scanning applications such as architecture, BIM, civil engineering, facility management, industrial manufacturing, forensics, and accident reconstruction. The ultra-portable Focus3D X 130 enables fast, straightforward, and accurate measurements of objects and buildings. It records architectural façades, complex structures, production and supply facilities, accident sites, and large-volume components. Combining the highestprecision scanning technology with true

44

www.martonline.in

mobility and ease-of-use, this new device offers reliability, flexibility, and real-time views of recorded data. With its integrated GPS receiver, the laser scanner is able to correlate individual scans in postprocessing. These advances in performance do not come at the expense of safety as the Focus3D X 130 comes with a class 1 “eye safe” laser. “The touch-screen of the Focus3D X 130 is as easy to operate as a smartphone,” says Ralf Drews, Managing Director of FARO Europe. “With a battery runtime of 4.5 hours, the laser scanner also has a high level of flexibility and endurance. The Focus3D’s light weight, small size and SDcard storage capability makes the scanner truly mobile. We can offer this quality at prices which are certainly unique to the market.” With the introduction of Focus3D X 130, FARO offers its customers a choice between mid-range Focus3D X 130 (130 meters) and long-range Focus3D X 330 (330 meters) laser scanners with the best

technology and at the most affordable price in the market. For more information visit: www.faroasia.com/LaserScanner/in January March 2014


CFRIP: Open the chainflex jacket quickly with the “zipper” The CFRIP speed tool from igus strips chainflex control and motor cables twice as fast. The tearproof igus thread, introduced under the name of CFRIP for fast stripping of chainflex cables, is now integrated into 230 chainflex cable types. The CFRIP stripping aid has been added to all control cable series with PVC jackets and in motor cable families. Via the unique CFRIP principle, chainflex cables can be stripped quickly and safely in large lengths without damaging cores. The CFRIP stripping cord, developed by igus, is simple and effective: Like a zipper it opens by simply pulling on the CFRIP tearing thread within the jacket to the desired length. Afterwards the appropriate cores can be taken out of the jacket with ease. With it, installers save up to 50 percent of the usual required time for stripping. Apart from that, specific stripping tools are no longer required. The clever design of the tearing thread that is integrated into the cable prevents damaging of the stranded element when the chainflex cable needs to be stripped.

Strip 230 chainflex cables simply and safely. Along with PVC control cables chainflex CF5, tearing thread in the outer jacket and the shielded version chainflex CF6, tearing thread in the inner jacket – now the control cable families CF5, CF6, CF130 and CF140 as well as the complete multi-core motor cable families are equipped with the CFRIP thread. 230 chainflex cable types with integrated CFRIP tool are currently available. More cable series with integrated CFRIP are in development. A short video clip at http://www.igus.in/ wpck/8487/cfrip clearly demonstrates the CFRIP functional principle. The igus GmbH is a world`s leading manufacturer in the field of energy chain systems and polymer plain bearings. The family-run company is based in Cologne, represented in 29

Thanks to CFRIP installers can save up to 50 percent of required time for stripping cables

countries and contracts 2,200 employees worldwide. In 2012 igus generated a turnover of 399 million Euro. igus operates the largest test laboratories and factories in its industry to offer customers innovative and tailor-made products and solutions within the shortest time. For more details visit www.igus.in or write to Sreejith Menon at sreejith@igus.in

Kollmorgen expands in India New distribution contract completed with Ruju Corporation Kollmorgen is expanding its presence in India. The motion control specialists completed a distributor agreement with the Ruju Corporation at the recent SPS/ IPC/Drives Expo in Nuremberg. Ruju, based in Ahmedabad in the western Indian state of Gujarat, is part of Hiecon Technologies. Founded in 1996, the leading Industrial automation solution provider is especially active in the textile, packaging and plastics industries as a drive and control technology provider. During the contract signing, Udo Panenka, Managing Director of Kollmorgen Europe commented, “For us the partnership with Ruju is an important building block to enable our continued growth in a strong market.” Hiren Joshi, owner and CEO of Ruju was very pleased with the prospects offered by the agreement, “Kollmorgen’s high level of expertise in servo drive technology and motion control solutions March 2014

immediately provides us with real benefits as a premier supplier of automation equipment in our country.” The two executives are also satisfied because the first joint packaging technology projects are already in completion. Alexander Hack, Market Development Manager for Kollmorgen, concludes further benefits of the deal, “Based on At SPS/IPC/Drives, the signing of the distributor agreement: our open and standardized Kollmorgen Managing Director Udo Panenka Ruju, Ruju owner Hiren product platform, and Joshi and Market Development Manager Alexander Hack (from left) together with Ruju, we are looking forward to the joint agreement for the Indian market. can develop well scaled motion and machine control These also include increased opportunities applications for machine builders in India to effectively address the rising energy that are accurately tailored and implement costs in India with efficient solutions. faster.” www.martonline.in

45


Lapp Group offers adept and flexible factory of the future Machines, plants and devices are made “intelligent” by connecting them to one another using the “Internet of Things”. The resulting cyber-physical systems form the basis of the intelligent factory of the future - its vision: to create maximum flexibility and efficient production with batch size 1. Cyber-physical systems are functional units with embedded hardware, software and mechanics. The fact that they are capable of communicating with one another is opening up new horizons for plant and machinery manufacturers, who can break plants down into individual modules that only have to be programmed and tested once.

cables must withstand high mechanical stress, extreme temperatures, vibrations and contamination. This kind of environment may also be exposing them to aggressive media.

Ethernet cables used in industrial applications must also be shielded against much stronger EMC interference as that found in the vicinity of motors or live cables that are generating an electromagnetic field. Lapp is researching “production work 4.0” under the leadership of the Fraunhofer IAO. The research mainly focuses on the work environment look in a factory of the future, kinds of tasks factory workers will This leads to fundamental changes in undertake and how can they be supported the cabling of an industrial plant. For the in fulfilling their tasks? In addition Lapp manufacturers of connection technology, is involved in the SmartFactoryKL e.V. this means that the cables with inserts technology initiative run by the German that have previously been used primarily in Research Center for Artificial Intelligence office environments now need to be made (DFKI). The solutions developed in this suitable for industrial applications. The context aim to support companies in achieving resource efficient and ergonomic production, with “We are certain that the ‘Fourth industrial dynamic integration revolution’, by which we mean the increasing of their customers and networking within production facilities and business partners into the associated transition to a more flexible the value chain. type of production, as well as the increasing Lapp is taking the lead customization of product variants, will be the on the quality inspection defining development in German industry over module for the research the next few years” and demonstration platform involving Siegbert Lapp testing innovative Member of the Board, Lapp Holding AG cabling and connection solutions for data

network cables. Quality inspection includes the use of a high-resolution camera that raises a particular challenge in itself as it must be able to transfer data consistently and reliably at the highest data rate. In this case, the highly flexible ETHERLINE ® FD Cat.6A cable, together with the fieldconfigurable X-coded M12 data connector ensures this function. Data rates of up to 10 Gbit/s are possible for high-resolution cameras in moving applications. Industrial Ethernet assemblies comprising robust, resilient cables with M12 connectors, also ensure a reliable connection in areas where contamination and damp must be taken into account. This extensive networking paves the way for new possibilities in maintenance, storage and production. With this in mind, Lapp is planning on attaching RFID chips to its cables, among other innovations. The “fourth industrial revolution” has many challenges and to achieve this vision companies are in need of ingenious solutions that allow the vertical and horizontal integration of their value creation processes.

Indo-MIM bestowed Best Exporters Award Indo-MIM was acknowledged with an award for Best Exporter- Gold for the year 2011-12 and 2012-13 in Bangalore Rural -District category. Organised by Visvesvaraya Trade Promotion Centre (VTPC), the award was presented by Prakash B Hukkeri, Honorable Minister for Small Scale Industries Muzrai & Sugar to Anand SK and Manjunath H of Indo-MIM on 21st February 2014. Karnataka Chief Minister Siddaramaiah was the chief guest along with Anup Pujari, DGFT Delhi, who was the guest of honor at the occasion. Karnataka Government had introduced the State Award for best performance in

46

www.martonline.in

exports in 1992-93 as one of the paramount steps towards recognizing the efforts of exporters wherein Visvesvaraya Trade Promotion Centre is the nodal agency for selecting and conferring the awards to the companies for their outstanding performance. These awards are an annual event which is aimed at encouraging exporters who have excelled in exporting their products. These awards play an important role in infusing a spirit of healthy competition amongst the industries & exporters of the State to achieve greater export performance. Indo-MIM has achieved a leadership

position in the field of MIM, providing precision-engineered products to customers in more than thirty countries in the Americas, Europe and Asia. Indo-MIM is a fully integrated MIM parts producer with capabilities and proficiency in design, tooling, materials and a full range of finishing and assembly operations. IndoMIM had earlier won the award in the same category in 2009-10 & 2010-11 for their outstanding performance towards exporting the products by maintaining their core belief that is to provide lasting value to their customers and shareholders alike. January March 2014


March 2014

www.martonline.in

47


48

www.martonline.in

January March 2014


THE LAST LEAF Dear All, Today, the need for face to face communication that could provide empathy, understanding and reassurance – a kind of human connection, is fundamental to customer service. And telepresence can be a powerful and cost effective tool for such communications. Holographic telepresence makes a three-dimensional moving image of a user to be reproduced at each meeting location. The hologram technology has tremendous scope to be utilized in areas like education, enhanced movies, television programming, advertising, gaming, 3D mapping, aerospace navigation and robot control. The technology company Musion, based in the UK, adapts the illusion commonly used in theatres and theme parks known as the Pepper’s ghost effect. An HD projector illuminates a thin, effectively invisible, sheet-like “foil” from a 45-degree angle, creating a 3D image almost indistinguishable from an actual person. The Musion TelePresence system can now transmit full-sized people and objects in real-time “without any significant delay in communication”, the company says. The system achieved a Guinness World Record in 2012 by helping Indian politician Narendra Modi deliver a 55-minute campaign speech to audiences in 53 different locations simultaneously. Leia Display System, a Polish company, is currently working on yet another alternative technology to accomplish what could be called true holograms. It has built a holographic room, measuring 3m (10ft) by 2.5m (8ft), which uses laser projectors to beam 3D images onto a thin cloud of water vapour — providing not only a giant 3D multi-touch screen, but also the ability to walk through the images and see them from any point of view. (Courtsey : bbc.com) Meanwhile, the world’s biggest high-tech fair CeBIT opened its doors on March 15 in Hanover, Germany, showcasing the must-have computer, telecommunications and consumer electronics products of the future. It has drawn more than 6,000 exhibitors from 77 countries and more than 430,000 visitors. The gadgetry exhibited at this Fair ranged from time-saving to life-saving robots. RoboThespian, a life-sized humanoid robot, delivered an articulate welcome address to the guests, which included German Chancellor Angela Merkel and British Prime Minister David Cameron. Further, a hands-free gadgetry gave a new hope for frequent travelers in form of “Bag2Go”, a suitcase at the mock-up of an Airbus cabin, that was equipped with a SIM card, transmission module and display, to ensure it never gets lost. Some other exhibits included a BMW sports car that can talk and listen, and a mobile phone that doubles as a pillow and a bathroom mirror that can give current stock quotes. As always, we need your input on the industry news, views and any observation about the industry around you. Your feedback will be useful to us to better inform our reader’s about tomorrow’s manufacturing solutions. Till then, Happy Technology ! Manoj Kabre Member, Editorial Advisory Board (EAB) March 2014

www.martonline.in

49


50

www.martonline.in

March 2014


March 2014

www.martonline.in

51


RNI No.: KARENG/2004/13614 Regd. Regn. No: KRNA/BGE/1016/2012-2014 Posted at MBC, Bangalore GPO, Bangalore - 560001 on 15th of every month

52

www.martonline.in

March 2014

MART March 2014  

India's leading engineering manufacturing monthly "INDUSTRIAL BUSINESS MART" now online at issuu.com

Advertisement