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Lean manufacturing

Intrigue or intriguing? FOCUS Aerospace manufacturing

P. 38, 42

ROUND-TABLE Winning in the new normal

EM - Interview

P. 30

Dr N Ravichandran Executive Director Lucas-TVS Ltd




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e d i to r i a l

Stable growth in modern economies “Implementing lean manufacturing techniques substantially lowers overhead costs and engages employees to think critically about process improvement”

We have all now realised one more time that stable growth, although very important, is difficult to achieve in modern economies. In this scenario, most of the manufacturers have learned that “Lean” is the way to manage the current growth challenges. Lean manufacturing is the technology or ‘know-how’ to utilise man, machine, and material effectively while reducing waste, increasing productivity and improving quality. Implementing lean manufacturing techniques substantially lowers overhead costs and engages employees to think critically about process improvement. From plant workers to process managers, manufacturers must seek out waste in the form of errors, defects and especially unnecessary production steps. Companies must open communication lines between upper management and those on the production floor in each facility or location. For example, Toyota operates one of the most widely known lean production systems worldwide. According to Harvard Business Review, the Toyota system is one where “every activity, connection, and production path…must have built-in tests that signal problems immediately.” The Cover Story this time discusses the thinking behind succeeding with Lean approach, with success stories from Toyota and Boeing. IMTEX metal-forming, the leading machine tool exhibition by IMTMA is round the corner. Many of the participants are hopeful that the event will help the industry gain the necessary confidence in today’s uncertain market situation. Check out the preview feature in this issue, for more details. You will find lots of other interesting technology-based articles in this issue. Hope you will enjoy reading them. Do send us your feedback. Best wishes for a successful 2014!

Shekhar Jitkar Publisher & Chief Editor editorial advisory board Sonali Kulkarni President & CEO Fanuc India

S Ravishankar Dy Managing Director Yamazaki Mazak India

Satish Godbole Vice President, Motion Control Div Siemens Ltd

Dr Wilfried Aulbur Managing Partner Roland Berger Strategy Consultant

N K Dhand CMD Micromatic Grinding Technologies

Raghavendra Rao Vice President Manufacturing & Process Consulting Frost & Sullivan

Vineet Seth Managing Director India & Middle East Delcam Plc

Dr P N Rao Professor of Manufacturing Technology Dr K Subramanian Department of Technology President, STIMS Institute, USA University of Northern Iowa, USA Training Advisor, IMTMA Overseas Partner: China, Taiwan, Hong Kong & South-East Asia

EM | Jan-Feb 2014






Aerospace manufacturing

Cover Story 10 NEWS 16 “We will continue to focus on innovation”

Interview with Parind Prabhudesai, General Manager - Industrial Technique, Atlas Copco 18 “companies are facing complex

22 Intrigue or intriguing?

38 Aero engine machining

The article analyses the simplicity behind the implementation of lean manufacturing principles with Boeing’s example

The article deals with principal strategies and solutions for machining aero engines part-by-part 42 Keeping weight in control

The feature highlights technology USPs like 5,000 psi-technology provided by Eaton’s Aerospace Group for Airbus’ A380

28 Technology, methodology & peoplelogy

Interview with Dr N Ravichandran, Executive Director, Lucas-TVS Ltd


Interview with Rafiq Somani, Country Sales Manager, ANSYS India


30 Winning in the new normal

Industry thought leaders share their views on the strategies required to manage growth in the current business environment and the best practices to thrive in the new normal


90 Enabling manufacturing excellence

An event preview of IMTEX Forming 2014 and Tooltech 2014 100 Championing complete machining solution

An event report on Walter Machining Solutions Meet held at Pune

34 Upgrading to new age solutions

A facility visit to Eaton’s Vehicle Group’s engine valve manufacturing unit at Ahmednagar

102 The ultimate source for productivity solutions

An event report on Productivity Summit, IMTMA-SIEMENS Productivity Championship Awards and Productivity Buzz 106 Building confidence in the future

A post event report on AMS India Conference organised in Pune





Layer-based manufacturing

The article outlines the different applications and future developments in layer-based manufacturing rapid prototyping technology


Unchaining the value of RFID

The article talks about how companies are unlocking the value of RFID to improve overall tracking and control throughout the enterprise

New Products 108 M  illing cutters; Triple action presses; bridge type-milling machine; Multi-tasking machines


Software for successful manufacturing

A read into innovative ERP technologies which enable manufacturers streamline their business processes


Optimising cleaning quality


Designing a holistic solution


Efficient future mobility




Fast feed and precise positioning An application story on encoders that guaranty maximum process reliability for precision assembly systems used in micro-electronics and micro-optics industries

Portable CMM & 3D scanning

An article on the use of Faro’s solutions by Faurecia Shanghai to simplify its product development process and reduce R&D cost

The article deals with today’s solventbased parts cleaning systems and their benefits

109 CNC servo motor driven ram turret punch press; 25-speed electric gripper; PVD & CVD coated carbide grades; Grinding tools with diamond & CBN

The article deals with holistic material handling in manufacturing AUTOMOTIVE MANUFACTURING

An article on Schaeffler’s drivable concept car which offers up to 10% reduction in fuel consumption

110 Cutting tools; Multi-tasking grinding machines; CNC machine simulation software; CNC cylindrical grinding machine

Columns 07 08 112 112

Editorial Contents Highlights – Next issue Company index

Cover image courtesy: Boeing


market | news

Renishaw co-chairs Advanced Manufacturing Group meeting

German machine tool orders rising again

Rhydian Pountney, GM – ROW Sales Division, Renishaw, recently co-chaired In the third quarter of 2013, order bookings for Germany’s machine tool the Advanced Manufacturing Group of the industry rose by 9% compared to the third quarter of 2012. Domestic India-UK Joint Economic and Trade orders were up by 12%, while orders Committee (JETCO) which took place on from abroad were up by 6% on the December 9, 2013, in New Delhi. The preceding year’s figure. For the first meeting was part of a wider JETCO nine months of 2013, there was an programme that involved Vince Cable MP, overall drop of 6%, domestic orders UK Secretary of State for Business, fell by a 10th and orders from abroad Innovation & Skills; Anand Sharma, Indian by 4%. “Demand for machine tools Renishaw recently co-chaired Minister for Commerce & Industry and a has achieved the long-awaited the Advanced Manufacturing trade delegation of UK businesses. turnaround”, said Group of the India-UK Joint “Renishaw is a highly successful UK exporter Dr Wilfried Schäfer, Executive Director Order bookings and sales in the German Economic and Trade Committee of high technology products for the – Sectoral Organisation, VDW (German machine tool industry engineering sector with its own sales and Machine Tool Builders’ Association) manufacturing operations in India,” said Rhydian Pountney. “British in Frankfurt am Main. The two months of August and September, in businesses like Renishaw are doing good business in India providing an particular, saw double-digit growth. This applies to both domestic and inspirational example to the army of small and medium sized UK firms who export orders and to the two technology segments involved, metal-cutting could also do well in this market. Trade with India is up by 20% this year and forming machine tools. Schäfer sees this as reflecting not least a boost building toward our shared goal of doubling two way business by 2015,” from the EMO Hannover 2013, the trade fair for the metalworking sector, which was held from September 16 to 21, 2013. said Vince Cable, UK Business Secretary. > MORE@CLICK EM01057 |

Mazak offers Siemens control option Yamazaki Mazak has offered Siemens Sinumerik control, an alternative CNC option for machine tool users who are established Siemens control users. The SINUMERIK 840D sl is available across a select number of Mazak machines in the VARIAXIS, VTC 800 series and eH multitasking machine ranges. Three new models equipped with Siemens SINUMERIK 840D sl CNC were displayed on the Mazak stand during EMO 2013. The VTC 800/30SDR is a simultaneous 5-axis vertical travelling column machining SINUMERIK 840D sl is available centre designed and built at Mazak’s European across a select number of Mazak manufacturing plant in the UK, specifically for machines in the VARIAXIS series, European customers. The new SDR variant including the VARIAXIS i-500 delivers the ideal solution for the efficient machining of large critical components requiring the highest levels of accuracy and exceptional productivity due to enhanced swarf management, enabling extended continuous cutting without stoppage. The INTEGREX e-500H II, also equipped with SINUMERIK 840D sl control, is a complete fusion of machining centre and turning centre, which makes it possible to meet a wide range of production requirements. > MORE@CLICK EM01059 |


> MORE@CLICK EM01058 |

Italian production likely to increase by 4.6% The Italian machine tool, robot, and automation system manufacturing industry reached the end of 2013 in a stationary condition. As per Studies Department of UCIMU-SISTEMI PER PRODURRE, in 2013 production stood at €4,780 million, with a 1% decrease compared to previous year. Luigi Galdabini, President, UCIMU-SISTEMI PER PRODURRE, stated, “The most evident data is the increase in domestic consumption, which after years of stagnation seems to show a positive trend, however small. In other words, demand is there, but there is still a problem of liquidity among Italian companies, which can obtain bank As per Galdabini, loans with extreme difficulty.” In 2014, production is likely to increase by 4.6%, imports will benefit from the increase in demand reaching €5,000 million. With a 4.6% increase, from Italian users exports will register a new record standing at €3,780 million. The export/production ratio will remain stable at 75.6%. After being down for three consecutive years, deliveries will show a positive trend, thanks to a 4.7% increase, they will reach €1,220 million, driven by the recovery in domestic consumption, which will reach €2,145 million, 4.4% more than in 2013. > MORE@CLICK EM01060 |

EM | Jan-Feb 2014

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market | news

Knorr-Bremse sets up truck braking systems’ plant

Mahindra Auto Steel invests in new facility

Knorr-Bremse has set up a new plant in Pune to make complete braking systems for trucks. It has also established a technology centre for engineering design in the city. “Set up with an investment of €14 million, the facility will address the needs of the domestic market and serve as the leading plant worldwide for automatic slack adjusters”, said Klaus Deller. Board member, Knorr Bremse. Deller, is responsible for the commercial vehicle business globally. “The greenfield plant can build braking systems for 80,000 trucks per year, and production is scalable.” India, at present, accounts for 2 per cent of the company’s global revenue. According to Deller, the target is to double this in the next three years. Knorr-Bremse’s Technical Centre India will have over 200 engineers working on global development projects for both truck and rail systems. The building also houses a software centre for the company’s rail division. The company plans to open its greenfield plant for railway systems in Faridabad soon.

Mahindra Auto Steel has invested ` 150 crore to set up a new facility at Chakan to process steel and make blanks, trapezoids and profiles. The company is a joint venture between Mahindra Intertrade, Taiwan-based China Steel Global Trading Corporation and Singaporebased Mitsui & Co (Asia Pacific) Pte. The facility will have an annual processing capacity of 130,000 tonne when it begins operations in approximately a year’s The facility will have an annual processing time. It will offer a package capacity of 130,000 tonne when it begins of services beginning from operations in approximately a year’s time sourcing steel, warehousing, forex risk management to make customised deliveries of SKUs and products to auto companies. “We are trying to redefine the steel supply chain in India.” Half the capacity from the new plant will be for use within the Mahindra Group, while the rest of the business will come from auto companies in the Chakan-Talegaon belt,” said Harsh Kumar, MD, Mahindra Intertrade.

> MORE@CLICK EM01061 |

> MORE@CLICK EM01062 |

Prof Shoji Shiba praises India’s indomitable spirit Padmashri awardee and acclaimed Japanese management guru, Prof Shoji societal manufacturing and industry collaboration with academia were vital Shiba recently released his book on ‘7 Dreams to Reality: Transforming to the progress and improvement of Indian manufacturing industry “The CII Indian Manufacturing’ in the presence of Jamshyd VLFM Institute aims at transforming manufacturing Godrej, Past President CII and Chairman CII VLFM into an activity that is attractive to all students Institute and Kiyoshi Asako Consul General of not just manufacturing. To build an impact on Japan at the exclusive session on “Transforming society and build lasting impact so that the Indian Manufacturing” organised by CII, National transformation that takes place creates jobs, Manufacturing Competitiveness Council (NMCC), creates skills, market, individuals and groups Govt of India & JICA. “The book represents the who look at manufacturing as a desirable and human bond between India and Japan which will uplifting activity”, said Jamshyd N Godrej, Past be passed from generation to generation,” said President, CII & Chairman, CII-VLFM Institute. In Shiba. He along with the various business leaders the exclusive session on “Transforming Indian spoke about the book — the seven stories of Manufacturing” business leaders thanked Shiba change in Indian manufacturing. “It is very Prof Shoji Shiba released his book ‘7 Dreams to for his role and support in the transformation important to dream and to have a creative Reality: Transforming Indian Manufacturing’ in the process. CS Patel, Member of Anand Supervisory mindset for fostering innovation and growth” presence of Jamshyd Godrej, Past President CII & Board, Anand Group described how his company asserted Shiba. He credited institutions like Chairman CII VLFM Institute and Kiyoshi Asako, realised that it was essential to tread the path of NMCC, MHRD, DEA, IIMC, IITK, IITM, CII and JICA Consul General of Japan self-improvement before bringing about an for facilitating the transfer of knowledge and improvement in its suppliers to bring about a wisdom for facilitating transformation through India-Japan partnership. He transformational change. > MORE@CLICK EM01063 | stressed on the new product development, organisational transformation,


EM | Jan-Feb 2014







Page _OMRON-rep-A&D-wo-Elecrama_210X273 Saturday, January 11, 2014 1:12:38 PM

market | news

Bajaj Electricals sets up R&D centre Bajaj Electricals has planned to establish an integrated R&D centre that will drive innovation and help it create cutting-edge technology across its three business verticals. The company, which gets nearly half its top-line from the consumer durables and kitchen appliances business, is also increasing its focus on nonurban centres. Citing the example of Bajaj Auto, which Bajaj Electricals plans to establish an has created its own technology integrated R&D centre that will drive for its motorcycles, Shekhar innovation and help it create cutting-edge Bajaj, CMD, Bajaj Electricals technology across its three business said, “The R&D centre will verticals study market needs and make what the consumer wants.” “Cutting-edge technology is the only way for products to remain strong. The product could then be sold across geographies. At present, exports account for a mere 1% of Bajaj Electricals’ sales, and there is a lot of scope on this front,” said Anant Bajaj, JMD. > MORE@CLICK EM01064 |

Kirloskar Brothers celebrates its golden jubilee Kirloskar Brothers Limited (KBL) recently celebrated the golden jubilee of its Dewas Plant in Madhya Pradesh. Established in 1962, the plant accurately reflects KBL’s research and development (R&D) capabilities and its commitment to corporate social responsibility (CSR). “The facility has been a role model for implementing several notable initiatives over the past 50 years; in R&D, CSR and technology segments. The plant has made significant contributions to some of our key projects like SMS, JIT, MOST, and TPS. And our vision is to Kirloskar Brothers Limited (KBL) expand the production to 6,00,000 celebrates the golden jubilee of its pumps per year, and double the Dewas Plant in Madhya Pradesh turnover in next 5 years,” said Sanjay Kirloskar, Chairman & MD, KBL. “Since my first visit to the plant, I have been pleased by the advancements made at Dewas. Several innovative marketing initiatives have been implemented such as REACH, SMDS setting a benchmark for our other facilities, aiding the plant to go beyond what it set to achieve”, said Jayant Sapre, Executive Director, KBL. > MORE@CLICK EM01065 |

CII holds Manufacturing Summit 2013 The 12th edition of CII’s flagship event for the Indian manufacturing sector Indian Manufacturing: Winning in an era of shocks, swings, and shortages’ — the Manufacturing Summit 2013, was released by CII and BCG India. was scheduled on November 22, Speaking about the report, Arindam 2013, in Mumbai. The last decade Bhattacharya, MD, The Boston has significantly altered the global Consulting Group, said, “Industry landscape for manufacturing. would have to learn and prepare to According to a recent report by CII, operate in a volatile environment, the share of manufacturing in India which could be caused by a has dropped by 15.1 per cent this depreciating rupee or an earthquake year, the least since the past ten in some part of the world. It is years. According to a survey believed that by 2015, the US will conducted jointly by the become one of the most Confederation of Indian Industry manufacturing competitive nations (CII) and the Boston Consulting During the inaugural session, a report on ‘Powering Past Headwinds – Indian in the world. There are changes Group, 83 per cent executive Manufacturing: Winning in an Era of shocks, swings, and shortages’ was released taking place in China and Africa and directors of companies that by CII and BCG India all these present turbulence participated in the survey felt that companies that adapt will thrive.” slowdown in domestic demand had the biggest impact on India’s The summit aimed to conduct table discussions that revolved around the manufacturing sector in the past 12 months. More than 75 executive changing context and the implications of the changes in the manufacturing directors of manufacturing companies in India participated in the survey. sector on companies. > MORE@CLICK EM01066 | During the inaugural session, a report on ‘Powering Past Headwinds –


EM | Jan-Feb 2014

market | interview

“We will continue to focus on innovation” Parind Prabhudesai, General Manager – Industrial Technique, Atlas Copco, shares his insights on the trends shaping up in the motor vehicle industry, the first Indian application centre in Pune and recent innovations, during an interview with Srimoyee Lahiri What are the major demand trends shaping up in the motor vehicle industry? The two most predominant trends related to requirement of assembly tools that are seen in the motor vehicle industry are increase in the use of electric assembly tools and rise in sophistication in terms of interfacing of assembly systems with central systems and building error-proof stations. A shift has been witnessed in the type of tools which are used on the assembly line; from pneumatic assembly tools to electric assembly tools due to the following reasons. With the rising power cost customers are now making a conscious decision of shifting to electric tools since air is the costliest utility in any manufacturing company. The electric tools also offer features like data storage and traceability. Traceability becomes essential if the plant intends to export the vehicles to countries in Europe or USA. Since the assembly line has become more flexible in terms of producing more variants on the same line, electric tools are able to adapt to this due to ease of changing the torque or programs to be executed. Manufacturers are seen aiming at ‘doing things right the first time’. As the vehicle moves down the assembly line, the cost of rectification becomes costlier. Atlas Copco Tools and Assembly Systems has inaugurated facility housing, its first Indian application centre in Pune in the beginning of 2013. Which advantages have been derived from the application centre? This facility is a perfect platform to demonstrate the company’s commitment toward delivering quality and total solutions to our customers. Our entire team of proposal, project management, engineering, purchase and global product development increases our efficiency in operations through operational synergy. Our product demonstration area in the

facility helps customers to have hands-on experience of our solutions and capabilities in a better way complementing our sales strategy. What are the latest products and acquisitions offered by Atlas Copco to the motor vehicle industry? The three major acquisitions for motor vehicle industries are SCA (adhesive solutions), Saltus (torque wrenches and hand tools) and Synatec GMBH (data collection and analysis systems). With these acquisitions, the company is now able to offer a wider product range and a better solution for its MVI customers. How does R&D function in Atlas Copco— Industrial technique? R&D works in close coordination with the marketing department. It is the customer future demand which drives the R&D engineers to innovate and develop new product. The R&D engineers also travel around the world to see the various plants and assembly lines and study the problems customers are facing. The company has also taken some initiatives like VOC (voice of customer) where customers are interviewed to understand their future requirement. Apart from this, external agencies are also hired to conduct global surveys to see the demands. In the last few years, there is a big focus in developing tools for the Asian market. The company has set up Asia Centre of Excellence for this reason. What kind of strategies have you planned to sustain the growth momentum in today’s challenging market situations? We will continue to focus on innovation as a market leader, tap new/unexplored markets for new products and increase market coverage. We will use extended arms like distributors/dealers and effectively leverage on state-of-the-art facility in Pune to become a preferred supplier for the Indian customers. ☐ > MORE@CLICK EM01067 |


EM | J a n - F e b 2 0 1 4

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market | interview

“Companies are facing complex pressures” Rafiq Somani, Country Sales Manager, ANSYS India, elaborates on the futuristic technology trends in the manufacturing sector, strategies adopted to sustain growth momentum and recent innovation developments, during an interview with Srimoyee Lahiri. In your new position, what is your vision for ANSYS India? ANSYS has been in the engineering simulation business for the past 43 years. We develop and market engineering simulation software used by product engineers and academia. Our technology enables organisations to predict that their products will thrive in the real world. Our goal is to ensure that all product development companies in India embrace “Simulation Driven Product Development” (SDPD) upfront to realise their product promise - a vision that ANSYS is committed globally. Customers trust our software to help ensure product integrity and drive business success through innovation. On the whole, we want to bring clarity and insight to customers' most complex design challenges through fast, accurate and reliable engineering simulation. What are the major demand trends shaping up in the manufacturing and allied sectors? Historically, Indian manufacturers have been ‘build to build’. This has started to change and we see the top tier manufacturers now moving into ‘design to build’ mindset. What this means is that several manufacturers are now also getting into designing or at least attempting to understand the design process better, instead of manufacturing just off blueprints designed by someone else. In my view, this is the right trend and builds India’s capability in both design and manufacturing. Which of strategies have you planned to sustain the growth momentum in today’s challenging market situations? India is one of the fastest growing engineering simulation markets in the world with already a significant customer base for us. In the past couple of years, we have had significant acquisitions, addition of partners, sales & support staff and developments on the product side. Hence, we will continue to serve our customers through our sales and partner offices located across India. Innovation will continue to fuel product growth across industries in India in the future. The company


is well-positioned to add significant value in a context where customers are facing increasing and complex pressures on their product development processes. With the fast changing technologies in the manufacturing sector, which are the futuristic technology trends likely to be witnessed? The digitisation of manufacturing and 3D printing will transform the way goods are made. The potential to print off a physical object is transformational to say the least. What are the recent innovation developments by your company in industries that are important for India’s economic growth? Indian organisations are facing complex (and sometimes competing) pressures like never before. There is a need to create the next “must-have” products which are affordable, first time right and yet priced such that organisations make profit. To create such products understanding multi physics and its effects play a big role. Hence “multiphysics” analysis becomes imperative while creating such products. The innovative multiphysics software offers a comprehensive and integrated structural, thermal, fluid and electromagnetic analysis under one framework. What is top on your agenda for 2014? Any major expansion plans coming up. Automotive is in fact a very important area of potential for ANSYS in India and we have several ongoing initiatives with our existing auto customers. Aerospace, defence and O&G are other important verticals for our India business. On the whole, we do see these as growth verticals. We are also connected with academia in several ways by supporting student competitions, sponsoring academic projects to funding and helping out professors. ☐ > MORE@CLICK EM01068 |

EM | J a n - F e b 2 0 1 4

c o v e r s to r y


Lean manufacturing

Intrigue or intriguing?

Lean manufacturing and management has become one of the best competitive strategies in this century. But is the implementation of ‘lean’ as simple as thought by many companies? Is following lean tools the key to success? Let’s find out with the example of manufacturing practices in Boeing factory… 22

Sanjeev Baitmangalkar Principal Consultant Stratmann Consulting

EM | Jan-Feb 2014


Becoming lean or transforming an organisation to become ‘real’ lean is not difficult. That has been my experience over the past two plus decades so far. Why then many organisations struggle with the process and fall short of becoming a truly lean company? What makes companies attempt sporadic implementation with a few tools at random and live in the wonderland of misconception that they too are a lean organisation? Using a dozen tools and structuring a production system with measurements, keys, score cards, rating by copying similar attempts does not make a ‘true’ lean company. Such companies who wish for lean results are dominated by short term thinking. If Toyota uses over ninety tools, how many do you think are known outside Toyota? Alix Partners of New York found that of the surveyed one hundred companies who had embarked on their lean journey, over 95% could not get expected results, while only half the remainder are making progress. Why?

What is lean? Lean manufacturing principles are ostentated by companies as an effective way to eliminate waste and boost the bottomline and yet many often do not achieve decent levels of productivity or savings. Lean principles have grown in popularity over the past four decades after Toyota showed lean thinking as a key driver of continuous improvement and not just cost cutting. Most companies don’t apply lean principles in a way that gives them and their customers the maximum benefits. Many view lean implementation as a checklist of do’s and don’ts as a part of their business process rather than a broader way to run an entire company. Lean manufacturing philosophies can lead to significant change. Companies must be cautious not to throw out the principles as some fail to implement them correctly. Lean

EM | Jan-Feb 2014


success stories tell us that where lean programmes are properly executed, long-term all-round benefits have been substantial. Managements must view long-term cultural change as their topmost priority, to get the maximum results. Such change is also essential if lean benefits are to be sustained. “Lean is a manufacturing philosophy that shortens the timeline between customer order and shipment by eliminating waste”, John Shook. This does not mean that we keep a large amount of inventory and ship as & when we get an order. But it means that we build what the customer orders as soon as possible, after the order has been received and the total lead time is as short as possible. When a product sits in a queue anywhere anytime – it is a waste. Building a product and its parts in a one piece flow, in a levelled and mixed production sequence is vastly superior to large ‘batch and queue’ production. Lean production is ‘lean’ because it uses less of everything (human effort, space, investment, development time, etc) as compared to the batch or mass production. It facilitates in creating a flowing inventory rather than stationary, resulting in very little inventory stocks, therefore, fewer defects and can produce a greater variety of products.

Ways of thinking The concepts of ‘batch or mass production’ and ‘lean production or lean manufacturing’ do not refer to production systems. They reflect the ‘ways of thinking’ about production. They are the assumptions that underline how people and institutions formulate solutions to problems of organising people, equipment, material and capital to create & deliver products to customers. Batch or mass and lean are thus paradigms that reflect and inform the thinking about production within different eras and their cultures.


c o v e r s to r y


The newer versions – Boeing 777 and the Dreamliner Boeing 787 are presently assembled in four days, and by 2014 they will bring assembling time down to three days with the help of lean tools

For most part of the twentieth century, the original Ford production system and all systems subsequently developed by the auto industry and copied by rest of the manufacturing world reflects the mass paradigm. The rise of the Japanese manufacturing took place after WW-II within the constraints of effective operations in mass paradigm, giving birth to a new approach to manufacturing that today we call lean manufacturing – best exemplified by Toyota Production System (TPS). Hence, TPS is nothing more or less than a set of solutions designed to achieve the lean ideal.

continue to be visible are: T  he way manufacturing works with sales makes scheduling and running the plants difficult. In some companies, the way sales works with manufacturing makes their manufacturing discrete.  he above is compounded by the way we order material • T from suppliers.  abour and management still don’t trust each other. • L  he way we measure performances doesn’t provide • T information useful to run a plant and may encourage wrong decisions. • I n many places, the equipment is designed for the old Becoming lean paradigm, combined in layouts that seek economies of To become a lean manufacturer requires the elements of scale, singing ‘bigger is better.’ flow, pull & strive for excellence. It requires a way of thinking • S enior management is reluctant to get involved and take charge of the lean implementation. that focuses on making the product flow through the value Lean manufacturing includes a set of techniques that stream without interruption; a pull system that cascades back from customer demand by replenishing what the next comprise a system that are derived from a philosophy. The operation takes away at short intervals; and a culture in which benefits of lean will accrue if understanding and implementation everyone is striving continuously to improve. It’s quite simple! is accordingly. TPS is a system, not a set of isolated practices. But, is it that simple in practical? The answer may be ‘no’. This Some of its fundamental principles fly in the face of common sense batch or mass production thinking. Everybody wants is where a Sensei can help you. Employees of lean companies participate in problem- to build in quality, so they need reliable equipment. Nobody solving through quality circles. While true lean companies build wants a messy disorganised shop floor. But focusing on quality, in quality rather than inspect it after the occurrence. Quality machine reliability/TPM/OEE, Kanban, workplace organisation consultants may have made hay teaching SQC methods and and visual factory (5S), does not get us continuous flow, pull problem-solving techniques. Although true lean companies and striving for excellence. The batch or mass production thinking is incapable of focus on customer, quality alone will not be enough as we cannot stop at competing on quality; we must also compete on understanding why we shut down a machine after just enough production has been made, or why we would like to eliminate cost, on-time delivery and service. Where there is trouble in conceptually understanding lean the safety stocks, or why we might prefer to use number of manufacturing, there is more difficulty in implementation. smaller machines dedicated to separate product lines rather Most of the concepts are simple, many are common sense and than one machine that provides economies of scale, or why we others are counterintuitive. Many would claim to understand would change over a machine several times in a shift instead more or less how we need to change the way we run our plants, of running one product through the shift to improve the but still struggle to make it happen. Some problems that equipment utilisation.


EM | Jan-Feb 2014

c o v e r s to r y


The Boeing 747 uses about six million parts using the tools of design, standardisation and rationalisation

Becoming lean is to focus on reducing non-value added wastes; where waste is anything that impedes the flow of product as it is being transformed in the value chain. This means getting the product where it is needed, when it is needed and in the exact quantities needed. Inventory buffers, quality problems and time spent in transit are all impediments to flow. Only when we drive out the non-value added wastes continuously, will we begin the lean journey. Lean manufacturing is perhaps the best competitive strategy companies can implement to gain competitive advantage. Toyota has demonstrated this many times, from the oil crisis of the 1970’s to the recent brake pedal floor mat issue of 2011. Every time they have come out stronger and better. Likewise, Mysore Kirloskar demonstrated how lean thinking could be used to turnaround a company from closure. Bridgeport’s JV in Indonesia demonstrated how after five years of losses, lean thinking could turn its fortunes! Recently, I had visited the Boeing factory that spreads over 1,010 acres of land attached to the Paine Field runway (longest in the world). Applying lean thinking has enabled them to assemble a Boeing 747 in three days. Surely, this is a huge change from 1970 or 1989 when the Boeing 747-400 entered the market. Beginning to learn from TPS in the 1990’s and implementing the concepts has created this change. The newer versions like Boeing 777 and the Dreamliner Boeing 787 are presently assembled in four days, and by 2014 they will bring assembling time down to three days. The Boeing 747 uses about six million parts, while the Boeing 777 uses half the number, and Boeing 787 even less; perhaps using the tools of design, standardisation and rationalisation. The Boeing 777 is a long haul aircraft; which was test flown non-stop for 22 hours and 42 minutes! It’s little surprise that the Dubai Air Show awarded it orders worth USD 100 billion. Better, faster, safer and farther is the way to go for the airline industry.


Culture Lean is a way of life; therefore it is about culture and not about tools. Culture is what the leadership builds. Lean is a way of thinking about value and adding value. Lean is an evolution; therefore it is about innovation, ideas and solving problems. Lean is as imagined through TPS, although I am open to new ideas, I don’t think there is scope for non-lean companies to reimagine lean their way. I believe that true lean companies are constantly attempting to make it better, faster and cheaper. Speaking recently in the USA, I was asked many questions on how we build the lean culture. They all understand the tools. Tools are almost a no-brainer, although they are used to solve problems. Building culture is another ball game. That’s why when Toyota Sensei once said, “I can teach you everything, but you still can’t do it.” He was defining the distinction between leading change and wishing it to happen. It takes a committed, dedicated and dynamic leadership to transform an organisation to become true lean. It involves leadership modifying their daily routine to fall in compliance with the implementation process. This includes learning, experimenting, practicing and training others. It involves spending the required time on the Gemba (shop floor). Change requires to be led in every activity by doing (body language) and not by lip service. People look at what you do and not at what you say. The old maxim of ‘monkey see, monkey do’ still works. Companies don’t succeed, people do; people don’t succeed, their attitudes do! Succeeding with lean is about bringing those required attitudes to surface and putting in some relentless work. Get a good Sensei who’s been where you want to go, and he can help. After all, there is no gold medal to win in lean; everyone who stays the course and goes the distance wins! ☐ > MORE@CLICK EM01069 |

EM | Jan-Feb 2014

management | interview

Technology, methodology & peoplelology Dr N Ravichandran, Executive Director, Lucas-TVS Ltd, and a manufacturing professional with a huge experience in various spheres of manufacturing management, is a firm believer of technology, methodology and peoplelology as the tools necessary for manufacturing excellence. He shares his views & recommendations on current manufacturing challenges, new production concepts and their adoption in his company and benchmarking approach, in this interview with Shekhar Jitkar. Do you think there is a paradigm shift in the global manufacturing industry in terms of the approach towards productivity, quality, and advancements in technology? The whole world is becoming a borderless state and we face fast changing business environment as a characteristic of this decade. There is a big paradigm shift today compared to yesterday. The advancements in technology and at the same time globalisation have revolutionised every sphere of business and commerce; these advancements have paved way for significant improvements in productivity, quality, technical superiority, product differentiation and thus the bottomline of business, besides customer service. There is also a shift in quality definition. Quality over the years has evolved from product quality to organisational


design. The biggest shift is building highly productive manufacturing solutions in enhancing quality of organisational design. Organisations are compelled to move from existing competitive space to future competitive space, that means we need to build innovative organisations leading to product innovation, process innovation and business model innovation. Quality assurance methods like advanced product quality planning, statistical process control techniques, effective tool management system, process capability improvements, preventive maintenance, producer control and small group activities form the backbone of the system approach adopted. The real challenge is producing products using tomorrow’s technology, innovative skills of people and adopting appropriate methodology.

EM | J a n - F e b 2 0 1 4

interview | management

“Lucas-TVS has scripted yet another new dimension to manufacturing by not only adopting the cellular manufacturing system / JIT, but also extending the same to its suppliers” Dr N Ravichandran

What are your recommendations on achieving another new dimension to manufacturing by not only adopting the cellular manufacturing system / JIT, but also extending the manufacturing excellence? To achieve manufacturing excellence, we need organsations same to its suppliers. to concentrate on three areas — technology, methodology and peoplelology. Now that the whole world is open to lndian What are the immediate concerns and challenges that needs manufacturers, we have to constantly look for technologies to be addressed in the Indian manufacturing sector? in the global space and adapt to our requirements. This The biggest challenge for manufacturing sector is sustainability is company and product specific. ln case of methodology, in a changing market place where the products life cycle is it’s time companies bring in TQM as part of their route to shortening, consumer behaviour and requirements are getting business excellence. TQM is a management approach that transformed every three years, a shift in work ethics and culture aims to succeed in faster and stable growth of an organisation both in case of engineers and operators, leading to problems by involving all its members in economically producing the like retainability and ownership. There is significant escalation in all costs; most importantly quality that its customer wants. price pressure due to high level of competitiveness in the market ln what way an organisation should benchmark its place. In case of machine tools and cutting tools industry, it’s performance with other successful corporations? How is time we develop lean and mean machines with clues from the computer industry where the power to weight ratio and cost Lucas-TVS’s approach towards this? Talking about benchmarking, we see the history of human are coming down year-on-year. development and scientific promotions are always through benchmarking. Somebody innovates somewhere in the world Can you brief us on the various manufacturing tools and and those principles are used in developing systems, products, production concepts used in various plants of Lucas-TVS processes based on those innovations/developments. It’s time that helped transform them into worldclass facilities? lndian organisations constantly benchmark in all the areas for Lucas-TVS uses LTMS (Lucas-TVS Manufacturing System) focusing on the following ‘7 zeros’: zero tools, zero changeover, good practices in technology, methodology and peoplelology. Any manufacturing industry continuously goes through zero defects, zero breakdowns, zero inventory, zero waste big changes in technology and we need to understand and zero injury. Products are manufactured using state-ofmultimaterial processing like light weight material, adoption the-art facilities organised in product units, modules, nagare of nano-technology and more electronic usage of virtual reality cells and assembly cells, while incorporating quick change of planning and manufacturing. As far as skill and competency tooling, Poka Yoke, Chakku Chakku (auto unloading). The are concerned, IT knowledge will become more and more condition of machines is monitored and maintained by TPM important and in case of engineers, multi-disciplinary function techniques and the schedule adherence is monitored by DRM will become the order of the day. ln case of operators, multitask (Daily Routine Management) while process & product quality is sustained and improved by ZED-Q (Zero Defect Quality) and multiprocess handling will be the focus. ln Lucas-TVS, we constantly benchmark and practice activities. The manufacturing system is competently backed a culture of continuous improvement at all levels from up by an advanced tool room and an inhouse SPM / process top to bottom. This helps us to compete with worldclass plant manufacturing facility. The entire organisation is firmly competitors, sustain and improve our position in the market entrenched in the change process and committed to CIP place. In its continuous pursuit of both technological as well (Continuous Improvement Programme). ☐ > MORE@CLICK EM01070 | as methodological excellence, the company has scripted yet

EM | J a n - F e b 2 0 1 4


r o u n d - ta b l e | m a n a g e m e n t

Winning in the new normal Share of manufacturing in India’s gross domestic product (GDP) has declined to 15.1 % — the lowest level in the past ten years. With this in the background, here’s a discussion on the factors responsible for the demand slowdown in the Indian manufacturing industry, imperatives for the government in the present scenario and key policy actions that are required to respur growth, held during CII Manufacturing Summit. Over the past few years, demand has slowed down considerably across several sectors – auto, home appliances, and building material industries, among others. Infrastructural bottlenecks and factor constraints have become even more acute. For instance, power requirements of several manufacturing clusters are up to 80% catered to by inefficient higher-cost DG sets due to non-reliability on lower-cost SEB power. Import-dependent sectors are reeling under the pressure of a weakening rupee – adding to the margin pressures that companies are facing, while new avenues are opening up for the export dependent sectors with increased demand from foreign


Srimoyee Lahiri Sub-editor& Correspondent

markets. With increasing urbanisation, employment is shifting from agriculture to industrial sectors. About 75% of new factories in the last decade have come up in rural areas. Therefore, in many ways, the very context of running a manufacturing company now is different and a ‘new normal’ is being created – characterised by slowing demand, continued volatility in input costs, sustained infrastructural bottlenecks and forced local reliance. Arun Maira, Member of Planning Commission; Ajay Shankar, Member Secretary, National Manufacturing Competitiveness Council (NMCC); Baba Kalyani, Chairman &

EM | Jan-Feb 2014

m a n a g e m e n t | r o u n d - ta b l e

“It is necessary for companies to step back and filter out the structural trends effecting manufacturing from the noise of day- to day firefighting” Jamshyd N Godrej, Chairman, Manufacturing Summit, CII and Chairman & Managing Director, Godrej & Boyce Mfg Co Ltd

“Imports of manufactured items have gone up due to the removal of imports duty, coinciding with a drop in our industrial productivity in manufacturing.” Baba Kalyani, Chairman & Managing Director, Bharat Forge

Managing Director, Bharat Forge; Jamshyd N Godrej, Chairman, Manufacturing Summit, CII and Chairman & Managing Director, Godrej & Boyce Mfg Co Ltd; K Venkataraman, Managing Director & CEO, Larsen and Toubro; Arindam Bhattacharya, Managing Director, Boston Consulting Group; Joginder Singh, President & MD, Ford India and Pradeep Bhargava, Former Chairman, CII WR and Director, Cummins Generator Technologies India Ltd, came under one platform to discuss the reasons behind demand slowdown in the Indian manufacturing industry, imperatives for the government in the new normal and key policy actions required to re-spur growth and shared case studies from companies that have continued growing profitably despite slowdown in demand, during the 12th Manufacturing Summit, held on November 22, 2013 in Mumbai.

“The present depression has bottomed out and with economic revival is on it’s way back”. Ajay Shankar, Member Secretary, National Manufacturing Competitiveness Council (NMCC)

“The present depression has bottomed out and with economic revival is on its way back. The manufacturing sector will soon get back to the 14-16% growth rate, which was the norm a decade ago. Business cycles are a part of economic life in all open economies and India will have to come to terms with such cycles. Economic revival will boost manufacturing. The major problem in India is that manufacturing is not as strong as it should be. Corporate captains should evolve a Demand slowdown consensus on pushing the case for manufacturing. India is a Demand slowdown has resulted in a temporary cool-off in democracy and the government listens to the public opinion,” the war for entry-level talent, but the war for good quality mid- affirms Shankar. management talent continues unabated. Factory inputs, such as “This is the first time since 2002 that the industry is going power have become even scarcer, leaving huge impact on the through such difficult circumstances. Given the fact that the cost and reliability of operations, especially in the sub-scale auto industry, in particular, has a multiplier effect, it becomes SMEs. even more worse. The government needs to take both short and “Over the past 7 to 8 years, imports of manufactured items long term measures. For the next six to nine months, there will have gone up due to the removal of import duty, coinciding be problems and the recovery may happen by the end of 2014,” with a drop in our industrial productivity in manufacturing. says Singh. The fundamental problem in India is that there is nothing to “It is necessary for companies to step back and filter out the manufacture because everything we need is imported. structural trends affecting manufacturing from the noise of Manufacturing as a share of GDP has come down from 17% to day-to-day firefighting. We believe that the concept of 14.6% at present, while the dream was to make manufacturing manufacturing has undergone a massive change. The new account for 25% of GDP by 2025. There is no country in the environment is characterised by shocks, swings and shortages. world that is more competitive than India in manufacturing. The growth slowdown has put the focus on what industry can We have the skills set and the capability if channeled in the do and the company’s internal strength and its own DNA would right direction. Indian companies should look at more exports make a difference in the sphere of manufacturing”, says by adding value to their products,” asserts Kalyani. Godrej.

EM | Jan-Feb 2014


r o u n d - ta b l e | m a n a g e m e n t

“The government needs to take both short and long term measures. For the next six to nine months, there will be problems and the recovery may happen by the end of 2014” Joginder Singh, President & MD, Ford India

“Industry has failed to influence the government to bring in policies favourable for manufacturing” Pradeep Bhargava, Former Chairman, CII WR (western region) and Director, Cummins Generator Technologies

Maira on the other hand, pointed out that India’s people are its main resource in making manufacturing a success story in the country. He urged that manufacturing sector should recognise that employees are their assets as they sought to succeed in a difficult economic environment. He also pointed out that the manufacturing sector needed to speak in an united voice. “Industry is facing many bottlenecks and it needs to declare its strategic intent and strategic plan. The reason for this is that industry is not coming together. There is a need to bring about clarity and improve coordination and collaboration”.

Challenges & recommendations According to Maira, physical infrastructure is a major constraint for the manufacturing sector. In spite of investment flowing into the infrastructure projects, some of the investment is stuck because of contentious issues, which has resulted in fewer investments flowing in. So, there is a need for things to move in a collaborative fashion. “Around 80% of the regulations applying to industry are formulated by state governments. The state government needs to frame regulations so as to attract both domestic and foreign investments. In these difficult times, some companies are still making huge profits as they have been treating themselves as internal learning institutions. Learning from experience is very essential for the progress and sustenance of industry” asserts Maira. “Industry needs to learn and prepare to operate in a volatile environment, which could be caused by a depreciating rupee or an earthquake in some part of the world. It is believed that by 2015, the US will become one of the most manufacturing competitive nations in the world and there are changes taking place in China and Africa as well,” says Bhattacharya.


“Industry is facing many bottlenecks and it needs to declare its strategic intent and strategic plan.” Arun Maira, Member of Planning Commission

Policy initiatives With the onset of the new normal and the accompanying set of new challenges, it is imperative for the state to bolster growth by providing support at every stage. Several regulations and initiatives within India like NIMZs, subsidising cost of building manufacturing clusters, special focus on few sectors like electronics, etc, and large scale investments in infrastructure are available to aid growth in the manufacturing sector. While there have been multiple initiatives, frequent delays and long pending approvals in implementing, these have pulled down the already slow paced growth of the sector. Despite delays in approval, some states and select industries have continued to grow with the right level of intervention and support by the government (for e.g. the latest spate of increased duties in electronic goods and plastics have begun to protect Indian companies in these sectors). “If you see India’s requirement, we need manufacturing on a massive scale and have no option but to succeed. The government has announced a National Manufacturing Policy with the aim of generating 100 million jobs. But we have to create an environment to make that happen. Industry should come up with creative solutions for the problems bedeviling economic growth. Instead of complaining about the rigid

EM | Jan-Feb 2014

m a n a g e m e n t | r o u n d - ta b l e

labour laws which made it impossible to set up factories in India that can employ a million people, industry needs to come up with solutions to the labour laws and advocate the same to the government so that such factories can come up. Indian manufacturing is strong in all sectors and is extremely competitive. The world is no longer with the Anglo-Saxon model of financial services and veering back to the importance of manufacturing, particularly after seeing the success of Germany. A recent survey of global CEOs found India to be the 4th most popular manufacturing destination after the US, Germany and China”, confirms Shankar. Similarly, Venkataraman talked about how Larsen & Tourbo has bucked the economic downturn by increasing its exports and achieving excellence in its various verticals, and urged others to do the same. But he added that given the size of India,

the domestic market would always remain the focus of the company. He further pointed out that India still had sectors that provided enormous opportunities to manufacturers such as nuclear power and defence industry, which were just opening up. Godrej on the other hand, praised the small and medium enterprises (SME), which are critical to the manufacturing ecosystem. “SME contributes a lot and we need to look into the infrastructural and structural problems faced by them.” “MNCs are increasingly looking at India to set up their manufacturing units. Collectively, industry has failed to influence the government to bring in policies favourable for manufacturing”, says Bhargava. ☐ > MORE@CLICK EM01071 |


EM | Jan-Feb 2014


m a n a g eme n t | c o m pa n y p r o f i l e

Upgrading to new age solutions Eaton Vehicle Group’s engine valve manufacturing unit at Ahmednagar is fully equipped with latest technologies to serve the rising demands for fuel efficient solutions for automotive, railways & other sectors. A report from its shopfloor… Eaton has been known in the global automotive industry for their engine air management expertise and capability to create and manage power while improving efficiency and emissions of internal combustion engines. Its ultra light engine valve helps produce better fuel economy. They have been pioneering innovations in variable valve actuation technology for over a quarter of the century. In 2008, Eaton acquired the engine valves business from a leading diesel engine manufacturer and integrated two engine valves manufacturing plants at Ahmednagar and Nashik into its India operations. Eaton’s Ahmednagar plant is specialised in manufacturing of engine valves for passenger cars, locomotives, generators and commercial vehicle markets. The manufacturing includes all in-house operations from forging to finishing. While elaborating


Sumedha Mahorey Deputy Editor

on the cultural transformation the plant has seen over the years, Krishnakumar Srinivasan, Managing Director – India, Vehicle Group, Eaton, avers, “When we took over this plant, we realised the need to bring in the latest technologies for manufacturing valves.” Highlighting on the processes that the company followed to establish Eaton standards after the business transition, he says, “One of the basic requirements was to upgrade the knowledge base. Thus, our main focus was on training through skill matrix development across the plant. We also initiated the ‘Buddy Scheme’, wherein a senior person advises and trains an individual for a certain process. Apart from this, we conduct in-house trainings to develop the required skill levels. These steps helped change the culture and bring up the skills as per Eaton standards.”

EM | Jan-Feb 2014

c o m pa n y p r o f i l e | m a n a g eme n t

“We manufacture more than 240 valve variants with new age technologies. Our strategy is to cater to valve requirements from various diameters up to various lengths”

Krishnakumar Srinivasan, Managing Director – India, Vehicle Group, Eaton

Continuous improvement strategy

made with special materials, such as high nickel based materials, which give required wear resistance. Also, in the future, valve The plant follows a continuous improvement framework. actuation systems will become prevalent in the Indian market. Explaining this, Srinivasan notes, “Eaton provides a set of tools Variable valve timing is also one of the areas where we are which can be leveraged at the right level of necessity to give the working with our customers. It helps in improving fuel required amount of output. It ensures a continued work process efficiency and good emission control.” Commenting on and builds in a discipline work culture. For the implementation expansion plans of the company, he affirms, “We manufacture of these tools, the management needs to identify the problem super charger and many leading valve technologies. Currently, areas and decide on which tools need to be used. To come up we are in discussion with our customers. Once these get with a solution, the management brainstorms and identifies the finalised, we will expand our manufacturing capabilities and tools needed to bring the performance up to Eaton’s standards. bring in these new technologies for the Indian market.” ☐ > MORE@CLICK EM01072 | This is done with the help of performance matrix.” The company has rolled out thematic Kaizens wherein the staff comes up with ideas or innovations, which helps in continuous Advt improvement of the plant.

Technology at its core The plant has also brought many new valve technologies to the Indian market. Srinivasan affirms, “We are discussing very unique technologies like sodium filled valves for some clients at present. These are used in very high temperature applications. We work with our customers, right from the drawing board stage to correctly design customised applications for their solutions. We manufacture valves with a process of rapid chrome plating for surface protection. It helps get the required wear resistance on the valves.” The company has recently added an extrusion press line in its manufacturing operations. The line has a completely automatic set up and is first-of-its-kind setup in Indian valve manufacturing industry. It has the capacity of producing 55,000 valves per day. Srinivasan notes, “The idea is to make the line fully integrated, from parts shearing to finish forging. The processes are fully robotised to ensure that there is minimal manpower interference. With this line, we expect better quality, output, and productivity, which will help in our overall production operation and lead to cost savings.” Highlighting on the new valve technologies being developed by Eaton, Srinivasan elaborates, “Sodium filled valves is a completely new valve technology that is being used in Europe and we are bringing it in India. There are also valves which are

EM | Jan-Feb 2014




12:03 Uhr

Seite 1


A e r o s pa c e ma n u fa c t u r i n g | F o c u s

Aero engine machining The article outlines principal strategies and solutions for machining aero engines, part-by-part for competitive gains.


EM | Jan-Feb 2014

F OCUS | A e r o s pa c e ma n u fa c t u r i n g

Exploding or dissecting a typical aero engine reveals a series of core components that have their own unique demands in terms of feature generation and material.

Turbine discs These complex turned parts feature profiled pockets, internal and external grooves, scallops and off-centre bosses and holes, all typically with challenging clearance requirements. Adding to the scale of difficulty is the material, which is normally a hard-to-machine alloy such as Inconel 718, Waspaloy or Udimet 720. For machining pockets and grooves that are difficult to access, 90°, 45° or T-shape angled inserts are a necessity, preferably featuring sharp, ground geometries. Grades with a PVD coating score are best as they can maintain sharp edges over a longer time in cut. Other grade properties to major on include superior notch wear resistance and good edge line toughness. With regard to the turning operations, the deployment of a modular tooling system with blades designed to fit turbine disc profiles and pockets is a good strategy. Select a tool that delivers the necessary radial and axial clearances, and use round inserts with high-pressure coolant (HPC) capability as these offer the best productivity in both roughing and finishing operations on tough materials. Interestingly, it can be demonstrated that by choosing trochoidal turning for roughing operations over the more traditional ramping method, productivity can be doubled with the added bonus of improved security and tool life. Trochoidal programming maintains chip thickness throughout the machining operation, which minimises the risk of heat and pressure variations. This allows the optimisation of harder, more productive grades, and insert types, resulting in reduced cycle times. For machining turbine disc scallops, exchangeable head milling cutters provide economical solutions as their shorter cutting length designs are not only optimised for small depths of cut and close tolerances, but also for stability. Of course, this is in addition to the obvious benefit of tool change and tool setting times, which are reduced substantially in comparison with traditional end mills and chucks.

Turbine/combustion casings These large, complex turned parts are conical in shape and EM | Jan-Feb 2014

feature round and square external bosses, as well as circumferential and axial holes. Inconel and Waspaloy represent the typical alloys of choice, and large amounts of material need to be removed. Using a turn-mill machine, rough milling around an external boss can be optimised using a light-cutting face and profile mill with through-spindle coolant. In combination with round inserts, which reduce notch-wear and allow high feed rates, these provide smooth entries and exits, thus delivering vibration-free use in extended reach applications. Sandvik Coromant, for example, uses ceramics on this application very successfully. The same cutter can be used for the helical ramping of the casing’s larger holes from solid. Here, the cutting forces produced are much lower than in conventional drilling – in fact, the latter also struggles with the interrupted exit into the bore. It should be possible to ramp down to diameters as small as 32 mm. Finish the bores using a suitable end mill and circular interpolation. Again, one tool can finish a range of diameters to reduce tool inventory. Indeed, the same theory applies to chamfers. Rather than deploying a dedicated cutter, always select a chamfering tool that can also perform de-burring operations – and not just on holes. For smaller holes, ensure the solid carbide drill technology selected provides geometry that is optimised for heat resistant super alloys such as Inconel and Waspaloy. This will help produce a high number of drilled holes with security and low axial cutting forces, which is particularly important on thinwalled casing sections. The face milling of turbine casings using ceramic inserts in conventional / up milling mode can remove metal from turbine casings up to five times faster (1000 m/min) than conventional carbide inserts in climb milling mode. As a result, metal removal rates of 106 m³/min are achievable. No coolant is deployed. For finish profile milling, an end mill with 50° helix facilitates the required light cutting action. To maximise productivity, shallow radial cuts and high axial cuts work best.

Fan casings These hollow bowl shaped components offer plenty to test production engineers. Aside from a series of external and internal profiles and grooves, fan casings are machined from titanium, a material renowned for its low machinability. Unlike nickel-based alloys, ceramic inserts cannot be applied to titanium. As a result, keeping the cutting temperature low is the 39

A e r o s pa c e ma n u fa c t u r i n g | F o c u s

The modular CoroTurn SL70 tooling system features blades that fit typical profiling and pocketing features

key to success, with a nod to both insert shape and HPC. A quick change tooling system in combination with a high specification toolholder is also necessary to help deliver the right support and stability at the right clearance when machining difficult-to-access fan casing features, particularly on VTLs. VTLs of course offer a significant advantage, as they allow HPC to be piped through the ram directly to the spindle. This means there are no coolant pressure restrictions, as is the case with turret lathes and rotating spindles. From an insert perspective, round inserts offer the best accessibility and productivity due to reduced entry angle and chip thickness. However, for highly effective semi-rough turning into fan casing shoulders, an insert is required that combines the advantages of square 45° lead approach angle tools and rhomboid 90° lead angle tools. Such an insert will allow an increase in feed and speed, leading to a potential doubling of metal removal rate.


Blisks/impellers Machining these complex parts is best facilitated on a fiveaxis machining centre with good simultaneous dynamics. Inconel or titanium is the most likely work piece material. When roughing impellor slots in titanium, the best machining technique is point milling. Because this operation demands full slot milling, the axial depth of cut is limited to half the diameter of the tool. A bull nose exchangeable insert cutter will provide a great balance of productivity and economy. When performing the same operation on impellers made from Inconel, the application of trochoidal milling with high speed machining techniques will prove advantageous. It is best to program the tool with a roll entry and exit from the cut as this will control the arc of engagement, giving low cutting forces. A ball nose end mill with a 50° relieved shank provides both axial depth of cut twice the diameter and low radial cuts.

Fan discs

Spools feature deep internal chambers and external blade Made from titanium, these components have deep internal tulip grooves. Dampened blades deployed with a high specification toolholder will help overcome the tendency to chambers and large tulip grooves. To rough-machine the former, the most productive and secure method is with direct grooving. vibrate as well as provide effective chip evacuation. To machine internal spool chambers, which are typically up As a point of note, it is imperative to select an insert with to 150 mm deep, long and slender tools are required. Using oval geometry that can split the chips into separate segments and serration blade systems, normally with 100 mm high blades, avoid jamming situations. Once the bulk of material has been will offer the best coolant delivery to assist in chip removal. removed, a round carbide insert together with HPC profile and Here, profiling and pocketing using trochoidal turning strong cutting edge geometry will deliver the best results. Traditionally tulip slots have been broached, but with new strategies combined with a ceramic grade insert can reduce the number of machining passes required, often allowing technology this has been replaced with milling. Machine shops productivity to be doubled as the superior notch wear resistance should use tailored side and face cutters for rough groove and pre-form opening, and profile end mills for semi-finishing and permits higher depths of cut. For other turning operations, selecting a carbide insert that finishing. ☐ fits in the same pocket as the ceramic insert will reduce the Courtesy: Sandvik Coromant number of tools, as well as the set-up time. A geometry offering > MORE@CLICK EM01073 | low cutting forces and good chip control is preferred.


EM | Jan-Feb 2014

A e r o s pa c e ma n u fa c t u r i n g | F o c u s

Keeping weight in control The feature highlights technology USPs like 5,000-psi technology provided by Eaton’s Aerospace Group for Airbus’ A380, the world’s largest passenger aircraft. This technology has not only slashed weight but also boosted reliability, fuel efficiency and operating performance

When Airbus set out to design the world’s largest passenger aircraft, the A380, weight reduction was critical to program goals. In 2001, Airbus awarded the hydraulic system contract to Eaton’s Aerospace Group, a world leader in aircraft hydraulic power generation, fluid conveyance and motion control systems. In addition to using lightweight, advanced materials in the airplane’s construction, Airbus wanted innovative systems that not only slashed weight but also boosted reliability, fuel efficiency and operating performance. Central to Airbus’ vision was the A380 hydraulic system, which would be required to operate some of the world’s largest flight-control surfaces, landing gear and utility systems. For example, the A380’s tail is as big as the wing of a typical 150-passenger aircraft. Figuring out how to increase hydraulic system power while reducing aircraft weight called for unique and novel engineering solutions. Applying its vast experience in higher-pressure military aircraft hydraulic systems, Eaton answered the challenge by designing the world’s first higher-pressure 5,000-


psi commercial hydraulic power generation system for the A380. The revolutionary new system, unveiled by Eaton, was hailed by Allan McArtor, Chairman, Airbus Americas, Inc, as “a tremendous historical achievement for Airbus, Eaton and the industry.” “The development of the 5,000-psi (34,475 kPa) power generation system is a great example of Eaton’s continued growth as a solutions provider for the industry, especially with the increased focus on higher fuel efficiency and lower emissions,” said Jay Iyengar, Vice President — Engineering and Technology, Eaton’s Aerospace Group. “Eaton contributed significant original engineered content on the A380 that helped Airbus achieve program goals and paved the way to performance breakthroughs for next-generation aircraft.” The 5,000-psi system was just the beginning of Eaton innovations on the A380. The company developed a broad array of products and technologies that optimised efficiency, reliability, safety and weight savings. It also worked with engine manufacturers to meet new performance criteria for fuel

EM | Jan-Feb 2014

Image Courtesy: EATON

F OCUS | A e r o s pa c e ma n u fa c t u r i n g

efficiency, weight reduction and engine prognostics.

The 5,000-psi technology Eaton’s leadership and experience in 4,000-psi to 8,000-psi (27,579 kPa – 55,158 kPa) hydraulic fluid power technology spans four decades and has contributed significantly to critical component weight and volume reduction in overall aircraft system design. Elevating the hydraulic system pressure standard for commercial passenger aircraft from 3,000 psi to 5,000 psi (20,685 kPa – 34,475 kPa) enabled Airbus to achieve significant weight savings by reducing the diameter of hydraulic fluid lines and the size of components that operate the primary flight-control system. Eaton solutions for the A380 eliminated a full metric tonne of additional weight, which made a significant impact on fuel efficiency and emissions reduction. The A380’s fuel burn is around 13% lower than its closest competitor, and it’s also the first long-haul aircraft to consume

EM | Jan-Feb 2014

less than three litres of fuel per passenger over 100 km (95 miles perimperial gallon) — a fuel economy comparable with small, modern turbo-diesel cars. The total Eaton system includes eight engine-driven hydraulic pumps per aircraft and four 5,000-psi (34,475 kPa) AC motor pumps with associated electronic controls and protection systems. The hydraulic pumps provide fluid power to the aircraft’s primary flight controls, landing gear, nose wheel steering and other aircraft utility systems. Each pump is powered by the engine accessory gearbox and delivers a rated flow of 160 l/min (42 gpm) at 3,775 rpm. The pump integrates an 11-piston rotating group coupled with a spherical-type attenuator, boost impeller, electrical depressurisation valve and scavenge pump. Eaton’s higher-pressure pumps are also the first commercial units designed to incorporate a manual and electrically actuated disengage clutch mechanism. The ability to mechanically disengage from the main engine gearbox prevents fluid contamination from entering the hydraulic system and


A e r o s pa c e ma n u fa c t u r i n g | F o c u s

The hydraulic pumps provide fluid power to the aircraft’s primary flight controls, landing gear, nose wheel steering and other aircraft utility systems

significantly improves operational availability to the service airline. The action can be safely accomplished in flight or on the ground.

Hydraulic system reliability In the unlikely event a pump issue is detected, Eaton’s patented clutch allows aircraft service technicians to manually disconnect pumps from the engine transmission. Unlike previous system architectures, this feature helps airlines dispatch aircraft on time, thereby avoiding passenger delays. If a hydraulic pump issue is detected in flight, pilots can electrically disengage an engine’s pumps, which can minimise further damage to hardware and avoid potentially costly repairs. Each of the A380’s four engines has two engine-driven pumps, plus four 21.3 kW electric motor pumps that are used primarily during ground servicing and a slat drive system that incorporates a bi-directional variable displacement hydraulic motor — another first for a commercial aircraft. In addition to supplying higher-pressure pumps, Eaton designed pumps with significantly lower pressure pulsation levels, even lower than seen in traditional 3,000-psi aircraft systems. Eaton lowered pressure pulsation levels by increasing the number of pump pistons, which improved the pumps’ ripple performance, and integrating an inline attenuator into the pump design. The attenuator dampens and reduces the pump’s outlet pressure pulsations by as much as 98%. Isolating the aircraft system from pump-generated pressure pulsations lowers wear rates on moving parts of hydraulic system components and reduces strain on hydraulic lines and fittings. The company’s pump innovations help operators reduce overall system operating costs by providing improved hydraulic system reliability.

Innovations in A380 Eaton produced a number of product and technology innovations to match new performance requirements for the


A380. The company provides the A380’s hydraulic fluid distribution technology standard, including the Rynglok™ tube-fitting system and hose products. The Rynglok tubefitting system was specifically designed for higher-pressure hydraulic power generation systems. The all-metal lightweight titanium alloy construction and “zero-leak” design make it an ideal standard fitting technology for theA380’s overall hydraulic fluid conveyance system, which includes primary and secondary flight controls and landing gear. The company also developed new wing-transfer fuel-pump technology for the A380. It supplies a total of 21 electrically driven fuel pumps and associated canisters for each aircraft that transfer fuel from various tanks to the aircraft’s engines and also between tanks during flight. The transfer system consists of three different pump types (transfer, engine feed and trim) that operate from a variable frequency power supply — an innovation in fuel-pump system design. The fuel pumps use brushless DC motors, with power conditioning and control electronics incorporated into the pump design. The fuel itself serves as the cooling medium. Pumps are fitted in tank-mounted canisters that enable them to be removed without having to drain the fuel tank. The company contributes technologies that improve the A380’s safety, such as fuel and inerting systems and fire shutoff valves. Inerting systems enhance aircraft safety by injecting inert gas into fuel tanks to significantly reduce the potential for ignition sources, while fire shutoff valves are used to shutoff the hydraulic line at the pump inlet in the event of major system or engine failure. The A380 is equipped with four fire shutoff valves fitted with size 32 hydraulic ports that are designed for nominal flow of 350 l/min under a pressure of 220 psi (1,516.9 kPa).

Powering & protecting A380 engines Eaton is a key program supplier not only for Airbus but also for both engine models designed to power the A380. One model features an engine build-up system developed by Eaton that comprises nine sub-systems containing more than 85

EM | Jan-Feb 2014

F OCUS | A e r o s pa c e ma n u fa c t u r i n g

F OCUS | A e r o s pa c e ma n u fa c t u r i n g

Eaton-designed components. These engine sub-systems support cabin air, starter air, thermal anti-ice, hydraulics, variable frequency generator cables and cooler pipes, drains and fire extinguishing. Both engines are equipped with Eaton oil debris-monitoring technologies that detect particles in lubrication systems to determine if critical engine component failures are imminent. These technologies include a chip detector, which uses a magnetic plug to draw ferrous particles from lube oil and an indicator light to signal when chip counts increase; and Eaton’s quantitative debris-monitoring system, which enhances engine health and aircraft safety by capturing, retaining and analysing oil debris particles. The quantitative debris-monitoring system not only separates particles and air from oil, but also employs a magnetic, inductive particle sensor that analyses the number and size of particles for a more accurate and detailed assessment of engine activity. The sensor sends signals to a conditioner that generates a digital pulse when a particle’s mass exceeds a preset threshold. In addition to the sensor and signal conditioner, Eaton’s oil debris-monitoring system includes the patented Lubriclone® three-phase vortex debris separator, the industry’s only highefficiency deaerator fitted with QDM®. Higher efficiency allows the oil reservoir to be smaller, which provides weight savings in addition to earlier, more accurate information about engine conditions. Data is relayed to pilots and maintenance crews so actions can be taken, if necessary, to prevent engine damage and improve flight safety. “The many solutions developed for the A380 program demonstrate Eaton’s focus on being a lifecycle partner with our customers, which means much more than simply providing them with a product or service,” Iyengar said. “We look at the big picture in our development programmes to anticipate and address issues that will help customers improve aircraft performance, increase fuel efficiency and control cost over the long term.” ☐ Courtesy: EATON > MORE@CLICK EM01098 |

EM | Jan-Feb 2014


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R A P I D P R OTOT Y P I N G | t e c h n o l o g y

Layer-based manufacturing This article discusses the current status of layer-based manufacturing Rapid Prototyping (RP) technology and how it is being successfully implemented as a tool for product development (PD), highest commercial impact on the market. It also outlines different applications and future developments of this technology. Rapid Prototyping (RP) can be defined as a group of techniques used to quickly fabricate a scale model of a part or assembly using three-dimensional computer aided design (CAD) data. What is commonly considered to be the first RP technique, stereo lithography, was developed by 3D systems of Valencia, CA, USA. It is an automated process that quickly builds physical prototypes from 3D CAD files composed of surface quality or solid models. In the manufacturing arena, productivity is achieved by guiding a product from concept to market quickly and inexpensively. Rapid prototyping technology aids this process. These processes produce objects by addition of material on a layer-by-layer basis while in case of conventional methods, this is done by removal of materials. It has also been


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referred to as solid free-form manufacturing, computer automated manufacturing, and layered manufacturing. Rapid prototyping is used to increase effective communication, decrease development time, decrease mistakes and minimise sustaining engineering changes. It also decreases development time by allowing corrections to a product to be made early in the process. By giving engineering, manufacturing, marketing, and purchasing a look early in the design process, mistakes can be rectified and changes can be made while they are still inexpensive. The trends in manufacturing industries continue to emphasise the increasing number of variants of products; increasing product complexity; decreasing product lifetime before obsolescence and decreasing delivery time.

EM | Jan-Feb 2014

R A P I D P R OTOT Y P I N G | t e c h n o l o g y

With rapid advancements in technology, there has also been progress in rapid prototyping in various sectors

Methodology of rapid prototyping

technique. Replacing the solid core with internal ribs cut 1.3 kg (2.9 lbs) from the device. One of the advantages of direct A CAD model is constructed, and then converted to STL digital manufacturing is improved functionality. Since the format. The resolution can be set to minimise stair stepping. additive process can easily produce organic shapes that sweep The RP machine processes the STL file by creating sliced layers and flow, the tool designers can maximise performance while of the model. The first layer of the physical model is created. improving handling characteristics. The model is then lowered by the thickness of the next layer Aerospace: The nature of the aerospace industry demand and the process is repeated until completion of the model. The that all parts are as reliable as they possibly can be. No corners model and any supports are removed. The surface of the model can be cut when it comes to the design and manufacture of is then finished and cleaned. With rapid advancement in aerospace parts which is why the best processes available need technology there has also been progress in rapid prototyping to be implemented. It is the most benefited industry from rapid in various aspects like use of materials, cost, speed and accuracy prototyping and 3D printers. This technology is already which has resulted in it being used widely in various industries making a mark in various industries, mainly in aerospace considering its applications, mechanical requirement and where it is very difficult to produce components with regular based on its material used (photopolymer, thermoplastic and manufacturing technology. Previously used method had adhesives). Recent time has seen remarkable development in produced a model using a CNC machine or power tools and terms of material being used for rapid prototyping. This is also used to mould a composite layup mandrel. Producing a model true for 3D printing. Considering the need of different and moulding a composite layup tool cost about the same. materials because of their different properties in various fields Initial tooling design sometimes presented problems. In these of application, Objet Ltd, the Israeli-based innovator and cases, ACS company incurred ample additional expenses and manufacturer of 3D printers announced their latest new the project was belated while the tooling was repaired or rebuilt materials for their Objet Connex range of multi-material 3D from scratch. But with the dawn in recent technology, ACS has printing systems that is capable of printing 107 different switched to produce nearly all of its tools using additive materials. manufacturing on a Fortus Fused Deposition Modeling (FDM) machine. A typical FDM layup tool takes only about $400 and 24 hours to produce. This low cost and short lead time means Recent development ACS can easily remake tools that are found to have problems Automotive: In a recent example, automobile giant BMW on the manufacturing floor. ACS also used FDM-built tooling at its plant in Regensburg, Germany, has produced hand tools to fabricate a capsule component for a remotely piloted vehicle. for automobile assembly and testing. The plant’s department of The company built a consumable core, core co-bond tool, cover jigs and fixtures uses a Stratasys 3D production system to build layup tool, cover trim tool and cover drill with the FDM hand-tools for automobile assembly and testing. The freedom material ABS-M30 thermoplastic. The traditional approach to of design allows engineers to create configurations that producing hollow composite parts is to use CNC machines to improve handling, reduce weight, and improve balance. make patterns from polyurethane boards that are then used to According to BMW, the tool designs they create cannot be mould clamshell tools. The FDM method offeres substantial matched by machined or moulded parts. In one example, BMW time and cost savings. The scope of Rapid Prototyping is not reduced the weight of a device by 72% with a sparse-fill build only limited to aerospace and automobile but also in medical,


EM | Jan-Feb 2014

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R A P I D P R OTOT Y P I N G | t e c h n o l o g y

Rapid prototyping aims in achieving productivity by guiding a product from concept to market quickly and inexpensively

commercial, architecture and defence. Combined with this there has been tremendous growth of 3D printers. It is easy to foresee the use of it in manufacturing industry. As this technology is available in consumer market, in the future this may get even cheaper. Auto giants like BMW and Jaguar Land Rover as well as lean aftermarket providers like Minimiser have found that nothing accelerates automotive design and manufacturing like 3D printing. According to Wohlers Associates, the use of 3-D printing for part production applications continues to grow. In a recent development in 3D printing, Airbus has unveiled plans for a 3D printed plane by 2050. The project faces a number of key challenges in the creation of a 3D printer large enough to create the concept aircraft entirely in 3D that requires the development of a 3D printer, the size of an aircraft hanger. The largest 3D printer in operation has printed structures of a few metres high. With the use of materials which will be transparent, people can get actual experience of flying through clouds. Many have even started dreaming of building a concrete house using 3D printing.

Scope for development in technology There are many different ways in which the part layers can be made and consequently there are numerous different RP machines and manufacturers. Though this technology is used mainly for product development and prototyping, it is not far when we will see it in full-fledged manufacturing. It should be noted that RP technology has many future compass for development and it is appropriate at this stage to list the most common. Part strength: Since parts are built in layers, which are then bonded together in some way, it is likely that these bonded regions represent weaknesses in the overall structure. Even within the material range of a particular process, it is commonly found that the mechanical strengths of parts made are slightly inferior to parts made with the same material in other manufacturing processes (e.g. injection moulding).


Speed: RP is not as rapid as many people realise and would like it to be. Parts generally take a matter of hours, to perhaps a couple of days to fabricate, depending on the chosen process and size of part. Whilst this is a significant improvement on conventional model making approaches (with the addition of improved accuracy, material properties, etc), there is always a demand for further increase in speed. Many potential users may not be prepared to wait for models to be made in this time frame. Cost: The capacity to create models quickly, accurately and reliably using RP technology must come at a price. RP technology is still something of a novelty and machines are generally constructed in small volume production. Many of the higher end machines are over US$200,00. Having said that, the prices of all machines are steadily coming down and smaller machines that are focused more at the concept modeling sector, generally with limited properties, are approaching a cost similar to many high-end computer products (around US$30,000). Many concept-based applications can be addressed using these lower-cost machines. Composite materials: By mixing filler materials together but without alloying them, it is possible to make composite material structures taking advantage of the constituent material properties. This can lead to stiffer, harder, or more heat resistant parts but the planar nature of the layers still represents a major source of mechanical weakness. If the layers do not represent the directionality of (for example, the computeraided design & applications) stiffness required using carbon fibre reinforced components, then the performance of the part will be compromised. Functionally gradient materials: If a beam is built with steel on one side and copper on the other, the interface between the two materials represents a significant problem. Physical bonding of the materials, thermal and chemical effects will lead to stress, bending, cracking and corrosion. Instead of having a clear junction between the two materials, grading them by varying the ratio across the boundary can alleviate some of these problems. There are still material affinities to

EM | Jan-Feb 2014


deal with relating to temperature, chemistry, etc. Multiphase perfect materials: Taking the previous examples to an extreme, RP represents a technology that can produce multiphase perfect materials. This is a process of choosing material compositions and geometries to meet the requirements of a particular performance-related task. This has resulted into development of use of different material like polyjet photopolymers, thermoplastics, polymer ionomers, nonpolymeric materials, including metals, titanium, stainless steel, nickel, cobalt and other engineering alloys, ceramics and composites. These are able to match the required properties of materials like mechanical properties, thermal properties and electrical properties.

Future of cutting tools This will create a pessimistic effect on cutting tool industries as conventional metal-cutting manufacturing methods like milling, turning, and boring will be replaced with techniques of rapid prototyping. This will create a serious need for development in cutting tools to be able to contend with this advent in technology. As a manufacturer, you will be definitely implementing that method of machining which will be able to save cost, time and create complex products. Tools available at cheap and working efficiently will be the need of the day.

Conclusion Rapid Prototyping is the future for the current and next generation of design and manufacturing. The key advantages highlighted are decreasing development time, minimise sustained engineering changes and increasing the number of variants of products. It is an emerging technology that promises a brighter and efficient future. A technology that is worth looking forward to the future, or perhaps a technology, which would be able to take over the current technology. � > MORE@CLICK EM01074 |

EM | Jan-Feb 2014


m a n u fa c t u r i n g IT | T e c h n o l o g y

Software for successful manufacturing Innovative ERP technologies are introduced to enable manufacturers to streamline their business processes while remaining agile and responsive to customer needs Anish Kanaran Director — Channel, Middle East, Africa & India Epicor Software

If a country has little capacity to manufacture, then it also has limited potential to achieve economic growth. Manufacturing is a wealth-producing sector that needs to be constantly expanded and enhanced. By harnessing tools such as enterprise resource planning (ERP), manufacturers can gain a competitive edge in today’s extremely aggressive business landscape. An ERP solution is not a ‘silver bullet,’ though. Considerable thought and planning must be invested in identifying and acquiring the right ERP solution to achieve the right results.

ERP software In the past, material requirements planning (MRP) systems simply focused on materials and making sure that the correct materials were available at the right time. Today, leading ERP systems are much more advanced. They focus on the customer and offer significantly more end-to-end support and


information. They provide one solution with one set of data accessed through one interface. ERP software enables enterprises to use integrated applications to manage all aspects of operations, including development, manufacturing, sales and marketing. ERP systems facilitate the flow of information across all internal business functions and also manage connections to external stakeholders. They help achieve many manufacturing business goals, such as increasing efficiency, reducing the number of independent systems, and streamlining operations. An ERP system represents a major corporate investment that goes beyond simply buying software. Manufacturers must consider their system requirements, the total cost of ownership involved and how a particular solution complements their business objectives. An ERP purchase should be justified against an organisation’s business goals to ensure that it not only supports them but also acts as a vehicle.

EM | Jan-Feb 2014

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m a n u fa c t u r i n g IT | T e c h n o l o g y

ERP software enables enterprises to use integrated applications to manage all aspects of operations, including development, manufacturing, sales and marketing

Ensuring proper management of organisational change and business transformation are also essential to the overall success of the system. Facilitating the transition from the organisation’s old business model to the new, streamlined structure of operations requires planning and effective communication with stakeholders. This will help to create a positive environment, smooth the path for change and inspire management to think differently about how they do things. Epicor offers a tightly integrated ERP solution that helps manufacturers consider and respond to various day-to-day challenges and variables. Epicor manufacturing is based on a True Service-Oriented Architecture (True SOA™) – a paradigm for designing and developing software in the form of interoperable services. It features various modules for the management of finance, customer relationship, sales, human capital, service, supply chain, production, project and product data as well as for planning and scheduling. The system also offers business intelligence, ecommerce and an on-demandbusiness-architecture. By using a SOA-based approach, Epicor ERP is able to mix and match self-contained, platform independent portions of business logic or ‘services’ to deliver more agile functionality, particularly in terms of decreased time and cost of change. With its comprehensive experience in providing solutions for all sizes of enterprises coupled with its focus on key manufacturing industries, the company delivers ERP solutions that pose minimal risk in adoption. A customised ERP solution means that manufactures can assess their unique requirements and then precisely plan their workflow to maximise productivity.

Scalable & modular software ERP software that is scalable and modular with rich functionality sets to support growth with rapid implementation and flexibility, irrespective of the size and complexity of the manufacturing process at hand, is paramount for successful manufacturing. • P roduction planning is paramount to the feasibility and profitability of the manufacturing process. Being able to


accurately cost and execute a job using a single business platform that provides the right tools to efficiently assemble, ship, and deliver so that customers receive the goods they want, when they want them at the right price. S cheduling assists manufacturers with day-to-day control, long term planning and decision making to support business strategies ensuring that customer deadlines and demands are met. Materials management capabilities ensure that the correct components are available at exactly the right time. Lean production is crucial in a highly aggressive global market. Being productive using fewer resources while being flexible enough to meet varying customer requirements are essential for gaining competitive edge and ensuring profitability. Manufacturing execution systems (MES) are most effective when they allow real-time visibility throughout the manufacturing process. It is essential that they are integrated, accurate and offer up-to-the-minute data to management on what is occurring on the plant floor by employee, job and scheduling priorities. It must also allow the plant floor to access vital data such as product drawings, process drawings and detailed instructions. Quality management capabilities ensure that manufacturers have complete visibility of the quality of operations right down to individual item level tying together all quality functions from scrapping end-parts, rejecting raw materials or tracking first article inspections.

Technology for growth Advanced ERP solutions are crucial to the country’s development plans for its manufacturing base. Today’s manufacturing landscape requires out-of-the-box, cutting-edge strategies for addressing challenges and raising productivity with fewer resources. These technologies built by leading developers such as Epicor represents a game changing opportunity for the manufacturers to maximise productivity and meet their customers’ needs by being agile and responsive. ☐ > MORE@CLICK EM01075 |

EM | Jan-Feb 2014

t e s t & me a s u r eme n t | t e c h n o l o g y

Fast feed & precise positioning An innovative, true-absolute measuring encoder guarantees maximum process reliability for precision assembly systems used in the micro-electronics and micro-optics industries. Process reliability is one of the principal factors governing the economic operation of high-value micro-assembly machines that produce miniature electronic and optical components. Amicra Mikrotechnologie GmbH has achieved major improvements with Renishaw’s future-oriented absolute measuring system, RESOLUTE, which allows micro-assembly cells to be commissioned more quickly and in particular, independently of the operator’s vigilance. This is particularly important for micro-electronics and micro-optics applications in the automotive sector, telecommunications and IT industries. The components to be bonded and mounted, such as active / passive semi-conductors, lenses, MEMS and processors, are


picked up with the aid of linear axes and special grippers from feed stations. The components are then positioned on boards or wafers, where they are bonded with adhesives, soldered conventionally or soldered with a laser beam. Surface mounting on wafers and stack die technology make particular demands on mounting and production technology. Stack die technology is used to construct three-dimensional memory and computer structures; semi-conductors are not only mounted horizontally next to each other and connected (SoC), but also vertically in several planes (TSV). Further miniaturisation is achieved as a result of a higher packing density. Amicra Mikrotechnologie GmbH in Regensburg, Germany, develops and manufactures MicroRESOLUTE application

EM | Jan-Feb 2014

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t e s t & me a s u r eme n t | t e c h n o l o g y

Sharing common information facilitates far more rapid and effective processes

assembly cells designed for this purpose. These machines are known in particular for their high levels of accuracy and reliability. Depending on the model, they will mount microcomponents with an accuracy of up to ±0.5 µm, achieving a process capability Cpk of 1.66. The NovaPlus series from Amicra has been designed for maximum productivity. Using a large array of horizontal and vertical linear axes, they surface mount wafers with practically no unproductive downtime. While a component is being positioned, a second handling unit is already picking up the next component from a buffer store. At the same time, the work tables and other linear axes with lasers and UV lamps move to the positions required for the soldering and bonding processes. In addition, other axes position the integrated process monitoring cameras.

Collisions absolutely ruled out As Horst Lapsien, Managing Director, Amicra, explained the high process reliability of these installations is particularly instrumental in their economic operation. A crash between the alternate positioning grippers and linear axes must be avoided. “This can be achieved through the extremely precise programming of the motions” said Lapsien. “Furthermore, the measuring systems on the linear axes have to detect the current position of the slides reliably and very precisely”. This could only be achieved to a limited extent with the incremental measuring systems used previously. “In the past, starting up the production and mounting cycle after a stoppage was unsatisfactory because the read heads of all the linear axes had to travel to a reference position. Only in this way was the control system able to detect the actual position of the axes, but that took an unnecessarily long time,” he added.


Absolute measurements without reference run Thanks to Renishaw’s RESOLUTE absolute encoders, Amicra’s mechatronic engineers have been able to improve their machines considerably. The main advantage of these measuring systems according to Lapsient is that they detect the absolute position immediately at switch-on, without a reference run. Consequently, the micro-assembly cells can start their automated cycle quicker, without relying on the operator’s vigilance, after a stoppage or on commissioning for the first time. Process reliability is improved, unproductive times are reduced and expensive crashes are prevented. Thomas Renner, Technical Sales, Renishaw GmbH, explained the advantages of the absolute RESOLUTE positioning horizontal and vertical axes measuring system. “Compared to the previous absolute measuring systems, RESOLUTE has a single track scale that combines both the absolute position and the embedded phase information into one single code. This means that RESOLUTE has very wide set-up tolerances and so it can be installed easily and continues to operate reliably over long-term use, even if the axes settle or move over time”. The RESOLUTE readhead also features a unique set-up LED for simple installation and commissioning, providing a simple visual check that the scale is being read correctly. The RTLA absolute measuring scale can be bonded directly to the substrate or inserted into a special FASTRACK™ guide, both made from stainless steel. As a result, it easily installs compactly inside the Amicra machines, achieving ±5 µm/m accuracy. The tough stainless steel tape scale is highly resistant to damage, but if necessary, the FASTRACK guide allows easy scale replacement at any time. RESOLUTE encoders feature unique position detection method, analogous to a very high speed digital camera,

EM | Jan-Feb 2014

t e c h n o l o g y | t e s t & me a s u r eme n t

t e c h n o l o g y | t e s t & me a s u r eme n t

capturing very high resolution images of the scale. These images are then analysed by a powerful digital signal processor (DSP) that applies cross-checking and error-rejection, to determine position to 1 nm. Combined with a built-in positionchecking algorithm, the encoder has high immunity to contamination. As confirmed by Lapsien, since their introduction into three-shift production operation, his machines have recorded zero stoppages on account of reading errors of the measuring system caused by dirty measuring tapes. The advanced detection technique also enables RESOLUTE absolute encoders to achieve high levels of accuracy with just Âą40 nm cyclic error and jitter lower than 10 nm RMS. The result is excellent positional stability and a very low noise level. Therefore, the micro assembly cells equipped in this way benefit from higher levels of reliability and performance.

Conclusion RESOLUTE is a ground-breaking absolute encoder system for both linear and rotary applications, featuring 1 nm resolution at speeds up to 100 m/s (36,000 rpm), wide set-up tolerances and high dirt immunity. A range of pure serial protocols are available, including Fanuc, Mitsubishi and Panasonic, for use in a wide range of applications including electronics assembly, flat panel display manufacturing, solar PV production, semiconductor processes, machine tools and precision motion control.� Courtesy: Renishaw

> MORE@CLICK EM01076 |

EM | Jan-Feb 2014



© I.H.M.








Page _TAGMA_210X273 Wednesday, January 09, 2008 3:47:44 PM



A Company within the SWAROVSKI Group

t e s t & me a s u r eme n t | t e c h n o l o g y

Portable CMM & 3D Scanning An application story on the use of Faro’s solutions by Faurecia Shanghai to simplify its product development process, improve design efficiency and reduce R&D cost. Audi, BMW, Citroën, Chrysler, Mercedes, Peugeot and billion in 2010. Volkswagen are car manufacturers that produce vastly different Consistency in quality control across its facilities is very high-end automobiles for the consumer market. Despite the important to Faurecia. “A large part of maintaining standards is huge differentiation in products, these manufacturers have one about precision, as well as being able to get the same results thing in common — they are all clients of automotive parts each time, every time,” said Leo Sun, Engineer, Faurecia giant, Faurecia. Automotive Systems, Shanghai. The FaroArm’s portability As the world’s leading automobile engineering solution enables Faurecia to measure a car seat easily, right on the shop provider and auto parts manufacturer, Faurecia is an important floor. partner to automakers. It is dedicated to the development of four categories of automotive components, namely – seating How it all started? systems, exhaust emission control systems, interior and exterior When Faurecia decided to set up shop in Shanghai in 2005, trim. With 75,000 employees working in 238 factories located in it was for the specific purpose of research and development. 33 countries worldwide, Faurecia’s global presence is undeniable. Faurecia Shanghai was to be the technical hub, where product The Group is the largest listed company in the Pan-European development, testing, design and quality control would be done. Stock Exchange, and it has grown tremendously since entering “Faurecia Shanghai helps to enhance the various lines of the Chinese market in the 1990s. With over 6,000 employees in products that we supply to car makers,” added Leo. “Products 25 Chinese factories now, sales volume for China was €1.03 are designed, developed and tested adequately here before they


EM India | Jan-Feb 2014

t e s t & me a s u r eme n t | t e c h n o l o g y

The ScanArm ES is the latest advancement in FARO’s Laser Line scanning sensors, featuring Enhanced Scanning Technology (EST)

are rolled out.” Right from the beginning, Faurecia Shanghai chose to go with Faro® solutions for their metrology needs. When asked how the company arrived at the decision, Leo shared, “Our European counterparts introduced the FaroArm® to us when we first started our operations. Based on our colleagues’ prior experience and Faro’s excellent reputation, Faurecia Shanghai decisively bought three sets of the measuring device at once.”

3D scanning in design The product of choice for Faurecia Shanghai is the FaroArm Platinum equipped with Laser ScanArm® capabilities, selected to aid in the company’s design and inspection processes. The FaroArm Platinum with Laser ScanArm is a portable coordinate measuring machine (CMM) with built-in functions of a noncontact 3D scanner. Capable of performing measurement tasks such as inspection, point cloud-to-CAD comparison, rapid prototyping, reverse engineering, and 3D modeling, it is a versatile device that suited Faurecia Shanghai’s varied metrology needs. As the first of four R&D facilities in China, Faurecia Shanghai is responsible for many of the earlier product development projects. “We deal solely with product development and design here, so the FaroArm is a vital piece of equipment,” said Leo. “What we really like about the arm is its ability to perform high-speed 3D scanning. Reverse engineering can be done quickly, allowing designers to modify three-dimensional data on the computer. Sample parts can be pieced together virtually, thereby speeding up the design process.”

Performing first-article inspections The application of the FaroArm was not restricted to just design and early product development phases. Inspection was also one of Faurecia Shanghai’s main measurement needs. “First-article inspections are extremely important as they enable


us to identify design problems quickly,” said Leo. “Being able to rectify these problems immediately translates to substantial time-savings for us. In addition, our customers can appreciate the reports and data that are generated, thereby increasing their faith in our products.” As Faurecia deals with a wide variety of auto parts that are of different shapes and sizes, it is a tremendous benefit that the FaroArm can tackle all of them. “We inspect automotive parts both large and small, with measurements ranging from 10 mm to 1.5 m,” shared Leo. “The FaroArm is versatile enough to measure all our products, regardless of the size and product line it comes from.”

Further explorations Even as Faurecia Shanghai enjoys the benefits of owning the FaroArm, its staff continues to learn new and better ways to utilise the device. “Using the FaroArm is akin to discover an underwater treasure, whereby there are many areas of exploration,” shared Leo. “We continue to find creative ways to better employ the FaroArm on our premises.” Overall, the FaroArm has helped Faurecia Shanghai to simplify its product development process, improve its design efficiency and reduce its R&D cost. While time-savings and benefits differ across projects, one thing is for sure — Faurecia Shanghai’s success has a lot to do with their early decision and ideal choice in Faro solutions. “Faurecia has been extremely satisfied with Faro’s products as they have served us well over the past several years. To be honest, we’re not sure how else we would be able to achieve our current level of productivity otherwise!” admitted Leo. “We’ve never had to use other measurement solutions, and it’s most likely that we’ll never have to.” ☐ Courtesy: Faro > MORE@CLICK EM01077 |

EM India | Jan-Feb 2014

s u p p ly c h a i n m a n a g e m e n t | t e c h n o l o g y

Unchaining the value of RFID

I m age c ourT es y: Zebra Technologies

Businesses in a wide range of industries are realising significant benefits from radio frequency identification (RFID) technologies. This article talks about how companies are unlocking the value of RFID by ‘unchaining’ the technology from strictly supply chain-based projects, to improve overall tracking and control throughout the enterprise

Outside the supply chain, RFID systems are created to improve an organisation’s own processes — not those of a business partner or an upstream or downstream distributor. Businesses can match RFID technology and its application to specific requirements. The technology provides many benefits for manufacturers and non-manufacturers alike. Businesses can use it to automate most processes for identifying objects, controlling employee access, and recording their location or movements. The technology often creates value by automatically recording these activities, reducing labour costs and providing more complete and accurate information than manual record keeping. Unattended


Sachin Tare Head - Indian Subcontinent Zebra Technologies Corporation

readers can ensure the recording of all asset movements, and can issue alerts if unauthorised material movement occurs.

Asset tracking Every organisation needs to manage its assets, which can take many forms including inventory, raw materials, files, product samples, and even people. Different RFID technologies are well suited for tracking and identifying many types of assets in many environments, so virtually any organisation can benefit from RFID asset tracking. Automated, often unattended RFID reading reduces the cycle time and error rate of the recording process. Utilising RFID to

ensure accurate record keeping also helps keep assets available and eliminates the hidden costs associated with searching for lost or misplaced items. For example, if employees spend an average of only 10 minutes a day looking for tools, equipment, or materials, they spend the equivalent of one full week each year on non-value added searching, as the following calculation illustrates: (10 minutes/day x 5 days/week x 50 weeks/year) = 2,500 minutes/year ÷ 60 minutes/hour = 41.67 hours) To find the labour cost impact to a business, multiply this time by the number of employees involved in searches, and then by their average per hour salary. The total impact is actually higher, because

EM I n d i a | J a n - F e b 2 0 1 4

I ma g e co urT es y: Zebra Technologies

s u p p ly c h a i n m a n a g e m e n t | t e c h n o l o g y

Tagging helps ensure workers to accurately identify equipment & components, and confirm that the correct items are serviced

employees cannot utilise missing assets, instance of a container exiting or entering which often require premature a facility using unattended RFID portals, replacement. There are other costs forklift-mounted readers, or handhelds. associated with asset management when Workers can use mobile readers in the manual labour is required to inventory field to record container drop-offs and and record assets, track asset movements, pick-ups. By leveraging business database and enter the information into systems, departments can associate information systems. RFID can eliminate containers with customer records, manual labour, plus the time delays providing detailed visibility and billing between when workers move or use data. assets and when the activity is recorded. Managers typically use databases to get a real-time view of RTI availability. As a result, businesses can track overdue Reducing operating expenses containers for each customer, with Using automatic identification documentation provided to aid return systems to track pallets, racks, trays, totes and recovery. By actively monitoring and and other returnable transport items managing container usage, businesses (RTI) within a facility can provide a can improve cycle times and inventory strong return on investment by lowering turns while lowering their fixed asset operating expenses. Many companies do base. not have accurate information about the quantity and location of their shipping Simplify service and containers because the assets often maintenance operations remain at other facilities for extended Maintenance operations typically use periods of time. As a result, businesses purchase more returnable containers to RFID tags on equipment to serve as ensure they have an adequate supply, remote databases that house configuration creating excess capacity and locking data and service history information. Recapital into fixed assets. Identifying and writable memory on RFID tags lets tracking returnable containers provides technicians access and update essential the information businesses need to information in remote and challenging improve returns and recoveries. To do so, environments where other database or businesses must permanently identify wireless access is unavailable. Tagging each asset with an RFID tag encoded helps ensure workers accurately identify with a company-specific ID number and/ equipment and components and confirm or a standardised global returnable asset that the correct items are serviced. identifier (GRAI) code. Departments can Consider the aerospace giant, Boeing. automatically identify and record every After testing Zebra RFID smart label


printer/encoders, Boeing committed to use RFID to identify critical parts on its advanced Dreamliner 787 aircraft in order to help airlines improve maintenance operations, save time during pre-flight inspections, improve traceability and safety, and streamline record keeping. Smart labels logged more than 1,500 flight hours and provided 100 per cent read rates and 100 per cent data accuracy, providing Boeing with the confidence to move forward with RFID tagging.

Implement precise file tracking Imagine having to find a misfiled document in a filing cabinet where hundreds of forms are packed tightly into a compact space. A manual search is like looking for a needle in a haystack, without any guarantee that the needle is actually in the haystack. Designers can build RFID readers into inboxes and filing cabinets to automatically record each folder and document someone files and removes. For records and archive operations, readers can automatically check entire boxes of records in and out in seconds, saving countless time for manual data entry. Departments can also use RFID to automatically associate the files with the person who signed them out by reading RFID employee ID badges as part of the process. Businesses often use multiple RFID technologies in the same system to support different process needs. For

EM I n d i a | J a n - F e b 2 0 1 4

t e c h n o l o g y | s u p p ly c h a i n m a n a g e m e n t


example, warehouses can track forklifts with RTLS tags, while the pallets they handle contain UHF Gen 2 smart label tags, and the goods within the pallets contain individual HF item-level tags. For instance, hospitals use 13.56 MHz RFID to monitor supplies on shelves and to signal replenishment, plus RTLS technology to automatically locate defibrillators, monitors and other critical equipment throughout the facility. When not constrained by compliance requirements, organisations can choose RFID products with the frequency, range, memory, rewrite capability, security and other features that suit their specific process requirements.

Capitalise on the value Many RFID applications gain rapid ROI because users have the flexibility to choose technology and tailor process improvement solutions to solve their specific business problems. Processes in which manual data recording creates a bottleneck, is error-prone, or incomplete, are prime candidates for improvement with RFID. Enterprises in both the private and public sector can benefit from RFID technology throughout a wide variety of use-cases and environments, while realising opportunities for improving efficiency and reducing operational costs. � > MORE@CLICK EM01078

EM I n d i a | J a n - F e b 2 0 1 4


c o n d i t i o n m o n i to r i n g & m a i n t e n a n c e | t e c h n o l o g y

Optimising cleaning quality Today’s solvent-based parts cleaning systems are perfectly tailored to satisfy the current industry requirements. They offer maximum flexibility and high capacity with respect to throughput and volumes, with optimised cost efficiency as the result.

Rising demands for the quality of parts require increasingly complex solutions from industrial parts cleaning processes. With its EcoCCore system now superseding the previous 81C/P equipment series, Dürr Ecoclean has set new standards in solvent-based part cleaning. This is due to a one-third increase in product throughput and load weight which yields a marked reduction of per-unit cleaning cost. On the other hand, the new machines are equipped for improved cleaning performance, superior process reliability and significant energy savings. Designed to use non-halogenated hydrocarbons and modified alcohols, the EcoCCore also boasts superior ease of operation, less space demand and a translucent design. Users’ priority lists are topped by process reliability, cost and energy efficiency, high speed, availability, short delivery times and eco-compatibility. Accordingly, when Dürr Ecoclean set about developing the innovative EcoCCore, the focus was placed on these factors. The new system is characterised by an extensive standard equipment level including, for example, two flood tanks, heat recovery, and full-flow plus bypass filtration capabilities. Switching from non-halogenated hydrocarbons to modified alcohols and back is particularly easy, so the EcoCCore – which operates under full vacuum conditions is a forwardlooking solution which also addresses changing future needs. In combination with appropriate solvents, this system can even 76

remove chlorinated oils from parts surfaces.

High throughput for reduced cost per unit The work chamber is designed to hold cleaning tanks measuring upto 670 x 480 x 400 mm, thereby offering onethird more loading volume than the 81C/P predecessor system. Throughput can thus be doubled, depending on the basket size. The maximum load weight capacity has likewise been increased by more than 30% to 200 kg. With a cycle time of less than 8 minutes this provides a significant reduction in per-unit cleaning cost.

Innovative technology A major step toward improved cleaning quality lies in the new preliminary steam degreasing process. Here the oilcontaining distillate is not passed into the flood tank but is directed straight into the distilling system. This minimises oil deposits in the flood tank and an undesirable oil enrichment of the solvent. The result is an enhanced degreasing performance that will be found particularly beneficial with parts to be coated or laser-welded after cleaning. In addition,

EM India | Jan-Feb 2014

c o n d i t i o n m o n i to r i n g & m a i n t e n a n c e | t e c h n o l o g y

The new EcoCCore is designed to use non-halogenated hydrocarbons and modified alcohols

the preliminary steam degreasing step offers advantages under elevated oil drag-in conditions or when a second flood tank is used for a preservation treatment. This is made possible by an almost doubled distilling capacity. Another innovation boosting cleaning performance is the capability to use ultrasound and filtration simultaneously. Here particles are discharged throughout this process cycle, opposed to conventional systems whereby they can settle at the bottom of the work chamber before being filtered. To this end, the EcoCCore pumps are equipped with variablefrequency drive units and control the volumetric flow rate in such a manner that the ultrasonic system can exert its effect. This efficient and flexible combined filtration system ensures an effective discharge of particles. Moreover, the unit comes with a frequency-controlled rotary drive for turning and highaccuracy positioning of parts. A “gentle” operating mode prevents sensitive parts from getting dropped or displaced during start-up or handling operations.

instance, both flood tanks are heated entirely with thermal energy recovered from the distilling circuit. The heat input from the distilling system can be adjusted as needed in multiple stages. As a result, energy is saved on the one hand while on the other, a high throughput is guaranteed even with high oil drag-in rates. For the discharge of oil, a new process based on jacket heating is fully decoupled from the distilling system ensuring optimised, gentle oil evaporation. As a result, a much broader range of oil grades can be removed in safe and reliable manner. Moreover, oil encrustation requiring costly and time-consuming cleaning is avoided. Cost savings are also achievable by the new level control system which effectively prevents a carryover of preserving medium, thereby reducing its consumption. Switching from cleaning to preserving mode can be made simply by the push of a button on the operator panel.

High process reliability

The design of this equipment, honoured with the 2013 Design Award of the state of Baden-Wuerttemberg, is striking not least due to the integral loading system and its all-round enclosure made of safety glass. Moreover, the universal EcoCCore machine requires around 5% less floor space than its 81C/P predecessor. A further benefit is that its top height can be reduced to only 2.25 m by removing just a few components where access to the installation area is difficult. This capability can also cut freight charges, e.g. for shipment to Asia, the US or South America. The new EcoCCore is designed to use non-halogenated hydrocarbons and modified alcohols. Due to a one-third increase in product throughput and load weight it enables a marked reduction of per-unit cleaning cost. ☐

Operating the EcoCCore machine is made simple, fast and safe by the new 7” colour display based on self-explanatory pictographs. Thus, for instance, a temperature needs to be preset only for the first flood tank; a matching setting for the second tank is then selected automatically. Process tracking and maintenance, too, are rendered intuitive and more convenient by the integrated part visualisation system. An optional full visualisation capability can be integrated above the control panel.

Efficient in every respect In developing this system, particular attention has been paid to high efficiency and ease of maintenance. Thus, for


Smart and attractive machine design

Courtesy: Dürr Ecoclean > MORE@CLICK EM01079 |

EM India | Jan-Feb 2014

Image courtesy: Š2014 Trilogiq

m at e r i a l h a n d l i n g | t e c h n o l o g y

DESIGNING A Holistic solution The article deals with holistic material handling in manufacturing that involves elimination of poor choices and rapid identification of best possible options Holistic material handling and manufacturing is a new concept. Product acquisitions are purchased individually without consideration to the process. Rather than strategically planning to work with a singular vendor to analyse, assess and acquire the best overall integrated solutions, purchasing managers call favourite suppliers to order a required item. It is folly and poor practice. Thin operating margins are driving more holistic material handling and manufacturing by progressive management leaders versed in lean manufacturing, Six Sigma and continuous process improvement theories. The role of modern material handling and holistic integrated solutions rests with inventive systems integrators who must offer the full gamut of services based on wisdom and experience of potential solutions’ options.

Pioneers of the new holistic automation process A majority of system integrators in material handling too


Thomas R Cutler President & CEO TR Cutler, Inc

often can be described as order-takers. Rather than actively seeking all the possible integrated automation solutions for the end-user customer, products are ordered, delivered, and installed. Trilogiq USA, based in Livonia, Michigan, pioneered the holistic team consultative approach using an evaluation methodology. Lean manufacturing is an elevated concept, yet much of the waste to be eliminated and continued process improvement can be made in the very smallest incremental improvements.

Tubing selection increases in productivity Bob Rechul, Sales Engineer, Trilogiq USA, with two decades in the tube and joint field processed reviews to reduce waste, improved manufacturing quality, reduce cost and improved operator ergonomics. “Tubing is one area in which manufacturers can immediately realise increased productivity while lowering manufacturing costs. Simply using the best tubing solution often results in a 12-15% increase per year in

EM | Jan-Feb 2014

Grinding technology made by JUNKER Quality, performance, service - As you need it Whether you are looking for a standard machine or a premium solution: as a leading-edge technology provider we provide custom solutions for every conceivable high-speed precision grinding application. From stand-alone machines through to complete production lines - our outstanding reliability and premium quality as well as our servicing excellence set high international standards the world over.

Erwin Junker Maschinenfabrik GmbH India Branch OfďŹ ce OfďŹ ce No. 104, City Square 29-2, K.M. Gandhi Path, Bhamburda Shivaji Nagar, Pune 411 005 Phone: 020 255 338 96 E-Mail:

Image courtesy: Š2014 Trilogiq

m at e r i a l h a n d l i n g | t e c h n o l o g y

Lightbox is just a tool to quickly generate design information that can create CNC produced part protection

productivity,� said Rechul. Holistic material handling experts often define the elimination of poor choices and rapid identification of best options. Rechul worked to implement 5S and ran Kaizen events at General Motors, Ford and Chrysler as well as many aerospace, medical device and food service industries. Tubing improvements must be combined with all of the elements of efficient material handling elements for holistic process improvement. Vendors sell tubes and joints; the product approach is not a lean best-practice. A partnership approach with the customer from conception to long after the execution is required to ensure products and solutions surpass the needs of manufacturing customers.

Quality control The thermoplastic extrusion process to coat steel tubes must provide several strength improvements over powder coating and other coating alternatives. Damaged tubes cost big money, requiring diagnosis, replacement, and repair. This down-time is a huge waste that can be easily avoided. Tubing connectors with a non-slip nub, which grips the thermoplastic coating, is considerably better without marking or damaging the tube. Inspection is always an import job by tube and connector suppliers. Tube fittings are often manufactured in accordance to conform to the ISO 9001:2000 quality standard. From tubing to CNC to light, a holistic approach can be


observed, quantified, and measured in quality. The three functional areas are material flow, material presentation, and material protection. Tube and joint solutions typically function in the first two areas where CNC and lightbox solutions work in the third. The impact on quality, specifically part quality, is different in each area. Material flow is measured when parts are moved in the plant; damage can result from forklifts and transportation, people, other parts or process. Tube and joint solutions (along with AGCs, autonomous mobile robots, and integrated part protection) help to address each of those causes of errors by right sizing the material flow and better containing the parts when moved. Tube and joint structures provide the best ergonomic presentation of parts. It not only improves environmental, health and safety (EH&S) measures, but also allows the operator to handle parts in the easiest way to respect the part’s quality integrity. Material protection is the most valuable area of part quality that holistic integrated lean solution providers can implement. This discipline can exist independently, or work in conjunction with material flow and material presentation. Experienced and thoughtful systems integrators consider how parts are best packaged, moved, and presented until they are finally used. Most of the damage to parts inside of a manufacturing facility occurs due to poor protection and packaging design at some point in the process.

EM | Jan-Feb 2014

t e c h n o l o g y | m at e r i a l h a n d l i n g

Lightbox quickly generates design information

Eliminating part damage and process errors

Lightbox is just a tool to quickly generate design information that can create CNC produced part protection. This part protection considers part characteristics (class A surface, odd appendages, weak/strong points) and correct packaging materials to allow the part to flow and move through the facility with the least amount of risk. Shadow boards, kit trays, dunnage, rails & partition trays are other elements to a holistic process suggested Troligiq USA’s Luman Temby, “When parts are moved in the plant, damage can result from forklifts and transportation, people, other parts, or process. Custom packaging and part protection solutions provide answers to reduce risk in part movement and handling in all of those areas.” Creating customised visual ID tool boards, error-proofing shadow board and part protection trays on the lightbox all are quality driven considerations that ‘order-takers’ rarely review.

Holistic best practices are demonstrated in two specific areas of quality, part damage and process errors. Part damage results from parts not being sufficiently contained, protected, or packaged thus being subject to conditions that can impair their quality (dents, scratches, and impacts). Process errors result from the wrong type or quantity of parts arriving to an operator that can cause process delays and losses. “Designing integrated material flow, material presentation, and material protection systems using a variety of methods and materials is critical. The purpose of these systems is to consider how a part moves through a facility (or value stream) and reduce the risk of damage at each step,” said Temby. Resolving issues and designing a holistic solution is the only best practice. ☐

EM | Jan-Feb 2014

> MORE@CLICK EM01080 |


A u to m ot i v e ma n u fa c t iuurri inngg | | tteecchhnnoollooggyy

Efficient future mobility An article on Schaeffler’s drivable concept car specially tailored for Indian driving conditions with drive train innovations that offers up to 10% reduction in fuel consumption The demand for automobile industry is increasing in India by leaps and bounds. The spurt in demand for cars can be attributed to the aspirational lifestyle of people. In spite of the raging petrol-diesel prices, car manufacturers are engaging in more production and supply of cars to meet the needs of the mileage-crazy customers. Schaeffler recently presented a new concept vehicle for the Indian automobile market featuring advanced drive train technologies that can offer up to 10% reduction in fuel consumption combined with better comfort and driving experience.

The concept car The efficient future mobility India concept car is based on subcompact hatchback and shows a range of solutions for


Srimoyee Lahiri Sub-editor& Correspondent

Priyanka Banerjee Freelance Writer

optimising engine and transmission technology currently available in India. The vehicle features advanced drive train innovations like dual VCT (Variable Cam Timing), coated tappets, smart thermo management and shift detection. According to the company, it is based on a current version of the ‘Segment B’ hatchbacks — an effort to bridge the gap between demand for performance, comfort, economy and supply. Due to multiple factors like stop and go traffic simulations, cost-effectiveness, customer habits and manual transmission are the most preferred version of cars in the subcompact segment these days. The vehicle features a combination of start-stop systems with manual transmission resulting in enhanced driving experience while reducing fuel consumption. This is made possible with the electronic clutch management (ECM). It also features other advanced drive train

EM | Jan-Feb 2014





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A u to m ot i v e ma n u fa c t u r i n g | t e c h n o l o g y

“Schaeffler being a technological driven organisation, drives innovation not only within but at the supplier end as well”

Joydeep Roy, Managing Director of Luk India and INA Bearings India Ltd

innovations like dual VCT, coated tappets, smart thermo management and shift detection. “The efficient future mobility India car is the result of Schaeffler’s intensive research and development toward optimising drive train performance according to peculiarities of driving conditions, patterns and behaviour as well as customer preferences in India. It reflects Schaeffler’s vision for the future of drive train in emerging markets,” says Dharmesh Arora, Managing Director & CEO, Schaeffler India. “Beside that, we are actively developing new concepts and technologies for the two-wheeler and commercial vehicle segment. Our recent innovations include low-friction bearings and new range of clutches for motorcycles in India,” he added.

“Indian automotive industry is aspiring and continuously improving its processes and capability in the area of R&D and manufacturing” Matthias Zink, President, Automotive, Schaeffler Asia Pacific

front dashboard, Schaeffler has put an add-on for gear shift indicator visually,” asserts Roy. “In an area of transmission the existing shift tower has been replaced with detent sensor with magnet shift tower, reassembled gearbox with optmised ball and needle bearings Technology development and finally electronic clutch management which is an Joydeep Roy, Managing Director, Luk and INA Bearings upgradation from existing manual transmission and step India, with “efficient future mobility”, gives a better perspective down from AMT,” he added. But how can these innovations of the technological development of the concept car. “Schaeffler be commercialised by automotive manufacturers? What will is working on optimisation of the complete ‘drive train’ system. be the increased cost percentage while adopting these This approach gives answers to all questions on this subject technologies? Addressing these challenges, Roy adheres that starting from optimisation of the internal combustion engine concept vehicle has been equipped with mix of existing and and drive train, over hybridisation to full electric drive train by innovative products. “We encourage and positively look innovations with the aid of systems competence in mechatronics,” forward toward all automotive manufacturers and are keen to said Roy. ‘Efficient future mobility India concept’ vehicle uses have further discussion on the same. There will be a variation Schaeffler brand LuK’s electronic clutch management system. in cost percentage when these technologies will be transited As an integrated clutch actuator with electric motor, sensor from prototypes into mass production.” system and LCU (local control unit) the hydrostatic clutch actuator (HCA) developed by LuK is suitable for actuating Fuel efficiency individual clutches such as those in clutch-by-wire and ECM Much technological advancement is themed on fuel applications. “By far, during the re-integration of concept car, we have not done any major design changes into the overall efficiency these days. The fuel saving techniques that have body of the car. All the products have been fitted intelligently been used by this vehicle are dual variable camshaft timing, into drivetrain considering the space constraints. Only on a coated tappets, smart thermo management and shift detection.


EM | Jan-Feb 2014

MOTORUM 3048TG.MOTORUM 3048TG does more than to

Muratec Ball Screw Press BB4013 is driven by AC servo motor and ball screw mechanism.

Ball Screw Press Brake

The New 300kN Solution Latest Technology from the Inventor of the Electric Turret Punch Press.

A u to m ot i v e ma n u fa c t u r i n g | t e c h n o l o g y

The electronic clutch management reduces fuel consumption

“We are not only working on the topics engine, transmission and chassis, but also on new concepts like Hybrid drive trains or e-mobility; we see in today’s combustion engines depending on the design - still potential for consumption optimisation in the two-digit per cent area in the specific issues valve train, power take-off and thermal heat management; moreover offers the combination with a more efficient automised transmission further potentials. Schaeffler resolves the area of conflict between the internal combustion engine and electromobility by driving forward innovations with the aid of systems competence in mechatronics. The foundation for success include interdisciplinary ways of thinking, understanding of systems and comprehensive approaches to problem solving, customer focus and the highest quality objectives. As a basis for planning, the internal combustion engine will continue to be a significant element in automotive engineering and offers considerable potential for optimisation. We will cover the “Ecosystem Electromobility” comprehensively from the eMobility Systems Division: from renewable energy generation, via pedelecs, to the passenger car,” says Matthias Zink, President, Automotive, Schaeffler Asia Pacific.

respect to local machines, trained and well-skilled manpower with knowledge of automobiles,” shares Roy.

Future in Indian market

Zink believes that as part of the Efficient Future Mobility project, concept vehicles will be created in three countries – USA, China and India and these vehicles reflect Schaeffler‘s strong commitment to its ‘in the region, for the region’ principle while strengthening its efforts to build a truly global network of engineering excellence and innovation to create solutions that can be applied by the automotive industry anywhere in the world. “Schaeffler has developed these concept vehicles to present tangible, working solutions — matched to relevant markets for demands and challenges of automotive industry today and tomorrow. As Indian automotive industry is aspiring and continuously improving its processes and capability in an area of R&D and manufacturing, to innovate solutions not only ‘fit to purpose’ for India but for global market. Such concept cars components, subsystem and systems have definite potential and future in Indian market. We see the future of this technology very optimistic; depending on the customer acceptance, the support through the OEMs, the quote could be in timely manner,” asserts Zink. On the other hand, Schaeffler in India Challenges for high-end products has developed an innovative clutch for motorcycles along with High-end technological products always come with finger follower systems, chain drives and optimise bearings for challenges, especially in material planning. Roy believes that engines. “We have a competency to offer dual tandem wheel Schaeffler being a technological driven organisation, drives bearings and needle bearings for gear boxes of the heavy innovation not only within but at the supplier end as well. commercial vehicles. With respect to LCVs we have a wide “During the launch of any high-end products (e.g. shift tower, variety of products right from engine components, to belt and clutch release systems, etc), it is very difficult to identify a local chain drive with hydraulic tensioners, wheel bearings and competent supplier. But having said that, India being emerging needle bearings for their gear boxes, steering column application as an auto component manufacturer cluster in the recent past, and suspension struts,” concludes Roy. ☐ has supported us in identifying and developing right suppliers. > MORE@CLICK EM01081 | However, it is still a considerable way to go ahead in future with


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Enabling manufacturing excellence Indian Machine Tool Manufacturers’ Association (IMTMA) will be organising international forming technology exhibition - IMTEX FORMING 2014 and concurrent show Tooltech 2014 on January 23-28, 2014 at its state-of-the-art exhibition facility — BIEC, Bengaluru. A preview on this mega trade fair…

IMTEX Forming 2014 is an exclusive business-to-business exhibition attracting manufacturing domain experts specialised in press working, sheet metal forming and processing from all over the world. The uniqueness of IMTEX is its focus on the exhaustive range of forming technologies for varied engineering applications. IMTEX Forming 2014 includes all forming technologies predominantly in metals, plastics, ceramics, composites and exotic materials; manifestation of which has one ultimate objective – enabling manufacturing excellence through superior technologies, world-class productivity and cost-competitiveness.


SumedhaMahorey Deputy Editor

Concurrent Show Tooltech 2014, in its 16th edition, will feature recent innovations and tooling technologies for precision finish of dies & moulds, forming tools, machine accessories, metrology and CAD/CAM. The exhibition promises to showcase contemporary innovations ranging from the most efficient and advanced machineries. Sharing the USPs of the trade fair, Shailesh Sheth, Media Chairman, IMTMA, said, “Over the years, IMTEX has been a driving force for the exponential growth of the Indian machine tool industry. The key emphasis of IMTEX Forming 2014 is to enable manufacturing excellence through superior technologies,

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“IMTEX Forming 2014 is dedicated for the ‘metal forming’ segment of the machine tool industry. Hence, we can expect to receive major demand from related industries like automobile, energy, power, among others for forming machineries” L Krishnan, President, IMTMA

world-class productivity and cost-competitiveness. IMTEX Forming 2014 promises to be a specialised-trade fair on metal forming machine tool industry that will attract buyers and manufacturing professionals and will enhance technological efficiency across various sectors.”

Key highlights Exhibitors from across 25 countries including India will be participating in the exhibition this year. Key countries participating include Australia, Germany, France, Korea, Switzerland, Turkey, Sweden, Japan, Thailand, UK, USA, and many more. The exhibition will also have group participation from four countries – China, Czech Republic, Germany & Taiwan. High-level domestic delegations from ISRO, Bharat Heavy Electricals (BHEL), DRDO, Society of Indian Automobile Manufacturers’ (SIAM), Naval Dockyard are also anticipated to visit the show. With the aim to provide an opportunity for Indian academic and R&D institutions to showcase their R&D capabilities in metal working field, a unique academic pavilion has been set up during IMTEX 2014. Prior to the main exhibition, IMTMA is also organising an ‘International Seminar on Forming Technology 2014’ to address the latest trends, developments and research in forming technology on January 22, 2013 at BIEC. The highlights of the show will include the display of ‘live technologies’ in the forming segment such as laser, servo presses, robotics & automation, welding & joining, and wire-forming & drawing.

Demand trends Sharing his views on the machine tool industry, L Krishnan, President, IMTMA, said, “The machine tool industry has sustained performance during the economic slowdown. The current market size of the machine tool industry stands at US$ 2050 million of which the domestic production makes for around 33% of the total consumption. The last two quarters have shown signs of improvement in order inflow. The key user industries such as the automobile, auto components, defence, aerospace and power are set to fuel the growth of Indian machine tool industry”. Adding further, he said, “Consumer durables, electronics and auto industries have seen strong growth in the near past to which the metal

EM | Jan-Feb 2014

“The key emphasis of IMTEX Forming 2014 is to enable manufacturing excellence through superior technologies, world-class productivity and costcompetitiveness” Shailesh Sheth, Media Chairman, IMTMA

forming industry serves as the core-manufacturing machinery provider. This change has opened new doors of development and growth for our industry. Emerging sectors like medical equipments, aerospace, pharmaceutical equipments, office infrastructure, white goods, ship building, energy & power, process equipment & machinery, construction, railway & heavy transportation, communication & consumer electronics, among others, have also boosted the tide of increasing demand for the metal forming industry. Hence, India can expect to see a considerable growth in the near future for its metal forming industry.” Commenting on the segment of the industry wherein major demand is likely to be witnessed, Krishnan said, “IMTEX Forming 2014 is dedicated for the ‘metal forming’ segment of the machine tool industry. Hence, we can expect to receive major demand from related industries like automobile, energy, power, among others for forming machineries.”

Leveraging on the opportunity Sharing his thoughts on how to make the most of IMTEX 2014 while adhering to price and demand constraints, Krishnan asserted, “For exhibitors and visitors both, IMTEX Forming 2014 is an opportunity to learn, understand and implement the latest technologies from variety of forming segments from India and overseas. It enables technology up-gradation and ways to improve productivity and competitiveness; helps in moving up the value chain in tune with market realities; understanding the emerging segments where demand and volumes exists; sharing new technologies, forge partnerships and harness business relationships while creating possibilities of witnessing a range of manufacturing solutions available in the metal forming segment, as also the


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potential technologies likely to shape up in future under one roof.” Commenting on the demand trends and market outlook for Indian manufacturing sector in 2014-15, he noted, “The Indian manufacturing sector has realised the need for the latest technology up-gradation. Demand for flexible machines with facilities, like inbuilt safety devices, quick change over, automatic parts transfer and other features designed to make them more productive, will drive demand in future.” Harkiran Sandhu Country Manager Faro India

What are your expectations for generation of business leads in the year 2014? At Faro, we believe that brand awareness efforts need to be regular and consistent. The volume of business leads generated, and the eventual sales conversion, is dependent on the level of awareness and brand recall. This year, our strategy is to continue our efforts to create a greater awareness for us in the region. This will be done through our participation in major trade shows, webcast of informative seminars, customer visits, as well as sharing of new product launches and success stories via media channels. By the team’s persistent efforts with these various means, we expect to maintain market presence and consistently receive a healthy number of business leads this year. With our participation in IMTEX, we expect to create a greater awareness for Faro in the region, which in turn would bring about an increase in business volume. We are primarily looking to generate more business leads and interact with new visitors. We also look forward to catching up with our current customers and partners, updating them with our latest product offerings and technology during the show.

From which segment of the industry are you expecting major demand? As a global 3D measurement solutions company, we serve a broad range of industries. The company’s products are used widely in various applications in many sectors, including automotive, aerospace, heavy machinery, die & mould, shipbuilding, architecture, heritage, forensic, plant management, and mining. This year, we expect slightly stronger demands from the automotive, metal fabrication and aerospace markets.

Which are the technologies that will be highlighted by your company at IMTEX-2014? Faro will be showcasing three key products at IMTEX 2014: FARO® Edge


Thoughts from IMTEX exhibitors To understand the expectations of key machine tool manufacturers from IMTEX 2014 and to analyse technologies & new innovations to be showcased during the six-day mega trade fair, we at EM spoke to leading machine tool players. Here are the excerpts of these interactions…

ScanArm ES, FARO® Laser Tracker Vantage and FARO® Laser Scanner Focus3D X 330. In particular, the latest addition to our best-selling FaroArm product line is the FARO® Edge ScanArm ES with Enhanced Scanning Technology (EST). EST is the combination of multiple hardware and software improvements designed to boost performance by improving the ability to scan challenging surfaces that are dark or reflective. Combining the laser line probe with the flexibility of the FaroArm, the ScanArm ES is the ideal tool for product development, inspection, and quality control. In addition, the device also offers capabilities such as point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling. Please share key technology demand trends and market outlook for Indian manufacturing in 2014-15. In 2014, we believe that non-contact optical measurement technology will continue to gain more ground. Research suggests that additive manufacturing is catching on globally. According to IT analyst house Gartner’s first forecast of the consumer and enterprise 3D printer (3DP) market, worldwide shipments of 3DPs priced less than $100,000 will grow 49 per cent in 2013 to reach a total of 56,507 units. That number is expected to further increase in 2014, growing 75 per cent to 98,065 units, followed by a near doubling of unit shipments in 2015. 3D printers, scanners, design tools and materials will continue to advance. With that, applications of 3D print technology will naturally become more widespread, as the cost of complexity of creating 3D printed items decrease. In addition, our observations indicate that 3D printing is indeed gaining popularity. For one, it is increasingly common for tradeshow organisers to have a dedicated feature area for 3D printing-related technologies, a move that is well received by both exhibitors and visitors. In particular, companies that do rapid prototyping appreciate 3D printing, because it positively impacts their product design process by way of two very important factors – time and confidentiality. 3D printing is speedy and it eliminates the need for model fabrication at an external vendor’s facility, both of which are attractive attributes. ☐

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Philip Mascarenhas Managing Director Chrystec Machine Tools Pvt Ltd

What are your business expectations for 2014? The previous year witnessed a continuation of slowdown in manufacturing in India that has been one of the longest and most severe. Though one is generally optimistic that 2014 will see a revival, it most likely would take a little longer and may take place only towards the second half of the year. Keeping in mind the longterm prospects of growth in the domestic market and interest of many companies to expand their export business, we hope to conclude business from our existing customers looking for better technology products and solutions, that can address their quality requirements and volumes of their global customers and markets. How is IMTEX 2014 likely to boost business prospects? We expect leads from progressive customers who are looking at long-

Mohini Kelkar Managing Director Grind Master Machines Pvt Ltd

What are your expectations for generation of business leads in the year 2014? It all depends on economic and political situation in India. Several projects are on hold and therefore, capital goods industry has suffered. But, in light of the forthcoming elections, we expect to generate more business leads in 2014. From which segment of the industry are you expecting major demand to come in? Automotive and auto component sector has always been a major demand centre for all machine tool industry. Since sourcing of auto components from India is increasing, we expect more demand from this sector. How will overseas exposure help your company gain a substantial stronghold in the global market share? Export market / foreign buyer have always been in focus for us irrespective of the Indian market situation. In order to sustain the steady growth of the company, it is absolutely essential to look for export markets very actively. This also helps in upgrading your products and improving the whole organisational performance. Which are the technologies that will be highlighted by your company at IMTEX-2014? We are launching robotic fettling and deburring solutions at IMTEX 2014. The technologies to be displayed include:


term investments for both domestic and export markets, who have the capacity to invest in such technology and the inherent strengths to effectively use them, as future prospective buyers for such high performance machines. The justification for such investments would depend on the quality and complexity of parts manufactured and the volumes that are needed. Due to the high efficiency of such machines, advantages would be savings in power, manpower, consumables, less raw material wastage, etc. Which technologies will be showcased by your company at IMTEX 2014? The products that we will be showcased are hot forming and cold forming machines from Hatebur, Switzerland. For Indian manufacturing industry to grow we need to also effectively utilise such technology to compete in the global market and get over basic issues of capable manpower to run them, quality power and consumables. It is time that we develop the infrastructure to use such equipment since as a country we have immense potential to be among the best in the world. ☐

• • • •

 utomatic trimming and beading machines from our partners Omera A in Italy - These are high production machines for curling, clinching, beading and similar metal forming operations on sheet metal pressed parts. Deburring machines for sheet metal parts – We will show different deburring processes which are selected on the basis of amount of burr and material of the part. Precision burring machines for pump parts, valve plates and sintered parts. Stainless steel sheet finishing machines – from our partners Timesavers in Holland. Robotic fettling of aluminium die castings – Manual fettling being inconsistent, it leads to rejections of aesthetically important parts like backrest of 2 wheeler. Robotic operation not only gives consistent finish but also gives much higher productivity. Press Automation – For automatic feeding of sheet metal parts on press tools, tube polishing machine for round and square tubes’ and tube notching machines.

Please share key technology demand trends for Indian manufacturing sector in 2014-15. Automation will remain in demand. The demand of machines with auto loading/unloading will be on rise. Also, there is demand of combining operations so as to avoid handling between the two machines and two processes. This creates opportunities for the machine tool makers to come together and provide such solutions. We have done this together with Micromatic Grinding and a combined machine cell for grinding, deburring and superfinishing of gear pump shaft was provided. This will eliminate three operators and ensure high productivity. ☐

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Paras Vaghela Director Godson Bending Systems Pvt Ltd

The year 2013 was not very encouraging in terms of overall demand situation in India. What are your expectations for generation of business leads in the year 2014? Yes, 2013 was not encouraging, neither in demand nor in terms of manufacturing for the Indian industries. Our expectations are always high and positive, hence we at Godson, consider 2014 as the year of bustling market, compensating the dues of 2013 for the Indian economy. From which segment of the industry are you expecting major demand to come in? We anticipate more demand from automobile, agriculture and infrastructure industries in 2014. With slow growth in the manufacturing sector, are you looking at export markets / foreign buyers to sustain the growth momentum amid current economic fluctuations? We increase our exports every year. We are very positive about exporting more machines in 2014 as well. Which are the technologies that will be highlighted by your company during IMTEX-2014? We are launching quick bending roll machine, which is plate bending machine having only one roll. It assures high production with more accuracy. Are you exploring for suppliers/vendors/overseas distributors at the mega trade fair? Yes, since mega trade fairs provide many opportunities for future partnerships of mutual benefits. Please share key technology demand trends in 2014-15. Itâ&#x20AC;&#x2122;s an era of computer technology and automation. We have adopted many new innovations in our machine for better performance and easy operation of the machine for the end users. â&#x2DC;?

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Vishwas Kirpekar Managing Director Kirpekar Engineering Pvt Ltd

What are your expectations for generation of business leads in the year 2014? The economic situation is improving worldwide but not in India due to uncertain political situation and lack of reforms. On the other hand, quality of manufacturing is improving, hence exports is the right way to move forward.

fuse gear, etc. We will be displaying a welding machine for welding of fuel tank automatically. A standard seam welder is connected with a 4-axis motion with servo motors. The clamping of the fuel tank is with pneumatic cylinder and all programmable motions with servo drives. Such a process ensures fast and consistent production. This is perhaps the first time such a machine is built in India. We also make machines for feeding presses automatically and will be displaying numerically controlled feeder with accuracies of feeding within 50 microns. We are also exploring suppliers/vendors/overseas distributors at the mega trade fair.

From which segment of the industry are you expecting major demand to come in? Power and infrastructure are and will be the key areas of growth.

How will overseas exposure help gain a substantial stronghold in the global market share? For any success, quality products are important. Those who will match or exceed quality requirements of export market will be a great success.

Which are the technologies that will be highlighted by your company at IMTEX-2014? Quality and consistency are important. Our designs will highlight these features during IMTEX. We began with manufacturing resistance welding machines in 1996. The machines are made to suit the application. Hence, are not standard and with some innovation. We are mostly making machines for electrical industry for applications like switchgear,

Please share key technology demand trends & market outlook for Indian manufacturing in 2014-15. Low cost automation and simple operational techniques are the present day requirements, not to do away with labour. We expect the business outlook to be positive. â&#x2DC;?

Soumitra Joshi Managing Director TRUMPF India

The year 2013 was not very encouraging in terms of overall demand situation in India. What are your expectations for business leads generation in 2014? We foresee a moderate recovery in the economic growth in 2014 as the elections may delay reforms in India. Nevertheless, it could be a breakthrough year for the economy as the recent developments in Indian politics show a different shift towards governance. This could serve as a mainstream enabler for economic revival. Therefore, business leads may improve in the second half of 2014 as any positive developments will require maturity time to produce visible results. From which segment of the industry are you expecting major demand to come in? Automotive sale is expected to see some improvement from the second half of 2014. Similarly, we expect improvement in demand coming from infrastructure projects, electrical industry, IT-, telecom-, medical-, agriculture- and construction-equipment manufacturers.


Please highlight on innovations to be launched during IMTEX-2014. IMTEX 2014 will see the TRUMPF India Premiere of a path-breaking machine in the laser cutting arena â&#x20AC;&#x201C; The TruLaser 1030 Fiber. This machine is easy to operate, with compact dimensions and easy on the budget. The key features include its ability to cut non-ferrous metals and its capacity for integration into a network, wherein the laser beam can also be used for welding. Pls share key technology demand trends & market outlook for Indian manufacturing in 2014-15. With the weaker rupee and higher borrowing costs, the operating environment is more challenging for Indian manufacturing companies. The current capacity utilisation for manufacturing companies is at a four-year low and needs progress on implementation of already laid out roadmap of the National Manufacturing Policy. A development and reform-focused government with a strong majority is critical for a better market outlook for the sluggish Indian manufacturing sector. Time is and always will be the key driver for technology upgrades and the key trends for 2014-15 would be on the same lines with automated assembly support, laser assisted manufacturing and high productive and effective technology trends. â&#x2DC;?

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S Ravishankar Deputy Managing Director Yamazaki Mazak India Pvt Ltd

The year 2013 was not very encouraging in terms of overall demand situation in India. What are your expectations for generation of business leads in the year 2014? Considering present economic scenario and the forthcoming general elections, we cannot expect any major improvements till the new government is formed and starts acting. This could mean not until the end of 2014. So, 2014 will be another testing year for Indian industries. From which segment of the industry are you expecting major demand to come in? The slowdown is clearly visible in all sectors. Those who are into exports to the US and other growing markets seem to be doing as per their plans. Which are the technologies that will be highlighted by your company at IMTEX-2014? Mazak will unveil its state-of-the-art Mazak laser technology with live demonstration of Mazak laser machine with “non set-up cutting demo’ during show; emphasis on ‘Mazak – total solution for laser cutting applications; interactive displays with sheet metal and structural fabrication case studies for various industry applications, and solution gallery with sample displays/case studies for 3D laser applications. Pls share key technology demand trends & market outlook for Indian manufacturing in 2014-15. The manufacturing sector is on constant pressure to deliver high quality products at very short lead times and at lower costs. Hence, the trend is to look for automation in handling parts, multi-tasking machines. Multi-tasking machines offer higher product quality (because all operations are done in one set up) low throughput time, especially for critical parts of small batch sizes. The latest trend in Mazak laser machines are 3D laser cutting machines which make the pipe cutting and structural fabrication, more precise and very less time consuming thereby reducing the cost and lead time of construction projects (like structures in airports, stadiums etc) up to 30-40%. ☐

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Ameer Munaff Managing Director FEIN Power Tools India Pvt Ltd

What are your expectations for generation of business leads in the year 2014? The first half of 2014 is going to be tough and eventually has to bounce back in second half of 2014 to its earlier trends. Government policies and initiatives are to be carefully drawn this year, thereby boosting the economy. More investment and government expenditure with regulated interest rates is the need of the hour to have multiplier effect, which will propel the growth. If the markets return to normalcy, then growth is not only back but it is here in India. Despite this, we are bullish about the business potential which is unstoppable in India in the near future due to the drift in high demand for quality consciousness and efficient manufacturing systems & methods. We are concentrating only on high-end niche market in the professional tools. From which sectors are you expecting major demand to come in? Our main focus will be on metal, interior construction and automotive sectors. In this competitive market, success of an enterprise largely depends on its innovative abilities, the manner in which it can launch new products at cost-effective price points and promote the same as distinct from the wide range of similar products available in the market. How will overseas exposure help gain a substantial stronghold in the global market share? In the current scenario, exports are must for sustaining and to keep the growth momentum on. We are looking to increase our exports by further 7 to 10% over last year and penetrate untapped developing markets. However, India is a very significant, important and interesting market

Rolern Lee Vice General Manager Dees Hydraulic Industrial Co Ltd

How will IMTEX help your company tap the global & Indian market platform? We know IMTEX is the largest exhibition in India and we hope to increase reputation and find a local dealer/distributor through this event. Do you face any challenges to operate in the Indian market? There is no doubt that lower product price is a problem for us. Which are the technologies that will be highlighted by your company at IMTEX-2014? Dees provides a full line of large capacity high speed presses to help customers drastically cut down production cost. Dees self-developed HD-FASTech technology, released in early 2012, has received excellent responses from the stamping industry. HD-FASTech hydraulic machine completely solves conventional deep-drawing’s low efficiency and elevated SPM, greatly improving production efficiency.

for the FEIN Group. The presence here will strengthen its position globally and highlight the strategic importance of the Indian market while writing the next chapter in its success story as an inventor of extremely reliable power tools and a flourishing international business. Which are the technologies that will be highlighted by your company at IMTEX-2014? We are planning to launch products like automatic metal core drilling machine, cordless fastening tool and the new angle grinders. There will be a live demo of the new products at the event for the visitors to feel and understand the features of the tools. Please share key technology demand trends and market outlook for Indian manufacturing in 2014-15. In this competitive market of speed and precision, machines that brings a huge difference by way of giving cost effective and efficient solutions for the toughest industrial applications for day-to-day work has unlimited opportunities available. Success of a machine manufacturer or enterprise largely depends on its innovative abilities, the manner in which it can launch new products at cost-effective price points and promote the same as distinct from the wide range of similar products available in the market. In the coming years, new product design and applications will see the emergence of a phase in business value chain that is fiercely knowledgedriven and is sustained by rapid innovation and speedy delivery of the new or improved cost effective solutions to markets, followed by enhanced productivity, higher precision, increased reliability, better finishing, and improved aesthetics and design. Therefore, the creation, protection, effective exploitation and leveraging of existing and new knowledge in the marketplace will differentiate the winners from the losers. ☐

IMTEX-2014? Listening needs from all of our potential customers is the priority for us. We offer better value at reasonable price for our customer. Meanwhile, apart from best services, we offer mechanical operation guideline to our clients all the time. Are you looking at distributors/vendors/suppliers in the Indian market? Yes, we are looking for distributors in India. We look forward to getting any co-operation opportunity during IMTEX. Please share innovations that will be showcased in IMTEX 2014. As the development of high speed hydraulic press completed, Dees reached a new pinnacle for high speed drawing. Advancing hydraulic press’ processing capacity is our main goal. With our new HD-FASTech technology integrated into various forming application, our latest engineering accolade is the completion of the hydraulic transfer press. From home appliance to automotive stamping, this transfer press is not just space-saving or labour saving and but budget saving too. This ‘hydraulic driven’ transfer press will boost SPM and lead to a new era of hydraulic stamping. ☐

What are the measures being taken to foster business opportunities at


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Championing complete machining solution Technology leaders like Walter, with their decades of experience and engineering competence, backed by a vast range of standard and customised special tools, assist modern day manufacturers boost their productivity even up to 100%, and lower the cost per component at least up to 20-30%. Addressing this, Walter Tools India recently held a Machining Solutions Meet at Pune. A report… In a normal machining environment, the machine hourly rate, cost of labour & other overhead charges are fixed and form the majority of the manufacturing cost, while cutting tool price contribute only a single digit percentage of the total machining cost. In this context, to showcase their competence in providing complete machining solution, Walter Tools India recently organised their “Walter Machining Solutions Meet” on December 17, 2013, at its Hinjewadi-based Technology Centre in Pune. Delegations from manufacturing majors like BHEL, BOSCH, Eastern Engineering Company, among others, attended the meet.


SumedhaMahorey Deputy Editor

The event “Walter Machining Solutions Meet” is designed for showcasing to the company’s customers, the latest technological and product innovations added during 2012-2013, and give the manufacturers an opportunity to witness live demonstration of these cutting edge technological breakthroughs. This meet also serves as a platform for Walter to gauge industry requirements for various machining applications from a wide spectrum of industries. The event is designed around Walter’s state-of-the-art

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“For the aerospace sector, we are using Walter tools, and it is giving us very good results with reduction in the operation time from 5 to 3 hours” TS Krishna Prasad, Director & COO, Eastern Engineering Company

technology centre in Pune which is equipped with four latest machines – 5-axis machine centre, multi-tasking turning centre, CNC milling centre and CNC turning centre. During the meet, the Walter team also discussed on topics like new prototype development, prove-outs of new products and process optimisation solutions along with technology exchange and specialised training for customers & engineers. Addressing representatives from the industry, Vivek Bhonsle, Managing Director, Walter Tools India, elaborated, “In the present scenario, companies cannot have a machining strategy focused at a single tool. One must really look beyond cutting tools for every operation. Thus, we provide complete machining strategy to our customers with the help of our strong engineering department and process optimisation experience.” Walter’s competitive advantage also lies in the fact that it has the widest product assortment of turning, milling, drilling and threading solutions. Bhonsle further affirmed, “For example, even though our competitors are offering taps and drills, this is just an extension of their existing range. They have provided niche products only in one field, ie drilling or milling, etc. But in our case, the entire product portfolio has been in existence for over a century with our strong brands like Walter, Walter Titex and Walter Prototyp. We have more than 49,000 product ranges in our standard portfolio, apart from our special tailor-made offerings. This is one of the reasons that for the last two years, we are probably the only company which has posted positive growth figures in double digits.” “The customer is always looking out for machining cost reduction, whether it is a booming or a slow market. In the current demand situation, the customer has more time to talk to us, experiment and looks at us for an opportunity to reduce overall costs while increasing productivity” he further added.

The users’ perspective Sharing his experience with Walter Tools, KSN Murthy, Additional General Manager, Technology/T&C, Bharat Heavy Electricals Ltd, a major user of Walter solutions, said, “BHEL is a huge engineering company, where power plant equipment is manufactured. We use various applications for machining many components including casings, rotors, and blades to name a few. In recent time, because of technology advancements and requirement of shorter cycle times, we have upgraded our facilities. Matching to those facilities, we needed new age

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“Since 2008, we are using nearly 35% of tooling solutions from Walter. Now, they are driving BHEL through their tooling technologies” KSN Murthy, Additional General Manager, Technology/T&C, Bharat Heavy Electricals Ltd

“We try to achieve a minimum of 20-30% machining cost saving for the customer” Vivek Bhonsle, Managing Director, Walter Tools India

cutting tools. Most of the cutting tools are sourced from the top players in the world like Walter. In our shop, we have many state-of-the-art machines like 5-axis machining centres with single and multi-spindle options. Walter has developed many tools and applications for us, which are the best in the industry. Since 2008, we are using nearly 35% of tooling solutions from Walter. Now, they are driving BHEL with their tooling technologies.” Another participant at the meet was Eastern Engineering Company which recently started using Walter tools. Representing the company, TS Krishna Prasad, Director & COO, Eastern Engineering Company (P) Ltd, said, “Ours is a 42-year-old company and we work in sectors like aerospace, O&G, energy, among others. For the aerospace sector, we are using Walter tools, and it is giving us very good results with the operation time reduced from 5 to 3 hours. If they are able to satisfy cost per component, quality and delivery in the long term, there will be no competition for them in the market. Though we have recently started working with them, looking at their competencies, we look forward towards working closely with Walter.” The meet provided a platform for both Walter and its partners to discuss existing as well as new solutions and its varied applications, and map the expectations of the industry for various machining requirements in different sectors. ☐ > MORE@CLICK EM01083 |


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The ultimate source for productivity solutions Manufacturing companies are continuously challenged to reduce costs through productivity improvement measures. Focused efforts in improving productivity holds the key to enhance and sustain competitiveness in the Indian manufacturing industry. With this in the background IMTMA had recently organised Productivity Summit 2013 in Pune from November 15 to 16, 2013, to showcase best productivity improvement projects in metal working industries which have excelled in achieving superior performance through sustained productivity improvements. A report... Productivity Summit, IMTMA-SIEMENS Productivity personalities from the world of Indian manufacturing and Championship Awards and Productivity Buzz were held at productivity mesmerised the audience with their wisdom and Pune on November 15 & 16, 2013. Championing the cause of experience. R Gopalakrishnan, Director, Tata Sons, shared his productivity, Indian Machine Tool Manufacturer’s Association thoughts against “India has blown it” and Shekar Viswanathan, organised the three concurrent mega-events wherein the old Vice Chairman, Toyota Kirloskar Motor, propounded on and new champions of productivity amalgamated from across “Productivity and Macro Variables”; while Dr N Ravichandran, Indian cities. ED, Lucas- TVS Ltd won the audience with his theories on “Next generation manufacturing through lean management”. Earlier in the day, the inauguration ceremony kickstarted the Highlights - 1st day event followed by welcome speech from L Krishnan, President About 400 odd participants witnessed the events unfold in IMTMA and vote of thanks by Rajesh Khatri, Chairman Pune on 15th morning as the keynote speakers, all renowned IMTMA Western Region Council.


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Sonali Kulkarni President & CEO Fanuc India Pvt Ltd

From which segment of the industry are you expecting major demand to come in? The automobile sector, which accounts for the lion’s share of demand in our industry, is facing its own challenges. For the first time in 11 years, yearly sales have declined. In this scenario, there will be focus on improving capacity utilisation and not just buying new machines. This will be a necessary first phase of recovery and only then investment in expansion will begin. The scenario is not bleak; it is just bottoming out before we see the recovery. Having said this, there are notable exceptions even right now – expanding capacity with an eye to leverage market share in the coming year. With slow growth in the manufacturing sector, are you looking at export markets/foreign buyers to sustain the growth momentum amid current economic fluctuations? Regardless of the state of our domestic market, it is important for manufacturers to aim at having a greater share of their revenue from overseas. Recent strong growth in our industry has been entirely domestic driven, and this too cedes market to imports. Moving toward greater share from exports will help balance out market fluctuations and will also upgrade our manufacturing. As for Fanuc in India, we serve mainly the domestic market, plus neighbouring countries. Which are the technologies that will be highlighted by your company at IMTEX-2014? This time we are showing a turnkey solution for InMould Labelling (IML) on our all electric injection moulding machine “Roboshot”. The entire effort from concept to execution has been carried out by Fanuc India team at our Bangalore Technical Centre. IML is a sunrise application for India, and our team is the first amongst all injection moulding machine makers to pull off this total solution with record cycle time of just 4.3 seconds. We achieved this using a Fanuc Robot which handles the labels, affixes them onto the mould cavity and the Roboshot proceeds to bring out labelled moulded parts (hinged lids in this case). Since the label and the lid are made of the same material, the product is easily recyclable, going through the waste stream faster. Not only is our cycle time the shortest, we also achieve Zero defect production (Shot weight consistency being within +/- 0.1%) and lowest total cost of production per piece. This IMTEX, we will also exhibit our workhorse welding cell with the latest arc welding robot, Roboweld 100iCe with Lincoln power source and state-of-the-art STT Technology. We shall be showing live, spatterless welding using high speed Servo positioner (7th axis) with robotic component loading using 3D area sensor. Components will come in randomly stacked and be picked by robot with 3D vision system. To show our range, there will be live demo of robot welding thin sheet as well as heavy welding. It is our principle to showcase only realistic cells, with an eye to final end use by our customers. This automation can be equally well applied to high volume, mass production as well as low volume, precise and high quality unmanned welding. Are you exploring for suppliers/vendors/overseas distributors at the mega trade fair? Our products are entirely manufactured by Fanuc Corporation in Japan. Certainly, we welcome relationships with like-minded dealers as well as system integrators, who have excellent market reach, a hunger to grow and uncompromising ethics. Please share key technology demand trends and market outlook for Indian manufacturing in 2014-15. It is an oddity, but in a populous country such as ours, there continues to be acute shortage of workers. Automation remains the single major driver for a manufacturer to underline reliable productivity. Robots being versatile and hardy, will be the trend in coming years. ☐

> MORE@CLICK EM01082 |

EM | Jan-Feb 2014


HANNOVER MESSE 2014 Innovation is a factor in success ■ Global market overview ■ Groundbreaking innovative technology ■ Transfer of knowledge and future trends

7 – 11 April 2014 Hannover ▪ Germany

Get new technology first

Hannover Milano Fairs India Pvt. Ltd. · Tel. +91-22- 42369719 ·

event | preview

More than 40 solution providers displayed their highly focussed productivity solutions in metal working

The day witnessed expert case studies from Mahindra & Mahindra Swaraj, Godrej & Boyce Mfg Co Ltd, Tata Steel Processing and Distribution Ltd, Laxmi Oil Pumps Pvt Ltd (SME), Bosch Ltd and Rane (Madras) Ltd.

Highlights – 2nd day The summit presentations to delivered concepts and practical uses of productivity ideas in front of the learned jury on day 2. Keynote speeches by Janak Mehta, Chairman, TQM International, who spoke on “Role and substance of lean leadership” and by expert duo team of R K Saxena, Head Strategy and Akhilesh Agarwal, Head - Production Control & Business Development, Hi Tech Gears, who spoke on “Journey towards Excellence,” delighted the audience. The audience was also enthralled by case studies from Reliable Autotech Pvt Ltd, Rane TRW Steering Systems Ltd, Hero Moto Corp and TVS Motor Co Ltd (Hosur). Entire range of cases studies dealt with various aspects of productivity from lean practices, redesigning, process optimisation, automation, capacity enhancement and introduction of flexible manufacturing, etc. Selected from over 300 serious cases studies from across the spectrum of companies representing myriads of productivity practices from across the cities in India, ‘ten’ final cases studies were selected by the jury to be presented for final scrutiny.

Productivity Buzz The 2nd edition of Productivity Buzz, a unique platform initiated by IMTMA where solution providers and solution seekers came together and were able to exchange ideas and new concepts to resolve productivity challenges in metal working was part of the overall summit. More than 40 solution providers displayed highly focused productivity solutions in


the areas of machining, manufacturing technology, automation, workholding & fixturing, metal forming, die & mould, welding and IT enabled solutions, amongst others.

Productivity Champions Awards The Summit culminated “Productivity Champions” of 2013. While the participants had a tough task proving their potential, the jury faced a mammoth challenge judging the sessions. In common, the jury observed that the depth of work done and level of understanding have predominantly gone up in the summit over the years and would like to see an improvement in the quality of the case studies presented at the summit in coming years. Siemens representative expressed happiness in coming together with IMTMA to provide the platform and work jointly toward improving productivity in the country and make Indian OEMs, customers more productive and competitive. The first prize citation, trophy and a cash award of ` 1 lakh each was awarded to three winning teams — Hero Motocorp, Rane (Madras) and TVS Motor Co; three second prize citations, trophy and a cash award of ` 60,000 each was awarded to teams of Rane TRW, Godrej & Boyce Mfg Co Ltd and Bosch Ltd; three third prize citations, trophy and a cash award of Rupees ` 40,000 each was awarded to teams of Mahindra & Mahindra Swaraj, Reliable Autotech and Laxmi Oil Pumps Pvt Ltd. The ‘Vox Populi’ was won by Rane Madras, the best display award went to Electropneumatics & Hydraulics (India) Pvt Ltd and the certificate of appreciation was awarded to Tata steel processing and Distribution Ltd. Overall, the summit was a great success in showcasing, spearheading and furthering the productivity cause in India. ☐ Courtesy: IMTMA > MORE@CLICK EM01084 |

EM | Jan-Feb 2014

event | REPORT

building Confidence in the future Indian car-makers are confronting a challenging market with optimism for the future, looking to further develop production efficiencies through innovation and improved supplier collaborations …this was the message delivered from various discussions in AMS India Conference, organised by Ultima Media, held recently in Pune The automotive industry is facing nothing less than “iconic BMW has to tackle costs and capacity restraints. Frittrang change”, said Robert Frittrang, MD, BMW, in the opening noted that the main cost lies in the materials used and that presentation of the AMS India Conference 2013, held recently minimising waste is one of the OEM’s “main targets” to drive in Pune. He claimed that the external factors of legislation, cost down, taking this principle right back to component especially CO2 regulation, and changing customer expectations design. are pushing vehicle manufacturers toward more sustainable production. For BMW, this takes the shape of a dual strategy: Lightweight production in India — the “evolutionary” improvement of its conventional cars and Shrikant Marathe, Director, Automotive Research the “revolutionary” development of alternative drivetrains. The latter is epitomised by the new BMWi sub-brand, consisting of Association of India (ARAI), discussed vehicle lightweighting the all-electric i3 and the sports hybrid i8. The “holistic” BMWi and the implications for production, where ‘one of the biggest concept, as Frittrang described it, covers the whole production questions’ is how to join such components. Marathe named chain and involves the use of lightweight aluminium and carbon the key challenges as the optimisation of the production fibre parts, plus the removal of standard press shop and process, the availability of materials in India, repair processes paintshop stages. William Sarver, Senior Consultant, Global and safety. The final speaker in the opening session, Rajesh Nath, MD, Automotive Accounts, Rockwell Automotive, asked what plans


EM | Jan-Feb 2014

REPORT | event

German Engineering Federation (VDMA), provided a comprehensive overview of the country’s automotive industry. Over the past two years, India has been relying on its traditional two-wheeler staple; production has increased by 18% and dragged total growth up to 12.5%; the passenger car segment declined by 3.9%, while commercial vehicles (CVs) dropped by 19.8%, he informed. Nath also reviewed the robotics and machine tool industries which depend on business from automotive. Looking to the future, he painted a positive picture for both, saying there will be substantial potential for robot supply in India. In-plant logistics was the focus of the presentation from Shailesh Kathed, Head of Car Supply Chain Management, Fiat India, gave examples of optimised systems at the Ranjangaon plant which was the destination of this year’s AMS India tour.

Bumps in the road Pankaj Munjal, MD, Hero Motors, highlighted the history of one of India’s most famous brands and discussed the values which have made it such a success story - trust, service and focus. He said it was these principles which led Honda to select Hero as its joint venture (JV) partner in 1981, helping to propel a very small company to become one which now churns out 40,000 products a day. Munjal issued a rallying cry for Indian manufacturing, asking why the country is lagging behind competitors such as China. Sudheesh Vasudevan, Purchase Manager, Jaguar Land Rover India, opened the final session by referring to an earlier remark by the conference Chairman Simon Duval Smith, about metaphorical “bumps in the road” in India. He said that setbacks can actually help to take a breath and realign to the current situation. Vasudevan mixed positive statements about Indian automotive production with several criticisms, such as a culture of denial among suppliers. In Vasudevan’s opinion, suppliers in India are not that mature and the country’s automotive industry is too OEM-driven. One of his key messages for supplying to foreign OEMs is that “ownership and responsibility has to be taken by the suppliers”.

The next speaker, Pranab Ghosh, Assistant GM, Tata Motors, gave an extensive assessment of risks in automotive production, together with their likely impacts.

India’s potential Vinay Patil, Deputy GM (Manufacturing Operations), General Motors, championed India as a player in the automotive industry, saying that the country has unique skill sets which put it in a good position vis-à-vis many countries. He cited the availability of skilled manpower and praised the government apprenticeship scheme. The technical sessions at AMS India 2013 covered: the two and three-wheeler segments; paintshop; driveline developments; stamping; truck, bus and off-highway manufacturing; material handling and automation; BIW; and production control, IT and energy management. ☐ Courtesy: Ultima Media > MORE@CLICK EM01085 |


Challenges in the market Rajiv Bajaj, Principal at Roland Berger Consultants, gave a comprehensive overview of the state of India’s automotive industry, in the context of ongoing “VUCA” (volatility, uncertainty, complexity and ambiguity). He said that although the global light vehicle industry has rebounded “much better than expected” after the economic downturn, 2013 was “a difficult year for India” – although he added that “nobody believes the long-term story is negated”.

EM | Jan-Feb 2014


technology | news

Milling cutters

Triple action presses

Walter AG offers high performance milling cutters from its succesful Walter Xtra·tec® programme which further optimises the cost efficiency of machining workpieces. The combination of the Tiger·tec® Silver cutting tool materials along with the Xtra·tec® tooling systems forms a nearly perfect basis for economical machining at peak productivity on all kinds of materials & components. The highest dimensional accuracy, best possible surface finish quality and increases in productivity of up to 100% can be achieved using a combination of milling cutters, high-performance drills and threading tools from the competence brands Walter, Walter Titex & Walter Prototyp. Equipped with the powerful Tiger·tec® Silver indexable inserts, they are The unique 4 point contact perfectly suited for roughing to finishing applications. surfaces of the indexable Their hard-nickel plated surface provides protection insert ensures free chip from corrosion and wear and ensures improved chip flow, that leads to a high evacuation. The Xtra·tec® F4033 with a diameter metal removal rate, even on range of 40-200 mm, is supplied in two different low-performance machines pitches. A narrow pitch enables it to be used with maximum productivity on transfer lines with short projection lengths. The medium pitch is suitable for weaker machines or unstable clamping conditions in different machining centres.

Dees provides full line of large capacity triple action presses to help customers drastically cut down production cost. The inner/outer slide can work individually or inter-locked to achieve higher capacity of working force. Established in 1976, SPC Dees hydraulic has been recognised as one of the most experienced and Triple action presses integrate a platform to reliable manufacturer in the the location of the presses in order to provide industry. The triple action easier access for the operator presses integrate a platform to the location of the presses in order to provide easier access for the operator. Meanwhile, the actual presses clamp, and cushion capacity is determined by the nature of the operations. SPC triple action presses units also offer user friendly control system to relieve unnecessary stress for operators. Quality hydraulic presse machine provides easy-to-operate function, apart from professional services to the customers.

> MORE@CLICK EM01086 |

> MORE@CLICK EM01087 |

Bridge-type milling machine

Multi-tasking machines

Nicolas Correa has introduced the FOX milling machine that mechanically combines welded & cast structural elements and linear slide ways with box guide to provide a solid balance between rigidity, damping capacity. Its rigidity and damping capacity includes large section & properly ribbed structural elements; wide section box guide way on The FOX milling machine mechanically the Z-axis and drive system combines welded & cast structural elements of the three axes X, Y, Z and linear slide ways to provide a solid duly designed for high axial balance between rigidity, damping capacity thrust. Its design is based & precision on rigidity, damping capacity and high precision with a table surface of 6000 x 2000 mm. The wide range of mechanical heads up to 6000 rpm & 1300 Nm in S1 with 0.020 resolution that ensures rigidity & precise positioning.

Yamazaki Mazak recently showcased two of its biggest multi-tasking machines from its flagship INTEGREX range at EMO 2013. The e-800H II is the largest machine in the INTEGREX e-H series, designed for the machining of large and heavy products. The machine is ideally suited to machine tool users in the oil & gas, The e-800H II is designed for the machining of aerospace and renewable large and heavy components such as landing energy sectors, for the gear and crank shafts machining of a wide range of components including large valves, landing gear and crank shafts. The new INTEGREX has a maximum swing of 1,300 mm and is capable of machining workpieces up to 15 tonnes. In addition, it has one of the biggest Y-axis strokes of any machine in its class, capable of a stroke up to 800 mm, along with a best-in-class NC steady-rest with capacity of 800 mm ø. The e-800H II is also ideally suited for most complex machining applications, including deep hole boring, with the using of either a long boring bar (120x1500 mm) and a super long boring bar (200x2000 mm).

> MORE@CLICK EM01088 |


> MORE@CLICK EM01089 |

EM | Jan-Feb 2014

news | technology

CNC servo motor driven ram turret punch press

25-speed electric gripper

Meiban Engineering Technologies has launched the Muratec M-3048TG â&#x20AC;&#x201D; the new 30 tonne machine with C frame design that comes with two- piece design to isolate the press frame from the table base with maximum tonnage shock. It is isolated from the table resulting in higher quality parts. Also this machine comes with in-line punch drive wherein the servo motor is A wide table base which has twin parallel to press frame resulting in ball screws on Y-axis is controlled greater rigidity, less stress and long by synchronised servo motors that tool life. A wide table base which has results in accuracy and stability twin ball screws on Y-axis is during high-speed movements. controlled by synchronised servo motors which results in accuracy and stability during high-speed movements. This machine comes with advanced CNC control functions such as scheduling function, processing graphic function, expanded tool library, tool management, machine control functions, turret monitor function and tool replacement. It assists the operator and increases machine productivity.

The mechatronic SCHUNK EGP 25-speed gripper for small components is the smallest electric gripper with integrated electronics in the market. With a maximum stroke of 3 mm, it takes 0.03 s for its fingers to close, thus offering optimal prerequisites for minimal cycle times. The tiny, power dense gripper weighs 100 g and has a gripping force of 7 N. It is suitable for rapid handling of work-pieces up to 35 g in friction-fit clamping. Brushless and thus wear- and maintenance-free servomotors as well as a powerful junction roller guide guarantee a high level of efficiency and make the gripper into a The EGP-speed takes dynamic and high-performance expert for screws on the side demanding pick & place applications. Since In or at the base, which many cases, users can transfer the sensor increases its flexibility systems used in the SCHUNK MPG-plus to the within a system design SCHUNK EGP-Speed, and easily convert existing systems from pneumatic to electrical operation. The EGP-speed takes screws on the side or at the base, which increases its flexibility within a system design

> MORE@CLICK EM01090 |

PVD and CVD coated carbide grades TaeguTec has recently introduced (TT3540 & TT9540) the PVD and CVD coated carbide grades. These improved coating and advanced substrate achieve optimal balance of improved toughness and wear resistance. High heat & wear resistant materials meet the challenges of performance and reliability but their complex compositions reduce machinability which has resulted in the soaring demand TT3540, with its high toughness, is for qualified, high performance excellent choice for low-medium cutting grade and geometries. These speeds, while TT9540 with increased wear new grades ensure longer tool resistance is ideal for medium to high life and stable machining in cutting speeds hard materials. TT3540, with its high toughness, is excellent choice for low-medium cutting speeds, while TT9540 with increased wear resistance is ideal for medium to high cutting speeds. Its features include higher toughness that prevents breakage during machining; longer tool life and stable machining in hard materials and improved substrate composition for stainless steel and heat resistant super alloys (HRSA). > MORE@CLICK EM01092 |

EM | Jan-Feb 2014

> MORE@CLICK EM01091 |

Grinding tools with diamond & CBN TYROLIT STARTEC XP-P product line includes high performance grinding tools with diamond and CBN. The area of application is solid carbide and HSS cutting tool production. STARTEC XP-P products deliver an improved profile retention and a high traverse speed at the same time. Customers benefit is a low power consumption at maximum cutting depth. This high performance is supported by a perfect combination of new bond systems and optimised abrasives. The new metallic bond system New diamond crystals shows an optimum adhesion to the are used for creep feed grain. This leads to improved life time grinding in solid carbide at higher traverse speed. The same level of productivity is given with CBN as abrasive grit. The high cutting ability of the new STARTEC XP-P grinding wheels reduces the grinding forces. The heat development is reduced at the same time. The high profile retention at full cutting depth is remarkable. > MORE@CLICK EM01093 |


technology | news

Cutting tools

Multitasking grinding machine

S series cutting tools from HG Technology Co Ltd, Taiwan, is a suitable choice for hard and high-speed cutting. The whole series is made of the German material, S series material with a special tool angle and unique coating technology which can be applied to a wide range of material processing, such as SB, SRD (high hardness steel), SEPS.SEPI (stainless steel), SEI (titanium alloy), SGBF.SGEB (graphite), SBF.SEM (miniature deep rib), and so on. The service range extensively covers 3C, semiconductor, medical care equipment, aerospace and The tools offer benefits like precision molding industries. The tools offer extended lifespan of tools, benefits like extended lifespan of tools, increased work efficiencies, increased work efficiencies, and minimised and minimised production costs production costs in terms of wear & tear of tools. For HGT carbide end mills, from material to finished products, the company utilises the processes provided by the original European manufacturers for the production. It uses high quality and stable German carbide rods, German and Swiss 6-axis CNC grinding machines, advanced Swiss coating technologies, and sophisticated German digital measuring instruments.

Rollomatic’s ShapeSmart NP5 precision grinding machine is a multi-talented resource for grinding cylindrical workpieces. The ShapeSmart™ NP5 is a five-axis precision grinding machine with a range of 0.025 to 25 mm in diameter. Not only does it manufacture high-quality tool blanks, but also it is suitable for producing ejector pins, The multi-function cylindrical grinding stamping and forming tools, machine ShapeSmart™ NP5 can grind press needles and other precise threads into the blank material components with a complex length/diameter ratio. The machine features a three-axis robot loader that handles up to 1,000 workpieces in a batch without any operator intervention. Now, with a flipper and the CCD camera option, the shank chamfer and coolant-hole slots and the pre-shaped points on drill blanks, can actually be ground in a single step. The multi-function grinding machine also grinds threads into the blank material, for exchangeable tool heads. Whether handling hard metal or HSS, the grinding wheels not only achieve ultra-low tolerances of 1 µm but also such a high material removal rate that there is absolutely no more re-tooling or re-alignment is required.

> MORE@CLICK EM01094 |

> MORE@CLICK EM01095 |

CNC machine simulation software CGTech has recently introduced VERICUT 7.3, a CNC machine simulation and optimisation software. It features many enhancements that significantly improve performance thereby simplifying manufacturing engineers’ ability to simulate the CNC programming and machining process. In version 7.3, the first thing the user notices is the all-new icons, available in multiple sizes. There are several user-selectable colour themes, and every window and icon can be optionally displayed or hidden. To help objects stand out in the machine simulation scene, an edge There are several user-selectable colour display option analyses models themes, and every window and icon can on-the-fly and finds and displays their be optionally displayed or hidden edges, all without affecting simulation speed. A significant in-house development effort produced enhancements to VERICUT’s industry leading collision algorithms, removing the need to adjust complex machine models to improve performance. It features drag/drop files from windows for quick setup; checks cutting tool wear limits based on time, distance, and volume. > MORE@CLICK EM01096 |


CNC cylindrical grinding machine Wendt has offered the latest state-of-the-art 3-axis CNC cylindrical grinding machine with Siemens 802D Solution controls. The special feature of this machine is the modular design concept incorporating rigid, multi-piece grey cast iron base housing all units such as grinding wheel head, work head, in feed slide and oscillation slide assembly. Its features include linear The special feature of this motion guide ways of rigid machine is the modular linear rail and carriage block for the design concept incorporating wheel head in feed axis; centralised rigid, multi-piece grey cast lubrication for linear bearings and ball iron base housing screw assembly; pneumatic system for air purge of the linear scale; retraction of grinding wheel head; work room enclosure with top cover to take care of the grinding mist in the operational area as optional and coolant filtration system is offered with paper band and magnetic separator. Its application areas include precision grinding of auto components and cylindrical grinding of precision components. > MORE@CLICK EM01097 |

EM | Jan-Feb 2014









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h i g h l i g h t s | c o m pa n y i n d e x | Im p r i n t

Highlights - Mar/Apr 2014 impRINT Publisher / Chief Editor  Shekhar Jitkar Deputy Editor Sumedha Mahorey Sub-editor & Correspondent Srimoyee Lahiri

»»Die & Mould Die and mould makers in India today compete globally and have over the years recorded transformational and high all round market growth. The next issue will take a look at the trends that would lead to rapid manufacturing growth of toolings in the coming years.

»»Sheet metal working Modern sheet metal technology allows pinpoint accuracy & low-cost production of virtually any material in any shape. The next issue will discuss latest technology trends in this area. »»Grinding machines The grinding process is evolving, becoming more automated & productive. The next issue will highlight advances in grinding technology.

»»Engineering materials With technological progress in various fields, the demand for new and advanced engineering materials and composites has gone up sharply. The next issue will provide insights on the recent achievements and new application zones for such materials.

Dhiraj Bhalerao (Regional Head - West & South) Contact: +91 9820211816 Ankit Garg New Delhi Contact: +91 9999205874

DieMould India 2014 Tool & Gauge Manufacturers Association - India has announced the 9 th Biennial Die & Mould International Exhibition from April 17-20, 2014 at Bombay Exhibition Centre, Mumbai. The next issue will feature a preview of this event.

company Index Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Ace Micromatic Group . . . . . . . . . . . . . . . . 59 Atlas Copco . . . . . . . . . . . . . . . . . . . . . . . . 16 Ansys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Ann Way Machine Tools . . . . . . . . . . . . . . . . 45 Boston Consulting Group . . . . . . . . . . . . . . . 30 Bajaj Electricals . . . . . . . . . . . . . . . . . . . . . . 12 Bharat Forge . . . . . . . . . . . . . . . . . . . . . . . . 30 B&R Industrial Automation . . . . . . . . . Cover, 8,9 Bening Enterprise . . . . . . . . . . . . . . . . . 54,55 BFW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Blaser Swisslube . . . . . . . . . . . . . . . . . . . . . 47 CGTech . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Chrystec Machine Tools . . . . . . . . . . . . . . . . 92 Cutler Media . . . . . . . . . . . . . . . . . . . . . . . . 80 Comsol Multiphysics . . . . . . . . . . . . . . . . . . 61 Cummins Generator Technologies India Ltd . . . 30 CII . . . . . . . . . . . . . . . . . . . . . . . . . 12, 14, 30 Dees Hydraulic Industrial Co . . . . . . 33, 98, 108 Durr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Doosan Infracore India . . . . . . . . . . . . . . . . . 25 Epicor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Eaton . . . . . . . . . . . . . . . . . . . . . . . . . . 34, 42 Emuge India . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ervin Junker Maschinenfabrik . . . . . . . . . . . . 81 Everising Machines . . . . . . . . . . . . . . . . . . . 53 Fanuc India . . . . . . . . . . . . . . . . . . . . . . . . . 99 Faro Business Technologies . . . . . . . . 70, 73, 91

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Frost & Sullivan . . . . . . . . . . . . . . . . . . . . . 105 Grind Master Machines . . . . . . . . . . . . . . . . . 92 Godson Bending Systems . . . . . . . . . . . . . . . 95 Godrej & Boyce . . . . . . . . . . . . . . . . . . . . . . 30 Haas Automation . . . . . . . . . . . . . . . . . . . . . . 1 Hannover Milano Fairs India . . . . . . . . . . . . . 103 HG Technology Co . . . . . . . . . . . . . . . 107, 112 Hong Ji Precision Machinery Limited . . . . . . . 69 ifm electronic India . . . . . . . . . . . . . . . . . . . 36 IMTMA . . . . . . . . . . . . . . . . . . . . . 85, 90, 102 Jyoti CNC Automation . . . . . . . . . . . . . . . . . . 5 Kanefusa India . . . . . . . . . . . . . . . . . . . . . . 57 Kim Union Industrial . . . . . . . . . . . . . . . . . . . 35 Kirloskar Brothers Ltd . . . . . . . . . . . . . . . . . . 12 Knorr-Bremse . . . . . . . . . . . . . . . . . . . . . . . 14 Kamikaze B2B Media . . . . . . . . . . . . . . . . . 111 Kirpekar Engineering . . . . . . . . . . . . . . . . . . 96 Korloy India Tooling . . . . . . . . . . . . . . . . . . . 37 Larsen & Tourbo . . . . . . . . . . . . . . . . . . . . . 30 Mahindra Auto Steel . . . . . . . . . . . . . . . . . . 14 Lico Machinery Company . . . . . . . . . . . . . . 63 Lucas TVS . . . . . . . . . . . . . . . . . . . . . . . . . 26 Marox Tools Industrial Co . . . . . . . . . . . . . . . 97 Meiban Engineering . . . . . . . . . . . . . . . 87, 109 Mitsubishi Electric . . . . . . . . . . . . . . . . . . . . . 3 Mitsubishi Heavy Industries . . . . . . . . . . . . . . . 2 Mitutoyo South Asia . . . . . . . . . . . . . . . . . . . 17

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Page Noppen Conference & Exhibition . . . . . . . . . . 64 Omron Automation . . . . . . . . . . . . . . . . . . . . 13 Quaker Chemical . . . . . . . . . . . . . . . . . . . . . 11 Renishaw . . . . . . . . . . . . . . . . . . . . 10, 51, 58 Rollomatic India . . . . . . . . . . . . . . . . . . 65, 112 Schaeffler . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Sandvik Coromant . . . . . . . . . . . . . . . . . . . . 38 Schunk Intec India . . . . . Front Inside Cover, 109 Seco Tools . . . . . . . . . . . . . . . . . . . . . . 71, 48 Stratmann Consulting . . . . . . . . . . . . . . . . . . 22 SHW Machine Tools . . . . . . . . . . . . . . . . . . . 49 TaeguTec India . . . . . . . Back Inside Cover, 109 TAGMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 TAITRA . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Taiwan Diamond Industrial Company . . . . . . . . 95 Taiwan Takisawa Technology . . . . . . . . . . . . . 77 Tyrolit India Superabrasive Tools . . . . . . . 67, 109 Ultima Media . . . . . . . . . . . . . . . . . . . . . . 106 UCAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 UCIMU-SISTEMI PER PRODURRE . . . . . . . . . 10 Vargus India . . . . . . . . . . . . . . . . . . . . . . . . . 6 Walter Tools . . . . . . . . . . Back Cover, 100, 108 Wendt . . . . . . . . . . . . . . . . . . . . . . . . 79, 112 Worldwide Industrial Machinery Limited . . . . . . 89 Yamazaki Mazak India . . . . . . . 10,15, 97, 108 YG1 . . . . . . . . . . . . . . . . . . . . . . . . . . .20,21

Festo Controls . . . . . . . . . . . . . . . . . . . . . . . 46 Ford India . . . . . . . . . . . . . . . . . . . . . . . . . . 30 FEIN Power Tools India Pvt Ltd . . . . . . . . . . . . 98

MMC Hardmetal . . . . . . . . . . . . . . . . . . . . . 27 MP Organisation . . . . . . . . . . . . . . . . . . . . . 93 Nicolas Correa SA . . . . . . . . . . . . . . . 19, 108

Zebra Technologies . . . . . . . . . . . . . . . . . . . 74


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EM | Jan-Feb 2014

RNI No.: MAHENG/2010/34603

EM Jan-Feb 2014